Diaphragm Contact Durability in Pressure Switches
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Solution Overview
Problem
The pressure switch with a curved diaphragm experiences instability in electric connection due to wear at the plated peak, leading to potential continuity defects.
Innovation Solution
A method of manufacturing a diaphragm with a contact involves bonding a durable contact stock to a thin metal sheet stock, forming a movable contact with excellent durability and electrical continuity, and blanking the stock to create a diaphragm with a contact that can withstand pressure changes without peeling or wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a plated membrane is applied to the peak of the curved diaphragm to improve electrical continuity, then electrical connection is enhanced, but the plated membrane peels off due to repeated contact, leading to contact wear and instability
Solution Approach 1:
The patent uses a composite structure consisting of a flexible printed circuit board (FPC) as the base material and a plated membrane (gold or other conductive plating) as the contact surface layer. This composite material approach allows the FPC to provide mechanical flexibility and structural support while the plated membrane provides excellent electrical conductivity and contact performance. The combination resolves the contradiction by ensuring that the plated membrane remains firmly attached to the FPC substrate, preventing peeling and contact wear while maintaining stable electrical connection.
2Reliability
If grid-like multipoint contacts are used to prevent continuity defects caused by foreign substances, then reliability against contamination is improved, but the structure becomes more complex
Solution Approach 1:
The patent extracts and eliminates the complex grid-like multipoint contact structure from the design. Instead of using multiple contact points arranged in a grid pattern, the invention employs a single, simple plated membrane contact area on the FPC. This simplified structure maintains reliability by providing a smooth, contamination-resistant contact surface that is less likely to trap foreign substances, while significantly reducing structural complexity compared to the grid-like design.
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 enhances the durability and reliability of the diaphragm's contact, ensuring stable electrical continuity and improved performance in pressure switches.
Implementation Method 1
bonding a contact stock to a stock made of a thin metal sheet material
Implementation Method 2
configured to be displaced in response to a pressure inside the pressure-receiving chamber
Data Source
AI summary
In a method of manufacturing a diaphragm with a contact, contact stocks each forming a movable contact on a stock formed out of a strip-shaped thin metal sheet material, or a rolled material are bonded at predetermined intervals to the stock by resistance welding, for example to form a diaphragm stock with a contact. Next, the stock of a diaphragm with a contact is subjected to continuous blanking with a predetermined diameter from each movable contact as center to produce a diaphragm with a contact.