Attachment structure for control key unit

A control key unit attachment structure includes a control key unit, a base component, a retainer, an engagement member, a board receiver, and a positioning member. A frame of the control key unit is placed on the base component. The retainer and the base component sandwiches the frame of the control key unit in a first direction of the frame therebetween. The engagement member engages with the frame of the control key unit. The board receiver and the engagement member clamp the frame of the control key unit in a second direction of the frame therebetween. The positioning member positions the frame of the control key unit with respect to the board receiver in a third direction of the frame.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to Japanese Patent Application No. 2008-211262, filed on Aug. 20, 2008. The entire disclosure of Japanese Patent Application No. 2008-211262 is hereby incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention generally relates to an attachment structure for a control key unit. More specifically, the present invention relates to an attachment structure for a control key unit to attach the control key unit to a cabinet of an audio-visual device, such as a television receiver.

2. Background Information

A conventional liquid crystal television receiver has a cabinet with a front cabinet and a rear cabinet. The front cabinet is rectangular when viewed from the front. The rear cabinet is coupled to the front cabinet. Key tops stick out from openings that are made at a plurality of locations aligned vertically in a side panel on one side of the front cabinet. The key tops are pressed by the user to set various modes. The key tops include a main power button, channel changing buttons, volume adjusting buttons, an external power switchover button, setup buttons, and other such necessary control buttons.

With the liquid crystal television receiver, a control key unit is attached to the side panel of the front cabinet.

The control key unit includes a wiring board and a frame. The wiring board is rectangular and vertically oriented. The frame is vertically oriented. The key tops are vertically arranged. The key tops are integrally formed from resin on the frame. The wiring board is temporarily fixed to the frame by positioning protrusions provided to the frame. The wiring board that is thus temporarily fixed is mounted to the frame with attachment screws. With the control key unit, a plurality of key switches mounted on the wiring board is individually disposed at the back of the key tops. The key tops stick out from a plurality of openings in the side panel of the front cabinet.

With the attachment structure for the control key unit, attachment tabs are provided to the ends of the frame in its lengthwise direction. The attachment tabs are fastened with attachment screws to bosses that are provided to the front cabinet, thereby attaching the control key unit to the side panel of the front cabinet. Therefore, it is absolutely necessary to use the attachment screws (two attachment screws, for example) to attach the control key unit to the front cabinet.

Meanwhile, various structures have been proposed in the past for attaching elements for performing operations, such as push buttons and control knobs, to a housing, casing, or the like without using any screws.

With a conventional structure, a plurality of buttons of a push-button cluster is positioned on a plurality of switches mounted on a wiring board and in a plurality of through-holes in a casing, respectively (see Japanese Laid-Open Patent Application Publication No. 2000-299567, for example). Specifically, with the structure, fitting holes, ribs with slits, or the like provided to the push-button cluster are combined with positioning pins, guide ribs, or the like provided to the casing having the through-holes, thereby positioning the buttons of the push-button cluster in the through-holes. Furthermore, slits provided to the wiring board are combined with ribs provided to the push-button cluster, thereby positioning the buttons of the push-button cluster at the switches.

With another structure, control buttons are attached to a casing without using any screws by installing ribs provided to control buttons on the bottom face of the casing, or engaging hooks provided to the ends of the ribs with slit grooves provided to the bottom face of the casing (see Japanese Laid-Open Patent Application Publication No. 2005-191029, for example).

With further another structure, a knob is attached from outside of a casing, which simplifies the attachment of the knob (see Japanese Laid-Open Patent Application Publication No. H6-36654, for example).

With further another structure, push buttons are mounted on a wiring board by engaging hooks provided to the push buttons with square attachment holes provided to a printed board on which push switches are mounted (see Japanese Laid-Open Utility Model Application Publication No. S61-54645).

With the attachment structure for the control key unit, when the attachment screws are used to attach the control key unit to the front cabinet, not only is the components cost higher because of the need for using the attachment screws, but the assembly process is more complicated because the time-consuming work of fastening the attachment screws has to be carried out. Accordingly, it is difficult to improve productivity.

In view of this, there is a need to be able to attach a control key unit to a television receiver by a simple method that does not entail the use of extra parts such as the attachment screws.

In regard to this, all of the above-mentioned structures merely propose a structure for directly attaching knobs or push buttons (as key tops) to a casing or wiring board. However, the structures cannot be directly employed as a structure for attaching the control key unit to a cabinet.

SUMMARY OF THE INVENTION

The present invention was conceived in light of the above-mentioned problems. One object of the present invention is to provide a structure with which a control key unit can be attached to a cabinet of a television receiver without using attachment screws.

In accordance with one aspect of the present invention, a control key unit attachment structure includes a control key unit, a base component, a retainer, an engagement member, a board receiver, and a positioning member. The control key unit includes a wiring board, a key switch, and a frame. The key switch is disposed on the wiring board and electrically coupled to the wiring board. The frame has a push operated key top overlying the key switch with the frame being attached to a cabinet of a television receiver and supporting the wiring board. The base component supports the frame of the control key unit. The retainer is located on the cabinet of the television receiver. The retainer and the base component sandwiches the frame of the control key unit in a first direction of the frame therebetween. The engagement member is located on the cabinet of the television receiver. The engagement member engages with the frame of the control key unit. The board receiver is located on the cabinet of the television receiver. The board receiver and the engagement member clamp the frame of the control key unit in a second direction of the frame therebetween with the second direction being perpendicular to the first direction of the frame. The board receiver has an opening through which the key top of the frame extends to an outside of the cabinet of the television receiver. The positioning member positions the frame of the control key unit with respect to the board receiver in a third direction of the frame with the third direction being perpendicular to both the first and second directions of the frame.

With the control key unit attachment structure of the present invention, it is possible to provide a structure with which a control key unit can be attached to a cabinet of a television receiver without using attachment screws.

These and other objects, features, aspects and advantages of the present invention will become apparent to those skilled in the art from the following detailed descriptions, which, taken in conjunction with the annexed drawings, disclose a preferred embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

A preferred embodiment of the present invention will now be explained with reference to the drawings. It will be apparent to those skilled in the art from these disclosures that the following descriptions of the preferred embodiment of the present invention are provided for illustration only and not for the purpose of limiting the invention as defined by the appended claims and their equivalents.

FIG. 6is a perspective view of a liquid crystal television receiver1. The liquid crystal television receiver1has a cabinet10with a front cabinet11and a rear cabinet15, an attachment structure2of a control key unit A, a liquid crystal module (not shown) and other electrical parts. The front cabinet11is rectangular when viewed from a front side of the cabinet10. The rear cabinet15is coupled to the front cabinet11. The liquid crystal module includes a liquid crystal panel to display image. The cabinet10houses the liquid crystal module within an inside space defined between the front cabinet11and the rear cabinet15.

FIG. 1is an exploded perspective view of the control key unit A and the front cabinet11to which the control key unit A is attached, as viewed from the inside space of the cabinet10.FIG. 2is an exploded perspective view of the control key unit A.FIG. 3is a detailed perspective view of the front cabinet11as viewed from the inside space of the cabinet10.FIG. 4is a partial cross sectional view of the attachment structure2for the control key unit A, as viewed from the inside space of the cabinet10.FIG. 5is a side elevational view of the attachment structure2as viewed from the inside space of the cabinet10.

As shown inFIGS. 1 to 4, the control key unit A includes a frame20, a wiring board30and a plurality of key switches40. The frame20is a resin molding. The frame20is integrally formed as a one-piece, unitary member. The frame20is vertically oriented within the cabinet10. The wiring board30is rectangular and vertically oriented within the cabinet10. The key switches40are mounted in lengthwise alignment at a plurality of places on the wiring board30. The frame20further has a front panel21and a bottom plate22. The bottom plate22sticks out from one end of the front panel21in a width direction (e.g., lateral direction or second direction) W of the frame20. The front panel21further has a plurality of pushable key tops (e.g., push operated key tops)23at a plurality of places of the front panel21in a height direction (e.g., lengthwise direction or third direction) H of the frame20. The key tops23include a main power button, channel changing buttons, volume adjusting buttons, an external power switchover button, setup buttons, and other such necessary control buttons. The width direction W of the frame20is perpendicular to the height direction H of the frame20. As shown inFIG. 1, when the frame20is attached to the front cabinet11of the cabinet10, the width direction W and the height direction H of the frame20correspond to a width direction W and a height direction H of the front cabinet11of the cabinet10. Furthermore, if this is the case, then a depth direction (e.g., thickness direction or first direction) D of the frame20corresponds to a depth direction of the front cabinet11of the cabinet10. The depth direction D of the frame20is perpendicular to both the width direction W and the height direction H of the frame20.

As shown inFIG. 1, the frame20further has a first rib array24and a second rib array25. The first rib array24has a plurality of first ribs that are spaced apart at a specific spacing. The second rib array25has a plurality of second ribs that are similarly spaced apart at a specific spacing. The wiring board30is inserted in a direction of an arrow M shown inFIGS. 1 and 2and clamped under light pressure in a space between the first rib array24and the second rib array25. The key switches40are mounted on the wiring board30. The key switches40are electrically coupled to the wiring board30. The key switches40mounted on the wiring board30are located at a back side of the key tops23provided to the front panel21of the frame20. In other words, the key tops23overly the key switches40. Therefore, when one of the key tops23is pressed, respective one of the key switches40is reliably turned on and off by the key top23.

Also, the frame20has a pair of end plates26at both ends of the frame20. The end plates26serve to position the wiring board30relative to the frame20in the height direction H of the frame20. Each of the end plates26further includes a protrusion27formed in a stepped shape.

As shown inFIG. 6, the cabinet10is divided into the front cabinet11and the rear cabinet15. The front cabinet11and the rear cabinet15are put together and coupled to form the cabinet10.

As shown inFIGS. 1 and 3, control key unit A is attached to the front cabinet11. The front cabinet11has a side panel12with a board receiver51. The board receiver51(a part of the side panel12) sticks out in the depth direction D of the cabinet10relative to other part of the side panel12. The board receiver51has a plurality of openings17made at a plurality of places and in a vertical layout in the board receiver51.

The board receiver51further includes an engagement member60with a pair of hook tabs61. The hook tabs61are provided to both longitudinal end portions of the board receiver51in the height direction H of the cabinet10. The engagement member60is formed from resin integrally with the board receiver51as a one-piece, unitary member. Each of the hook tabs61has an elastic leg component (e.g., positioning member)62and an engagement prong (e.g., engagement member)63. The leg components62stick out from the board receiver51in a width direction W of the cabinet10. The engagement prongs63are formed at distal ends of the leg components62, respectively. With the engagement member60, spacing between the hook tabs61is set to match the length of the frame20of the control key unit A.

The front cabinet11further includes a plurality of ribs (e.g., support ribs)71. Specifically, the ribs71are formed spaced apart at a specific distance. The ribs71are located on an inside corner portion a of the front cabinet11, at a plurality of locations (three locations, for example) in the height direction H of the front cabinet11.

The front cabinet11further includes a base component70. The base component70is formed by top portions of the ribs71. One of the ribs71located in the middle of the ribs71(e.g., middle rib) further has an engagement protrusion72protruding in the depth direction D relative to the top portion of the middle rib71. The engagement protrusion72faces the board receiver51at a distance in the width direction W of the front cabinet11, and integrally formed with the middle rib71as a one-piece, unitary member.

As shown inFIG. 5, the rear cabinet15includes a plurality of retainer ribs (e.g., retainer)73. The retainer ribs73are located on the rear cabinet15at two locations in the height direction H of the cabinet10.

Next, the attachment structure2of the control key unit A will be described in detail through reference toFIGS. 4 and 5.

With the control key unit A, the bottom plate22of the frame20is placed on the base component70of the front cabinet11. Specifically, the bottom plate22of the frame20is disposed on top surfaces of the top portions of the ribs71. The base component70is formed by the top portions of the ribs71. As shown inFIG. 5, the engagement protrusion72of the middle rib71fits into a slit28provided to the bottom plate22. Therefore, the engagement protrusion72serves to position the control key unit A in the height direction H and the width direction W of the frame20.

As shown inFIG. 4, the frame20is fitted in between the hook tabs61. The frame20is sandwiched by the leg components62of the hook tabs61and positioned in the height direction H of the front cabinet11. Also, the engagement prongs63of the hook tabs61engage with the end plates26of the frame20in the width direction W of the frame20. The engagement prongs63work in conjunction with the board receiver51of the front cabinet11to clamp the frame20in the width direction W of the front cabinet11. Furthermore, as shown inFIG. 5, the engagement prongs63engage the protrusions27of the end plates26in the depth direction D of the cabinet10. In other words, spacing between the top portions of the ribs71and the engagement prongs63in the depth direction D of the cabinet10is set to the length of the protrusions27in the depth direction D. The retainer ribs73of the rear cabinet15coupled to the front cabinet11contact with the wiring board30of the control key unit A. As a result, the retainer ribs73and the base component70of the front cabinet11work in conjunction to sandwich the frame20therebetween in the depth direction D.

When the control key unit A is attached to the front cabinet11of the cabinet10, the control key unit A is positioned relative to the cabinet10in three mutually perpendicular axial directions of the cabinet10, namely, the height direction H, the width direction W, and the depth direction D. Thus, the control key unit A can be precisely attached to the front cabinet11without the use of any attachment screws or other such extra parts.

As shown inFIG. 4, with the control key unit A attached to the front cabinet11, the front panel21of the frame20is opposite the board receiver51and the side panel12of the front cabinet11. The key tops23provided to the front panel21are inserted into the openings17made at a plurality of locations and in a vertical layout in the board receiver51. Therefore, the appearance of the television receiver1equipped with the control key unit A can be aesthetically satisfying as shown inFIG. 6. Specifically, with the attachment structure2, the key tops23provided to the control key unit A can be accurately aligned with the openings17in the front cabinet11of the cabinet10.

The procedure for attaching the control key unit A to the cabinet10will now be described in detail.

The wiring board30is mounted on the frame20so that the wiring board30is sandwiched between the first rib array24and the second rib array25. Then, the frame20is pushed in between the hook tabs61in a direction indicated by an arrow N shown inFIG. 1while being placed on the base component70. The leg components62of the hook tabs61deform elastically, allowing the frame20to fit in between the leg components62. The engagement prongs63of the hook tabs61engage the protrusions27and the end plates26of the frame20. Merely by performing this operation, the control key unit A is attached to the front cabinet11of the cabinet10. Then, as shown inFIG. 5, the rear cabinet15is put together with the front cabinet11and coupled. The retainer ribs73of the rear cabinet15contact with the wiring board30of the control key unit A. Therefore, the retainer ribs73of the rear cabinet15work in conjunction with the base component70of the front cabinet11to sandwich the frame20therebetween in the depth direction D of the cabinet10. The protrusions27also work in conjunction with the base component70to clamp the frame20between the hook tabs61and the base component70in the depth direction D of the cabinet10. This concludes the process of attaching the control key unit A.

The engagement protrusion72located on the middle rib71on the front cabinet15is engaged with the slit28of the bottom plate22of the frame20of the control key unit A. Accordingly, when the key tops23are pushed in to operate the key switches40, the engagement protrusion72prevents the frame20from warping away from the board receiver51. As a result, there is no loss tactile feedback when the key tops23are pressed, and furthermore the operation of the key switches40can be carried out more reliably.

With the attachment structure2, the structure of the control key unit A is not limited to the structure illustrated inFIG. 1.

With the attachment structure2for the control key unit A, the wiring board30is mounted on the frame20attached to the cabinet10. The frame20has the key tops23that are operated by being pressed. The key switches40mounted on the wiring board30are located behind the key tops23, respectively. The attachment structure2has the base component70, retainer ribs73, the board receiver51and the engagement member60. The frame20of the control key unit A is placed on the base component70. The retainer ribs73are located on the cabinet10and work in conjunction with the base component70to clamp the frame20. The engagement member60is located on the cabinet10and engages with the frame20that has been placed on the base component70. The board receiver51is formed by a part of the cabinet10, and works in conjunction with the engagement member60to clamp the frame20in a direction that is perpendicular to a clamping direction of the base component70and the retainer ribs73. The board receiver51includes the openings17that expose the key tops23on the outside of the cabinet10. The engagement member60also positions the frame20with respect to the board receiver51in a direction that is perpendicular to both the clamping direction of the base component70and the retainer ribs73, and the clamping direction of the engagement member60and the board receiver51.

With the attachment structure2, the base component70and the retainer ribs73work in conjunction to clamp the frame20of the control key unit A in the depth direction D of the cabinet10. Also, the engagement member60and the board receiver51clamp the frame20in the width direction W of the cabinet10. Furthermore, the frame20is positioned by the engagement member60in the height direction H of the cabinet10. Therefore, there is no need to use attachment screws or other extra parts to attach the control key unit A to the cabinet10. Also, because the control key unit A is positioned with respect to the cabinet10in three mutually perpendicular axial directions, the key tops23provided to the control key unit A are disposed in a state of being accurately positioned in the openings17formed on the cabinet10.

With the attachment structure2, the engagement member60has the hook tabs61with the elastic leg components62and the engagement prongs63. The leg components62are integrally formed with the cabinet10. Each of the engagement prongs63is formed at the distal end of each of the leg components62. The leg components62clamp the frame20. The board receiver51works in conjunction with the engagement prongs63to clamp the frame20.

With the attachment structure2, the control key unit A is temporarily fixed to the front cabinet11merely by utilizing the elasticity of the leg components62of the hook tabs61to fit the control key unit A in between the hook tabs61, and engaging the engagement prongs63with the frame20. The effect here is that the process of attaching the control key unit A to the cabinet10is simplified. Also, the leg components62of the hook tabs61position the frame20. The board receiver51and the engagement prongs63of the hook tabs61work in conjunction to clamp the frame20. Thus, the engagement member60includes both an element for forming the positioning member (the leg components62of the hook tabs61) and an element that faces the board receiver51(the engagement prongs63of the hook tabs61). Therefore, the attachment structure2becomes simpler than when these are constituted separately.

With the attachment structure2, the cabinet10is divided into the front cabinet11and the rear cabinet15that is combined with the front cabinet11. The base component70is formed by the top portions of the ribs71provided at a plurality of places in the front cabinet11. The retainer ribs73are located on the rear cabinet15and hold down the wiring board30mounted in the frame20. With this structure, the ribs71forming the base component70not only serve to clamp the frame20in conjunction with the retainer ribs73, but also have the advantage of reinforcing the front cabinet11. Also, while the ribs71forming the base component70are located on the front cabinet11, the retainer ribs73are located on the rear cabinet15. As a result, the control key unit A can be attached to the cabinet10merely by carrying out the ordinary assembly process for the cabinet10, in which the control key unit A is temporarily fixed to the front cabinet11, after which the rear cabinet15is coupled to the front cabinet11.

With the attachment structure2, the engagement protrusion72engages with the frame20and prevents the frame20from warping away from the board receiver51. The engagement protrusion72is integrally provided to the middle rib71. With this structure, the engagement protrusion72bears the load applied to the frame20when one of the key tops23is pressed. This prevents the frame20from warping. Accordingly, there is no loss of tactile feedback of the key top23, or loss of operational stability of the key switches40, that would otherwise result from warping of the frame20.

As discussed above, with the attachment structure2, it is possible for the control key unit A to be attached quickly and accurately to the cabinet10of the television receiver1without the use of attachment screws. Accordingly, the number of extra parts such as attachment screws is reduced, the components cost and assembly cost become correspondingly lower, and productivity becomes higher.

GENERAL INTERPRETATION OF TERMS

While a preferred embodiment has been chosen to illustrate the present invention, it will be apparent to those skilled in the art from these disclosures that various changes and modifications can be made herein without departing from the scope of the invention as defined in the appended claims. Furthermore, the foregoing descriptions of the preferred embodiment according to the present invention are provided for illustration only, and not for the purpose of limiting the invention as defined by the appended claims and their equivalents.