Phacops
Registered
After a minor shock to a new Miniwave LED the internal switch assembly fell apart. Princeton Tec did the right thing and fixed the light when it was sent back to them (at my cost).
Looking at the replacement, the metal casing of the switch is not crimped to the base and it appears that the prongs holding the casing to the base were spot glued (face to face) at the mating points during automated manufacturing. The prongs are not even positioned in place by cutouts on the base. This is not a design for robust service. Very cheap and prone to several modes of failure unlike properly designed slider or potted rotary switches.
Solution is to use adhesive microsphere filled epoxy to captivate the prongs - at least mediate the problem of shear between adhesive bonded parts due to use or shock.
Looking at the replacement, the metal casing of the switch is not crimped to the base and it appears that the prongs holding the casing to the base were spot glued (face to face) at the mating points during automated manufacturing. The prongs are not even positioned in place by cutouts on the base. This is not a design for robust service. Very cheap and prone to several modes of failure unlike properly designed slider or potted rotary switches.
Solution is to use adhesive microsphere filled epoxy to captivate the prongs - at least mediate the problem of shear between adhesive bonded parts due to use or shock.
