Movable Sensor Interface Assembly for Tactile Overmolded Controls
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Solution Overview
Problem
Existing methods for manufacturing electronic assemblies, such as injection molded structural electronics, face challenges in creating durable and adaptable interface structures with movable elements that provide tactile feedback, as molding materials often fix these elements in place, limiting their functionality and user interaction.
Innovation Solution
An interface assembly with a functional multilayer structure and a movable member, where the sensor arrangement is embedded in the molded material layer, allowing for detection of position changes and enabling tactile feedback through magnetic, mechanical, or shape interlocking attachments, ensuring durability and adaptability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If molding material is used to encapsulate electronic components, then structural integrity and protection are improved, but movable interface elements become fixed and lose functionality
Solution Approach 1:
The interface assembly is divided into distinct segments: a functional multilayer structure that remains fixed and provides structural integrity, and separate movable members (buttons, knobs, sliders) that are not encapsulated by the molding material. This segmentation allows the fixed structure to provide protection while movable elements maintain their functionality through magnetic, mechanical, or shape interlocking attachments.
Solution Approach 2:
Movable interface elements are extracted from the molded structure and positioned separately. The molding material forms a recess or cavity that accommodates these movable members without encapsulating them, allowing them to move freely while remaining attached to the functional multilayer structure through non-permanent attachment mechanisms.
2Adaptability or versatility
If complex electrical circuits are produced on substrate to achieve functionalities, then functional capabilities are improved, but electronics vulnerability and structural complexity increase
Solution Approach 1:
Multiple functional layers are merged into a single integrated functional multilayer structure. This structure combines electronics, mechanical support, and interface element mounting in one unified assembly, reducing the number of separate components and connections that could fail, while maintaining full functional capabilities.
Solution Approach 2:
The functional multilayer structure serves multiple functions simultaneously: it provides structural support, houses electronic components, accommodates movable interface elements, and enables various user interactions. This multi-functionality reduces the need for separate specialized components, thereby reducing overall system complexity and potential failure points.
3Reliability
If interface elements are overmolded to protect them, then durability is improved, but tactile feedback capability is lost
Solution Approach 1:
Movable interface elements are extracted from the molded structure and positioned in recesses or cavities formed by the molding material rather than being encapsulated within it. This extraction allows the elements to maintain their mechanical movement capability and tactile feedback properties while the molding material provides protective enclosure and structural support.
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
The solution enables the creation of robust, durable interface assemblies that provide tactile feedback to users, while maintaining structural integrity and material efficiency, allowing for both linear and rotational movements without detaching from the functional multilayer structure.
Implementation Method 1
The sensor arrangement and the at least one detection portion are mutually arranged so that a position or a change of position of the movable member is detectable by the sensor arrangement based on a position or a change of position of the at least one detection portion relative to the sensor arrangement
Data Source
AI summary
An interface assembly includes a functional multilayer structure that includes a first substrate, a molded material layer on a first side of the first substrate, and a sensor arrangement including at least one sensor, wherein the sensor arrangement is arranged at least partly embedded into the molded material layer. The assembly further includes a movable member being movable relative to the functional multilayer structure, wherein the movable member includes at least one detection portion, and the sensor arrangement and the at least one detection portion are mutually arranged so that a position or a change of position of the movable member is detectable by the sensor arrangement based on a position or a change of position of the at least one detection portion relative to the sensor arrangement.