Trigger Switch Wiring Path Integration in Insulating Wall
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Solution Overview
Problem
Conventional trigger switches for rechargeable electrical power tools require a significant bottom surface area to accommodate lead wires connecting to auxiliary devices, which hinders the miniaturization of the grip and affects operability.
Innovation Solution
The trigger switch integrates a wiring path for lead wires within an insulating wall between power supply terminals, eliminating the need for additional insulating walls and bosses, thereby reducing the bottom surface area while maintaining dust resistance and allowing connection to auxiliary devices like lighting systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If lead wires are derived from the seam of housings with additional insulating walls and bosses, then dust resistance is maintained, but the bottom surface area increases significantly
Solution Approach 1:
The patent merges the insulating wall for isolating power supply terminals with the insulating structure for deriving lead wires. The insulating wall is extended to form both functions simultaneously, eliminating the need for separate insulating walls and bosses for lead wire derivation. This integration maintains dust resistance while significantly reducing the bottom surface area of the trigger switch.
Solution Approach 2:
The insulating wall is designed to serve multiple functions: isolating power supply terminals from each other, providing a wiring path for lead wires, and maintaining dust resistance. By making the insulating wall multi-functional, the patent eliminates the need for additional separate components, thereby reducing the overall bottom surface area while maintaining all necessary protective functions.
2Reliability
If additional insulating walls and bosses are added for lead wire derivation, then insulation and stress distribution are improved, but device complexity increases
Solution Approach 1:
The patent combines multiple insulating functions into a single integrated insulating wall structure. Instead of having separate insulating walls for terminal isolation and lead wire derivation, plus separate bosses for stress distribution, the design merges these functions into one unified structure that performs all necessary insulating and mechanical support functions.
Solution Approach 2:
The extended insulating wall is designed to universally handle multiple tasks: providing electrical isolation between power terminals, creating wiring paths for lead wires, and distributing mechanical stress. This multi-functional approach reduces the number of separate components needed while maintaining or improving overall insulation performance.
3Ease of operation
If the grip size is increased to accommodate lead wire derivation, then operability is maintained, but the tool becomes less user-friendly
Solution Approach 1:
By merging the insulating wall functions and eliminating redundant components like separate bosses and additional insulating walls, the patent reduces the space required for lead wire derivation. This allows the grip to maintain its compact size while still providing adequate space for lead wire connection, thereby preserving user comfort and ease of operation.
Solution Approach 2:
The patent utilizes the vertical dimension by extending the insulating wall upward to create wiring paths, rather than expanding horizontally. This dimensional approach allows lead wires to be derived efficiently within the existing grip footprint, avoiding the need to increase grip size while maintaining all necessary functional clearances.
Data Source
AI summary
A trigger switch performs speed control of a motor according to a pull-in amount of a trigger. A wiring path for lead wires connects the trigger switch and an auxiliary device. The wiring path is formed in an insulating wall. The insulating wall isolates a pair of power supply terminals, each connected to a power supply, from each other.