Optical Trigger Switch for Carpet Stapler Durability

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Solution Overview

Problem

Existing electric carpet staplers require frequent maintenance due to the fragility of mechanical microswitches, which are prone to damage from recoil and vibration during staple driving, leading to high maintenance costs.

Innovation Solution

A trigger and switch assembly utilizing a photo sensor with a light emitter and silicon photo transistor, where the trigger's motion controls the passage of infrared light to change the sensor's state, sending signals to the control circuit to supply power to the winding, eliminating the need for a mechanical microswitch and enhancing durability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a mechanical microswitch is used to trigger the control circuit, then the device can reliably detect trigger actuation, but the microswitch is damaged by recoil and vibration during staple driving, requiring frequent maintenance

Engineering Contradiction:

Improvetrigger detection reliabilityVSAvoidmaintenance frequency

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The patent replaces the mechanical microswitch with an optical sensor system consisting of a light source, optical pathway, and light detector. This substitution eliminates mechanical contact components that are susceptible to damage from recoil and vibration, thereby reducing maintenance frequency while maintaining reliable trigger actuation detection.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces an optical intermediary (light beam) as the medium for signal transmission between the trigger mechanism and the control circuit. The light beam serves as a non-contact mediator that transfers the trigger state information without being affected by mechanical shock and vibration, resolving the contradiction between reliability and maintenance requirements.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If a mechanical microswitch is used, then the trigger signal can be generated, but the delicate mechanical components are prone to damage from the extreme recoil and vibration

Engineering Contradiction:

Improvetrigger signal generationVSAvoidrecoil and vibration damage

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the mechanical microswitch with an optical sensing system that uses light transmission through an optical pathway. This eliminates mechanical contact components that are vulnerable to recoil and vibration, allowing reliable trigger signal generation without susceptibility to mechanical damage.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the operating parameter from mechanical contact (microswitch closure) to optical transmission (light beam interruption or modulation). This parameter change transforms the trigger detection mechanism from one affected by mechanical stress to one that is immune to recoil and vibration, resolving the contradiction between operational ease and resistance to harmful factors.

Inventive Principle:

Principle #35Parameter changes

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 solution provides a durable and reliable trigger and switch assembly that reduces maintenance costs by using electronic sensors, ensuring accurate power supply to the winding while withstanding vibrations and electrical interference, allowing for single actuation per trigger pull and ergonomic operation.

Implementation Method 1

Methodology Applied

Scientific EffectPhotoelectric Effect: Photoelectric Effect

Data Source

PatentUS20230150102A1Electric carpet stapler with optical switch assembly

Publication Date: 2023.05.18 CRAIN CUTTER CO INC

AI summary

An electric carpet stapler comprises a trigger and switch assembly that has an actuation caused by a change of state of a sensor, which causes the sensor to send a signal to a control circuit to begin a process to supply power to a winding. The trigger and switch assembly includes a trigger that moves in a trigger actuation direction to move a sensor actuator in a sensor actuation direction, causing a change of state in the sensor, which causes the control circuit to begin the process to supply power to the winding. The trigger and switch assembly may also include a toggle. At the actuation of the trigger and switch assembly, the toggle creates a mechanical instability, and a toggle signal to the user, which may be produced mechanically.