Patent Application
20180115142
The present invention relates generally to electric switches, and particularly to electric switches that include mechanical actuators.
Electrical switches are used, of course, to control the state of electrical loads such as lighting elements, fans, and other such equipments. Electrical switch units are typically wall mounted in a location that is proximate the load. For example, light switches are usually located at the entry point of a room or a space so that a person entering the room can turn the lights ON before entering. Wall mounted electrical switches often include mechanical actuators such as toggle switch actuators, lever switch actuators, paddle switch actuators, push-button actuators and the like.
Based on consumer taste and convenience, there is a need for a push button actuated electrical switch. The push button switches currently on the market almost always include electronic switch actuators because of the in-out motion of a push switch lends itself to electronic push-button switch actuators rather than mechanical switch actuators. However, electronic switch actuators have drawbacks relative to mechanical switch actuators. They are more expensive, generate more thermal energy (heat), are larger, and are not as robust. What is needed, therefore, is a push button switch that includes a mechanical actuator to mitigate the aforementioned drawbacks.
In one approach that has been considered, a push button actuator is coupled to a rotatable block by a pressure-transmission gear. This approach has several drawbacks associated with it. The pressure-transmission gear is laterally unstable and the interface between the pressure-transmission gear and the rotatable block is prone to being jammed when the user applies downward pressure to the push button actuator. Another drawback to this approach relates to the tendency for contaminants to enter the mechanical switch space and fouling the switch contacts. What is needed, therefore, is a push button switch that includes a mechanical actuator that overcomes the aforementioned drawbacks.
Another issue that arises in various types of switching devices relates to the function and placement of indicator lights on the switching device itself. Some switches are known to include a pilot light that is illuminated when the switch is turned OFF. A load light is one that is illuminated when the switch is turned ON; this type of light provides the user with an indication that power is being delivered to the load. Another type of indicator is a “power-available light.” This indicator shows the user that power is available to the switch, and thus, is illuminated—when power is available—regardless of whether the switch is ON or OFF. One drawback associated with mechanical switch devices (that include indicator lights) relates to the fact that the switch actuator is moveable. If the light indicator element within the switch moves with the switch actuator, then the light output is substantially uniform. On the other hand, the electrical wiring must move with the light element (to provide electricity); as a result, the wiring is continually being flexed. If, on the other hand, the light indicator element within the switch is stationary, the continual flexure of the electrical wiring is avoided while providing the mechanical switch actuator freedom of motion. The drawback with this solution is that the light output of a stationary light will be non-uniform. For one type of indicator light or another, the light output will be more effective in one actuator position than another. This issue becomes especially apparent for the power-available light or for universal light assemblies that can be wired by the installer to accomplish the various functions. What is needed, therefore, is an indicator arrangement (within the switch) that provides efficient and consistent light output regardless of actuator position.
Turning now to another consideration, there are several drawbacks associated with conventional installation methods and conventional protective electrical wiring devices. Conventional protective electrical wiring devices often do not make efficient use of space. In addition, mounting the wiring device's ground strap to the device box is tedious, time consuming, and therefore costly. The same can be said of mounting the cover plate to the electrical wiring device. Moreover, in multi-gang installations, the finished look is often ragged because the plurality of electrical devices and their respective cover plates are typically not in alignment. This misalignment can be, and very often is, in all three dimensions. Retrofitting an electrical installation can also be problematic from the standpoint of the finished look because the device box, or an old work box, may not be precisely aligned to the plane of the wall surface. This is especially true if the wall surface itself is uneven. After remodeling a space, homeowners often seek to replace an existing wall plate with one that better matches the new décor. Thus, a homeowner may inadvisably remove the faceplate cover from an energized wiring device and inadvertently become exposed to a shock hazard from the “hot” electrical wiring.
What is needed therefore is a switch that addresses the drawbacks articulated above. A switch of this type is also needed that can be employed in a number of different form factors including one suitable for use in a modular framing system such that it does not require fasteners to be securely installed within the device box.
The present invention addresses the needs described above by providing a push-switch with a mechanical switch actuator that addresses the drawbacks articulated above. The switch of the present invention can be employed in a number of different form factors including a form factor suitable for use in a modular framing system.
One aspect of the present invention is directed to a switch that includes a device housing configured to be installed in an outlet box, the device housing including front portion and a back body portion. A switch assembly is disposed in the device housing, the switch assembly including a switch actuator having a user-accessible surface and coupled to the front portion. The user accessible surface includes an indicator element disposed therein. The switch actuator also includes an interior channel optically coupled to the indicator element. The switch assembly further includes a mechanical linkage and a set of electrical contacts disposed within the back body portion. The switch actuator is configured to actuate the mechanical linkage by moving between a first actuator position and a second actuator position in response to a user-stimulus, the mechanical linkage actuation driving the set of electrical contacts between a first contact state and a second contact state. A lighting assembly is coupled to the back body portion at a fixed position so that a light emitting portion of the lighting assembly is disposed within the interior channel and optically coupled to the indicator element. The interior channel is configured to move relative to the light emitting portion when the switch actuator moves between the first actuator position and the second actuator position. The light emitting portion is optically coupled to the indicator element when the interior channel moves relative to the lighting portion.
In one embodiment, the lighting assembly is a modular component removably coupled to the back body portion.
In one embodiment, the back body portion includes an elongated chamber configured to accommodate the lighting assembly, the elongated chamber including a tapered portion configured to position the light emitting portion at the fixed position.
In one embodiment, the switch actuator includes a light transmitting element configured to optically couple the interior channel to the indicator element.
In one version of the embodiment, the light transmitting element is in a fixed positional relationship with the interior channel.
In one version of the embodiment, the light transmitting element includes an LED element.
In one embodiment, the switch actuator includes a light transmitting element having a first optical port and a second optical port, the first port being coupled to the indicator element and the second port being coupled to the interior channel, and wherein the first optical port is substantially aligned with a central axis of the device housing and the second optical port is substantially offset from the axis.
In one version of the embodiment, the light transmitting element includes a plurality of light transmitting segments disposed between the first port and the second ports.
In one version of the embodiment, the plurality of light transmitting segments includes at least one portion configured to direct incident light at a 45° angle.
In one embodiment, the interior channel is polished.
In one embodiment, the interior channel is plated with an optically reflective material.
In one embodiment, the set of electrical contacts are switchably coupled to a plurality of terminals at least partially disposed in the back body portion, the plurality of terminals being accessible via the back body portion.
In one version of the embodiment, the plurality of terminals including a line terminal, a load terminal or a traveler terminal.
In one embodiment, the indicator element is a lens element.
In one version of the embodiment, the lens element is formed by machining a portion of the user accessible surface.
Another aspect of the invention is directed to a switch device that includes a switch actuator assembly having a switch actuation plate coupled to an actuator guide portion that has a perimeter guide wall substantially enclosing an interior volume therewithin. The actuator guide portion is coupled to a force transmission member and further includes an interior channel. The switch actuation plate includes a lens element optically coupled to a light transmission structure at least partially disposed in the interior channel. A back body member includes a perimeter back body wall, portions of the perimeter back body wall being configured to mate with corresponding portions of the perimeter guide wall so that the perimeter guide wall is disposed within the perimeter back body wall in a nesting arrangement so that the interior volume is substantially inaccessible to an exterior region of the device. The back body member includes an elongated chamber configured to position a lighting element at a fixed position within the back body so that the lighting element extends into the interior channel. The actuator guide is configured to slide within the back body member in a substantially linear motion between a non-switch actuating position and a switch actuating position so that a relative distance between the light transmission structure and the lighting element varies within the interior channel. The interior channel is configured so that light intensity emitted by the lighting element via the lens element is substantially constant while the relative distance varies. A mechanical switch assembly configured to convert the linear motion of the actuator guide into a rotational movement when the switch actuator plate is depressed so that the mechanical switch mechanism moves between a first switch state and a second switch state.
In one embodiment, the interior channel is polished.
In one embodiment, the interior channel is plated with an optically reflective material.
In one embodiment, the light transmitting element includes a first optical port and a second optical port, the first port being coupled to the lens element and the second port being coupled to the interior channel, and wherein the first optical port is substantially aligned with a central axis of the device housing and the second optical port is substantially offset from the axis.
In one version of the embodiment, the light transmitting element includes a plurality of light transmitting segments disposed between the first port and the second ports.
In one version of the embodiment, the plurality of light transmitting segments includes at least one portion configured to direct incident light at a 45° angle.
In one embodiment, the actuator guide portion includes a plurality of guide portions formed in the perimeter wall within the interior volume, the perimeter back body wall having a plurality of registration elements, each of the plurality of registration elements being insertably disposed within a corresponding one of the plurality of guide portions.
In one version of the embodiment, the plurality of registration elements are configured to substantially prevent rotational movement of the actuator guide within the back body member about an axis of the switch device normal to the direction of linear movement.
In one version of the embodiment, the plurality of registration elements are configured to substantially prevent rotational movement of the actuator guide within the back body member about the central axis.
In one version of the embodiment, the guide elements includes a first guide channel and a second guide channel formed on a first perimeter guide wall and a second perimeter guide wall, respectively, and a first guide post and a second guide post formed on a third perimeter guide wall and a fourth perimeter guide wall, respectively.
In one version of the embodiment, the plurality of registration elements includes a first registration column and a second registration column configured to be inserted within the first guide channel and the second guide channel, respectively, so that the first registration column, the second registration column, the first guide channel and the second guide channel are substantially disposed within the interior volume.
In one version of the embodiment, the plurality of registration elements includes a first registration key way and a second registration key way configured to retain therewithin the first guide post and the second guide post, respectively, so that the first registration key way, the second registration key way, the first guide post and the second guide post are substantially disposed outside the interior volume.
In one embodiment, the lighting element includes a light emitting diode.
In one version of the embodiment, the back body includes a rear portion coupled to the perimeter back body wall, the elongated chamber including an ingress aperture formed in the rear portion, and wherein the lighting element is removably disposed in the elongated chamber.
In one version of the embodiment, the lighting element is directly terminated to a source of AC power.
In one embodiment, the switch actuator assembly includes a transmission mechanism coupled to the actuator guide, the transmission mechanism being configured to convert the linear motion of the actuator guide into a rotational movement when the switch actuator plate is depressed and the actuator guide is driven toward the switch actuating position.
In one version of the embodiment, the transmission mechanism includes a plurality of gear teeth, the plurality of gear teeth being configured to apply a rotational movement to the mechanical switch mechanism in response to the linear motion of the actuator guide.
In one version of the embodiment, the device further comprises a switch actuator portion coupled between the transmission mechanism and at least a portion of the mechanical switch assembly, the switch actuator portion being configured to move the mechanical switch assembly between the first switch state and the second switch state in response to the rotational movement of the transmission mechanism.
In one embodiment, the device further comprises a housing having a front portion and a back body portion, the housing being configured to be installed in an outlet box.
In one version of the embodiment, the mechanical switch mechanism includes a set of electrical contacts switchably coupled to a plurality of terminals at least partially disposed in the back body portion, the plurality of terminals being accessible via the back body portion.
In one version of the embodiment, the plurality of terminals including a line terminal, a load terminal or a traveler terminal.
In one version of the embodiment, the housing assembly further comprises a separator member coupled between the back body member and the switch actuator assembly, the separator member providing a barrier between the mechanical switch assembly and the interior volume.
In one version of the embodiment, the separator member includes at least one ancillary registration element configured to mate with a corresponding structure disposed in the perimeter guide wall.
Additional features and advantages of the invention will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the invention as described herein, including the detailed description which follows, the claims, as well as the appended drawings.
It is to be understood that both the foregoing general description and the following detailed description are merely exemplary of the invention, and are intended to provide an overview or framework for understanding the nature and character of the invention as it is claimed. The accompanying drawings are included to provide a further understanding of the invention, and are incorporated in and constitute a part of this specification. The drawings illustrate various embodiments of the invention and together with the description serve to explain the principles and operation of the invention.
Reference will now be made in detail to the present exemplary embodiments of the invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts. An exemplary embodiment of the push switch of the present invention is shown in
As embodied herein, and depicted in
Thus, a frame enclosure lip 10-5 is disposed around the perimeter of the frame 10. The frame enclosure lip 10-5 is configured to substantially abut the wall surface 1 (not shown in this view) such that a front edge of a properly installed wall box does not substantially touch the rear side 10-2 of the frame 10. This is true even when old work boxes are deployed. Old work boxes, of course, have flanges that are mounted to the outer surface of the wall surface 1. The frame enclosure lip 10-5 raises the rear surface 10-2 overtop the work box to avoid any interference with the flanges and prevent the frame 10 from contacting the wall surface 1.
As shown, the frame 10 includes a frame opening 10-13 that has an interior serrated edge or lip 10-6 that is configured to mate with the modular alignment conductors 20 and/or the electrical wiring device 100 in the manner disclosed below. Once electrical wiring device(s) and/or the modular alignment connectors are installed within the frame opening 10-13, the enclosure is completed. The interior serrated lip 10-6 extends along lateral portions of the frame opening 10-13 to adjoin a connector landing element 10-7 disposed at either end of the frame opening 10-13. The interior serrated lips 10-6 and the connector landing elements 10-7 extend perpendicularly around the entire frame opening 10-12 to form a rim or skirt that is inserted inwardly within the device box interior during installation. Accordingly, the region under the rear frame surface 10-2 between the outer enclosure lip 10-5 and the interior rim (i.e., serrated lips 10-6 and landing 10-7) is disposed over the wall surface 1. Once the wall box fasteners 10-10 are inserted into the fastener slots 10-12 and tightened, the interior of the device box is accessed via the frame opening 10-13. After device installation, however, the frame opening 10-13 is completely occupied by some combination of modular wiring devices (30, 40, 42 or 50) and/or modular alignment connectors 20 to thereby complete the enclosure. All of the wiring is under the frame assembly and cannot be accessed.
As embodied herein and depicted in
Reference is made to U.S. patent application Ser. No. 13/608,675, which is incorporated herein by reference as though fully set forth in its entirety, for a more detailed explanation of the frame member 10.
Reference is made to U.S. patent application Ser. No. 13/608,675, which is incorporated herein by reference as though fully set forth in its entirety, for a more detailed explanation of the modular alignment connector 20.
As embodied herein and depicted in
In reference to
Referring to
The rotating actuator 116 is mounted on a center opening formed in the separator member 106. As shown below, rotating actuator 116 includes a V-shaped portion or a notch that secures the switch pendulum 120 to the rotatable actuator 116. A center spring element 118 is disposed between the rotatable actuator 116 and the pendulum 120; the spring element 118 provides a “snap-action” to the switch mechanism as it moves between switch positions.
The separator 106 also includes four bosses 106-1 that are situated at the four corners of the separator 106. In one embodiment, each boss 106-1 accommodates a compression spring 106-2. The bosses 106-1 and the springs 106-2 mate with guide openings 110-1 formed at the corners of the slidable actuator guide 110. Thus, when the user applies a push force to the actuator plate 102, the slidable actuator guide 110 compresses the springs 106-2 as the bosses 106-1 move within the guide openings 110-1 formed in slidable guide 110. Once the push force is removed, the springs 106-2 release their stored energy and push the slidable guide 110 in the opposite direction to restore equilibrium. In an alternate embodiment (shown in
Note also that the separator 106 includes stiffeners 106-4 formed in the upper side thereof to stabilize the shape of the separator. As explained in greater detail below, the guide posts 110-3 and the channels 110-4 also mate with registration elements (108-1, 108-2) formed in the back body 108. Thus, the slidable actuator guide 110 is restrained from above and below to prevent an off-center push-force applied to actuator plate 102 from jamming the switch. Stated differently, the combination of the springs 106-2 (in either embodiment) and the multi-level registration features (i.e., 106-4, 106-5, 108-1, 108-2) ensure that the slidable guide member travels straight and true. In other words, the slidable guide member does not jam due to features incorporated in both the separator and the back body. Moreover, because the slidable guide member is constrained on either side by the separator and the back body, dust and other contaminants are substantially prevented from penetrating to the interior of the back body 108 where the pendulum switch 120 resides.
In reference to
In reference to
In Reference to
In reference to
With respect to the sectional line D-D, note that is proceeds in a straight line from the left of the device until it reaches the center point of the device 100; after this the sectional line D-D proceeds in an angular direction to expose the light tunnel 108-3. Briefly stated, the insertable light 30 is an optional feature. If the user desires to use it, it is inserted from the rear of the back body 108 into the light tunnel 108-3 until the light emitter portion 30-3 abuts the stop portion 106-3 formed in the separator member 106. When this occurs, the light emitting head 30-3 is positioned within the slidable guide member 110 proximate and adjacent to one end of the light pipe 104-1. This portion of the slidable guide member 110 includes a polished interior region 110-30 that directs the emitted light into the light pipe 104-1. As noted previously, the light pipe 104-1 includes two 45° bends that direct the light toward lens 104 where it is emitted out into the ambient environment. Due to these bends in the light pipe, lens 104, transmission element 114, and pendulum 120 are all in substantially alignment with the central axis of push switch 100. At the other end of the lighting device 30, hot and neutral pig-tails (2, 4) extend backwardly from the light tunnel for connection to the line terminal 122 and a traveler terminal (124 or 126), to traveler terminals (124,126), to an auxiliary power supply, or to line hot and neutral conductors, respectively.
In reference to
In
If plate 102 is then pushed again the process is repeated only this time the actuation surface 116-2 on the left is higher and so is the one that gets depressed by its respective gear tooth 114-2. Pendulum 120 rotates in the opposite direction until it returns to the switch state shown in
Referring to
The components employed in
All references, including publications, patent applications, and patents, cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.
The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. The term “connected” is to be construed as partly or wholly contained within, attached to, or joined together, even if there is something intervening.
The recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein.
All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate embodiments of the invention and does not impose a limitation on the scope of the invention unless otherwise claimed.
No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.
It will be apparent to those skilled in the art that various modifications and variations can be made to the present invention without departing from the spirit and scope of the invention. There is no intention to limit the invention to the specific form or forms disclosed, but on the contrary, the intention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention, as defined in the appended claims. Thus, it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.
This is application is a continuation of U.S. patent application Ser. No. 14/810,050, filed on Jul. 27, 2015, which is a continuation of U.S. patent application Ser. No. 13/782,195, filed on Mar. 1, 2013 (U.S. Pat. No. 9,095,053), which is a continuation-in-part of U.S. patent application Ser. No. 13/680,675 filed on Nov. 19, 2012 (U.S. Pat. No. 9,301,410), which claims priority to U.S. Provisional Patent Application No. 61/635,432, the contents of each is relied upon and incorporated herein by reference in their respective entireties, and the benefit of priority under 35 U.S.C. § § 119(e) and/or 120, respectively, is hereby claimed.
| Number | Date | Country | |
|---|---|---|---|
| 61635432 | Apr 2012 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 14810050 | Jul 2015 | US |
| Child | 15850422 | US | |
| Parent | 13782195 | Mar 2013 | US |
| Child | 14810050 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 13680675 | Nov 2012 | US |
| Child | 13782195 | US |
