Welded Microswitch Housing for Sealing and Contact Capacity
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Solution Overview
Problem
Existing microswitches face issues with imperfect hermetic sealing and limited internal volume due to external fastening elements and gaskets, which restrict the size of electrical contacts and the currents they can handle.
Innovation Solution
A microswitch design featuring two half-shells joined by partial mutual welding, eliminating external fastening elements and gaskets, allowing for increased internal volume and high sealing efficiency without increasing overall dimensions, enabling the use of larger electrical contacts and higher currents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If external fastening elements (screws, rivets, bolts) and gaskets are used to join half-shells, then the hermetic sealing is improved, but the internal volume of the compartment is reduced
Solution Approach 1:
The patent removes external fastening elements (screws, rivets, bolts) and gaskets from the assembly, eliminating the components that occupied internal volume. Instead, the half-shells are joined directly through welding, extracting the problematic sealing and fastening elements from the system while maintaining both hermetic sealing and maximum internal volume.
Solution Approach 2:
The patent merges the functions of fastening and sealing into a single welding operation. The welding process simultaneously joins the half-shells structurally and creates the hermetic seal, eliminating the need for separate gaskets and fastening elements, thereby maximizing internal volume while ensuring reliable sealing.
2Strength
If external fastening elements are used to join half-shells, then the structural strength is improved, but the internal volume of the compartment is reduced
Solution Approach 1:
The patent removes external fastening elements from the design, eliminating the volume they occupied within the compartment. The welding process provides structural strength without requiring physical fastening elements that would intrude into the internal space.
Solution Approach 2:
The patent replaces the mechanical fastening system (screws, rivets, bolts) with a thermal joining process (welding). This substitution eliminates the need for mechanical fastening elements that would occupy internal volume while maintaining or enhancing structural strength through direct metallurgical bonding of the half-shells.
3Reliability
If gasket housing and gasket are included between half-shells, then the hermetic sealing is improved, but the internal volume of the compartment is reduced
Solution Approach 1:
The patent removes the gasket and its housing from the assembly, eliminating the volume they occupied. The hermetic sealing function is achieved directly through the welding of half-shells, which creates a seamless seal without requiring additional sealing components.
Solution Approach 2:
The patent merges the sealing function into the structural joining process itself. The welding operation simultaneously provides both the structural connection and the hermetic seal, eliminating the need for separate gasket and gasket housing components, thereby maximizing internal volume.
4Quantity of substance
If the compartment volume is increased to house larger electrical contacts, then the current handling capacity is improved, but the overall dimensions of the microswitch increase
Solution Approach 1:
By removing fastening elements and gaskets from the design, the patent recovers internal volume within the existing external dimensions. This recovered volume can be utilized to house larger electrical contacts or improve the layout, increasing current handling capacity without expanding the overall microswitch dimensions.
Solution Approach 2:
The patent changes the joining method from mechanical fastening to welding, which alters the spatial parameters of the assembly. This parameter change eliminates the volume occupied by fastening elements and allows for optimized positioning of electrical contacts, enabling larger contacts within the same external envelope.
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 provides a compact microswitch with enhanced sealing and increased internal volume, enabling the handling of high amperage currents while maintaining small dimensions and simplifying manufacturing, reducing the risk of fixing errors and ensuring reliable contact operations.
Implementation Method 1
said at least two half-shells are stably joined together by at least partial mutual welding of the respective perimeter edges
Data Source
Figure 1~2
Figure 3~6
Figure 7~8
AI summary
A microswitch comprises a case (11) formed by at least two half-shells (35, 36) mutually joined at respective mutually facing and overlapping perimeter edges to define a compartment (12) which houses a first electrical contact (15), a second electrical contact (16) and a contact element (19) movable with respect to the first electrical contact (15) and to the second electrical contact (16) and wherein the two half-shells (35, 36) are stably joined together by at least partial mutual welding of the respective perimeter edges.