Security Electric Switch Contact Assembly Simplification
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Solution Overview
Problem
Existing electric switches are complex to produce and assemble, leading to inefficiencies in interrupting electric circuits during overloads or short circuits, with suboptimal current paths that fail to effectively deflect electric arcs and maintain low contact resistance.
Innovation Solution
A security electric switch with a simplified design featuring a pivotally embedded movable contact within a cradle, supported by a flat spring, which allows for quick arc commutation and improved discharging resistance, utilizing a bimetallic membrane and magnetic field to trigger circuit interruption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a complex contact assembly design is used, then the switch can achieve basic circuit interruption, but the production and assembly processes become inefficient and costly
Solution Approach 1:
The patent combines the movable contact, spring element, and pivot mechanism into an integrated contact assembly unit. The movable contact is pivotally embedded within a cradle that incorporates the spring support structure, eliminating the need for separate assembly steps for these components and simplifying both production and assembly processes.
Solution Approach 2:
The contact assembly is segmented into distinct functional modules: the cradle structure, the pivotally embedded movable contact, the spring element, and the fixed contact support. This modular segmentation allows for simplified manufacturing of individual components while maintaining overall functionality, and enables easier assembly and replacement.
2Reliability
If the movable contact is pressed firmly against the fixed contact, then contact resistance is reduced, but the velocity of contact pivoting during circuit interruption decreases
Solution Approach 1:
The spring element is designed to provide dynamic force adjustment: during normal operation, it maintains firm pressure between contacts for low resistance; during circuit interruption, the rapid pivoting motion overcomes the spring force, enabling high velocity separation. The spring constant and pre-compression are optimized to balance these opposing requirements.
Solution Approach 2:
The spring element is pre-compressed during assembly to store potential energy that assists in the rapid pivoting motion during circuit interruption. This preliminary energy storage ensures that when the movable contact needs to pivot away from the fixed contact, the stored spring energy contributes to the acceleration, maintaining high pivoting velocity despite the firm contact pressure during normal operation.
3Object-affected harmful factors
If the current path is optimized to deflect electric arcs, then arc extinguishing improves, but the device complexity increases
Solution Approach 1:
The patent utilizes the electric arc itself as a beneficial tool by positioning the movable contact to pivot through an arc-deflecting path. The arc, normally a harmful phenomenon, is channeled along a controlled trajectory that naturally extends the arc length and facilitates extinguishing, converting the harmful arc into a mechanism that aids its own suppression.
Solution Approach 2:
The current path is designed with curved trajectories rather than straight lines. The movable contact pivots along a curved path that naturally deflects the electric arc, extending its length and cooling it more effectively. This curved geometry is achieved through the pivotal mounting arrangement and contact geometry, adding arc-deflection capability without significant complexity increase.
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 switch effectively interrupts circuits with reduced contact resistance and enhanced arc extinguishing, enabling faster operation and improved reliability, while simplifying production and assembly processes.
Implementation Method 1
said movable contact, which is pivotally embedded in said cradle, is pressed towards said fixed contact by means of a flat spring
Implementation Method 2
utilizing a bimetallic membrane and magnetic field to trigger circuit interruption
Implementation Method 3
a bimetallic washer and a needle, which may impact said disconnecting mechanism either due to thermal dilatation of said bimetallic washer
Data Source
Figure 1~2
Figure 3~5
Figure 6~8
AI summary
The purpose of the invention is to improve a security electric switch by increasing its reliability and also by simplification thereof. The switch according to the invention said switch assembly (2) consists of an immovable contact member (21), which is made of an electric conductive material and is electrically connected with said coil (31) of the interrupting assembly (3), which coil is electrically connected with said first contacting terminal (13) on the casing (1) of the switch, by which said immovable contact member is arranged within said casing (1) outside of said interrupting assembly (3) and on that side thereof, which is faced towards said seat (11), as well as of a movable contact member (22), which is also made of an electric conductive material and is inside of said casing (1) of the switch arranged adjacent to said immovable contact member (21) and is electrically connected with the other connecting terminal (14) on the casing (1) of the switch, wherein said movable contact member (22) is pivotally embedded within a cradle (220), which is formed on a free end portion of a cantilever beam (221) in the area in front of said needle (32) of said interrupting assembly (3) and is mechanically and electrically connected with said second connecting terminal (14), so that said movable contact member (22), which is embedded in said cradle (220), is pressed towards said immovable contact member (21 ) by means of a spring (222), by which it is supported in the adjacency of said cradle (220), but can be also moved in the opposite direction i.e. away from said immovable contact member (21) and against the force of said spring (222) when said switch member (4) is pivoted due to impact of the needle (32).