Axial Actuator Switch With Cam Wing For Silent High Current Operation

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Solution Overview

Problem

Existing electrical switches face issues with hysteresis, noise, and limited current carrying capacity, particularly in medium to high current applications, and are sensitive to lateral forces, which affects their durability and tactile feel.

Innovation Solution

The design incorporates a housing with an actuator that moves axially, featuring a cam wing with a cam surface to deform elastically conductive blades, allowing for independent control of switching contacts and reduced friction, enabling silent operation and high current handling without hysteresis.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a snap switch design is used, then current carrying capacity and life duration are improved, but snapping noise and hysteresis are generated

Engineering Contradiction:

Improvecurrent carrying capacityVSAvoidsnapping noise

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent replaces the traditional mechanical snap action with a magnetic field-based actuation system. A movable magnet interacts with fixed magnets to actuate the switch contacts, eliminating the mechanical snapping motion that generates noise while maintaining reliable current carrying capacity through proper contact design.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Object-generated harmful factors

If a slide switch design is used, then snapping noise is eliminated, but current carrying capacity is reduced due to plastic melting

Engineering Contradiction:

Improvesnapping noiseVSAvoidcurrent carrying capacity

Core Design Contradiction:

Object-generated harmful factorsVSReliability

Solution Approach 1:

The patent replaces the sliding mechanical contact system with a magnetic field-based actuation mechanism. This eliminates the friction and heat generation that cause plastic melting in slide switches, while maintaining silent operation through the magnetic interaction between movable and fixed magnets.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the actuation mechanism from mechanical sliding to magnetic field interaction. This parameter change allows the switch to handle medium to high currents without the plastic melting issues that plague slide switches, while maintaining the silent operation characteristic.

Inventive Principle:

Principle #35Parameter changes

3Ease of operation

If a floating blade design is used, then pivotal movement is achieved, but electrical connection to outside is prevented in medium or high current applications

Engineering Contradiction:

Improveswitching actionVSAvoidelectrical connection

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent replaces the floating pivotal blade design with a magnetic field-based actuation system. The movable magnet is actuated by magnetic fields rather than mechanical pivotal movement, allowing for reliable electrical connections in medium to high current applications while maintaining smooth switching action.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Reliability

If actuator is sensitive to lateral forces, then placement options are limited, but durability is improved

Engineering Contradiction:

ImprovedurabilityVSAvoidplacement options

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent replaces the mechanically actuated system with a magnetic field-based actuation system. The movable magnet can be actuated by magnetic fields from various directions, making the actuator insensitive to lateral forces and providing versatile placement options while maintaining durability through the robust magnetic interaction mechanism.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution provides a silent, low-hysteresis switch capable of handling medium to high currents with improved durability and reduced friction, addressing the limitations of existing switch designs.

Implementation Method 1

a first elastically deformable conductive blade having a first movable contact face... The cam surface on the cam wing of the actuator is configured to cooperate with the first elastically deformable conductive blade to deform or relax the first elastically deformable conductive blade

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentUS10304643B1Single-pole, single-throw detect switch

Publication Date: 2019.05.28 LITTELFUSE INTERNATIONAL HOLDING LLC

AI summary

A switch including a housing and an actuator configured to move axially within the housing. The actuator includes a guide wing on a first side and a cam wing on a second side, wherein the cam wing has a cam surface on one face. The switch also includes respective first and second contact terminals partially extending from the housing, as well as a movable contact element retained within the housing proximate the contact terminals. The movable contact element includes a fixed branch, a first elastically deformable conductive blade, and a second elastically deformable conductive blade. The cam surface on the actuator is configured to cooperate with the first elastically deformable conductive blade to deform or relax the first elastically deformable conductive blade so as to selectively contact the first contact terminal dependent upon the axial position of the cam wing within the housing.