Overmolded Haptic Actuator Field Member Design
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Solution Overview
Problem
Existing haptic actuators face challenges in efficiently providing tactile feedback with reduced part count, complexity, and improved resonance and damping characteristics, while minimizing welding, gluing, and inspection operations.
Innovation Solution
A haptic actuator design featuring a housing with coils and a field member having a metal frame with embedded magnets, overmolded endcaps, and flexures, which are metal or plastic with strategic material combinations and mold features for optimized resonance and damping, and reduced part count and assembly complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional haptic actuator designs are used, then the structure is simple to manufacture, but the part count is high and assembly complexity increases
Solution Approach 1:
The patent combines multiple separate components into integrated assemblies. The flexure assembly merges the flexure, endcaps, and magnet holders into a single integrated unit. The overmolded endcaps integrate multiple functions including structural support, magnet retention, and flexure mounting. This merging reduces the total part count and simplifies assembly operations while maintaining manufacturability.
Solution Approach 2:
The overmolded endcaps serve multiple functions simultaneously: they provide structural support for the frame, retain the magnets through integrated holders, mount the flexures through embedded features, and provide damping characteristics. This multi-functionality reduces the need for separate components and simplifies the overall assembly.
2Adaptability or versatility
If multiple separate components are used in the field member, then each component can be optimized independently, but the assembly complexity and number of welding/gluing operations increase
Solution Approach 1:
The patent integrates multiple components into the overmolded endcaps, which combine structural support, magnet retention, and flexure mounting features into a single molded part. This reduces the number of welding and gluing operations required while maintaining the ability to optimize each functional element during the molding process.
Solution Approach 2:
The overmolded endcaps utilize composite construction combining metal frame elements with molded plastic or polymer materials. This composite approach allows optimization of each material for its specific function while reducing assembly operations, as the composite structure is created through overmolding rather than separate joining operations.
3Ease of manufacture
If conventional materials are used for the frame and endcaps, then manufacturing is simpler, but resonance and damping characteristics are not optimized
Solution Approach 1:
The patent employs composite materials in the overmolded endcaps, combining metal frame elements with specially formulated plastic or polymer materials that provide optimized damping characteristics. The composite construction allows tailoring of resonance and damping properties while maintaining manufacturability through overmolding processes.
Solution Approach 2:
The patent optimizes resonance and damping characteristics by changing material parameters in the overmolded endcaps, including selecting specific polymer compositions, densities, and viscoelastic properties. These parameter changes are achieved while maintaining compatibility with standard manufacturing processes.
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 enhances haptic feedback efficiency, reduces part count and assembly complexity, and improves resonance and damping characteristics, making the haptic actuator more robust and efficient in conveying information through tactile feedback.
Implementation Method 1
A haptic actuator may include a housing and at least one coil carried by the housing. The haptic actuator may also include a field member movable within the housing responsive to the at least one coil.
Implementation Method 2
The haptic actuator may include a first flexure having an inner end coupled to the first overmolded endcap, and an outer end coupled to adjacent portions of the housing.
Data Source
AI summary
A haptic actuator may include a housing, a coil carried by the housing, and a field member movable within the housing responsive to the coil. The field member may include a frame having opposing first and second ends, at least one magnet carried by the frame, and a first overmolded endcap coupled to the first end of the frame. The field member may also include a second overmolded endcap coupled to the second end of the frame. The haptic actuator may include a first flexure having an inner end coupled to the first overmolded endcap, and an outer end coupled to adjacent portions of the housing. The haptic actuator may also include a second flexure having an inner end coupled to the second overmolded endcap, and an outer end coupled to adjacent portions of the housing.