Toggle Spring Cup for Symmetric Biasing
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Solution Overview
Problem
Traditional toggle style switches experience inconsistent actuation due to random biasing of compression springs, resulting in a crisp snap in one direction and a sloppy switching action in the other, lacking balanced and consistent feedback.
Innovation Solution
A toggle assembly with a spring cup that includes a lower portion concentric with the compression spring and an upper portion forming a recess, ensuring symmetric biasing and crisp actuation by minimizing clearance between the spring seat and the spring, allowing for consistent switching motion in both directions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a compression spring is used to bias the toggle in traditional toggle switches, then the toggle can be biased in one of two positions, but the spring can bias randomly to one side or the other due to clearance between the spring seat and the inner diameter of the compression spring, resulting in inconsistent switching action
Solution Approach 1:
A spring cup is introduced as an intermediary component between the compression spring and the spring seat. The spring cup has a lower portion that fits within the compression spring and an upper portion that forms a recess receiving the spring seat. This intermediary structure eliminates the clearance problem by providing a precise fitting interface, ensuring the spring biases concentrically and consistently in both switching directions.
Solution Approach 2:
The spring cup is designed with a lower portion that nests within the compression spring and an upper portion that nests the spring seat. This nested structure creates a hierarchical arrangement where each component fits precisely within the previous one, eliminating clearance and ensuring consistent concentric biasing of the spring throughout its full range of motion.
2Ease of manufacture
If there is clearance between the spring seat and the inner diameter of the compression spring, then the spring can be easily installed, but the spring biases randomly rather than concentrically, causing sloppy switching action in one direction
Solution Approach 1:
The spring cup serves as a precision intermediary that interfaces between the compression spring and spring seat. The lower portion of the spring cup fits within the compression spring with minimal clearance, while the upper portion provides a precise recess for the spring seat. This intermediary structure achieves both easy installation and high concentricity by providing guided alignment throughout the assembly process.
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 symmetric biasing and crisp, robust actuation, ensuring consistent and balanced feedback in both on and off positions, enhancing user experience with a clean and robust snap action.
Implementation Method 1
a compression spring comprising a first end, a second end, and an inner diameter
Data Source
AI summary
The present disclosure provides techniques or an electrical wiring device with symmetric and robust actuation. An electrical wiring device includes a toggle assembly comprising a compression spring and a spring cup disposed at one end of the compression spring. The spring cup includes a lower portion and an upper portion. The lower portion includes an outer diameter at most as large at the inner diameter of the compression spring and is disposed within the end of the compression spring. The upper portion has a recess therein and is configured to receive a spring seat of a toggle, and allows the spring seat to rotate within the recess when the toggle is actuated.