Illuminated Pushbutton Switch High Current Handling
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Solution Overview
Problem
Conventional metal button switches are limited to small-current applications and require additional components or increased volume to handle large currents, leading to poor contact stability and increased costs.
Innovation Solution
A metal button switch design with enlarged contact and pin areas, incorporating a waterproof jacket, self-locking hook, and optional LED assembly, allowing for high-current control without volume increase or additional components, ensuring stable operation and waterproofing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the contact area and pin area are enlarged to increase current capacity, then the current handling capability is improved, but the volume of the switch increases
Solution Approach 1:
The patent implements nesting by placing the contact sheet with enlarged contact areas inside the existing switch housing, and positioning the pins with enlarged cross-sectional areas within the available internal space. The contact sheet is nested between the button assembly and the circuit board, while pins are nested within the housing structure, allowing larger current-carrying components to fit without increasing overall switch volume.
Solution Approach 2:
The patent transitions from increasing volume to optimizing area utilization. The contact sheet uses a planar structure with enlarged contact areas distributed across its surface, while pins are designed with enlarged cross-sectional areas. This dimensional optimization allows larger current capacity without proportional volume increase, as the enlargement occurs in two-dimensional areas rather than three-dimensional volume.
2Power
If additional electronic components are added to control large current, then the current handling capability is improved, but the device complexity and cost increase
Solution Approach 1:
The patent extracts the current handling function from the control circuit domain and places it directly in the mechanical switch domain. By designing the contact sheet and pins with inherently large current-carrying capacities, the need for additional electronic current-control components is eliminated. The switch itself becomes the current-handling element rather than requiring external assistance.
Solution Approach 2:
The patent makes the button switch universal by designing it to handle both small and large currents with the same basic structure. The contact sheet and pins are designed with sufficient capacity for large currents while maintaining compatibility with small-current applications, eliminating the need for different switch types or additional control electronics for different current requirements.
3Ease of manufacture
If the button switch structure is simplified for ease of manufacture, then manufacturing cost is reduced, but contact stability deteriorates
Solution Approach 1:
The patent merges the contact elements and pin elements into an integrated assembly where the contact sheet is directly connected to the pins, which are in turn connected to the circuit board. This unified structure ensures stable electrical contact throughout the current path. The button assembly is also merged with the housing structure, providing inherent positioning and stability without requiring complex additional components.
4Object-affected harmful factors
If the switch is designed for waterproofing, then environmental resistance is improved, but manufacturing complexity increases
Solution Approach 1:
The patent employs the housing structure as a protective shell that provides waterproofing. The button assembly is enclosed within the housing, and the contact sheet is positioned inside the sealed environment. This shell-based approach provides effective waterproofing without requiring complex gasket systems or multiple sealing layers, maintaining manufacturing simplicity while achieving environmental resistance.
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
Enables control of both small and large-current electronic devices within the same compact size, enhancing stability and durability while maintaining waterproof functionality.
Implementation Method 1
a first spring abutting against a center of the button part... a plurality of second springs abutting against a bottom side of the switch frame
Data Source
AI summary
An illuminated pushbutton switch is provided. The pushbutton switch includes a case, a button assembly received in the case, and a switch contact assembly disposed in the case. The button assembly includes a button part, a first spring against a center of the button part, a waterproof jacket assembled in the button part, and a frame fixed on the button part. The switch contact assembly includes a switch frame, a plurality of second springs against a bottom side of the switch frame, a contact sheet against the plurality of second springs, a rivet penetrating the contact sheet and the switch frame, a plurality of contacts disposed at an interval from the contact sheet, a plurality of pins used for fixing the contacts, and a bottom case receiving the pins.