Waterproof Switch Bracket Integrating Terminals and Sealing
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Solution Overview
Problem
Conventional vehicle trunk door switches require complex assembly processes and increased costs due to the use of printed circuit boards (PCBs), leading to increased assembly steps and reduced productivity.
Innovation Solution
A waterproof switch device is designed without using a PCB, featuring a switch bracket with integrated terminal parts and a waterproof structure that allows direct cable connection, eliminating the need for PCB manufacturing and assembly processes, and incorporating a dual waterproof structure for enhanced protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a PCB is used in the switch device, then the switch can be assembled with standardized components, but the assembly process becomes complex and productivity decreases
Solution Approach 1:
The patent merges the PCB function with the switch housing by integrating the terminal board directly into the housing structure. The terminal board is formed as an integral part of the housing through injection molding, eliminating the need for separate PCB assembly steps while maintaining electrical connection functionality. This resolves the contradiction by combining multiple components into one, thereby improving productivity without sacrificing reliability.
Solution Approach 2:
The housing is designed to serve multiple functions: it provides structural support, electrical insulation, and terminal board integration. The terminal board embedded in the housing performs both mechanical support and electrical connection functions. This multi-functionality approach eliminates the need for separate PCB components, simplifying the assembly process while maintaining reliable electrical connections.
2Reliability
If a PCB is used in the switch device, then electrical connections can be established, but manufacturing costs increase
Solution Approach 1:
The terminal board is merged with the housing as a single integrated component manufactured through injection molding. This eliminates the need for separate PCB manufacturing, component mounting, and soldering processes, significantly reducing manufacturing costs while maintaining reliable electrical connections through the integrated terminal structure.
Solution Approach 2:
The injection molding process automatically forms the terminal board structure and creates built-in cable guide grooves that self-align and secure cables during assembly. This self-service approach eliminates the need for additional manufacturing steps and reduces overall production costs while ensuring reliable electrical connections.
3Reliability
If multiple assembly steps are used, then the switch can be properly constructed, but the manufacturing process becomes complex
Solution Approach 1:
The housing and terminal board are merged into a single integrated component, reducing the number of assembly steps from multiple separate operations to a single injection molding process. This simplifies the manufacturing process while maintaining proper construction quality through the integrated design that ensures correct positioning and secure assembly of all components.
Solution Approach 2:
The terminal board structure and cable guide grooves are pre-formed during the injection molding process of the housing. This preliminary action eliminates the need for subsequent assembly steps to create these features, simplifying the overall manufacturing process while ensuring proper construction quality from the outset.
4Reliability
If a molding part is added for waterproofing, then waterproof function is achieved, but the device structure becomes more complex
Solution Approach 1:
The waterproof sealing function is merged with the terminal board structure. The terminal board is designed with integrated sealing features that combine electrical connection and waterproofing functions in a single component, eliminating the need for separate molding parts and simplifying the overall device structure while maintaining reliable waterproof protection.
Solution Approach 2:
Waterproof sealing is implemented locally at the cable entry points through the terminal board structure rather than requiring a complete separate waterproof housing. The terminal board incorporates localized sealing features where water penetration is most likely to occur, achieving effective waterproofing without adding overall structural complexity.
Data Source
AI summary
A waterproof switch device and a waterproof switch module for a vehicle trunk door employing the same are disclosed. Without using a PCB, terminal leads and a pair of switch terminal parts providing switch terminals are integrated with the switch bracket by injection molding. A push button unit is capable of switching the exposed switch terminals and is also sealingly coupled to the top side of the switch bracket so that the space containing the switch terminals and the switch contacts is waterproof. The lead portions of the switch terminals and the switch cables are connected in the terminal receiving space of the switch bracket, and the waterproofing part fills the terminal receiving space so that they are completely embedded so as to be waterproof. The waterproof switch module for a vehicle trunk door adopts the waterproof switch device and is composed of a double waterproof structure by applying an additional waterproof structure.