Microswitch Push-in Wire Connector Assembly
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Solution Overview
Problem
The assembly of microswitches with traditional screw or soldered connections is time-consuming and costly, and can lead to reliability issues if not properly executed.
Innovation Solution
The development of microswitches with push-in wire connectors featuring spring clamps and a housing design that allows for easy connection of lead wires by pushing them into wire receiving openings, eliminating the need for screws or soldering and enhancing reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional screw or soldered connections are used to attach lead wires to microswitch terminals, then the connection reliability may be maintained, but the assembly time and cost increase significantly
Solution Approach 1:
The patent extracts the complex connection process (screws, soldering, connectors) and replaces it with a simplified push-in mechanism. The spring clamp directly engages the lead wire within the housing, eliminating the need for external connectors and complex assembly steps while maintaining reliable electrical connection.
Solution Approach 2:
The spring clamp automatically secures the lead wire through elastic deformation when the wire is pushed in. The system serves itself by using the lead wire's own insertion action to trigger the clamping mechanism, eliminating the need for separate fastening operations like screwing or soldering.
2Reliability
If traditional screw or soldered connections are used to attach lead wires to microswitch terminals, then the connection may be secure, but the manufacturing cost increases
Solution Approach 1:
The patent merges the terminal, connector, and fastening functions into a single integrated housing structure with an internal spring clamp. This consolidation eliminates the need for separate connectors and fasteners, reducing part count and assembly complexity while maintaining secure electrical connection.
Solution Approach 2:
The spring clamp is designed as a simple, inexpensive elastic element that can be easily manufactured and replaced if needed. This disposable-like component approach reduces manufacturing cost compared to precision screw terminals or soldering fixtures while providing sufficient connection reliability.
3Reliability
If connectors are attached to wire leads and then slid onto protruding terminals, then the connection may be reliable, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The patent extracts the connector function from separate components and integrates it directly into the housing structure. The wire receiving opening with spring clamp is built into the housing, eliminating the need for separate connectors that must be attached to wires and then mounted to terminals.
Solution Approach 2:
The housing, terminal, and connector functions are merged into a single integrated structure. The wire receiving opening is formed directly in the housing, and the spring clamp is positioned inside the housing to directly engage the lead wire, eliminating multiple separate components and assembly steps.
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 simplifies the assembly process, reduces costs, and ensures reliable connections by securely locking lead wires in place with spring clips, thereby improving the overall reliability of the microswitch.
Implementation Method 1
A first spring clamp may be provided inside the housing and adjacent to the first wire receiving opening for receiving and clamping an end of a stripped lead wire that is pushed-in through the first wire receiving opening
Data Source
AI summary
A microswitch with push-in wire connectors is provided. In one illustrative embodiment, the microswitch may include a plunger for activating the switch, a first stationary contact, a second stationary contact, a movable contact, and a snap-spring assembly reactive to the plunger for switching the movable contact between making electrical contact with the first stationary contact and making electrical contact with the second stationary contact. The microswitch may include a first push-in wire connector for electrically connecting an end of a first wire to the first stationary contact, a second push-in wire connector for electrically connecting an end of a second wire to the second stationary contact, and a third push-in wire connector for electrically connecting an end of a third wire to the movable contact. Alternatively, or in addition, the microswitch may include a housing that, when viewed from the first surface, may have a footprint that is generally rectangular in shape except for a first housing projection and a second housing projection that extend out from different sides of the housing. The first housing projection and the second housing projection may house first and second push-in wire connectors, as desired.