US3770920A - Rocker-type electrical switch - Google Patents

Rocker-type electrical switch Download PDF

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Publication number
US3770920A
US3770920A US00224880A US3770920DA US3770920A US 3770920 A US3770920 A US 3770920A US 00224880 A US00224880 A US 00224880A US 3770920D A US3770920D A US 3770920DA US 3770920 A US3770920 A US 3770920A
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rocker
brush
contact
base
spring
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US00224880A
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J Poliak
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Leviton Manufacturing Co Inc
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Leviton Manufacturing Co Inc
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H23/00—Tumbler or rocker switches, i.e. switches characterised by being operated by rocking an operating member in the form of a rocker button
    • H01H23/02—Details

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  • ABSTRACT The invention relates to a rocker-type electrical wall switch which is used with alternating current and operates with limited angular movememt of a pivoted rocker. The ends of the rocker remain substantially flush with a wall plate in different operating positions of the rocker.
  • the pivoted rocker tilts a coil spring relative to the plane of a pivoted contact-carrying brush and moves the lower end of the brush into or out of engagement with fixed contacts.
  • Cams on the rocker are also urged into engagement wtth the pivoted brush by the coil spring. The cams hold the lower end of the brush in en 1 agement with one of the fixed contacts under pressure from the spring and increase the load carrying capacity of the switch.
  • the rocker and the brush are pivoted at spaced points in a cover and a base and the pivot points are aligned wih each other on the transverse center line of the switch.
  • the cams on the rocker engage with the pivoted brush at a point which provides a mechanical advantage to forces exerted by the coil spring through the cams in urging the lower end of the brush into engagement with the fixed contact.
  • the present invention relates to an improved rockertype electrical wall switch for use with agruating current. It relates, more particularly, to a rocker-type electrical switch which operates in response to light finger pressure and which is capable of carrying substantial load currents.
  • An object of the present invention is to provide a rocker-type switch which operates with limited angular movement of a pivoted rocker and in response to light pressure being exerted on the ends of the rocker.
  • the limited angular movement of the rocker permits the ends of the rocker to be kept substantially flush with a wall plate in different operating positions of the rocker so that they will not protrude objectionably beyond the wall plate.
  • Another object of the invention is to provide a rocker-type electrical switch in which a movable contact brush is held in firm engagement with an opposing fixed contact under spring pressure so that the switch can handle increased load currents with safety when the contacts are engaged. Another feature of the invention is that stalling of the switch in an open position is minimized.
  • a further object of-the invention is to provide a rocker-type electrical switch which is compact and which can be installed without difficulty in the usual wall box together with the ends of conductor wires which are connected to the switch.
  • Still another object of the invention is to provide a rocker-type electrical switch which is easy to assemble and inexpensive to manufacture.
  • FIG. 1 is a perspective view of an electrical wall switch embodying the invention and a wall plate;
  • FIG. 2 is a vertical section view of the switch and wall plate shown in FIG. 1;
  • FIG. 3 is a top plan view of the base of the switch shown in FIG. 2;
  • FIG. 4 is a fragmentary side view in vertical section of parts of the switch shown in FIG. 2 and which is drawn to an enlarged scale;
  • FIG. 5 is a fragmentary side view in vertical section corresponding to FIG. 4 with operating parts of the switch in different positions;
  • FIG. 6 is a fragmentary view in vertical section taken along transverse center line of the switch shown in FIG. 2 and is drawn to an enlarged scale;
  • FIG. 7 is a fragmentary side view in vertical section of a portion of the switch shown in FIG. 2;
  • FIG. 8 is an enlarged perspective view of parts of contact elements of the switch shown in FIGS. 1 and 2;
  • FIG. 9 is an exploded perspective view of the contact elements shown in FIG. 7;
  • FIG. 10 is a bottom plan view of the cover for the switch shown in FIG. 2;
  • FIG. 11 is afragmentary view in vertical section taken along line 11-11 of FIG. 10;
  • FIG. 12 is a fragmentary view taken along line 12-12 of FIG. 10;
  • FIG. 13 is a bottom plan view of the spacer for the switch shown in FIG. 2;
  • FIG. 14 is a fragmentary side view of the spacer shown in FIG. 13;
  • FIG. 15 is a view in vertical section taken along line 15-15 of FIG. 13.
  • FIG. 1 shows a rocker-type electrical switch 20 which embodies the invention with a wall plate 21 secured to the switch.
  • the switch 20 may be installed in the usual wall box 22 together with the ends of conductor wires (not shown) which connect the switch to a source of alternating current.
  • the switch 20 is supported in the wall or gem box 22 by means of a mounting strap 23 which extends along opposite sides of the switch and also serves to hold the switch together.
  • the ends of the conductor wires which are connected to the switch, are confined within the wall box 22 and the compact dimensions of the switch 20 facilitate such installation.
  • the pivoted rocker 24 has angularly disposed upper faces 243 which diverge from each other at an obtuse angle so that the ends of the faces 24a project only slightly beyond the wall plate 21 in different operating positions of the rocker 24. As shown in the drawings, angular movement of the rocker 24 should be limited to about 20 or less for this purpose.
  • a frame-like cover 25 surrounds the upper faces 24a of the rocker 24 and pivotally supports the rocker 24 at the transverse center line of the cover which is also the transverse center line of the switch. If desired, the frame-like cover 25 and the rocker faces 24a may be made of different colors and may also differ in color from the wall plate ,to provide a decorative appearance for the switch.
  • the pivoted rocker 24 and the framelike cover 25 along with other parts of the switch may be molded from suitable insulating materials and as will be described, the switch is constructed so that identical molding characteristics for the materials used are not required.
  • the switch 20 illustrated is a two-pole switch, but it will be understood that the'same construction can be employed for a single pole switch with minor modifications.
  • the switch 20 may be formed by combining two sub-assemblies, a lower or base assembly 26 and an upper or rocker assembly 27 which simplifies manufacture and assembly operations.
  • the upper or rocker assembly 27 is combined with the base assembly 26 and is secured thereto by means of the mounting strap 22 or other suitable fastening means.
  • novel features of the invention reside in the construction and operation of the switch 20 regardless of the manner in which the switch is assembled.
  • the base assembly 26, as shown in FIG. 3 comprises a hollow base 28 having an elongated, narrow shape and which is formed of a suitable insulating material.
  • the base 28 contains a cavity having a bottom 29 with upstanding side walls 30 and stepped end walls 31.
  • a pair of spaced terminal plates 32 are mounted within the cavity of the base and extend along the opposite side walls 30 at each end thereof.
  • the pair of terminal plates 32 are of similar construction and hence, only one need be described here.
  • Each of the terminal plates 32 carries a threaded terminal screw 33 which extends through a slotted opening 34 in the side wall 30 of the base 28 with a headed end of the screw being accessible for attachment of a conductor wire to the terminal plate.
  • a wire-locking tongue 35 is also provided for connecting a bare end of a conductor wire to the plate 32.
  • the wire-locking tongue 35 is formed by bending a lower edge of the plate 32 inwardly so that the tongue 35 extends along the bottom 29 of the base 28.
  • a free end of the tongue 35 extends over a wire-receiving opening 36 in the bottom 29 of the base and in opposing relation to a vertical inwardly bent end 32a of the plate 32.
  • the vertical end 32a of the plate 32 is located at one side of the wirereceiving opening 36 in the bottom and abuts the stepped end wall 31 at one end of the base 28.
  • the free end of the wire-locking tongue 35 is positioned to engage with the bare end of a conductor wire inserted through the opening 36 and to urge the end of the wire into electrical contact with the vertical end 32a of the terminal plate 32.
  • a portion of the terminal plate 32 extends vertically between the bottom 29 of the base and an upper edge of the side wall 30.
  • a recess formed by partitions and ribs on the bottom 29 of the base receives the lower end of the terminal plate 32.
  • the terminal plate 32 can be slid into place and as will be described, it is held in the base by the upper rocker assembly 27.
  • Each of the terminal plates 32 also carries a contactcarrying arm 37 at a lower end thereof.
  • the arms extend inwardly and in spaced relation transversely across a central depression or well 29a formed at the bottom 29 of the base 28.
  • the arms 37 are angularly inclined and each is displaced from the transverse center line of the base.
  • the contact-carrying arms 37 on the respective plates are located in spaced opposing relation to each other on opposite sides of the transverse center line of the base 28 with a contact button 38 formed ofa silver alloy or the like at the center thereof.
  • the buttons 38 have angularly inclined faces which mate with contact buttons 39 on the lower end of a pivoted contact brush 30.
  • the contact brush 40 is pivotally supported at the transverse center line of the base 28 by a common terminal plate 41 and is held in electrical engagement therewith.
  • the common terminal plate 41 has a vertical portion which extends between the bottom 29 of the base 28 and the upper edge of one of the side walls 30 in spaced relation to the terminal plates 32.
  • the common terminal plate 41 also carries a threaded terminal screw 42 which extends through a slotted opening 43 in the side wall 30 of the base 28 with a headed end being accessible for attachment of a conductor wire thereto.
  • the common terminal plate 41 is also provided with an inwardly bent wire-engaging tongue 44 at the lower end thereof.
  • the tongue 44 extends along the bottom 29 of the base 28 with a free end of the tongue extending over a wire-receiving opening 45 in the bottom 29 of the base 28 in opposing relation to a vertical inwardly bent portion 46 of the plate 41. When a bare end of a conductor is inserted through the opening 45 in the base, the tongue 44 urges it into electrical contact with the terminal plate 41.
  • a pair of flat spaced arms 47 are carried by the common terminal plate 411 at its upper edge.
  • the arms 47 extend in spaced relation lengthwise of the base 28 and across the transverse center line thereof and are connected by an offset transverse link 48.
  • the arms 47 are positioned in recesses 49 formed in the opposing side walls 30 of the base 28.
  • Each of the arms 47 contains a V-shaped notch 50 with the V-shaped notches 50 in the respective arms being aligned with each other and with the transverse center line of the base 28 so as to serve as pivot points for the movable contact brush 40.
  • Trunnions 51 extend outwardly from opposite sides of the pivoted contact brush 40 and have sharp, knifelike lower edges 51a which pivotally engage with the V-shaped notches 50 in the arms 47.
  • the trunnions 51 also have upwardly extending shoulders 52 which ex tend upwardly from the knife-like lower edges 51a.
  • the lower end of the pivoted brush 40 extends downwardly between the opposing fixed contact arms 37 and the buttons 38 formed thereon.
  • the contact buttons 39 are formed on opposite faces of the brush 40 and in operation of the switch, the contact buttons 39 on the brush 40 are moved into and out of engagement with the fixed contact buttons 38.
  • the indexing means illustrated comprises notches 53 formed in the upper edges of the side walls 30 of the base 28 which are aligned with the transverse center line of the base 28 and with the V-shaped notches 50 in the arm 47 which pivotally support the brush 40.
  • the indexing notches 53 in the base receive projections 54 carried by a spacer 55 of the upper rocker assembly 27. This aligns the transverse center lines of the lower or base assembly 26 and of the upper or rocker assembly 27.
  • the brush 40 together with a spring 65 may be installed in the base 28 or may be connected to the rocker 24.
  • the upper or rocker assembly 27 includes the framelike cover 25, the rocker 24 and the spacer 55.
  • the rocker 24 is pivotally mounted in the cover 25 and is held in place by the spacer 55.
  • the rocker 24 has upwardly facing V-shaped trunnions 56 which extend outwardly from opposite sides of the rocker 24 thereof and pivotally support the rocker 24 in the cover 25.
  • the upper ends of the V- shaped trunnions 56 are seated in enlarged V-shaped recesses 57 formed in the sides of the cover 25.
  • the V- shaped recesses 57 in sides of the cover 25 which serve as pivot points for the rocker 24, are located at the transverse center line of the cover 25. These pivot points are also aligned with the transverse center line of the spacer 55 by indexing means formed on the cover 25 and spacer 55.
  • the indexing means illustrated comprises notches 58 formed in opposite sides of the cover 25 to receive projections 60 carried by the spacer 55. When the spacer 55 is placed in the cover 25, it rests on shoulders 59 extending along opposite sides of the cover 25 and the projections 60 are seated in the notches 58.
  • the cover 25 together with spacer 55 are in turn aligned with the base 28 by engagement of the projections 54 on the lower face of the spacer 55 with the notches 53 in the upper edges of the side walls 30 of the base 28.
  • the pivot points for the movable brush 40 and the pivot points for the rocker 24 are aligned with each other at the transverse center line of the switch 20.
  • the mounting strap 23 has sides which extend along opposite sides of the cover 25 and which are seated on an outwardly extending lip or rim 250 formed on the sides of the cover 25.
  • Legs 61 having bifurcated ends extend downwardly from the ends of the mounting strap 23 and into tapered grooves 62 in the end walls of the base 28. When the bifurcated ends of the legs 61 are spread apart in the tapered grooves 62, they secure the upper or rocker assembly 27 to the base assembly 26.
  • the spacer 55 contains a central aperture 63 which is located beneath the rocker 24 and provides access to the cavity in the base 28.
  • the indexing means in the rocker assembly and the base assembly align the rocker pivot points in the cover 25 with the brush pivot points in the base and with the two sets of pivot points being located on the transverse center line of the switch.
  • the spacer 55 may be held in the cover 25 by means of tabs 25' which make a press fit with the cover 25 at notches 55a.
  • inwardly projecting tabs 310 on the end walls 31 of the base 28 may be provided to make a press fit with the ends of the spacer 55 to aid in assembling the switch.
  • a central aperture 63 in the spacer 55 accomodates a downwardly extending central leg or boss 24b carried by the rocker 24 which is supported in operating position above the central depression or well 29a in the base 28.
  • the upper end of the pivoted contact brush extends through the opening 63 into engagement with the rocker boss 24b.
  • the upper end of the pivoted brush 40 contains a yoke-like opening 64 having a base 64a and arms 64b which extend upwardly through the opening 63 in the spacer 55.
  • the upper ends of the arms 64b of the brush extend into slots 240 in the rocker boss 24b to position the brush 40 and aid in assembly.
  • a coil spring 65 is interposed and compressed between the base 64a of the yoke-like opening 64 in the brush 40 and the boss 24b on the rocker.
  • An upper end of the spring 65 is connected to the boss 24b on the rocker 24.
  • the spring 65 also urges the rocker 24 upwardly in the cover 25 and holds the trunnions 56 on the rocker 24 in pivotal engagement with the V-shaped notches 57 in the cover 25.
  • the coil spring 65 also urges the sharp edges 51a of the trunnions 51 of the brush 40 into electrical engagement with pivot points on notches 50 formed in the arms of the common contact 41.
  • the spring 65 exerts a force which rotates the rocker 24 toward an extreme or rest position.
  • split cams 66 on the rocker 24 are urged into engagement with the upwardly extending shoulders 52 of the trunnions 51 of the pivoted brush 40.
  • Such engagement takes place at a distance above the pivot point of the brush which is less than the distance from the pivot point of the brush to the lower end of the brush and the cams 66 urge the lower end of the brush 40 into engagement with one of the fixed contacts 38 under pressure from the spring 65.
  • the cams 66 on the rocker 24 engage with the shoulders 52 of the brush at a point close to the point where the trunnions 51 of the brush 40 are pivoted on the arms 47 of the common contact 41.
  • the distance of this point from the pivot point of the brush is about one quarter of the distance from the pivot point of the brush 40 to the lower end of the brush.
  • a mechanical advantage of about 4 to l is obtained in favor of the force exerted on the brush 40 by the spring 65 through the cams 66.
  • depression of a raised end of the rocker 24 causes the lower end of the pivoted brush 40 to move quickly into or out of engagement with one of the fixed contacts. After such movement, the lower end of the brush is urged into firm engagement with one of the fixed contacts under spring pressure exerted by the cams 66 of the rocker 24 on the upwardly extending shoulders 52 of the brush 40 when the rocker is in a rest position.
  • the firm engagement of the brush with the fixed contact enables the switch to carry increased load currents with safety.
  • the spring also prevents stalling of the pivoted brush in movement between the fixed contacts.
  • rubber bumpers 68 may be mounted in sockets 69 formed at the ends of the spacer 55.
  • the bumpers 68 extend upwardly from the spacer 55 in opposing relation to opposite ends of the rocker 24 so as to cushion the rocker 24 and prevent noisy operation.
  • one of the fixed terminal plates 32 may be eliminated.
  • the bumper 68 at one end of the spacer 55 may be raised so as to engage with and limit movement of the rocker 24 when the lower end of the brush 40 is moved away from or out of engagement with the fixed contact 38 in such a switch.
  • the first step is to combine the parts for the upper or rocker assembly 27 by placing the rocker 24 in the cover 25 together with the spacer 55.
  • the mounting strap 23 is placed on the cover 25 at this time.
  • the upper end of the contact brush 40 is inserted through the opening 63 of the spacer 55 with an end of the coil spring 65 in engagement with the boss 24!; on the rocker 24.
  • the base assembly 26 is formed by placing the terminal plates 32 and the common terminal 41 in the cavity in the base 28. To complete the assembly, the upper assembly 27 is placed on the base assembly 26 with the brush being pivotaily supported on the arms 47 of the common terminal late 41 and with its lower end extending downwardly therefrom into opposing relation to the fixed contact arms 37.
  • An electrical rocker switch of the quiet type for use with alternating current which includes: a housing; a rocker having flat angularly disposed outer faces for operating the switch; said rocker being pivotally supported in the housing at a first pivot point and being pivotally movable with limited angular movement of less than between first and second rest positions; a movable contact brush pivotally supported at a second pivot point in the housing; said first and second pivot points being spaced vertically relative to each other and each being aligned with a transverse center line of the housing; a boss carried by the rocker and extending downwardly therefrom; a spring compressed between the downwardly extending boss on said rocker and a lower end of said contact brush; said spring being movable under compression to inclined positions relative to the brush in response to pivotal movement of the rocker between said rest positions; said movement of the spring transmitting pivotal movement of the rocker to the brush; and a pair of spaced cams carried by the rocker and extending downwardly therefrom on opposite sides of an upper end of the brush;
  • An electrical rocker switch of the quiet type for use with alternating current as defined in claim 1 which includes: a fixed contact mounted in the housing; a lower end of the brush being movable toward and away from the fixed contact, said upper end of the brush including a shoulder extending above said second pivot point with the cams on the rocker extending downwardly on opposite sides thereof; said cams engaging, respectively with said shoulder and urging the brush in one direction about the second pivot point and urging the lower end of the brush in one direction under the influence of the spring when the rocker is in one of the rest positions.
  • An electrical rocker switch of the quiet type comprising; a cover having an opening therein; a rocker pivotally mounted in said cover for limited angular movement of less than twenty degrees between first and second rest positions; said rocker having flat angularly disposed upper faces located in and extending lengthwise of said opening in the cover; a hollow base located beneath the cover; said base containing a cavity communicating with a lower face of the rocker; a boss carried by said lower face of the rocker and extending downwardly therefrom facing said cavity; a fixed contact mounted in the cavity in the base; a common contact mounted in the base and being spaced from the fixed contact; a movable contact brush electrically connected to and being pivotally supported on said common contact; said pivoted brush having a shoulder extending upwardly from the pivot point thereof and a lower end extending into said cavity; said lower end of the brush opposing the fixed contact and being movable into and out of electrical contact therewith; a spring compressed between the boss on the rocker and the lower end of the movable contact brush; said spring
  • the spring comprises a coil spring having one end connected to the boss on the rocker and being held under compression between the rocker and the lower end of the movable contact brush: said one end of the spring being angularly movable under compression relative to the movable contact brush in response to pivotal movement of the rocker and transmitting said pivotal movement of the rocker to the brush.
  • an electrical rocker switch of the quiet type which comprises: a hollow base having a contact receiving cavity formed therein; at least one fixed contact mounted in said cavity; said fixed contact having a contact arm displaced from a transverse center line of the base; a movable contact brush; a common contact mounted in the base and pivotally supporting the movable contact brush at the transverse center line of the base; said brush having spaced upwardly extending shoulders and a lower end extending into said cavity; said lower end of the brush being movable toward and away from engagement with said fixed contact; a cover having an opening therein; a rocker pivitally supported in the cover at a transverse center line thereof and in alignment with the pivot of the brush; said rocker being movable between first and second rest positions thereof with an angular movement of or less; a boss carried by the rocker in opposing relation to the cavity in the base; said boss also containing transverse openings into which upper ends of the brush extend; said openings positioning the brush transversely of the cover and the base;
  • an electrical rocker switch of the quiet type which comprises: a frame-like cover defining an opening; a rocker pivotally supported in said cover at a transverse center line thereof; said rocker having flat angularly disposed upper faces exposed through said opening and being movable through an angle of less than twenty degrees to first and second rest positions; a base containing a cavity and having a transverse center line coinciding with the transverse center line of the cover; at least one fixed contact mounted in said base adjacent a bottom of the cavity; said fixed contact having a contact arm displaced relative to the transverse center line of the base; a common contact mounted in said base in spaced relation to the fixed contact; said common contact having spaced arms extending along opposite sides of the cavity at an upper end thereof; a movable contact brush pivotally mounted on said arms of the common contact at the transverse center line of the base and in electrical contact therewith; said contact brush having spaced upper ends extending upwardly therefrom and having a lower end extending into the cavity in the base in opposing relation to
  • the combination as defined in claim 10 which includes a mounting strap, said mounting strap having an opening therein and having sides engaging with and holding the cover and the rocker in operating position on the base.
  • the combinatin as defined in claim 10 which includes a rigid spacer fitted within the cover and supporting the cover on the base; said spacer supporting the rocker in pivotal engagement with the cover and having an opening therein through which the upper end of the brush extends into engagement with the rocker.
  • the fixed contact includes a terminal plate extending vertically along a side wall of the cavity in the base
  • the common contact includes a terminal plate extending vertically along a side wall of the cavity in the base in spaced relation to the fixed contact; said terminal plates having upper edges engaging with the spacer and being held in the cavity in the base thereby.
  • a rocker-type electrical switch which comprises a base having a cavity formed therein; said cavity having a bottom with upstanding side and end walls; at least one fixed contact mounted in said cavity; said fixed contact having a contact arm angularly displaced relative to a transverse center line of the base, a common contact mounted in the cavity in said base in spaced relation to the fixed contact; said common contact including oppositely disposed spaced arms extending along upper side edges of the cavity and across said transverse center line; said spaced arms containing V-shaped notches aligned with each other and with the transverse center line of the base; a movable contact brush; oppositely disposed trunnions carried by the brush; said trunnions pivotally supporting the brush in the V-shaped notches in said arms and in electrical contact therewith; said brush having spaced upper ends with shoulders formed thereon extending upwardly from said trunnions and a lower end extending downwardly into the cavity in opposing relation to the contact arm of the fixed contact; said lower end

Abstract

The invention relates to a rocker-type electrical wall switch which is used with alternating current and operates with limited angular movememt of a pivoted rocker. The ends of the rocker remain substantially flush with a wall plate in different operating positions of the rocker. In operation of the switch, the pivoted rocker tilts a coil spring relative to the plane of a pivoted contact-carrying brush and moves the lower end of the brush into or out of engagement with fixed contacts. Cams on the rocker are also urged into engagement wtth the pivoted brush by the coil spring. The cams hold the lower end of the brush in en1agement with one of the fixed contacts under pressure from the spring and increase the load carrying capacity of the switch. The rocker and the brush are pivoted at spaced points in a cover and a base and the pivot points are aligned wih each other on the transverse center line of the switch. Thus, variations in the lengthwise dimensions of the rocker or other parts due to manufacturing tolerances or the like do not affect assembly or operation of the switch. The cams on the rocker engage with the pivoted brush at a point which provides a mechanical advantage to forces exerted by the coil spring through the cams in urging the lower end of the brush into engagement with the fixed contact.

Description

United States Patent POlifik Nov. 6, 1973 ROCKER-TYPE ELECTRICAL SWITCH [75] Inventor: John M. Poliak, East Meadow, NY.
[73] Assignee: Leviton Manufacturing Co., Inc.,
[52] U.S. Cl. 200/67 A, 200/67 R, 200/166 H, 200/166 CT [51] Int. Cl. H0lh 13/28 [58] Field of Search 200/67 G, 67 A, 68, 200/67 R, 166 H, 166 CT [56] References Cited UNITED STATES PATENTS 2,899,513 11/1959 Schmidt 200/67 A 3,172,972 3/1965 Schleicher 200/166 H 3,532,846 10/1970 Schumacher... 200/166 CT 2,939,926 6/1960 Lamaudiere.... 200/67 A 2,570,281 10/1951 Russel] et a1 200/67 A 1,782,780 11/1930 Hafemiester.... 200/67 PK 3,300,605 1/1967 Ramsing et a1. 200/67 G 3,354,275 ll/l967 Schleicher 200/67 G Primary ExaminerD. S. Smith, Jr. Att0rneyHanse H. Hamilton [57] ABSTRACT The invention relates to a rocker-type electrical wall switch which is used with alternating current and operates with limited angular movememt of a pivoted rocker. The ends of the rocker remain substantially flush with a wall plate in different operating positions of the rocker.
In operation of the switch, the pivoted rocker tilts a coil spring relative to the plane of a pivoted contact-carrying brush and moves the lower end of the brush into or out of engagement with fixed contacts. Cams on the rocker are also urged into engagement wtth the pivoted brush by the coil spring. The cams hold the lower end of the brush in en 1 agement with one of the fixed contacts under pressure from the spring and increase the load carrying capacity of the switch.
The rocker and the brush are pivoted at spaced points in a cover and a base and the pivot points are aligned wih each other on the transverse center line of the switch. Thus, variations in the lengthwise dimensions of the rocker or other parts due to manufacturing tolerances or the like do not affect assembly or operation of the switch. The cams on the rocker engage with the pivoted brush at a point which provides a mechanical advantage to forces exerted by the coil spring through the cams in urging the lower end of the brush into engagement with the fixed contact.
14 Claims, 15 Drawing Figures PATENIEDuuv 61973 I 3.770.920
SHEET 10E 4 i I T131.
PAIENIEDNHY 61975 3.770.920 A SHEET 20$ 4 s 4 -00 MI! I ROCKER-TYPE ELECTRICAL SWITCH The present invention relates to an improved rockertype electrical wall switch for use with alernating current. It relates, more particularly, to a rocker-type electrical switch which operates in response to light finger pressure and which is capable of carrying substantial load currents.
An object of the present invention is to provide a rocker-type switch which operates with limited angular movement of a pivoted rocker and in response to light pressure being exerted on the ends of the rocker. The limited angular movement of the rocker permits the ends of the rocker to be kept substantially flush with a wall plate in different operating positions of the rocker so that they will not protrude objectionably beyond the wall plate.
Another object of the invention is to provide a rocker-type electrical switch in which a movable contact brush is held in firm engagement with an opposing fixed contact under spring pressure so that the switch can handle increased load currents with safety when the contacts are engaged. Another feature of the invention is that stalling of the switch in an open position is minimized.
A further object of-the invention is to provide a rocker-type electrical switch which is compact and which can be installed without difficulty in the usual wall box together with the ends of conductor wires which are connected to the switch.
Still another object of the invention is to provide a rocker-type electrical switch which is easy to assemble and inexpensive to manufacture.
Other objects and advantages of the invention will become apparent and will be better understood from the following description and the accompanying drawings in which:
FIG. 1 is a perspective view of an electrical wall switch embodying the invention and a wall plate;
FIG. 2 is a vertical section view of the switch and wall plate shown in FIG. 1;
FIG. 3 is a top plan view of the base of the switch shown in FIG. 2;
FIG. 4 is a fragmentary side view in vertical section of parts of the switch shown in FIG. 2 and which is drawn to an enlarged scale;
FIG. 5 is a fragmentary side view in vertical section corresponding to FIG. 4 with operating parts of the switch in different positions;
FIG. 6 is a fragmentary view in vertical section taken along transverse center line of the switch shown in FIG. 2 and is drawn to an enlarged scale;
FIG. 7 is a fragmentary side view in vertical section of a portion of the switch shown in FIG. 2;
FIG. 8 is an enlarged perspective view of parts of contact elements of the switch shown in FIGS. 1 and 2;
FIG. 9 is an exploded perspective view of the contact elements shown in FIG. 7;
FIG. 10 is a bottom plan view of the cover for the switch shown in FIG. 2;
FIG. 11 is afragmentary view in vertical section taken along line 11-11 of FIG. 10;
FIG. 12 is a fragmentary view taken along line 12-12 of FIG. 10;
FIG. 13 is a bottom plan view of the spacer for the switch shown in FIG. 2;
FIG. 14 is a fragmentary side view of the spacer shown in FIG. 13; and
FIG. 15 is a view in vertical section taken along line 15-15 of FIG. 13.
Referring to the drawings in detail, FIG. 1 shows a rocker-type electrical switch 20 which embodies the invention with a wall plate 21 secured to the switch.
As shown in FIG. 2, the switch 20 may be installed in the usual wall box 22 together with the ends of conductor wires (not shown) which connect the switch to a source of alternating current. The switch 20 is supported in the wall or gem box 22 by means of a mounting strap 23 which extends along opposite sides of the switch and also serves to hold the switch together. The ends of the conductor wires which are connected to the switch, are confined within the wall box 22 and the compact dimensions of the switch 20 facilitate such installation.
After installation in the wall box 22, the escutcheon or wall plate 21 is secured to the mounting strap 22 and an upper face of the pivoted 'rocker 24 is exposed through an opening therein. 7
As shown in FIG. 2, the pivoted rocker 24 has angularly disposed upper faces 243 which diverge from each other at an obtuse angle so that the ends of the faces 24a project only slightly beyond the wall plate 21 in different operating positions of the rocker 24. As shown in the drawings, angular movement of the rocker 24 should be limited to about 20 or less for this purpose. A frame-like cover 25 surrounds the upper faces 24a of the rocker 24 and pivotally supports the rocker 24 at the transverse center line of the cover which is also the transverse center line of the switch. If desired, the frame-like cover 25 and the rocker faces 24a may be made of different colors and may also differ in color from the wall plate ,to provide a decorative appearance for the switch. The pivoted rocker 24 and the framelike cover 25 along with other parts of the switch may be molded from suitable insulating materials and as will be described, the switch is constructed so that identical molding characteristics for the materials used are not required.
The switch 20 illustrated is a two-pole switch, but it will be understood that the'same construction can be employed for a single pole switch with minor modifications.
For assembly purposes, the switch 20 may be formed by combining two sub-assemblies, a lower or base assembly 26 and an upper or rocker assembly 27 which simplifies manufacture and assembly operations. In the assembly, the upper or rocker assembly 27 is combined with the base assembly 26 and is secured thereto by means of the mounting strap 22 or other suitable fastening means. However, it will be understood that novel features of the invention reside in the construction and operation of the switch 20 regardless of the manner in which the switch is assembled.
The base assembly 26, as shown in FIG. 3 comprises a hollow base 28 having an elongated, narrow shape and which is formed of a suitable insulating material. The base 28 contains a cavity having a bottom 29 with upstanding side walls 30 and stepped end walls 31.
In a two-pole switch, a pair of spaced terminal plates 32 are mounted within the cavity of the base and extend along the opposite side walls 30 at each end thereof. The pair of terminal plates 32 are of similar construction and hence, only one need be described here.
Each of the terminal plates 32 carries a threaded terminal screw 33 which extends through a slotted opening 34 in the side wall 30 of the base 28 with a headed end of the screw being accessible for attachment of a conductor wire to the terminal plate. A wire-locking tongue 35 is also provided for connecting a bare end of a conductor wire to the plate 32. The wire-locking tongue 35 is formed by bending a lower edge of the plate 32 inwardly so that the tongue 35 extends along the bottom 29 of the base 28. A free end of the tongue 35 extends over a wire-receiving opening 36 in the bottom 29 of the base and in opposing relation to a vertical inwardly bent end 32a of the plate 32. The vertical end 32a of the plate 32 is located at one side of the wirereceiving opening 36 in the bottom and abuts the stepped end wall 31 at one end of the base 28. Thus, the free end of the wire-locking tongue 35 is positioned to engage with the bare end of a conductor wire inserted through the opening 36 and to urge the end of the wire into electrical contact with the vertical end 32a of the terminal plate 32.
A portion of the terminal plate 32 extends vertically between the bottom 29 of the base and an upper edge of the side wall 30. A recess formed by partitions and ribs on the bottom 29 of the base receives the lower end of the terminal plate 32. Thus, the terminal plate 32 can be slid into place and as will be described, it is held in the base by the upper rocker assembly 27.
Each of the terminal plates 32 also carries a contactcarrying arm 37 at a lower end thereof. The arms extend inwardly and in spaced relation transversely across a central depression or well 29a formed at the bottom 29 of the base 28. The arms 37 are angularly inclined and each is displaced from the transverse center line of the base. When two terminal plates 32 are employed, as shown, the contact-carrying arms 37 on the respective plates are located in spaced opposing relation to each other on opposite sides of the transverse center line of the base 28 with a contact button 38 formed ofa silver alloy or the like at the center thereof. The buttons 38 have angularly inclined faces which mate with contact buttons 39 on the lower end of a pivoted contact brush 30.
The contact brush 40 is pivotally supported at the transverse center line of the base 28 by a common terminal plate 41 and is held in electrical engagement therewith. The common terminal plate 41 has a vertical portion which extends between the bottom 29 of the base 28 and the upper edge of one of the side walls 30 in spaced relation to the terminal plates 32. The common terminal plate 41 also carries a threaded terminal screw 42 which extends through a slotted opening 43 in the side wall 30 of the base 28 with a headed end being accessible for attachment of a conductor wire thereto. The common terminal plate 41 is also provided with an inwardly bent wire-engaging tongue 44 at the lower end thereof. The tongue 44 extends along the bottom 29 of the base 28 with a free end of the tongue extending over a wire-receiving opening 45 in the bottom 29 of the base 28 in opposing relation to a vertical inwardly bent portion 46 of the plate 41. When a bare end of a conductor is inserted through the opening 45 in the base, the tongue 44 urges it into electrical contact with the terminal plate 41.
A pair of flat spaced arms 47 are carried by the common terminal plate 411 at its upper edge. The arms 47 extend in spaced relation lengthwise of the base 28 and across the transverse center line thereof and are connected by an offset transverse link 48. The arms 47 are positioned in recesses 49 formed in the opposing side walls 30 of the base 28. Each of the arms 47 contains a V-shaped notch 50 with the V-shaped notches 50 in the respective arms being aligned with each other and with the transverse center line of the base 28 so as to serve as pivot points for the movable contact brush 40.
Trunnions 51 extend outwardly from opposite sides of the pivoted contact brush 40 and have sharp, knifelike lower edges 51a which pivotally engage with the V-shaped notches 50 in the arms 47. The trunnions 51 also have upwardly extending shoulders 52 which ex tend upwardly from the knife-like lower edges 51a.
The lower end of the pivoted brush 40 extends downwardly between the opposing fixed contact arms 37 and the buttons 38 formed thereon. The contact buttons 39 are formed on opposite faces of the brush 40 and in operation of the switch, the contact buttons 39 on the brush 40 are moved into and out of engagement with the fixed contact buttons 38.
To assure proper alignment of the pivot points of the brush and the rocker with the transverse center line of the switch, means are provided for indexing the base assembly 26 with the rocker assembly 27. The indexing means illustrated comprises notches 53 formed in the upper edges of the side walls 30 of the base 28 which are aligned with the transverse center line of the base 28 and with the V-shaped notches 50 in the arm 47 which pivotally support the brush 40. When the upper assembly 27 is placed on the base assembly 26, the indexing notches 53 in the base receive projections 54 carried by a spacer 55 of the upper rocker assembly 27. This aligns the transverse center lines of the lower or base assembly 26 and of the upper or rocker assembly 27. Prior to this assembly, the brush 40 together with a spring 65 may be installed in the base 28 or may be connected to the rocker 24.
The upper or rocker assembly 27 includes the framelike cover 25, the rocker 24 and the spacer 55. The rocker 24 is pivotally mounted in the cover 25 and is held in place by the spacer 55.
The rocker 24 has upwardly facing V-shaped trunnions 56 which extend outwardly from opposite sides of the rocker 24 thereof and pivotally support the rocker 24 in the cover 25. The upper ends of the V- shaped trunnions 56 are seated in enlarged V-shaped recesses 57 formed in the sides of the cover 25. The V- shaped recesses 57 in sides of the cover 25 which serve as pivot points for the rocker 24, are located at the transverse center line of the cover 25. These pivot points are also aligned with the transverse center line of the spacer 55 by indexing means formed on the cover 25 and spacer 55. The indexing means illustrated comprises notches 58 formed in opposite sides of the cover 25 to receive projections 60 carried by the spacer 55. When the spacer 55 is placed in the cover 25, it rests on shoulders 59 extending along opposite sides of the cover 25 and the projections 60 are seated in the notches 58.
The cover 25 together with spacer 55 are in turn aligned with the base 28 by engagement of the projections 54 on the lower face of the spacer 55 with the notches 53 in the upper edges of the side walls 30 of the base 28. Thus, the pivot points for the movable brush 40 and the pivot points for the rocker 24 are aligned with each other at the transverse center line of the switch 20.
The aligning of the pivot points with each other at the transverse center line of the switch permits variations in the lengthwise dimensions of the rocker 24 and other parts due to the use of different materials without interfering with proper operation of the switch.
The spacer 55 which fits inside the cover 25, rests on the shoulders 59 on the sides of the cover and the bot tom of the spacer 55 extends over the upper ends of the side walls of the base 28 when the switch is assembled. Thus, the spacer 55 holds the fixed terminal plates 32 and the common terminal plate 39 in place in the base 28.
The mounting strap 23 has sides which extend along opposite sides of the cover 25 and which are seated on an outwardly extending lip or rim 250 formed on the sides of the cover 25. Legs 61 having bifurcated ends extend downwardly from the ends of the mounting strap 23 and into tapered grooves 62 in the end walls of the base 28. When the bifurcated ends of the legs 61 are spread apart in the tapered grooves 62, they secure the upper or rocker assembly 27 to the base assembly 26.
The spacer 55 contains a central aperture 63 which is located beneath the rocker 24 and provides access to the cavity in the base 28. As noted above, the indexing means in the rocker assembly and the base assembly align the rocker pivot points in the cover 25 with the brush pivot points in the base and with the two sets of pivot points being located on the transverse center line of the switch.
To facilitate the assembly, the spacer 55 may be held in the cover 25 by means of tabs 25' which make a press fit with the cover 25 at notches 55a. In addition, inwardly projecting tabs 310 on the end walls 31 of the base 28 may be provided to make a press fit with the ends of the spacer 55 to aid in assembling the switch.
A central aperture 63 in the spacer 55 accomodates a downwardly extending central leg or boss 24b carried by the rocker 24 which is supported in operating position above the central depression or well 29a in the base 28. The upper end of the pivoted contact brush extends through the opening 63 into engagement with the rocker boss 24b.
The upper end of the pivoted brush 40 contains a yoke-like opening 64 having a base 64a and arms 64b which extend upwardly through the opening 63 in the spacer 55. The upper ends of the arms 64b of the brush extend into slots 240 in the rocker boss 24b to position the brush 40 and aid in assembly. A coil spring 65 is interposed and compressed between the base 64a of the yoke-like opening 64 in the brush 40 and the boss 24b on the rocker. An upper end of the spring 65 is connected to the boss 24b on the rocker 24. Thus, pivotal movement of the rocker 24 shifts the upper end of the coil spring 65 and tilts the axis of the spring relative to the plane of the movable brush 40. Depending on the direction in which the rocker 24 is moved, the tilting of the spring 65 causes the lower end of the pivoted brush 40 to move into or out of engagement with the fixed contact button .38.
The spring 65 also urges the rocker 24 upwardly in the cover 25 and holds the trunnions 56 on the rocker 24 in pivotal engagement with the V-shaped notches 57 in the cover 25. The coil spring 65 also urges the sharp edges 51a of the trunnions 51 of the brush 40 into electrical engagement with pivot points on notches 50 formed in the arms of the common contact 41.
In addition, the spring 65 exerts a force which rotates the rocker 24 toward an extreme or rest position. As the result of such rotation, split cams 66 on the rocker 24 are urged into engagement with the upwardly extending shoulders 52 of the trunnions 51 of the pivoted brush 40. Such engagement takes place at a distance above the pivot point of the brush which is less than the distance from the pivot point of the brush to the lower end of the brush and the cams 66 urge the lower end of the brush 40 into engagement with one of the fixed contacts 38 under pressure from the spring 65. The cams 66 on the rocker 24 engage with the shoulders 52 of the brush at a point close to the point where the trunnions 51 of the brush 40 are pivoted on the arms 47 of the common contact 41. In the illustrated embodiment, the distance of this point from the pivot point of the brush is about one quarter of the distance from the pivot point of the brush 40 to the lower end of the brush. Thus, a mechanical advantage of about 4 to l is obtained in favor of the force exerted on the brush 40 by the spring 65 through the cams 66.
Thus, engagement of the split cams 66 on the rocker 24 with the shoulders 52 on the brush 40 urges the lower end of the brush 40 into engagement with one of the opposing fixed contacts under pressure from the spring until the rocker 24 is moved in an opposite direction. Opposing surfaces of the split cams 66 on the rocker are spaces so that they will not interfere with pivotal movement of the brush 40 under the influence of the spring 65, but the cams 66 may strike the brush to aid in starting movement of the brush away from a fixed contact. In any event, the spring 65 urges the cams 66 on the rocker 24 into engagement with the upper end of the brush 40 at a point above the pivot point of the brush and thus, urges the lower end of the brush toward one of the fixed contacts.
In operation of the switch 20, depression of a raised end of the rocker 24 causes the lower end of the pivoted brush 40 to move quickly into or out of engagement with one of the fixed contacts. After such movement, the lower end of the brush is urged into firm engagement with one of the fixed contacts under spring pressure exerted by the cams 66 of the rocker 24 on the upwardly extending shoulders 52 of the brush 40 when the rocker is in a rest position. The firm engagement of the brush with the fixed contact enables the switch to carry increased load currents with safety. The spring also prevents stalling of the pivoted brush in movement between the fixed contacts.
To prevent the ends of the rocker 24 from striking the spacer in overtravel of the rocker 24, rubber bumpers 68 may be mounted in sockets 69 formed at the ends of the spacer 55. The bumpers 68 extend upwardly from the spacer 55 in opposing relation to opposite ends of the rocker 24 so as to cushion the rocker 24 and prevent noisy operation.
In a single-pole switch, one of the fixed terminal plates 32 may be eliminated. Inthis event, the bumper 68 at one end of the spacer 55 may be raised so as to engage with and limit movement of the rocker 24 when the lower end of the brush 40 is moved away from or out of engagement with the fixed contact 38 in such a switch.
To recapitulate briefly, the following procedure ena' bles the rocker switch described above to be assembled quickly and economically.
The first step is to combine the parts for the upper or rocker assembly 27 by placing the rocker 24 in the cover 25 together with the spacer 55. The mounting strap 23 is placed on the cover 25 at this time.
The upper end of the contact brush 40 is inserted through the opening 63 of the spacer 55 with an end of the coil spring 65 in engagement with the boss 24!; on the rocker 24.
The base assembly 26 is formed by placing the terminal plates 32 and the common terminal 41 in the cavity in the base 28. To complete the assembly, the upper assembly 27 is placed on the base assembly 26 with the brush being pivotaily supported on the arms 47 of the common terminal late 41 and with its lower end extending downwardly therefrom into opposing relation to the fixed contact arms 37.
The ends of the legs 61 on the supporting strap 23 are then spread apart in the grooves 62 in the base to hold the various parts together.
It will be understood that various changes in the modifications may be made by those skilled in the art in the embodiment of the rocker switch which has been illustrated and described herein without departing from the spirit or scope of the invention.
I claim:
1. An electrical rocker switch of the quiet type for use with alternating current, which includes: a housing; a rocker having flat angularly disposed outer faces for operating the switch; said rocker being pivotally supported in the housing at a first pivot point and being pivotally movable with limited angular movement of less than between first and second rest positions; a movable contact brush pivotally supported at a second pivot point in the housing; said first and second pivot points being spaced vertically relative to each other and each being aligned with a transverse center line of the housing; a boss carried by the rocker and extending downwardly therefrom; a spring compressed between the downwardly extending boss on said rocker and a lower end of said contact brush; said spring being movable under compression to inclined positions relative to the brush in response to pivotal movement of the rocker between said rest positions; said movement of the spring transmitting pivotal movement of the rocker to the brush; and a pair of spaced cams carried by the rocker and extending downwardly therefrom on opposite sides of an upper end of the brush; said cams engaging, respectiveiy, with said upper end of the brush at a point above said second pivot point; said rocker and cams being movable into engagement with the brush under pressure exerted by the spring on the rocker in said first and second rest position thereof.
2. An electrical rocker switch of the quiet type for use with alternating current as defined in claim 1 which includes: a fixed contact mounted in the housing; a lower end of the brush being movable toward and away from the fixed contact, said upper end of the brush including a shoulder extending above said second pivot point with the cams on the rocker extending downwardly on opposite sides thereof; said cams engaging, respectively with said shoulder and urging the brush in one direction about the second pivot point and urging the lower end of the brush in one direction under the influence of the spring when the rocker is in one of the rest positions.
3. An electrical rocker switch of the quiet type for use with alternating current as defined in claim 2, wherein: said cams engage with the shoulder of the brush at a point closer to the second pivot point than the distance from the second pivot point to the lower end of the brush.
4. An electrical rocker switch of the quiet type comprising; a cover having an opening therein; a rocker pivotally mounted in said cover for limited angular movement of less than twenty degrees between first and second rest positions; said rocker having flat angularly disposed upper faces located in and extending lengthwise of said opening in the cover; a hollow base located beneath the cover; said base containing a cavity communicating with a lower face of the rocker; a boss carried by said lower face of the rocker and extending downwardly therefrom facing said cavity; a fixed contact mounted in the cavity in the base; a common contact mounted in the base and being spaced from the fixed contact; a movable contact brush electrically connected to and being pivotally supported on said common contact; said pivoted brush having a shoulder extending upwardly from the pivot point thereof and a lower end extending into said cavity; said lower end of the brush opposing the fixed contact and being movable into and out of electrical contact therewith; a spring compressed between the boss on the rocker and the lower end of the movable contact brush; said spring urging the rocker about its pivot point in said rest positions thereof and being angularly movable to the inclined positions relative to the brush in response to pivotal movement of the rocker; said angular movement of the spring imparting said pivotal movement of the rocker to the brush; and a pair of spaced cams formed on the rocker and extending downwardly therefrom on opposite sides of the shoulder on the brush; said cams engaging, respectively, with the shoulder on the brush at points above the pivot point of the brush and urging the lower end of the brush in one direction under force exerted on the rocker by the spring in said rest positions thereof; said rocker and earns being movable relative to the brush in the rest positions of the rocker.
5. An electrical rocker switch of the quiet type as defined in claim 4 wherein: the spring comprises a coil spring having one end connected to the boss on the rocker and being held under compression between the rocker and the lower end of the movable contact brush: said one end of the spring being angularly movable under compression relative to the movable contact brush in response to pivotal movement of the rocker and transmitting said pivotal movement of the rocker to the brush.
6. An electrical rocker switch of the quiet type as defined in claim 4 wherein: the rocker and the contact brush are pivoted at spaced pivot points in the cover and base respectively and said pivot points are aligned with transverse center lines of the cover and base.
7. An electrical rocker switch of the quiet type as defined in claim 4 wherein: the spaced cams on the rocker engage with the shoulder on the movable contact brush at points spaced from the pivot point of the brush by a distance less than the distance from the pivot point of the brush to the lower end thereof.
8. In an electrical rocker switch of the quiet type, the combination as defined in claim 4 which includes: a
rigid spacer fitting within the cover; said cover holding the rocker in pivotal engagement with the cover; and securing the fixed contact and the common contact in the cavity in the base.
9. In an electrical rocker switch of the quiet type, the combination which comprises: a hollow base having a contact receiving cavity formed therein; at least one fixed contact mounted in said cavity; said fixed contact having a contact arm displaced from a transverse center line of the base; a movable contact brush; a common contact mounted in the base and pivotally supporting the movable contact brush at the transverse center line of the base; said brush having spaced upwardly extending shoulders and a lower end extending into said cavity; said lower end of the brush being movable toward and away from engagement with said fixed contact; a cover having an opening therein; a rocker pivitally supported in the cover at a transverse center line thereof and in alignment with the pivot of the brush; said rocker being movable between first and second rest positions thereof with an angular movement of or less; a boss carried by the rocker in opposing relation to the cavity in the base; said boss also containing transverse openings into which upper ends of the brush extend; said openings positioning the brush transversely of the cover and the base; a coil spring compressed between the boss on the rocker and the lower end of the contact brush; said spring urging the brush into electrical engagement with the common contact and having an end connected to the boss on the rocker; said end of the spring being angularly moveable relative to the brush in response to pivotal movement of the rocker; said angular movement of the spring imparting said pivotal movement of the rocker to the brush; and a pair of spaced cams formed on the rocker and extending downwardly therefrom on opposite sides of the shoulders on the brush; said cams engaging, respectively, with the shoulders at points above the pivot point of the brush; said pivotal movement of the brush moving the lower end of the brush into and out of engagement with the fixed contact; said rocker and cams being movable relative to the brush by said spring in the rest positions of the rocker; said movement urging one of the cams on the rocker into engagement with the shoulder on the contact brush; said engagement of the cam with the brush urging the lower end of the contact brush toward one position thereof under pressure exerted on the rocker by the spring.
10. In an electrical rocker switch of the quiet type, the combination which comprises: a frame-like cover defining an opening; a rocker pivotally supported in said cover at a transverse center line thereof; said rocker having flat angularly disposed upper faces exposed through said opening and being movable through an angle of less than twenty degrees to first and second rest positions; a base containing a cavity and having a transverse center line coinciding with the transverse center line of the cover; at least one fixed contact mounted in said base adjacent a bottom of the cavity; said fixed contact having a contact arm displaced relative to the transverse center line of the base; a common contact mounted in said base in spaced relation to the fixed contact; said common contact having spaced arms extending along opposite sides of the cavity at an upper end thereof; a movable contact brush pivotally mounted on said arms of the common contact at the transverse center line of the base and in electrical contact therewith; said contact brush having spaced upper ends extending upwardly therefrom and having a lower end extending into the cavity in the base in opposing relation to the fixed contact; said upper ends including shoulders extending upwardly from the pivot points of the brush; said lower end of the contact brush being movable into and out of opposing electrical engagement with the fixed contact; a boss formed on the rocker cooperating with the upper ends of the brush and positioning the brush transversely relative to the cavity in the base; said boss facing the cavity; a coil spring held under compression between the lower end of the pivoted brush and the boss on the pivoted rocker; said spring having one end connected to the boss on the rocker and being angularly movable relative to a plane extending through the brush in response to pivotal movement of the rocker; said angular movement of the spring imparting pivotal movement of the rocker to the contact brush and moving the lower end of the brush into and out of engagement with the fixed contact; and a pair of spaced cams formed on the rocker and extending downwardly from the rocker on opposite sides of the shoulders; said cams engaging, respectively, with the shoulders on the brush at points above the pivot points thereof; said cams also being movable relative to the brush under the influence of the spring in the rest positions of the rocker; said movement urging the lower end of the brush to one position under pressure from the spring.
11. In an electrical rocker switch of the quiet type, the combination as defined in claim 10 which includes a mounting strap, said mounting strap having an opening therein and having sides engaging with and holding the cover and the rocker in operating position on the base.
12. In an electrical rocker switch of the quiet type, the combinatin as defined in claim 10 which includes a rigid spacer fitted within the cover and supporting the cover on the base; said spacer supporting the rocker in pivotal engagement with the cover and having an opening therein through which the upper end of the brush extends into engagement with the rocker.
13. In an electrical rocker switch of the quiet type, the combination as defined in claim 12 wherein: the fixed contact includes a terminal plate extending vertically along a side wall of the cavity in the base; the common contact includes a terminal plate extending vertically along a side wall of the cavity in the base in spaced relation to the fixed contact; said terminal plates having upper edges engaging with the spacer and being held in the cavity in the base thereby.
' 14. In a rocker-type electrical switch, the combination which comprises a base having a cavity formed therein; said cavity having a bottom with upstanding side and end walls; at least one fixed contact mounted in said cavity; said fixed contact having a contact arm angularly displaced relative to a transverse center line of the base, a common contact mounted in the cavity in said base in spaced relation to the fixed contact; said common contact including oppositely disposed spaced arms extending along upper side edges of the cavity and across said transverse center line; said spaced arms containing V-shaped notches aligned with each other and with the transverse center line of the base; a movable contact brush; oppositely disposed trunnions carried by the brush; said trunnions pivotally supporting the brush in the V-shaped notches in said arms and in electrical contact therewith; said brush having spaced upper ends with shoulders formed thereon extending upwardly from said trunnions and a lower end extending downwardly into the cavity in opposing relation to the contact arm of the fixed contact; said lower end of the contact brush being movable into and out of opposing engagement with said fixed contact in pivotal movement of the brush; a cover supported on the base; a rocker pivotally mounted in the cover at points aligned with the V-shaped notches in the arms of the common contact; said cover containing a frame-like opening surrounding flat angularly disposed upper faces of the rocker; said rocker being pivotally movable between first and second rest position with limited angular movement of less than 20; a boss formed on the rocker and facing the cavity; said boss containing transverse slots into which the upper ends of the brush extend; said slots positioning the brush transversely of the cavity; a spring compressed betweeen the boss on the rocker and the lower end of the pivoted contact brush; said spring urging the brush into electrical engagement with the common contact and having an end connected to the boss on the rocker; said end of the spring being angularly movable relative to a plane extending through the brush in response to the pivotal movement of the rocker; said movement of the spring imparting angular movement of the rocker to the pivoted contact brush and moving the lower end of the contact brush into and out of engagement with the contact arm of the fixed contact; and a pair of spaced cams carried by the rocker and extending downwardly on opposite sides of the shoulders on the upper ends of the contact brush; said rocker and cams being movable relative to the brush under force exerted by the spring in said rest positions of the rocker; said force urging the cams, respectively, into engagement with the shoulders on the brush at points above the pivot point of the brush the rest positions of the brush; said spring also urging the rocker and the cams thereon into engagement with the shoulders on the contact brush and urging the lower end of the contact brush toward one position thereof under the force exerted on the rocker by the spring in one of the rest positions of the rocker.

Claims (14)

1. An electrical rocker switch of the quiet type for use with alternating current, which includes: a housing; a rocker having flat angularly disposed outer faces for operating the switch; said rocker being pivotally supported in the housing at a first pivot point and being pivotally movable with limited angular movemeNt of less than 20* between first and second rest positions; a movable contact brush pivotally supported at a second pivot point in the housing; said first and second pivot points being spaced vertically relative to each other and each being aligned with a transverse center line of the housing; a boss carried by the rocker and extending downwardly therefrom; a spring compressed between the downwardly extending boss on said rocker and a lower end of said contact brush; said spring being movable under compression to inclined positions relative to the brush in response to pivotal movement of the rocker between said rest positions; said movement of the spring transmitting pivotal movement of the rocker to the brush; and a pair of spaced cams carried by the rocker and extending downwardly therefrom on opposite sides of an upper end of the brush; said cams engaging, respectively, with said upper end of the brush at a point above said second pivot point; said rocker and cams being movable into engagement with the brush under pressure exerted by the spring on the rocker in said first and second rest position thereof.
2. An electrical rocker switch of the quiet type for use with alternating current as defined in claim 1 which includes: a fixed contact mounted in the housing; a lower end of the brush being movable toward and away from the fixed contact, said upper end of the brush including a shoulder extending above said second pivot point with the cams on the rocker extending downwardly on opposite sides thereof; said cams engaging, respectively with said shoulder and urging the brush in one direction about the second pivot point and urging the lower end of the brush in one direction under the influence of the spring when the rocker is in one of the rest positions.
3. An electrical rocker switch of the quiet type for use with alternating current as defined in claim 2, wherein: said cams engage with the shoulder of the brush at a point closer to the second pivot point than the distance from the second pivot point to the lower end of the brush.
4. An electrical rocker switch of the quiet type comprising; a cover having an opening therein; a rocker pivotally mounted in said cover for limited angular movement of less than twenty degrees between first and second rest positions; said rocker having flat angularly disposed upper faces located in and extending lengthwise of said opening in the cover; a hollow base located beneath the cover; said base containing a cavity communicating with a lower face of the rocker; a boss carried by said lower face of the rocker and extending downwardly therefrom facing said cavity; a fixed contact mounted in the cavity in the base; a common contact mounted in the base and being spaced from the fixed contact; a movable contact brush electrically connected to and being pivotally supported on said common contact; said pivoted brush having a shoulder extending upwardly from the pivot point thereof and a lower end extending into said cavity; said lower end of the brush opposing the fixed contact and being movable into and out of electrical contact therewith; a spring compressed between the boss on the rocker and the lower end of the movable contact brush; said spring urging the rocker about its pivot point in said rest positions thereof and being angularly movable to the inclined positions relative to the brush in response to pivotal movement of the rocker; said angular movement of the spring imparting said pivotal movement of the rocker to the brush; and a pair of spaced cams formed on the rocker and extending downwardly therefrom on opposite sides of the shoulder on the brush; said cams engaging, respectively, with the shoulder on the brush at points above the pivot point of the brush and urging the lower end of the brush in one direction under force exerted on the rocker by the spring in said rest positions thereof; said rocker and cams being movable relative to the brush in the rest positions of the rocker.
5. An electrical rocKer switch of the quiet type as defined in claim 4 wherein: the spring comprises a coil spring having one end connected to the boss on the rocker and being held under compression between the rocker and the lower end of the movable contact brush: said one end of the spring being angularly movable under compression relative to the movable contact brush in response to pivotal movement of the rocker and transmitting said pivotal movement of the rocker to the brush.
6. An electrical rocker switch of the quiet type as defined in claim 4 wherein: the rocker and the contact brush are pivoted at spaced pivot points in the cover and base respectively and said pivot points are aligned with transverse center lines of the cover and base.
7. An electrical rocker switch of the quiet type as defined in claim 4 wherein: the spaced cams on the rocker engage with the shoulder on the movable contact brush at points spaced from the pivot point of the brush by a distance less than the distance from the pivot point of the brush to the lower end thereof.
8. In an electrical rocker switch of the quiet type, the combination as defined in claim 4 which includes: a rigid spacer fitting within the cover; said cover holding the rocker in pivotal engagement with the cover; and securing the fixed contact and the common contact in the cavity in the base.
9. In an electrical rocker switch of the quiet type, the combination which comprises: a hollow base having a contact receiving cavity formed therein; at least one fixed contact mounted in said cavity; said fixed contact having a contact arm displaced from a transverse center line of the base; a movable contact brush; a common contact mounted in the base and pivotally supporting the movable contact brush at the transverse center line of the base; said brush having spaced upwardly extending shoulders and a lower end extending into said cavity; said lower end of the brush being movable toward and away from engagement with said fixed contact; a cover having an opening therein; a rocker pivitally supported in the cover at a transverse center line thereof and in alignment with the pivot of the brush; said rocker being movable between first and second rest positions thereof with an angular movement of 20* or less; a boss carried by the rocker in opposing relation to the cavity in the base; said boss also containing transverse openings into which upper ends of the brush extend; said openings positioning the brush transversely of the cover and the base; a coil spring compressed between the boss on the rocker and the lower end of the contact brush; said spring urging the brush into electrical engagement with the common contact and having an end connected to the boss on the rocker; said end of the spring being angularly moveable relative to the brush in response to pivotal movement of the rocker; said angular movement of the spring imparting said pivotal movement of the rocker to the brush; and a pair of spaced cams formed on the rocker and extending downwardly therefrom on opposite sides of the shoulders on the brush; said cams engaging, respectively, with the shoulders at points above the pivot point of the brush; said pivotal movement of the brush moving the lower end of the brush into and out of engagement with the fixed contact; said rocker and cams being movable relative to the brush by said spring in the rest positions of the rocker; said movement urging one of the cams on the rocker into engagement with the shoulder on the contact brush; said engagement of the cam with the brush urging the lower end of the contact brush toward one position thereof under pressure exerted on the rocker by the spring.
10. In an electrical rocker switch of the quiet type, the combination which comprises: a frame-like cover defining an opening; a rocker pivotally supported in said cover at a transverse center line thereof; said rocker having flat angularly disposed upper faces exposed through said opening and being movable through an angle of less than tweNty degrees to first and second rest positions; a base containing a cavity and having a transverse center line coinciding with the transverse center line of the cover; at least one fixed contact mounted in said base adjacent a bottom of the cavity; said fixed contact having a contact arm displaced relative to the transverse center line of the base; a common contact mounted in said base in spaced relation to the fixed contact; said common contact having spaced arms extending along opposite sides of the cavity at an upper end thereof; a movable contact brush pivotally mounted on said arms of the common contact at the transverse center line of the base and in electrical contact therewith; said contact brush having spaced upper ends extending upwardly therefrom and having a lower end extending into the cavity in the base in opposing relation to the fixed contact; said upper ends including shoulders extending upwardly from the pivot points of the brush; said lower end of the contact brush being movable into and out of opposing electrical engagement with the fixed contact; a boss formed on the rocker cooperating with the upper ends of the brush and positioning the brush transversely relative to the cavity in the base; said boss facing the cavity; a coil spring held under compression between the lower end of the pivoted brush and the boss on the pivoted rocker; said spring having one end connected to the boss on the rocker and being angularly movable relative to a plane extending through the brush in response to pivotal movement of the rocker; said angular movement of the spring imparting pivotal movement of the rocker to the contact brush and moving the lower end of the brush into and out of engagement with the fixed contact; and a pair of spaced cams formed on the rocker and extending downwardly from the rocker on opposite sides of the shoulders; said cams engaging, respectively, with the shoulders on the brush at points above the pivot points thereof; said cams also being movable relative to the brush under the influence of the spring in the rest positions of the rocker; said movement urging the lower end of the brush to one position under pressure from the spring.
11. In an electrical rocker switch of the quiet type, the combination as defined in claim 10 which includes a mounting strap, said mounting strap having an opening therein and having sides engaging with and holding the cover and the rocker in operating position on the base.
12. In an electrical rocker switch of the quiet type, the combinatin as defined in claim 10 which includes a rigid spacer fitted within the cover and supporting the cover on the base; said spacer supporting the rocker in pivotal engagement with the cover and having an opening therein through which the upper end of the brush extends into engagement with the rocker.
13. In an electrical rocker switch of the quiet type, the combination as defined in claim 12 wherein: the fixed contact includes a terminal plate extending vertically along a side wall of the cavity in the base; the common contact includes a terminal plate extending vertically along a side wall of the cavity in the base in spaced relation to the fixed contact; said terminal plates having upper edges engaging with the spacer and being held in the cavity in the base thereby.
14. In a rocker-type electrical switch, the combination which comprises a base having a cavity formed therein; said cavity having a bottom with upstanding side and end walls; at least one fixed contact mounted in said cavity; said fixed contact having a contact arm angularly displaced relative to a transverse center line of the base, a common contact mounted in the cavity in said base in spaced relation to the fixed contact; said common contact including oppositely disposed spaced arms extending along upper side edges of the cavity and across said transverse center line; said spaced arms containing V-shaped notches aligned with each other and with the transverse center line of the base; a movable coNtact brush; oppositely disposed trunnions carried by the brush; said trunnions pivotally supporting the brush in the V-shaped notches in said arms and in electrical contact therewith; said brush having spaced upper ends with shoulders formed thereon extending upwardly from said trunnions and a lower end extending downwardly into the cavity in opposing relation to the contact arm of the fixed contact; said lower end of the contact brush being movable into and out of opposing engagement with said fixed contact in pivotal movement of the brush; a cover supported on the base; a rocker pivotally mounted in the cover at points aligned with the V-shaped notches in the arms of the common contact; said cover containing a frame-like opening surrounding flat angularly disposed upper faces of the rocker; said rocker being pivotally movable between first and second rest position with limited angular movement of less than 20*; a boss formed on the rocker and facing the cavity; said boss containing transverse slots into which the upper ends of the brush extend; said slots positioning the brush transversely of the cavity; a spring compressed betweeen the boss on the rocker and the lower end of the pivoted contact brush; said spring urging the brush into electrical engagement with the common contact and having an end connected to the boss on the rocker; said end of the spring being angularly movable relative to a plane extending through the brush in response to the pivotal movement of the rocker; said movement of the spring imparting angular movement of the rocker to the pivoted contact brush and moving the lower end of the contact brush into and out of engagement with the contact arm of the fixed contact; and a pair of spaced cams carried by the rocker and extending downwardly on opposite sides of the shoulders on the upper ends of the contact brush; said rocker and cams being movable relative to the brush under force exerted by the spring in said rest positions of the rocker; said force urging the cams, respectively, into engagement with the shoulders on the brush at points above the pivot point of the brush the rest positions of the brush; said spring also urging the rocker and the cams thereon into engagement with the shoulders on the contact brush and urging the lower end of the contact brush toward one position thereof under the force exerted on the rocker by the spring in one of the rest positions of the rocker.
US00224880A 1972-02-09 1972-02-09 Rocker-type electrical switch Expired - Lifetime US3770920A (en)

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Cited By (21)

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US4123634A (en) * 1977-04-20 1978-10-31 Cutler-Hammer, Inc. Snap-action switch with contact wiping action
US4636597A (en) * 1984-07-03 1987-01-13 Leopold Kostal Gmbh & Co., Kg Electrical snap switch
US5207317A (en) * 1992-03-31 1993-05-04 Lutron Electronics Co., Inc. Snap-action switch actuator
EP0593077A1 (en) * 1992-10-16 1994-04-20 A. Ahlstrom Corporation Apparatus switch
EP0593079A1 (en) * 1992-10-16 1994-04-20 A. Ahlstrom Corporation Switch
US5380972A (en) * 1993-11-19 1995-01-10 Motorola, Inc. Rocker switch
US5382768A (en) * 1992-11-13 1995-01-17 Leviton Manufacturing Co., Inc. Rocker-type electrical switch
US5384441A (en) * 1992-12-09 1995-01-24 Leviton Manufacturing Co., Inc. Electrical rocker type switch
US5570778A (en) * 1994-04-26 1996-11-05 Leviton Manufacturing Co., Inc. Electrical rocker switch
EP0805469A2 (en) * 1996-05-04 1997-11-05 ABBPATENT GmbH Electrical switchgear
US5836443A (en) * 1994-04-26 1998-11-17 Leviton Manufacturing Co., Inc. Electrical rocker switch
US5934451A (en) * 1998-01-21 1999-08-10 Leviton Manufacturing Co., Inc. Illuminated rocker switch cover assembly employing electroluminescent lamp member
US5950812A (en) * 1999-03-26 1999-09-14 Leviton Manufacturing Co., Inc. Rocker switch using a star spring
US20050098420A1 (en) * 2003-11-07 2005-05-12 Gouhl Erik J. Modular block switch assembly
US7026564B1 (en) * 2004-01-27 2006-04-11 Pass & Seymour/Legrand Paddle switch assembly
US7132616B1 (en) 2004-03-16 2006-11-07 Pass & Seymour, Inc. Electrical wiring device with arc minimizer switch assembly and method
US20100270053A1 (en) * 2001-03-06 2010-10-28 Cheetah Usa Corp. Connection box assembly method
US8029301B2 (en) 2005-01-11 2011-10-04 Cheetah Usa Corp. Wide safety strap for electrical fixtures
CN102592868A (en) * 2012-02-24 2012-07-18 昆山利尔电气实业有限公司 Manufacture method of rotating shaft transmission switch
US8299359B2 (en) 2006-07-18 2012-10-30 Leviton Manufacturing Company, Inc. Wiring device and cover plate snap-on assembly
US11545315B1 (en) 2022-01-24 2023-01-03 Leviton Manufacturing Co., Inc. Outdoor and/or waterproof switch

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Cited By (27)

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Publication number Priority date Publication date Assignee Title
US4123634A (en) * 1977-04-20 1978-10-31 Cutler-Hammer, Inc. Snap-action switch with contact wiping action
US4636597A (en) * 1984-07-03 1987-01-13 Leopold Kostal Gmbh & Co., Kg Electrical snap switch
US5207317A (en) * 1992-03-31 1993-05-04 Lutron Electronics Co., Inc. Snap-action switch actuator
EP0593077A1 (en) * 1992-10-16 1994-04-20 A. Ahlstrom Corporation Apparatus switch
EP0593079A1 (en) * 1992-10-16 1994-04-20 A. Ahlstrom Corporation Switch
US5382768A (en) * 1992-11-13 1995-01-17 Leviton Manufacturing Co., Inc. Rocker-type electrical switch
US5500498A (en) * 1992-11-13 1996-03-19 Liviton Manufacturing Co., Inc. Rocker-type electrical switch
US5595289A (en) * 1992-11-13 1997-01-21 Leviton Manufacturing Co Rocker-type electrical switch
US5630502A (en) * 1992-11-13 1997-05-20 Leviton Manufacturing Co Rocker-type electrical switch
US5384441A (en) * 1992-12-09 1995-01-24 Leviton Manufacturing Co., Inc. Electrical rocker type switch
US5380972A (en) * 1993-11-19 1995-01-10 Motorola, Inc. Rocker switch
US5836443A (en) * 1994-04-26 1998-11-17 Leviton Manufacturing Co., Inc. Electrical rocker switch
US5570778A (en) * 1994-04-26 1996-11-05 Leviton Manufacturing Co., Inc. Electrical rocker switch
US5865303A (en) * 1994-04-26 1999-02-02 Leviton Manufacturing Co., Inc. Electrical rocker switch
EP0805469A2 (en) * 1996-05-04 1997-11-05 ABBPATENT GmbH Electrical switchgear
EP0805469A3 (en) * 1996-05-04 1998-10-21 ABBPATENT GmbH Electrical switchgear
US5934451A (en) * 1998-01-21 1999-08-10 Leviton Manufacturing Co., Inc. Illuminated rocker switch cover assembly employing electroluminescent lamp member
US5950812A (en) * 1999-03-26 1999-09-14 Leviton Manufacturing Co., Inc. Rocker switch using a star spring
US20100270053A1 (en) * 2001-03-06 2010-10-28 Cheetah Usa Corp. Connection box assembly method
US8109785B2 (en) 2001-03-06 2012-02-07 Cheetah Usa Corp. Connection box assembly method
US20050098420A1 (en) * 2003-11-07 2005-05-12 Gouhl Erik J. Modular block switch assembly
US7026564B1 (en) * 2004-01-27 2006-04-11 Pass & Seymour/Legrand Paddle switch assembly
US7132616B1 (en) 2004-03-16 2006-11-07 Pass & Seymour, Inc. Electrical wiring device with arc minimizer switch assembly and method
US8029301B2 (en) 2005-01-11 2011-10-04 Cheetah Usa Corp. Wide safety strap for electrical fixtures
US8299359B2 (en) 2006-07-18 2012-10-30 Leviton Manufacturing Company, Inc. Wiring device and cover plate snap-on assembly
CN102592868A (en) * 2012-02-24 2012-07-18 昆山利尔电气实业有限公司 Manufacture method of rotating shaft transmission switch
US11545315B1 (en) 2022-01-24 2023-01-03 Leviton Manufacturing Co., Inc. Outdoor and/or waterproof switch

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