Traveler Conductor Bracing Structure for Contact Bounce Reduction

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Solution Overview

Problem

Micro-vibrations or bouncing of electrical contacts in electrical wiring devices cause intermittent connections, leading to arcing and degradation of contacts over time.

Innovation Solution

A traveler conductor with a bracing portion that is coupled to a support structure in the housing, utilizing a bent and planar portion with an inlet to stabilize the conductor and reduce vibrations through interference fit with a thermoplastic support structure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the movable contact impacts the stationary contact during switching, then the circuit can be closed, but micro-vibrations and bouncing occur causing intermittent connections and arcing

Engineering Contradiction:

Improveconnection stabilityVSAvoidmicro-vibrations and bouncing

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent applies beforehand cushioning by providing a bracing portion on the stationary conductor that engages with a support structure before the movable contact impacts the stationary contact. This bracing portion includes a planar portion with an inlet that receives a support structure (such as a tab or rib) from the housing, creating prior stabilization. When the movable contact impacts during switching, the bracing portion prevents excessive movement and bouncing, thereby reducing micro-vibrations and intermittent connections while maintaining reliable circuit closure.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Reliability

If the stationary conductor is rigidly fixed to prevent bouncing, then contact stability improves, but the device complexity increases

Engineering Contradiction:

Improvecontact stabilityVSAvoidconductor support structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies segmentation by dividing the stationary conductor into two functional portions: a majority portion that provides the electrical connection path, and a bracing portion that provides mechanical support. The bracing portion includes a planar portion with an inlet that separately engages with a support structure in the housing. This segmentation allows the conductor to be stabilized without requiring complete rigid fixation of the entire conductor, thereby improving contact stability while minimizing increases in device complexity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent uses an intermediary approach by introducing a bracing portion as a mediator between the stationary conductor and the housing support structure. The bracing portion includes a planar portion with an inlet that receives a tab or rib from the housing, creating an intermediate connection element. This intermediary structure provides the necessary mechanical support and stability to prevent bouncing, while maintaining design flexibility and avoiding direct complex attachment mechanisms.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Duration of action of stationary object

If the conductor material is made more durable to resist arcing, then contact longevity improves, but manufacturing cost increases

Engineering Contradiction:

Improvecontact longevityVSAvoidmanufacturing cost

Core Design Contradiction:

Duration of action of stationary objectVSEase of manufacture

Solution Approach 1:

The patent applies beforehand cushioning to reduce the frequency and intensity of arcing events by stabilizing the stationary conductor with a bracing portion before impact occurs. The planar portion with inlet engages a support structure to minimize bouncing and intermittent connections, thereby reducing wear and degradation from repeated arcing. This approach extends contact longevity through mechanical stabilization rather than relying solely on more expensive durable materials, maintaining ease of manufacture.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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

Significantly reduces the number and duration of micro-bounces, minimizing contact degradation and arcing, with the improved conductor experiencing fewer vibrations and improved durability.

Implementation Method 1

The bracing portion is interference fit onto the support structure

Methodology Applied

Scientific EffectInterference fit:

Data Source

PatentUS20260024709A1Device for eliminating bouncing of electrical contacts in electrical wiring devices

Publication Date: 2026.01.22 EATON INTELLIGENT POWER LTD

AI summary

An electrical wiring device includes a traveler conductor with a bracing portion that couples the traveler conductor to a support structure formed in the housing of the device. The bracing portion and the support structure facilitate an interference fit between the bracing portion and the support structure. A flipper conductor of the wiring device is structured to be actuated between a first position and a second position, in order to supply power and cut off power to a load electrically connected to the wiring device. When the flipper conductor moves from the second position to the first position, there is an impact on the traveler conductor. The bracing portion has angled cuts that enable the bracing portion to tilt slightly back and forth upon impact from the flipper conductor. The angled cuts and the thermoplastic material properties of the support structure significantly reduce bouncing of the overall traveler conductor structure.