1. Field of the Invention
The present invention relates to a rocker switch and, more specifically, to a rocker switch that is structured to operate without an, or with a minimally, audible click.
2. Background Information
Rocker switch assemblies are well known in the art. A rocker switch assembly generally includes a housing, a handle, a conductor, and at least two buses. The handle is coupled to the housing and mounted on a rotational axis overlying the conductor. The handle includes extensions projecting in generally opposite radial directions from the rotational axis and a plunger extending radially from the rotational axis and generally perpendicular to the extensions. The plunger contacts a rocker actuator that is structured to move the conductor. Alternatively, the plunger may act as the rocker actuator and contact the conductor directly. The conductor is coupled to a first terminal. The second, distal end is located adjacent to a second terminal and is structured to move between a first position, wherein the conductor is spaced from the second terminal, and a second position, wherein the conductor contacts the second terminal. The rocker actuator pivots in a seesaw fashion to move the conductor between the first and second positions. This type of rocker switch has a relatively long opening/closing time and a contact bounce, as well as an audible noise. As such the prior art rocker switches are noisy and prone to overheating and contact degradation. Generally, switches carrying one amp, or more, of current should have a quick opening/closing time and a short contact bounce.
There is, therefore, a need for a rocker switch having a quick opening/closing time and a short contact bounce to prevent overheating and contact degradation.
There is a further need for a rocker switch having a quick opening/closing time and a short contact bounce to be economically manufactured.
There is a further need for a rocker switch having a quick opening/closing time and a short contact bounce to be quiet.
These needs, and others, are met by the present invention which provides a rocker switch assembly having a handle member and a contactor assembly, wherein the contactor assembly includes a generally arcuate actuator segment. The contactor assembly further includes an elongated, generally stiff, but flexible, conductor. The generally arcuate actuator segment is disposed between the plunger and the conductor, or may be integral to the conductor. Similar to the prior art, the handle member is structured to be rotationally coupled to a housing and includes extensions projecting in generally opposite radial directions from the rotational axis and a plunger extending radially from the rotational axis and generally perpendicular to the extensions. In operation, the handle member plunger contacts the contactor assembly generally arcuate actuator segment. As the handle member rotates, the plunger moves along the arcuate segment and the moveable contact is moved between the first and second positions. The shape of the arcuate segment causes the conductor to move at a slower speed as the plunger moves towards the ends of the arcuate segment while allowing the conductor to move quickly when the plunger is contacting the central portion of the arcuate segment. Thus, the movable contact moves quickly between the first and second positions as the plunger moves along the center portion of the arcuate segment, but does not produce a loud audible noise because the handle member moves slower as the plunger moves to the ends of the arcuate segment.
There are two variations of three types of components that may be combined into one of six embodiments. The variations of the elements include (1) the location of the arcuate segment, i.e. the arcuate segment as being either integral to the conductor body or an arcuate actuator member, (2) the conductor being fixed to a terminal or free to rock, and, (3) the arcuate segment being either a two or three position arcuate segment. The difference between the two embodiments of the first type of component is self explanatory. The second type of component relates to the conductor being coupled to a terminal. In one embodiment, one end of the conductor is coupled to a terminal as set forth above. That is, a first end of the conductor is coupled to a first terminal and the second end of the conductor, which has a contact, is structured, i.e. flex, to move between a first position where the contact is spaced from a second terminal to a second position where the contact engages the second terminal. This is, essentially, a simple switch having an open and a closed position. Alternatively, the conductor may be free at both the first and second ends. In this embodiment, both ends of the conductor have contacts. Thus, the conductor is structured to rock between a first position where the contact at the first end engages a first terminal and a second position where the contact at the second end engages the second terminal. In this embodiment, one terminal is coupled to a load while the other terminal may be connected to a separate load or not connected to a load.
The third type of component, the arcuate segment being either a two or three position arcuate segment, relates to how the arcuate segment causes the conductor to move. With a two position arcuate segment, the arcuate segment has a generally smooth arcuate portion that allows the conductor to move smoothly between the first and second positions. A three position arcuate segment includes a neutral position portion structured to arrest the motion of the conductor between the first and second positions so that neither the first end or the second end engages a terminal. This position is the neutral position. In the embodiment where the arcuate segment is an actuator member, the neutral position portion is, preferably, a flat section on the face of the actuator member that engages the conductor. In the embodiment where the arcuate segment is an integral to the conductor, the neutral position portion is, preferably, a detent located near the middle of the arcuate segment.
A full understanding of the invention can be gained from the following description of the preferred embodiments when read in conjunction with the accompanying drawings in which:
As shown in
As shown in
The contactor assembly 50 includes a fixed end elongated conductor 52, an arcuate segment 54, and a movable contact 56. The conductor 52 is rigid, yet flexible, and is preferably made from copper or a copper alloy. In this embodiment, the contactor assembly 50 is configured for use as a two position switch. That is, the conductor 52 has a first end 58 and a second end 60. The movable contact 56 is coupled to the conductor second end 60. The first end 58 is coupled to the first terminal 16 within the enclosed space 15. Typically, in this configuration the first terminal 16 is not connected to a load. The conductor 52 is coupled to the center terminal 17, which is coupled to a line. As shown best in
In this embodiment, the arcuate segment 54 is a two position arcuate actuator member 70 as shown in
When assembled, the conductor 52 is disposed within the enclosed space 15 and the conductor first end 58 is coupled to the first terminal 16. The conductor 52 extends through the yoke 62 towards the second terminal 18. The conductor 52 is shaped so that the movable contact 56 is biased to a first position, wherein the movable contact 56 is spaced from the stationary contact 19. The conductor 52 is sufficiently flexible to allow the movable contact 56 to be moved into a second position, wherein the movable contact 56 engages the stationary contact 19. The arcuate actuator member 70 is disposed within the yoke 62 with the vertex of the arcuate actuator member 70 generally disposed at the yoke 62. In this configuration, the arcuate actuator member 70 may move between a first position, wherein the arcuate actuator member 70 is tilted toward the first terminal 16, to a second position, wherein the arcuate actuator member 70 is tilted toward the second terminal 18. Because the arcuate actuator member 70 contacts the conductor 52 at the yoke 62, as the arcuate actuator member 70 moves between the arcuate actuator member 70 first and second positions, the movable contact 56 is moved between the movable contact 56 first and second positions. That is, as the arcuate actuator member 70 moves, the arcuate actuator member 70 contacts the conductor 52 and causes the conductor 52 to flex at the yoke 62.
The handle member 22 is rotatably coupled to the housing 14 at the handle member pivot point 32. The handle member 22 is structured to move, and, more specifically, pivot about the pivot point 32, between a first position, wherein the plunger 30 extends toward the first terminal 16, and a second position, wherein the plunger 30 extends toward the second terminal 18. The plunger 30 extends through the enclosed space 15 towards the arcuate actuator member 70 and the piston 44 contacts the upper surface of the arcuate actuator member 70. The spring 42 ensures that the piston 44 engages the arcuate actuator member 70. When the handle member 22 is in the first position, the plunger 30 biases the arcuate actuator member 70 to the arcuate actuator member 70 first position, and therefore the movable contact 56 is in the first position. As the handle member 22 is moved to the second position, the plunger 30 travels over the upper surface of the arcuate actuator member 70 causing the arcuate actuator member 70 to move into the second position. Accordingly, the movable contact 56 is also moved into the second position. Because the outer face 71 of the two position arcuate actuator member 70 is smooth, the motion between the first an second positions is smooth.
Although the first embodiment was shown as having a fixed end elongated conductor 52, it is understood that the same components, e.g. a two position arcuate actuator member 70, may also be used in conjunction with a rocking conductor 252 as described below.
A second embodiment of the invention is shown in
As shown in
As shown in
The handle member 22 is coupled to the housing 14 as described above. In this embodiment, however, the piston 44 contacts the upper surface of integral arcuate portion 170. The spring 42 ensures that the piston 44 engages the integral arcuate portion 170. When the handle member 22 is in the first position, the plunger 30 biases the arcuate integral arcuate portion 170 to the integral arcuate portion 170 first position, and therefore the movable contact 156 is in the first position. As the handle member 22 is moved to the second position, the plunger 30 travels over the upper surface of the integral arcuate portion 170 causing the integral arcuate portion 170 to move into the second position. Accordingly, the movable contact 156 is also moved into the second position.
Although the second embodiment was shown as having a fixed end elongated conductor 152, it is understood that the same components, e.g. a two position integral arcuate portion 170, may also be used in conjunction with a rocking conductor 352 that does not include a neutral position portion 371, as described below.
A third embodiment of the invention is shown in
Accordingly, in this embodiment, the contactor assembly 250 includes an elongated conductor 252, an arcuate segment 254, a first movable contact 255 and a second movable contact 256. The conductor 252 has a first end 258 and a second end 260. The first movable contact 255 is coupled to the first end 258. The second movable contact 256 is coupled to the second end 260. The conductor 252 is rigid, yet flexible, and is preferably made from copper or a copper alloy. Additionally, the first terminal 16 also includes a stationary contact 19. The conductor 252 is pivotally coupled to the center terminal 17. That is, as shown best in
In this embodiment, the arcuate segment 254 is a three position arcuate actuator member 270, as shown in
When assembled, the conductor 252 is disposed within the enclosed space 15. The conductor 252 extends through the yoke 62 with the first end 258 extending towards the first terminal 16 and the second end 260 extending toward the second terminal 18. The conductor first end 258 and the conductor second end 260 are angled upwards relative to the mounting point 64. The conductor 252 is structured to move between a first position where the first movable contact 255 at the conductor first end 258 contacts the stationary contact 19 on the first terminal 16, to a neutral position where neither the first or second movable contacts 255, 256 at conductor first or second end 258, 260 engage a stationary contact 19, to a second position where the second movable contact 256 at the conductor second end 260 contacts the stationary contact 19 on the second terminal 18.
The arcuate actuator member 270 is disposed within the yoke 62 with the vertex of the arcuate actuator member 270 generally disposed at the yoke 62. In this configuration, the arcuate actuator member 270 may rock from a first position, wherein the arcuate actuator member 270 is tilted toward the first terminal 16, to a neutral position where the arcuate actuator member 270 is generally perpendicular to the yoke 62 and the piston 44 engages the detent 275, to a second position, wherein the arcuate actuator member 270 is tilted toward the second terminal 18. Because the arcuate actuator member 270 contacts the conductor 252 at the yoke 62, as the arcuate actuator member 270 moves between the arcuate actuator member 270 first and second positions, the movable contacts 255, 256 are moved between the movable contact 255, 256 first and second positions. That is, as the arcuate actuator member 270 moves, the arcuate actuator member 270 contacts the conductor 252 and causes the conductor 252 to rock at the yoke 62. When the arcuate actuator member 270 is in the neutral position, the conductor 252 is also in the neutral position.
A fourth embodiment of the invention is shown in
In this embodiment, the contactor assembly 350 includes an elongated conductor 352, an arcuate segment 354, a first movable contact 355 and a second movable contact 356. The conductor 352 has a first end 358 and a second end 360. The first movable contact 355 at conductor first end is coupled to the first end 358. The second movable contact 356 at conductor second end is coupled to the second end 360. The conductor 352 is rigid, yet flexible, and is preferably made from copper or a copper alloy. Additionally, the first terminal 16 also includes a stationary contact 19. The conductor 352 is pivotally coupled to the center terminal 17. That is, as shown best in
In this embodiment, the arcuate segment 354 is disposed between the conductor first end 358 and second end 360 as a three position integral arcuate portion 370, as shown in
When assembled, the conductor 352 is disposed within the enclosed space 15. The integral arcuate portion 370 is disposed within the yoke 62 with the vertex of the integral arcuate portion 370 generally disposed at the yoke 62. In this configuration, the integral arcuate portion 370 may rock from a first position, wherein the integral arcuate portion 370 is tilted toward the first terminal 16 so that the first movable contact 355 engages the stationary contact 19 coupled to the first terminal 16, to a neutral position where the integral arcuate portion 370 is generally perpendicular to the yoke 62 and the piston 44 engages the detent 373, to a second position, wherein the integral arcuate portion 370 is tilted toward the second terminal 18 so that the second movable contact 356 engages the stationary contact 19 coupled to the second terminal 18. That is, as the integral arcuate portion 370 moves, the integral arcuate portion 370 contacts the conductor 352 and causes the conductor 352 to rock at the yoke 62. When the integral arcuate portion 370 is in the neutral position, the conductor 352 is also in the neutral position.
While specific embodiments of the invention have been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. For example, in an embodiment where a terminal is not coupled to a load, the terminal may be eliminated and the conductor 52, 152, 252, 352 is coupled to, or contacts, the housing 14. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of invention which is to be given the full breadth of the claims appended and any and all equivalents thereof.
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