Rocker Switch Actuator Subassembly With Removable Shaped Member
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Solution Overview
Problem
Rocker switches face challenges in modifying operating characteristics post-assembly without disassembly, accommodating dimensional tolerance variations, and ensuring sufficient space for lighting elements, as existing designs are inflexible and space-constrained.
Innovation Solution
The introduction of a compact actuator subassembly with a sub-actuator that is removably coupled to the operating member and plunger, providing multiple operating characteristics while occupying less than one-third of the housing cavity width, allowing for easy modification and accommodating tolerance variations, and enabling the placement of lighting elements within the rocker switch housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a traditional rocker switch design is used, then the structure is simple and manufacturing is easy, but the operating characteristics cannot be modified after assembly and the design lacks flexibility
Solution Approach 1:
The rocker switch is divided into separate modular components: an operating member, an actuator with a shaped member, and a housing. This segmentation allows the actuator to be removed and replaced to change operating characteristics without replacing the entire switch assembly, enabling customization while maintaining overall structural simplicity.
Solution Approach 2:
The actuator component serves multiple functions: it transmits actuation force, defines operating characteristics through its shaped member profile, and enables different switch behaviors (momentary or sustained) by simply changing the actuator design. This universal component allows a single base structure to support multiple operating modes.
2Volume of moving object
If internal components are made small to save space, then lighting elements can be accommodated, but the components must still accommodate dimensional tolerance variations
Solution Approach 1:
The shaped member features an asymmetric profile with a sloped surface that guides the plunger's movement. This asymmetric geometry provides mechanical guidance that compensates for dimensional tolerances, ensuring reliable operation even when component sizes vary within manufacturing limits. The sloped surface naturally guides the plunger into the correct position.
Solution Approach 2:
The design incorporates a spring-loaded plunger that provides mechanical compliance and tolerance absorption. The spring mechanism beforehand cushions against dimensional variations, ensuring that the actuator and housing components work together reliably despite manufacturing tolerances in the compact design.
3Volume of moving object
If the actuator is made compact to occupy less space, then lighting elements can be placed in the housing, but the actuator must still provide sufficient operating force and reliability
Solution Approach 1:
The shaped member incorporates a curved or sloped surface that provides mechanical advantage during actuation. This curvature allows the plunger to efficiently transfer force from the operating member to the contact elements, maximizing operating force within the compact actuator depth while maintaining reliability.
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 solution allows for quick and easy modification of rocker switch operating characteristics, accommodates dimensional variations, and allows for centralized lighting within the switch, enhancing user experience and operational reliability.
Implementation Method 1
The operating member includes a spring biased plunger structured to engage with the shaped member
Data Source
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AI summary
An actuator subassembly (200,200',200",200"',200"") is provided for a rocker switch (102) including a housing (104), a plunger (106) and a number of contact elements (108,110). The actuator subassembly (200,200',200",200"',200"") includes an operating member (202,202',202",202"',202"") movably coupled to the rocker switch housing (104) at or about an opening (118), and including at least one projection (204,206; 204',206'; 204",206"; 204"',206"'; 204"",206"") which extends into a cavity (116) of the housing (104). A sub-actuator (210,210',210",210"',210"") is removably coupled to such projection (204,206; 204',206'; 204",206"; 204"',206"'; 204"",206"") and includes a shaped portion (212,212',212",212"',212""), a number of contacting portions (214,216; 214',216'; 214",216"; 214"', 216"'; 214"",216"") and a depth (218). The shaped portion (212,212',212",212"',212"") cooperates with a plunger (106) to provide a plurality of operating characteristics of the operating member (202,202',202",202"',202""), including a plurality of positions thereof. Each contacting portion (214,216; 214',216'; 214",216"; 214"',216"'; 214"",216"") contacts a corresponding one of the contact elements (108,110) when the operating member (202,202',202",202"',202"") is disposed in a corresponding one of the positions. When the actuator subassembly (200,200',200",200"',200"") is coupled to the housing (104), the depth (218) of the sub-actuator (210,210',210",210"',210"") occupies less than one-third of the width (120) of the cavity (116).