Surface Mount Snap Switch with Perpendicular Terminals
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional high life-cycle snap switches are limited by increased costs and restricted mounting configurations due to insert-molded screw machine terminal contacts, which are costly and inflexible in construction.
Innovation Solution
A surface mount snap switch design featuring a housing with channels for terminal accommodation, a snap-fit cover, and an actuator that deflects a blade contact to electrically couple terminals, using stamped conductive terminals and a thermoplastic material for reduced costs and enhanced customization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insert-molded screw machine terminal contacts are used, then the snap switch achieves high life cycle and reliability, but the construction cost increases and mounting configuration flexibility is limited
Solution Approach 1:
The patent changes the terminal contact configuration from screw machine type to surface mount type with perpendicular mounting legs, transforming the mounting parameters and method to reduce construction costs while maintaining electrical performance and reliability
Solution Approach 2:
The terminal contacts are segmented into separate surface mount components with distinct mounting legs, allowing independent optimization of each terminal's mounting configuration and reducing the complexity and cost of the overall terminal assembly
2Reliability
If insert-molded screw machine terminal contacts are used, then the snap switch achieves high life cycle and reliability, but the mounting configuration flexibility is limited
Solution Approach 1:
The surface mount terminal design with perpendicular mounting legs provides universal adaptability to standard PCB surface mount configurations, enabling the snap switch to be mounted in various orientations and configurations on printed circuit boards, thereby increasing mounting flexibility while maintaining reliable electrical connections
3Reliability
If conventional thermoset plastic housing with screw machine terminals is used, then the snap switch achieves high life cycle, but the construction cost increases
Solution Approach 1:
The patent employs composite construction combining thermoplastic housing material with metal surface mount terminal contacts, optimizing the material selection for each component to reduce overall construction costs while maintaining the mechanical durability and electrical reliability required for high life cycle applications
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 reduces construction costs and offers greater flexibility in mounting configurations while maintaining a suitable power rating and life cycle, enabling efficient and cost-effective integration into various applications.
Implementation Method 1
the actuator is configured to interact with the blade contact so as to deflect the blade contact when the actuator is slid inwardly toward the blade contact
Implementation Method 2
the cover is configured for snap-fit engagement with the housing
Data Source
AI summary
A surface mount snap switch and method of making the same, including a housing having a plurality of channels formed therein and a cover configured for snap-fit engagement with the housing. The snap switch also includes an actuator slidably disposed at least partially within the housing, a first terminal having an external surface mount portion and another portion press-fittingly held within one of the plurality of channels of the housing, and a second terminal having an external surface mount portion and another portion press-fittingly held within another one of the plurality of channels of the housing. The snap switch further includes a blade contact having a first end portion pivotally associated with the first terminal and a second end portion comprising a blade contact button, and the actuator is configured to interact with the blade contact to electrically couple the first terminal and the second terminal.