Waterproof Case With Segmented Membrane Buttons

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Solution Overview

Problem

Current waterproof housings for electronic devices are not designed to allow clear sound transmission and effective actuation of toggles or screens, often relying on costly and complex rubber over-molded elements, which increases tooling and unit costs and results in bulky designs.

Innovation Solution

A waterproof case with mechanically assembled buttons and a separate bumper that provides actuation while maintaining an air and water-tight seal, using a compliantly mounted membrane to enhance sound transmission and reduce material costs by eliminating the need for rubber over-molding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If rubber over-molded elements are used to create integrated waterproof buttons, then button actuation and sealing are achieved, but tooling cost and unit cost increase significantly

Engineering Contradiction:

Improvewaterproof sealingVSAvoidtooling cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The button assembly is divided into separate components: a rigid button body, a flexible membrane seal, and a bumper. This segmentation eliminates the need for complex rubber over-molding while maintaining waterproof sealing through the membrane component that flexes during actuation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A flexible membrane acts as an intermediary between the button actuation force and the waterproof seal requirement. The membrane transmits the actuation force while maintaining the seal, replacing the need for integrated rubber over-molded buttons.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If rubber over-molded elements are used to create integrated waterproof buttons, then button actuation and sealing are achieved, but device complexity increases

Engineering Contradiction:

Improvewaterproof sealingVSAvoidbutton integration complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

3Strength

If thicker layers of protective material are used to protect the device, then protection is improved, but case volume increases making it bulky

Engineering Contradiction:

Improveimpact protectionVSAvoidcase volume

Core Design Contradiction:

StrengthVSVolume of moving object

Solution Approach 1:

Protective material is strategically placed only where impact protection is most needed, such as corners and edges, rather than uniformly throughout the entire case. This localized approach provides adequate protection while minimizing overall case volume.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The case uses composite material construction with strategic placement of different materials - harder materials for impact-resistant areas and lighter materials for other areas. This provides protective functionality while reducing overall case volume and weight.

Inventive Principle:

Principle #40Composite materials

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 allows for effective actuation of device buttons and improved sound transmission without the use of rubber over-molded elements, reducing tooling and unit costs while maintaining protection and functionality without bulkiness.

Implementation Method 1

Air trapped within the protective case transfers acoustic energy to at least one membrane wherein the membrane vibrates in response to an air pressure differential transmitting sound to an exterior or interior of the case

Methodology Applied

Scientific EffectAcoustic energy transmission: Sound

Implementation Method 2

The plug core transmits force directly to the underlying device and displaces the flexible membrane so that it undergoes elastic deformation but is still secured to the case member to toggle the device

Methodology Applied

Scientific EffectMechanical force transmission: Mechanical Force

Implementation Method 3

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentUS11844407B2Waterproof case

Publication Date: 2023.12.19 CATALYST LIFESTYLE

AI summary

A protective case for an electronic device that includes a case member, the case member including slots and ports formed therein for allowing interaction with a device positioned within the case member. The case member includes inner and outer surfaces. Separate button features are assembled to the case member sealing the case member and providing actuation of the device. The case member and lid are removably joined to define an air and water tight volume receiving the device. The button features are assembled from outside the case member and include a membrane attached to an inside of the case member. The plug core transmits force directly to the underlying device and displaces the flexible membrane so that it undergoes elastic deformation but is still secured to the case member to toggle the device.