Magnetic Switch Mobile Element Anchoring for Sensitivity
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Solution Overview
Problem
Existing switches face challenges in manufacturing due to residual stresses that lead to deformation, requiring higher magnetic field strengths for actuation, and are often unreliable and space-consuming.
Innovation Solution
The development of a switch with a mobile element featuring a plurality of anchoring members spaced apart to minimize deformation, accompanied by a beam that moves to establish an electrical pathway, reducing initial deformation and increasing magnetic sensitivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional mobile elements are used in switch manufacture, then the manufacturing process is simpler, but residual stresses cause deformation requiring greater magnetic field strength for actuation
Solution Approach 1:
The mobile element is divided into multiple segments (first mobile element and second mobile element) that can independently respond to magnetic fields. This segmentation allows each segment to be smaller and more controllable, reducing the overall magnetic field strength needed while maintaining actuation effectiveness and minimizing deformation from residual stresses.
Solution Approach 2:
Different portions of the mobile element structure are given different properties - the anchoring members provide stable attachment points while the beam portions remain flexible for actuation. This local differentiation allows the structure to resist deformation where needed while maintaining mobility where required, reducing the magnetic field strength needed for actuation.
2Use of energy by moving object
If reed switches are used, then power consumption is minimal, but they are unreliable, delicate, and space-consuming
Solution Approach 1:
The switch design incorporates mobile elements that can dynamically respond to magnetic fields with controlled movement. The mobile elements are designed to move reliably between contact and non-contact states, providing dependable switching action while maintaining low power consumption through magnetic field actuation rather than continuous electrical power.
Solution Approach 2:
The invention uses magnetic field patterns or templates to guide the formation of mobile elements during manufacturing, ensuring consistent and reliable structure formation. This copying approach allows for precise replication of the desired element geometry, improving reliability while maintaining the low-power magnetic actuation characteristic.
3Ease of manufacture
If mobile elements have residual stress from manufacture, then manufacturing is straightforward, but deformation occurs requiring greater magnetic field strength
Solution Approach 1:
The manufacturing process includes preliminary stress relief treatments and precise formation steps that prepare the mobile elements before final assembly. By addressing residual stress issues during the formation process itself rather than as a separate correction step, the elements achieve accurate shapes with minimal deformation while maintaining manufacturing feasibility.
Solution Approach 2:
The invention employs controlled changes in material parameters and processing conditions during mobile element formation to minimize residual stress buildup. By adjusting deposition parameters, annealing conditions, or structural geometry parameters, the manufacturing process produces elements with reduced internal stresses that would otherwise cause deformation, achieving both ease of manufacture and shape accuracy.
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
The solution enables switches to be actuated by a lower strength magnetic field, improving sensitivity and reliability while reducing the need for higher magnetic field strengths, resulting in a more efficient and reliable switching mechanism.
Implementation Method 1
a beam extending from the plurality of anchoring members, the beam having an end portion that is adapted to move toward the second conductive portion upon exposure to an external force
Data Source
AI summary
Switches that are actuated through exposure to a magnetic field are described. A mobile element of a switch includes one or more anchoring members that are in electrical contact with one of the conductive portions. The mobile element also has a beam that is attached to the one or more anchoring members. The beam can be attached to the one or more anchoring members by flexures. The beam has an end portion that is configured to move toward the other conductive portion when exposed to an external force, such as a magnetic field. Various configurations of anchoring members may significantly decrease initial upward beam deformation upon manufacture of the mobile element, resulting in an increased sensitivity upon exposure to a magnetic field. Methods for manufacturing switches that exhibit increased sensitivity to magnetic fields are also disclosed.