Retrofittable Switch Module with Swiveling Electronic Component
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Solution Overview
Problem
Conventional rocker switches with lighting means for floor lighting or ON/OFF indicators are complex in design, require careful wiring, and often expose live wires when the rocker is removed, posing safety risks and requiring skilled assembly, with non-retrofitable electronic modules and undesirable light leakage.
Innovation Solution
A novel switch design featuring a retrofittable electronic module that swivels with the rocker, using resilient connectors for secure electrical connections, and a compact layout to prevent light leakage, with a photo sensor and potentiometer for ambient light control and adjustable luminance, ensuring safe and easy assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electronic circuit for lighting means is integrally formed with the INSERT, then the switch provides floor lighting or indicator function, but the manufacturing becomes complex and wiring becomes tedious due to limited space
Solution Approach 1:
The electronic module is separated from the INSERT and housed in a dedicated electronic module casing. This segmentation allows the lighting circuit to be independently designed and manufactured, reducing overall complexity while maintaining the lighting function. The module can be retrofitted without affecting the main switch structure.
Solution Approach 2:
A resilient connector acts as an intermediary between the INSERT and the electronic module. This connector provides flexible electrical connection, allowing the module to move independently with the rocker while maintaining reliable electrical contact, thus simplifying wiring requirements.
2Reliability
If the electronic circuit for lighting means is integrally formed with the INSERT, then the switch provides lighting function, but the wiring and assembly require skilled persons and become tedious
Solution Approach 1:
By separating the electronic module from the INSERT, the assembly process is simplified. The module can be independently assembled and then retrofitted into the switch housing, eliminating the need for skilled wiring work during initial assembly.
Solution Approach 2:
The resilient connector provides self-adjusting electrical connection that automatically maintains contact as the rocker moves. This eliminates the need for precise wiring alignment and reduces assembly complexity, allowing even unskilled persons to assemble the switch.
3Reliability
If conventional rocker switches are designed with lighting means, then the switch provides indicator function, but live wires become exposed when rocker is removed creating safety hazards
Solution Approach 1:
The electronic module with lighting circuit is extracted from the INSERT and housed in a separate casing. When the rocker is removed, the live wires remain enclosed within the INSERT and electronic module casing, preventing exposure and eliminating safety hazards while maintaining the indicator function.
4Ease of manufacture
If the electronic module is made retrofittable, then the switch becomes easier to assemble and maintain, but the electrical connection must be reliable during rocker movement
Solution Approach 1:
The resilient connector is designed to be flexible and dynamic, allowing it to accommodate the movement of the rocker while maintaining reliable electrical contact. This dynamic connection enables the electronic module to be retrofittable without compromising connection reliability.
Solution Approach 2:
The resilient connector acts as a flexible electrical connection medium that can bend and stretch with rocker movement. This flexibility allows the electronic module to be independently positioned and retrofitted while ensuring continuous reliable electrical contact during operation.
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 simplifies the switch construction, prevents light leakage, and ensures electrical safety by keeping live parts enclosed, making the switch easier to assemble and cost-effective while allowing for ambient light adaptation and adjustable illumination.
Implementation Method 1
EP 1944784 suggests the use of light guide for guiding the light out of the switch
Implementation Method 2
The control PCB is provided with a photo sensor for monitoring the ambient light condition
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The present invention relates to a switch (101) comprises a rocker (102), a electronic module (103), an intermediate cover (104), an insert (105), a supply PCB (108), a control PCB (109), and a lighting means (110). The rocker (102) is configured to perform rocking movement between an ON position and an OFF position and being operable to turn said switch (101) ON/OFF and the electronic module (103) is provided with illuminating means (110) configured to assume an elevated position or a depressed position relative to said switch's frontal plane in response to the movement of the electronic module (103). The rocker (105) is provided with a light transmitting portion (111) and the light emitted from said illuminating means (110) emerges through said light transmitting portion (111) of the rocker. The present invention also provides a novel electronic module (103) for rocker type switch.