Elastic Sheet Horizontal Positioning for Low-Profile Electronic Switch
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Solution Overview
Problem
Conventional electronic switches have a high vertical bulk due to the vertical stacking of components, which increases their size and can compromise mechanical resistance and switch life, and the use of a metal cage to maintain the pushbutton position adds height, making it challenging to reduce the overall height without affecting operation.
Innovation Solution
The design incorporates a horizontal bottom plate with an elastically deformable contactor and a second intermediate elastic sheet that positions the pushbutton horizontally, using a cylindrical recess and a radially abutting insert to maintain contact without increasing the switch's height, and a pushbutton made of permanently deformable material crimped onto the insert to secure it in place.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a metal cage is used to maintain the pushbutton position on the contactor, then the pushbutton is horizontally positioned and upward displacement is blocked, but the overall height of the switch is increased
Solution Approach 1:
The patent replaces the rigid metal cage with a flexible elastic sheet that has a recess receiving the pushbutton. The elastic sheet's flexibility allows it to provide positioning and retention functions without the height of a rigid cage structure, thereby reducing the overall switch height while maintaining pushbutton positioning capability.
Solution Approach 2:
The elastic sheet acts as an intermediary element between the contactor and the pushbutton, providing a compliant interface that positions the pushbutton horizontally and retains it without requiring the additional height of a metal cage. The sheet's elasticity allows it to deform and accommodate the pushbutton while maintaining the required positioning function.
2Length of stationary object
If the vertical dimension of each component is reduced to reduce overall height, then the switch height is reduced, but the mechanical resistance is reduced which can reduce switch life
Solution Approach 1:
The patent changes the material parameter of the contactor to an elastically deformable material, allowing it to be made thinner while maintaining mechanical strength through elastic deformation capability. This enables reduction of vertical dimension without proportionally reducing mechanical resistance, as the elastic material can withstand repeated deformation cycles within a reduced thickness.
Solution Approach 2:
The patent uses composite construction with multiple elastic sheets and deformable components that work together to provide both reduced height and maintained mechanical resistance. The combination of elastic materials with different properties allows the structure to be compact while retaining the necessary durability and resistance for long-term operation.
3Ease of manufacture
If components are vertically stacked to assemble the switch, then assembly is simplified, but the vertical bulk is increased
Solution Approach 1:
The patent merges multiple functions into the elastic sheet component, which simultaneously provides protection for the contactor, horizontal positioning of the pushbutton, and retention of the pushbutton. This consolidation eliminates the need for separate components like the metal cage, thereby reducing vertical bulk while maintaining assembly simplicity through the integrated elastic sheet structure.
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 configuration reduces the vertical bulk of the switch while maintaining mechanical resistance and operation, allowing for smaller dimensions without compromising reliability or switch life.
Implementation Method 1
A contactor (14) may be positioned on the top side of the bottom plate (12) and may be elastically deformable to electrically link at least two electrical contacts
Implementation Method 2
The second sheet (28) may include an elastic insert with a central orifice passed through by the pushbutton, the insert radially abutting against the vertical walls of the recess
Implementation Method 3
The pushbutton (24) may be made of a permanently deformable material, which is joined to the insert by crimping
Data Source
AI summary
An electronic switch may include a horizontal bottom plate, a top side of the plate may support at least two electrical contacts. A contactor may be positioned on the top side of the plate and may be elastically deformable to electrically link the at least two electrical contacts. A pushbutton may be positioned vertically above the contactor such that manual displacement of the pushbutton downward may provoke the elastic deformation of the contactor. A first elastic sheet may include a top film protecting the contactor. The top film may be fixed to the top side of the plate to secure the contactor vertically on the plate to form an opening so that the pushbutton may act directly on the contactor. A second elastic sheet may position the pushbutton horizontally relative to the contactor on a top side of which the top film may be fixed.