Snap-action disk switch with integrated PCB housing
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Solution Overview
Problem
Existing switching devices for converting mechanical movement into electrical signals require additional components like plastic housings and keycaps, increasing production costs and complexity.
Innovation Solution
A simplified design where the snap-action disk and body form an airtight housing, directly connected to the printed circuit board, eliminating the need for additional encapsulation and actuation aids, with a resilient switching contact accessible from the outside for mechanical actuation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional components like plastic housings and keycaps with plungers are used to encapsulate and actuate the snap-action disk, then hermeticity and actuation functionality are improved, but manufacturing cost and device complexity increase
Solution Approach 1:
The patent merges the encapsulation housing and actuation mechanism into a single integrated structure. The printed circuit board serves dual functions: as the structural base for mounting the snap-action disk and as the actuation element itself, eliminating the need for separate plastic housings and keycaps with plungers. This integration maintains hermeticity while reducing component count and manufacturing complexity
Solution Approach 2:
The printed circuit board is designed to perform multiple functions simultaneously: it provides mechanical support for the snap-action disk, creates the hermetic enclosure when combined with the disk, and serves as the actuation interface. This multi-functionality eliminates the need for dedicated separate components for each function, reducing overall device complexity
2Reliability
If additional components like plastic housings and keycaps with plungers are used to encapsulate and actuate the snap-action disk, then hermeticity and actuation functionality are improved, but manufacturing cost increases
Solution Approach 1:
The patent combines multiple functions into fewer components that can be manufactured using standard processes. The printed circuit board, manufactured using conventional PCB fabrication techniques, replaces the need for separate injection-molded plastic housings and assembled keycap-plunger mechanisms, thereby reducing manufacturing cost while maintaining hermeticity
Solution Approach 2:
The printed circuit board serves its own structural and functional needs without requiring external housing components. The board itself provides the mounting structure, sealing surface, and actuation interface, eliminating the need for additional manufactured parts and reducing overall manufacturing complexity and cost
3Device complexity
If the snap-action disk is directly connected to the printed circuit board without additional encapsulation, then manufacturing cost and assembly complexity are reduced, but hermeticity may be compromised
Solution Approach 1:
The snap-action disk and printed circuit board are designed to work together as an integrated hermetic system. The disk is mounted directly on the board with the circuit traces extending to the mounting holes, creating a sealed enclosure without requiring additional housing components. This integration maintains hermeticity while simplifying assembly
Solution Approach 2:
The snap-action disk itself serves as both the functional switching element and the sealing element. The flexible membrane structure of the disk creates the hermetic seal when mounted on the rigid printed circuit board, eliminating the need for separate rigid housing enclosures while maintaining environmental protection
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
This design reduces manufacturing costs and simplifies assembly by integrating the snap-action disk and switching contact directly with the printed circuit board, maintaining hermeticity and enabling efficient conversion of mechanical actuation to electrical signals without additional components.
Implementation Method 1
a snap-action disc (6) made of a flexible, electrically conductive material which, when actuated, closes an electrically conductive contact
Data Source
Figure 1
Figure 2a
Figure 2b
AI summary
The device (1) has a printed circuit board (4) electrically coupled with an electrical switching contact (3). A snatching disk (6) is made of bend-resilient-and electrical conductive material, and a thin walled body (2) forms a housing by which the electrical switching contact is sealed in an air- or watertight manner. Two ring segments (11) are attached at the snatching disk, where free ends of the ring segments facing circuit board are firmly connected with each other. The snatching disk and the body are firmly connected by an injection molding process. The snatching disk is provided with a bend-resilient coat that is made of plastic, rubber or a plastic rubber mixture. The switching contact in a cross-section is designed as an H-shaped body (16) or a ball-shaped body and hemisphere-shaped body. The switching contact is made of electrical conductive material.