Sealed Electrical Switch for Power Tools
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Solution Overview
Problem
Existing electrical switches for tools like angle grinders are prone to premature failure due to dirt, dust, and water ingress, which can lead to hazardous voltage flashovers, especially in single-handed operations.
Innovation Solution
The electrical switch is designed with sealed electrical connections and a protective housing that includes a flexible seal around the supply lines, a foldable cover for easy assembly, and a snap-action switching mechanism to prevent metal dust accumulation and ensure secure sealing, allowing for safe operation in harsh environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If electrical connections are arranged in a freely accessible form on the housing, then ease of connection is improved, but protection against hazardous substances deteriorates
Solution Approach 1:
The patent employs flexible seals (thin films) that surround the electrical supply lines where they penetrate the housing. These seals maintain flexibility to accommodate connection operations while providing continuous protection against hazardous substances like metal dust and water, resolving the contradiction between accessibility and protection.
2Reliability
If the contact system has a complex design, then switching performance is improved, but device complexity increases
Solution Approach 1:
The patent extracts the essential switching function from a complex contact system design and implements it through a simplified mechanism with clearly defined fixed contacts and switching contacts. The complexity is reduced by focusing only on the necessary elements for reliable switching while maintaining performance through proper sealing and contact geometry.
3Adaptability or versatility
If the seal is designed to fit different conductor cross sections, then adaptability is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent designs the seal with adjustable parameters, specifically its cross-sectional dimensions, to accommodate different conductor sizes. The seal can be manufactured with slight dimensional variations or designed with a flexible cross-section that adapts to different conductor diameters, maintaining both versatility and acceptable manufacturing 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
The solution effectively prevents dangerous voltage flashovers, extends the switch's lifespan, and ensures safe operation by protecting internal components from hazardous substances, while reducing component count and costs.
Implementation Method 1
The electrical connection has a seal and/or a seal is associated to the electrical connection. The seal expediently surrounds the supply line in the form of encapsulation.
Implementation Method 2
The seal can be produced from a flexible elastic material, such as a thermoplastic elastomer, a foam in the form of a foam seal, or the like. In consequence, the seal rests on the respective supply line for the connection with a certain contact pressure, which in turn further improves the sealing effect.
Data Source
AI summary
The invention relates to an electrical switch for an electrical appliance, in particular for an electrical tool, such as a drill, a grinder, a saw, a plane, an angle grinder or the like, and having a housing. The switch has a contact system which is located in the housing, and electrical connections, which lead into the housing and/or are located in the housing, for electrical supply lines to the contact system. Furthermore, the switch may have an operating member for switching action on the contact system, with the contact system being operatively connected to the operating member by means of an elastic element. The electrical connections have seals.