Power Tool Switch PCB and Silicone Layer Against Accidental Start
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Solution Overview
Problem
Existing power tool switches fail to effectively prevent inadvertent switching on, lack ergonomic design, and provide inadequate protection against water, dirt, and dust.
Innovation Solution
A switch comprising a printed circuit board with microswitches and a silicone layer with a blocking switch and membrane, where the silicone layer's actuation activates the microswitches, ensuring the power tool can only be switched on after a deliberate user action and providing protection against environmental factors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a mechanical switch with a spring element and electronic switching element is used, then the power tool can be switched on or off, but the user must ensure a component is in a blocking position to prevent inadvertent switching on
Solution Approach 1:
The blocking switch is actuated in advance to activate an unblocked state, which then allows the membrane switch to be functional. This preliminary action ensures the power tool cannot be accidentally activated without the user first deliberately engaging the blocking switch, thereby preventing inadvertent switching while maintaining ease of operation.
Solution Approach 2:
The silicone layer with the blocking switch acts as an intermediary between the user and the membrane switch. The blocking switch must be activated first to enable the membrane switch functionality, creating a two-stage activation process that prevents accidental activation while maintaining user-friendly operation.
2Reliability
If a purely electronic switching solution is used, then inadvertent switching on is prevented, but the solution is only implementable for certain power tools like grinders with continuous running buttons
Solution Approach 1:
The hybrid switching solution combines electronic switching elements with a silicone layer and blocking switch mechanism to create a universal switching system that can be applied to various power tool types, including both continuous running tools and tools that require continuous switch actuation. This multi-functional design overcomes the limitation of purely electronic solutions.
Solution Approach 2:
The invention uses a composite structure combining a silicone layer with integrated blocking switch and membrane switch elements mounted on a printed circuit board. This composite design allows the switching mechanism to be adapted to different power tool types while maintaining both safety and ergonomic benefits.
3Reliability
If continuous actuation of a switch is required for tools that run only when switched continuously, then the power tool operates correctly, but the user experiences fatigue in the hand or individual parts of the hand
Solution Approach 1:
The blocking switch is actuated once to activate the unblocked state, which then allows the membrane switch to be actuated. This preliminary action eliminates the need for continuous actuation, reducing user hand fatigue while maintaining proper power tool operation.
Solution Approach 2:
The blocking switch serves as an intermediary that, once activated, enables the membrane switch to remain functional without requiring continuous actuation. This two-stage mechanism reduces the burden on the user's hand while ensuring the power tool operates correctly.
4Device complexity
If mechanical switches are used without additional protection, then the switching function is simple, but the switch and its components lack protection against dust, dirt and water
Solution Approach 1:
A silicone layer is used to cover the blocking switch and membrane switch, providing flexible protection against dust, dirt, and water while maintaining the simplicity of the underlying switching mechanism. The silicone layer acts as a protective barrier without adding significant complexity to the switching function.
Solution Approach 2:
The combination of silicone material with the switching components creates a composite structure that provides both the simple switching function and protection against environmental harmful factors. The silicone layer integrates with the mechanical and electronic elements to provide comprehensive protection.
Data Source
AI summary
A switch for a power tool, the switch including a printed circuit board and a silicone layer. The printed circuit board has a first microswitch, while the silicone layer has a blocking switch, the silicone layer being present arranged on the printed circuit board such that an actuation of the blocking switch leads to an actuation of the first microswitch. Furthermore, the printed circuit board can have a second microswitch, and the silicone layer can have a membrane, an actuation of the membrane leading to an actuation of the second microswitch. A method for switching on a power tool, the power tool including a switch having a printed circuit board and a silicone layer. An ergonomically advantageous switch is also provided, which switch is furthermore well protected against dust, dirt and/or water and enables inadvertent switching on of the power tool to be effectively avoided.