Angled Carrier Element for 3D Switchgear Mounting
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Solution Overview
Problem
Existing switching units on printed circuit boards are costly due to gold plating requirements and are limited to two-dimensional designs, which do not accommodate the geometric needs of user-activated interfaces in vehicles, such as those in motor vehicle roofs with numerous SMD components.
Innovation Solution
A switching unit with a carrier element having a contact layout on a base area that can be angled from 0° to 90°, preferably 45° or 90°, and made of plastic, with projections for secure attachment to a substrate, allowing for three-dimensional configurations and reducing the need for gold plating by using a gold-plated contact layout.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the contact layout is made gold-plated for reliable switching function, then the reliability is improved, but the manufacturing cost increases noticeably
Solution Approach 1:
The patent divides the switching unit into a modular carrier element that can be separately manufactured and then mounted onto the printed circuit board. This segmentation allows the gold-plated contact layout to be confined only to the necessary contact areas on the carrier element, rather than requiring the entire PCB to be gold-plated, thereby reducing material costs while maintaining switching reliability.
Solution Approach 2:
The invention applies gold plating locally only to the contact surfaces on the carrier element where electrical contact is required, rather than applying it to the entire printed circuit board. This localized application of expensive material reduces overall manufacturing costs while ensuring reliable electrical connection at the critical contact points.
2Adaptability or versatility
If the printed circuit board is used with SMD components, then the functionality is improved, but the switching units are limited to two-dimensional plane
Solution Approach 1:
The patent introduces a three-dimensional carrier element with vertical mounting projections that extend perpendicular to the PCB surface. This allows switching units to be arranged in multiple layers and at various heights, transforming the traditionally two-dimensional PCB layout into a three-dimensional structure that can accommodate complex geometric requirements of vehicle user interfaces.
Solution Approach 2:
The carrier element is designed to be mounted onto the PCB substrate, with the switching unit effectively nested within the overall assembly. The carrier element can accommodate the contact layout and actuating elements in a compact three-dimensional arrangement, allowing multiple switching functions to be integrated in a space-efficient manner.
3Reliability
If additional parts are added to ensure force transfer to the contact layout, then the switching function is improved, but the device complexity increases
Solution Approach 1:
The patent combines the force transfer function with the mounting structure by integrating vertical projections directly into the carrier element. These projections serve dual purposes: they mechanically secure the carrier element to the PCB substrate while also providing the necessary force transfer path from the actuating element to the contact layout, eliminating the need for separate force transfer components.
Solution Approach 2:
The mounting projections on the carrier element are designed to perform multiple functions simultaneously: mechanical attachment to the substrate, structural support for the contact layout, and force transfer from the actuating element to the contacts. This multi-functionality reduces the overall number of parts while ensuring reliable switching operation.
Data Source
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AI summary
The unit has an electrical contact-layout (22) provided on a carrier surface (20), and an actuating element e.g. elastomer safety shutsdown mat, snapping element and contact spring, provided with electrically conductive contact. The carrier surface comprising the contact-layout is provided on a carrier element (24), which is attached with a base (26) on a substrate. The carrier element comprises two contact surfaces (32) for an electrical connection of the contact-layout with electrical connections associated with the substrate. An independent claim is also included for a system comprising a substrate and a switching unit.