Trigger Switch Terminal Sealing via Gasket Compression
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Solution Overview
Problem
Conventional trigger switch assembly methods degrade workability due to adhesive curing time and increased man-hours required for lead wire connection, particularly in ensuring liquid-tightness at the connection point.
Innovation Solution
A switch unit design featuring a case with projecting terminals, a gasket with through-holes, and a pressing member that maintains close contact between the gasket and terminals, allowing for improved assembly workability and liquid-tightness by sliding the terminal unit into the casing members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive is used to seal the lead wire connection point, then liquid-tightness is improved, but assembly time increases due to curing time
Solution Approach 1:
The patent extracts the adhesive sealing step from the assembly process by providing pre-formed through-holes in the case that accommodate the lead wires. This eliminates the need for adhesive application and curing time, while still achieving liquid-tightness through the precise fit of the through-holes and lead wire insulation.
Solution Approach 2:
The through-holes are pre-formed in the case during manufacturing, with dimensions and positions optimized for the lead wires. This preliminary preparation eliminates the need for on-site adhesive application and curing, allowing direct assembly without time loss.
2Reliability
If packing is used to cover the motor connection terminal, then liquid-tightness is improved, but assembly complexity increases due to threading requirements
Solution Approach 1:
The patent removes the separate packing component and its associated threading operation by integrating the sealing function directly into the case structure through the pre-formed through-holes. The lead wire insulation works with the through-hole geometry to provide liquid-tightness without additional parts or complex assembly steps.
Solution Approach 2:
The sealing function previously performed by a separate packing component is merged into the case structure itself through the through-hole design. This integration eliminates the need for additional parts and simplifies the assembly process while maintaining liquid-tightness.
3Reliability
If lead wire connection is sealed with adhesive or packing, then liquid-tightness is improved, but assembly workability deteriorates due to increased man-hours
Solution Approach 1:
The through-holes are pre-formed with precise dimensions during case manufacturing, allowing lead wires to be inserted directly without requiring adhesive application, curing time, or threading operations. This preliminary preparation dramatically reduces assembly man-hours while maintaining liquid-tightness.
Solution Approach 2:
The case structure with pre-formed through-holes provides its own sealing capability through the geometric fit between the holes and lead wire insulation, eliminating the need for external adhesive or packing components. This self-sealing design simplifies assembly and improves productivity.
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
Enhances assembly efficiency and ensures liquid-tightness at the external connection terminals, reducing assembly time and man-hours while maintaining the design flexibility of the case.
Implementation Method 1
a region between the through-holes of the gasket is pressed while nipped between the pressing member and the base member. A surrounding region in the gasket is pressed while nipped between an inside surface of the case and the base member
Data Source
Figure 1
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AI summary
Liquid-tightness at a position where an external terminal of a case is located, and assembly workability are obtained. Trigger switch 1 includes case 2, external terminals 4a and 4b that partially project to an outside of case 2 from an opening, a gasket that includes two through-holes, a base member, and pressing member 5. A region between the through-holes in the gasket is pressed against pressing member 5, and a surrounding region of the gasket is pressed by case 2.