Release Lever Design for Electrical Installation Apparatus
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Solution Overview
Problem
Existing electrical installation devices with release levers are prone to breaking or falling off due to excessive force, and their design complicates the manufacturing process, leading to longer production times and reduced service life of molds.
Innovation Solution
The design incorporates a latching attachment on the mandrel connected to the outer wall, a release lever with a flat underside and corrugations for improved grip, and a two-leg structure with angled legs, along with an elastic connection to the base part, eliminating the need for undercuts and guide elements in the mold, allowing for easier demolding and universal actuation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the release lever is designed with a film hinge connection to the base, then the release lever can pivot to actuate the clamping spring, but the release lever can be overstretched and the film hinge can break causing the release lever to fall off
Solution Approach 1:
The release lever is divided into two legs (first leg and second leg) connected by a mandrel, creating a segmented structure that distributes mechanical stress and prevents single-point failure of the film hinge connection
Solution Approach 2:
The mandrel integrates multiple functions: it connects the two legs of the release lever, provides the latching attachment, and serves as the pivot point for actuation, combining structural support and actuation functions in one element
2Ease of operation
If the release lever is pressed heavily to achieve full depression, then the release position can be reached, but the release lever can break in the middle due to excessive force
Solution Approach 1:
The latching attachment on the mandrel engages with the outer wall edge in advance during the actuation process, providing progressive mechanical support that prevents sudden structural failure under heavy pressing forces
Solution Approach 2:
The latching attachment acts as an intermediary element between the release lever and the base part, distributing the pressing force through the outer wall engagement and preventing concentration of stress that would cause breaking
3Manufacturing precision
If a slot is incorporated in the release lever for the mandrel, then the mandrel can guide the release lever movement, but the injection molding process requires additional guide elements that increase production time and mold wear
Solution Approach 1:
The mandrel is integrated directly into the release lever structure without requiring separate guide elements or slots, merging the positioning and actuation functions into a single component that simplifies injection molding
Solution Approach 2:
The mandrel serves multiple functions simultaneously: it connects the two legs of the release lever, provides the latching attachment for positioning, and enables pivot movement, eliminating the need for dedicated guide structures
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 configuration significantly reduces the risk of the release lever breaking or falling off, enhances operational safety, and simplifies the manufacturing process by preventing overstretching and allowing for easier assembly with reduced production complexity.
Implementation Method 1
a contact housing (6) having a clamping spring (8) for clamping at least one electrical line
Implementation Method 2
in the release position of the release lever (10), the mandrel (12) actuates the clamping spring (8) of the contact housing (6) through the recess (2b) to release the electrical conductor
Data Source
Figure 1
Figure 2~4
Figure 5~6a
AI summary
The present invention relates to an electrical installation device (1), such as a switch or push button, for mounting in a mounting opening along a mounting direction (M), comprising at least one base part (2) with at least one receptacle (4) in which a contact housing (6) is arranged. The contact housing (6) has a clamping spring (8) for clamping at least one electrical conductor, and a pivotable release lever (10) is arranged outside an outer wall (2a) of the base part (2), which runs parallel to the mounting direction (M) in the area of the receptacle (4). In a home position of the release lever (10), an electrical conductor inserted into the contact housing (6) is secured by the clamping spring (8) of the contact housing (6), wherein in a release position of the release lever (10), the clamping spring (8) is actuated and releases the electrical conductor.The release lever (10) has a pin (12) on a lower side (10a) facing the outer wall (2a) of the base part (2), wherein a recess (2b) is arranged in the outer wall (2a) in the area of the pin (12), and wherein the pin (12), the recess (2b), the contact housing (6) and the clamping spring (8) are arranged such that in the release position of the release lever (10) the pin (12) actuates the clamping spring (8) of the contact housing (6) through the recess (2b) to release the electrical conductor. The pin (12) has a locking projection (12a) extending from the pin (12), wherein the locking projection (12a) is located in the base part (2) in the basic position without an inserted electrical conductor and is in operative contact with a part of the edge of the outer wall (2a) in the area of the recess (2b), wherein the operative contact prevents the locking projection (12a) from exiting the base part (2).