The present disclosure relates generally to an electrical wiring device and, more particularly, relates to a switch actuator assembly for activating a switch in an electrical wiring device.
Electrical wiring devices, such as switches, dimmer switches, etc., typically include a spring mechanism to actuate the switching component. When a user pushes an actuator on a wiring device, the spring mechanism is typically configured so that the spring mechanism is displaced along its longitudinal axis. However, this type of design has disadvantages because there is limited space in a wiring device, and a spring mechanism configured to be displaced along its longitudinal axis takes up valuable space and requires substantial depth in the wiring device to accommodate the movement of the spring mechanism. In addition, a design with the spring mechanism displaced along its longitudinal axis typically requires other components to be included in the wiring device, such as a lever mechanism, which takes up additional space and increases manufacturing costs. These types of designs are particularly disadvantageous in interchangeable color change kits that typically include the mechanism components in the rocker-frame assembly, which is separate from the rest of the electrical device.
It would be desirable for a wiring device to have an actuator biased by a component that is not displaced along its longitudinal axis. This would allow for the overall depth of the wiring device to decrease without compromising the balanced “feel” by the user when pressing the actuator. In addition, the number of unique parts required for manufacturing wiring devices would decrease, which would also reduce manufacturing complexity and costs, including inventory costs, labor costs, molding costs, etc.
A switch actuator assembly for activating a switch in an electrical wiring device is disclosed. The switch actuator assembly preferably includes a frame having a peripheral wall, a rocker, first and second resilient member supports, a tab having a contact surface, and a resilient member. The first and second resilient member supports may extend from opposite sides of either the frame or the rocker, and the tab may extend from the other of the frame or the rocker. The first and second resilient member supports are preferably arranged and configured to be in registered alignment with respect to one another to form an axis. The resilient member preferably includes a first end, a second end, and a middle portion. A longitudinal axis of the resilient member may be defined between the first and second ends. The first and second ends are preferably configured to engage the first and second resilient member supports respectively, and the middle portion is preferably configured to interact with the tab. In use, the rocker is preferably pivotally mounted to the frame and configured to rotate between a first position and a second position. The contact surface of the tab preferably deflects the resilient member in a direction that is perpendicular to the longitudinal axis of the resilient member when the rocker is in the first position and the second position.
In a second, alternate embodiment of a switch actuator assembly for activating a switch in an electrical wiring device, the switch actuator assembly preferably includes a frame, a rocker, and a resilient member. The frame preferably includes first and second frame mounting members, a bottom wall, and first and second trunnions. The first and second frame mounting members preferably extend from the bottom wall, and the first and second trunnions are parallel to the bottom wall and project inwardly. The rocker preferably includes a bottom surface, a tab, and first and second sides. The tab preferably includes first and second surfaces, and the tab preferably extends from the bottom surface of the rocker. The first and second sides of the rocker preferably include first and second rocker mounting members respectively. The first and second rocker mounting members are preferably arranged and configured to pivotally mount to the first and second frame mounting members respectively. The resilient member preferably includes first and second ends and a bearing surface. A longitudinal axis of the resilient member may be defined between the first and second ends. The first and second ends are preferably configured to engage the first and second trunnions respectively, and the bearing surface is preferably arranged and configured to interact with the tab of the rocker. In use, the rocker is preferably adapted and configured to pivotally rotate between a first position and a second position. The first surface of the tab preferably deflects the bearing surface of the resilient member when the rocker is in the first position, and the second surface of the tab preferably deflects the bearing surface of the resilient member when the rocker is in the second position.
One or more aspects of the present invention are particularly pointed out and distinctly claimed as examples in the claims at the conclusion of the specification. The foregoing and other objects, features, and advantages of the present invention may be more readily understood by one skilled in the art with reference being had to the following detailed description of several embodiments thereof, taken in conjunction with the accompanying drawings wherein like elements are designated by identical reference numerals throughout the several views, and in which:
The present disclosure describes an apparatus, assembly and method for an electrical wiring device having an actuator (e.g., a rocker) biased by a resilient member. Embodiments will be described below while referencing the accompanying figures. The accompanying figures are merely examples and are not intended to limit the scope of the present disclosure.
According to one aspect of the present invention, the electrical wiring device 90 preferably includes a resilient member to impart a force on the rocker 10, biasing the rocker 10 through a range of travel, for example, from the first position and the second position. More preferably, the resilient member extends horizontally across the electrical wiring device 90 (e.g., along a minor axis of the rocker 10). The resilient member may be any resilient member or material that can apply a biasing force now or hereafter known in the art including a spring, a wire (as shown in
As will be described in greater detail below, the rocker 10, the frame 40, the resilient member, and the optional slide potentiometer or slide switch 80 for dimmer and motor load control applications may be incorporated into a rocker-frame assembly 5 so that the rocker-frame assembly 5 is removable from the base 85. In this manner, the rocker-frame assembly 5 may be provided as an interchangeable color changing kit that enables an installer or end user to easily change the color of the visible portions of the device 90 to coordinate with changes in the building décor or occupant preferences. Alternatively, as will be appreciated by one of ordinary skill in the art, the rocker 10 may be permanently coupled to the base 85.
Referring to
As shown in
The tab 18 may include a contact surface 21 having a first surface 20 and a second surface 22. As will be described in greater detail below, the first and second surfaces 20, 22 are preferably angled relative to a planar surface E-E, which is substantially parallel to a longitudinal axis Y′ of the resilient member or spring 70 (see
In addition, the rocker 10 may include first and second pins 12, 14. The first and second pins 12, 14 may project from opposite sides 30, 32 of the rocker 10, and define a pivot axis 19. The top surface 11 of the rocker 10 is configured to be pressed by a user to change the position of the rocker 10. As shown, the top surface 11 is positioned at an inward angle towards the pivot axis. However, in other embodiments, any other suitable shape, contour, dimensions, angles, surfaces, etc. may be used for functional and/or aesthetic reasons.
As shown in
The frame 40 may also include first and second openings 62, 64 that are formed in the bottom wall 41. As will be described in more detail below, the first opening 62 is adapted and configured to be in registered alignment with and accommodate the tab 18 of the rocker 10 to allow the tab 18 to extend at least partially through the first opening 62 when the rocker 10 is in the first position; and, the second opening 64 is adapted and configured to be in registered alignment with and accommodate the arm 26 of the rocker 10 and the switch 99 of the electrical device 90 (see
The frame 40 preferably includes first and second resilient member supports 60, 65. The first and second resilient member supports 60, 65 may be arranged and configured to be in registered alignment with respect to one another to form an axis. In the embodiment of
The frame 40 may also include a hinge 54 extending from the bottom wall 41 thereof and positioned at one end 49 of the frame 40. The hinge 54 may include first and second feet 66, 68 that are positioned on opposite sides 45, 47 of the frame 40, respectively. Furthermore, the frame 40 may include first and second snaps 46, 48 extending from the bottom wall 41 and/or the peripheral wall 43, on opposite sides 45, 47 of the frame 40, respectively. The first and second snaps 46, 48 may each include a latch portion 50, 52, respectively. As will be described in more detail below, the hinge 54, feet 66, 68 and snaps 46, 48 are adapted and configured to engage with the front housing 105 of the electrical wiring device 90 to secure the rocker-frame assembly 5 to the electrical wiring device 90 (see
As shown in
To assemble the rocker-frame assembly 5, the first and second ends 72, 74 of the spring 70 are coupled to the first and second trunnions 56, 58, respectively. Furthermore, the first and second pins 12, 14 of the rocker are received by the first and second slots 42, 44 of the frame 40, respectively, thereby enabling the rocker 10 to pivot within the frame 40 about the pivot axis 19. In other embodiments, the rocker may include first and second rocker mounting members that extend from the first and second sides of the rocker, respectively; and, the frame may include first and second frame mounting members that extend from the bottom wall and/or the peripheral wall. The first and second rocker mounting members may be arranged and configured to pivotally mount to the first and second frame mounting members respectively. The first and second rocker mounting members may include first and second pins respectively, the first and second pins defining a pivot axis. In addition, the first and second frame mounting members may include first and second slots respectively, the first and second slots arranged and configured to receive the first and second pins.
In use, the rocker 10 may pivotally rotate about the pivot axis 19 through a range of travel, for example, from a first position (see
As shown in
In both the first and second positions, the tab 18 applies force on the spring 70, displacing or bending the spring 70 so that the spring 70 follows the path of an arc; and, the buckling resistance of the spring 70 imparts a force on the rocker 10. That is, the spring 70 provides a biasing force to keep the rocker 10 in the first or second position until a user applies pressure to an end 15, 17 of the rocker 10, causing the rocker 10 to pivot about the pivot axis 19 to the other respective first or second position.
As shown in
In the exemplary embodiment described above, the tab 18 extends from the rocker 10, and the frame 40 is adapted and configured to engage with the spring 70 via the first and second support members 55, 57 and the first and second trunnions 56, 58. However, it will be understood by one of ordinary skill in the art that in other embodiments, the tab may extend from the frame; and, the first and second resilient member supports, and/or any other attachment feature or component that is adapted and configured to receive an end of the spring, may extend from the rocker. For example, the first and second resilient member supports may extend from the bottom surface of the rocker, the first and second sides of the rocker, etc.
The frame 40 may be attached to the electrical wiring device 90 in any convenient manner. As previously mentioned, in the exemplary embodiment shown in
In the exemplary embodiment described above, the spring 70 is positioned horizontally between the rocker 10 and the frame 40, wherein the first and second ends 72, 74 of the spring 70 are held in place by the first and second trunnions 56, 58 respectively so that the spring 70 may not be displaced along its longitudinal axis Y′, and the first and second ends 72, 74 are prevented from translating toward or away from the bottom surface 13 of the rocker 10. Thus, the overall depth of the rocker-frame assembly 5 may be minimized because extra space is not needed for the spring 70 to be displaced along its longitudinal axis and/or for the first and second ends 72, 74 of the spring 70 to translate. A decrease in overall depth of the rocker-frame assembly 5 may be ideal for applications, such as but not limited to, interchangeable color change kits that enable an installer or end user to easily change the color of the visible portions of the device to coordinate with changes in the building decor or occupant preferences.
In addition, in the exemplary embodiment described above, a slide potentiometer or slide switch 80 is positioned in the frame 40 adjacent the rocker 10. However, it will be understood by one of ordinary skill in the art that in other embodiments, the electrical wiring device may not include a slide potentiometer or slide switch, or may include a slide potentiometer or slide switch but of a different shape, size, etc. Furthermore, in other embodiments, the slide potentiometer or slide switch may be in a different position or configuration on the device, such as but not limited to, being positioned within the rocker. Furthermore, in other embodiments, the incorporation of a horizontally aligned spring according to the description herein may be employed in switching of a dimmer or any other electrical wiring device.
A method for assembling an electrical device 90 will now be described. The spring 70 is positioned on the frame 40 as described in detail above. The first end 72 of the spring 70 may pass over the first trunnion 56 of the frame 40, and the second end 74 of the spring 70 may pass over the second trunnion 58 of the frame 40. The rocker 10 may be pivotally attached or mounted to the frame 40 to enable the tab 18 on the rocker 10 to deflect the spring 70 perpendicular to a longitudinal axis of the spring 70 when the rocker 10 is in a first position and a second position. The first and second slots 42, 44 on the frame 40 are adapted and configured to receive the first and second pins 12, 14 on the rocker 10.
To attach the rocker-frame assembly 5 to the front housing 105, the user aligns a hinge 54 on the frame 40 with the opening 92 on the front housing 105, and inserts the first and second feet 66, 68 and the hinge 54 on the frame 40 into the openings 92, 96, 98 on the front housing 105, respectively. The user may then pivot the rocker-frame assembly 5 into the installed position by inserting the first and second snaps 46, 48 of the frame 40 into the openings 91, 93 on the front housing 105 that are adapted and configured to be aligned with the snaps 46, 48 until the latches 50, 52 on the snaps 46, 48 engage the openings 91, 93 to hold the rocker-frame assembly 5 in the installed position.
Referring to
While certain embodiments of the disclosure have been described herein, it is not intended that the disclosure be limited thereto, as it is intended that the disclosure be as broad in scope as the art will allow and that the specification be read likewise. Therefore, the above description should not be construed as limiting, but merely as exemplifications of particular embodiments. Those skilled in the art will envision additional modifications, features, and advantages within the scope and spirit of the claims appended hereto.
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Number | Date | Country | |
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20150279593 A1 | Oct 2015 | US |