Electrical Switch Sealing Member for Irregular Housing Surfaces
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Solution Overview
Problem
Existing electrical switches in hand-held devices and home appliances face challenges in preventing ingress of dust and water due to their inflexible sealing methods, which can lead to short-circuiting, degradation, and safety hazards, particularly in harsh environments.
Innovation Solution
An electrical switch unit with an elastically-resilient polymeric sealing element that complements the three-dimensional shape of the housing members, using a saw-tooth cross-sectional contour to effectively seal irregular surfaces and prevent ingress, combined with recesses or grooves for seating, and optionally overmolding or adhesive for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If O-rings are used to seal the electrical switch housing, then sealing against dust and water ingress is improved, but the ability to seal irregular or non-flat surfaces deteriorates
Solution Approach 1:
The patent uses a flexible sealing member made of elastomeric material that can conform to irregular surfaces. The sealing member includes a body portion with a sealing surface that flexes to adapt to non-flat housing surfaces, and a protruding portion that extends into the housing to provide additional sealing contact points, enabling effective sealing on irregular geometries where rigid O-rings would fail.
Solution Approach 2:
The sealing member changes its physical parameters (shape, position) in response to environmental factors. The elastomeric material allows the sealing surface to deform and adapt its geometry to match irregular housing surfaces, while the protruding portion can move to maintain sealing contact under varying compression conditions, thus adapting to different surface contours.
2Reliability
If resin is used to permanently encapsulate electrical switch components, then protection against particulates and water is improved, but the ability to disassemble for repair or replacement deteriorates
Solution Approach 1:
The patent divides the electrical switch housing into separate, disassemblable sections (first housing member and second housing member) that can be separated without damaging the sealing member. The sealing member is positioned between these modular sections, allowing the housing to be taken apart for component replacement or repair while maintaining sealing integrity when reassembled, thus eliminating the need for permanent resin encapsulation.
3Reliability
If ultrasonic bonding is used to bond housing sections, then water proof sealing is improved, but the risk of component damage and sealing imperfection increases
Solution Approach 1:
The patent introduces a sealing member as an intermediary element between the first and second housing members. This sealing member provides the water-proof barrier function without requiring direct ultrasonic bonding of the housing sections, thereby eliminating the risk of component damage from ultrasonic energy and preventing sealing gaps that can occur with imperfect bonding. The sealing member acts as a mediator that achieves waterproofing through mechanical contact rather than thermal or vibrational bonding.
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 effective sealing against particulates and water ingress, enhances durability, and maintains sealing integrity even on non-flat or irregular surfaces, reducing material and assembly complexity while ensuring safety and longevity.
Implementation Method 1
an sealing element including an elastically-resilient polymeric material, said sealing element being configured for location between the first and second housing members
Data Source
AI summary
An electrical switch unit for use in controlling operation of an electrical device, the electrical switch unit including: an electrical switch unit housing for housing at least a pair of electrical switching contacts of the electrical switch unit, said electrical switch unit housing including a first housing member and a second housing member that are configured for attachment together at peripheral regions of the first and second housing members so as to cooperatively form an enclosed space for housing the pair of electrical switching contacts therein; an actuator member operably-connected with at least one of the pair of electrical switching contacts, the actuator being configured for movement relative inwardly and outwardly of an opening in the electrical switch unit housing so as to arrange the pair of electrical switching contacts into at least one of a closed configuration wherein power is able to be supplied from a power source to motor or other electrically-operable element of the electrical device via the pair of electrical switching contacts, and, an opened configuration wherein power is not able to be supplied from the power source to the motor or other electrically-operable element of the electrical device via the pair of electrical switching contacts; and an sealing element including an elastically-resilient polymeric material, said sealing element being configured for location between the first and second housing members and extending about the peripheral regions of the attached first and second housing members so as to occlude passage and ingress of particulates and water into the electrical switch unit housing.