Miniaturized Switch With Detachable Power Reset Unit
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Solution Overview
Problem
Current switches with reset mechanisms are limited in miniaturization due to the parallel arrangement of power switch and reset mechanisms, leading to increased size and complexity, and require labor-intensive disassembly for maintenance and voltage specification changes, which complicates production and recycling.
Innovation Solution
A switch design where the power retaining and releasing mechanism is detachably attached from the bottom of the housing, allowing for independent attachment and detachment without interfering with other components, enabling miniaturization and easy voltage specification changes by stacking and sliding the mechanism, thus simplifying assembly and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the power reset mechanism and power switch mechanisms are disposed in parallel in the housing, then the switch can be provided with a reset function, but the size of the switch is enlarged in lateral direction
Solution Approach 1:
The patent repositions the power reset mechanism from a parallel arrangement to a stacked arrangement on top of the power switch mechanism. This vertical stacking transforms the spatial configuration from horizontal parallel disposition to vertical layered disposition, reducing the lateral footprint while maintaining all functional capabilities.
Solution Approach 2:
The power reset mechanism is positioned to overlap with the power switch mechanism in the plan view, creating a nested or layered configuration where components are stacked vertically rather than arranged horizontally. This nesting approach allows multiple mechanisms to occupy the same lateral space at different vertical levels.
2Reliability
If a long movable piece is disposed in the housing to enable turning for power on/off, then the power switch function is achieved, but the size in longitudinal direction is enlarged
Solution Approach 1:
The movable piece is reconfigured from a long linear structure extending in the longitudinal direction to a compact structure where the turning motion occurs in a shorter path. The power switch mechanism and reset mechanism are stacked vertically, allowing the movable piece to achieve its switching function within a reduced longitudinal envelope.
3Stability of the object's composition
If the switch is designed as an integrated unit, then structural stability is maintained, but disassembly for maintenance and voltage specification changes becomes labor-intensive
Solution Approach 1:
The switch is divided into separable modules: the power switch mechanism and the power reset mechanism. The reset mechanism can be detached from the housing without requiring disassembly of other components, enabling independent maintenance, repair, and voltage specification changes while maintaining structural integrity during operation.
Solution Approach 2:
The power reset mechanism is designed to be extractable from the housing as a separate component. This extraction capability allows the reset mechanism to be removed for maintenance or replacement without disturbing the power switch mechanism or other components, significantly reducing disassembly effort.
4Reliability
If the biasing force of the spring is enhanced to securely separate contact portions, then welding is reduced, but manipulation feeling is degraded and lifetime is shortened due to accelerated abrasion
Solution Approach 1:
The spring mechanism is designed with optimized local properties at the contact separation point, providing sufficient biasing force only where needed to separate welded contact portions. This localized quality enhancement avoids applying excessive force throughout the entire switch mechanism, thereby preventing accelerated abrasion and extending switch lifetime while maintaining contact separation reliability.
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 design results in a compact, miniaturized switch that can be efficiently assembled and maintained, allowing for effective component utilization even with conduction errors and enabling voltage specification changes post-production, improving productivity and reducing waste.
Implementation Method 1
a solenoid that is incorporated for the reset signal in the switch
Implementation Method 2
The movable piece is inverted by a reset signal output from a controller
Implementation Method 3
a returning spring that biases the manipulator in a swing manipulation direction
Data Source
Figure 1A~1B
Figure 2
Figure 3
AI summary
An object of the invention is to provide a miniaturized, slim switch (100), in which effective components can be utilized without disposing all the components even if a conduction error is generated in a contact portion and a voltage specification can be changed in the produced switch, and a method for producing the switch (100). The switch (100) is configured to be dividable, one side of the divided switch (100) is treated as a housing (110) including a manipulator portion a power switch mechanism (130, 160, 170), and a stacked attachment portion (112) to which a returning spring and a power reset mechanism are stacked and attached, the other side of the divided switch (100) is treated as a power reset unit (180) including the returning spring (140) and the power reset mechanism (150), which are attached to the stacked attachment portion (112) of the housing (110), and the power reset unit (180) can be attached and detached from a bottom of the stacked attachment portion (112) of the housing (110).