Multiple State Switch Assembly with Stacked Disc Contacts
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Solution Overview
Problem
Existing switch assemblies face challenges in achieving a compact, sealed, and cost-effective design with multiple stages of tactile feedback, while maintaining mechanical stability and allowing for a high density of switches without increasing size, and ensuring reliability and electromagnetic compatibility.
Innovation Solution
The solution involves a multiple stage switch assembly with stacked convex disc contacts connected via flexible component carriers and controlling members made from materials like Polyoxymethylene (POM) and PI SF305C 1025, allowing for distinct tactile feedback and mechanical flexibility, and incorporating sealing and EMC certification for harsh conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If switches are made more compact to reduce space, then the area occupied by switches is reduced, but maintaining mechanical stability and tactile feedback becomes more difficult
Solution Approach 1:
The patent implements nested convex disc contacts where multiple disc contacts are stacked one above another in vertical alignment. Each disc contact is positioned within the same horizontal footprint, allowing multiple switching stages to occupy minimal planar space while maintaining individual mechanical stability through the nesting arrangement
Solution Approach 2:
The patent transitions from horizontal arrangement of switch contacts to vertical stacking in the third dimension. Multiple disc contacts are arranged along the vertical axis with their centers substantially aligned, enabling high-density switching functionality without increasing the horizontal area occupied by the switch assembly
2Ease of operation
If multiple disc contacts are stacked vertically to achieve tactile feedback, then tactile feedback is improved, but the height of the switch assembly increases
Solution Approach 1:
The switch assembly is segmented into multiple discrete disc contact stages, each providing independent tactile feedback. The first, second, and third disc contacts are positioned at different vertical levels, allowing operators to sense distinct snapping movements for each switching stage while maintaining a compact overall structure
Solution Approach 2:
The patent optimizes the spacing and dimensions of individual disc contacts to achieve tactile feedback with minimal vertical height. By carefully controlling the spaced relationship between stacked disc contacts and their respective centers being substantially aligned, the assembly provides clear tactile feedback while minimizing the increase in assembly height
3Reliability
If switches are sealed to prevent corrosion, then reliability is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The assembly casing serves multiple functions simultaneously: it provides structural support for the stacked disc contacts, enables vertical alignment of multiple switching stages, and provides sealing protection against contaminants. This multi-functional design achieves reliability without requiring separate complex sealing components
Solution Approach 2:
The patent merges the structural framework and sealing functions into a single integrated assembly casing. The casing is designed to house all disc contacts and controlling members while providing inherent sealing, eliminating the need for additional separate sealing structures and simplifying the overall device complexity
4Productivity
If high density of switches is achieved through vertical stacking, then productivity and space efficiency are improved, but electromagnetic compatibility becomes more challenging
Solution Approach 1:
The patent applies localized electromagnetic shielding and filtering measures at specific critical points within the vertically stacked switch assembly. By targeting EMC protection at specific disc contacts and controlling members rather than throughout the entire assembly, the design achieves electromagnetic compatibility while maintaining high switch density and manufacturing efficiency
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
This design results in a compact, stable, and cost-effective switch assembly with clear tactile feedback, high density, and robustness, enabling efficient production and meeting mechanical and electromagnetic compatibility requirements.
Implementation Method 1
The first and second disc contact are adapted to flex into an electrical connection when the actuator means is pressed and to flex back into a non-electrical connection when the actuator means is released
Data Source
Figure 1~5
Figure 6~9
AI summary
The present invention relates to an electrical multiple stage switch assembly 1 comprising an assembly casing, a first component carrier, and at least one multiple stage switch 21, comprising a first convex disc contact 21 a, at least one second convex disc contact 21 b, and an actuator means. The first and second disc contact 21 a, 21 b are positioned with their centres substantially aligned, and said first and second disc contact 21 a, 21 b are adapted to flex into an electrical connection when the actuator means is pressed and to flex back into a non-electrical connection when the actuator means is released. The switch assembly comprises one second component carrier 13 for each second disc contact 21 b. A controlling member comprises a controlling part 31 a for each switch 21, and a controlling member is positioned between the component carriers 12, 13 in a way so that each disc contact 21 a, 21 b is facing a controlling part 31 a. The controlling part 31 a comprises a spacing member 32 adapted to limit the smallest possible distance d between adjacent component carriers 12, 13.