Switch Base Integrated Resistive Element for Circuit Monitoring
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Solution Overview
Problem
Existing micro-switches in industrial and automotive applications face challenges due to uncertainty about defects in the switch or wiring under heavy mechanical stress, and the integration of diagnostic functions is complex and costly, with limited ability to detect faulty connections specifically.
Innovation Solution
A switch with integrated circuit monitoring using a conductive plastic body or conductive layer with adjustable resistance values, replacing traditional resistors, allowing for reliable diagnostic functionality and reduced manufacturing costs through miniaturization and elimination of additional components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional resistors and additional printed circuit boards are used for diagnostic functions, then circuit monitoring capability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the diagnostic resistive element directly into the switch base structure, eliminating the need for separate resistors and printed circuit boards. The base itself is designed with integrated conductive paths that serve both structural support and diagnostic monitoring functions, thereby reducing device complexity while maintaining circuit monitoring capability.
Solution Approach 2:
The switch base is designed to perform multiple functions simultaneously: it provides mechanical support for the contact system, establishes electrical connections between terminals, and enables diagnostic monitoring through integrated resistive elements. This multi-functionality eliminates the need for separate dedicated diagnostic components.
2Reliability
If traditional resistors and additional printed circuit boards are used for diagnostic functions, then circuit monitoring capability is improved, but manufacturing cost increases
Solution Approach 1:
The diagnostic resistive element is merged into the switch base structure, eliminating the need for separate resistors and printed circuit boards. This integration reduces the number of components that need to be sourced, assembled, and tested, thereby reducing manufacturing cost while maintaining circuit monitoring capability.
Solution Approach 2:
The switch base is designed to perform multiple functions simultaneously: mechanical support, electrical connection, and diagnostic monitoring. This multi-functionality reduces the total component count and assembly steps, leading to lower manufacturing costs.
3Reliability
If additional printed circuit board and components are added for diagnostic functions, then diagnostic functionality is improved, but space requirement increases
Solution Approach 1:
The diagnostic resistive element is merged directly into the switch base structure, eliminating the need for separate printed circuit boards and discrete components. This integration achieves full diagnostic functionality within the existing switch housing space without increasing the overall footprint.
Solution Approach 2:
The conductive paths and resistive elements are nested within the existing base structure, utilizing the internal volume and space already allocated for the switch components. This nesting approach enables diagnostic functionality without increasing the external dimensions of the switch.
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 enables reliable circuit monitoring, reduced manufacturing costs, and miniaturization of switches, allowing for more economical production while providing clear diagnostic states for switch and wiring integrity.
Implementation Method 1
The resistive element has a specific resistance value. The resistive element is a conductive material formed on the base, the terminals being electrically connected by the conductive material.
Implementation Method 2
The resistive element is a conductive material formed on the base, the terminals being electrically connected by the conductive material.
Data Source
AI summary
The invention relates to a switch including a switch housing, a contact system and a base disposed in the switch housing, a resistive element for diagnosing a state of a switch, and at least two terminals leading from the base. The resistive element has a specific resistance value. The resistive element is a conductive material formed on the base, the terminals being electrically connected by the conductive material.