Rolling-ball switch with segmented terminals for flexible PCB mounting
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Solution Overview
Problem
Conventional rolling-ball switches face challenges in manufacturing complexity and high production costs due to the need for bendable terminal rods, difficulty in controlling terminal lengths, and unstable connections between terminal sides and hole walls.
Innovation Solution
A rolling-ball switch design featuring a housing with through holes and conducting units with plate-like connecting members and terminals that can be easily assembled and fixed on a circuit board, allowing for adjustable orientation and stable connections using surface mount technology.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If terminal rods are made bendable to allow various mounting orientations, then adaptability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The terminal rod is divided into two separate components: a rigid terminal rod and a separate bending member. The bending member can be bent to different orientations and then connects to the terminal rod, allowing various mounting orientations without making the entire terminal rod bendable. This segmentation reduces manufacturing complexity while maintaining adaptability.
Solution Approach 2:
A bending member acts as an intermediary between the rigid terminal rod and the circuit board. This bending member can be bent to different angles and shapes, serving as a flexible connector that adapts to various mounting orientations while keeping the main terminal rod structure simple and easy to manufacture.
2Device complexity
If terminal rods are made as single individual bodies, then device complexity is reduced, but manufacturing precision deteriorates due to difficulty in controlling terminal lengths
Solution Approach 1:
The terminal connection structure is segmented into the terminal rod, bending member, and connecting portion. This segmentation allows each component to be manufactured with standard tolerances, and the assembly process ensures proper positioning. The connecting portion with its specific geometry provides natural positioning that compensates for individual component variations, achieving good manufacturing precision without requiring extremely tight tolerances on single components.
3Ease of manufacture
If terminal rod side surfaces are made smooth, then ease of manufacture is improved, but reliability deteriorates due to weak connections with hole walls
Solution Approach 1:
The terminal rod has different surface qualities at different locations. The main body of the terminal rod has smooth surfaces for ease of manufacture, while the connecting portion has a roughened surface. This local quality change ensures that the connection area has high friction and strong bonding with the hole wall, while the rest of the terminal rod remains easy to manufacture. The roughened surface is applied only where needed for connection strength.
Data Source
AI summary
A rolling-ball switch includes a housing defining a chamber and having a bottom wall provided with four spaced-apart through holes, and two conducting units respectively having plate-like connecting members disposed in parallel below the bottom wall. Each connecting member has at least one abutment surface in abutment with the bottom wall, and first, second, and third connecting surfaces adapted to be selectively fixed on a circuit board. Each conducting unit further includes two terminals extending into the chamber via the corresponding through holes and being spaced apart from each other in a longitudinal direction of the corresponding connecting member. A conductive ball is disposed movably in the chamber to move toward or away from the terminals.