Patent Application
20100025214
The present invention relates to appliance control panel constructions, and particularly to constructions of control panels, switches and electronics assemblies and housings suitable for use in laundry appliances, such as automated laundry washing machines and dryers.
Automated laundry appliances (such as laundry washing machines and dryers) typically include an external generally rectangular cabinet, a control panel for controlling the washer/dryer operation, and a hinged lid or door that may be swung open to provide top or front-load access to a rotatable cylindrical wash basin (in the case of a washer). In use of an automated laundry washing machine, after placing a load of laundry in the wash basin, along with a suitable type and quantity of laundry detergent, a wash process is initiated by an operator through interaction with the control panel. Similarly, with a dryer, a wash load drying process is initiated through interaction with a control panel. The control panel provides a user interface through which a user may make selections of cycles and various wash (or dry) control parameters. Controlled operation sequences may be carried out using an electronic controller that may, e.g., be provided as an integral part of the control panel, or mounted separately and suitably connected therewith. Such a controller may comprise one or more suitably programmed microprocessors or application specific integrated circuits (ASICs), operably connected to suitable circuitry, e.g., for driving the wash basin drive motor, actuating operation components (e.g., valves and a pump) to fill the wash basin and drain it, dispense additives, etc. Such operations will be carried out in accordance with commands of the controller, generated on the basis of program control and possibly also signals received from various sensors monitoring various operation-related parameters.
In a modern trend, laundry appliances are taking on a more prominent stylistic role in the home. Along with this, greater emphasis is being placed on convenience, user friendliness and the “look and feel” of laundry appliances. To this end, greater use is being made of LED lighting and other control panel arrangements and features that may be more aesthetically attractive and easier to use. In addition, the range of functionalities and operation options provided in laundry appliances has increased appreciably. As more functionality is packed into a control panel, it becomes a greater and greater challenge to arrange the components for ease of use, e.g., for function and options selection. At the same time, the added complexity presents additional challenges from a manufacturing/assembly standpoint. A control panel construction capable of long term reliable operation, and that facilitates both consumer use and appeal, and the manufacture/assembly of the appliance, would be a significant contribution. Various efforts have been made in this regard.
Song U.S. Pat. No. 6,750,407 discloses, in a laundry appliance, a control panel assembly with operation buttons provided as part of a film applied to the outside of the control panel. An electronics enclosure is provided for retaining a PCB, and a “frame” in the form of a plate that overlays the PCB on its front. The frame provides light guiding supporters 54, and “intermediate buttons” in the form of planar springs. See
Kim et al. PGP 2005/0178167 discloses groups of “windows” flexibly joined (ganged) together so as to compensate for dimensional discrepancies in a control panel assembly.
Kim et al. PGP 2005/0178166 discloses non-illuminated button sleeve couplers ganging together (flexibly joining) a plurality of button sleeves and groups of button sleeves, to thereby compensate for dimensional discrepancies in a control panel assembly.
Kim PGP 2006/0016096 disclosures a control panel with an “LED window” provided with a “refracting member so as to exactly display light outside through the display hole.” Abstract.
Kim PGP 2005/0145468 discloses an LED illuminated control panel assembly wherein an elastic button is coupled directly to the rear side of the front control panel (see, e.g.,
Aspects of the present invention provide a construction that unitizes the control panel electronics of a laundry appliance, i.e., washer or dryer. An electronics enclosure and associated components form a self-contained, unitized assembly, including control buttons and illuminated indicator elements that can be mated as a single piece with an outer user interface control panel (fascia). Such an arrangement can facilitate assembly during production, as well as disassembly for any maintenance/repair.
In another aspect of the invention, a front panel of the electronics enclosure provides a mounting location for various buttons and lighted indicators that will show through mating apertures provided in the control panel fascia. This may include light pipe collars and integral spring levers. An aspect of the integral spring levers is that raised surface portions extending in a closed loop are formed at the ends of the spring levers to surround, in spaced relation, a rearward contact portion of an associated push-button, and thereby serve to provide electrostatic discharge (ESD) protection to the underlying switch and printed circuit board (PCB).
Relatedly, a mount of planar spring button pieces on the front enclosure panel, over the associated spring levers with cups, results in an assembly incorporating two springs serving to bias the associated button to its return position. In addition to assuring a positive button return action, the second planar spring formed with the button serves to keep the button post and mating cup firmly engaged, to thus avoid rattle or looseness that might otherwise result from the play between the separate parts.
In a further aspect, the inventive construction provides, as a single molded part, a linear array of sleeves that, upon installation, surround a corresponding linear array of control panel operation buttons. The sleeves are light transmissive so as to provide decorative, button location identifying illuminated rings in the operation control panel of the appliance. Each sleeve is associated with a light pipe that extends rearwardly from the sleeve. The light pipe stem is sized and configured to place an end surface thereof directly in front of a corresponding light source, e.g., a printed circuit board (PCB) mounted light emitting diodode (LED). The light pipe may be provided in the form of a curved and tapered stem extending rearwardly from a cylindrical wall portion adjacent the rear cylindrical end of the sleeve.
In another aspect, the invention provides a push-button with an integrally formed planar spring mounting base, that may be backlit, such as by a PCB mounted LED. In the design, the elastic arms, which connect the button to a surrounding support, comprise linear segments extending at right angles to each other and tangentially of the button, so as to form rectangular inside corners. The button body includes a tubular (e.g., cylindrical) portion extending rearwardly from the depressible face of the button, through the spring plane and beyond the mounting base. The mounting base allows the button body to be mounted on the front panel of an electronics enclosure that houses the PCB.
The above and other objects, features and advantages of the present invention will be readily apparent and fully understood from the following detailed description of preferred embodiments, taken in connection with the appended drawings.
a and 9b are enlarged perspective views of component parts of the control panel assembly shown in
a is a section cut taken on the section line A-A shown in
b is a section cut taken on the section line B-B shown in
Referring to
Referring now to
The illustrated main control knob 9 is rotatable in order to permit the user to select operation cycle settings and other control parameters, with reference to selections indicated by words, icons or other indicia that may be arrayed (in printed form or otherwise) on fascia 8 about the control knob. Illumination elements 13 are also arrayed about the control knob 9 to provide a visual indication of a particular operation selection corresponding to the knob position, the progression of which may be visually indicated on display screen 11. Alternatively, illumination of elements 13 may indicate the current operation state in the case of a progressive wash/dry operation comprising multiple sequential cycles or stages. As will be described, these and other illumination elements of control panel assembly 7 may comprise light pipes that serve to transmit light from a source behind the panel, such as printed circuit board (PCB) mounted light emitting diododes (LEDs), to the surface of the control panel fascia 8. A central shaft of the main control knob is operably connected to the shaft 14 of a rotary encoder (see
Option selections and input prompts may appear on the LCD screen display 11 as a result of program control executed by a CPU, ASIC or the like. Display screen 11 may be overlaid by a transparent window 16 (see
A relatively large operation push-button 19 may be used as a main power switch control to turn the appliance on or pause the operation. A smaller push-button 21 next to that may serve as an operation cancel button.
Further to the right are a series of additional push-buttons 23 (e.g., two or three) of intermediate size. Above each of these buttons is a linear array of illumination elements, i.e., light indicators 25. The illustrated dryer embodiment of
To the right side of buttons 23 and light indicator arrays 25 is a vertical linear array of small push-buttons 26. These may serve to allow user selection of additional options that may be added to the selected cycle. As will be described, push-buttons 17 and 26 may be surrounded by light transmitting sleeves providing rings of light about each button.
In the present inventive arrangement, the various operation buttons and other control panel components are mounted on first and second a front enclosure panels 27, 28 which are mated with a rearward electronics enclosure housing 29 (see, e.g.,
Referring to
A progressive disassembly of control panel assembly 7 is sequentially illustrated beginning with
In
The horizontally arranged linear array of push-buttons 17, and the vertically oriented linear array of push-buttons 26, are similarly each integrally molded as a single piece. These structures are more clearly illustrated in
As mentioned, the front facing enclosure panels 27 and 28 collectively provide a mounting location for various buttons and lighted indicators that will show through the mating apertures provided in the outer control panel fascia 8. This includes light pipe receiving collars 59. The large hole 65 in front enclosure panel 27, accommodates a PCB-mounted buzzer/sound generation device 67 to provide audible user alerts, such as end-of-cycle signals. In addition, a plurality of button spring levers 61 are formed integrally as part of the front enclosure panel 27, as will now be described with reference to
Spring levers 61 serve to provide a flexible mount for the variety of operation push-buttons included in the control panel assembly. Each includes a cantilever-mounted resilient spring arm that provides a spring bias to return its associated button to its rest position after being depressed to actuate an associated switch, and then released. An aspect of the integral spring levers 61 is that cup structures 63 are integrally molded at the free ends of the spring arms and serve an electrostatic discharge (ESD) protection function. These cups 63, formed by raised surface portions (e.g., a wall or rib) extending in a closed loop, receive in them, in a surrounding and spaced relationship, columns or posts protruding rearwardly from the centers of associated push-buttons, e.g., the three push-buttons 17, as seen in
Although the cup structures may be configured to serve a push-button centering or retention function in addition to their ESD protection function, this is not the purpose of the cups in the illustrated embodiment. Since other structure is provided to assure proper registry of the switch actuation mechanism, the cups 63 can be more freely configured to maintain an ESD protection-enhancing spacing between the cup walls and the push-button post or column.
In the illustrated embodiment, the buttons that mount on the spring levers 61 include, themselves, planar button springs. As mentioned, and with reference to
The mount of the planar spring button pieces on the front enclosure panel 27, over associated spring levers (an arrangement present for each button shown, except button 19, to be described separately), results in an assembly incorporating two springs per button serving to bias the associated button to its return position. This arrangement can be seen, e.g., in
Referring now to
Each sleeve is associated with an integrally formed light pipe 71 that extends rearwardly from the sleeve 69, through apertures provided in the associated button-mounting base/platform, e.g., mounting bases 55a, 55b. The stem of each light pipe 71 is sized and configured to place an end surface thereof directly in front of a corresponding LED 74 mounted on PCB 58 (see
The light pipes 71 may be provided in the form of a curved and tapered stem extending rearwardly and laterally from a generally central, or further rearward, cylindrical wall portion of the sleeves 69, to the associated LEDs 74, which are offset from the central axes of their respective buttons. In the illustrated embodiments, the light pipes have a generally rectangular cross-section with rounded corners. Circular, oval or other cross-sectional shapes could be used. The light pipes transmit light from the LEDs 74 to the sleeves 69, and the sleeves transmit light along their lengths, so as to illuminate the exposed cylindrical front ends thereof in such a manner as to create a ring of light surrounding the associated button. The common mounting bases 55a, 55b may include opaque walls or blinds between the adjacent buttons in order to avoid light bleed between the illuminated buttons/sleeves, which might otherwise cause uneven lighting. Such blinds 70a, 70b, associated respectively with mounting platforms 55a, 55b, are best seen in
The linear array of sleeves 69 and light pipes 71 are integrally molded with, and interconnected by, a common planar connecting element 72 which may serve as a runner in the molding process. The planar connecting element 72 includes relatively short, thin connecting members 73 that extend from the elongated, wider main body 75 of the planar connecting element to each of the sleeves 69. The sleeves 69, the light pipes 71 and the planar connecting element 72 may be integrally formed of the same light transmissive (e.g., transparent) plastic material, such as by injection molding. Upon installation, the sleeves 69, light pipes 71 and planar connecting element 72 are all fixed within the control panel assembly, with the sleeves in surrounding relationship with their respective buttons.
The light transmissive joint 77 between the sleeves 69 and their associated light pipes 71 is specially configured to obtain an even distribution of light around the cylindrical body of the sleeve 69, so as to emit a bright even ring of light from the opposite front end 70 of the button sleeve 69, which is exposed on the front face (fascia 8) of the control panel, in surrounding relationship with the associated button. As shown, the front end 70 has a slight taper or draft and a shoulder at its base. This configuration assists with proper flush positioning/mating of the ring 70 in a correspondingly configured hole of fascia 8. In addition, the configuration allows for a greater wall thickness, which can improve molding and increase light transmission below the surface while achieving the desired visible ring thickness above the surface. Optimally, in conjunction with some surface texturing on the visible front end (ring) 70, the configuration can be effective to substantially avoid noticeable concentrated points of light (“hot spots”).
Instead of simply abutting with a rear end of the light transmissive sleeve 69 parallel to the sleeve axis, so as to point directly toward the opposite front end to be illuminated, the joining portion 77 of the light pipe 71 extends to the sleeve wall tangentially. The “direct line of sight” of the pipe is toward an opposite side of the ring and at a relatively small forward angle pointing toward a wall portion just rearwardly of the front surface of the ring, so as to direct light toward, but not directly our of, the front surface. The forward angle will vary depending, e.g., on the connection point of the pipe to the sleeve, and the length of the sleeve. In the illustrated embodiment of part 57a, the angle is approximately 35°, and in the illustrated embodiment of part 57b, the angle is approximately 16°. In addition, the joining portion 77 of the light pipe stem 71, along with the adjacent arcuate portion, flares gently to a larger width section which joins with the cylindrical sleeve wall generally tangentially. The result is that light is able to be dispersed about the circumference of the sleeve 69 and be evenly transmitted to the exposed end (ring) 70 to be illuminated. The configuration generally directs the light in such a circumferential, forwardly directed, manner as to “spiral” along the cylindrical walls of the sleeve from the point of entry to the opposite front end (ring) 70 to be illuminated.
With reference now to
The button body includes a tubular (e.g., cylindrical) portion 85 extending rearwardly from the depressible face of the button 19, through the spring plane and beyond the mounting base 78. The mounting base 78 allows the button body to be mounted on front panel 27 of the electronics enclosure housing 29, such as with resilient spring tabs 86. When so mounted, and as seen in
a shows a modified construction of button 19, formed in a 2-shot injection molding process. In this embodiment, a main base portion 91 may be formed of transparent polycarbonate; an over molded cap portion 93 may be formed of ABS, and that part may be chrome-plated. An icon, such as is visible on the face of button 19 seen in
In the illustrated embodiments, the control panel assembly and components are implemented in a control panel of an automated laundry washing machine and dryer. It will be understood, however, that aspects of the invention may be applied to other automatic washing/drying appliances, e.g., dishwashing machines, and to electronic appliances in general.
The present invention has been described in terms of preferred and exemplary embodiments thereof. Numerous other embodiments, modifications and variations within the scope and spirit of the appended claims will occur to persons of ordinary skill in the art from a review of this disclosure.
