U.S. patent application number 11/306303 was filed with the patent office on 2007-06-28 for waterproof remote function actuator with electronic display.
This patent application is currently assigned to LEAR CORPORATION. Invention is credited to Frank Buccinna, John Marcel Burca.
Application Number | 20070144938 11/306303 |
Document ID | / |
Family ID | 37712184 |
Filed Date | 2007-06-28 |
United States Patent
Application |
20070144938 |
Kind Code |
A1 |
Buccinna; Frank ; et
al. |
June 28, 2007 |
WATERPROOF REMOTE FUNCTION ACTUATOR WITH ELECTRONIC DISPLAY
Abstract
A waterproof remote function actuator is formed by bonding a
clear plastic foil over the body of a plastic housing having an
opening for display of componentry. The clear plastic foil creates
a chemical and mechanical bond over the entire surface of the
housing, including the opening. This eliminates potential water
leakage paths around the opening. In alternative arrangements, the
clear plastic foil also covers one or more actuator buttons
contained within other openings in the plastic housing to prevent
water leakage paths between the one or more actuator buttons and
the plastic housing.
Inventors: |
Buccinna; Frank; (Livonia,
MI) ; Burca; John Marcel; (Rochester Hills,
MI) |
Correspondence
Address: |
ARTZ & ARTZ, P.C.
28333 TELEGRAPH ROAD, SUITE 250
SOUTHFIELD
MI
48034
US
|
Assignee: |
LEAR CORPORATION
Southfield
MI
|
Family ID: |
37712184 |
Appl. No.: |
11/306303 |
Filed: |
December 22, 2005 |
Current U.S.
Class: |
206/305 ;
206/811 |
Current CPC
Class: |
H01H 9/0242 20130101;
H01H 9/04 20130101; G07C 9/00944 20130101 |
Class at
Publication: |
206/811 ;
206/305 |
International
Class: |
B65D 85/38 20060101
B65D085/38 |
Claims
1. A waterproof remote function actuator comprising: a plastic
housing having a first opening; a clear plastic polymeric foil
overlay coupled over said plastic housing and said first opening,
wherein a portion of said clear plastic polymeric foam overlay
located over said first opening defines a window display; and an
electronic display contained within said plastic housing and
visible through said window display.
2. The waterproof remote function actuator of claim 1, wherein said
plastic housing comprises a lower plastic housing sealingly coupled
to an upper plastic housing.
3. The waterproof remote function actuator of claim 1 further
comprising at least one actuator button coupled within a second
opening of said plastic housing and contained within said clear
plastic polymeric foil overlay.
4. The waterproof remote function actuator of claim 1, wherein said
clear plastic polymeric foil overlay is selected from the group
consisting of a clear polycarbonate foil overlay, a clear
polyethylene terephthalate foil overlay and a clear
polythiourethane foil overlay.
5. The waterproof remote function actuator of claim 1, wherein said
plastic housing comprises a polycarbonate plastic housing.
6. The waterproof remote function actuator of claim 1, wherein said
plastic housing comprises an acrylonitrile-butadiene-styrene
plastic housing.
7. The waterproof remote function actuator of claim 2, further
comprising a drop in gasket coupled between said upper plastic
housing and said lower plastic housing for sealingly coupling said
lower plastic housing to said upper plastic housing.
8. The waterproof remote function actuator of claim 2, wherein said
lower plastic housing includes a molded-in gasket for sealingly
coupling said upper plastic housing to said lower plastic
housing.
9. The waterproof remote function actuator of claim 2, wherein said
upper plastic housing includes a molded-in gasket for sealingly
coupling said upper plastic housing to said lower plastic
housing.
10. A method for forming a waterproof remote function actuator, the
method comprising: providing a thin sheet of a clear polymeric
material; forming a lower plastic housing; introducing said thin
sheet of said clear polymeric material to a first forming tool;
forming a preformed foil overlay from said thin sheet of said clear
plastic polymeric material within said first forming tool;
introducing said preformed foil overlay to a second forming tool,
said second forming tool having an inner cavity shaped to
correspond with a plurality of features contained within said upper
plastic housing; forming an upper plastic housing having a first
opening within said inner cavity, said upper plastic housing being
sealingly coupled to said preformed foil overlay, wherein a portion
of said preformed foil overlay corresponding to said first opening
defines a window display; and sealingly coupling the lower plastic
housing to said upper plastic housing, said lower plastic housing
and said upper plastic housing defining an interior region there
between, wherein said interior region is visible through said
window display and said first opening.
11. The method of claim 10, wherein forming a preformed foil
overlay comprises vacuum forming a preformed foil overlay.
12. The method of claim 10, wherein forming an upper plastic
housing comprises: providing a polymeric material in a liquid form;
injecting said liquid polymeric material within said inner cavity
at a predefined temperature and a predefined vacuum pressure, said
liquid polymeric material pressing against said inner cavity and
against said preformed foil overlay; cooling said liquid polymeric
material within said inner cavity to form a hardened upper plastic
housing; and removing said hardened upper plastic housing from said
second forming tool.
13. The method of claim 12, wherein providing a polymeric material
in a liquid form comprises providing a thermosetting polymeric
material in liquid form, said thermosetting polymeric material
comprising a matrix resin and a crosslinking agent.
14. The method of claim 12, wherein providing a polymeric material
in a liquid form comprises providing a thermoplastic polymeric
material in liquid form, said thermoplastic polymeric material
selected from the group consisting of a thermoplastic
polycarbonate-based polymeric material and a thermoplastic
acrylonitrile-butadiene-styrene based polymeric material.
15. The method of claim 10, wherein said thin sheet of a clear
polymeric material is selected from the group consisting of a clear
polycarbonate material, a clear polyethylene terephthalate material
and a clear polythiourethane material.
16. The method of claim 10, forming an upper plastic housing having
said first opening within said inner cavity comprises: forming an
upper plastic housing having said first opening and a second
opening within said inner cavity, wherein said upper plastic
housing is sealingly coupled to said preformed foil overlay and
wherein a portion of said preformed foil overlay covers each of
said first opening and said second opening.
17. The method of claim 16 further comprising: coupling an actuator
button within said interior region such that said actuator button
is contained within said second opening and between said interior
region and said preformed foil overlay when said lower plastic
housing is sealingly coupled to said upper plastic housing.
18. The method of claim 17 further comprising: coupling an
electronic display and a printed circuit board within said interior
region such that said electronic display is visible through said
window display when said lower plastic housing is sealingly coupled
to said upper plastic housing, wherein said electronic display is
electrically coupled to said printed circuit board.
19. The method of claim 18 further comprising electrically coupling
said actuator button to said printed circuit board.
Description
TECHNICAL FIELD
[0001] The present invention relates generally to remote function
actuators with electronic displays, and more particularly to
waterproof remote function actuators with electronic displays.
BACKGROUND
[0002] Remote function actuators are devices used in a wide variety
of applications requiring push-button technology and visible screen
displays. Non-limiting examples of remote function actuators of
this type include key fobs, cellular telephones, garage door
openers and the like.
[0003] Typically, remote function actuators included a two-piece
plastic housing sealed using a molded-in or drop in gasket. The
plastic housing has any number of openings that contain a
corresponding number of push buttons. A clear lens such as glass or
plastic is then coupled within another opening in the housing
through which an electronic display may be viewed. Contained within
the plastic housing is electronic circuitry, including a printed
circuit board, that is electrically coupled to both the push
buttons and the electronic display.
[0004] In conventional remote function actuators, the clear lens is
sealed to the plastic housing by insert-molding a clear plastic
layer around the perimeter of the lens. However, given the
repetitive expansion and contraction encountered during a water
test over a large temperature range, the seal around the perimeter
of the lens was compromised, therein providing a leakage point
through which the underlying electronic circuitry may be exposed
and damaged.
[0005] It is therefore desirable to minimize or otherwise eliminate
water-sealing issues typically encountered with the present
design.
SUMMARY OF THE INVENTION
[0006] The present invention provides a method for waterproofing
remote function actuator devices that include a window display
built therein.
[0007] The present invention bonds a clear plastic foil over the
body of a plastic housing having a window for display. The solution
creates a chemical and mechanical bond over the entire surface of
the housing, not just around the perimeter of the window. This
eliminates the potential for seal breakage at the window/housing
interface by exposure to water at varying temperatures. The foil
overlay may also extend over one or more actuator buttons coupled
within other openings in the body of the plastic housing, and
similarly provides a moisture seal around these buttons.
[0008] Other objects and advantages of the present invention will
become apparent upon considering the following detailed description
and appended claims, and upon reference to the accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 a perspective view of a remote function actuator
according to one preferred embodiment of the present invention;
[0010] FIG. 2 is a section view of FIG. 1 taken along line 1-1;
and
[0011] FIG. 3 is a logic flow diagram for coupling the clear
plastic foil overlay to the upper plastic housing in accordance
with the preferred method of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)
[0012] The present invention is directed to a method for
waterproofing devices having a display window contained therein.
The method of the present invention will be described by way of
example in forming a remote function actuator having an electronic
display. However, it should be understood that the present method
is not limited by reference to this example, but is merely
exemplary of any number of potential devices that may be formed
according to the preferred method.
[0013] Referring now to FIGS. 1 and 2, a perspective view of a
remote function actuator 20 is shown according to a preferred
embodiment of the present invention as having a plastic housing 22
consisting of an upper housing 23 and a lower housing 24, one or
more function actuator buttons 26 contained within a first opening
31 of the upper plastic housing 23. The upper plastic housing 23 is
sealingly coupled to the lower plastic housing 24 using a water
seal 32 such as a molded-in gasket or drop-in gasket (shown
herein). The molded-in gasket may be molded as either a portion of
the upper plastic housing 23 or as a portion of the lower plastic
housing 24. The upper plastic housing 23, lower plastic housing 24,
window display 30 and water seal 32 together define an interior
region 34.
[0014] Coupled within the interior region 34 of the housing 22 is a
printed circuit board 36 electrically coupled to an electronic
display 38. The printed circuit board 36 is also electrically
coupled to the one or more function actuator buttons 26. The
electronic display 38 is situated such that it is visible through a
second opening 33 in the upper plastic housing 23.
[0015] A clear plastic foil overlay 40 is sealingly coupled over
the openings 31, 33 in the upper plastic housing 23 and over at
least a significant portion of the outer portion 42 of the upper
plastic housing 23. A portion of the foil overlay 40 therein
constitutes a window display 30 that covers the opening 33. The
electronic display 38 is visible through the window display 30.
Moreover, the actuator buttons 26 are visible and pressable through
the foil overlay 40 during use.
[0016] The foil overlay 40 eliminates a water leakage path that
typically occurs between the clear lens and inner periphery opening
in the upper plastic housing coupled within the opening that
commonly occurred in prior art remote function actuators due to the
repetitive expansion and contraction of the lens and housing 23
that can occur in the presence of water under varying temperature
conditions. The foil overlay also prevents another water leakage
pass between the plastic housing and uncovered actuator buttons of
the prior art actuator devices.
[0017] The plastic housing 22 is preferably formed of a durable
polymeric material such as polycarbonate or
acrylonitrile-butadiene-styrene ("ABS") that has been preformed to
a desired shape and thickness. The plastic housing 22 may be
thermoplastic or thermosetting in nature, and may include various
fillers, pigments, light stabilizers, and other additives that are
typically utilized to give the plastic housing its desired coloring
and durability. As one of ordinary skill recognizes, a
thermosetting plastic housing 22 is formed by the reaction of a
matrix polymer resin and a crosslinking agent (in the form of
another polymer or other reacting material).
[0018] The clear plastic foil overlay 40 is preferably formed of a
polymeric material that provides good mechanical and chemical
adhesion to both the underlying upper plastic housing 23 and window
display 30. The foil overlay 40 is a water, chemical, and
light-resistant durable polymer material that is substantially
clear when cured or otherwise formed to its final shape. The foil
overlay 40 may include a number of printed on graphics, button
colors, or outside colors as desired. Preferably, the clear plastic
foil overlay 40 is formed from about a 0.15-1.25 mm, and more
preferably about 0.60 mm thick, sheet of polycarbonate, although
the thickness may vary depending upon the application and the
desired clarity. Moreover, other polymeric materials that provide
good mechanical and chemical adhesion at sufficient clarity and
thickness are specifically contemplated by the present invention,
including for example thin sheets of polyethylene terephthalate
("PET") and/or polythiourethane ("PTU").
[0019] Referring now to FIG. 3, a logic flow diagram is shown
illustrating the preferred method for forming the plastic foil
overlay 40 and coupling the formed overlay 40 to the upper plastic
housing 23.
[0020] Beginning with Step 100, a thin sheet a suitable clear
plastic polymeric material used to make the foil overlay 40 is
provided in a flat form at the desired thickness.
[0021] Next, in Step 110, the thin sheet is printed with graphics,
button colors, and/or outside colors by conventional printing
methods well known to those of ordinary skill in the art.
[0022] In Step 120, the flat sheet is introduced to a first forming
tool and shaped to form a preformed foil overlay, which corresponds
roughly to the shape of the foil 40. For a polycarbonate sheet
about 0.60 mm thick, the sheet is heated to about 100-110 degrees
Celsius and pressed against the inner walls at about 3-5 kilograms
of pressure using a vacuum forming or pressing technique to form
the preformed foil overlay. The preformed foil overlay is then
removed from the first forming tool.
[0023] In Step 130, the lower plastic housing 24 is formed to its
desired shapes utilizing standard molding techniques. Examples of
such techniques include injection molding, compression molding and
reaction injection molding. As one of ordinary skill recognizes,
the temperature range and pressure range in the particular molding
applications vary greatly based on numerous factors, including but
not limited to the type of polymer molded, the amount of cavities
formed within the mold, and the thickness of the overall part
formed.
[0024] In the case of a thermoplastic lower plastic housing 24, the
liquid polymeric material used to form the lower housing 24 are
introduced within the forming tool in a liquid state and allowed to
cool and harden to its predetermined final shape. In the case of a
thermosetting lower plastic housing 24, the liquid polymeric
materials are introduced within the first forming tool and reacted
to form the thermosetting lower plastic housing 24.
[0025] Next, in Step 140, the upper plastic housing 23 is formed
and sealingly coupled to both the foil overlay 40 and around the
window display 30 and actuator buttons 26.
[0026] To accomplish this, the preformed foil overlay is first
coupled within an inner cavity of a second forming tool at a
predetermined location. The inner cavity of the second forming tool
is shaped to include a plurality of features that correspond to the
various contours and shapes of the upper plastic housing 23,
including specifically the openings 31, 33 through which the window
display 30 and actuator buttons 26 may be displayed.
[0027] Next, the polymeric component of the upper plastic housing
is injected in liquid form within the inner cavity under heat and
vacuum pressure.
[0028] The vacuum pressure created within the cavity presses the
liquid plastic material against walls on the inner cavity, and
specifically presses against the preformed foil overlay 40.
Moreover, the liquid polymer is prevented from entering areas
corresponding to the openings 31, 33.
[0029] The heat generated in the inner cavity of the second forming
tool during the injection process also causes the foil overlay 40
to be adhered to the upper plastic housing 23. The upper plastic
housing 23 and coupled foil overlay 40, including the formed window
display 30, are cooled and removed from the second forming
tool.
[0030] In the case of a thermosetting upper plastic housing 23, the
liquid polymeric materials components of the housing 23, including
a polymer matrix resin component and a crosslinking agent, are
typically injected separately and mixed and reacted, via a
crosslinking reaction, within the cavity. The matrix resin and
crosslinking agent therein form a complex polymer network that
hardens within the cavity as it reacts to form the thermosetting
upper plastic housing. The fully reacted thermosetting upper
plastic housing 23 is then cooled and removed from the second
forming tool.
[0031] In Step 150, the actuator 20 is assembled by sealingly
coupling the lower plastic housing 24 to the upper plastic housing
23, which includes the previously coupled foil overlay 40 and
formed window display 30, utilizing the water gasket or seal 32,
such that the printed circuit board 36, actuator buttons 26, and
electronic display 38 are contained within the interior region 34
and coupled to either the lower plastic housing 24 or upper plastic
housing 23. The printed circuit board 36 is also electrically
coupled to the one or more function actuator buttons 26 and
electronic display 38. The actuator 20 is now available for
use.
[0032] The foil overlay 40 therein prevents water leakage to the
interior region 34 of the assembly 20 through openings 31, 33. The
solution creates a chemical and mechanical bond over the entire
surface of the upper plastic housing 23. This eliminates the
potential for seal breakage at the foil/opening interface by
exposure to water at varying temperatures.
[0033] While the invention has been described in terms of preferred
embodiments, it will be understood, of course, that the invention
is not limited thereto since modifications may be made by those
skilled in the art, particularly in light of the foregoing
teachings.
* * * * *