Low-Profile Rocker Switch With Parallel Pin Channel
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Solution Overview
Problem
Rocker switches with large external portions are prone to accidental activation or deactivation and are aesthetically unpleasing, limiting their use due to bulkiness and requiring multiple components, making them costly to manufacture.
Innovation Solution
A low-profile rocker switch design with a reduced housing size and fewer components, featuring a rocker with a channel and pivot point that allows rotational movement of a pin for circuit control, enabling easier operation and integration with existing electrical components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large external portion is used for the rocker switch, then the switch mechanism can function properly with sufficient space for internal components, but the switch becomes prone to accidental activation and is aesthetically unpleasing
Solution Approach 1:
The patent repositions the pin channel from a radial orientation perpendicular to the rocker pivot to an orientation parallel to the rocker pivot axis. This dimensional change allows the pin to move linearly within the channel while the rocker rotates, eliminating the need for a large external rocker portion and reducing the housing size while maintaining reliable switch function.
Solution Approach 2:
Instead of having the pin move in an inverse arc relative to the rocker pivot (traditional design), the patent inverts the mechanism so that the pin moves linearly within a channel that is parallel to the rocker pivot axis. This inversion simplifies the mechanical relationship between the rocker and pin, reducing the required external portion size.
2Reliability
If a large housing is used to accommodate the switch mechanism, then the switch can function properly with adequate space for components, but the overall device size increases and placement options are limited
Solution Approach 1:
The patent reorients the pin channel from a radial direction to a direction parallel to the rocker pivot axis, fundamentally changing the spatial arrangement. This allows the switch mechanism to be compacted, reducing the housing volume while maintaining adequate space for all internal components to function properly.
Solution Approach 2:
The patent integrates the pin channel directly into the rocker structure, eliminating the need for separate housing portions to accommodate the pin movement. This merging of components reduces the overall housing size while ensuring the switch mechanism has sufficient space to operate reliably.
3Device complexity
If a traditional rocker switch design with radial pin channel is used, then the switch mechanism is simple, but the external portion must be large to accommodate the pin's inverse arc movement
Solution Approach 1:
The patent changes the pin channel orientation from radial (perpendicular to pivot) to parallel with the pivot axis. This dimensional reorientation transforms the pin's movement from an inverse arc path to a linear path within the channel, significantly reducing the external portion area required while maintaining mechanism simplicity.
Solution Approach 2:
The patent inverts the traditional relationship between rocker rotation and pin movement. Instead of the pin moving in an arc opposite to the rocker rotation, the pin moves linearly within a channel parallel to the pivot axis, simplifying the mechanical coupling and reducing the required external area.
4Ease of manufacture
If multiple separate components are used to form the housing, then the switch can be manufactured with standard assembly processes, but the manufacturing cost increases and the housing becomes bulky
Solution Approach 1:
The patent integrates the pin channel directly into the rocker component, eliminating the need for separate housing portions to accommodate the pin mechanism. This merging reduces the total component count and eliminates bulky housing structures, while the integrated design remains compatible with standard manufacturing and assembly processes.
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 design reduces the risk of accidental activation, enhances aesthetics, and lowers manufacturing costs by minimizing the switch's spatial requirements and component count, allowing for more versatile and compact applications.
Implementation Method 1
The depression of the first end of the rocker causes a rotational movement of the channel in a curvilinear path around the pivot point, causing a rotational movement of the crank
Data Source
AI summary
A rocker switch having a housing and a rocker extending from the housing. The rocker has a first side with a first end and a second end, a second side adjacent to the first side, and a channel. The channel is disposed on the second side of the rocker and has a first end and a second end. A pivot point is disposed on a crank. A pin, disposed on the crank, is located in a first side of the channel. The depression of the first end of the rocker causes a rotational movement of the channel in a curvilinear path around the pivot point, causing a rotational movement of the crank, moving the pin from the first end of the channel toward the second end of the channel.