Switch Button Travel Limit Feature for Durability
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Solution Overview
Problem
Existing switch systems face challenges in achieving durability, moisture and debris sealing, cost-effectiveness, and desirable aesthetic and tactile characteristics, while protecting electrical switch assemblies from excessive force and ensuring reliable operation.
Innovation Solution
A switch system with a housing, circuit board assembly, electrical switch assembly, and a user-activatable button featuring a button travel limit feature that inhibits excessive force transfer, utilizing a flexible membrane and a button travel limit feature integrated into the housing to protect the electrical switch assembly and maintain seal integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a plunger element is used to compress a conductive elastomeric dome to complete an electrical circuit, then the switch assembly can achieve electrical circuit completion, but the switch assembly becomes vulnerable to overloading and reduced durability
Solution Approach 1:
The button travel limit feature is positioned in advance to prevent excessive button travel before overloading can occur. This preliminary mechanical constraint stops the button from traveling too far toward the electrical switch assembly, thereby preventing overloading of the elastomeric dome and circuit before damage can occur.
Solution Approach 2:
The button travel limit feature acts as an intermediary mechanical element between the user-activatable button and the electrical switch assembly. It mediates the force transmission by providing a physical stop that prevents excessive force from reaching the vulnerable elastomeric dome and circuit components.
2Reliability
If traditional switch assemblies are designed with limiting mechanisms to prevent overloading, then durability is improved, but manufacturing cost and device complexity increase
Solution Approach 1:
The button travel limit feature is integrated with existing components of the switch assembly, such as the housing or circuit board, rather than being a separate additional component. This merging approach provides the limiting function while minimizing the quantity of parts and reducing manufacturing complexity.
Solution Approach 2:
The button travel limit feature serves multiple functions: it limits button travel to prevent overloading, provides structural support, and can be integrated into the housing or circuit board assembly. This multi-functionality reduces the need for dedicated separate limiting mechanism components, thereby lowering manufacturing cost.
3Reliability
If a button travel limit feature is positioned to inhibit motion of the activation surface, then the electrical switch assembly is protected from excessive force, but the button's travel distance and tactile feedback may be reduced
Solution Approach 1:
The button travel limit feature is positioned to change the parameter of button travel distance to an optimal value. It allows sufficient travel distance for reliable switch activation and user tactile feedback, while preventing excessive travel that would cause overloading. The positioning is optimized to balance protection needs with operational requirements.
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 provides enhanced durability, cost-effectiveness, and improved aesthetic and tactile qualities by limiting excessive force, sealing against moisture and debris, and ensuring reliable operation of the switch system.
Implementation Method 1
a flexible membrane connecting the activation member to the housing such that the user-activatable button is movable between an activating and non-activating position
Data Source
AI summary
A switch system having a user-activatable button and button travel limit feature is disclosed. The switch system includes a housing comprising an opening, a circuit board assembly positioned in the housing, and an electrical switch assembly connected to the circuit board. The button travel limit feature is adapted to inhibit motion of an activation surface of the user-activatable button towards the electrical switch assembly when the electrical switch assembly is activated.