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.

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.