Torque Spring Biasing for Mini Toggle Switch
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Solution Overview
Problem
Toggle switches used in harsh environments and critical operations require a reliable biasing mechanism to prevent failure, especially in situations where vibrations, temperature extremes, and moisture are present, and to ensure safe return to the initial position after actuation, as failure can lead to catastrophic control system failures.
Innovation Solution
A toggle switch design incorporating a torque spring as a biasing mechanism, which is attached to the housing and actuating lever, simplifies the biasing system, reduces the number of components, and allows for smaller housing dimensions while maintaining reliable operation by compressing when the actuating lever moves, ensuring a consistent return to the open position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional biasing mechanism is used in toggle switches, then the switch can maintain reliable operation, but the device complexity increases and the housing dimensions increase
Solution Approach 1:
The patent combines the biasing mechanism directly into the actuating lever by integrating a spring element within the lever structure itself, eliminating the need for separate biasing components. This merging of functions reduces device complexity while maintaining reliable operation, as the actuating lever now inherently provides both actuation and biasing functions through its integrated design
2Reliability
If a traditional biasing mechanism is used in toggle switches, then the switch can maintain reliable operation, but the housing dimensions increase
Solution Approach 1:
The patent nests the spring element within the actuating lever structure, placing one component inside another. The spring is positioned within the hollow interior of the actuating lever, allowing the biasing mechanism to occupy no additional external space. This nesting approach reduces housing dimensions while maintaining reliable operation through the integrated spring-lever assembly
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 torque spring biasing mechanism enhances the reliability and durability of toggle switches by reducing the complexity and likelihood of part failures, allowing for efficient operation in harsh conditions and minimizing the risk of catastrophic control system failures.
Implementation Method 1
a biasing mechanism configured to bias the actuator assembly into the first position, wherein the biasing mechanism comprises a torque spring
Implementation Method 2
compressing a torque spring disposed about the actuating lever in response to the moving
Data Source
AI summary
Embodiments relate generally to methods and systems for providing a bias mechanism for a momentary toggle switch. A toggle switch may comprise a housing; a plurality of contacts disposed within the housing; an actuating lever coupled to a pivot pin, wherein the actuating lever extends into the housing; an actuator assembly coupled to the actuating lever, configured to actuate a movable contact of the plurality of contacts between a first position and a second position; and a biasing mechanism configured to bias the actuator assembly into the first position, wherein the biasing mechanism comprises a torque spring.