Stackable Low-Profile Contact Block With Nested Actuation Clearance
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Solution Overview
Problem
Existing electrical contact blocks are not fully stackable, limiting their use as modules in applications such as push button assemblies, and they often have a high profile which is undesirable.
Innovation Solution
The electrical contact block design features a housing with a bottom side that functions as a connection interface, allowing for easy stacking. The actuation head of the lower contact block can be inserted into the clearance of the upper contact block, and the return spring is positioned to allow for unobstructed insertion, enabling the blocks to be stacked while maintaining a low profile.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the contact block is designed with a low profile, then the height is reduced, but the block cannot be fully stackable
Solution Approach 1:
The actuation head of the lower contact block is nested within the clearance space of the upper contact block. The lower actuation head protrudes upward and fits into the clearance below the upper pusher, allowing the lower block to be actuated through the upper block without increasing the overall stack height significantly.
Solution Approach 2:
The stacking mechanism utilizes the vertical dimension by allowing the actuation head to protrude upward from the lower block and insert into the clearance of the upper block. This vertical arrangement enables full stackability while maintaining a compact profile, as the actuation components are arranged along the height axis rather than requiring lateral space.
2Adaptability or versatility
If the return spring is positioned to allow unobstructed insertion of the actuation head, then stackability is enabled, but the spring must extend into the clearance
Solution Approach 1:
The return spring acts as an intermediary element that mediates between the pusher and the actuation head. The spring extends into the clearance space and connects to the actuation head, allowing the actuation head to move freely for stacking purposes while the spring provides the necessary restoring force. This intermediary positioning enables both stackability and functional operation.
3Ease of operation
If the actuation head protrudes from the top side, then it can be actuated, but it obstructs the clearance needed for stacking
Solution Approach 1:
Instead of the actuation head protruding downward from the top (which would obstruct stacking), the actuation head protrudes upward from the bottom of the lower block. This inverted arrangement allows the actuation head to insert into the clearance of the upper block, enabling both actuation capability and stackability simultaneously.
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 allows for the creation of a low-profile, fully stackable electrical contact block that can be used as upper or intermediate members in a contact block stack, enhancing its usability in modular applications.
Implementation Method 1
a return spring biasing the actuation pusher towards its resting position
Data Source
Figure 1~2
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Figure 5~6
AI summary
A stackable electrical contact block (100) comprising a housing (102), the housing (102) having a top and bottom side and accommodating a first (108) and second (110) electrical terminal, an actuation pusher (112) adapted to move from a resting position (Pr) to an actuated position to break the contact between the first and second terminals (108, 110), the actuation pusher (112) having a head (130) protruding from the top side, a clearance below the actuation pusher, and a return spring (114) biasing the actuation pusher (112) towards its resting position, a bottom end of the return spring extending into the clearance. The housing's bottom side is a connection interface with an entrance (128) providing access to the clearance. A central part of the clearance is taken up by the bottom end of the return spring (114), and a peripheral part is a space for receiving the actuation head of a component connected to the contact block (100) via the connection interface.