Switch Seal Structure Preventing Rubber Cover Sagging

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Solution Overview

Problem

Conventional seal structures in electric power tools suffer from durability issues and poor usability due to sagging rubber covers and difficulty in identifying the position of the operating member when a lock-on mechanism is used, leading to ineffective sealing and user experience problems.

Innovation Solution

A seal structure integrating a rubber cover with the operating member using a fixing cover that has a U-shaped transverse section and engagement nails, preventing the rubber cover from contacting the edge of the opening and allowing easy recognition of the lock-on mechanism's state.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a rubber cover is used to seal the gap between the opening and the operating member, then sealing performance is improved, but the rubber cover sags and contacts the edge of the opening causing damage and reduced durability

Engineering Contradiction:

Improvesealing performanceVSAvoiddurability of rubber cover

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

A fixing cover is introduced as an intermediary component between the rubber cover and the operating member. The fixing cover has a U-shaped transverse section that covers the front surface and side surfaces of the rubber cover, preventing it from sagging and contacting the opening edge. Engagement nails penetrate through the rubber cover and engage with the operating member to integrate all three components, eliminating the sagging problem while maintaining sealing performance.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The rubber cover is designed as a flexible sealing element that can deform to seal the gap between the opening and the operating member. However, without the fixing cover, this flexibility causes the rubber cover to sag and contact the opening edge. The fixing cover provides structural support to maintain the rubber cover's position and prevent damage.

Inventive Principle:

Principle #30Flexible shells and thin films

2Reliability

If a lock-on mechanism is covered with the rubber cover to maintain sealing, then sealing performance is improved, but it becomes difficult for users to identify the operating member's position

Engineering Contradiction:

Improvesealing performanceVSAvoidusability and position identification

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The rubber cover acts as a flexible transparent or translucent shell that covers the lock-on mechanism while allowing visual identification of the operating member's position. The fixing cover provides structural support to maintain the rubber cover's position and prevent it from obscuring the position indication, thus maintaining both sealing performance and usability.

Inventive Principle:

Principle #30Flexible shells and thin films

3Reliability

If the rubber cover is made larger to ensure complete coverage and sealing, then sealing performance is improved, but the rubber cover is more prone to damage from contact with the opening edge

Engineering Contradiction:

Improvesealing performanceVSAvoiddamage from contact with opening edge

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The fixing cover serves as a protective intermediary that shields the rubber cover from direct contact with the opening edge. The U-shaped transverse section of the fixing cover covers the front surface and side surfaces of the rubber cover, preventing mechanical damage while allowing the rubber cover to maintain its sealing function.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The rubber cover is designed as a flexible sealing element with optimal dimensions to seal the gap effectively. The fixing cover provides structural support to prevent the rubber cover from excessive deformation and contact with the opening edge, thus protecting it from damage while maintaining sealing performance.

Inventive Principle:

Principle #30Flexible shells and thin films

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 seal structure effectively prevents damage to the rubber cover, enhances durability, and improves usability by maintaining a suitable seal and allowing easy identification of the operating member's position, even with a lock-on mechanism.

Implementation Method 1

a rubber cover attached to the operating member from a front-side of the operating member and having a rear end engageable with the opening... wherein the rubber cover seals gap between the opening and the operating member

Methodology Applied

Scientific EffectSealing:

Implementation Method 2

the fixing cover may have an engagement nail which penetrates through the rubber cover and engageable with an engagement portion provided on the operating member

Methodology Applied

Scientific EffectMechanical Fastening: Mechanical Fastener

Data Source

PatentUS8698022B2Seal structure for switch mechanism and electric power tool

Publication Date: 2014.04.15 MAKITA CORP

AI summary

A seal structure for a switch mechanism includes a switch disposed in a housing, an operating member protruding forward from the housing through an opening formed in the housing and configured to turn on or off the switch, a rubber cover attached to the operating member from a front-side of the operating member and having a rear end engageable with the opening, and a fixing cover fixed to the operating member from outside the rubber cover so as to integrate the rubber cover with the operating member. In this seal structure, the rubber cover seals gap between the opening and the operating member.