Interlocking Switch Connector Assembly to Reduce Tolerance Stack-Up
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Solution Overview
Problem
Existing button structures for electronic devices are cumbersome due to multiple components, leading to increased assembly time, space consumption, and tolerance stack-up, which affects the tactile quality of the push-button.
Innovation Solution
A button structure comprising a switch assembly with a switch and a connector that interlock, reducing the number of components and assembly steps, while providing a stable and secure connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple components (button, button retainer, sealing element, screws) are used to connect the button to the housing, then the connection is secure and sealing is provided, but the assembly time increases and manufacturing becomes more complex
Solution Approach 1:
The patent combines the button retainer and sealing element into a single integrated component. The sealing element is formed as an integral part of the button retainer, eliminating the need for separate sealing elements and reducing the number of assembly steps while maintaining both structural support and sealing functions
Solution Approach 2:
The button retainer is designed to perform multiple functions simultaneously: it provides mechanical support for the button, creates sealing engagement with the housing, and serves as the mounting structure for electrical connections. This multi-functional design reduces the total component count while maintaining reliability
2Reliability
If multiple components (button, button retainer, sealing element, screws) are used to connect the button to the housing, then the connection is secure, but the space consumption increases
Solution Approach 1:
The patent combines the button retainer and sealing element into a single integrated component, reducing the total volume occupied by multiple separate parts and their associated fastening elements. The integrated design eliminates gaps and interfaces between separate components, optimizing space utilization
3Reliability
If multiple components (button, button retainer, sealing element, screws) are used to connect the button to the housing, then the connection is secure, but the tolerance stack-up increases and tactile qualities deteriorate
Solution Approach 1:
The patent combines the button retainer and sealing element into a single molded component, reducing the number of interfaces and mating surfaces where tolerances accumulate. This integration minimizes tolerance stack-up and improves the precision of button positioning and tactile response
Solution Approach 2:
The button assembly is segmented into functionally integrated components rather than fully separate parts. The sealing element is integrated into the retainer as a unified component with specific geometric features, reducing assembly variability while maintaining functional separation between sealing and mechanical support roles
Data Source
Figure 1(a)~1(c)
Figure 2(a)~3
Figure 4(a)~4(b)
AI summary
A switch assembly (1) comprising a switch (2) and a connector (3), the switch (2) and the connector (3) being configured to interlock, and wherein the switch (2) comprises connection means (4) extending at least partially along a center axis (C) of the switch, the connection means (4) being configured to receive at least a part of the connector (3).