Sealed Switch Actuator with Self-Aligning Optical Assemblies
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing handheld lighting instruments are large, consume substantial power, and are not well-suited for industrial or mobile uses due to their size and inefficiency, lacking in adaptability for various applications and being prone to dust and moisture exposure.
Innovation Solution
The development of smaller, more compact lighting instruments with sealed push-button actuators and optical assemblies that provide brighter, uniform illumination, featuring self-aligning components for easy assembly and dust/moisture resistance, along with a self-aligning docking station for battery recharging, ensuring correct alignment and efficient operation in hazardous environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If handheld lighting instruments use traditional large-size construction, then they provide sufficient illumination, but they consume substantial power and are not suitable for mobile uses
Solution Approach 1:
The patent applies parameter changes by transitioning from traditional incandescent or halogen light sources to light-emitting diodes (LEDs), which fundamentally alter the energy conversion efficiency parameter. LEDs convert electrical energy to light with significantly higher efficiency, reducing power consumption while maintaining or improving illumination intensity. This parameter change enables the lighting instrument to be smaller and more suitable for mobile uses while providing sufficient brightness.
2Reliability
If push button actuators are left unsealed, then assembly is simpler, but they are prone to dust and moisture exposure
Solution Approach 1:
The patent employs flexible sealing boots made of elastomeric material that wrap around the push button actuator components. These flexible shells conform to the contours of the actuator parts and create effective seals against dust and moisture without requiring complex rigid sealing structures. The elastomeric material provides both flexibility for assembly and sufficient barrier properties for environmental protection.
Solution Approach 2:
The sealing boot acts as an intermediary element between the internal actuator components and the external environment. It provides a transition zone that isolates the sensitive electrical and mechanical components from dust and moisture while allowing the actuator to function normally. This intermediary sealing structure simplifies the overall design compared to attempting to seal each component individually.
3Manufacturing precision
If components require precise manual alignment during assembly, then operational accuracy is improved, but assembly complexity and time increase
Solution Approach 1:
The patent implements self-aligning features where components are designed with built-in alignment mechanisms that automatically position critical elements correctly during assembly. For example, the optical components and actuator elements incorporate geometric features such as tapered surfaces, keyed interfaces, or compliant mounting structures that guide them into precise alignment without requiring manual adjustment. This self-service alignment capability maintains manufacturing precision while dramatically simplifying the assembly process.
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 results in smaller, more efficient lighting instruments that provide brighter, uniform illumination, are adaptable to various uses, and can operate in hazardous environments while minimizing assembly complexity and maintaining reliability and durability.
Implementation Method 1
a coil spring disposed around the body and against an underside of the head of the plunger
Implementation Method 2
a coil spring disposed around the body and against an underside of the head of the plunger
Implementation Method 3
a resilient, cup-shaped boot open surrounds the actuator assembly
Data Source
AI summary
An electronic lighting instrument features separate optical assemblies for flood lighting and spot lighting. The optical assemblies include primary, secondary, and tertiary optical elements. The housing of the instrument features a trilobal cross section and includes dust-and-moisture-sealed push buttons and lenses as part of the housing construction. Self-aligning assemblies to ensure correct electrical and mechanical assembly are provided. The housing also self-aligns with a mating docking station for recharging the instrument batteries in situ. The lighting instrument may be controlled by a microprocessor circuit to provide floodlight and spotlight beams and several operational states thereof depending on the need for illumination or signaling.