Touch sensor assembly and method of manufacturing same
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Solution Overview
Problem
Touch sensors in household appliances face challenges in maintaining accurate positioning and operational reliability, particularly with piezo-type sensors that are sensitive to misalignment, leading to reduced sensitivity and increased risk of damage during installation.
Innovation Solution
A touch sensor assembly with a sensor mounting portion on an insulating substrate, featuring a copper coating film and a protective top layer, uses a soldering spot formed by solder cream to securely fix the touch sensor on the sensor PCB, ensuring correct alignment and stability, and automates the installation process for improved productivity and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a touch sensor is installed on a sensor PCB, then the touch sensor can detect user touches, but the touch sensor may be misaligned or damaged during installation, reducing sensitivity and operational reliability
Solution Approach 1:
The soldering spots are pre-formed on the sensor mounting portion before the touch sensor is installed. This preliminary preparation ensures that when the touch sensor is placed and heated, it aligns correctly with the pre-positioned soldering spots, preventing misalignment and damage during installation.
Solution Approach 2:
Soldering spots act as an intermediary substance between the touch sensor and the sensor mounting portion. These soldering spots facilitate proper alignment and secure fixation of the touch sensor, preventing direct mechanical damage while ensuring accurate positioning through the soldering process.
2Productivity
If manual installation methods are used for touch sensors, then flexibility is maintained, but productivity is reduced and consistent positioning is difficult to achieve
Solution Approach 1:
The manual mechanical installation process is replaced with an automated soldering process. The soldering spots are formed using automated dispensing or printing techniques, and the subsequent heating process automatically melts the solder to secure the touch sensor, eliminating the need for manual alignment and attachment operations.
3Ease of manufacture
If the copper coating film is exposed without protection, then soldering is facilitated, but the copper coating is vulnerable to oxidation and damage
Solution Approach 1:
The protective layer is applied selectively to cover only the areas not requiring soldering, while leaving the sensor mounting portion exposed. This local differentiation allows the copper coating to remain protected in most areas while being accessible for soldering at the specific mounting location.
Solution Approach 2:
The protective layer is applied over the copper coating film before the soldering process. This preliminary protection prevents oxidation during manufacturing and handling, and the soldering spots are then formed through the protective layer or at designated openings, maintaining both protection and solderability.
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 the touch recognition rate, maintains sensitivity, and prevents damage to the touch sensor by ensuring correct positioning and secure fixation, while also reducing manufacturing costs through the use of copper coating films and automating the installation process.
Implementation Method 1
a soldering spot provided at the sensor mounting portion, wherein a touch sensor is stably fixed to the sensor mounting portion by the soldering spot
Implementation Method 2
a top layer (a protective layer) printed on the copper coating film, wherein the copper coating film is protected by the top layer
Data Source
AI summary
A touch sensor assembly may include a sensor mounting portion formed at a insulating substrate, and a soldering spot provided at the sensor mounting portion, wherein a touch sensor is stably fixed to the sensor mounting portion by the soldering spot. In addition, the touch sensor assembly according to an embodiment of the present disclosure includes a copper coating film coated on a insulating substrate, and a top layer printed on the copper coating film, wherein the copper coating film is protected by the top layer.