Injection-Molded Control Panel With Encapsulated Internal Connector
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Solution Overview
Problem
Conventional control panel assemblies are complex and costly due to multiple components and potential failure points, especially in small or uniquely shaped products with complex controls, leading to manufacturing challenges and reliability issues.
Innovation Solution
An injection molded control panel with two film layers bonded to either side of the resin, featuring a first surface with in-mold decorated plastic film and a second film with a printed circuit containing capacitive touch sensors, electronic components, and a novel method for internal circuit termination, which is encapsulated with molten resin for protection and simplified assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple separate components (control panel, housing, PCB, interconnect wires) are used in conventional assemblies, then functional requirements can be met, but device complexity and manufacturing cost increase significantly
Solution Approach 1:
The patent combines the control panel, housing, PCB, and interconnect wires into a single integrated injection molded component. The control panel assembly includes integrated control elements (switches, indicators, knobs, slides, displays) and circuit board assemblies with interconnect wires all molded as one piece, eliminating the need for separate components and reducing assembly complexity
Solution Approach 2:
The injection molded control panel assembly serves multiple functions simultaneously: it provides the structural housing, the decorative control panel surface, the circuit board with electronic components, and the interconnect wiring all in a single universal component that replaces multiple specialized parts
2Adaptability or versatility
If multiple separate components and interconnects are used, then functional requirements are met, but the number of potential failure points increases
Solution Approach 1:
By merging the control panel, housing, PCB, and interconnect wires into a single integrated component molded from the same material, the patent eliminates the interfaces and connections between separate components that serve as failure points. The integrated structure ensures consistent material properties and eliminates potential failure points at connection interfaces
3Ease of manufacture
If conventional separate component assembly is used, then manufacturing flexibility is maintained, but manufacturing cost increases due to multiple components and assembly steps
Solution Approach 1:
The patent merges multiple manufacturing steps and components into a single injection molding process that produces the integrated control panel assembly in one operation, reducing the number of assembly steps and lowering manufacturing cost while maintaining flexibility through the molding process itself
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution significantly reduces complexity and cost, enhances reliability by minimizing failure points, and provides protection against moisture, corrosion, and physical damage, resulting in a more robust and cost-effective control panel assembly.
Implementation Method 1
molten resin is injected in between the 2 films completely encapsulating both the second surface decoration on the A side film and the conductive circuit with the mounted components on the B side of the molded article
Data Source
AI summary
Provided are systems and methods for a control assembly including: a first film that is in-molded that includes decorative graphics, a front surface and a rear surface; and a second film molded to the rear surface of the first film having a printed circuit that includes sensors, control circuits and interconnects and a front and rear surface; and an internal connector.