Control panel for an appliance

A control panel for an appliance includes a tactile switch positioned on a PCB. An elastic spacer sheet is positioned over the PCB, and the tactile switch is disposed within an opening of the elastic spacer sheet. A rigid backer plate is positioned over the elastic spacer sheet, and a plastic film is positioned on the rigid backer plate. A related method for forming a control panel for an appliance is also provided.

FIELD OF THE INVENTION

The present subject matter relates generally to control panels for appliances and methods for producing the same.

BACKGROUND OF THE INVENTION

Appliances generally include a control panel having a plurality of buttons, keys, or other input devices. Utilizing the control panel, an appliance user can input control commands to the appliance and operate the appliance. Certain control panels include tactile switches. Tactile switches have benefits. For example, tactile switches can provide feedback to a user of the appliance during actuation.

Tactile switches can also have drawbacks. For example, constructing a control panel with tactile switches can be problematic due to thickness constraints on control panel components. In particular, tactile switches generally operate when actuated a certain distance. Sizing control panel components to provide consistent actuation while also providing a pleasant cosmetic appearance can be difficult.

Accordingly, a control panel with features for providing uniform tactile switch actuation would be useful. In addition, a method for producing control panels for an appliance that provides uniform tactile switch actuation for each control panel would be useful.

BRIEF DESCRIPTION OF THE INVENTION

The present subject matter provides a control panel for an appliance. The control panel includes a tactile switch positioned on a PCB. An elastic spacer sheet is positioned over the PCB, and the tactile switch is disposed within an opening of the elastic spacer sheet. A rigid backer plate is positioned over the elastic spacer sheet, and a plastic film is positioned on the rigid backer plate. A related method for forming a control panel for an appliance is also provided. Additional aspects and advantages of the invention will be set forth in part in the following description, or may be apparent from the description, or may be learned through practice of the invention.

In a first exemplary embodiment, a control panel for an appliance is provided. The control panel includes a printed circuit board (PCB) having a first surface. A tactile switch is positioned on the PCB at the first surface of the PCB. An elastic spacer sheet is positioned over the PCB at the first surface of the PCB. The elastic spacer sheet defines an opening. The tactile switch is disposed within the opening of the elastic spacer sheet. A rigid backer plate is positioned over the elastic spacer sheet such that the rigid backer plate is positioned opposite the PCB about the elastic spacer sheet. A plastic film is positioned on the rigid backer plate such that the plastic film is positioned opposite the elastic spacer sheet about the rigid backer plate.

In a second exemplary embodiment, a control panel for an appliance is provided. The control panel includes a carrier and a printed circuit board (PCB) having a first surface and a second surface. The second surface is positioned opposite the first surface on the PCB. The PCB is mounted to the carrier at the second surface of the PCB. A tactile switch is positioned on the PCB at the first surface of the PCB. An elastic spacer sheet is positioned on the PCB at the first surface of the PCB. The elastic spacer sheet defines an opening. The tactile switch is disposed within the opening of the elastic spacer sheet. A metal backer plate is positioned on the elastic spacer sheet such that the metal backer plate is positioned opposite the PCB about the elastic spacer sheet. A plastic film positioned on the metal backer plate such that the plastic film is positioned opposite the elastic spacer sheet about the metal backer plate.

In a third exemplary embodiment, a control panel for an appliance is provided. The control panel includes a carrier and a printed circuit board (PCB) having a first surface and a second surface. The second surface is positioned opposite the first surface on the PCB. The PCB is mounted to the carrier at the second surface of the PCB. A tactile switch is positioned on the PCB at the first surface of the PCB. An elastic spacer sheet is positioned on the PCB at the first surface of the PCB. The elastic spacer sheet defines an opening. The tactile switch is disposed within the opening of the elastic spacer sheet. A plastic film adhered to the elastic spacer sheet such that the plastic film is positioned opposite the PCB about the elastic spacer sheet. The plastic film has a thickness of no less than twenty thousandths of an inch.

DETAILED DESCRIPTION

In the present disclosure, when a layer, sheet or plate is being described as “on” or “over” another layer, substrate, sheet or plate, it is to be understood that the layers may either be directly contacting each other or have another layer or feature between the layers. Thus, these terms are simply describing the relative position of the layers to each other and do not necessarily mean “on top of” since the relative position above or below depends upon the orientation of the device to the viewer.

FIG. 1provides a front elevation view of an oven appliance100according to an exemplary embodiment of the present subject matter. As may be seen inFIG. 1, oven appliance100includes a door104with a handle106that provides for opening and closing access to a cooking chamber within oven appliance100. A user of the oven appliance100can place a variety of different items to be cooked in the cooking chamber, and oven appliance100includes heating elements (not shown) for heating the cooking chamber. For example, oven appliance100may include a broil or top heating element and a bake or bottom heating element to provide heat for cooking, as will be understood by those skilled in the art. The top and bottom heating elements can be gas burners, electric resistance heating elements, microwave elements, or combinations thereof. A window110on door104allows the user to view the cooking chamber during the cooking process.

Oven appliance100also includes a user interface or control panel102having a display103and a variety of controls112. Control panel102may be positioned on a top panel114of oven appliance100.FIG. 2provides a front elevation view of control panel102of oven appliance100. Control panel102and controls112allow a user of oven appliance100to select various options for the operation of oven appliance100including e.g., temperature, time, and/or various cooking and cleaning cycles.

Operation of oven appliance100can be regulated by a controller (not shown) that is operatively coupled or in communication with control panel102, the top and bottom heating elements and other components of oven appliance100. As an example, in response to user manipulation of control panel102, the controller can operate the top and bottom heating elements. The controller can also receive measurements from a temperature sensor (not shown) within the cooking chamber and provide a temperature indication to the user with display103. Input/output (“I/O”) signals are routed between the controller and various operational components of appliance100, such as the top and bottom heating elements, controls112, display103, sensor(s), alarms, and/or other components as may be provided. In one embodiment, control panel102may represent a general purpose I/O (“GPIO”) device or functional block.

As will be understood by those skilled in the art, oven appliance100is provided by way of example only. Thus, although shown as a single wall oven appliance in the exemplary embodiment ofFIG. 1, the present subject matter can also be used with other oven appliances. For example, the present subject matter may be used with double wall oven appliances, oven range appliances, etc. In addition, the present subject matter may be used in any other suitable appliance, in alternative exemplary embodiments. For example, the present subject matter may be used with refrigerator appliances, dishwasher appliances, etc.

FIG. 3provides a partial perspective view of certain components of control panel102.FIG. 4provides a section view of control panel102, andFIG. 5provides another section view of control panel102. Control panel102and construction of control panel102are discussed in greater detail below in the context ofFIGS. 3, 4 and 5.

As may be seen inFIG. 3, control panel102includes a carrier120and a printed circuit board (PCB)130. Carrier120may be constructed of or with any suitable material, such as molded plastic. PCB130is mounted or connected to carrier120. Carrier120supports PCB130, e.g., in order to limit deformation of PCB130. Thus, carrier120may be configured to reinforce or support PCB130. As an example, fasteners136may extend through PCB130into a leg, boss or rib122of carrier120, as shown inFIG. 4, to mount PCB130to carrier120.

PCB130has a first surface132and a second surface134. First surface132and second surface134of PCB130are positioned opposite each other about PCB130. Thus, first surface132and second surface134of PCB130are spaced apart from each other. PCB130may be positioned on and/or mounted to carrier120at second surface134of PCB130, and a plurality of tactile switches140is positioned on PCB130at first surface132of PCB130. Thus, tactile switches140and carrier120may be positioned opposite each other about PCB130. A respective one or more of tactile switches140may be associated with each one of controls112on control panel102. Heads138of fasteners136may also be positioned on or at first surface132of PCB130, e.g., such that fasteners136extend from first surface132of PCB130through PCB130into carrier120.

Control panel102also includes an elastic spacer sheet150. Elastic spacer sheet150is positioned over PCB130at first surface132of PCB,130. Thus, elastic spacer sheet150and carrier120may be positioned opposite each other about PCB130. Elastic spacer sheet150defines a plurality of openings152. Tactile switches140are disposed within openings152of elastic spacer sheet150. In particular, each tactile switch of tactile switches140may be disposed within a respective opening of openings152of elastic spacer sheet150.

Control panel102also includes a rigid backer plate160. It should be understood that rigid backer plate160is rigid relative to elastic spacer sheet150but may be less rigid compared to other components of control panel102. Rigid backer plate160is positioned over or on elastic spacer sheet150. Rigid backer plate160may be positioned opposite PCB130about elastic spacer sheet150. Thus, e.g., rigid backer plate160may be mounted to elastic spacer sheet150, and elastic spacer sheet150may extend between and/or connect PCB130and rigid backer plate160. Rigid backer plate160may also define a plurality of openings162, and each opening of openings162of rigid backer plate160may be positioned over and aligned with a respective opening of openings152of elastic spacer sheet150. Thus, tactile switches140may be accessible through elastic spacer sheet150and rigid backer plate160via openings152of elastic spacer sheet150and openings162of rigid backer plate160.

Elastic spacer sheet150and rigid backer plate160may be constructed of or with any suitable materials. For example, elastic spacer sheet150may be constructed of a with a first material, such as a skived plastic foam or elastomer, and rigid backer plate160may be constructed of or with a second material, such as a steel, aluminum or a rigid plastic. The first material may have a Young's modulus that is significantly less than a Young's modulus of the second material. As used herein, the term “significantly less” means no less than an order of magnitude less than when used in the context of Young's moduli. As a particular example, elastic spacer sheet150may be a double-sided foam tape or panel, and the double-sided foam tape or panel may be adhered to and extend between PCB130and rigid backer plate160. Thus, an adhesive may be provided at a first interface154between PCB130and elastic spacer sheet150and/or at a second interface156between elastic spacer sheet150and rigid backer plate160. As another particular example, elastic spacer sheet150may be an elastomer sheet, and rigid backer plate160may be a metal plate that is adhered or mechanically fastened to elastic spacer sheet150.

Control panel102further includes a plastic film170. Plastic film170is positioned on or over rigid backer plate160, e.g., on a smooth or flat surface of rigid backer plate160. For example, plastic film170may be adhered to rigid backer plate160. Plastic film170may be positioned opposite elastic spacer sheet150about rigid backer plate160. Plastic film170may also extend or be positioned over openings152of elastic spacer sheet150and/or openings162of rigid backer plate160. Plastic film170may be elastically deformable such that a user may press on plastic film170above tactile switches140at openings152of elastic spacer sheet150in order to actuate tactile switches140. Graphics may be provided on plastic film170, as shown inFIG. 2, in order to provide an indication of the input or command associated with each tactile switch of tactile switches140.

Elastic spacer sheet150and rigid backer plate160of control panel102may assist with constructing control panel102such that tactile switches140are consistently actuatable by a user. In particular, rigid backer plate160may assist with providing a flat, uniform surface to which plastic film170may be adhered or mounted, e.g., such that bubbling or wave forming on plastic film170is limited or prevented. In addition, elastic spacer sheet150may uniformly position rigid backer plate160and/or plastic film170over tactile switches140, e.g., such that tactile switches140actuate uniformly or evenly across control panel102.

As shown inFIG. 5, rigid backer plate160defines a thickness TB, e.g., at opening162of rigid backer plate160, and elastic spacer sheet150defines a thickness TS, e.g., at opening152of elastic spacer sheet150. Tactile switch140also extends away from PCB130to a distal end142of tactile switch140by a height H, e.g., such that the height H of tactile switch140is defined between first surface132of PCB130and distal end142of tactile switch140. A sum of the thickness TB of rigid backer plate160and the thickness TS of elastic spacer sheet150may be about equal to the height H of tactile switch140. As used herein, the term “about” means within one-half millimeter of the stated value when used in the context of thicknesses and/or heights.

Control panel102may be constructed easily and/or quickly relative to other control panel designs, e.g., due to the tolerances provided by components of control panel102. An exemplary method for constructing control panel102is discussed in greater detail below.

To construct control panel102, PCB130with tactile switches140positioned on first surface132of PCB130may be provided. Openings152of elastic spacer sheet150may also be cut into elastic spacer sheet150. For example, as discussed above, elastic spacer sheet150may be a double-sided foam tape or panel, and the double-sided foam tape or panel may be die-cut to form openings152in the double-sided foam tape or panel. As another example, elastomer spacer sheet150may be molded from an elastomer with openings152formed during molding.

Elastic spacer sheet150may then be positioned on or over PCB130with tactile switches140disposed within openings152of elastomer spacer sheet150. In particular, elastic spacer sheet150may be adhered directly to PCB130. Rigid backer plate160may then be positioned over elastic spacer sheet150. In particular, rigid backer plate160may be adhered directly to elastomer spacer sheet150, e.g., such that elastomer spacer sheet150extends between PCB130and rigid backer plate160. Plastic film170may be positioned on rigid backer plate160before or after positioning rigid backer plate160over elastomer spacer sheet150.

In such a manner, control panel102may be constructed with a short, simple tolerance loop that is robust to process variation in component parts of control panel102. Thus, control panel102may have more uniform actuation force and button feel across controls112on control panel102. In particular, control panel102may be constructed as a near vertical stack assembly relative to other control panel designs. In addition, tooling cost for constructing control panel102may be lower relative to other control panel designs, e.g., when elastomer spacer sheet150is die cut to provide openings152or size elastomer spacer sheet150and/or when openings162of rigid backer plate160are formed with a laser cutter.

FIG. 6provides a section view of a control panel200according to another exemplary embodiment of the present subject matter.FIG. 7provides a top plan view of a button210of control panel200. As may be seen inFIGS. 6 and 7, control panel200includes the similar components to control panel102(FIG. 3) and may be constructed in a similar manner. However, rather than openings162as shown inFIG. 4, rigid backer plate160includes a cantilevered arm or button210over tactile switch140and opening152of elastic spacer sheet150. Button210may provide desirable feedback to a user of control panel200during actuation of tactile switch140. In control panel200, the thickness TS of elastic spacer sheet150may be about equal to the height H of tactile switch140due to button210. As shown inFIG. 7, rigid backer plate160may be cut or otherwise formed to provide button210on rigid backer plate160.

In alternative exemplary embodiments, control panel200may be constructed or assembled without rigid backer plate160. Thus, control panel200need not include rigid backer plate160in such alternative exemplary embodiments. A thickness of elastic spacer sheet150may be relatively large to compensate for removing rigid backer plate160. As an example, the thickness of elastic spacer sheet150may be no less than twenty thousandths of an inch (0.020″), e.g., in order to limit or prevent a wavy appearance for elastic spacer sheet150, and the thickness TS of elastic spacer sheet150may be about equal to the height H of tactile switch140due to button210. In particular, the thickness TS of elastic spacer sheet150may be no more than ten thousandths of an inch (0.010″) greater than the height H of tactile switch140or no more than five thousandths of an inch (0.005″) greater than the height H of tactile switch140, e.g., such that elastic spacer sheet150does not require significant elastic deformation to actuate button210.