Electrical Switch Assembly Heat Sink Integration

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Solution Overview

Problem

Compact electrical appliances and slim handheld power tools face challenges in accommodating both mechanical on-off switches and electronic control modules due to limited space, leading to increased manufacturing costs and complexity in wire connections.

Innovation Solution

A compact electrical switch assembly with a cuboidal housing that integrates a switching module, electronic control module, and heat sink, using a partitioned design to separate components and facilitate easy assembly and replacement, along with a semiconductor switching device like TRIAC for efficient control of the electric motor.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a mechanical on-off switch is added to a slim power tool, then the tool can be operated, but there is insufficient space to accommodate additional electronic control modules

Engineering Contradiction:

Improveability to accommodate electronic control moduleVSAvoidinterior space

Core Design Contradiction:

Adaptability or versatilityVSVolume of moving object

Solution Approach 1:

The patent combines the mechanical on-off switch and electronic control module into a single integrated housing structure. The mechanical switch is positioned on the housing surface while the electronic control module is mounted inside the same housing, eliminating the need for separate enclosures and reducing overall space requirements.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The electronic control module is mounted on the inner surface of the housing in a planar arrangement, utilizing the two-dimensional surface area of the housing interior rather than requiring three-dimensional volume. This allows efficient use of limited space within the slim power tool envelope.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Ease of manufacture

If wires are connected between the electronic control module and mechanical switch in confined space, then electrical connection is established, but the process becomes labour intensive and time consuming

Engineering Contradiction:

Improveease of wire connectionVSAvoidassembly time

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

The electronic control module is designed as a separate, pre-assembled unit with connection terminals that interface with the mechanical switch through the housing wall. This modular approach extracts the wiring complexity from the final assembly process, allowing the module to be pre-tested and pre-connected before installation into the power tool.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The housing structure itself serves as an intermediary that provides built-in connection pathways and mounting interfaces between the mechanical switch and electronic control module. This eliminates the need for separate wire connections during final assembly, as the housing structure facilitates electrical connection through its design.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Volume of moving object

If the electronic control module is integrated into the mechanical switch housing, then space is saved, but heat dissipation becomes a concern

Engineering Contradiction:

Improvehousing spaceVSAvoidheat dissipation

Core Design Contradiction:

Volume of moving objectVSTemperature

Solution Approach 1:

The housing is segmented into distinct functional zones: a mechanical switch section for user interaction, an electronic control module section for circuitry, and a heat dissipation section with thermal pathways. This segmentation allows each component to be optimized for its specific function while maintaining compact overall dimensions.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The housing structure is designed to convert the heat generated by the electronic control module into a beneficial feature by incorporating thermal pathways that conduct heat away from sensitive components and dissipate it through the housing exterior. The same housing that provides mechanical support also serves as a heat sink.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 allows for a compact, efficient, and cost-effective integration of control electronics within limited spaces, enabling easier upgrades and reducing manufacturing complexity while maintaining reliable operation and heat dissipation.

Implementation Method 1

a heat sink in thermal contact with the semiconductor switching device for dissipating the heat of the semiconductor switching device during operation

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentEP2908324B1Electrical switch assembly

Publication Date: 2020.10.21 DEFOND COMPONENTS

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AI summary

An electrical switch assembly (10) for an electrical appliance having an electrical load e.g. motor (20), comprises a housing (100) with an opening (121), switch terminals (T1 to T4), and an on/off mechanical switching module 200. Included are an electronic control module (300) operable with a semiconductor switching device e.g. TRIAC (350) to control the operation of the motor (20), and a heat sink (400) in thermal contact with the TRIAC (350) for dissipating heat thereof. The heat sink (400) is electrically conductive and is in electrical circuit connection with a first terminal of the TRIAC (350) and one of the switch terminals (T4). The heat sink (400) closes the opening (121) and forms part of the housing (100).