Continuous Printed Key Panel Bezel for Harsh Environments
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Solution Overview
Problem
Existing harsh environment key panels and bezel structures face challenges in preventing moisture and debris from reaching underlying circuitry, often resulting in damage and reduced tactile feedback, with current solutions either requiring multiple parts and tight tolerances or compromising on durability and feedback quality.
Innovation Solution
A 3D printed key panel and bezel structure formed as a continuous assembly with a deformable interface between the bezel and button, using multiple materials and durometers to prevent moisture and debris ingress while maintaining button actuation, and optionally incorporating light guides for enhanced usability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a flexible rubber substrate is placed over buttons or switches to prevent moisture and debris ingress, then protection against environmental contaminants is improved, but manufacturing complexity increases due to multiple parts and tight tolerances
Solution Approach 1:
The patent combines the button, bezel, and sealing function into a single integrated structure where the button is directly mounted to the printed board within a recess in the bezel. The bezel itself forms the sealing barrier against moisture and debris, eliminating the need for separate rubber substrates or gaskets. This integration reduces the number of parts and assembly steps while maintaining protective functionality.
Solution Approach 2:
The bezel structure serves multiple functions simultaneously: it provides the mounting framework for buttons, creates protective recesses for switches, and forms the sealing barrier against environmental contaminants. This multi-functionality eliminates the need for dedicated sealing components, reducing manufacturing complexity while maintaining reliability.
2Reliability
If a flexible rubber substrate is used to protect against moisture and debris, then environmental protection is improved, but tactile feedback quality deteriorates due to cushioning effect
Solution Approach 1:
The patent removes the rubber substrate or gasket material from the design, allowing buttons to be directly mounted to the printed board. This extraction of the cushioning element eliminates the degradation of tactile feedback while the bezel recess structure provides the necessary protection against moisture and debris ingress.
3Ease of manufacture
If membrane type switches are used instead of mechanical switches to prevent moisture ingress, then manufacturing cost and weight are reduced, but tactile feedback quality and durability deteriorate
Solution Approach 1:
The patent combines the mechanical switch directly with the button structure, mounting the switch to the printed board within a recess in the bezel. This integration allows the use of durable mechanical switches with good tactile feedback while the bezel recess provides protection against moisture and debris, avoiding the need for membrane switches.
4Object-affected harmful factors
If small amounts of gasket material are used around buttons to keep dust out, then debris protection is improved, but moisture protection deteriorates especially when buttons are pressed during exposure
Solution Approach 1:
The patent merges the dust barrier function with the moisture barrier function into a single integrated bezel structure. The recess in the bezel that receives the button forms a continuous sealing surface that prevents both dust and moisture ingress, even when the button is pressed during exposure to environmental contaminants.
Data Source
AI summary
Harsh environment key panel and bezel structures for a user interface device are disclosed. In embodiments, a user interface device includes a printed board, a switch mounted to the printed board, and a key panel disposed upon the printed board. The key panel includes a plurality of printed device layers forming a bezel, a button configured to actuate the switch, and a deformable interface between the bezel and the button. The plurality of printed device layers can include at least one continuous printed device layer that forms portions of the bezel, the button, and the deformable interface. The continuous printed device layer may include at least one rigid device material that forms a portion of the bezel and a portion of the button and a deformable device material that forms a portion of the deformable interface between the bezel and the button.