Wireless Switch Connector Insert-Molded Terminals
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Solution Overview
Problem
The existing switch apparatus with wireless functionality is costly and large due to the need for soldering processes and space required for soldering terminals, which increases both cost and size.
Innovation Solution
The apparatus integrates a cover and holding portion to surround the connector terminal, eliminating the need for soldering by using insert-molded terminals and a connector housing formed integrally with the body, which positions and holds pins, allowing for connector alignment without soldering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering terminals to the board is used to connect the antenna coil and connector, then reliable electrical connection is achieved, but manufacturing cost and device size increase
Solution Approach 1:
The patent merges the terminal function directly into the connector body by using insert-molded terminals that are integrated with the housing. This eliminates the separate soldering process and reduces the number of discrete components, thereby lowering manufacturing cost while maintaining reliable electrical connection through the molded-in terminal design.
Solution Approach 2:
The patent extracts the soldering process from the assembly sequence by pre-molding terminals into the connector housing during manufacturing. This removes the need for subsequent soldering operations, reducing both manufacturing complexity and cost while ensuring reliable electrical connections are established during the molding process itself.
2Reliability
If soldering terminals to the board is used to connect the antenna coil and connector, then reliable electrical connection is achieved, but device size increases
Solution Approach 1:
The patent combines the terminal and housing into a single integrated component through insert molding. This merger eliminates the need for separate terminal components and their associated mounting space, reducing overall device size while maintaining reliable electrical connection through the integrated design.
Solution Approach 2:
The patent embeds the terminals within the housing structure during the molding process, creating a nested configuration where the terminal is contained within the housing body. This nesting approach minimizes the space required for electrical connections while ensuring reliable connectivity.
3Reliability
If separate terminals and board soldering are used, then electrical connectivity is achieved, but manufacturing complexity increases
Solution Approach 1:
The patent merges the terminal fabrication and housing manufacturing into a single insert molding process. This integration eliminates multiple separate manufacturing steps including terminal fabrication, terminal mounting, and soldering, thereby reducing manufacturing complexity while ensuring reliable electrical connectivity through the molded-in terminal design.
Solution Approach 2:
The patent extracts the terminal assembly step from the manufacturing sequence by pre-integrating terminals into the housing during molding. This removal of the assembly step simplifies the overall manufacturing process, reducing complexity while maintaining electrical connectivity through the integrated terminal-housing structure.
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
This design reduces the cost and size of the switch apparatus by eliminating soldering and ensuring accurate connector alignment, resulting in a more compact and affordable wireless switch solution.
Implementation Method 1
Operation of the knob of the switch apparatus triggers transmission of a drive radio wave from the antenna coil. When entering a transmission area of the drive radio wave, the portable device generates power from the drive radio wave and transmits the ID with the generated power.
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
This switch apparatus having a wireless function is provided with: a body (3); a knob (2), which is assembled to the body (3), and which can be switch-operated; an antenna coil (4) for communication operations, said antenna coil being wound on the body (3); and a connecter terminal (8). The connecter terminal (8) includes: at least one terminal (5, 6), which is provided to the body (3) by insert molding, and which is bonded to the antenna coil (4); and at least one pin (12).