Actuator biased by horizontal resilient member
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Electrical wiring devices with spring mechanisms displaced along their longitudinal axis occupy valuable space and increase manufacturing costs due to the need for additional components, particularly in interchangeable color change kits.
Innovation Solution
A switch actuator assembly with a resilient member biased perpendicular to its longitudinal axis, allowing the rocker to pivot and actuate the switch without requiring additional depth, using a frame, rocker, and resilient member configuration that minimizes space usage and component count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the spring mechanism is displaced along its longitudinal axis, then the actuator can be actuated, but the overall depth of the wiring device increases
Solution Approach 1:
The spring mechanism is reconfigured to deflect perpendicular to its longitudinal axis rather than along it. The resilient member extends between opposite sides of the frame and deflects upward when the actuator is pressed, utilizing a different spatial dimension for the mechanical action. This dimensional change allows the same actuation function to be achieved without increasing the overall depth of the device.
2Ease of operation
If the spring mechanism is displaced along its longitudinal axis, then the actuator can be actuated, but additional components such as lever mechanism are required
Solution Approach 1:
The resilient member is directly coupled to the actuator body, merging the spring mechanism and actuator into a single integrated assembly. The actuator body itself serves as the lever arm that pivots on the axis, eliminating the need for separate lever mechanisms. This consolidation reduces the number of components while maintaining the actuation function.
Solution Approach 2:
The actuator body performs multiple functions: it serves as the lever arm for actuation, the mounting structure for the resilient member, and the component that directly interfaces with the switch mechanism. This multi-functionality eliminates the need for separate dedicated lever components.
3Ease of operation
If the spring mechanism is displaced along its longitudinal axis, then the actuator can be actuated, but manufacturing costs increase
Solution Approach 1:
The resilient member and actuator body are designed as an integrated assembly that can be molded as a single piece or pre-assembled unit. This reduces the number of separate manufacturing steps, inventory requirements, and assembly operations, thereby lowering manufacturing costs.
Solution Approach 2:
The design eliminates the need for separate lever mechanisms and associated manufacturing processes. By integrating the lever function into the actuator body itself, the manufacturing process is simplified, inventory management is reduced, and assembly time is decreased, all of which contribute to lower manufacturing costs.
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 design reduces the overall depth of the wiring device, simplifies manufacturing, and decreases costs by eliminating the need for extra components, while maintaining a balanced user experience and enabling easy color changes.
Implementation Method 1
a resilient member extending between opposite sides of the frame and deflecting perpendicular to a longitudinal axis of the resilient member when the rocker is in the first position and the second position
Data Source
AI summary
An exemplary embodiment of an electrical device is disclosed. The electrical wiring device preferably includes a frame, a rocker, and a resilient member. In use, the rocker pivotally rotates through a range of travel, for example, from a first position to a second position. As the rocker moves, the resilient member imparts a force on the rocker, biasing the rocker in the first position and the second position. In a particularly preferred embodiment, the resilient member extends horizontally across the electrical wiring device (e.g., along a minor axis of the rocker).