Toggle Electro-Mechanical Assembly for Vibration Resistance
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Solution Overview
Problem
Conventional pressure switches have limitations in reliability, vibration resistance, shock resistance, and heat resistance due to their single contact lead design and susceptibility to corrosion and failure in hermetically sealed environments.
Innovation Solution
A toggle assembly comprising a disk spring, normally open and closed contacts, and a yoke mechanism that snaps between positions to ensure continuous operation, with a large contact area and redundancy to withstand pressure changes and environmental stressors, and a hermetically sealed chamber with 'L' shaped apertures for enhanced durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single contact lead design is used in pressure switches, then the device complexity is reduced, but the reliability deteriorates due to susceptibility to corrosion and failure
Solution Approach 1:
The patent divides the contact system into multiple independent contact leads (at least two contact leads per contact element) instead of using a single contact lead. This segmentation provides redundancy so that if one contact lead fails due to corrosion or other issues, the other contact leads can maintain electrical continuity and keep the switch operational.
2Ease of manufacture
If conventional pressure switch design is used, then the manufacturing simplicity is maintained, but the vibration resistance deteriorates
Solution Approach 1:
The patent employs a bellows element with a curved, accordion-like structure that provides mechanical compliance and shock absorption. This curved geometry helps dampen vibrations and mechanical shocks transmitted to the contact elements, improving vibration resistance while maintaining a relatively simple manufacturing process using standard bellows components.
3Device complexity
If conventional pressure switch design is used, then the structural simplicity is maintained, but the heat resistance deteriorates
Solution Approach 1:
The patent uses a bellows element constructed from flexible, thermally stable materials that can withstand high temperatures. The bellows structure acts as a flexible barrier that isolates the contact elements from thermal stress while maintaining structural integrity, providing improved heat resistance without significantly complicating the overall design.
4Object-affected harmful factors
If a hermetically sealed environment is used, then the protection against corrosion is improved, but the reliability deteriorates when the seal is breached
Solution Approach 1:
The patent implements redundancy in the contact lead system beforehand, so that if the hermetic seal is breached and corrosion occurs, there are backup contact leads available to maintain electrical continuity. This prior cushioning through redundant design ensures that a single point of failure (seal breach leading to corrosion) does not result in complete switch failure.
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 toggle assembly provides reliable and durable pressure switching with increased resistance to vibration, shock, and high temperatures, ensuring continued operation even if the hermetic seal is breached, by utilizing a redundant contact system and a large contact area.
Implementation Method 1
a disk spring; a plurality of normally closed contacts disposed in a plane below the disk spring; a plurality of normally open contacts disposed in a plane above the disk spring; where a movement of the actuating pin away from a header assembly snap deflects the disk spring to a first position to contact the plurality of normally open contacts
Data Source
AI summary
An assembly including: a disk spring; a plurality of normally closed contacts disposed in a plane below the disk spring; a plurality of normally open contacts disposed in a plane above the disk spring; a pivot ring supporting a lower surface of the disk spring; and an actuating pin having a shoulder in contact with an upper surface of the disk spring; where a movement of the actuating pin away from a header assembly snap deflects the disk spring to a first position to contact the plurality of normally open contacts, and a movement of the actuating pin towards the header assembly snap deflects the disk spring to a second position to contact the plurality of normally closed contacts.