Compact Switch Assembly with Epoxy Sealed Lumen
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Solution Overview
Problem
Existing switch assemblies for personal communication equipment in military aircraft cockpits are prone to unintentional activation, are bulky, difficult to use with thick gloves, and susceptible to moisture and fracturing in high vibration environments.
Innovation Solution
A compact switch assembly with a tubular housing featuring a lumen with varying diameters for secure retention, a push button, and a snap-fit cover with epoxy-filled spacings for sealing, providing a secondary cable channel and tactile feedback through a push-on/push-off mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the switch assembly is made compact, then it becomes easier to operate with thick gloves and less prone to unintentional activation, but it becomes more difficult to provide adequate spacing for cable connections and sealing
Solution Approach 1:
The switch body is nested within the housing, with the push button extending through the housing wall. The cable terminals are integrated into the housing structure, and the sealing epoxy is injected through access holes in the housing. This nested arrangement allows all components to be contained within a compact volume while maintaining adequate spacing for connections and sealing.
Solution Approach 2:
The patent utilizes three-dimensional space efficiently by positioning the push button to extend through the housing wall in one dimension, while cable terminals are arranged in different spatial orientations. The epoxy sealing fills void spaces in multiple dimensions, maximizing space utilization and maintaining compactness while providing adequate connection points.
2Volume of moving object
If the switch assembly is made compact, then it reduces bulkiness, but it becomes harder to feel and locate the rocker switch
Solution Approach 1:
The push button is designed with an asymmetric profile that extends through the housing wall at an angle, creating a distinctive tactile shape that is easy to locate by touch. The uneven surface profile and angled orientation provide unique tactile cues that allow pilots to quickly find and operate the switch without visual confirmation, even when wearing thick gloves.
Solution Approach 2:
The push button incorporates tactile feedback mechanisms including an audible click and tactile resistance changes during actuation. These sensory feedback elements compensate for the reduced visual prominence, allowing the pilot to feel the switch position and operation status through touch alone.
3Volume of moving object
If the switch assembly is made compact, then it becomes more durable against fracturing, but it becomes more difficult to provide adequate sealing against moisture
Solution Approach 1:
The patent changes the physical state of the sealing material by injecting epoxy in a viscous state that flows into all void spaces and cracks within the compact housing, then allows it to cure into a rigid, moisture-impermeable solid. This parameter change from liquid to solid state enables effective sealing in a compact configuration where traditional gaskets would be too bulky.
Solution Approach 2:
The housing is constructed as a composite structure combining the rigid housing material with the epoxy sealing material. The epoxy acts as both a structural adhesive bonding internal components and a moisture barrier filling all interstitial spaces. This composite approach provides both structural integrity and moisture sealing in a compact package.
4Volume of moving object
If the switch assembly is made compact, then it prevents unintentional activation by bumping, but it becomes harder to actuate deliberately
Solution Approach 1:
The push button incorporates a spring-loaded mechanism that provides dynamic resistance during actuation. The spring allows the button to be easily pressed with deliberate force while requiring a specific actuation threshold, preventing accidental activation from minor bumps. The dynamic spring force adapts to the operator's input, providing easy deliberate actuation while maintaining protection against unintentional activation.
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 results in a durable, moisture-resistant, and easily actuable switch assembly that prevents inadvertent activation, is compact enough for use with thick gloves, and offers enhanced tactile feedback.
Implementation Method 1
The first peripheral spacing, the second peripheral spacing and the cavity are filled with epoxy or similar type non-conductive material
Data Source
AI summary
A durable and secured switch assembly includes an alternate action switch with a push button on one end and two primary cable terminals on the opposing end. The switch is secured in a housing with a lumen configured to securely retain the switch body. A first section of the lumen at the proximal end includes peripheral spacing for epoxy between the switch body and the inside wall of the housing. A second section of the lumen at the distal end includes a second peripheral spacing for epoxy between the switch body and the inside wall of the housing. The second section includes a peripheral notch for securing a cover that encloses the primary cable terminals in a cavity that is filled with epoxy. The housing includes a primary channel that connects a primary cable to the primary cable terminals and secondary channel for securing a secondary cable to the housing.