Fixed Contact Pattern with I-Shaped and L-Shaped Gaps for Switch Reliability
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Solution Overview
Problem
Conventional switch devices with complex contact patterns suffer from non-sensitive regions due to uneven gap distances, leading to unreliable operation, especially when the movable contact is inclined, resulting in a bulky and complicated design.
Innovation Solution
A fixed contact pattern featuring an I-shaped gap with L-shaped and lateral gaps arranged point-symmetrically, ensuring equal distances between open ends and orthogonal extensions beyond a virtual straight line, enhancing contact reliability even when the movable contact is inclined.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional contact patterns with multiple gaps and conductive layers are used, then contact reliability is improved, but device complexity and size increase
Solution Approach 1:
The fixed contact is divided into multiple conductive portions (first, second, third, fourth conductive portions) separated by gaps. This segmentation allows the contact pattern to detect inclined movements of the movable contact by establishing electrical connections between different conductive portions, thereby improving contact reliability while maintaining a relatively simple overall structure.
Solution Approach 2:
The gaps are designed with asymmetric characteristics - the first gap has a first distance from one open end to the movable contact and a second distance from the other open end, where these distances differ. This asymmetric gap design enables the contact pattern to reliably detect inclined contacts by creating different electrical connection paths depending on the angle of contact.
2Ease of manufacture
If conventional contact patterns with unequal gap distances are used, then manufacturing is simplified, but non-sensitive regions are created leading to unreliable operation
Solution Approach 1:
Different gaps in the contact pattern are designed with different local characteristics - the first gap has specific distance relationships (first distance and second distance) that differ from other gaps. This local quality variation ensures that each gap is optimized for its specific position, eliminating non-sensitive regions while maintaining manufacturing feasibility.
3Ease of operation
If the movable contact is allowed to be inclined during operation, then ease of operation is improved, but contact detection reliability deteriorates
Solution Approach 1:
The contact pattern is designed to dynamically adapt to inclined contacts through its segmented conductive portions and asymmetric gaps. When the movable contact is pushed at an angle, the electrical connection is established between specific conductive portions based on the inclination angle, allowing the system to maintain reliable detection across various operational orientations.
Data Source
AI summary
Gaps that divide a conductive portion include an I-shaped gap that passes through the center of a fixed contact, and L-shaped gaps that are located on both sides of the I-shaped gap. Longitudinal gap of the L-shaped gaps extend beyond a virtual straight line A-A that passes through the center of the fixed contact and extend in the direction orthogonal to the I-shaped gap, and are connected to lateral gaps. The L-shaped gaps are arranged point-symmetrically about the center of the fixed contact.