Note: Descriptions are shown in the official language in which they were submitted.
CA 02637522 2008-07-14
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DIMMER SWITCH
BACKGROUND
Technical Field
[00021 The present invention relates to a switching device used to control
electrical
systems and/or devices and, more particularly, relates to a switch for
selectively adjusting or
varying a state of a current load.
Description ofRelated Art
[0003] Switches and controls for electrical systems and devices have been
developed that
control more than one state of an electrical load or device. While it is now
commonplace for
devices to control a plurality of states, such as the ON/OFF/DI1VI/BRIGHT
state of a lighting
load, the integration of multiple control features in a single device
typically requires more
complicated manufacturing processes to accommodate the different features.
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[0004] The present disclosure relates to an integrated control device that is
simple to
manufacture and less expensive to produce.
SUMMARY
[0005] In an embodiment of the present disclosure, a switching device includes
a paddle
actuator biased to a rest position and configured to pivot relative to a
housing to a depressed
position to engage an air-gap switch disposed within the housing. The air-gap
switch is
configured to change a first state of a load connected to the switching device
upon engagement
by the paddle actuator. The paddle actuator is defined by a pair of opposing
long sides and a pair
of opposing short sides and has at least one slot defined therein parallel to
the pair of opposing
short sides thereof and centrally disposed between the pair of opposing long
sides thereof. A
rocker actuator is disposed in the at least one slot and is configured to
pivot relative thereto to
engage at least one switch. The at least one switch is configured to change a
secbnd state of the
load connected to the switching device upon engagement by the rocker actuator.
[0006] According to another embodiment of the present disclosure, a switching
device
includes a paddle actuator biased to a rest position and configured to pivot
relative to a housing
to a depressed position to engage an air-gap switch disposed within the
housing. The air-gap
switch is configured to change a first state of a load connected to the
switching device upon
engagement by the paddle actuator. The paddle actuator is defined by a pair of
opposing long
sides and a pair of opposing short sides and has at least one slot defined
therein parallel to the
pair of opposing short sides thereof and centrally disposed between the pair
of opposing long
sides thereof. A rocker actuator is disposed in the at least one slot and is
configured to pivot
relative thereto to engage at least one switch. The at least one switch is
configured to change a
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second state of the load connected to the switching device upon engagement by
the rocker
actuator. A light pipe is operably coupled to the rocker actuator and has a
plurality of LEDs
disposed thereon configured to indicate at least one of the first state and
the second state of the
load connected to the switching device upon the actuation of at least one of
the paddle actuator
and the rocker actuator.
BRIEF DESCRIPTION OF THE DRAWINGS
[00071 Various embodiments of the presently disclosed switching device are
described
herein with reference to the drawings wherein:
100081 FIG. 1 is a perspective view of a switching device in accordance with
the present
disclosure having paddle actuator which incorporates a rocker-like intensity
control disposed
therein;
[0009] FIG. 2 is a perspective view of a housing for mechanically supporting
the paddle
actuator of FIG. 1;
[00010] FIG. 3 is a partial cross sectional view of an actuating assembly
operatively
associated with the switching device of FIG. 1;
[00011] FIG. 4 is a perspective view of an actuator of the actuating assembly
of FIG. 3;
[00012] FIG. 5 is a top view showing a circuit board operatively coupled to
the actuating
assembly and the switching device of the present disclosure;
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1000131 FIG. 6 is a partial cross sectional view showing the relative movement
of a
power/disengagement switch for use with the switching device of the present
disclosure;
[00014] FIG. 7 is a partial cross sectional view showing the relative movement
of a micro-
switch in accordance with the present disclosure;
[000151 FIGS. 8 and 9 are side views showing the relative movement of the
power switch
relative to the housing;
[00016] FIGS. 10 and 11 are perspective views of a switching device in
accordance with
embodiments of the present disclosure;
[00017] FIG. 12 is a perspective view of an actuator operatively associated
with the
switching device of FIG. 11; and
[00018] FIG. 13 is a top' view showing a circuit board operatively coupled to
the
switching device of FIG. 11.
DETAILED DESCRIPTION
[00019] Particular embodiments of the present disclosure are described
hereinbelow with
reference to the accompanying drawings wherein like reference numerals
identify similar or
identical elements. In the following description, well-known functions or
constructions are not
described in detail to avoid obscuring the present disclosure in unnecessary
detail.
[000201 The switching device described herein in accordance with the present
disclosure
relates to a dimmer-like switch characterized by a large paddle actuator
having an intensity
actuator embedded therein. The paddle actuator is substantially rectangular in
shape having a
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pair of opposing long sides and top and bottom short sides. The paddle
actuator is biased to a
rest position by a one or more springs (e.g., leaf springs) formed in a sub-
panel below the paddle.
A user may press the paddle to overcome the bias and cause the paddle to
rotate about one or
more pivots to a depressed position wherein an ON/OFF switch is actuated. When
released, the
paddle returns to a biased rest position. Thus, the ON/OFF switch is actuated
only momentarily.
In this way, the paddle has a depressed position and a rest position rather
than alternating
between an "ON" position and an "OFF" position common to most household
switches.
[00021J As mentioned above, an intensity actuator is disposed on a surface of
the paddle
actuator and is configured to rock about one or more additional pivots. The
intensity actuator is
biased to a rest position by one or more springs formed in the sub-panel.
Springs are configured
to bias the intensity actuator in a neutral, generally central position. A
user may press the
intensity actuator to overcome the bias of either leaf spring to adjust
(decrease or increase)
intensity as desired. More specifically, this action may be configured to
change the state of a
load connected to the switching device from DIM to BRIGHT and/or any one or
more levels
therebetween (e.g., greater than DIM and.less than BRIGHT). When the intensity
actuator is
released, it returns to the neutral position.
[000221 The intensity actuator is located within an opening defined in the
paddle actuator
and is configured to operate independently of the paddle actuator. In
embodiments, the opening
is defined horizontally relative to the paddle actuator. That is, the opening
is defined parallel to
the top and bottom short sides of the paddle actuator. Further, opening may be
defined close to
the top short side of the paddle actuator or, alternatively, close to the
bottom short side of the
paddle actuator.
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[000231 Referring now to FIGS. 1, 2, and 4, depicted therein is a switching
device
generally identified as reference numeral 10 which includes a housing 104, a
housing cover 102,
and a paddle actuator 100. The paddle actuator 100 includes an opening 112
defined
therethrough which is dimensioned to receive a light pipe 111 and a rocker
switch 108 therein.
The paddles actuator 100 includes a series of mechanical interfaces 110A, 110B
and 1 l OC which
matingly engage a corresponding number of mechanical interfaces (slots 144,
146 and 148) to
maintain the paddle actuator 100 in pivotable relationship with the housing
104. A paddle
actuating tab 113 (described in more detail below) includes locking elements
113C which
mechanically interface with a corresponding slot 125 defined within the
housing cover 102. The
paddle actuator may optionally also include a light 114 (light emitting diode
("LED")) embodied
therein and configured to provide a visual status of the switching* device.
Alternatively, more
than one light 114 can be provided which turn on and off sequentially upon
pressing rocker
switch 108. The paddle actuator 100 is configured to be installed in
conjunction with a faceplate
106 adapted to mechanically engage the housing 104 which, in turn, is
installable within a
standard electrical switch box.
1000241 Referring now to FIGS. 2, 3, and 5, a perspective view of the housing
cover 102 is
depicted showing the so-called neutral orientation of the rocker switch 108.
As shown in FIG. 3,
the housing cover 102 includes leaf springs 138, 140 which are movable to
electromechanically
engage contacts 134a and 136a disposed in housing 104. The light pipe l 11 may
be formed as
an integral part of the housing cover 102 and illuminates to facilitate user
control of the rocker
switch 108. As mentioned above, housing cover 102 also includes slots 144, 146
and 148
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formed therein which are positioned to engage corresponding interfaces 110A
1lOB, 110C,
respectively, in a snap-fit manner.
[00025] With continued reference to FIG. 2, the light pipe 111 extends
outwardly from the
surface of the housing cover 102 and includes a peg 142A configured and
dimensioned to be
received within a pivot aperture 108a defined through rocker switch 108 to
support rocker switch
108 in a pivot-like manner. As shown in FIG. 3, the rocker switch '108 is
mounted to move leaf
springs 138 and 140 into contact with contacts 134a and 136a when rotated
about peg 142A.
Light pipe 111 has legs 111 A, 111 B, 111 C, 111 D, 111 E, 111 F, and 111 G
which are configured
to stabilize the rocker switch 108 during rotation thereof.
[00026] FIG. 3 shows the interaction of rocker switch 108 with leaf springs
138 and 140
(shown in phantom representation). Each contact 134a and 136a is operably
connected to a
corresponding micro-switch 134 and 136 respectively. The contacts 134a and
136a may be
spring-loaded to enhance tactile feel of the rocker switch 108 through a range
of motion. In
other words, when rocker switch 108 is depressed to pivot, the leaf spring,
e.g., 138, engages
contact 136a which, in turn, pushes down to activate micro switch 136. Upon
release of rocker
switch 108, leaf spring 138 recoils back to a neutral or original position
allowing contact 136a of
micro switch 136 to spring back into position. Pivoting rocker switch 108 in
the opposite
direction, causes a similar effect on micro switch 134.
[00027] Light pipe 111, peg 142A, leaf springs 138 and 140, and micro-switches
136 and
134 together form a rocker switch assembly that, when activated, may be used
to control the
intensity of a light, the relevant speed of a fan, the temperature setting of
a thermostat, or any
other similar electrical device and/or system connected to the switch of the
present disclosure. In
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embodiments, light pipe 111, peg 142A, leaf springs 138 and 140, and micro-
switches 136 and
134 together fonn a rocker switch assembly that, when activated, may be used
to actuate an
ON/OFF switch.
[00028] Referring now to FIG. 4, a rear perspective view of the paddle
actuator 100 shown
in FIG. 1 is depicted. Integrally formed on the rear of paddle actuator 100 is
a power switch
actuator tab 110. It should be understood that the power switch (not
explicitly shown) can be
implemented with an air-gap switch actuating tab 110C and corresponding air
gap switch
interface 248 adapted to disconnect a power line from one side of a switch or
other device when
oriented in an open orientation. It will be readily understood that the power
switch can be
implemented with other types of switches and is not limited to an air-gap
switch. Formed on
actuator tab 110 are mechanical interfaces 110A, 110B, and 110C. Also formed
on paddle
actuator 100 is a switch actuating tab 113A and a paddle locking tab 113. As
mentioned above,
paddle locking tab 113 includes mechanical interfaces 113C which operatively
lock the paddle
actuator 100 to housing cover 102.
[00029] Referring now to FIG. 5, depicted therein is a printed ci'rcuit board
131. Certain
elements of printed circuit board 131 are positioned to engage corresponding
elements of the
paddle actuator 100 of FIG. I and housing cover 102 of FIG. 2. That is, when
switch 10 is
assembled, housing cover 102 is sandwiched between paddle actuator 100 and
printed circuit
board 131. Paddle actuator 100, housing cover 102, and circuit board 131 are
operatively
coupled to each other to form a sub assembly within housing 104 to complete
the switching
device 10 of FIG. 1. As shown in FIG. 5, printed circuit board 131 includes a
micro switch 132
having a spring-loaded plunger 132A. In embodiments, the power switch (not
explicitly shown)
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may be implemented with an air-gap switch actuating tab. In embodiments, air-
gap switch' may
be mounted on another printed circuit board (not explicitly shown) located
relative to printed
circuit board 131 or may be integrally-associated with printed circuit board
131.
[00030] An air-gap switch interface 248 extends through a cut out in printed
circuit board
131 as shown. Micro-switches 134 and 136 and their corresponding spring-loaded
plungers
134A and 136A are also disposed on printed circuit board 131 and positioned to
correspond to
the placement of leaf springs 138 and 140 (FIG. 2), respectively. LEDs 534,
536, 538, 540, 542,
544 and 546 are positioned to correspond to the locations of the legs 111 A-G
of light pipe 111
(FIG. 2) such that when housing cover 102 and circuit board 131 are
cooperatively assembled,
each corresponding LED 534, 536, 538, 540, 542, 544 and 546 is positioned
directly beneath a
corresponding leg 111 A-G of light pipe 111.
1000311 In use, when rocker switch 108 is depressed to pivot, any one or more
of LEDs
534, 536, 538, 540, 542, 544, and 546 is configured to illuminate to provide a
visual status of a
load connected to the switching device 10. By way of example, a first
depression of rocker
switch 108 may illuminate LED 546 and a second depression of rocker switch 108
may
illuminate LED 544 and turn off LED 546. Alternatively, the second depression
of rocker switch
108 may illuminate LED 544 such that LEDs 546 and 544 are illuminated
simultaneously and/or
in sequence from left to right. In this scenario, each subsequent depression
of rocker switch 108
illuminates the LED to the right (e.g., LED 542, LED 540, etc.) or the LED
following the LED
illuminated by the_previous depression of rocker switch 108 (e.g., a third
depression of rocker
switch 108 illuminates LED 542). In embodiments, LEDs 534, 536, 538, 540, 542,
544, and 546
may illuminate individually or in sequence from right to left. For example, a
first depression of
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rocker switch 108 may illuminate LED 534 and each subsequent depressions of
rocker switch
108 illuminates the LED to the left (e.g., LED 536, LED 538, etc.) or the LED
following the
LED illuminated by the previous depression of rocker switch 108.
[00032] In embodiments, paddle actuator 100 may be configured to cause any one
or more
of LEDs 534, 536, 538, 540, 542, 544, and 546 to illuminate in the same manner
as described
above with respect to rocker switch 108 (e.g., individually, sequentially from
right to left,
sequentially left to right, or any other possible combination, etc.). The
seven LED 534, 536, 538,
540, 542, 544, and 546 configuration (FIG. 5) and corresponding seven leg 111A-
G
configuration (FIG. 2) are illustrative only. That is, the switching device 10
may include any
suitable number of LEDs and corresponding legs (e.g., 3, 5, 9, etc.) as would
be necessary to
effect the switching device 10 operating as intended and in accordance with
the present
disclosure.
[00033] With retumed reference to FIG. 2, housing cover 102 has a slot or an
opening 148
defined therethrough positioned such that actuator tab 110C of air-gap
actuator 110 (FIG. 4)
extends to engage air-gap switch interface 248 (FIG. 5) when housing cover 102
is mated with
paddle actuator 100 and circuit board 131. If the air-gap switch is not closed
by virtue of the
paddle actuator 100 being physically incorporated atop housing cover 102,
energy will not flow
through the switching device electrical elements to operate the switching
device 10.
[00034) FIG. 6 shows the details of the air-gap switch actuating tab 110c and
interface
248. As depicted, when paddle actuator 100, housing cover 102 and circuit
board 131 are
cooperatively assembled, pressing paddle actuator 100 in the direction
indicated by directional
arrow 153 extends air-gap switch actuating tab 110c of air-gap actuator 110
through opening 148
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in housing cover 102 to engage spring-loaded lever 248A of air-gap switch 248.
It should be
understood that the operation of air-gap switch 248 can be the reverse of the
above description.
That is, when the paddle actuator 100 is depressed, air-gap switch 248
connects the power line
(not explicitly shown) to the switch 10 and when paddle actuator 100 is pulled
outward from the
rest position to a pulled out position, the air-gap switch 248 disconnects the
power line from the
switch 10. Pulling paddle actuator 100 from the rest position to the pulled
out position may be
accomplished by pulling the bottom portion of paddle actuator 100 in the
direction indicated by
directional arrow 157 in Fig. 9 to pivot paddle actuator 100 about mechanical
interfaces 110B
and/or rotate paddle actuator 100 in the clock-wise direction from the rest
position. Rotation of
paddle actuator 100 in the clock-wise direction from the rest position to the
pulled out position
may also be achieved by depressing a top portion of paddle actuator 100 by
applying sufficient
force thereto. Optionally, a detent (not shown) may be provided such that when
paddle actuator
100 is pulled and the air-gap switch 248 disconnects power to the switch 10,
the paddle actuator
100 will remain in a pulled out position.
[00035] When paddle actuator 100, housing cover 102 and circuit board 131 are
cooperatively assembled, paddle actuator 100 pivots along mechanical
interfaces 110A, 110B
which are snap-fit into wells 144 and 146, respectively. Located directly
beneath the point of
resilient contact between tab 113A and leaf spring 124 is micro-switch 132 and
spring-loaded
plunger 132A. This arrangement, depicted in FIG. 7, brings actuating tab 113A
into resilient
contact with a leaf spring 124 formed in housing cover 102 (see FIGS. 2, 4,
and 7) to actuate the
spring-loaded plunger 132A disposed in housing 104 which activates micro-
switch 132 to
connect the switching device 10 to line phase or electrical power or interrupt
connection of the
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switching device 10 to line phase or electrical power. This action changes the
state of a load
connected to switch 10 from OFF to ON or vice-versa. In embodiments, this
action may be
configured to change the state of a load connected to switch 10 from DIM to
BRIGHT and/or
any one or more levels therebetween (e.g., greater than DIM and less than
BRIGHT).
[00036] The sloping ramp configuration of locking surface 113C shown in FIGS.
8 and 9
permits retraction of tab 113 and locking surface 113C from opening 125 (FIG.
2) when
sufficient force is applied to a bottom portion of paddle actuator 100, as
shown in FIG. 9.
[000371 Still referring to FIG. 9, when the bottom portion of paddle actuator
100 is pulled
in the direction indicated by directional arrow 157, surface 113C disengages
from tab 124 and
permits paddle actuator 100 to pivot about mechanical interfaces I 10B and/or
rotate in the clock-
wise direction.
[00038] Referring now to FIG. 10, another embodiment of the present disclosure
is shown
depicting another dimmer switch. This dimmer switch includes a housing 104, a
housing cover
102, and a paddle actuator 100. The paddle actuator 100 includes an opening
112 defined
therethrough which is dimensioned to receive a light pipe 111 and a rocker
switch 108 therein.
In the illustrated embodiment, light pipe 111 is disposed below rocker switch
108.
[000391 Referring now to FIG. 11, another embodiment of the preserit
disclosure is shown
depicting another dimmer switch This dimmer switch includes a housing 104, a
housing cover
102, and a paddle actuator 100. The paddle actuator 100 includes an opening
112 defined
therethrough which is dimensioned to receive a light pipe 111 and a rocker
switch 108 therein.
A rear perspective view of the paddle actuator 100 shown in FIG. 11 is
depicted in FIG. 12.
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[00040] Referring now to FIG. 13, depicted therein is a printed a circuit
board 131 having
certain elements positioned to engage corresponding elements of the paddle
actuator 100 and
housing cover 102 of FIG. 11.
[00041] While several embodiments of the disclosure have been shown in the
drawings
and/or discussed 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.
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