Ball Switch Insulation via Dielectric Sealing Ring
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Solution Overview
Problem
The existing multi-ball switch arrangements in layer/plate construction are procedurally complex and require multiple steps for production, particularly due to the need for galvanically coated holes for electrical connections between plates, which complicates the manufacturing process.
Innovation Solution
A simplified structure using three plastic circuit boards - a base board, a chamber board, and an optional cover board - where the circular disk and contact track are on one plane, with a concentric dielectric sealing ring isolating the metallic chamber wall from the circular disk and conductor track, allowing for adhesive connection and reduced complexity in production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If galvanically coated holes are used for electrical connections between plates, then electrical insulation and connection are achieved, but manufacturing complexity increases
Solution Approach 1:
The patent extracts the galvanic coating process from the manufacturing sequence by pre-coating the contact tracks on the circuit board before assembling the chamber plate. This eliminates the need for post-assembly galvanic coating operations, reducing manufacturing complexity while maintaining electrical insulation reliability
Solution Approach 2:
The contact tracks are galvanically coated in advance during circuit board fabrication, before the chamber plate is assembled. This preliminary action ensures electrical insulation is already in place, eliminating the need for complex post-assembly coating operations and simplifying the overall manufacturing process
2Reliability
If multiple plates with vertical contacts are used, then electrical connections are established, but production steps increase
Solution Approach 1:
The patent merges the electrical connection function into the planar contact tracks on the circuit board, eliminating the need for separate vertical contacts. The contact tracks extend directly from the circular disk to the chamber wall, combining multiple functions into a single integrated structure that reduces assembly steps
Solution Approach 2:
The patent transitions from vertical three-dimensional contacts to planar two-dimensional contact tracks on the circuit board. This dimensional change allows electrical connections to be established through the planar structure during board fabrication, eliminating the need for separate vertical contact assembly operations and improving production efficiency
3Reliability
If concentric circular disk and chamber arrangement are used, then electrical isolation is achieved, but manufacturing precision requirements increase
Solution Approach 1:
The patent introduces a dielectric layer as an intermediary between the circular disk and the chamber wall. This dielectric layer provides inherent electrical isolation, allowing the concentric arrangement to be manufactured with standard tolerances rather than requiring high-precision concentricity, thus reducing manufacturing precision requirements while maintaining reliable electrical isolation
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
This approach enables the production of multi-ball switches with reduced procedural steps, ensuring electrical isolation and hermetic sealing, thus maintaining long-term switching reliability and reducing production costs by eliminating the need for vertical contacts.
Implementation Method 1
The base plate and the chamber plate are connected/pressed to one another via an adhesive layer which surrounds the circular disk and extends to the edge of the base plate
Implementation Method 2
The circular disk on the base plate of the ball switch is surrounded by a concentric ring made of dielectric material, the sealing ring
Data Source
Figure 1
Figure 2
AI summary
The ball switch in a multiball switch arrangement in layered /laminated construction has a flat contact guide away from the ball switch contacts. The metallic inner wall (11) of the chamber (3) of the ball switch ends on both sides of the chamber plate (9) in annular strips (4, 5). The circular disk (1) on the base plate (6) is surrounded by a concentric sealing ring (7) made of dielectric material on which the opposite annular strip (4) on the chamber plate completely and concentrically rests in the assembled condition. The base plate (6) and the chamber plate (9) are joined/pressed together via an adhesive layer (10) surrounding the circular disk in such a way that the chamber wall is electrically insulated from the circular disk (1) and the outgoing conductor track (2), and between the annular strip (4) of the chamber and the base plate (6) an atmospheric seal exists across the intermediate sealing ring (7). Optionally, the ball switch can be covered in various ways.