Switch Structure With Restriction Body For Multi-Layer Stacking
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Solution Overview
Problem
Conventional switch structures have limitations in structural design and application, particularly when multiple layers are stacked, leading to restricted operation space and difficulty in inserting both flat-head and bare leads due to limited height, resulting in compromised structural strength and increased manufacturing costs.
Innovation Solution
The improved switch structure incorporates a main body with a cavity, a retainer member, a conductive metal member, and a reciprocally movable carrier body with an elastic member and restriction body, allowing for flexible operation and enhanced lead locking ability, enabling the connection of both flat-head and bare leads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the housing thickness is limited to 1cm-1.5cm for multi-layer stacking, then the switch can be applied to automatic control systems with space constraints, but the operation space of the screw is limited and the structural strength is compromised
Solution Approach 1:
The switch structure is divided into multiple independent components: main body, carrier body, retainer member, and restriction body. This segmentation allows each component to be optimized independently for strength while maintaining overall compactness for multi-layer stacking.
Solution Approach 2:
The carrier body with arm and elastic member is nested within the restriction body chamber. The retainer member is assembled with the carrier body. This nested arrangement maximizes the use of limited space within the 1cm-1.5cm housing thickness while maintaining structural integrity.
2Reliability
If the washer is punched and bent to form arched wing sections to prevent screw dropout, then the screw is restricted from dropping out, but the washer structure becomes complicated and manufacturing cost increases
Solution Approach 1:
The screw retention function is extracted from the washer and implemented by the retainer member assembled with the carrier body. The retainer member has a head that abuts the screw, providing a simpler and more reliable retention mechanism without complicating the washer structure.
Solution Approach 2:
The retainer member acts as an intermediary between the screw and the carrier body. It provides the screw with a stopping surface (head) and transmits the pressing force to the carrier body, simplifying both the screw retention mechanism and the overall structure.
3Ease of manufacture
If the washer thickness is reduced to 0.6mm for easy punching and bending, then the washer can be formed with arched wing sections, but the structural strength of the washer is lowered and lead locking ability deteriorates
Solution Approach 1:
The lead locking function is extracted from the washer and implemented by the retainer member pressing the lead into electrical connection with the conductive metal member. This allows the washer to maintain optimal thickness for strength while the retainer member provides the necessary pressing action.
Solution Approach 2:
The functions of the conventional washer are segmented: the washer provides electrical connection and basic support, while the retainer member provides the pressing force and lead retention. This segmentation allows each component to be optimized for its specific function without compromise.
4Volume of moving object
If the housing height is limited for multi-layer stacking, then the switch fits space constraints, but only flat-head terminal leads can be inserted and bare leads with larger diameter cannot be inserted
Solution Approach 1:
The carrier body is designed to be reciprocally movable along the pressing direction within the restriction body chamber. This dynamic design allows the carrier body to adjust its position to accommodate different lead types (flat-head and bare leads) while maintaining the compact housing height for multi-layer stacking.
Solution Approach 2:
The switch structure is designed to universally accept both flat-head terminal leads and bare leads with larger diameters. The retainer member and carrier body combination provides a versatile pressing and retention mechanism that works with different lead geometries without requiring different housing heights.
5Ease of operation
If the screw is unscrewed to insert terminal lead through perforation into cavity, then the lead can be inserted, but the screw drops out of the housing
Solution Approach 1:
The retainer member is pre-assembled with the carrier body before lead insertion. The retainer member head is positioned to abut the screw, providing a stopping surface that prevents screw dropout. This preliminary arrangement ensures screw retention is already in place before the lead insertion operation is performed.
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 increased structural strength, improved lead locking ability, and reduced manufacturing costs, making the switch structure more versatile and operable for various lead types, while maintaining optimal structural integrity within height constraints.
Implementation Method 1
The carrier body has an arm assembled with an elastic member. A restriction body is disposed in the cavity. The restriction body is formed with a chamber for receiving the arm and the elastic member of the carrier body.
Data Source
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AI summary
A switch structure connectable with both bare lead and flat-head terminal lead. The switch structure includes a main body (40) formed with at least one cavity (41). A retainer member (70) and a conductive metal member (50) are arranged in the cavity (41) for pressing the terminal lead into electrical connection with the conductive metal member (50). A reciprocally movable carrier body (60) is assembled with the retainer member (70). The carrier body (60) has an arm (64) assembled with an elastic member (66). A restriction body (80) is disposed in the cavity (41). The restriction body (80) is formed with a chamber (81) for receiving the arm (64) and the elastic member (66) of the carrier body (60). The restriction body (80) restricts the moving direction or distance of the carrier body (60) to increase the structural strength of the switch structure and enhance the lead locking ability of the switch structure.