Sensor-Embedded Interface Assembly for Tactile Movable Controls
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Solution Overview
Problem
Existing methods for manufacturing electronic assemblies with movable elements, such as buttons or knobs, face challenges in providing tactile feedback while maintaining structural integrity and material efficiency, as overmolding can fix the elements in place and require complex electrical circuits.
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 providing tactile feedback through magnetic, capacitive, or optical sensing, while maintaining structural durability and material efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If overmolding is used to encase movable elements, then structural integrity is improved, but the movable elements become fixed and tactile feedback is lost
Solution Approach 1:
The assembly is divided into distinct segments: a molded structural layer providing integrity, and a separate movable member layer allowing operation. The movable members are not encased within the molded material but are positioned above it, maintaining both structural strength and operational freedom.
Solution Approach 2:
A non-conductive adhesive layer serves as an intermediary between the molded structural layer and the movable members. This adhesive provides mechanical support and positioning while allowing the movable members to maintain their operational independence and tactile feedback capability.
2Adaptability or versatility
If complex electrical circuits are used to provide tactile feedback, then functionality is improved, but device complexity increases
Solution Approach 1:
The patent replaces complex electrical sensing circuits with a simplified mechanical-sensing approach. The movable members are directly coupled to the molded structural layer, allowing mechanical movement to be detected through the interaction between the movable members and the structural features, eliminating the need for complex electrical circuitry.
Solution Approach 2:
The movable members themselves serve as the sensing elements through their mechanical interaction with the molded structural layer. The movement and position of the movable members are detected through their physical coupling and interaction with the structural features, rather than requiring separate sensing circuits.
3Stability of the object's composition
If movable elements are attached to the molded layer, then structural stability is improved, but movement capability deteriorates
Solution Approach 1:
The attachment characteristics are localized and differentiated: the movable members are attached to the molded structural layer at specific locations with controlled bond strength. The adhesive provides stable positioning while allowing the necessary degree of movement for operational feedback, creating different mechanical properties at different locations and interfaces.
4Loss of substance
If sensor arrangement is embedded in molded material layer, then material efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The sensor arrangement and movable members are prepared and positioned in advance on the molded structural layer before final assembly. This preliminary positioning allows for optimized material usage and simplified integration, as the components are pre-configured and then attached in a controlled manner rather than requiring complex embedded placement during molding.
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 and are structurally stable, with the movable member and multilayer structure being securely attached yet allowing for movement, addressing the limitations of existing technologies.
Implementation Method 1
providing tactile feedback through magnetic, capacitive, or optical sensing
Implementation Method 2
providing tactile feedback through magnetic, capacitive, or optical sensing
Implementation Method 3
providing tactile feedback through magnetic, capacitive, or optical sensing
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.