Single-Use High Power Switch with Shear Tab Activation
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Solution Overview
Problem
Conventional high power electrical switches are often too large for smaller electronic assemblies and are not designed for single-use applications, which can be a limitation in applications requiring compact and reliable activation mechanisms.
Innovation Solution
A high power, single-use electrical switch featuring a spring-biased plunger contact with an insulated spacer and a shear tab that separates the contacts before activation, utilizing frangible fasteners to enable compact form factor and secure engagement between the contacts, ensuring continuous electrical contact upon activation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional high power switches are used, then reliable high power switching is achieved, but the switch size becomes too large for smaller electronic assemblies
Solution Approach 1:
The switch is segmented into distinct functional components: a removable shear tab assembly containing the spacer, a plunger contact, a socket contact, and a housing. This segmentation allows the switch to be activated by removing only the shear tab portion, while maintaining reliable electrical contact between the remaining components. The segmentation enables a compact design that fits smaller assemblies while preserving the reliability of high power switching through proper contact design.
Solution Approach 2:
The spacer is extracted from the permanent structure and made removable through the shear tab mechanism. Before activation, the spacer is removed by shearing the tab, allowing the plunger and socket contacts to engage. This extraction principle enables the switch to transition from a non-conductive state (with spacer) to a conductive state (without spacer), achieving reliable high power contact in a compact form factor suitable for smaller assemblies.
2Device complexity
If conventional reusable switches are used, then durability is improved, but the device complexity and size increase
Solution Approach 1:
The shear tab is designed as a disposable component that is removed during activation. The tab contains the spacer and is secured by frangible fasteners that break upon application of activation force. This disposable approach simplifies the overall device complexity by eliminating the need for complex reusable mechanisms, while still achieving the required single-use functionality for applications such as payload deployment or fuse activation where reuse is not required.
Solution Approach 2:
The spacer is discarded after serving its purpose of maintaining separation between contacts during storage and transport. The shear tab assembly is designed to be easily removed and discarded after activation, while the main switch body with contacts remains intact. This principle reduces device complexity by eliminating the need for recovery and reuse mechanisms, while ensuring reliable single-use operation.
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 compact and reliable high power switch suitable for smaller assemblies, ensuring continuous electrical contact and meeting the requirements of size, weight, and power constraints, particularly in military and other high-demand applications.
Implementation Method 1
a spring-biased plunger contact that mates with a corresponding socket contact
Implementation Method 2
the frangible fasteners break to enable removable of the shear tab and the spacer relative to the housing and the contacts of the switch
Data Source
AI summary
A high power, single-use electrical switch includes a spring-biased plunger contact that mates with a corresponding socket contact, a spacer that provides a separation clearance between the contacts prior to activation of the switch, and a shear tab that supports the spacer and is removed from the switch to enable engagement between the contacts and activation of the switch. Using the shear tab for activation of the switch enables a compact and small form factor assembly that is suitable for use in smaller electronic assemblies.