Integrated Moveable Contact Assembly for Orientation-Independent Switching
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing switching components face challenges such as misalignment leading to electrical arching or failure in forming connections due to gravity, and are complex and expensive to produce, with limited operational life and orientation dependence.
Innovation Solution
A switching component design featuring a housing with a moveable carrier and integrated moveable contact assemblies that allow two degrees of freedom movement, utilizing a guiding element and blade spring elements to ensure reliable contact regardless of orientation, and are simpler and less costly to manufacture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional switching components are used, then the structure is simple, but misalignment occurs leading to electrical arching or failure in forming connections due to gravity
Solution Approach 1:
The moveable contact assembly is designed to move with two degrees of freedom (lateral and vertical movement) relative to the stationary contact, allowing it to dynamically adjust its position to maintain proper alignment and form reliable electrical connections regardless of the switching component's orientation or gravitational effects
Solution Approach 2:
The moveable contact assembly is divided into separate functional components including the moveable contact, substrate, guiding element, and blade spring element, allowing each component to be optimized for its specific function while working together to solve the alignment problem
2Ease of manufacture
If traditional switching components are used, then the manufacturing process is straightforward, but production is complex and expensive
Solution Approach 1:
The guiding element and blade spring element are integrated into a single unitary component that can be formed as one piece, reducing the number of separate parts that need to be manufactured and assembled, thereby simplifying production while maintaining the functional integrity and reliability of the switching component
3Duration of action of moving object
If traditional switching components are used, then the design is simple, but the operational life is limited with gravity-induced failures
Solution Approach 1:
The guiding element acts as an intermediary component that surrounds and guides the substrate, constraining the moveable contact assembly's motion to ensure it moves along the correct path and maintains proper alignment with the stationary contact, thereby extending operational life by preventing misalignment and electrical arching
4Adaptability or versatility
If traditional switching components are used, then the component is orientation-independent, but contact reliability fails under different orientations
Solution Approach 1:
The moveable contact assembly's ability to move with two degrees of freedom allows it to adapt dynamically to different orientations and gravitational forces, maintaining reliable contact regardless of how the switching component is positioned or oriented in space
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 design significantly increases the operational life of switching components, ensures reliable contact in any orientation, and reduces production complexity and costs, with the ability to maintain functionality over 1.5 million operations without gravity-induced failures.
Implementation Method 1
a guiding element surrounding at least a portion of the substrate, wherein at least a portion of the guiding element is configured to abut a surface of the moveable carrier
Implementation Method 2
the set of moveable contacts is configured to move with two degrees of freedom to make contact with the set of stationary contacts in order to actuate an electrical bridge
Data Source
AI summary
Methods, apparatuses and systems for providing a switching component are disclosed herein. An example switching component may comprise: a housing; a moveable carrier a moveable carrier disposed within the housing; at least one integrated moveable contact assembly, the moveable contact assembly comprising a substrate, a set of moveable contacts disposed on a first surface of the substrate and a guiding element surrounding at least a portion of the substrate, wherein at least a portion of the guiding element is configured to abut a surface of the moveable carrier; and a set of stationary contacts adjacent the set of moveable contacts, wherein the set of moveable contacts is configured to move with two degrees of freedom to make contact with the set of stationary contacts in order to actuate an electrical bridge in response to movement of the moveable carrier.