Compression-Activated Seat Switch Assembly for Multi-Device Control
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Solution Overview
Problem
Existing switches for vehicle and non-vehicle applications lack a reliable, compact, and inexpensive compression-activated mechanism to simultaneously control the flow of current to multiple devices, particularly in seat-based systems, where structural efficiency and weight-sensing capabilities are essential.
Innovation Solution
A compression-activated switch assembly featuring electrically conductive contact layers with a resilient foam layer and optional thermal protection, allowing for horizontal or vertical arraying of contact pairs, which are connected to power sources and applications via conductive lines, enabling simultaneous and independent control of current delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple discrete switches are used to control multiple devices, then each device can be controlled independently, but the device complexity and space requirements increase
Solution Approach 1:
Multiple discrete switches are merged into a single integrated switch assembly by stacking contact layer pairs vertically. Each contact layer pair functions as an independent switch, but they share common structural elements including the resilient foam layer, envelope, and mounting mechanism, thereby reducing overall complexity and space requirements while maintaining independent control capability.
Solution Approach 2:
The switch assembly employs a nested structure where multiple contact layer pairs are vertically stacked and nested within a single envelope. The resilient foam layer serves as a common element across all switches, and the entire assembly is nested within a unified structural framework, allowing multiple switches to occupy the space of a single switch.
2Volume of moving object
If a compact switch design is used, then space is saved, but manufacturing precision and assembly difficulty increase
Solution Approach 1:
The switch assembly is segmented into modular contact layer pairs that can be manufactured independently and then assembled by stacking. Each contact layer pair is a discrete unit with standardized dimensions and features, allowing for precise manufacturing of individual modules that are then easily aligned and assembled into the compact vertical stack, reducing the overall manufacturing precision burden.
Solution Approach 2:
The resilient foam layer acts as a flexible element that accommodates minor variations in contact layer positioning during assembly. Its compressible nature provides tolerance for manufacturing imperfections while maintaining reliable electrical contact, thereby reducing the stringency of manufacturing precision requirements for the rigid contact layers.
3Reliability
If conventional switches are used, then current control is achieved, but weight-sensing capability and compression activation are lacking
Solution Approach 1:
The switch assembly is designed with multi-functionality, serving both as a reliable current control mechanism through electrical contact and as a weight-sensing device through its compression-activated resilient foam layer. The same structural elements that enable switching also provide weight detection capability, eliminating the need for separate sensing mechanisms and enhancing versatility.
Solution Approach 2:
The conventional mechanical switch mechanism is replaced with a compression-activated system where the resilient foam layer's mechanical compression under weight directly triggers electrical contact between contact layers. This substitution integrates mechanical weight sensing with electrical switching in a unified mechanism, providing both functions through a single system.
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 provides a sturdy, reliable, and cost-effective means to control multiple devices with weight-activated switches, ensuring efficient current delivery and adaptable structural configurations for various applications, including anti-bounce functions and weight-sensing capabilities.
Implementation Method 1
weight placed on the switch compresses the resilient layer and thereby advances the first contact layer toward the second contact layer until the first and second contact layers make electrically conductive contact
Implementation Method 2
a resilient layer sandwiched between first the and second contact layers and having at least one resilient layer port
Implementation Method 3
an electrically conductive first contact layer for electrically connecting to a power source, and a conductive second contact layer spaced from the first contact layer for connecting to an application
Data Source
AI summary
A compression activated switch includes an electrically conductive contact layer pair formed of a conductive first contact layer for electrically connecting to a power source, and a conductive second contact layer spaced from the first contact layer for connecting to an application, and a resilient layer sandwiched between said first and second contact layers and having at least one resilient layer port; so that weight placed on the switch compresses the resilient layer and thereby advances said first contact layer toward said second contact layer until the first and second contact layers make electrically conductive contact through the at least one resilient layer port, closing the switch. A switch assembly includes multiple compression activated switches arrayed either horizontally or vertically and separated by insulating structures.