Electrical switching unit for an electrical device

Abstract

An electrical switching unit for an electrical device is disclosed, comprising a housing and a signaling module. The housing accommodates an actuator movably installed in the housing. The signaling module comprises a printed circuit board comprising a first region with a variable resistance element having a contact surface of the variable resistance element; a foil comprising a first foil contact surface and a second foil contact surface, wherein the first foil contact surface of the foil has a first electrically conductive layer, and wherein the electrically conductive layer of the first foil contact surface is spaced from the contact surface of the variable resistance element by a spacer element;and a movable member operatively connected to the actuator and capable of advancing the electrically conductive layer of the first foil contact surface to form contact with the contact surface of the variable resistance element in a plurality of contact point structures, such that the effective resistance of the variable resistance element is configured to change in response to advancing the electrically conductive layer of the first foil contact surface to form contact with the contact surface of the variable resistance element in each of the plurality of contact point structures.;

Description

Technical area

[0001] The present invention relates to an electrical switching unit for an electrical device, such as an electrical device and a garden tool. State of the art

[0002] Some electrical devices, such as power tools and electric garden tools, convert input DC power into mechanical power in the form of output torque or motion by using a brushed or brushless DC motor.Typically, the electrical device includes the following: a variable speed trip mechanism; an electrical switch contact used to selectively connect and disconnect a DC power supply and a DC motor in response to movement of an actuator of the variable speed trip mechanism; a motor signaling circuit used to transmit an electrical signal indicative of a DC motor speed required in response to movement of the actuator; and a motor control circuit including power switching means used to selectively energize a stator winding input of the DC motor in response to the signal received from the motor signaling circuit to allow the DC motor to operate at the required speed.

[0003] Conventional speed control in electrical devices is achieved by a potentiometer or similar device. Such a potentiometer or similar device is provided with a variable resistor mounted on a circuit board, e.g., a thin carbon foil. In response to the movement of the actuator, for example, the effective resistance of the thin carbon foil can be changed by sliding an electrically conductive slide bar of the potentiometer across the surface of the thin carbon foil. A variable voltage measured by a variable resistor can be used as the basis for indicating the movement of the actuator and controlling the speed of an electric motor.Because the thin carbon foil is subjected to repeated sliding motion of the electrically conductive slide bar, the thin carbon foil and the electrically conductive slide bar can be subject to considerable wear, which can ultimately lead to inaccurate or unstable speed control. Furthermore, the thin carbon foil is frequently exposed to contaminating particles, which not only tend to short-circuit a track on the electrically conductive slide bar, but can also exacerbate the damage caused by the electrically conductive slide bar scraping along the thin carbon foil.

[0004] The applicant's previously filed US patent for the invention US10547257B2 discloses a variable speed controller for an electrical device. The presence of a foil between a variable resistance element and a sliding block contributes to reducing wear on a contact surface of the variable resistance element and the wear on the sliding block, both because they are not in direct physical contact. Therefore, compared to a conventional variable speed controller, the reliability and stability of the variable speed controller's operation can be maintained over a longer service life. Furthermore, the presence of the foil can help prevent contaminants from inadvertently short-circuiting the track on the contact surface of the variable resistance element, thus contributing to reducing unstable or inaccurate operation of the variable speed controller.The contact surface of the variable resistance element in the patent includes a first region and a second region, wherein the first region and the second region are arranged in at least one of a series and parallel configuration. It is necessary to selectively electrically bridge various paths in the first region with an electrically conductive layer in the second region in order to selectively apply a variable voltage to an input pin of an integrated circuit chip, thereby changing the speed of the electric motor. However, since the paths in the first region and the electrically conductive layer in the second region are arranged in parallel in the same plane, the required space is relatively large and the material cost is relatively high. Contents of the present invention

[0005] The present invention aims to solve at least one of the above-mentioned problems.

[0006] The present invention relates to several general embodiments. Embodiments of the present invention may include one or any combination of various general embodiments described herein.

[0007] In a first general embodiment, the present invention provides an electrical switching unit for an electrical device used to control an operation of a DC motor of the electrical device, the electrical switching unit comprising: a housing accommodating an actuator movably installed in the housing, the actuator being configured to move, in response to operation of a finger-actuable trigger, to an ON position from an OFF position in a direction toward an interior of an opening in the housing along a movement axis and to move to the OFF position from the ON position in a direction toward an exterior of the opening in the housing along the movement axis; and a signaling module linked to the electrical switching unit and a motor signaling circuit, wherein the motor signaling circuit is configured to detect a movement of the actuator and used to output a signal from the signaling module indicating the movement or position of the actuator; wherein the signaling module comprises: a circuit board having a first region having a variable resistance element, the variable resistance element having a contact surface of the variable resistance element; a foil comprising a first foil contact surface and a second foil contact surface, wherein the first foil contact surface of the foil has a first electrically conductive layer, wherein the electrically conductive layer of the first foil contact surface is spaced from the contact surface of the variable resistance element by a spacer element and thus a space is formed therebetween, and wherein one end of the first electrically conductive layer of the first foil contact surface is electrically connected to the circuit board;and a movable member operatively connected to the actuator, thus the movable member moving in response to movement of the actuator relative to the second foil contact surface of the foil and being capable of promoting the first electrically conductive layer of the first foil contact surface to form contact with the contact surface of the variable resistance element in a plurality of contact point structures, and thus the effective resistance of the variable resistance element is configured to change in response to promoting the first electrically conductive layer of the first foil contact surface to form contact with the contact surface of the variable resistance element in each of the plurality of contact point structures.;

[0008] Preferably, the variable resistance element is a continuously variable resistor or is connected by connecting several resistors with fixed values ​​in series.

[0009] Preferably, an exhaust air opening passing through the top and bottom of the circuit board is arranged at a position on the circuit board corresponding to the room.

[0010] Preferably, one end of the first electrically conductive layer of the first foil contact surface is in contact with the circuit board.

[0011] Preferably, the end of the first electrically conductive layer of the first foil contact surface corresponding to the second foil contact surface is configured with a contact spring, under the pressure of which the end of the first electrically conductive layer of the first foil contact surface can be conveyed such that it is in contact with the circuit board.

[0012] Further preferably, the end of the first electrically conductive layer of the first foil contact surface is bonded to the circuit board by an electrically conductive adhesive layer.

[0013] Preferably, the electrical switching unit further comprises: a pair of electrical switch contacts, at least one of the pair of electrical switch contacts being operatively connected to the actuator, wherein, in response to movement of the actuator from the OFF position to the ON position along the axis of movement, the pair of electrical switch contacts is arranged as a closed structure such that power from a DC power supply can be supplied to the DC motor via the pair of electrical switch contacts; and wherein, in response to movement of the actuator from the ON position to the OFF position along the axis of movement, the pair of electrical switch contacts is arranged as an open structure such that no power from the DC power supply can be supplied to the DC motor via the pair of electrical switch contacts; a power module comprising at least one solid-state power switching device for controllably supplying power from the DC power supply to the DC motor; and a control module comprising a control circuit used to receive a signal from the signaling module and to output a signal from the control module in response to the received signal from the signaling module to control the at least one solid-state power switching device of the power module, wherein the at least one solid-state power switching device controllably supplies power from the DC power supply to the DC motor to enable the DC motor to operate at a speed corresponding to the movement or position of the actuator.

[0014] In another general embodiment, the present invention provides an electrical switching unit for an electrical device used to control an operation of a DC motor of the electrical device, the electrical switching unit comprising: a housing accommodating an actuator movably installed in the housing, the actuator being configured to move, in response to operation of a finger-actuable trigger, to an ON position from an OFF position in a direction toward an interior of an opening in the housing along a movement axis and to move to the OFF position from the ON position in a direction toward an exterior of the opening in the housing along the movement axis; and a signaling module linked to the electrical switching unit and comprising a motor signaling circuit, the motor signaling circuit being used to detect movement of the actuator and to output a signal from the signaling module indicating the movement or position of the actuator; wherein the signaling module comprises: a circuit board comprising a first region having a variable resistance element and a second region having a signal control element, the first region and the second region being arranged to be physically separate and spaced apart from each other, the variable resistance element having a contact surface for the variable resistance element and the signal control element having a contact surface for the signal control element; and a film comprising a first film contact surface and a second film contact surface, wherein the first film contact surface of the film has a first and a second electrically conductive layer, wherein the first and the second electrically conductive layer of the first film contact surface are each spaced from the contact surface of the variable resistance element and the contact surface of the signal control element by a spacer element, thus forming a space therebetween, and wherein one end of the first and the second electrically conductive layer of the first film contact surface is each electrically connected to the circuit board; and a movable member operatively connected to the actuator, the movable member thus moving in response to movement of the actuator relative to the second foil contact surface of the foil and being capable of promoting the first electrically conductive layer of the first foil contact surface to form contact with the contact surface of the variable resistance element in a plurality of contact point structures, and thus the effective resistance of the variable resistance element is configured to change in response to promoting the first electrically conductive layer of the first foil contact surface to form contact with the contact surface of the variable resistance element in each of the plurality of contact point structures; wherein, in response to movement of the movable component along the second foil contact surface of the foil, the second electrically conductive layer of the first foil contact surface can be promoted to make contact with the contact surface of the signal control element in a plurality of contact point structures, whereby an effective resistance of the signal control element is configured to change in response to the second electrically conductive layer of the first foil contact surface being promoted to make contact with the contact surface of the signal control element in each of the plurality of contact point structures; or wherein the circuit of the signal control element is configured to switch the signal in response to the second electrically conductive layer of the first foil contact surface being promoted to make contact with the contact surface of the signal control element in one of the plurality of contact point structures.

[0015] Preferably, the variable resistance element is a continuously variable resistor or is connected by connecting several resistors with fixed values ​​in series.

[0016] Preferably, the signal control element is a continuously variable resistor, is connected by connecting a plurality of resistors with fixed values ​​in series, or is a normally closed / normally closed circuit. Preferably, the movable component is a rolling part comprising a first rolling portion and a second rolling portion, wherein the first rolling portion is configured to promote the first electrically conductive layer to form contact with the contact surface of the variable resistance element, and wherein the second rolling portion is configured to promote the second electrically conductive layer to form contact with the contact surface of the signal control element.

[0017] Preferably, an exhaust air opening passing through the top and bottom of the circuit board is arranged at a position on the circuit board corresponding to the room.

[0018] Preferably, one end of the first or second electrically conductive layer of the first foil contact surface is in contact with the circuit board.

[0019] Typically, the end of the first or second electrically conductive layer of the first foil contact surface, which corresponds to the second foil contact surface, is each configured with a contact spring, under the pressure of which the end of the first or second electrically conductive layer of the first foil contact surface can be conveyed such that it is in contact with the circuit board.

[0020] Further preferably, the end of the first or second electrically conductive layer of the first foil contact surface is each bonded to the circuit board by an electrically conductive adhesive layer.

[0021] Preferably, the electrical switching unit further comprises: a pair of electrical switch contacts, at least one of the pair of electrical switch contacts being operatively connected to the actuator, wherein, in response to movement of the actuator from the OFF position to the ON position along the axis of movement, the pair of electrical switch contacts is arranged as a closed structure such that power from a DC power supply can be supplied to the DC motor via the pair of electrical switch contacts; and wherein, in response to movement of the actuator from the ON position to the OFF position along the axis of movement, the pair of electrical switch contacts is arranged as an open structure such that no power from the DC power supply can be supplied to the DC motor via the pair of electrical switch contacts; a power module comprising at least one solid-state power switching device for controllably supplying power from the DC power supply to the DC motor; and a control module comprising a control circuit used to receive a signal from the signaling module and to output a signal from the control module in response to the received signal from the signaling module to control the at least one solid-state power switching device of the power module, wherein the at least one solid-state power switching device controllably supplies power from the DC power supply to the DC motor to enable the DC motor to operate at a speed corresponding to the movement or position of the actuator. Short description of the drawing

[0022] The present invention will be better understood from the following detailed description of preferred, non-limiting embodiments described with reference to the drawings, in which: Fig. 1A to Fig. 1B respectively show a stereogram and an exploded view of an electrical switching unit as a signal switch in a first embodiment, wherein, by pressing a trigger with a user's finger, an actuator moves inward from an OFF position to an ON position along a movement axis (X-X') relative to an opening in a housing. When the user's finger releases the trigger, the return spring urges the actuator to move outward from the ON position to the OFF position along the movement axis (X-X') relative to the opening in the housing; Fig. 2A to Fig. 2C show a stereogram, an exploded view, and a sectional view of an electrical switching unit as an integrated switch in the first embodiment, respectively. By pressing a trigger with a user's finger, an actuator moves inward from an OFF position to an ON position along a movement axis (X-X') relative to an opening in a housing. When the user's finger releases the trigger, the return spring urges the actuator to move outward from the ON position to the OFF position along the movement axis (X-X') relative to the opening in the housing. Fig. 3A to Fig. 3B show a stereogram and an exploded view of the assembly of a signaling module and the actuator in the first embodiment, respectively. By pressing a trigger with a user's finger, an actuator moves from an OFF position to an ON position along a movement axis (X-X'). When the user's finger releases the trigger, the return spring urges the actuator to move from the ON position to the OFF position along the movement axis (X-X'); Fig. 4A to Fig. 4B show a perspective view of an operation sequence of the signaling module in the first embodiment, wherein a rolling part engages with the second foil contact surface in a rolling manner, and thus the rolling part promotes a first and a second electrically conductive layer of the first foil contact surface to be in contact with a contact surface of a variable resistance element and a contact surface of a signal control element, respectively, and wherein the rolling part in Fig. 4A is in the ON position and the rolling part in Fig. 4B is in the OFF position; Fig. 4C to Fig. 4F show an exploded view and an assembly view of the signaling module in the first embodiment in the ON and OFF positions, respectively, wherein the signaling module comprises the rolling part, a foil, a spacer element, the contact surface of the variable resistance element and the contact surface of the signal control element, and wherein the rolling part in Fig. 4C and Fig. 4E in the ON position and the rolling part in Fig. 4D and Fig. 4E is in the OFF position; Fig. 5A to Fig. 5D show a side view of the signaling module in the first embodiment, wherein, when the rolling part rolls on the second foil contact surface, a first rolling portion of the rolling part promotes the first electrically conductive layer to form contact with the contact surface of the variable resistance element, and a second rolling portion of the rolling part promotes the second electrically conductive layer to form contact with the contact surface of the signal control element, and wherein Fig. 5A and Fig. 5C show that one end of the first electrically conductive layer or the second electrically conductive layer is crimped to a printed circuit board via a contact spring, the variable resistance element or the signal control element in Fig. 5A by connecting several resistors in series with fixed values, and the variable resistance element or the signal control element in Fig. 5C is a continuously variable resistor; where Fig. 5B and Fig. 5D show that one end of the first or second electrically conductive layer is bonded to the circuit board by an electrically conductive adhesive layer, the variable resistance element or the signal control element in Fig. 5B by connecting several resistors with fixed values ​​in series and the variable resistance element or the signal control element in Fig. 5D is a continuously variable resistor; Fig. 6A to Fig. 6D show a control circuit diagram of the electric switching unit in the first embodiment, wherein the Fig. 6A is a continuously variable resistor and the signal control element is a normally closed / normally closed circuit; wherein both the variable resistance element and the signal control element are Fig. 6B are the continuously variable resistors; where the Fig. 6C is connected by connecting a plurality of resistors with fixed values ​​in series, and the signal control element is a normally closed / normally closed circuit; and wherein both the variable resistance element and the signal control element are Fig. 6D are connected by series connection of several resistors with fixed values; Fig. 7A to Fig. 7F shows a voltage change diagram of the Fig. 6A shown control circuit, where Fig. 7A shows that a first area is continuously changed from a low level to a high level and a second area is switched from a low level to a high level; Fig. 7B shows that a first area is continuously changed from a high level to a low level and a second area is switched from a low level to a high level; Fig. 7C shows that a first area is continuously changed from a low level to a high level and a second area is switched from a high level to a low level; Fig. 7D shows that a first area is continuously changed from a high level to a low level and a second area is switched from a high level to a low level; Fig. 7E shows that a first area is continuously changed from a low level to a high level and a second area is switched from a low level to a high level and simultaneously switched from the high level to the low level; and Fig. 7F shows that a first area is continuously changed from a high level to a low level and a second area is switched from a low level to a high level and simultaneously switched from the high level to the low level; Fig. 8A to Fig. 8B shows a voltage change diagram of the Fig. 6B shown control circuit, where Fig. 8A shows that a first range is continuously changed from the low level to the high level and a second range is continuously changed from the high level to the low level; and Fig. 8B shows that a first area is continuously changed from the high level to the low level and a second area is continuously changed from the low level to the high level; Fig. 9A to Fig. 9F show a voltage change diagram of the Fig. 6C shown control circuit, where Fig. 9A shows that a first area is gradually changed from a low level to a high level and a second area is switched from a low level to a high level; Fig. 9B shows that a first area is gradually changed from a high level to a low level and a second area is switched from a low level to a high level; Fig. 9C shows that a first area is gradually changed from a low level to a high level and a second area is switched from a high level to a low level; Fig. 9D shows that a first area is gradually changed from a high level to a low level and a second area is switched from a high level to a low level; Fig. 9E shows that a first area is gradually changed from a low level to a high level and a second area is switched from a low level to a high level and simultaneously switched from the high level to the low level; and Fig. 9F shows that a first area is gradually changed from a high level to a low level and a second area is switched from a low level to a high level and simultaneously switched from the high level to the low level; Fig. 10A to Fig. 10B shows a voltage change diagram of the Fig. 6D shown control circuit, where Fig. 10A shows that a first range is gradually changed from the low level to the high level and a second range is gradually changed from the high level to the low level; and Fig. 10B shows that a first area is gradually changed from the high level to the low level and a second area is gradually changed from the low level to the high level; Fig. 11A to Fig. 11B show a perspective view of an operating sequence of the signaling module in a second embodiment, wherein a rolling part engages with the second foil contact surface in a rolling manner, and thus the rolling part promotes a first electrically conductive layer of the first foil contact surface to be in contact with a contact surface of a variable resistance element, and wherein the rolling part in Fig. 11A is in the ON position and the rolling part in Fig. 11B is in the OFF position; Fig. 11C to Fig. 11F show an exploded view and an assembly view of the signaling module in the second embodiment in the ON and OFF positions, respectively, wherein the signaling module comprises the rolling part, a foil, a spacer element, the contact surface of the variable resistance element, and wherein the rolling part in Fig. 11C and Fig. 11E in the ON position and the rolling part in Fig. 11D and Fig. 11E is in the OFF position; Fig. 12A to Fig. 12D show a side view of the signaling module in the second embodiment, wherein, when the rolling part rolls on the second foil contact surface, a first rolling portion of the rolling part promotes the first electrically conductive layer to form contact with the contact surface of the variable resistance element, and wherein Fig. 12A and Fig. 12C show that one end of the first electrically conductive layer is crimped to a printed circuit board via a contact spring, the variable resistance element in Fig. 12A by connecting several resistors in series with fixed values, and the variable resistance element in Fig. 12C is a continuously variable resistor; where Fig. 12B and Fig. 12D show that one end of the first electrically conductive layer is bonded to the circuit board by an electrically conductive adhesive layer, the variable resistance element in Fig. 12B by connecting several resistors with fixed values ​​in series and the variable resistance element in Fig. 12D is a continuously variable resistor; Fig. 13A to Fig. 13B shows a control circuit diagram of the electric switching unit in the second embodiment, wherein the Fig. 13A is a continuously variable resistor and the resistor shown in Fig. 13B is connected by connecting several resistors of fixed values ​​in series; Fig. 14A to Fig. 14B shows a voltage change diagram of the Fig. 13A shown control circuit, where Fig. 14A shows that a first range is continuously changed from the low level to the high level and Fig. 14B shows that a first range is continuously changed from the high level to the low level; Fig. 15A to Fig. 15B shows a voltage change diagram of the Fig. 13B shown control circuit, where Fig. 15A shows that a first range is gradually changed from the low level to the high level and Fig. 15B shows that a first range is gradually changed from the high level to the low level. Detailed embodiments

[0023] Preferred embodiments of the present invention will now be described with reference to the Fig. 1 to Fig. 15. The embodiments of the present invention are described herein for use relevant to a power tool, which power tool may include, for example, a manually operated electric drill, an electric polisher, an electric grinder, an electric saw, an electric rotary power tool, and the like. It will be clarified and understood that although the embodiments are described for use relevant to a power tool, this is only for the convenience of describing functionality, and alternative embodiments of the present invention may, of course, be used in any other type of electrical device, such as an electric garden tool.It should also be understood that although the power tool embodiments described herein relate to variable speed power tools, the alternative embodiments of the present invention may also be applied to uses relevant to non-variable speed power tools.

[0024] The power tool includes a brushed or brushless DC motor. The brushless DC motor includes a rotor and a stator, and the stator is used to provide a magnetic field that drives the rotor. The rotor of the brushless DC motor includes a plurality of output shafts supported by a bearing to provide output torque and is surrounded by a stationary magnet that generates the magnetic field. The stator is installed around the rotor, and there is an air gap between the stator and the rotor. Located in the air gap is a stator winding that is arranged relatively parallel to the output shaft of the rotor and can typically be connected as a delta structure or as a three-phase star connection.When a current flows through the stator winding, the current generated in the stator winding creates the magnetic field, which becomes magnetically coupled to the rotor, with the rotor being "dragged along" as the magnetic field surrounds it. The magnetic field generated by the stationary magnet in a rotor assembly tends to align itself with the magnetic field generated by the stator, causing the rotor to experience rotational motion. Therefore, by controlling the timing of the stator winding and sequential electrification, the rotational motion of a rotor shaft can be controlled to set it at any expected operating speed and in any expected direction, as further described below.

[0025] Fig. 1 to 10 and Fig. 11 to Fig. 15 show a first embodiment and a second embodiment of an electrical switching unit of the present invention. Each of the embodiments includes an electrical switching unit comprising a housing 300; wherein the housing 300 includes a lower shell 300A and a surface cover 300B; wherein the lower shell 300A and the surface cover 300B can be snapped or screwed together to substantially close at least some parts in parts of a signaling module. The housing 300 houses a pair of electrical switch contacts 310 and an actuator 320 operably connected to at least one of the pair of electrical switch contacts 310, wherein the molded plastic housing 300 is attached to a main body of a power tool that approximates a handle of a power tool.The electrical switch contacts 310 are arranged in series in a circuit between a brushed or brushless DC motor and a DC power supply (e.g., a battery pack) of the power tool. As shown in . Fig. 1A to Fig. 1B and Fig. 2A to Fig. 2C, by pressing a trigger 330 with a user's finger, an actuator 320 moves from an OFF position to an ON position inwardly along an axis of movement XX' relative to an opening in the housing 300. When the user's finger releases the trigger 330, the return spring 340 urges the actuator 320 to move from the ON position to the OFF position outwardly along the axis of movement XX' relative to the opening in the housing 300. The actuator 320 is operatively connected to the electrical switch contacts 310 such that, in response to movement of the actuator 320 to the ON position, the electrical switch contacts 310 form a closed circuit arrangement and thus power can be supplied from the DC power supply to the brushed or brushless DC motor via the pair of electrical switch contacts 310.In contrast, the pair of electrical switch contacts 310 is arranged in an open circuit structure in response to the promotion of the actuator 320 in the OFF position, and thus the DC power supply cannot supply power to the brushed or brushless DC motor through the pair of electrical switch contacts 310.Specifically, the pair of electrical switch contacts 310 includes a contact terminal and a fixed terminal. When the trigger 330 is not pressed, one end of the contact terminal is opposite to the fixed terminal, the other end of the contact terminal abuts against a side surface of the actuator 320, and the contact terminal and the fixed terminal are separated; when the trigger 330 is pressed, the other end of the contact terminal is separated from the side surface of the actuator 320, a tension spring 350 pulls the contact terminal toward the fixed terminal, and the contact terminal and the fixed terminal are connected and conductive; when the trigger 330 is released, the other end of the contact terminal continues to abut against the side surface of the actuator 320, and the contact terminal and the fixed terminal are separated. As shown in FIG. Fig. 3A to Fig. 3B and Fig. As shown in Figure 4, the actuator 320 can move within a position within a specific range along the motion axis XX' depending on the magnitude of a force exerted by the user's finger on the trigger 330, and depending on the linear movement of the actuator 320 along the motion axis XX', the brushed or brushless DC motor is configured to operate at a variable operating speed. Specifically, the actuator 320 is connected to the signaling module disposed within the housing 300, wherein the signaling module includes a signaling circuit configured to detect the linear movement of the actuator 320 relative to a reference position and output a signal from the signaling module indicative of the movement or position of the actuator 320 and thus indicative of a user-expected operating speed of the motor.

[0026] As in Fig. 2A to Fig. 2C, a power module 360 ​​is provided, wherein the power module 360 ​​includes at least one solid-state power switching device, which in this embodiment is MOSFETs, each connected in series via motor cables to the corresponding stator windings of the brushed or brushless DC motor. These MOSFETs are configured to selectively and controllably apply current to the inputs of the corresponding stator windings of the brushed or brushless DC motor. The respective stator windings are sequentially activated according to a controlled timing and in a controlled order with respect to the control module, with a permanent magnet of the rotor continuously following a driving magnetic field generated by the stator windings.

[0027] As in Fig. 2A to Fig. 2C, the control module 370, which includes a motor control circuit, receives the signaling module signal from the signaling module and outputs an electrical signal of the control module 370, which is operated by driving the power module 360 ​​in response to the received signal of the signaling module, wherein the power module 360 ​​includes a plurality of MOSFETs connected to corresponding input terminals of the stator windings of the brushless DC motor. The control module 370 includes a microcontroller, the microcontroller being programmed to output the signal of the control module 370. The signal of the control module 370 drives the plurality of MOSFETs of the power module 360 ​​to electrify the stator windings corresponding to the MOSFETs according to a predetermined timing and sequence, such that the brushless DC motor operates in a predetermined mode (i.e.,Speed, direction, and torque) corresponding to the movement of actuator 320 indicated by the signal from the signaling module. The speed and torque of the brushed or brushless DC motor depend on the amount of power that can be supplied to the stator windings via corresponding input MOSFETs of the stator windings. In these embodiments, the amount of power supplied to the stator windings can be controllably changed using pulse-width modulation technology. Therefore, an output of a timing signal generator (e.g., a "555" circuit) serves as the input to a grid electrode of each MOSFET to achieve rapid on / off switching of the MOSFETs. Therefore, the power obtained by switching the MOSFETs to the stator windings provides the speed and torque of an expected amount produced by the brushed or brushless DC motor.A signal from the timing signal generator can thus serve as a signal for the control module 370, which controls the operation of the MOSFETs. In some embodiments, the control module 370 may also include voltage regulation and protection circuitry to regulate an input voltage from the DC power supply to each of the MOSFETs.

[0028] In the embodiments of the present invention, the control module 370 and the electrical switching contacts 310 and / or the signaling module are integrally and electrically formed together, so that a relatively direct electrical connection between the electrical switching contacts 310 and / or the signaling module and the control module 370 is possible. In this respect, the control module 370 and the signaling module can typically be formed on a single circuit board 120 and are directly electrically connected, as they can be integrated into the circuit board itself. In particular, the electrical connection between the electrical switching contacts 310, the signaling module, and the control module 370 is provided by electrically conductive pins, electrically conductive paths, electrically conductive buses, and the like, which can be embedded in the circuit board 120 itself. Fig. 2A to Fig. The electrical switching unit shown in Figure 2C is an integrated switch (integrated switch) with a switching module. In addition to the signaling module, the control module 370 and the power module 360 ​​are also integrated into its circuit board 120. By integrating a signal switch and the control module 370, which were originally separate, into an integrated switch, installation is facilitated and installation time is reduced. In some embodiments, the signaling module and the control module 370 can also be formed on physically separate circuit boards, wherein the physically separate circuit boards are suitably arranged relative to each other to enable a relatively direct and integrated electrical connection between the control module 370 and the electrical switch contacts 310 and / or the signaling module. Fig. 1A to Fig. The electrical switch unit shown in Figure 1B is a non-integrated switch (the signal switch) without the switching module, which has the signaling module but not the control module 370 and the power module 360, and can be connected to the circuit board integrated with the control module 370 and the power module 360 ​​via a wire row 400 and a cable 410.

[0029] In the embodiments of the present invention, the power module 360, the control module 370, and the signaling module of the electrical switching unit are integrally formed together on the single circuit board 120. Since the MOSFETs arranged on the power module 360 ​​tend to generate a relatively large amount of heat, as shown in Fig. 2A to Fig. 2B, one or more heat distribution and / or dissipation elements, such as heat dissipation fins 380, are installed on the surface of the power module 360 ​​to distribute and / or dissipate thermal energy from the MOSFETs to the ambient air. Due to the common topologically irregular surfaces of the MOSFETs and other parts on the power module 360, a thermal pad, thermal paste, or thermal compound can serve as an intermediate heat transfer layer between the surface of each MOSFET and the heat dissipation fin 380, etc., to achieve more effective thermal connection to the MOSFETs. In some embodiments, the signaling module and the control module 370 can be integrally formed on a single circuit board, while the power module 360 ​​is formed on another physically separate circuit board.The two circuit boards may be installed relative to each other in a structure in which the two circuit boards are spaced parallel to each other, or they may be installed relative to each other in a structure in which the two circuit boards are relatively perpendicular to each other, so that the thermal energy from the MOSFETs installed on the power module 360 ​​can be spaced away from the circuit board of the control module 370 and the signaling module, thus reducing likely thermal damage to these modules.

[0030] In the embodiments of the present invention, a direction control assembly is further provided. As shown in Fig. 1A to Fig. 1B and Fig. 2A to Fig. 2C, it includes a deflection rod 390 rotatably connected to the housing 300, a sliding block portion 420 operatively connected to another end of the deflection rod 390, and a deflection track structure provided between the sliding block portion 420 and the circuit board 120 to control the deflection of the brushed or brushless DC motor.The sliding block part 420 is provided on one side of a rotation plane of the deflection rod 390, and the sliding block part 420 driven by the deflection rod 390 can be connected to the deflection track structure in a reciprocating manner. The deflection track structure includes a deflection brush blade 430 facing the circuit board 120 and provided on the sliding block part 420, and a first electrically conductive slide bar, a second electrically conductive slide bar, and a third electrically conductive slide bar, which are sequentially provided at a distance along a movement path of the sliding block part 420 on the circuit board. One end of the deflection brush blade 430 is continuously slidably connected to the first electrically conductive slide bar, and the other end slides between the second electrically conductive slide bar and the third electrically conductive slide bar in a switched manner.From the above structure, it is known that the deflection rod 390, during rotation, drives the deflection brush blade 430 on the sliding block part 420 to slide on the deflection track structure of the circuit board 120, generating a signal that controls the deflection of the brushed or brushless DC motor. The control module 370 receives and processes the control signal. A specific operation process of the direction control assembly is as follows: When the deflection rod 390 is in the center, one end of the deflection brush blade 430 is constantly connected to the first electrically conductive slide bar, and the other end is located between the second electrically conductive and third electrically conductive slide bars. At this time, the switch is not electrified, and the signal of the brushed or brushless DC motor is not generated.When the deflection rod 390 rotates clockwise, the deflection brush blade 430 is connected to the first electrically conductive slide bar and the third electrically conductive slide bar, respectively, and when the switch is electrified, a forward signal of the brushed or brushless DC motor is generated. And when the deflection rod 390 rotates counterclockwise, the deflection brush blade 430 is connected to the first electrically conductive slide bar and the second electrically conductive slide bar, respectively, and when the switch is electrified, a reverse signal of the brushed or brushless DC motor is generated, thus achieving deflection control of the brushed or brushless DC motor.

[0031] In the exemplary embodiment, the signaling circuit is at least partially formed on the circuit board 120. In detail, as in Fig. 4A to Fig. 4F and Fig. <h2 style=";text-align:left;direction:ltr">5A bis<h2 style=";text-align:left;direction:ltr"> Fig. As shown in Figure 5D, the circuit board 120 includes a first region with a variable resistance element and a second region with a signal control element, wherein the variable resistance element has a variable resistance element contact area 110A and the signal control element has a signal control element contact area 110B. In embodiments of the present invention, the variable resistance element located in the first region may be a continuously variable resistor or connected by series connection of multiple resistors with fixed values, while the signal control element located in the second region may be a continuously variable resistor or connected by series connection of multiple resistors with fixed values, or may be an open / close circuit.Optionally, if the variable resistance element is a continuous variable resistor and the signal control element is a normally closed / normally closed circuit, its control circuit diagram may be as shown in . Fig. 6A and its voltage change diagram as in Fig. 7A to Fig. 7F; when both the variable resistance element and the signal control element are continuously variable resistors, its control circuit diagram looks as shown in Fig. 6B and its voltage change diagram as in Fig. 8A to Fig. 8B; when the variable resistance element is connected by connecting several resistors with fixed values ​​in series and the signal control element is the normally closed / closed circuit, its control circuit diagram is as shown in Fig. 6C and its voltage change diagram as in Fig. 9A to Fig. 9F; and when both the variable resistance element and the signal control element are connected by series connection of several resistors with fixed values, its control circuit diagram looks as shown in Fig. 6D and its voltage change diagram as in Fig. 10A to Fig. 10B. The control circuit is for receiving signals from the variable resistance element and the signal control element and for outputting the signal from the control module 370 in response to the received signal from the signaling module. In detail, as shown in Fig. 6A to Fig. As shown in Figure 6D, one end of the variable resistance element in the first region is connected to a positive electrode of a regulated power supply and the other end thereof to a negative electrode of the regulated power supply, while one end of the signal control element in the second region is connected to a normally closed terminal and the other end thereof to a normally open terminal. A connection end between the variable resistance element and the negative electrode of the power supply is also electrically connected to the deflection track structure of the direction control assembly to achieve deflection control of the brushed or brushless DC motor.A bottom surface of the first electrically conductive layer 130A is in butt contact with the contact surface 110A of the variable resistance element, and one end of the first electrically conductive layer 130A is connected to an output, while a bottom surface of the second electrically conductive layer 130B is in butt contact with the contact surface 110B of the signal control element, and one end of the second electrically conductive layer 130B is connected to a common terminal. For example, if the variable resistance element or the signal control element is connected by connecting a plurality of resistors with fixed values ​​in series, the variable resistance element or the signal control element may, for example, comprise a group of nine resistors, which may be configured to be connected in series between the power supply of the electrical device and the input pin of the control module 370.Eight electrically conductive traces extend from eight central nodes of the nine series-connected resistors, with the eight electrically conductive traces printed on the surface of the circuit board 120 to form a series of independent, discrete traces on the contact area 110A of the variable resistance element or the contact area 110B of the signal control element. It should therefore be understood that by optionally electrically bridging various traces in the contact area 110A of the variable resistance element and the contact area 110B of the signal control element with the first electrically conductive layer 130A and the second electrically conductive layer 130B, respectively, a variable voltage can be selectively applied to the input pin of the control module 370.In a specific embodiment of the present invention, the contact surface 110A of the variable resistance element and the contact surface 110B of the signal control element are provided in parallel in the same plane, with the first region and the second region arranged to be physically separated and spaced apart. For example, two independent narrow and elongated stripes are printed on the surface of the circuit board 120, as shown in FIG. Fig. 4A to Fig. 4F shown.

[0032] With reference to Fig. 5A to Fig. 5D, the signaling module further comprises a relatively thin and flexible film 130, which may be formed, for example, from a polymer, a copolymer, or a polymer composite material. The film 130 comprises a first film contact surface 130C on the underside of the film 130 and a second film contact surface 130D on the top side of the film 130, wherein the first film contact surface 130C on the underside of the film 130 has the first electrically conductive layer 130A and the second electrically conductive layer 130B. The first electrically conductive layer 130A and the second electrically conductive layer 130B are formed by an electrically conductive material printed on the first film contact surface 130C of the film 130.The foil 130 is installed on the circuit board 120 in an adhesive manner such that the first foil contact surface 130C of the foil 130 faces the contact surface 110A of the variable resistance element and the contact surface 110B of the signal control element, and is spaced from the contact surface 110A of the variable resistance element and the contact surface 110B of the signal control element by a spacer 140, forming a space 150 therebetween. A periphery of the spacer 140 around the foil 130 is located between the first electrically conductive layer 130A and the second electrically conductive layer 130B, as well as the contact surface 110A of the variable resistance element and the contact surface 110B of the signal control element. The spacer 140 may further comprise a polymer, a copolymer, or a polymer composite material.One end of the spacer is bonded to the first electrically conductive layer 130A and the second electrically conductive layer 130B of the first foil contact surface 130C, and the other end is bonded to the contact surface 110A of the variable resistance element and the contact surface 110B of the signal control element. By default, the first electrically conductive layer 130A and the second electrically conductive layer 130B are biased in positions spaced apart relative to the contact surface 110A of the variable resistance element and the contact surface 110B of the signal control element. The bias can be achieved by forming a pattern of the foil 130 itself and / or by using an external biasing element such as the spacer element 140.Regardless of whether the user presses the trigger 330 or not, the first electrically conductive layer 130A and the second electrically conductive layer 130B are each connected to the contact surface 110A of the variable resistance element and the contact surface 110B of the signal control element at a certain contact point and are conductive.

[0033] In the exemplary embodiment, one end of each of the first electrically conductive layer 130A and the second electrically conductive layer 130B of the first foil contact surface 130C is electrically connected to the circuit board 120, for example, by a wire. In this exemplary embodiment, one end of each of the first electrically conductive layer 130A and the second electrically conductive layer 130B of the first foil contact surface 130C of the foil 130 is in contact with the circuit board 120. Optionally, one end of each of the first electrically conductive layer 130A and the second electrically conductive layer 130B of the first foil contact surface 130C can be crimped to the circuit board 120 via both contact springs 170 to achieve the electrical connection.Under the pressure of the contact springs 170, one end of each of the first electrically conductive layer 130A and the second electrically conductive layer 130B of the first foil contact surface 130C can be conveyed into contact with the circuit board 120 (contact position 190), as shown in FIG. Fig. 5A and Fig. 5C. One end of the first electrically conductive layer 130A and the second electrically conductive layer 130B of the first foil contact surface 130C of the foil 130 can each be further bonded to the circuit board 120 by an electrically conductive bonding layer 180 (for example, electrically conductive adhesive, an electrically conductive tape, or adhesive such as an epoxy adhesive, a polyurethane adhesive, and an acrylic adhesive) to achieve the electrical connection (contact position 190), as shown in Fig. 5B and Fig. 5D. In some embodiments, one end of the first electrically conductive layer 130A and the second electrically conductive layer 130B of the first foil contact surface 130C of the foil 130 may each be welded to the circuit board 120 using a silver solder or the like to achieve the electrical connection.

[0034] In the exemplary embodiment, the movable member is operatively connected to the actuator 320 and configured to move along the second foil contact surface 130D of the foil 130 in response to the movement of the actuator 320. The movable member may be a sliding member such as a sliding block and a sliding bar. In the exemplary embodiments of the present invention, the movable member is a rolling member 100, such as a roller. Since the rolling member 100 rolls on the second foil contact surface 130D of the foil 130, friction and wear between the rolling member 100, the foil 130, and the contact surface 110A of the variable resistance element and the contact surface 110B of the signal control element can be reduced, so that the reliability and stability of the electrical switching unit's operation can be maintained over a longer service life. As shown in Fig. 4A to Fig. 4F, the rolling member 100 includes a first rolling portion 100A and a second rolling portion 100B. As the rolling member 100 moves along the second foil contact surface 130D of the foil 130, the first electrically conductive layer 130A and the second electrically conductive layer 130B of the first foil contact surface 130C are urged to make contact with the contact surface 110A of the variable resistance element and the contact surface 110B of the signal control element, respectively, at a plurality of contact point structures, thanks to a vertical force caused by the rolling member 100 pressing on the second foil contact surface 130D of the foil 130.In each of the plurality of contact point structures, the contact points are formed such that the first rolling portion 100A of the rolling member 100 forces a portion of the first electrically conductive layer 130A to make contact with the contact surface 110A of the variable resistance element, while the second rolling portion 100B forces a portion of the second electrically conductive layer 130B to make contact with the contact surface 110B of the signal control element.As the rolling member 100 rolls along the second foil contact surface 130D of the foil 130, the first electrically conductive layer 130A and the second electrically conductive layer 130B can therefore be selectively electrically bridged with the contact surface 110A of the variable resistance element and the contact surface 110B of the signal control element, and the effective resistance of the variable resistance element and the signal control element can be changed accordingly in a controlled manner, resulting in the changed voltage signal being applied to the input of the control module 370. The variable voltage input indicates the movement of the actuator 320, and the control module 370 is programmed to control the operation of the brushed or brushless DC motor with reference to the variable voltage signal. Furthermore, the signal control element can also be the normally closed / closed circuit for the signal control.The circuitry of the signal control element is configured to switch signals in response to the second electrically conductive layer being encouraged to contact the contact surface of the signal control element in one of the plurality of contact point structures. The selectable signal includes, among other things, switching on / off and selecting various signals, and the like.

[0035] In the embodiment shown in Fig. 3A to Fig. 3B, the rolling part 100 can be biased by a compression spring 100C in a direction substantially perpendicular to the direction of movement of the rolling part 100. Furthermore, the rolling part 100 can be attached to a bracket 100E via a pin shaft 100D, with the bracket 100E being mounted in a slot of the actuator 320 near one side of the circuit board 120. The rolling part 100 can have a spherical, ellipsoidal, cylindrical shape, or any shape suitable for rolling. The structures of the first rolling portion 100A and the second rolling portion 100B of the rolling part 100 can be selected to match the structures of the contact surface 110A of the variable resistance element and the contact surface 110B of the signal control element. In this embodiment, the first rolling portion 100A and the second rolling portion 100B are independently separated and spaced from each other.

[0036] In the exemplary embodiment, an exhaust port 160 extending through the top and bottom surfaces of the circuit board 120 is provided at a position of the circuit board 120 corresponding to the space 150. Optionally, a round hole is provided at a position of the spacer 140 corresponding to the exhaust port 160 on the circuit board 120. The round hole is connected to the space 150 corresponding to the contact surface 110A of the variable resistance element and the contact surface 110B of the signal control element through a first stripe-shaped hole and a second stripe-shaped hole, respectively. When the rolling part 100 moves along the second film contact surface 130D of the film, the space 150 surrounded by the spacer 140 is compressed. The exhaust port 160 is used for venting when the space 150 is compressed.

[0037] Advantageously, in the signaling module of the electrical switching unit, the sizes of the foil 130, the spacer 140, and the circuit board 120 can be reduced by spacing the first electrically conductive layer 130A and the second electrically conductive layer 130B of the first foil contact surface 130C from the contact surface 110A of the variable resistance element and the contact surface 110B of the signal control element, respectively, by the spacer 140, so that the space occupied by the actuator 320 and the electrical switch is reduced. Furthermore, the number of moving parts can also be reduced. Conventional two groups of moving parts are reduced to one group of moving parts, thus reducing material costs.

[0038] In a second embodiment, the signaling circuit is at least partially formed on the circuit board 220. In detail, as shown in Fig. 11A to Fig. 11F and Fig. 12A to Fig. As shown in Figure 12D, the circuit board 220 includes a first region with a variable resistance element, wherein the variable resistance element has a contact surface 210A of the variable resistance element. In the embodiments of the present invention, the variable resistance element located in the first region may be a continuously variable resistor or connected by connecting a plurality of resistors with fixed values ​​in series. Optionally, if the variable resistance element is a continuously variable resistor, its control circuit diagram may be as shown in Fig. 13A and its voltage change diagram as in Fig. 14; when the variable resistance element is connected by series connection of several resistors with fixed values, its control circuit diagram looks as shown in Fig. 13B and its voltage change diagram as in Fig. 15. In detail, as shown in Fig. 13A to Fig. As shown in Figure 13B, one end of the variable resistance element in the first region is connected to a positive electrode of a power supply, and the other end thereof is connected to a negative electrode of the power supply. A connection end between the variable resistance element and the negative electrode of the power supply is also electrically connected to the deflection track structure of the direction control assembly to achieve deflection control of the brushed or brushless DC motor. A bottom surface of the first electrically conductive layer 130A is in butt contact with the contact surface 210A of the variable resistance element, and one end of the first electrically conductive layer 230A is connected to an output.

[0039] For example, if the variable resistance element is connected by connecting multiple resistors with fixed values ​​in series, the variable resistance element may comprise, for example, a group of nine resistors that may be configured to be connected in series between the power supply of the electrical device and the input pin of the control module 370. Eight electrically conductive traces extend from eight central nodes of the nine series-connected resistors, with the eight electrically conductive traces being printed on the surface of the circuit board 220 to form a series of independent discrete traces on the contact pad 210A of the variable resistance element.It is therefore understood that by optionally electrically bridging various tracks in the contact area 210A of the variable resistance element with the first electrically conductive layer 230A, a variable voltage can be selectively applied to the input pin of the control module 370.

[0040] With reference to Fig. 12A to Fig. 12D, the signaling module further comprises a relatively thin and flexible film 230, which may be formed, for example, from a polymer, a copolymer, or a polymer composite material. The film 230 comprises a first film contact surface 230C on the underside of the film 230 and a second film contact surface 230D on the top side of the film 230, wherein the first film contact surface 230C on the underside of the film 230 has the first electrically conductive layer 230A. The first electrically conductive layer 230A is formed by an electrically conductive material printed onto the first film contact surface 230C of the film 230.The foil 230 is installed on the circuit board 220 in an adhesive manner such that the first foil contact surface 230C of the foil 230 faces the contact surface 210A of the variable resistance element and is spaced from the contact surface 210A of the variable resistance element by a spacer 240, forming a space 250 therebetween. A periphery of the spacer 240 around the foil 230 is located between the first electrically conductive layer 230A and the contact surface 210A of the variable resistance element. The spacer 240 may further comprise a polymer, a copolymer, or a polymer composite material. One end of the spacer is bonded to the first electrically conductive layer 230A of the first foil contact surface 230C, and the other end is bonded to the contact surface 210A of the variable resistance element.By default, the first electrically conductive layer 230A is biased in a position spaced relative to the contact surface 210A of the variable resistance element. The bias can be achieved by forming a pattern of the film 230 itself and / or using an external biasing element such as the spacer element 240. Regardless of whether the user presses the trigger 330 or not, the first electrically conductive layer 230A is connected to the contact surface 210A of the variable resistance element at a specific contact point and is conductive.

[0041] In the alternative embodiment, one end of the first electrically conductive layer 230A of the first foil contact surface 230C is electrically connected to the circuit board 220, for example, by a wire. In this embodiment, one end of the first electrically conductive layer 230A of the first foil contact surface 230C of the foil 230 is in contact connection with the circuit board 220. Optionally, one end of the first electrically conductive layer 230A of the first foil contact surface 230C can be crimped to the circuit board 220 via a contact spring 270 to achieve the electrical connection. Under the pressure of the contact springs 270, one end of the first electrically conductive layer 230A of the first foil contact surface 230C can be conveyed into contact with the circuit board 220 (contact position 290), as shown in Fig. 12A and Fig. 12C. One end of the first electrically conductive layer 230A of the first foil contact surface 230C of the foil 230 may be further bonded to the circuit board 220 by an electrically conductive bonding layer 280 (for example, electrically conductive adhesive, an electrically conductive tape, or adhesive such as an epoxy adhesive, a polyurethane adhesive, and an acrylic adhesive) to achieve the electrical connection (contact position 290), as shown in Fig. 12B and Fig. 12D. In some embodiments, one end of the first electrically conductive layer 230A of the first foil contact surface 230C of the foil 230 may be welded to the circuit board 220 using a silver solder or the like to achieve the electrical connection.

[0042] In the alternative embodiment, the movable member is operatively connected to the actuator 320 and configured to move along the second foil contact surface 230D of the foil 230 in response to the movable member. The movable member may be a sliding member such as a sliding block and a sliding bar. In the embodiments of the present invention, the movable member is a rolling member 200, such as a roller. Because the rolling member 200 rolls on the second foil contact surface 230D of the foil 230, friction and wear between the rolling member 200, the foil 230, and the contact surface 210A of the variable resistance element can be reduced, so that the reliability and stability of the electrical switching unit's operation can be maintained over a longer service life. As shown in Fig. 11A to Fig.As shown in Figure 11F, the rolling member 200 includes a first rolling portion 200A. As the rolling member 200 moves along the second foil contact surface 230D of the foil 230, the first electrically conductive layer 230A of the first foil contact surface 230C is urged to make contact with the contact surface 210A of the variable resistance element at a plurality of contact point structures thanks to a vertical force caused by the rolling member 200 pressing on the second foil contact surface 230D of the foil 230. In each of the plurality of contact point structures, the contact points are formed such that the first rolling portion 200A of the rolling member 200 forces a portion of the first electrically conductive layer 230A to make contact with the contact surface 210A of the variable resistance element.As the rolling member 200 rolls along the second foil contact surface 230D of the foil 230, the first electrically conductive layer 230A can therefore be selectively electrically bridged with the contact surface 210A of the variable resistance element, and the effective resistance of the variable resistance element can be changed accordingly in a controlled manner, resulting in the changed voltage signal being applied to the input of the control module 370. The variable voltage input indicates the movement of the actuator 320, and the control module 370 is programmed to control the operation of the brushed or brushless DC motor with reference to the variable voltage signal.

[0043] In the alternative embodiment, the rolling member 200 may be biased by a compression spring 200C in a direction substantially perpendicular to the direction of movement of the rolling member 200. Furthermore, the rolling member 200 may be attached to a bracket 200E via a pin shaft 200D, with the bracket 200E mounted in a slot of the actuator 320 near one side of the circuit board 120. The rolling member 200 may have a spherical, ellipsoidal, cylindrical shape, or any shape suitable for rolling.

[0044] In the alternative embodiment, an exhaust port 260 extending through the top and bottom surfaces of the circuit board 220 is provided at a position on the circuit board 220 corresponding to the space 250. Optionally, a round hole is provided at a position of the spacer 240 corresponding to the exhaust port 260 on the circuit board 220. The round hole is connected to the space 250 corresponding to the contact surface 210A of the variable resistance element by a strip-shaped hole. When the rolling part 200 moves along the second film contact surface 230D of the film, the space 250 surrounded by the spacer 240 is compressed. The exhaust port 260 is used for venting when the space 250 is compressed.

[0045] Advantageously, in the signaling module of the electrical switching unit, the sizes of the foil 230, the spacer 240, and the circuit board 220 can be reduced by spacing the first electrically conductive layer 230A of the first foil contact surface 230C from the contact surface 210A of the variable resistance element by the spacer 240, thus reducing the space occupied by the actuator 320 and the electrical switch. Furthermore, the number of moving components can also be reduced. Conventional two groups of moving components are reduced to one group of moving components, thus reducing material costs.

[0046] In the alternative embodiment of the present invention, it is possible to use the following arrangement. For example, the circuit board is alternatively fabricated on a flexible sheet material, and the first rolling portion of the rolling member may be configured to convey the circuit board to form contact with the variable resistor in a manner different from that in the above embodiments.

[0047] Those skilled in the art will recognize that the present invention described herein is susceptible to further changes and modifications besides the specifically described embodiments without departing from the scope of the present invention. These changes and modifications, which will be obvious to those skilled in the art, are all considered to be within the spirit and scope of the present invention as described above. It is to be understood that the present invention includes all such changes and modifications. The present invention further includes all the steps and features recited or indicated in the description, individually or together, as well as any or all combinations of two or more steps or features.

[0048] Any prior art mentioned in the description shall not be regarded as acknowledging or in any way implying that the prior art is part of the common knowledge. QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] US 10547257B2

[0004]

Claims

[1] An electrical switching unit for an electrical device used to control an operation of a DC motor of the electrical device, the electrical switching unit comprising: a housing accommodating an actuator movably installed in the housing, the actuator being configured to move, in response to operation of a finger-actuable trigger, to an ON position from an OFF position in a direction toward an interior of an opening in the housing along a movement axis and to move to the OFF position from the ON position in a direction toward an exterior of the opening in the housing along the movement axis; and a signaling module linked to the electrical switching unit and comprising a motor signaling circuit, the motor signaling circuit being used to detect movement of the actuator and to output a signal from the signaling module indicating the movement or position of the actuator; characterized by that the signaling module includes: a circuit board having a first region having a variable resistance element, the variable resistance element having a contact surface of the variable resistance element; a foil comprising a first foil contact surface and a second foil contact surface, wherein the first foil contact surface of the foil has a first electrically conductive layer, wherein the electrically conductive layer of the first foil contact surface is spaced from the contact surface of the variable resistance element by a spacer element, thus forming a space therebetween, and wherein one end of the first electrically conductive layer of the first foil contact surface is electrically connected to the circuit board; and a movable member operatively connected to the actuator, thus the movable member moving in response to movement of the actuator relative to the second foil contact surface of the foil and being capable of promoting the first electrically conductive layer of the first foil contact surface to form contact with the contact surface of the variable resistance element in a plurality of contact point structures, and thus the effective resistance of the variable resistance element is configured to change in response to promoting the first electrically conductive layer of the first foil contact surface to form contact with the contact surface of the variable resistance element in each of the plurality of contact point structures. [2] An electrical switching unit according to claim 1, wherein the variable resistance element is a continuously variable resistor or is connected by connecting a plurality of resistors having fixed values ​​in series. [3] The electrical switching unit according to claim 1, wherein an exhaust port passing through the top and bottom surfaces of the circuit board is provided at a position of the circuit board corresponding to the space. [4] Electrical switching unit according to claim 1, wherein one end of the first electrically conductive layer of the first foil contact surface is in contact connection with the printed circuit board. [5] Electrical switching unit according to claim 4, wherein the end of the first electrically conductive layer of the first foil contact surface corresponding to the second foil contact surface is configured with a contact spring, under the pressure of which the end of the first electrically conductive layer of the first foil contact surface can be conveyed such that it is in contact connection with the circuit board. [6] Electrical switching unit according to claim 4, wherein the end of the first electrically conductive layer of the first foil contact surface is bonded to the circuit board by an electrically conductive adhesive layer. [7] An electrical switching unit according to claim 1, further comprising: a pair of electrical switch contacts, at least one of the pair of electrical switch contacts being operatively connected to the actuator, wherein, in response to movement of the actuator from the OFF position to the ON position along the axis of movement, the pair of electrical switch contacts is arranged as a closed structure such that power from a DC power supply can be supplied to the DC motor via the pair of electrical switch contacts; and wherein, in response to movement of the actuator from the ON position to the OFF position along the axis of movement, the pair of electrical switch contacts is arranged as an open structure such that no power from the DC power supply can be supplied to the DC motor via the pair of electrical switch contacts; a power module comprising at least one solid-state power switching device for controllably supplying power from the DC power supply to the DC motor; and a control module comprising a control circuit used to receive a signal from the signaling module and to output a signal from the control module in response to the received signal from the signaling module to control the at least one solid-state power switching device of the power module, wherein the at least one solid-state power switching device controllably supplies power from the DC power supply to the DC motor to enable the DC motor to operate at a speed corresponding to the movement or position of the actuator. [8] An electrical switching unit for an electrical device used to control an operation of a DC motor of the electrical device, the electrical switching unit comprising: a housing accommodating an actuator movably installed in the housing, the actuator being configured to move, in response to operation of a finger-actuable trigger, to an ON position from an OFF position in a direction toward an interior of an opening in the housing along a movement axis and to move to the OFF position from the ON position in a direction toward an exterior of the opening in the housing along the movement axis; and a signaling module linked to the electrical switching unit and comprising a motor signaling circuit, the motor signaling circuit being used to detect movement of the actuator and to output a signal from the signaling module indicating the movement or position of the actuator; characterized by that the signaling module includes: a circuit board comprising a first region having a variable resistance element and a second region having a signal control element, the first region and the second region being arranged to be physically separate and spaced apart from each other, the variable resistance element having a contact surface for the variable resistance element and the signal control element having a contact surface for the signal control element; and a film comprising a first film contact surface and a second film contact surface, wherein the first film contact surface of the film has a first and a second electrically conductive layer, wherein the first and the second electrically conductive layer of the first film contact surface are each spaced from the contact surface of the variable resistance element and the contact surface of the signal control element by a spacer element, thus forming a space therebetween, and wherein one end of the first and the second electrically conductive layer of the first film contact surface is each electrically connected to the circuit board; and a movable member operatively connected to the actuator, the movable member thus moving in response to movement of the actuator relative to the second foil contact surface of the foil and being capable of promoting the first electrically conductive layer of the first foil contact surface to form contact with the contact surface of the variable resistance element in a plurality of contact point structures, and thus the effective resistance of the variable resistance element is configured to change in response to promoting the first electrically conductive layer of the first foil contact surface to form contact with the contact surface of the variable resistance element in each of the plurality of contact point structures; wherein, in response to movement of the movable component along the second foil contact surface of the foil, the second electrically conductive layer of the first foil contact surface can be promoted to make contact with the contact surface of the signal control element in a plurality of contact point structures, whereby an effective resistance of the signal control element is configured to change in response to the second electrically conductive layer of the first foil contact surface being promoted to make contact with the contact surface of the signal control element in each of the plurality of contact point structures; or wherein the circuit of the signal control element is configured to switch the signal in response to the second electrically conductive layer of the first foil contact surface being promoted to make contact with the contact surface of the signal control element in one of the plurality of contact point structures. [9] An electrical switching unit according to claim 8, wherein the variable resistance element is a continuously variable resistor or is connected by connecting a plurality of resistors with fixed values ​​in series. [10] An electrical switching unit according to claim 8, wherein the signal control element is a continuously variable resistor or is connected by connecting a plurality of resistors with fixed values ​​in series or is an open / close circuit. [11] The electrical switching unit according to claim 8, wherein the movable member is a rolling member comprising a first rolling portion and a second rolling portion, the first rolling portion being configured to promote the first electrically conductive layer to make contact with the contact surface of the variable resistance element, and the second rolling portion being configured to promote the second electrically conductive layer to make contact with the contact surface of the signal control element. [12] The electrical switching unit according to claim 8, wherein an exhaust port passing through the top and bottom surfaces of the circuit board is provided at a position of the circuit board corresponding to the space. [13] Electrical switching unit according to claim 8, wherein one end of the first and second electrically conductive layers of the first foil contact surface is in contact connection with the printed circuit board. [14] Electrical switching unit according to claim 13, wherein the end of the first or second electrically conductive layer of the first foil contact surface, which corresponds to the second foil contact surface, is each configured with a contact spring, under the pressure of which the end of the first or second electrically conductive layer of the first foil contact surface can be conveyed such that it is in contact connection with the printed circuit board. [15] Electrical switching unit according to claim 13, wherein the end of the first electrically conductive layer or the second electrically conductive layer of the first foil contact surface are each bonded to the circuit board by an electrically conductive adhesive layer. [16] An electrical switching unit according to claim 8, further comprising: a pair of electrical switch contacts, at least one of the pair of electrical switch contacts being operatively connected to the actuator, wherein, in response to movement of the actuator from the OFF position to the ON position along the axis of movement, the pair of electrical switch contacts is arranged as a closed structure such that power from a DC power supply can be supplied to the DC motor via the pair of electrical switch contacts; and wherein, in response to movement of the actuator from the ON position to the OFF position along the axis of movement, the pair of electrical switch contacts is arranged as an open structure such that no power from the DC power supply can be supplied to the DC motor via the pair of electrical switch contacts; a power module comprising at least one solid-state power switching device for controllably supplying power from the DC power supply to the DC motor; and a control module comprising a control circuit used to receive a signal from the signaling module and to output a signal from the control module in response to the received signal from the signaling module to control the at least one solid-state power switching device of the power module, wherein the at least one solid-state power switching device controllably supplies power from the DC power supply to the DC motor to enable the DC motor to operate at a speed corresponding to the movement or position of the actuator.

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