Lever Switch Screwless Integration for Photoconductor Placement
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Solution Overview
Problem
Conventional lever switches for steering wheels face challenges in being thin and compact while maintaining strength, as well as achieving a high degree of freedom in photoconductor position and shape due to the need for screw-fastening bosses and integration methods that restrict photoconductor placement.
Innovation Solution
A lever switch design where the operation lever's main and cover sections are integrated without screws, with the photoconductor held between them, using engaging sections and protrusions to secure the assembly, allowing for a thin profile and increased freedom in photoconductor placement and design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the main section and cover section are integrated with screws, then the structural strength is improved, but the lever switch thickness increases due to required boss length
Solution Approach 1:
The operation lever is divided into main section and cover section that are integrated without screws. The main section includes a body and a protrusion, while the cover section includes a recess that receives the protrusion, creating a screwless integrated structure that reduces thickness while maintaining strength
Solution Approach 2:
The screw fastening mechanism is completely removed from the design. Instead of using screws and bosses, the patent employs a protrusion-recess interference fit mechanism that eliminates the need for threaded fasteners, thereby reducing the required thickness for structural integrity
2Strength
If bosses are provided for screw fastening, then the integration strength is improved, but the photoconductor positioning freedom is reduced due to space occupation
Solution Approach 1:
The operation lever is segmented into functional zones: the protrusion-recess integration mechanism occupies minimal space, while the photoconductor is positioned in a dedicated recess area. This segmentation allows both strong integration and flexible photoconductor placement without interference from fastening structures
Solution Approach 2:
By removing the boss structure entirely, the patent eliminates the spatial constraint that would interfere with photoconductor positioning. The photoconductor can now be freely placed in the recess area of the cover section without needing to avoid screw fastening elements
3Productivity
If insert molding is used to integrate photoconductor, then the integration efficiency is improved, but the photoconductor design freedom is reduced
Solution Approach 1:
The cover section is designed with a recess that specifically accommodates the photoconductor. This recess structure allows the photoconductor to be positioned and fixed during assembly without requiring insert molding, maintaining design flexibility while achieving efficient integration through the protrusion-recess mechanism
Solution Approach 2:
The patent removes the insert molding process from the manufacturing sequence. Instead, the photoconductor is simply placed in the recess and held by the integrated main and cover sections, eliminating the constraint of mold cavity design on photoconductor shape and position
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 results in a thinner lever switch with enhanced photoconductor positioning and increased design flexibility, eliminating the need for screw-fastening bosses and allowing for secure and efficient assembly, while maintaining structural integrity.
Implementation Method 1
a photoconductor which is integrated with an operation lever of the lever switch by insert molding or the like so that the photoconductor guides light from a light source in a base section of the operation lever to a tip end section of the operation lever
Data Source
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AI summary
An operation lever (10) comprises a main section, a cover section and a photoconductor. While the photoconductor (50) is overlaid on the main section (60), sliding protrusions of the cover section (70) are inserted into guide grooves formed in the periphery of the main section, the cover section is slidingly pushed to insert a tip end section (71) of the cover section inside an overhanging fringe (66) of the main section. An engaging protrusion (78) and an engaging pawl of the cover section are engaged with the main section to assemble the operation lever.