Micro-switch Contact with Dual-Arched Geometry
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Solution Overview
Problem
Electric micro-switches face challenges in maintaining a consistent and short bounce time across various operating states and environmental influences due to mass, geometry, and electrical resistance issues, while also requiring efficient manufacturing with minimal precious metal usage.
Innovation Solution
The micro-switch features contacts with a bent portion and a planar counter contact, both made from stamped and hardened materials, with a rounded outer surface forming archings in two perpendicular planes, allowing for point-like contact and reduced mass, and coated with conductive materials like precious metals or carbon to minimize vibrations and electrical resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If contacts are made with large surface area to reduce electrical resistance, then electrical resistance decreases, but bounce time increases due to larger contact geometry
Solution Approach 1:
The contact element features a dual-arched geometry with different curvatures in perpendicular planes, creating locally optimized contact characteristics. The first arching in a first plane and second arching in a second plane perpendicular to the first plane creates point-like contact regions that maintain low electrical resistance while minimizing contact surface area to reduce bounce time.
2Strength
If contacts are made with high mass to increase durability, then strength increases, but bounce time increases due to larger moved mass
Solution Approach 1:
The contact element's geometry is optimized by introducing dual archings that create point-like contact regions. This parameter change in the contact geometry reduces the effective contact surface area and moved mass, thereby reducing bounce time while maintaining sufficient strength through the arched structural design.
3Loss of time
If contacts are made with complex geometry to maintain point-like contact, then bounce time decreases, but manufacturing complexity increases
Solution Approach 1:
The contact element incorporates dual arched geometries with curved surfaces in perpendicular planes, creating point-like contact regions. The first arching and second arching in perpendicular planes produce the desired point contact geometry that minimizes bounce time while being manufacturable through standard forming processes.
4Reliability
If contacts are made with extensive precious metal coating to reduce electrical resistance, then electrical resistance decreases, but manufacturing cost increases
Solution Approach 1:
The dual-arched geometry creates localized point-like contact regions, which means precious metal coatings are only required in these specific contact areas rather than across the entire contact surface. This local application of conductive material reduces the total amount of precious metal needed while maintaining low electrical resistance at the contact points.
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 achieves a short bounce time, maintains optimal contact geometry, and reduces precious metal usage, ensuring reliable switching performance and efficient manufacturing with minimized mechanical pulses and electrical resistance.
Implementation Method 1
coated with conductive materials like precious metals or carbon to minimize vibrations and electrical resistance
Data Source
AI summary
An electric micro-switch has at least one electric contact. The contact has a profiled section. The profiled section has a longitudinal extension, a bent portion formed in the longitudinal extension and having an outer surface that is, at least in section, formed in a rounded manner. A contact region is defined on the outer surface of the bent portion. A method for manufacturing the micro-switch is also disclosed.