Waterproof Switch With Magnetic Actuator Coupling

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Solution Overview

Problem

Electrical switches are prone to failure and safety hazards due to the ingress of water and dust through openings in their housings, which can render them inoperative and unsafe, especially in outdoor or high-moisture environments.

Innovation Solution

An electrical switch design featuring a housing with a barrier layer and magnetic coupling between internal and external actuators, where the barrier layer seals the opening to prevent moisture and dust ingress, and the magnetic coupling transfers movement from the external actuator to the internal actuator without physical contact, ensuring a waterproof and dustproof seal.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the actuator is coupled to the switching mechanism through interacting components extending through an opening in the housing, then the switch can be operated from the outside, but water and dust can enter the housing through the opening

Engineering Contradiction:

Improveactuator accessibilityVSAvoidwater and dust ingress

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

A magnetic field is introduced as an intermediary between the external actuator and the internal switching mechanism. The magnetic field allows force and motion transmission through the barrier (housing opening) without physical contact, enabling actuator operation while maintaining the seal against water and dust.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The direct mechanical coupling through the opening is replaced with a magnetic coupling system. Magnets on the external actuator interact with magnets on the internal actuator through the barrier, substituting the mechanical transmission path with a magnetic field-based transmission that does not require physical penetration of the housing.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Object-affected harmful factors

If a barrier is introduced to seal the opening, then water and dust ingress is prevented, but the actuator can no longer be coupled to the switching mechanism

Engineering Contradiction:

Improvewater and dust ingress preventionVSAvoidactuator coupling mechanism

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The magnetic field serves as an intermediary that transmits actuation force through the barrier without requiring physical connection. This allows the barrier to remain intact for sealing purposes while still enabling functional coupling between the external actuator and internal switching mechanism.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The mechanical coupling system requiring physical components extending through the opening is replaced with a magnetic coupling system. This substitution eliminates the need for complex sealed mechanical connections while maintaining the actuator-to-switching-mechanism coupling function.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of operation

If the actuator extends through the housing opening, then user access is enabled, but internal components are exposed to environmental contaminants

Engineering Contradiction:

Improveuser access to actuatorVSAvoidinternal component protection

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The magnetic field acts as an intermediary that allows user actuation while protecting internal components. The user interacts with the external actuator, and the magnetic field transmits this interaction to the internal actuator without exposing internal components to the external environment.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The direct mechanical extension of the actuator through the housing is replaced with a magnetic coupling system. This allows the actuator to remain accessible to users while the internal components stay sealed within the housing, protected from environmental contaminants.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 solution effectively prevents water and dust from entering the switch's internal components, enhancing its reliability and safety for use in various environments by maintaining the switch's operational integrity and user safety.

Implementation Method 1

a magnetic coupling arranged and configured to transfer movement of the external actuator to the internal actuator through the barrier

Methodology Applied

Scientific EffectMagnetic coupling: Magnetism

Data Source

PatentUS11545315B1Outdoor and/or waterproof switch

Publication Date: 2023.01.03 LEVITON MFG CO INC

AI summary

An electrical device such as, for example, an electrical switch is disclosed. The switch being arranged and configured to prevent ingress or intrusion of water, dust, or the like from the external environment thus making the switch particularly suitable for use outdoors or indoors where water and dust are expected. In one embodiment, the switch includes a base or housing, an internal actuator positioned within an internal cavity of the base, an external actuator accessible by a user, a barrier layer positioned between the internal actuator and the external actuator, the barrier layer arranged and configured to seal the internal cavity and the internal actuator, and a magnetic coupling arranged and configured to transfer movement of the external actuator to the internal actuator through the barrier layer.