Multi-Material Insulating Support for Electromechanical Switch

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Solution Overview

Problem

Existing methods for manufacturing electrically insulating supports for electromechanical switches often use a single material, which increases costs and does not effectively manage temperature variations across different portions of the switch, particularly in low and medium voltage applications.

Innovation Solution

A method involving the selection and combination of plastics with different temperature heat resistances, using an overmolding or multi-material injection process to create a single-piece support, where regions are optimized based on thermal conduction and chemical bonding criteria to manage temperature variations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a single high-temperature resistant material is used for the entire support, then the support can withstand the highest temperature requirements, but the manufacturing cost increases

Engineering Contradiction:

Improvetemperature resistanceVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent applies local quality by assigning different material properties to different regions of the support structure. Specifically, the first portion (support body) uses a thermosetting plastic with high temperature resistance, while the second portion (contact support) uses a thermoplastic with lower temperature resistance, matching the thermal requirements of each specific location rather than using a uniform high-performance material throughout.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent employs composite materials by combining two different plastics (thermosetting and thermoplastic) within a single support structure. This allows the support to exhibit different thermal properties in different regions, optimizing both cost and performance by using each material where it is most appropriate.

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If different thermoplastic components are combined using laser welding, then assembly is simplified, but the components must have specific laser absorption properties that limit material selection

Engineering Contradiction:

Improveassembly processVSAvoidmaterial selection flexibility

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The patent merges the molding of two different plastic portions into a single integrated manufacturing process. Through overmolding or multi-material injection molding, the first thermosetting plastic portion and the second thermoplastic portion are combined in one operation, eliminating the need for separate laser welding steps and associated material compatibility constraints.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of manufacture

If the entire support is made from one material, then manufacturing is simpler, but it cannot effectively manage temperature variations across different portions

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidtemperature management

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

Inventive Principle:

Principle #3Local quality

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 approach reduces material costs by using plastics with varying heat resistances tailored to specific temperature zones, enhancing the switch's performance and durability across different temperature conditions.

Implementation Method 1

manufacturing the support as a single piece by at least an overmolding process and/or a multi-material injection process

Methodology Applied

Scientific EffectOvermolding:

Implementation Method 2

manufacturing the support as a single piece by at least an overmolding process and/or a multi-material injection process

Methodology Applied

Scientific EffectMulti-material injection:

Data Source

PatentUS10643803B2Methods for manufacturing an electrically insulating support for an electromechanical switch and an electromechanical switch, and support and switch manufactured according to the methods

Publication Date: 2020.05.05 MARTINEZ MORALES ALVARO

AI summary

Provided is a method for manufacturing an electrically insulating support for an electromechanical switch. In some embodiments, the presently disclosed method includes manufacturing at least first and second portions of the support with respectively first and second plastics having different temperature heat resistances and manufacturing the support as a single piece by at least one of an overmolding process and a multi-material injection process. In some embodiments, the electrically insulating support is manufactured according to the method for manufacturing an electrically insulating support. Also provided is a method for manufacturing an electromechanical switch, which in some embodiments includes manufacturing an electrically insulating support according to the presently disclosed method for manufacturing an electrically insulating support and attaching electrically conductive elements to different regions thereof. Also provided is an electromechanical switch manufactured according to the presently disclosed method.