Standardized Lead Frame Layout for Multi-Circuit Switch Assembly

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Solution Overview

Problem

Existing switch devices require different lead frame layouts for different electrical circuit types, leading to increased costs due to the need for customized molds and designs.

Innovation Solution

A common lead frame design that integrates a first frame, a second frame, and a fixed contact piece, allowing for the formation of electrical circuits with or without resistance elements by installing resistance elements to specific installation parts and cutting the conductive connection part, and is integrated with a resin case through insert molding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If different lead frame layouts are used for different electrical circuit types, then the electrical circuit functionality is achieved, but the manufacturing cost increases due to customized molds and designs

Engineering Contradiction:

Improveelectrical circuit type varietyVSAvoidmanufacturing cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent applies universality by designing a single standardized lead frame that can serve multiple electrical circuit configurations. The lead frame includes a common body with multiple terminal parts and resistance element installation parts that can be configured to form different circuit types (series, parallel, or without resistance elements) through selective assembly and connection methods, eliminating the need for different lead frame designs for different circuit types.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If different lead frame layouts are used for different electrical circuit types, then the electrical circuit functionality is achieved, but the device complexity increases due to multiple mold designs

Engineering Contradiction:

Improveelectrical circuit type varietyVSAvoidmold design complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If resistance elements are exposed in the lead frame, then the electrical circuit functionality is achieved, but the reliability decreases due to heat and corrosion exposure

Engineering Contradiction:

Improveelectrical circuit functionalityVSAvoidresistance element protection

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent applies the nested doll principle by placing the resistance elements inside the lead frame body, nesting them within the protective structure. The resistance elements are mounted on installation parts that are integrated into the lead frame body, which encloses and protects them from external environmental factors such as heat and corrosion, while still allowing electrical connectivity.

Inventive Principle:

Principle #7Nested doll (Nesting)

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 the formation of multiple electrical circuit types using a standardized lead frame, reducing costs by sharing molds and improving assembly and sealing properties while preventing resistance element exposure to heat and corrosion.

Implementation Method 1

a resin sealing process of resin sealing the resistance elements mounted in the mounting process together with the first frame and the second frame and the fixed contact piece by insert molding

Methodology Applied

Scientific EffectInsert molding:

Data Source

PatentUS12412710B2Lead frame and manufacturing method of lead frame insert molded article

Publication Date: 2025.09.09 OMRON CORP

AI summary

A lead frame 10 includes first and second frames 13, 14 and a fixed contact piece 15. The fixed contact piece 15 is integrally formed with the first frame via a conductive connection part 16. The first frame and the fixed contact piece 15 and the second frame have installation parts 13a, 14a, 14b, 15b to which resistance elements are able to install. The first frame 13 and the fixed contact piece have installation parts 13b, 15a to which resistance elements are able to install. Electrical circuits of different types are formed through combinations of whether the resistance elements are installed to the respective installation parts and whether the conductive connection part 16 is cut off.