Non-Planar Toggle Switch for Thin Portable Devices
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current toggle-type switches in portable communications devices are relatively large, necessitating thicker devices and limiting space for other components like antennas and connector ports.
Innovation Solution
A compact toggle-type switch design featuring a non-planar circuit board with offset flanks and a central rib, integrated with a projecting lever that engages electrical contact elements, allowing for reduced size and thickness, enabling thinner devices with more space for other features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional toggle-type switches are used, then switching functionality is provided, but device thickness increases
Solution Approach 1:
The circuit board is folded along bend lines to transform from a planar configuration to a three-dimensional configuration with flanks extending in different directions. This dimensional transformation allows the switch components to be arranged vertically and laterally, reducing the thickness requirement while maintaining all necessary switching functions.
Solution Approach 2:
The switch components are nested within a cavity in the device housing. The circuit board with its flanks and the projecting lever are arranged to fit within this cavity space, maximizing space utilization and minimizing the overall device thickness while preserving full switching functionality.
2Reliability
If conventional toggle-type switches are used, then switching functionality is provided, but device width increases
Solution Approach 1:
By folding the circuit board to create a non-planar structure with flanks extending in different directions, the design converts lateral space requirements into vertical arrangements. The projecting lever engages contact elements on opposite flanks, achieving full switching functionality with reduced width by utilizing the third dimension (height/thickness) more effectively.
Solution Approach 2:
The circuit board features asymmetric folding patterns with flanks of different configurations, allowing optimized arrangement of contact elements and lever engagement points. This asymmetric design enables compact width by strategically positioning components to minimize lateral footprint while maintaining functional requirements.
Data Source
AI summary
A toggle-type switch for a portable communications device includes a circuit board to be positioned within a cavity of a portable communications device. In one instance, the circuit board includes a first flank, a second flank disposed opposite the first flank, and a central rib disposed between the first and the second flanks. The circuit board has a non-planar shape, such that the first flank and the second flank are each offset relative to the central rib. The toggle-type switch includes a first electrical contact element coupled to the first flank, a second electrical contact element coupled to the second flank, and a projecting lever located above the central rib and between the first flank and the second flank. The projecting lever has a first leg to engage the first electrical contact element and a second leg to engage the second electrical contact element.