Wireless Switch Assembly With Integrated Resilient Arm Actuation
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Solution Overview
Problem
Wireless switch assemblies for controlling electrical fixtures are more expensive to manufacture than conventional wired switches due to the need for additional components like transmitters, microprocessors, antennas, and batteries, and require complex alignment during manufacturing to ensure proper operation.
Innovation Solution
A self-powered wireless switch assembly with a low-profile rocker, dimmer, or push-button design that can be mounted without an electrical box, using a housing and shell to enclose circuitry on a printed circuit board, where resilient arms within the housing actuate switches on the circuit board, eliminating the need for separate spring components and allowing alignment during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If wireless switch assembly includes transmitter, microprocessor, antenna, and battery components, then wireless control functionality is achieved, but manufacturing cost increases
Solution Approach 1:
The patent combines the resilient arm and the switch actuator into a single integrated component. The resilient arm directly actsuates the switch on the circuit board without requiring separate spring components or complex alignment mechanisms. This merging reduces the number of parts and simplifies manufacturing, thereby reducing costs while maintaining wireless control functionality.
Solution Approach 2:
The resilient arm serves multiple functions: it acts as both the mechanical return spring and the direct actuator for the switch. This multi-functionality eliminates the need for separate components, reducing manufacturing complexity and cost while preserving the wireless control capabilities.
2Adaptability or versatility
If wireless switch assembly includes multiple electronic components, then wireless control capability is provided, but device complexity increases
Solution Approach 1:
By merging the resilient arm and switch actuator into one component, the patent eliminates the need for precise alignment between separate spring and switch components. The resilient arm is directly positioned to actuate the switch, simplifying the assembly process and reducing manufacturing complexity while maintaining full wireless control capability.
Solution Approach 2:
The patent extracts and eliminates unnecessary intermediate components (separate springs and complex alignment mechanisms) from the system. By removing these extraneous elements, the design achieves wireless control capability with reduced device complexity and simpler manufacturing requirements.
3Ease of manufacture
If conventional wired switch design is used, then manufacturing is simple and cost-effective, but wireless control functionality is lost
Solution Approach 1:
The patent merges the simplicity of conventional switch design with wireless functionality by integrating the resilient arm directly with the circuit board switch actuator. This eliminates complex alignment requirements while incorporating transmitter, microprocessor, and antenna components, achieving both manufacturing simplicity and wireless control functionality.
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 reduces manufacturing costs and simplifies installation by integrating necessary components within the switch assembly, providing a cost-effective and easily installable wireless control system that mimics conventional switches in appearance and functionality.
Implementation Method 1
two resilient arms 28 are provided in the housing 20 and project into the interior space defined by the sidewall 30
Data Source
AI summary
An assembly for a wall-mounted or surface-mounted switch comprises a housing, a shell, and circuitry board. The housing comprises a base and a sidewall defining an interior space, a resilient arm projecting from the base into the interior space. The shell has a sidewall and is mounted to the housing to enclose the interior space. The interior of the shell includes a switch contact surface. The circuitry includes a switch such as a tactile or linear switch. The shell is movable from a disengaged position to an actuating position in response to force applied to the exterior of the shell. Applied force causes the switch contact surface to actuate the switch and the shell to deflect the resilient arm. When the applied force is removed, the resilient arm returns the shell to a neutral position.