Modular Switch Contact Modules for Cost-Effective Production
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Solution Overview
Problem
Existing switch technologies require multiple expensive molds for various specifications, leading to high production costs due to the need for customized switching mechanisms for different circuit numbers and opening/closing characteristics.
Innovation Solution
A switch design utilizing pre-fabricated contact modules with actuator mechanisms that can be arranged in different orientations to create switches with varying numbers of normally open and closed contacts, allowing for cost-effective production of switches for various circuits by using only two kinds of nearly identically designed contact modules with differently positioned operating parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If customized switching mechanisms are prepared for different circuit numbers and opening/closing characteristics, then the switch can respond to various needs and specifications, but the production cost becomes high because many kinds of expensive molds are needed for producing their components
Solution Approach 1:
The patent applies universality by designing a single standardized contact module that can serve multiple functions and specifications. The contact module with its plunger, spring, and contact structure can be configured for different circuit numbers and opening/closing characteristics through arrangement and orientation rather than requiring different mold designs. This allows the same basic component to be universally applied across various switch specifications.
Solution Approach 2:
The patent segments the switch into standardized, interchangeable contact modules that can be independently produced and then assembled in different configurations. Each contact module is a discrete unit with standardized dimensions and mounting features, allowing them to be produced using the same molds and then combined to create switches with different numbers of circuits and different normally open/normally closed contact arrangements.
2Adaptability or versatility
If many kinds of expensive molds are needed for producing components with different specifications, then customized switches can be manufactured, but the production cost increases significantly
Solution Approach 1:
The contact module design enables a single mold to produce components that can be used in multiple switch configurations. The standardized plunger, spring assembly, and contact structure can be arranged in different numbers and orientations to create various switch specifications, eliminating the need for separate molds for each configuration.
Solution Approach 2:
By segmenting the switch into standardized contact modules, the patent reduces the number of molds needed from many specialized molds to a small set of universal molds that produce the modular components. These modules can then be assembled in different quantities and arrangements to fulfill various switch specifications.
3Adaptability or versatility
If contact modules are arranged in different orientations along the supporting axis of the actuator, then switches with varying numbers of normally open and closed contacts can be obtained, but the arrangement complexity increases
Solution Approach 1:
The contact modules can be arranged asymmetrically along the actuator's supporting axis, with some modules oriented to create normally open contacts and others oriented to create normally closed contacts. This asymmetric arrangement allows flexible configuration of contact types while maintaining a systematic approach to assembly.
Solution Approach 2:
The patent utilizes the spatial dimension along the actuator's supporting axis to arrange contact modules in different orientations. By positioning modules at different locations and orientations along this axis, the system achieves multiple contact configurations (normally open, normally closed, combinations) without requiring complex internal mechanisms within each module.
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
Enables the economical production of switches for multiple circuits by reducing the number of components and molds needed, allowing for flexible configuration of contact modules to meet various specifications without increasing production costs.
Implementation Method 1
a mobile piece (7) biased by a spring (9)
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
Switches for a variety of circuits for different purposes are formed by using similarly designed contact modules each having a module case including a normally closed or normally open contact mechanism and a plunger for operating this contact mechanism, a single actuator having two end parts and being biased so as to rotate around a supporting axis, this actuator undergoing a rotary motion if a force is applied to one of its end parts so as to operate the plunger of an associated one of the contact modules with at least one of the end parts, a switch case that includes the contact modules and the actuator, and a push button for applying a force on one of the end parts of the actuator from outside the switch case.