Seat Switch Button Cap Assembly for Stable Form-Fit Connection
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Solution Overview
Problem
Existing seat adjustment switches face challenges in achieving a stable and cost-effective connection between button caps and multidirectional force sensors, particularly due to the high mechanical stiffness of metal components which requires costly postprocessing and results in connections that do not meet pull-off and torsional force requirements across all tolerance positions and temperature ranges.
Innovation Solution
A seat adjustment switch design featuring multidirectional force sensors on a common carrier plate with sensor pins guided through receiving sleeves that are integrally formed and connected via flexible regions, allowing for a form-fit connection with button caps, eliminating the need for additional frictional or complex postprocessing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal components are used for high mechanical stiffness, then structural rigidity is improved, but manufacturing complexity and cost increase due to costly postprocessing
Solution Approach 1:
The patent uses a composite structure combining metal sensor pins (for stiffness) with plastic receiving sleeves (for ease of manufacture). The receiving sleeve is made of plastic material that can be easily molded into complex geometries including form-fit connection features, while the sensor pin remains metal for mechanical stiffness. This composite approach resolves the contradiction by assigning each material to its optimal function.
Solution Approach 2:
The connection structure is segmented into separate components: the sensor pin (metal) and the receiving sleeve (plastic). This segmentation allows each component to be manufactured independently using optimal processes for that material, then assembled together. The receiving sleeve can be molded with integrated form-fit features without requiring postprocessing of the metal sensor pin.
2Ease of manufacture
If frictional engagement is used for button cap connection, then assembly simplicity is improved, but connection reliability deteriorates as pull-off and torsional force requirements are not met
Solution Approach 1:
The receiving sleeve is made of plastic material that can be molded with integrated form-fit connection features (such as protrusions, grooves, or undercuts) that mechanically interlock with the button cap. This provides reliable mechanical connection through form-fit engagement rather than relying solely on friction, while the plastic material allows these features to be created during molding without additional postprocessing.
3Strength
If metal sensor pins are used, then mechanical strength is improved, but connection stability deteriorates due to limited form-fit connection possibilities
Solution Approach 1:
The receiving sleeve acts as an intermediary component between the metal sensor pin and the button cap. It provides the form-fit connection features that enable stable mechanical interlocking, while allowing the sensor pin to maintain its metal construction for strength. The receiving sleeve mediates the connection by combining the advantages of both metal (strength) and plastic (form-fit capability).
Data Source
AI summary
A seat adjustment switch includes a multidirectional force sensor, a carrier plate, and a button cap. The multidirectional force sensor is arranged on the carrier plate and includes a sensor pin. The sensor pin is pivotable via which the multidirectional force sensor is actuatable. The button cap is connected to the sensor pin. The button cap serves as an actuating element operable by an operator for pivoting the sensor pin in order to actuate the multidirectional force sensor. The carrier plate includes a receiving sleeve that is integrally formed with the carrier plate and is connected to other portions of the carrier plate via flexible regions, the sensor pin is guided through the receiving sleeve for the multidirectional force sensor to be arranged on the carrier plate. The button cap forms a form-fit connection with the receiving sleeve.