CA2902518A1 - Integrated cover plate and sensor system - Google Patents

Abstract

There is provided an integrated cover plate & sensor system (ICPSS) and apparatus for mounting sensors, controls and displays to a vertical surface. The ICPSS
houses these electronic devices, a power supply and interfaces in an enclosure. The enclosure is fabricated so that it may be mounted directly to an electrical switch or outlet that typically resides in a utility box in place of a standard cover-plate.

Description

TITLE
INTEGRATED COVER PLATE AND SENSOR SYSTEM
CROSS REFERENCE TO RELATED APPLICATIONS
[00011 This Application claims priority on U.S. Provisional Application No.
62/043,256, now pending, filed on August 28, 2014, which is herein incorporated by reference.
FIELD

[0002] The present subject-matter relates to an apparatus for providing enhanced environmental sensors and mounting options in a residential or commercial building.
IN

[0003] Many existing residential homes and commercial buildings have environmental sensors that provide measurements such as temperature, humidity, occupancy, motion, vibration, proximity, air quality, light levels etc., and which are often wall mounted. These same sensors are often integrated into heating, ventilation and air conditioning, cooling (HVAC) systems or into Alarm or Home or Building Automation systems. Likewise, the sensors may also be physically combined with control elements for user input, as in a wall-mounted thermostat, and may also include a display capability. The sensors and associated electronics may be powered from a source such as a battery or an energy harvesting system, using solar or RF energy. for example. Many of these other system components may also be wall mounted in some manner.

[0004] In some cases, these system components have provisions for mounting onto specially installed empty electrical utility boxes that follow national building or electrical code standards. In other cases, the system components have mounting methods such as adhesive backing strips or require fasteners such as wall anchors for mounting, thereby requiring holes to be drilled in the wall to install the apparatus.

[0005] In the case where this type of apparatus is to be moved, removed or replaced, problems may arise as the wall surface integrity or paint finish may have been damaged by the installation and will require repair. Preparing the wall for a new utility box or fasteners adds to the overall system expense during installation. Likewise a variety of different tools may need to be employed, which require skilled operation. Furthermore, different systems or system components provided by a range of suppliers and using different methods for mounting may be deployed within the same building or residence. These issues may add to the expenses of a subsequent building owner who wishes to install or replace said systems or system components.
Likewise, a building occupant who wishes to remove a system may have to deal with repairs to a wall or finish before vacating.

[0006] There are some known devices that use the cover plate on an existing light switch to house a secondary electronic or electrical device. For example, U.S.
Patent No.
5,914,826 A (1999) entitled "Light switch cover plate with audio recording and playback feature", provides a voice recording function housed in a light switch cover.
U.S. Patent No.

7,581,844 B1 (2009), entitled "Switch cover plate with lighting mechanism", provides a lighting function in the switch cover. U.S. Patent No. 7,321,120 B1 (2008), entitled "Motion Detector Module", describes a single motion detector that occupies an un-used electrical utility box and connects to the AC wiring. PCT Publication No. WO 1998049492 Al (1998), entitled "Switch cover plate providing automatic emergency lighting-, provides an emergency lighting function.
However, none of these devices appears to provide a means to mount all sensors needed for the control and monitoring of HVAC systems on a wall in an otherwise occupied utility box.
[0007] Thus, while the use of different types of sensors, thermostats, displays and controls is widely known in the art, there remains a need to improve the means of installing such system components on a wall or specifically on an occupied utility box.

SUMMARY

[0008] It would thus be desirable to provide a novel integrated cover plate and sensor system.

[0009] The embodiments described herein provide in one aspect an Integrated Cover Plate & Sensor System (ICPSS). comprising at least one type of a sensor, a power source, interface electronics and an enclosure, wherein the enclosure is mounted onto an electrical outlet or electrical switch situated within a utility box and acts as the safety cover for the utility box.

[00010] In an aspect, there is described generally a system and apparatus that provide a means of mounting sensors, controls and displays on a wall that has an electrical utility box used to house a wall switch or other electrical devices. More specifically, there is described a system and apparatus in which all said sensors, controls and displays are integrated into a protective cover plate for a wall switch that is installed on or in the utility box. Many countries have a very limited number of standard wall switch thrmats that utilize surrounding covers for both safety and decorative purposes. From a safety perspective, they cover any exposed parts that may have or the potential to have dangerously high voltage. Typically, these are called "cover plates" or "switch plates". These existing covers employ one of more fasteners to hold the cover plate in place tight around the existing electrical fixture and flush to the surrounding wall surface. With the exception of an empty utility box, the cover plates are normally connected directly to the electrical appliance outlet or switch which has threaded machine holes to accommodate mounting of the cover plate. FIGS. 1, 2,4 and 5 show examples of cover plates commonly known in the art.

[00011] Accordingly, there is provided a mounting system for sensors &
associated controls and displays called the integrated cover plate & sensor system (ICPSS). The ICPSS
typically has the lateral dimensions of a standard cover plate that attaches to an existing light switch, taking advantage of the pre-existing cover plate fasteners or provisions for fasteners, or machined threaded holes, to secure it in place. The ICPSS may thus be installed on a wall over an existing light switch without the need to attach any new fasteners to the wall. The ICPSS
maintains the benefits of safety and isolation from potentially dangerous high voltage provided by a conventional cover plate. The ICPSS housing contains the components required to operate environmental sensors and/or controls and/or display(s) and/or batteries and/or energy harvesting power systems required for 11 VAC or Alarm or Home Automation Systems and has support for secondary encapsulated covers or housings unique to the type of switch it is mounted on. Light switches are installed at locations and heights above the floor, usually specified in the local or national electrical codes, which are convenient for human operation. A
further 'feature of using an existing light switch as the mounting point for the ICPSS is that this mounting height is also beneficial for the operation of sensors, such as proximity and ambient light sensors, and 'for human interaction with other controls and displays that may be part of the sensor system.
BRIEF DESCRIPTION OF THE DRAWINGS

[00012] For a better understanding of the embodiments described herein and to show more clearly how they may be carried into effect, reference will now be made, by way of example only, to the accompanying drawings which show at least one exemplary embodiment, and in which:

[00013] FIG. 1 is a front elevation of a conventional toggle switch cover plate;

[00014] FIG. 2 is a perspective view of a conventional Decora switch cover plate manufactured by Leviton Manufacturing Company, Inc.;

[00015] FIGS. 3a and 3b are front perspective views of a conventional toggle switch;

[00016] FIGS. 3c and 3d are rear perspective views of the conventional toggle switch of FIGS. 3a and 3b;

[00017] FIGS. 4a, 4b and 4c are respectively rear, rear and front perspective views of a conventional toggle switch with a cover plate attached thereto;

[00018] FIGS. 4d. 4e, 4f, 4g and 4h are respectively top plan, rear elevation, left side elevation, front elevation and right side elevation views of the conventional toggle switch with a cover plate of FIGS. 4a to 4c;

[00019] FIG. 5 is a partly exploded view of a conventional toggle switch cover plate connected via fasteners to a switch body residing inside of a utility box;

[00020] FIG. 6 partially' shows the layout of a printed circuit board of an integrated cover plate & sensor system (ICPSS) in accordance with an embodiment thereof;

[00021] FIGS. 7a and 7b are respectively front and rear exploded views of the ICPSS
mounted on a Decorat type light switch in accordance with an embodiment thereof;
5 [00022] FIGS. 7c and 7d are respectively rear perspective and front perspective views of the ICPSS mounted on a Decora0 type light switch of FIGS. 7a and 7b;
[00023] FIGS. 7e, 7f and 7g are respectively front perspective, rear perspective and rear perspective views of parts of the assembly of FIGS. 7a to 7d;
[00024] FIGS. 8a and 8b are respectively front and rear exploded views of the ICPSS
mounted on a toggle type switch in accordance with an embodiment thereof;
[00025] FIGS. 8c and 8d are respectively rear perspective and front perspective views of the ICPSS mounted on a toggle type switch of FIGS. 8a and 8b;
[00026] FIGS. 8e, 81 and 8g are respectively' front perspective, rear perspective and rear perspective views of parts of the assembly of FIGS. 8a to 8d;
[00027] FIGS. 9a and 9b are respectively front and rear exploded views of a version of the ICPSS for ganged utility boxes, in accordance with another embodiment;
[00028] FIGS. 9c and 9d are respectively rear perspective and front perspective views of the ICPSS for ganged utility boxes of FIGS. 9a and 9b;
[00029] FIG. 9e, 91 and 9g are respectively front perspective, rear perspective and rear perspective views of parts of the assembly of FIGS. 9a to 9d;
[00030] FIGS. 10a and 10b are respectively front and rear exploded views of the ICPSS
with an apparatus blank for use with empty utility boxes, in accordance with yet another embodiment;
[00031] FIGS. 10c and 10d are respectively rear perspective and front perspective views of the ICPSS with an apparatus blank for use with empty utility boxes of FIGS.
10a and 1.0b;
[00032] FIG. 10e, 10f and 10g are respectively' front perspective, rear perspective and rear perspective views of parts of the assembly of FIGS. 10a to 10d; and [00033] FIG. 11 is a schematic block diagram showing details of the ICPSS.

DESCRIPTION OF VARIOUS EMBODIMENTS
[00034] A detailed description of an embodiment of the Integrated Cover Plate & Sensor System (ICPSS) follows and for convenience, and as an example, references the operation of the system when installed as part of a IIVAC single thermostat zone control system, such as = described in the applicants co-pending U.S. patent application No.
14/018,674, which is herein incorporated by reference.
[00035] Firstly, in order to provide a better understanding of the present subject-matter, the operation of a single thermostat zone control system (STZC) of U.S. patent application No.
14/018,674 will now be described. The STZC system has a single thermostat used to control the temperature in all zones of a building so that the user is presented with a single familiar control interface to establish the desired temperatures in all zones. A zone is generally defined as a space separated from other spaces, perhaps by a door or simply by size or by being on separate floors of the building. Zones may also be differentiated by one or more spaces affected by the outside environment, for example sunlight warming air through a window or differentiated by the amount of occupancy by people. The STZC uses actively controlled air handling vents with localized associated environmental sensor units to strive to provide a uniform environment that could be differentially stratified due to, for example, multiple building floors affected by air flow convection, thermal conduction, sunlight and other external environmental factors.
[000361 In order to determine the conditions throughout the building, the STZC system requires that a sensor unit be installed in each zone. The sensors are, in an STZC system, preferably wall mounted in order to be able to optimally detect proximity, temperature and ambient light levels. These sensor units may be battery powered and comprise multiple sensor & transducer types singularly controlled by a co-located micro-controller.
Examples of the sensor types for this application are temperature and relative humidity transducers and an IR
motion detection and light level sensor. The micro-controller periodically communicates sensor readings wirelessly to a central controller.
[00037] In an embodiment of the Integrated Cover Plate & Sensor System (1CPSS). one or more sensors, such as those needed to monitor the zones in the STZC
described above, are assembled into a mechanical housing that can be used as a switch cover and installed onto an existing electrical switch, replacing the conventional switch cover. The utility boxes for light switches are located at a height determined by local electrical codes, which is ideal for the location of the zone sensors in the Sift. The ICPSS can thus be installed without the need to drill any new holes or attach adhesives to the wall.
[00038] The mechanical design of the ICPSS accommodates the utility box and the installed light switch. A number of different designs of cover plates for a switch are currently in use in North America. FIG. I illustrates a wall toggle switch cover 10 widely used in North America and currently available commercially. FIG. 2 is shows a wall switch cover 20 used in North America and commonly referred to by the trade name Decora also available commercially. FIGS. 3a to 3d show a typical toggle wall switch 30.
[00039] FIGS. 4a to 4h illustrate an assembly 40 including a toggle wall switch, such as 30, oriented with a cover plate, such as 10. FIG. 5 illustrates an assembly 50 including a toggle wall switch 52 mounted in a typical electrical utility box 54.
[00040] A common feature of the cover plates is that the switch is located in a hole in the center of the cover plate, such as 10 and 20. The surrounding surface of the cover plate provides a surface area where the sensors, electronics and battery are located in the ICPSS. In the ICPSS
the electronic components are housed on a Printed Circuit Board (PCB) that is covered by the ICPSS enclosure. This enclosure may be made from molded or printed plastic or other non-conductive material that provides for adequate RF propagation with respect to the integrated radio.
[00041] FIG. 6 indicates portions of a physical layout of a main Printed Circuit Board (PCB) 601 that mounts inside of the ICPSS enclosure using two fasteners at locations indicated by 602. A motion sensor assembly with IR. lens is situated at the location indicated by 603. The location indicated at 604 is where temperature & humidity sensors are located, which have access via vents in the overall enclosure. The location indicated at 605 is where a light sensor is located, which has access via a hole in the overall enclosure. Batteries 606 for the ICPSS are attached to the PCB via a connecter at the location indicated.
[00042] FIGS. 7a and 7b are exploded views of the ICPSS assembly orientated with a typical electrical utility box 701 and a Decorag style switch 702 both of which are commercially available. Fasteners 712 are the normal and usual fasteners provided by the switch supplier and hold the switch 702 to the utility box 701. A ICPSS
insulated gasket 703 protects a PCB assembly 705 from contacting the electrical switch. Fasteners that hold the PCB
assembly 705 to the ICPSS enclosure are shown at 704. An IR motion sensor mounted on the PCB has a lens 706 that protrudes through a corresponding hole 715 on an enclosure housing 707. Batteries 711 clip into friction fit holders of the ICPSS enclosure indicated at location 708.
Holes to allow light to enter and leave the ICPSS enclosure are indicated at location 709 to serve the LED indicators and the ambient light sensor. Vents to allow airflow into the enclosure are indicated at location 710 and serve the needs of the temperature and humidity sensors.
Fasteners 713 hold the ICPSS enclosure to the switch 702 via the normal and usual switch cover plate threaded holes.
[00043] FIGS. 8a and 8b are exploded views of the ICPSS adapted for use with a typical wall toggle switch 805. When the ICPSS is deployed on a toggle type switch an injection molded toggle switch adapter plate 801 is used to mimic the face of a Decorag type switch.
The toggle switch adapter plate 801 is mounted on the body of the switch with fasteners 802.
The ICPSS assembly is subsequently then mounted with the fasteners shown as 713 & 803 to the toggle switch adapter plate.
[00044] FIGS. 9a and 9b are exploded views of the ICPSS made for use with ganged utility boxes, where the ICPSS enclosure 902 and gasket 901 are larger to suit the additional width of the utility box.
[00045] FIGS. 10a and 10b are exploded views of the ICPSS with an apparatus blank 1001 for use with empty utility boxes. The apparatus blank 1001 inserts into the ICPSS
enclosure using self-locking tabs 1002. The ICPSS mounts onto an adapter plate 1003, which is first mounted to the utility box.
1000461 F1G. 11 is a schematic block diagram showing details of the ICPSS which is contained within a housing 1101. Sensors 1102. 1103. 1104 and 1105 are connected to a Central Processor Unit (CPU) 1107 via a serial bus 1106.
[00047] The CPU 1107 has the capability' to periodically suspend and then reactivate operation based upon an internal timer facility, which allows the circuit to conserve battery power via a DC Power Manager 1112. The CPU 1107 is used to implement the control algorithm for the ICPSS. The control algorithm and other system parameters are stored in a digital memory 1109 connected to the CPU 1107. Alternatively, the control algorithm may be pre-programed on the CPU 1107 before assembly. The rear temperature sensor 1105 provides an independent measurement of the temperature with respect to main temperature sensor 1104 and can be used by the algorithm to nullify the differential effects of the temperature of the connected wall to the zone air temperature.
[00048] A local communications port 1115, such as a USB port, is provided to allow an external computer to be connected to the ICPSS for factory test and diagnostic purposes.
Alternatively, a LCD display with a touch screen input 1110 may be used for these purposes as well as operational control. Neither the external computer nor the touch screen is required to configure the ICPSS during the system installation or initial operation. The display and touchscreen 1110 may also be used to provide status information for users within in close proximity and provide the ability to manipulate system parameters. The display and touchscreen 1110 are connected to the CPU by an I/0 device that provides refresh capability as well as human proximity detection. The user interface may be further enhanced by providing audible digitally streamed or synthesized sound, for example when used as part of a communications facility or other central facility where bi directional sound would be applicable.
[00049] The wireless transceiver 1111 provides reliable secure communications between the ICPSS and the central controller. Additionally, an IR transceiver could also be used for communications with appliances such as wall-mounted air conditioning units or entertainment systems that are equipped to receive commands via IR remote control devices.
LEDs 1108 are used to display alarm, fault conditions or normal operational states. The reset switch when momentarily activated forces a CPU 1114 processor to stop and restart. The DC
power Manager 1112 monitors the health of the batteries. The ICPSS may also be supplied with a power harvesting circuit 1113 that recharges the batteries by converting radiated power such a solar energy into DC voltage.
[00050] It should be understood that that embodiment of the ICPSS with a STZC system is used as an example and other embodiments may be used in other types of 1-IVAC control systems or for example, facility surveillance alarm systems and/or facility entertainment systems and/or a facility energy conservation systems and/or a facility communication systems and/or a public communications systems and/or a facility automation system or any other system requiring sensors, displays or controls and combinations thereof'. For example, another application of the ICPSS provides sensing capability for a facility surveillance system by incorporating a different set of sensors for audible or ultrasonic sound, vibrations, images, CC) gas, CO2 gas, smoke, natural gas or air pressure.
5 [000511 While the above description provides examples of the embodiments, it will be appreciated that some features and/or functions of the described embodiments are susceptible to modification without departing from the spirit and principles of operation of the described embodiments. Accordingly, what has been described above has been intended to be illustrative of the embodiments and non-limiting, and it will be understood by persons skilled in the art that 10 other variants and modifications may be made without departing from the scope of the embodiments as defined in the claims appended hereto.

Claims (20)

11

1. An Integrated Cover Plate & Sensor System (ICPSS), comprising at least one type of a sensor, a power source, interface electronics and an enclosure, wherein the enclosure is mounted onto an electrical outlet or electrical switch situated within a utility box and acts as the safety cover for the utility box.

2. The ICPSS of Claim 1, where one or more sensors or multiples of sensors include any one of a temperature sensor, a humidity' sensor, an air pressure sensor, an IR
motion sensor, a light level sensor, a sound sensor, an ultrasonic sensor, a vibration sensor, a CO2 sensor, a CO
sensor, a natural gas sensor, a smoke detector, or an image sensor, or any combination of the above sensors.

3. The ICPSS of Claim 1, wherein the interface electronics includes a wireless transceiver that connects into a wireless communications link or mesh network to relay the sensor data to other devices in an external system.

4. The ICPSS of Claim 3, wherein the external system is a single or multiple thermostat HVAC zone control system.

5. The ICPSS of Claim 3, wherein the external system is a facility surveillance system, a facility entertainment system, a facility energy conservation system, a facility communications system, a public communications systems, a facility automation system or any combination thereof.

6. The ICPSS of Claim 5, where the sensors include all the room sensors needed to control an HVAC system or a STZC system or other external system.

7. The ICPSS of Claim 1, wherein the enclosure acts as an electrical switch cover plate or wall outlet cover plate or to replace an existing cover plate.

8. The ICPSS of Claim 1, where the assembly may be made as or as a replacement for outlet and/or switch covers that were designed for two or more switches and/or outlets in a gang arrangement.

9. The ICPSS of Claim 1, where the enclosure accommodates at least one of a conventional toggle switch and a Decorag type switch.

10. The ICPSS of Claim 1, wherein the enclosure is provided with weatherproof seals and/or hoods and is thus adapted to be used for outdoor applications.

11. The 1CPSS of Claim 1, wherein the interface electronics includes a digitally controlled display device capable of displaying alphanumeric letters and graphical images.

12. The interface electronics of Claim 11, wherein the display device includes a touch screen interface integrated within the display device.

13. The interface electronics of Claim 11, wherein a human proximity sensor is used to activate the display device when a human is present in close proximity'.

14. The ICPSS of Claim 1, wherein the interface electronics includes a digitally controlled auditory speaker system capable of projecting digitally streamed sound data and/or digitally recorded sound.

15. The ICPSS of Claim 1, wherein the interface electronics includes one or more LEDs to display installation operational and alarm conditions or states.

16. The ICPSS of Claim 1, wherein the interface electronics includes a removable memory device used for system parameters and event data storage.

17. The ICPSS of Claim 1, wherein the interface electronics includes a USB
interface for local connections.

18. The ICPSS of Claim 1, wherein the interface electronics includes a temperature sensor to measure the ambient temperature of the air in the room in which the ICPSS
is mounted and an additional temperature sensor used to measure the temperature of the connected wall, utility box or structure.

1 9. The ICPSS of Claim 1 , wherein the interlace electronics includes a bidirectional IR or RF transceiver to communicate with remote controls or appliances.

20. The ICPSS of Claim 1, where a temperature sensor is forward mounted near the enclosure vents, to measure the surrounding air temperature and another temperature sensor is rearward mounted to measure the temperature of the connected wall or light switch so that external temperature affects may be considered by the central controller.