Rotary Switch with Solderable Legs for PCB Integration
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Solution Overview
Problem
Existing electrical rotary switches are cumbersome to locate and connect, relying on screws and cables for fixation and connection, which is inefficient and not easily adaptable to circuit boards.
Innovation Solution
The design features a rotary switch with a casing, a rotor, and fixed contacts, where at least one fixed contact has a leg extending out of the casing for soldering onto a circuit board, and a moving contact with undulating profiles for stable angular positions, allowing for easy mounting and connection directly to a circuit board without screws or cables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional screw fixation and cable connection methods are used, then the switch can be securely fixed and connected, but the installation process becomes cumbersome and time-consuming
Solution Approach 1:
The patent merges the fixation function and electrical connection function into a single integrated component. The leg of the fixed contact serves dual purposes: it provides mechanical support for screw fixation and simultaneously acts as the electrical connection terminal, eliminating the need for separate connection components and reducing installation steps
Solution Approach 2:
The switch housing is designed with built-in fixation features including recesses that receive fixing elements and positioning protrusions that automatically align with corresponding features on the mounting surface. This self-positioning and self-fixing capability reduces the complexity of installation and minimizes installation time
2Ease of manufacture
If the fixed contact has a simple structure, then the manufacturing is easier, but the electrical connection reliability may be compromised
Solution Approach 1:
The fixed contact is segmented into two distinct parts: the contact body that interfaces with the moving contact and the leg that provides mechanical support and electrical connection. This segmentation allows each part to be optimized independently - the contact body for electrical performance and the leg for structural integrity and mounting reliability
Solution Approach 2:
The fixed contact is constructed from composite materials or plating combinations that provide both electrical conductivity and mechanical strength. The contact body may use highly conductive materials for optimal electrical performance, while the leg incorporates materials with higher mechanical properties for reliable mounting and connection
3Ease of manufacture
If the rotor has a simple circular shape, then the manufacturing is simpler, but the switching precision and contact reliability are reduced
Solution Approach 1:
The rotor employs a circular cross-section with a rounded peripheral surface that interfaces with the fixed contacts. This curved geometry provides continuous contact during rotation, ensuring reliable electrical connection throughout the switching cycle while maintaining simple manufacturing through standard rotational forming processes
Solution Approach 2:
The rotor design incorporates specific geometric parameters including the radius of curvature of the peripheral surface and the angular positioning of contact points. These parameters are optimized to ensure precise switching at predetermined angular positions while maintaining manufacturing feasibility through standard tolerances
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 design enables easy and convenient mounting and connection of the rotary switch to a circuit board, eliminating the need for screws and cables, and providing stable electrical contact through resilient and conductive components.
Implementation Method 1
resilient against which rotor periphery the fixed contacts bear for sliding contact with the moving contact
Implementation Method 2
for insertion through a circuit board and soldering therewith for mechanical and electrical connection
Data Source
AI summary
An electrical rotary switch has a casing, a rotor supported within the casing for rotation, a moving contact mounted on the rotor for rotation with the rotor, and four fixed contacts located laterally of the rotor for short-circuiting by the moving contact. Each fixed contact has a contact body in the casing for contact by the moving contact and a leg extending from the contact body and projecting out of the casing for insertion through a circuit board and soldering to the circuit board for mechanical and electrical connection.