Patent Application
20230057646
The present disclosure relates to the field of electronic components, and, more particularly, to a switching device and related methods.
Switches are common electrical components, and provide a fundamental function: selectively closing and opening an electrical connection between two or more points. On the macro scale, the switch typically connects an electrical device (e.g. a light source, a motor, or electronic circuitry) and a power source.
Given the electrical purpose of the switch, the deployment of the device in harsh environments can be problematic. For example, in outdoor applications, debris and moisture can work their way into the switch and cause unreliable operation. In some applications, the switch is submerged in a liquid, such as water. In these applications, the submerged switch may need to be hardened to resist environmental intrusion. This may be especially of interest for a rotary switch where an environmental seal that accommodates submerged rotary motion is typically used.
One approach to this submerged environment for a rotary switch is provided by the Model 1811-100 rotary switch, as available from the Hydracon Company, Inc. of Anaheim, Calif. This rotary switch comprises a plurality of O-ring seals to provide protection from the submerged environment.
Generally, an underwater device may include a waterproof housing defining a dry cavity therein and comprising a nonferrous switch interface wall. The underwater device may include a rotary switch within the dry cavity and comprising a switch body, and a switch shaft extending outwardly from the switch body. The underwater device may include a first magnetic body within the dry cavity and coupled between the switch shaft and the nonferrous switch interface wall, and a second magnetic body external from the waterproof housing and adjacent the nonferrous switch interface wall in alignment with the first magnetic body so that rotation of the second magnetic body rotates the switch shaft. Each of the first magnetic body and the second magnetic body may comprise a permanent magnet.
Also, the underwater device may include a cap coupled to the second magnetic body. The underwater device may include a detent feature defined between the waterproof housing and the cap. The underwater device may include a retainer coupling the second magnetic body to the waterproof housing.
More specifically, the waterproof housing may define a first recess adjacent the nonferrous switch interface wall rotatably receiving the first magnetic body therein. The waterproof housing may define a second recess adjacent the nonferrous switch interface wall rotatably receiving the second magnetic body therein.
The underwater device may include a switch retainer coupling the rotary switch to the waterproof housing. The waterproof housing may be devoid of a penetration associated with the first and second magnetic bodies. The underwater device may include an electrical device coupled to the rotary switch. In some embodiments, the nonferrous switch interface wall may comprise a flat wall.
Another aspect is directed to a switch assembly for an underwater device comprising a waterproof housing defining a dry cavity therein and comprising a nonferrous switch interface wall. The switch assembly may comprise a rotary switch to be positioned within the dry cavity and comprising a switch body, and a switch shaft extending outwardly from the switch body. The switch assembly may comprise a first magnetic body to be positioned within the dry cavity and coupled between the switch shaft and the nonferrous switch interface wall. The switch assembly may further include a second magnetic body to be positioned external from the waterproof housing and adjacent the nonferrous switch interface wall in alignment with the first magnetic body so that rotation of the second magnetic body rotates the switch shaft. Each of the first magnetic body and the second magnetic body may comprise a permanent magnet.
Yet another aspect is directed to a method for making an underwater device. The method may comprise forming a waterproof housing defining a dry cavity therein and comprising a nonferrous switch interface wall. The method may further include coupling a rotary switch within the dry cavity, the rotary switch comprising a switch body, and a switch shaft extending outwardly from the switch body. The method may comprise coupling a first magnetic body within the dry cavity and between the switch shaft and the nonferrous switch interface wall, and coupling a second magnetic body external from the waterproof housing and adjacent the nonferrous switch interface wall in alignment with the first magnetic body so that rotation of the second magnetic body rotates the switch shaft. Each of the first magnetic body and the second magnetic body may comprise a permanent magnet.
The present disclosure will now be described more fully hereinafter with reference to the accompanying drawings, in which several embodiments of the invention are shown. This present disclosure may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the present disclosure to those skilled in the art. Like numbers refer to like elements throughout, and base 100 reference numerals are used to indicate similar elements in alternative embodiments.
The typical rotary switch for submerged applications may have some drawbacks. In particular, these typical approaches may be complicated and expensive to manufacture. Moreover, the use of rotating shafts and one or more O-rings introduces a failure point. In light of the prior art, it may be helpful to provide a switch assembly for submerged applications that is inexpensive to manufacture and reliable.
Referring now to
The switch assembly 108 illustratively includes a waterproof housing 101 defining a dry cavity 102 therein. For example, the dry cavity 102 may be hermetically sealed from the external environment. In some embodiments, the seal of the dry cavity 102 may be to level less than or greater than hermetic. The waterproof housing 101 may comprise a rigid material with enough mechanical strength to resist pressures in any submerged application. For example, the submerged application may comprise a deep water application (e.g. pressure of 200 psi at approximately 150 meters of depth), and the rigid material may comprise stainless steel, or a resin.
The waterproof housing 101 illustratively comprises a first housing section 103a (front facing side), a second housing section 103b (rear facing side), and a plurality of fasteners 104a-104b coupled the first housing section and the second housing section together. In some applications, the second housing section 103b may be mounted onto a device being controlled. The first housing section 103a comprises a flanged rim 105 extending inwardly from a medial section, and a nonferrous switch interface wall 106 within the flanged rim. The first housing section 103a comprises an annular wall 107, and the annular wall and the flanged rim define an annular recess 110, which is part of the dry cavity 102.
Referring now additionally to
The switch assembly 108 illustratively includes a rotary switch 115 within the dry cavity 102 and coupled between the electrical device 113 and the power source 114. The rotary switch 115 illustratively comprises a switch body 116, a switch shaft 117 extending outwardly from the switch body, and a plurality of connection terminals 120a-120d carried by the switch body. The switch assembly 108 illustratively includes a plurality of visual indicators 119a-119c carried by the first housing section 103a and for indicating a state of the rotary switch 115.
In this illustrated embodiment, the number of connection terminals 120a-120d and wire couplers 112a-112d is four (i.e. a 3 position rotary switch with 4 poles), but this is merely exemplary, and other configurations are possible in differing embodiments. The switch assembly 108 includes a switch retainer 121 coupling the rotary switch 115 to the waterproof housing 101 via a plurality of fasteners 118a-118d.
Referring now additionally to
In the illustrated embodiment, both of the first magnetic body 122 and the second magnetic body 123 may each comprise a magnet (i.e. oriented so that the poles are inverted for an attraction magnetic force). For example, the magnet may comprise a permanent magnet.
Referring now additionally to
The switch assembly 108 illustratively includes a cap 126 coupled to the second magnetic body 123. The cap 126 also defines a cap cavity 127 therein receiving the shaft of the second magnetic body 123. More specifically, the cap 126 is coupled to the second magnetic body 123 via a fixation feature (i.e. fixing at least the rotational positioning between the cap and the second magnetic body). For example, the fixation feature may comprise a set screw (
The switch assembly 108 may include a retainer 130 coupling the second magnetic body 123 to the first housing section 103a of the waterproof housing 101. Although not shown, the retainer 130 is coupled to the first housing section 103a via a plurality of fasteners. Helpfully, this retainer 130 is not waterproof and permits fluid to surround the second magnetic body 123 and enter the cap cavity 127. For deep water applications where water pressure is relatively high, this permits pressure equalization and provides for easy movement of the cap 126 by the user 129. Also, the retainer 130 may include a stop portion for limiting the rotational movement of the cap, thereby preventing unintended reverse polarity operations.
In some embodiments, the cap 126 may be readily removed to provide for a hidden switch. In other words, the authorized user 129 may carry the cap 126 and install it on the exposed shaft of the second magnetic body 123 extending through the retainer 130.
Helpfully, in the switch assembly 108, magnetics are used to transfer torque over a gap. The waterproof housing 101 may be devoid of a penetration associated with the first magnetic body 122 and the second magnetic body 123. Since these bodies rotate during normal use, the lack of penetrations may improve reliability. Moreover, the complex rotating O-ring design of the typical rotary switch is avoided, which reduces costs. Also, the switch assembly 108 has a small physical profile, in contrast to the bulky typical switches.
Another aspect is directed to a switch assembly 108 for an underwater device 100 comprising a waterproof housing 101 defining a dry cavity 102 therein and comprising a nonferrous switch interface wall 106. The switch assembly 108 comprises a rotary switch 115 to be positioned within the dry cavity 102 and comprising a switch body 116, and a switch shaft 117 extending outwardly from the switch body, and a first magnetic body 122 to be positioned within the dry cavity 102 and coupled between the switch shaft and the nonferrous switch interface wall 106. The switch assembly 108 further includes a second magnetic body 123 to be positioned external from the waterproof housing 101 and adjacent the nonferrous switch interface wall 106 in alignment with the first magnetic body 122 so that rotation of the second magnetic body rotates the switch shaft.
Yet another aspect is directed to a method for making an underwater device 100. The method comprises forming a waterproof housing 101 defining a dry cavity 102 therein and comprising a nonferrous switch interface wall 106. The method comprises coupling a rotary switch 115 within the dry cavity 102, the rotary switch comprising a switch body 116, and a switch shaft 117 extending outwardly from the switch body. The method comprises coupling a first magnetic body 122 within the dry cavity 102 and between the switch shaft 117 and the nonferrous switch interface wall 106, and coupling a second magnetic body 123 external from the waterproof housing 101 and adjacent the nonferrous switch interface wall in alignment with the first magnetic body so that rotation of the second magnetic body rotates the switch shaft 117.
Referring now additionally to
Also, each of the first magnetic body 222 and the second magnetic body 223 respectively defines a radially extending passageway 233, 234 for receiving a fastener. The fasteners couple the switch shaft 217 to the first magnetic body 222, and the cap 226 to the second magnetic body 223.
Referring now additionally to
Many modifications and other embodiments of the present disclosure will come to the mind of one skilled in the art having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is understood that the present disclosure is not to be limited to the specific embodiments disclosed, and that modifications and embodiments are intended to be included within the scope of the appended claims.
