Switch Base Segmentation for Gap-Free Wall Mounting
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Solution Overview
Problem
Existing key-type switches require disassembly for maintenance or part replacement, are costly due to excessive material usage for screw fixation, and can suffer from incorrect reassembly and visible unevenness with the wall.
Innovation Solution
A switch design featuring a base with protrusions for easy manual positioning of the contact carrier case and an outer frame that keeps the protective cover separate from the wall, eliminating the need for screws and reducing material consumption by using smaller screws for cover fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If screws pass through the whole switch to fix it to the wall, then the switch is securely fixed, but the screws have considerable length and cost more
Solution Approach 1:
The switch is divided into separate components: a base that attaches to the wall and a protective cover that attaches to the base. This segmentation allows screws to be used only for the base-to-wall connection, eliminating the need for long screws that would pass through the entire switch assembly.
2Strength
If the outer protective cover is in contact with the wall, then the switch is fixed, but any unevenness of the wall is easy to identify visually
Solution Approach 1:
The base acts as an intermediary element between the wall and the protective cover. It provides a stable mounting surface that compensates for wall unevenness, allowing the protective cover to be positioned correctly without directly contacting the uneven wall surface.
3Strength
If the contact carrier case has two orifices all the way along for screw fixation, then the switch can be fixed to the wall, but manufacture is more complicated and expensive
Solution Approach 1:
The switch assembly is segmented into a base and a protective cover, with the base containing the fixation orifices. This eliminates the need for through-orifices in the contact carrier case, simplifying its manufacturing while still providing secure wall fixation through the base.
4Ease of repair
If the whole switch is dismantled for maintenance or part replacement, then all connections can be checked, but the process is time-consuming and complex
Solution Approach 1:
The switch is designed with separable components (protective cover, contact carrier case, base) that can be independently accessed. The protective cover can be removed to access the contact carrier case and its connections without dismantling the entire switch from the wall, as the base remains fixed.
Data Source
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AI summary
Switch of the type comprising a case (2) for carrying contacts and mechanisms of the switch and an outer protective cover (8), comprising a base (1) for fixing to a surface, said base comprising at least one protrusion (3) with which the case (2) for carrying contacts and mechanisms of the switch fits together, allowing the case (2) for carrying contacts and mechanisms to be positioned on the base (1), and in that the surface contact area of said base comprises an outer frame (9) that receives the outer protective cover.