Elastomer Switch Mounting in Power Tool Housings for Vibration Damping
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Solution Overview
Problem
Hand-held power tools face challenges in operational reliability due to vibrations and mechanical stress on switches, which can lead to damage or disconnection from the drive motor, exacerbated by assembly tolerances and vibrations during use.
Innovation Solution
The integration of elastomer elements both inside and outside the housing, connected via an opening in the housing wall, provides vibration damping and allows for increased assembly tolerance, securing the switch and reducing the risk of damage by acting as a resilient elastomer bearing for the switch and potentially other components, while also enhancing grip and handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the switch is mounted directly in the housing with rigid fixation, then the connection between switch and drive motor is secure, but vibrations and mechanical stress can damage the switch or cause disconnection
Solution Approach 1:
An elastomer element is introduced as an intermediary mounting component between the switch and the housing. This elastomer element absorbs vibrations and mechanical stress, protecting the switch from damage while maintaining secure connection. The elastomer acts as a mediator that decouples the rigid connection, allowing the switch to remain firmly mounted while isolating it from harmful vibrational forces generated during tool operation.
2Reliability
If assembly tolerances are reduced to ensure precise switch positioning, then vibration damage is minimized, but manufacturing complexity and cost increase
Solution Approach 1:
The elastomer element changes the mechanical parameters of the mounting system by introducing elasticity and compliance. This allows the mounting structure to accommodate tolerance variations in both the housing and switch dimensions while maintaining reliable connection. The elastomer's deformable nature compensates for dimensional variations, eliminating the need for tight tolerance specifications and simplifying manufacturing requirements.
3Reliability
If the switch mounting structure is made more robust to prevent damage, then operational reliability improves, but the device complexity and assembly difficulty increase
Solution Approach 1:
The elastomer element serves as a simple, inexpensive protective component that can be easily replaced if needed. Rather than designing a complex robust mounting structure, the solution uses a simple elastomeric component that provides vibration damping and shock absorption. This approach achieves reliable switch mounting through a simple, low-cost element rather than a complex structural 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 solution effectively dampens vibrations and maintains secure connections between the switch and drive motor, reducing the risk of damage and improving operational reliability and user comfort through enhanced grip and handling.
Implementation Method 1
the elastomer element located on the inside of the housing forms an elastomer bearing for mounting the switch. Due to the mounting of the switch inside the housing on the soft material, there is effective vibration damping of the switch
Implementation Method 2
elastomer elements are injection-molded on the outside of the housing and on the inside of the housing
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a hand-held power tool (1) having a drive unit in a housing (2) that is to be switched on and off by means of a switch device, which comprises a switch (10), which is accommodated inside the housing (2). Elastomer elements (9, 14) are molded onto the outside of the housing and onto the inside of the housing and are connected to each other via an opening in the housing wall, wherein the elastomer element (14) on the inside of the housing forms an elastomer bearing for supporting the switch (10).