Force Sensor Switch Assembly With Overload Protection

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Solution Overview

Problem

Conventional capacitive touchscreen technologies in vehicles are distracting for drivers and can be damaged by excessive force, as they lack effective overload protection mechanisms.

Innovation Solution

A switch assembly with an energy absorbing pad and protrusions that engage with a housing platform to absorb excess force, preventing damage to force sensors and other components, while allowing for multiple function control with minimal footprint.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional capacitive touchscreen technologies are used, then multiple functions can be controlled, but driver distraction increases and safety decreases

Engineering Contradiction:

Improvecontrol capabilityVSAvoiddriver distraction

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces capacitive touchscreen technology with mechanical switch assemblies that provide tactile feedback. These switches include force sensors, haptic exciters, and force transfer plates that convert user input into mechanical motion and feedback, eliminating the need for visual engagement while maintaining control functionality

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces force transfer plates and haptic exciters as intermediary components between the user input and the control system. These intermediaries provide tactile feedback through the force transfer plate, allowing drivers to confirm inputs without visual attention, thus reducing distraction while preserving control versatility

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-affected harmful factors

If mechanical switches are used, then driver distraction is reduced, but control flexibility and functionality are limited

Engineering Contradiction:

Improvedriver distractionVSAvoidcontrol flexibility

Core Design Contradiction:

Object-affected harmful factorsVSAdaptability or versatility

Solution Approach 1:

The patent designs switch assemblies where a single mechanical switch can control multiple vehicle functions. The force sensors and haptic exciters enable rich interaction modes (press, hold, release patterns) from a compact mechanical structure, providing control flexibility comparable to touchscreens while maintaining safety benefits

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent adds temporal and force-dimensionality to mechanical switches by incorporating haptic feedback timing and force magnitude detection. This allows a single mechanical component to encode multiple control commands through different press patterns, durations, and force levels, expanding control flexibility without increasing switch count

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Ease of operation

If excessive force is applied to switch assemblies, then control input is registered, but force sensors and components are damaged

Engineering Contradiction:

Improveinput registrationVSAvoidcomponent durability

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent incorporates energy absorbing pads positioned between the force transfer plate and the force sensors. These pads are designed to deform and absorb excess force before it reaches the sensitive force sensors, providing beforehand cushioning that protects components from damage while allowing normal operational forces to be transmitted

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The patent introduces energy absorbing pads as intermediary components between the user input and the force sensors. These pads act as a protective mediator that selectively absorbs harmful excessive force while transmitting appropriate operational forces to the sensors, preserving both input registration and component durability

Inventive Principle:

Principle #24Intermediary (Mediator)

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

The solution provides safe, non-distracting operation by absorbing excessive force and protecting the switch assembly components, enabling control of multiple vehicle functions without compromising safety or durability.

Implementation Method 1

an energy absorbing pad disposed between the force transfer plate first surface and the one or more force sensors that deforms to absorb excess force input

Methodology Applied

Scientific EffectDeformation: Deformation

Data Source

PatentUS20220357224A1Switch assembly with overload protection and methods of use

Publication Date: 2022.11.10 JOYSON SAFETY SYSTEMS ACQUISITION LLC

AI summary

Various implementations include a switch assembly that includes a housing and at least one printed circuit board (PCB) disposed within the housing, and one or more force sensors disposed on the PCB. Overload protection is provided for the one or more force sensors using one or both of an energy absorbing pad and/or a force transfer plate having one or more protrusions that engage with a platform defined by the housing to prevent excessive forces from being transferred to the one or more force sensors and damaging them and/or other components of the switch assembly.