Integrated Clutch and Ignition Switch with Sliding Contacts

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Solution Overview

Problem

Conventional clutch pedal systems for vehicles have a complex structure due to separate clutch and ignition-lock switches, leading to increased manufacturing costs, operation noise, and contact errors from contamination.

Innovation Solution

A combination switch device integrates clutch and ignition-lock switch functions into a single unit with a housing, stationary and movable terminals, and a power transmitter, featuring a shield to prevent foreign matter contamination and using sliding contacts for noise reduction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If clutch switch and ignition-lock switch are mounted separately, then each switch can be independently operated, but the structure becomes complicated and manufacturing cost increases

Engineering Contradiction:

Improveindependent operation capabilityVSAvoidstructure complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent combines the clutch switch and ignition-lock switch into a single integrated switch assembly. The switch assembly includes a common actuator that can operate both switches simultaneously or independently through different stroke positions. The housing integrates both switch mechanisms, eliminating the need for separate mounting locations and reducing overall structural complexity while maintaining independent operational capability through selective contact point engagement.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated switch assembly serves multiple functions: it acts as both a clutch switch and an ignition-lock switch. The single assembly includes multiple contact points that can be selectively engaged or disengaged based on the actuator position, enabling the same physical component to control different electrical circuits (clutch control circuit and ignition control circuit) independently or together.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If separate switches are used, then functional independence is maintained, but manufacturing cost increases

Engineering Contradiction:

Improvefunctional independenceVSAvoidmanufacturing cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

By merging the clutch switch and ignition-lock switch into a single manufactured assembly, the patent reduces the total number of parts that need to be produced, stocked, and assembled. The integrated housing and actuator mechanism can be manufactured as a single unit or pre-assembled module, reducing manufacturing steps and labor costs compared to producing and installing two separate switch assemblies.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The universal switch assembly design allows a single component to replace two separate components, directly reducing part count and associated manufacturing costs. The multi-functional design maintains functional independence through internal circuitry that can selectively activate or deactivate different contact points based on actuator position, eliminating the need for separate functional components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of manufacture

If contact points are exposed to outside, then installation is simple, but contact error occurs due to contamination

Engineering Contradiction:

Improveinstallation simplicityVSAvoidcontact reliability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The contact points are nested within the protected interior space of the switch housing. The housing forms an enclosing structure that contains the contact points, actuator mechanism, and internal components. This nested arrangement allows the contact points to remain accessible for electrical connection while being physically shielded from external contaminants such as dust, moisture, and debris that could cause contact errors.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The housing acts as a protective shell or enclosure that seals the internal components from the external environment. The housing structure provides a barrier that prevents contamination while allowing the switch to function normally. This shell protection maintains contact reliability without significantly complicating the installation process, as the entire sealed assembly can be installed as a unit.

Inventive Principle:

Principle #30Flexible shells and thin films

4Object-generated harmful factors

If sliding contact is used, then noise is reduced, but manufacturing precision requirements increase

Engineering Contradiction:

Improveoperation noiseVSAvoidcontact precision

Core Design Contradiction:

Object-generated harmful factorsVSManufacturing precision

Solution Approach 1:

The patent replaces traditional mechanical strike-contact switching with a sliding contact mechanism. Instead of contacts that strike together with impact, the design uses contacts that slide past each other along a defined path, eliminating the impact noise associated with traditional switch operation. This substitution reduces harmful noise generation while the precision requirements are managed through the guided sliding path provided by the housing structure.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS9006594B2Combination switch device for clutch pedal of vehicle

Publication Date: 2015.04.14 HYUNDAI MOTOR CO LTD

AI summary

A combination switch device for a clutch pedal of a vehicle in which functions of a clutch switch and an ignition-lock switch are combined and in which electrical contact action is carried out by a slide motion.