Deformable Cap Switch for Lock Position Detection

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Solution Overview

Problem

Existing lock device sensors are often bulky, complicated, and prone to errors, lacking sufficient protection against moisture and climate conditions.

Innovation Solution

A switch comprising a deformable cap in contact with a printed circuit board, enclosed by a potting compound, providing climate protection and enabling compact, reliable detection of movable components in lock devices.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a sensor is used to detect the position of a movable component in a lock device, then the position detection function is achieved, but the device becomes bulky, complicated, and error-prone

Engineering Contradiction:
Improveposition detection reliabilityVSAvoidsensor assembly complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent extracts the sensing function from a complex sensor assembly and implements it through a simple mechanical switch structure. The switch comprises a cap with a movable contact that directly detects the position of movable components (such as the bolt) through mechanical contact, eliminating the need for complex optical or electronic sensors. This extraction of the essential sensing function to a simple mechanical structure resolves the contradiction between reliability and complexity.

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The patent employs a simple, inexpensive mechanical switch structure instead of expensive, complex sensors. The switch uses basic components like a cap, movable contact, and stationary contact that can be easily manufactured and replaced. This approach trades the longevity and complexity of electronic sensors for a simple, durable mechanical structure that is easier to maintain and less prone to errors in the harsh environment of lock devices.

Inventive Principle:
Principle #27Cheap short-living objects (Disposable)

2Reliability

If prior art sensors are used in lock devices, then position detection is possible, but they lack sufficient protection against moisture and climate conditions

Engineering Contradiction:
Improveclimate protectionVSAvoidmoisture and water exposure
Core Design Contradiction:
ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent uses a cap made of flexible material that encapsulates the movable contact and provides protection against moisture and climate conditions. The cap acts as a flexible shell that seals the internal components while allowing mechanical deformation to occur. This flexible enclosure protects the switch components from harmful environmental factors like moisture and water, resolving the contradiction between reliability and environmental exposure.

Inventive Principle:
Principle #30Flexible shells and thin films

Solution Approach 2:

The cap serves as an intermediary element between the movable contact and the external environment. It provides a protective barrier that isolates the electrical components from moisture and climate conditions while still allowing the mechanical function to operate. The cap mediates between the need for environmental protection and the need for mechanical movement, solving the contradiction through this intermediate protective structure.

Inventive Principle:
Principle #24Intermediary (Mediator)

3Ease of operation

If a compact switch design is used, then easy integration into lock devices is achieved, but sufficient climate protection may be compromised

Engineering Contradiction:
Improveintegration easeVSAvoidclimate protection
Core Design Contradiction:
Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The patent merges multiple functions into a single compact structure. The cap simultaneously serves as the housing for the movable contact, the protection against climate conditions, and the element that deforms to activate the switch. By combining the protective enclosure and the actuating mechanism into one integrated component, the design achieves both compactness for easy integration and sufficient climate protection.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The cap is designed as a multi-functional element that provides structural support, environmental protection, and mechanical actuation capability. This universal component performs multiple functions within a single element, enabling the switch to be compact and easy to integrate while maintaining adequate protection against climate conditions. The multi-functionality of the cap resolves the contradiction between size and protection.

Inventive Principle:
Principle #6Universality (Multi-functionality)

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 switch offers durable, compact, and reliable detection of lock device states, with improved moisture resistance and reduced risk of false activations, enabling easy integration into lock devices without compromising design or functionality.

Implementation Method 1

the cap being arranged to be deformed from a disconnected state where the movable contact is separated from the stationary contact to a connected state where the movable contact contacts the stationary contact

Methodology Applied
Scientific EffectDeformation: Deformation

Implementation Method 2

a potting compound enclosing the PCB and the cap. The potting compound and the cap provide a full climate protection of the movable contact and the stationary contact, such as a protection against moisture and water

Methodology Applied
Scientific EffectPhysical containment: Physical Containment

Data Source

PatentEP4540847B1Switch and lock device
Publication Date: 2026.02.18 ASSA ABLOY AB
  • EP4540847B1 patent drawingFigure 1
  • EP4540847B1 patent drawingFigure 2
  • EP4540847B1 patent drawingFigure 3

AI summary

A switch (28) comprising a printed circuit board assembly, PCBA, (74) including a printed circuit board, PCB, (75) and a stationary contact (72); a cap (30) in contact with the PCB (75) such that the cap (30) and the PCB (75) define a switch chamber (68) for the stationary contact (72), the cap (30) carrying a movable contact (70), the cap (30) being arranged to be deformed from a disconnected state (36) where the movable contact (70) is separated from the stationary contact (72) to a connected state (92) where the movable contact (70) contacts the stationary contact (72), and the cap (30) being forced towards the disconnected state (36); an actuator (32) movable relative to the stationary contact (72) between an activated position (90) where the actuator (32) pushes the cap (30) to the connected state (92), and a deactivated position (34) allowing the cap (30) to be forced to the disconnected state (36); and a potting compound (76) enclosing the PCB (75) and the cap (30). A lock device (10) comprising a switch (28) is also provided.