Magnetic Switch Assembly Actuation via Segmented Magnets
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Solution Overview
Problem
Existing magnetic toggle switches and fluid-level sensing devices lack a comprehensive solution for selectively controlling electrical circuit continuity with enhanced responsiveness and protection from environmental factors.
Innovation Solution
A magnetic switch assembly featuring a toggle bar and switch actuator with interacting magnets, which rotate to selectively engage and disengage electrical contacts, controlling power flow to electrical loads by adjusting magnetic attraction and bias forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If magnetic forces are used to actuate the switch through the housing wall, then the switch can be sealed to protect from corrosion and environmental factors, but the response time and sensitivity may be reduced due to the housing wall interference
Solution Approach 1:
The patent uses magnetic fields as an intermediary to transmit actuation force through the housing wall without physical contact. The first magnet on the float and second magnet on the microswitch arm enable magnetic coupling across the housing wall, allowing the switch to remain sealed while maintaining responsive operation. This resolves the contradiction by providing both corrosion protection and fast response time through non-contact magnetic actuation.
2Speed
If a wide float switch body is used for enhanced water displacement, then the responsiveness is improved, but the device complexity and size increase
Solution Approach 1:
The patent replaces the traditional wide float mechanism with a magnetic actuation system. Instead of relying on a large float body for mechanical water displacement, the invention uses magnetic forces transmitted through the housing wall to actuate the microswitch. This substitution maintains responsiveness while significantly reducing the size and complexity of the float switch body.
3Measurement precision
If magnets are positioned close together for strong magnetic interaction, then the switching sensitivity is improved, but the risk of magnetic interference and unintended actuation increases
Solution Approach 1:
The patent segments the magnetic actuation system into two separate magnets positioned at different locations: the first magnet on the float and the second magnet on the microswitch arm. This segmentation allows for controlled magnetic interaction only when the float reaches the appropriate water level, providing high switching sensitivity while minimizing magnetic interference. The distributed magnet arrangement ensures that strong magnetic forces are generated only at the intended actuation point.
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 magnetic switch assembly provides reliable and responsive control of electrical circuit continuity, ensuring efficient power delivery and protection from environmental factors through precise magnetic interaction and bias mechanisms.
Implementation Method 1
A first magnet is mounted on the toggle bar and a second magnet is mounted on the switch actuator such that the magnetic fields selectively interact
Data Source
AI summary
A magnetic switch assembly comprising a toggle bar and a switch actuator each rotatable between a first position and a second position, at least one set of magnets including a first magnet mounted on the proximal end portion of the toggle bar and a second magnet mounted on the proximal end portion of the switch actuator and a corresponding pair of electrical contacts including a first electrical contact coupled to a first electrical conductor and a second electrical contact coupled to a second electrical conductor wherein the toggle bar is normally bias in the first position when the switch actuator is in the first position with the first magnet disposed in spaced relationship relative to the second magnet when each is in the first position and having a gap therebetween such that the first electrical contact and the second electrical contact engage each other to complete an electrical circuit between the first electrical conductor and the second electrical conductor and when the switch actuator is moved from the first position to the second position decreasing the gap between the first magnet and the second magnet as the magnetic attraction therebetween overcomes the toggle bar bias disengaging the second electrical contact from the first electrical contact to create an open electrical circuit.