This application generally relates to user interfaces, and more particularly to a novel dead-front user interface assembly including a masking layer and a vacuum metalized layer adapted to enhance the optical clarity of illuminated text and/or iconography.
Consumer appliances generally include one or more user interfaces configured to facilitate the interaction between a user and the appliance. Many user interfaces provide visual feedback regarding the status of a product feature in the form of visible text and/or iconography. To enhance the simplicity of operating an appliance, dead-front assemblies (comprising overlays or panels) were developed to make such text or iconography only visible under certain circumstances, for example, in response to a user's operation of the user interface or based on the status of a particular feature. To accomplish this purpose, some dead-front assemblies include a masking layer defining one or more openings for the passage of light to selectively illuminate text and/or iconography on the user interface. The masking layer also serves to block light from passing through concealed portions of the masking layer. To perform this function, a masking layer is generally made with dark-colored inks (e.g., black or navy blue) that effectively absorb light energy.
Dead front assemblies also generally include a coating layer intended to match a color of the user interface or the appliance in which the dead front assembly is received or mounted. But applying a light-colored coating layer (e.g., a white layer) over a dark-colored masking layer (e.g., black layer) is not feasible due to color bleed, whereby the intended color of the coating layer is altered by the color of the masking layer. Accordingly, some manufacturers use a masking layer comprising a light color (e.g., gray) to preclude color bleed. However, concealed portions of a light-colored masking layer may still glow when light is illuminated thereon, thereby compromising the optical clarity of the text and/or iconography illuminated on the user interface. Alternatively, some manufacturers apply multiple coating layers over a masking layer to conceal the evidence of the underlying masking layer. However, each additional coating layer reduces the amount of light that may pass through the dead front assembly, thereby resulting in blurry or dimly illuminated text or iconography. Therefore, it is desired to provide an improved dead front assembly that can resolve the foregoing issues.
The following presents a simplified summary of the disclosure in order to provide a basic understanding of some example aspects described in the detailed description. This summary is not an extensive overview. Moreover, this summary is not intended to identify critical elements of the disclosure nor delineate the scope of the disclosure. The sole purpose of the summary is to present some concepts in simplified form as a prelude to the more detailed description that is presented later.
In accordance with one aspect, there is provided a dead front assembly for a user interface of a component. The dead front assembly includes a masking layer, a coating layer, and a vacuum metalized layer. The masking layer includes an opening defining a two-dimensional graphic. The vacuum metalized layer is disposed between the masking layer and the coating layer and is configured to conceal the masking layer and preserve an intended color of the coating layer. The coating layer is configured to match a flat, non-metallic color of the component and conceal the vacuum metalized layer.
In accordance with another aspect, there is provided a user interface for a component. The user interface includes an illumination element configured to transmit emitted light. A molded component is arranged proximate the illumination element. In addition, a dead front assembly is disposed on the molded component. The dead front assembly includes a masking layer, a coating layer, and a vacuum metalized layer that is disposed between the masking layer and the coating layer. The masking layer includes an opening defining a two-dimensional graphic. Emitted light is selectively transmitted through the opening to convey user information. Further, the coating layer is configured to match a color of said component.
In accordance with yet another aspect, a method of forming a user interface of a component includes producing a dead front assembly by arranging a vacuum metalized layer between a coating layer configured to match a color of and a masking layer, and a masking layer defining a two-dimensional graphic for the passage of light therethrough. The method also includes applying the dead front assembly onto a molded component forming part of the user interface.
The accompanying drawings, which are not necessarily to scale, show various aspects of the disclosure.
The present disclosure generally relates to user interfaces for consumer appliances and/or devices, and more particularly to a dead-front assembly configured for use in light-colored (e.g., white) user interfaces and components in which the dead front assembly is received or mounted. Although the various examples herein illustrate a dead-front assembly described for use in a user interface of a refrigerator appliance, it should be understood that the various inventions described herein are also suitable for use in other devices, including, but not limited to, dishwashers, microwaves, ovens, ranges, clothes washers, dryers, coffee makers, blenders, air-conditioners, small electronic devices (e.g., thermostats, air-purifiers, voice assistant devices), office equipment, vehicles, industrial machinery, and the like.
Turning now to the drawings,
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The printed circuit board assembly 140 includes a printed circuit board 141 and a plurality of capacitive sensors 142 (i.e., arranged beneath the touch zones 164 as part of the capacitive touch buttons) and light elements 144 (e.g., illumination elements such as LEDS, bulbs, lamps, and the like) arranged thereon. The light elements 144 are selectively illuminable when the capacitive sensors 142 are actuated. In some embodiments, the capacitive sensors 142 are actuated when a user presses the touch zones 164. In such embodiments, it is contemplated that conductive spring elements 143 may be disposed between the touch zones 164 and the capacitive sensors 142 to facilitate actuating the capacitive sensors 142. For example, each conductive spring elements 143 can be affixed to the printed circuit board 141 about one capacitive sensor 142, and can extend upwards into contact with a bottom surface of the molded part 170. In some embodiments, actuating the capacitive sensors 142 will cause a controller (not shown) to actuate the corresponding light elements 144 arranged on the printed circuit board 141. While the examples described herein disclose capacitive sensors 142, it should be appreciated that other examples of control sensors may be utilized to selectively actuate the light elements, for example, resistive touch sensors, infrared touch sensors, tactile control elements, rotary encoders, proximity sensors, timers, and the like.
The printed circuit board assembly 140 may include a plurality of light guides 150 arranged on the board 141 aligned with the plurality of light elements 144 disposed thereon. Specifically, each light guide 150 may comprise a plurality of openings 152 extending between an upper surface 150a and a lower surface 150b thereof. Each opening 152 is positioned to direct light emitted from a respective light element 144 toward a corresponding opening 192 in a masking layer 190 of the dead front assembly 160, as discussed in detail below.
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The molded part 170 embodies a plastic component formed during a plastic injection process. Where capacitive touch sensors 142 (
In the illustrated embodiment, the molded part 170 is arranged between the printed circuit board assembly 140 and the dead front assembly 160. In some embodiments, the molded part 170 is formed with the dead front assembly 160 integrally applied thereon via an in mold decorative process. In such embodiments, it is contemplated that a transfer foil (not shown) is utilized to apply the dead front assembly 160 to molten plastic (e.g., injected into a mold cavity) during the plastic injection process. It is also contemplated that the molded part 170 may be formed with the dead front assembly 160 integrally formed thereon, for example, in embodiments wherein the dead front assembly is provided in the form of an in-mold label that is fused to molten plastic during the plastic injection process.
In other embodiments, the molded part 170 embodies an independently formed component defining a substrate for receiving the dead front assembly 160 thereon, for example, in embodiments wherein the dead front assembly 160 is provided in the form of a pressure sensitive label that is applied onto an upper surface 170a of the molded part 170. In such embodiments, it is contemplated that the dead front assembly 160 may comprise a plastic carrier (not shown) that may be peeled off to expose an adhesive printed onto a lower-most layer (e.g., the masking layer) of the dead front assembly 160, for example, when applying the dead front assembly 160 to the molded part 170.
It is contemplated that the molded part 170 may be made of a transparent material to enable light transmitted from the printed circuit board assembly 140 to pass therethrough. In some embodiments, it is contemplated that the molded part 170 may be easily deformable in the vicinity of the touch zones 164
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In some embodiments, the respective layers 190, 210, 220, and 230 may be separately printed to form part of a label, for example, via a silk screen printing (e.g., serigraphy) or flexographic printing process. In such embodiments, it is contemplated that some of the layers may be provided in sheet stock, for example, the hard coat layer 230 and/or the vacuum metalized layer 200. In these embodiments, it is contemplated that the hard coat layer 230 or the vacuum metalized layer 200 may define a substrate for printing other layers thereon.
Turning now to each respective layer, the masking layer 190 is disposed on the upper surface 170a of the molded part 170. The masking layer 190 includes an upper surface 190a and a lower surface 190b. A plurality of openings 192 extend between the upper surface 190a and the lower surface 190b and are aligned with the light elements 144 on the printed circuit board assembly 140 and with the plurality of openings 152 of the light guide 150. It is contemplated that the openings 192 may be formed via serigraphy or lithography.
In general, the plurality of openings 192 define a two-dimensional graphic comprising visual iconography or text that is selectively made visible (i.e., illuminated) by the user interface 120. In the illustrated embodiment, the plurality of openings 192 define a plurality of seven-segment displays for selectively displaying numerical temperature information on the user interface 120. Yet, it should be appreciated that the plurality of openings 192 may define other examples of visual iconography or text, for example, when it is desired to selectively display other forms of user information. For instance, and referring to
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Distinctively, the vacuum metalized layer 200 serves to conceal structure disposed beneath the vacuum metalizing layer 200, i.e., the underlying masking layer 190, the molded part 170, and the printed circuit board assembly 140. To perform this function, the vacuum metalized layer 200 comprises a thin layer of a reflective metallic coating (e.g., silver, tin, or gold) that serves to reflect ambient light A (to thereby conceal the underlying masking layer 190) while being translucent to light L emitted from light emitting structure (e.g., LEDs or similar) on the printed circuit board assembly 140.
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Additionally, because the vacuum metalized layer 200 comprises a metallic coating (e.g., gold, tin, silver), it has a significantly lighter color than the underlying masking layer 190, which preferably comprises a dark-colored ink (e.g., black, navy blue) as discussed in detail above. In this manner, the vacuum metalized layer 200 serves as an effective primer for enabling a light-colored coating layer 210 (e.g., a non-black color such as white) to be printed thereon such that the color of the masking layer 190 does not bleed through and alter the color of the coating layer 210. In other words, the vacuum metalized layer 200 is configured to preserve the intended color of the masking layer 190, e.g., such that the intended color of the masking layer is not altered (via color bleed) based on the darker colors of the underlying layers, for example, a black or navy-blue masking layer. This aspect of the disclosure is also beneficial for reducing the number of coating layers 210 printed on the masking layer 190, because absent the vacuum metalized layer 200, multiple coating layers 210 (e.g., of a light, non-black color such as white or gray) would be required to conceal the darker color of the underlying masking layer 290.
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Because the vacuum metalized layer 200 serves as an effective primer, a relatively light-colored (e.g., white, light blue, grey) coating layer 210 may be printed over the vacuum metalized layer 200 (thereby concealing the vacuum metalized layer and the masking layer) in one pass without being susceptible to color bleed, e.g., due to a darker-colored masking layer disposed beneath. This aspect of the present disclosure is particularly beneficial for enabling light transmitted through the coating layer 210 to remain optically clear. This is in distinction to embodiments wherein multiple coating layers are required to form a dead front assembly, which adversely affects the resulting clarity and color of the user information 162 (
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Although, in other embodiments, it is contemplated that the dead front assembly 160 may not require an indicia layer 220 (see, e.g.,
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Additionally, the hard coat layer 230 serves to maintain the optical clarity of the user information 162 (
In summary, the dead front assemblies according to the various inventions disclosed herein effectively enhance the optical clarity of illuminable iconography and text displayed by a user interface. Additionally, according to the present disclosure, the inventions facilitate implementing light-colored dead front user interfaces for use in light-colored components (e.g., white appliances, devices, equipment, etc.).
While the various inventions disclosed herein have been described with reference to the example embodiments described above, it should be understood that modifications and alterations will occur to others upon a reading and understanding of this specification without departing from the spirit and scope of the invention set forth in the appended claims. Example embodiments incorporating one or more aspects of the invention are intended to include all such modifications and alterations insofar as they come within the scope of the appended claims and their equivalents.
Moreover, while the foregoing description begins with a discussion of a lower-most component and concludes with a discussion of an upper most element, it should be understood that the order of discussion is not limiting and is only provided for ease of describing the various examples of dead front assemblies disclosed herein. Similarly, the positions (e.g., upper, lower) described herein are provided for ease of disclosing the illustrated embodiments. In this manner, it should be appreciated that positions would be different in other embodiments without departing from the scope of the present disclosure, for example, when viewing a dead front assembly from a different view than that which is shown in the drawings.