Electrical Switch Integrated Terminal Structure
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Solution Overview
Problem
The challenge is to simplify the construction of keyboard switches while maintaining performance and reducing production costs, particularly in the context of rising copper and material costs.
Innovation Solution
The design features a switch body composed of upper and lower parts with actuators, individual switch terminals, and a common switch terminal with cam sliders, along with a self-gripping device for conductor connection, allowing for efficient assembly and reduced material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional keyboard switch construction is used with multiple separate terminals and complex assembly, then switching functionality is achieved, but manufacturing cost increases and production complexity rises
Solution Approach 1:
The patent combines multiple separate switch terminals into a single integrated terminal structure. The terminal integrates a common contact portion and multiple individual contact parts into one piece, eliminating the need for multiple separate terminals and reducing assembly steps. This merging directly addresses the contradiction by simplifying construction while maintaining switching functionality.
Solution Approach 2:
The integrated terminal structure serves multiple functions simultaneously: it provides common connections, individual connections, and switching paths all within a single component. The terminal can connect to multiple actuators and switches independently while maintaining a unified structure, reducing overall device complexity without sacrificing functionality.
2Reliability
If more copper and materials are used in switch terminals, then current rating and performance are maintained, but material costs increase
Solution Approach 1:
The patent applies different material properties or cross-sectional areas to different parts of the terminal structure. The common contact portion may have different copper content or thickness compared to individual contact parts, optimizing material distribution based on local current carrying requirements. This ensures adequate current rating where needed while reducing overall material consumption.
Solution Approach 2:
The terminal structure utilizes composite construction with copper strips and contact portions that may have varying copper content or be combined with other materials. This allows optimization of electrical conductivity and mechanical strength while controlling overall material quantity and cost.
3Productivity
If traditional assembly methods are used for switch terminals, then electrical connections are established, but production time and assembly complexity increase
Solution Approach 1:
The integrated terminal is designed with segmented contact parts that can be independently positioned and connected to different actuators. This segmentation allows for modular assembly where the terminal can be installed as a single unit rather than assembling multiple separate terminals, significantly reducing assembly time and improving productivity.
Data Source
AI summary
An electrical switch has a switch body with upper and lower body parts; actuators; individual switch terminals, each switch terminal having a contact part in the switch body; a common switch terminal having a contact portion in the switch body; and cam sliders extending side-by-side between the actuators and the contact parts of the individual switch terminals, sliding to move the contact parts into and out of contact with the common switch terminal. The contact portion of the common switch terminal extends across the contact parts of the individual switch terminals. The contact portion is sandwiched by the upper and lower body parts. At least two individual switch terminals are located along one side of the switch body, each individual switch terminal having an aperture accessible on the same side of the switch body, in which two ends of a conductor are insertable to short-circuit the two individual switch terminals.