Electrical Switch Lateral Actuation Lever Force Limiting

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Solution Overview

Problem

Existing electrical switches risk damaging the release element when subjected to large-amplitude actions, such as impacts, due to the direct transfer of force, which can lead to premature failure.

Innovation Solution

An electrical switch design featuring a movable actuation pusher in the plane of the component-bearing plate, a hinged lever converting horizontal force into vertical force on an elastically deformable release element, and a mechanism allowing the lever to deform and absorb excess force, preventing full force transfer to the release element during high-amplitude actions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Force

If the pusher directly transfers large-amplitude action to the release element, then the actuation force is effectively transmitted, but the release element risks damage from excessive force

Engineering Contradiction:

Improveactuation force transmissionVSAvoidrelease element durability

Core Design Contradiction:

ForceVSReliability

Solution Approach 1:

The lever is designed with elastic deformability to serve as a cushioning element before excessive force reaches the release element. When impact force exceeds the threshold, the lever deforms elastically, absorbing the excess energy and preventing direct transmission to the release element, thus protecting it from damage while still allowing normal actuation forces to be transmitted effectively.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The lever's elastic deformability allows it to change its mechanical parameters dynamically. Under normal operating conditions, the lever remains rigid for efficient force transmission. Under excessive force conditions, it transitions to an elastic state, changing its stiffness parameter to absorb energy and limit force transmission to the release element.

Inventive Principle:

Principle #35Parameter changes

2Speed

If the lever is made rigid for efficient force transmission, then actuation is responsive, but impact forces are fully transmitted to the release element

Engineering Contradiction:

Improveactuation response speedVSAvoidimpact force transmission

Core Design Contradiction:

SpeedVSObject-affected harmful factors

Solution Approach 1:

The lever transitions from a static rigid structure to a dynamic element that can change its mechanical behavior based on applied force. It maintains rigidity during normal actuation for responsive performance but becomes elastic under impact conditions, allowing it to adapt its properties to different operational scenarios and protect the release element accordingly.

Inventive Principle:

Principle #15Dynamics

3Adaptability or versatility

If the pusher moves perpendicular to the wall, then the switch can be mounted on side walls, but force direction must be converted from horizontal to vertical

Engineering Contradiction:

Improvemounting position flexibilityVSAvoidforce conversion mechanism

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The lever acts as an intermediary mechanism that converts horizontal actuation force into vertical force on the release element. This mediator enables the pusher to be actuated horizontally while still achieving vertical actuation of the release element, allowing flexible mounting positions such as on side walls without requiring complex additional conversion mechanisms.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 limits the force transferred to the release element during large-amplitude actions, reducing the risk of damage and enhancing the switch's longevity by directing excess force to the component-bearing plate, thus improving the switch's durability and reliability.

Implementation Method 1

A lever (26) may be mounted in a hinged manner relative to the support about a horizontal axis and may convert the horizontal actuation force exerted on the pusher into a vertical release force applied to the release element. The lever may be configured to be elastically deformable to allow a movement of the pusher beyond the actuation position

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Implementation Method 2

At least one generally dome-shaped release element (20) may be accommodated in the housing of the support and may be configured to be elastically deformable from a rest position for establishing an electrical connection between the two fixed contacts

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentUS7982151B2Electrical switch with lateral operation and assembly comprising such a switch mounted on a plate

Publication Date: 2011.07.19 LITTELFUSE INTERNATIONAL HOLDING LLC

AI summary

An electrical switch may include a support bearing contacts, at least one elastically deformable release element for establishing an electrical connection between two contacts, an actuation pusher that is configured to be movable relative to the support along an overall horizontal path in the plane of the plate bearing electronic components and a lever that is configured to be mounted in a hinged manner relative to the support about a horizontal axis and which converts the horizontal actuation force exerted on the pusher into a vertical release force applied to the release element. The lever may be elastically deformable to allow a movement of the pusher beyond the actuation position.