Switching Unit Insulation via Retaining Pin Housing
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Solution Overview
Problem
Existing electrical switches face challenges in achieving good electrical insulation properties while maintaining easy assembly and allowing for torque transmission and connection to a switching mechanism.
Innovation Solution
The use of a non-conductive housing for the switching unit, where a contact lever with pins is pre-assembled with plates and inserted, with a retaining pin extending beyond the plates to secure the subassembly within the housing, and a rotor pin forming the pivot axis for the contact lever, enabling simple assembly and effective electrical insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a non-conductive housing is used for electrical insulation, then electrical insulation properties are improved, but assembly complexity increases
Solution Approach 1:
The switching unit is divided into a non-conductive housing and a separate contact lever assembly. The contact lever assembly with plates and pins is pre-assembled as a module that can be independently manufactured and then inserted into the housing, simplifying the overall assembly process while maintaining electrical insulation.
Solution Approach 2:
A retaining pin serves as an intermediary component that bridges the contact lever assembly and the non-conductive housing. The retaining pin extends through holes in the plates and is held in holding recesses of the housing, providing a simple mechanical connection that secures the assembly without requiring complex fastening mechanisms.
2Stability of the object's composition
If pins are used to hold the contact lever between plates, then the contact lever is securely positioned, but the assembly becomes difficult to insert into the housing
Solution Approach 1:
The contact lever, plates, and pins are pre-assembled into a complete module before insertion into the housing. The retaining pin is designed to extend beyond the plates during this pre-assembly stage, creating a protruding feature that facilitates subsequent insertion into the housing by engaging with holding recesses.
Solution Approach 2:
The retaining pin extends in the dimension perpendicular to the plates (beyond the plate surfaces), creating a three-dimensional engagement structure. This allows the assembly to be inserted into the housing by hanging the protruding pin ends into holding recesses, transforming a potentially difficult planar assembly into an easy vertical insertion operation.
3Ease of manufacture
If the pin length exceeds the distance between plates, then the assembly can be hung in the housing, but the pin becomes longer and more complex
Solution Approach 1:
The retaining pin serves multiple functions: it positions the contact lever between the plates, secures the assembly to the housing by engaging holding recesses, and provides a hanging feature for insertion. This multi-functionality eliminates the need for separate components, simplifying the overall structure despite the pin's extended length.
4Manufacturing precision
If individual housing components are assembled to form the overall housing, then the housing can be precisely manufactured, but the assembly process becomes time-consuming
Solution Approach 1:
The housing is designed as a one-piece non-conductive component that integrates all housing functions (electrical insulation, structural support, contact lever mounting, and torque transmission). This eliminates the need to assemble multiple housing components, significantly improving assembly speed while maintaining manufacturing precision through modern one-piece molding techniques.
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 configuration provides excellent electrical insulation, facilitates easy assembly, and allows for torque transmission, while ensuring that the switching unit can be rotated for on/off switching, with predetermined contact forces achieved through spring mechanisms.
Implementation Method 1
a contact lever with at least one electrical switching contact (30, 31) is held between two plates (40, 41) by means of pins (51, 52) in a non-conductive housing (105) of the switching unit (100)
Implementation Method 2
with the retaining pin (50) extending beyond the plates (40, 41) and thus enabling the subassembly preassembled with the plates, pins and contact levers to be hung in the non-conductive housing (105) of the switching unit (100)
Implementation Method 3
a rotor pin extends through the housing of the switching unit, the two plates and the pivoting contact lever, the rotor pin forms the virtual pivot axis for the pivoting contact lever
Implementation Method 4
in order to achieve predetermined contact forces, the contact lever can be pivoted relative to the housing of the switching unit, for example by means of springs
Data Source
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AI summary
The invention relates, inter alia, to an electrical switch with at least one switching unit (100) comprising: a contact lever (20) pivotable about a pivot axis, with at least one electrical switching contact (30, 31), and two parallel plates (40, 41) between which the contact lever is resiliently held by means of pins (50-53). According to the invention, the contact lever with the plates and the pins is inserted into an electrically non-conductive housing (105) of the switching unit (100), wherein at least one of the pins forms a retaining pin (50), the length of the retaining pin exceeding the distance between the parallel plates, and wherein the retaining pin extends through a hole (80) in each of the two plates and is held with one end (110) in a retaining recess (120) of the housing (105) and with its other end (140) in an opposite retaining recess (150) of the housing.