Push Button Switch Assembly Eliminating Printed Circuit Board
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Solution Overview
Problem
Existing push button switches are complex, prone to malfunction, and costly due to the use of multiple parts, including a printed circuit board that can be damaged during manufacturing and may degrade over time.
Innovation Solution
A simplified push button switch assembly with an integrally formed elastomeric housing, a snap dome, and a retaining disk, eliminating the need for a printed circuit board, featuring a silicone button, a rubber sheath, and a metallic snap dome that produces an audible click upon actuation, ensuring secure sealing and tactile feedback.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a printed circuit board is used in the switch assembly, then electrical connectivity is achieved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent combines the electrical connectivity function directly into the elastomeric body through conductive traces integrated into the rubber material itself, eliminating the need for a separate printed circuit board. This merging of functions reduces the number of components while maintaining electrical connectivity, directly resolving the contradiction between reliability and device complexity.
Solution Approach 2:
The invention extracts and removes the printed circuit board component from the switch assembly entirely. By taking out the PCB and replacing it with conductive traces formed directly in the elastomeric material, the patent simplifies the overall device structure while maintaining the necessary electrical functions, thereby reducing manufacturing complexity.
2Adaptability or versatility
If multiple distinct parts are used in the switch assembly, then functional requirements are met, but the ease of manufacture decreases
Solution Approach 1:
The patent merges multiple functions into the elastomeric body itself: the button, the circuit board, and the sealing housing are all integrated into a single piece of elastomeric material. This consolidation reduces the number of assembly steps and manufacturing operations required, directly improving ease of manufacture while maintaining full switch functionality.
Solution Approach 2:
The elastomeric body serves multiple functions simultaneously: it provides the button structure, contains the electrical circuitry through integrated traces, provides environmental sealing, and houses the internal components. This multi-functionality eliminates the need for separate parts, simplifying manufacturing while maintaining adaptability.
3Reliability
If a printed circuit board with wires is used, then electrical connectivity is achieved, but the risk of component damage and malfunction increases
Solution Approach 1:
The patent merges the electrical circuitry directly into the elastomeric material through conductive traces, eliminating separate wires and circuit boards that could be damaged during assembly or use. This integration removes the vulnerable wire connections and PCB mounting points, reducing the risk of component damage and improving reliability.
4Manufacturing precision
If careful positioning and handling of the printed circuit board is required, then functional assembly is achieved, but the productivity and manufacturing efficiency decrease
Solution Approach 1:
The patent combines the circuit board function directly into the elastomeric body, eliminating the need for separate PCB positioning and assembly operations. This integration removes the time-consuming steps of carefully placing and securing a separate circuit board, thereby improving manufacturing productivity while maintaining the necessary electrical connections.
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 reliable, cost-effective, and durable push button switch with reduced manufacturing complexity, enhanced durability, and improved user feedback through audible and tactile engagement, while minimizing the risk of component damage.
Implementation Method 1
a snap dome, which may be metallic, secured on the first surface of said retaining disk... the dome may produce or otherwise emit an audible sound, such as a click or snap, that indicates that the switch has been fully engaged
Data Source
AI summary
A switch assembly includes a unitary push button housing including an actuable button, a retainer having a first surface and a second surface, in which the retainer is secured within the push button housing, a snap dome secured on the first surface of the retainer, and at least one terminal passing through the second surface of the retainer to the first surface. The button is configured to be actuated into the snap dome, so that the snap dome is urged into contact with the terminal.