Multi-way Rocker Switch Hinge Plate Deformation
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Solution Overview
Problem
Multi-way toggle switches often experience undesirable multiple contact issues due to simultaneous activation of multiple sides, leading to wear and tear, which cannot be reliably prevented by existing designs.
Innovation Solution
A multi-way toggle switch with a hinge plate having intersecting hinge axes that deform to prevent simultaneous tilting, ensuring targeted contact by blocking secondary tilting axes, and manufactured as a single, inexpensive part from elastic material or spring steel to prevent wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a retaining element with projections is added to prevent multiple contact, then multiple contact is prevented, but the number of parts increases and manufacturing cost rises
Solution Approach 1:
The patent integrates the retaining function directly into the hinge plate by forming hinge axis sections that intersect when the toggle button is tilted. This merging of the retaining function into the existing hinge plate structure eliminates the need for separate retaining elements with projections, thereby preventing multiple contact while reducing the number of parts and manufacturing complexity
Solution Approach 2:
The hinge plate is designed to serve multiple functions: it provides the hinge axes for tilting movement and simultaneously acts as the retaining element through its deformed hinge axis sections. This multi-functionality allows the hinge plate to both enable controlled tilting and prevent unwanted multiple contact, eliminating the need for dedicated retaining components
2Reliability
If projections are used to prevent multiple contact, then contact control is improved, but wear and tear occurs over time
Solution Approach 1:
The patent replaces the mechanical contact between the toggle button and separate retaining projections with a deformation-based retaining mechanism. The hinge plate deforms about hinge axes to create intersecting hinge axis sections that passively prevent multiple contact through geometric constraints rather than mechanical friction, eliminating wear on retaining elements while maintaining reliable contact control
Solution Approach 2:
The patent changes the physical state of the hinge plate from rigid to elastically deformable, allowing it to dynamically adjust its geometry during operation. The hinge plate deforms about hinge axes when the toggle button is tilted, creating temporary geometric constraints that prevent multiple contact without requiring hard mechanical projections that would wear
3Ease of manufacture
If a single-piece hinge plate is used, then manufacturing cost is reduced, but preventing multiple contact becomes more difficult
Solution Approach 1:
The patent segments the hinge plate into multiple areas that can independently deform about different hinge axes. This segmentation is achieved through film hinges or embossed hinge axes that create distinct deformation zones within the single-piece structure, allowing each zone to function independently for preventing multiple contact while maintaining the cost advantages of single-piece manufacturing
Solution Approach 2:
The patent employs flexible film hinges or thin-walled structures within the single-piece hinge plate to enable controlled deformation. These flexible elements allow the hinge plate to dynamically change its geometry during operation, creating the necessary constraints to prevent multiple contact while maintaining the simplicity and cost-effectiveness of a single-piece construction
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 effectively prevents unwanted multiple contacting and reduces manufacturing costs while maintaining a compact design, ensuring reliable operation without wear and tear.
Implementation Method 1
a hinge plate with several intersecting hinge axes running parallel to the tilting axes of the toggle button, around which the hinge plate is deformed when the toggle button is tilted to transfer the tilting movement of the toggle button to the movable contacts
Data Source
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AI summary
The rocker switch has a hinge plate (20) with multiple hinge axes (a1, a2, b1, b2) that run parallel to tilting axes (A, B) of a toggle push button (12) and intersect each other. The hinge plate deforms about the hinge axes during the tilting of the button for the transmission of a tilt movement of the button on movable contacts. The hinge plate deforms about one associated hinge axis during the tilting of the button about the tilting axis (A) such that the hinge plate blocks a simultaneous tilting of the button about the other tilting axis (B) that intersects the tilting axis (A).