CA2637522A1 - Dimmer switch - Google Patents

Abstract

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 leas t one slot defined in the paddle actuator and is configured to pivot relative thereto to engage at least one switch. The at least one switch is configured to change a second state of the load connected to the switching device upon engagement by the rocker actuator.

Description

. z _ 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.

[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

-2-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;

-3-1000131 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

-4-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.

-5-[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

-6-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

-7-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)

-8-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

-9-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

-10-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

-11-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.

-12-[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.

-13-

Claims (19)

WHAT IS CLAIMED IS:

1. A switching device, comprising:

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 configured to change a first state of a load connected to the switching device upon engagement by the paddle actuator, the paddle actuator defined by a pair of opposing long sides and a pair of opposing short sides and having 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; and a rocker actuator disposed in the at least one slot and configured to pivot relative thereto to engage at least one switch, the at least one switch configured to change a second state of the load connected to the switching device upon engagement by the at least one rocker actuator.

2. A switching device according to claim 1, wherein at least one of the first state and the second state of the load is one of a connection of the switching device to a line phase and an interruption of the connection of the switching device to the line phase.

3. A switching device according to claim 1, wherein at least one of the first state and the second state of the load is an intensity of power of a line phase connected to the switching device during at least one of the other states of the load.

4. A switching device according to claim 1, further comprising a light pipe operably coupled to the rocker actuator and having at least one LED configured to indicate at least one of the first state and the second state of the load upon actuation of at least one of the paddle actuator and the rocker actuator.

5. A switching device according to claim 1, further comprising a light pipe disposed on the paddle actuator and having at least one LED configured to indicate at least one of the first state and the second state of the load upon actuation of at least one of the paddle actuator and the rocker actuator.

6. A switching device according to claim 1, further comprising at least one LED disposed on the paddle actuator and configured to provide a visual status of the switching device.

7. A switching device according to claim 4, wherein the light pipe includes a plurality of sequentially disposed LEDs configured to illuminate to indicate at least one of the first state and the second state of the load upon actuation of at least one of the paddle actuator and the rocker actuator.

8. A switching device according to claim 7, wherein the plurality of sequentially disposed LEDs are configured to sequentially illuminate to indicate at least one of the first state and the second state of the load upon actuation of at least one of the paddle actuator and the rocker actuator.

9. A switching device according to claim 7, wherein one of the plurality of sequentially disposed LEDs are configured to illuminate to indicate at least one of the first state and the second state of the load upon actuation of at least one of the paddle actuator and the rocker actuator.

10. A switching device according to claim 1, wherein at least one of the first state and the second state of the load is a fan speed.

11. A switching device according to claim 1, wherein at least one of the first state and the second state of the load is a thermostat setting.

12. A switching device according to claim 1, wherein the air-gap switch is configured to rotate clock-wise from the rest position upon one of pulling a bottom portion of the paddle actuator and depressing a top portion of the paddle actuator to change a first state of a load connected to the switching device.

13. A switching device, comprising:

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 configured to change a first state of a load connected to the switching device upon engagement by the paddle actuator, the paddle actuator defined by a pair of opposing long sides and a pair of opposing short sides and having 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 disposed in the at least one slot and configured to pivot relative thereto to engage at least one switch, the at least one switch configured to change a second state of the load connected to the switching device upon engagement by the at least one rocker actuator; and a light pipe operably coupled to the rocker actuator and having 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 actuation of at least one of the paddle actuator and the rocker actuator.

14. A switching device according to claim 13, wherein at least one of the first state and the second state of the load is one of an ON and OFF state.

15. A switching device according to claim 13, wherein at least one of the first state and the second state of the load is one of a DIM and BRIGHT state.

16. A switching device according to claim 13, wherein the first state of the load is one of an ON and OFF state and the second state of the load is varied between a DIM and BRIGHT state.

17. A switching device according to claim 13, wherein the first state of the load is varied between a DIM and BRIGHT state and the second state of the load is one of an ON and OFF
state.

18. A switching device according to claim 13, wherein at least one of the first state and the second state of the load is one of a connection of the switching device to a line phase and an interruption of the connection of the switching device to the line phase.

19. A switching device according to claim 13, wherein at least one of the first state and the second state of the load is an intensity of power of a line phase connected to the switching device during at least one of the other states of the load.