Abstract:
A switch assembly includes a base, a flat spring, a switch, and an actuating member. The base includes a central channel. The flat spring may be pivotally secured to a portion of the base. The switch is proximate the flat spring, and is configured to selectively open and close a circuit, such as an ignition circuit of a vehicle. The actuating member is positioned through the central channel and abuts the flat spring. The actuating member is configured to be engaged toward the flat spring in order to activate the switch, wherein movement of the actuating member in a first direction causes the flat spring to move in a second direction into the switch to activate the switch. The first direction may be perpendicular to the second direction.

Description:
RELATED APPLICATIONS 
   This application relates to and claims priority benefits from U.S. Provisional Patent Application No. 60/811,886 entitled “Seat Switch,” filed Jun. 8, 2006, which is hereby incorporated by reference in its entirety. 

   FIELD OF THE INVENTION 
   Embodiments of the present invention generally relate to a safety switch assembly, and more particularly to a safety switch assembly that may be used with respect to vehicle seats for deactivating the vehicle if an operator is not properly seated. 
   BACKGROUND OF THE INVENTION 
   Various motorized vehicles are configured to automatically deactivate if an operator is not properly seated. For example, a riding lawn mower may be configured to deactivate if an operator moves off a seat. The deactivation of the vehicle prevents the operator and others from being injured by a runaway vehicle that is not being controlled by anyone. 
   U.S. Pat. No. 4,795,865, entitled “Safety Switch for Automatic De-Activation of A Motor Vehicle” (the “&#39;865 patent”) discloses a safety switch assembly that includes a cover that moves in response to the presence of a vehicle operator on the seat and an actuator that moves with the cover to open and close switch contacts inside an actuator housing. Movement of the cover forces the actuator to cause a torsion spring switch piece to bridge a gap between the contacts in a normally open switch and moves the switch piece from between the contract in a normally closed switch. 
   As shown in the &#39;865 patent, the switch contacts 48 and 50 are, however, exposed. As such, if water or other liquids are spilled on the seat, the liquids may contact the exposed switch contacts. Moreover, the exposed switch contacts may be contaminated by deteriorating seat materials, such as foam within the seat. 
   Additionally, conventional switch assemblies may be susceptible to being stuck in an activated position. For example, an actuating member may be stuck in an activated position, such as if a spring member loses elasticity, or a portion of the actuating member is snagged by an internal feature of the assembly, even after an operator dismounts the vehicle. Thus, the vehicle may remain activated even when an operator is not positioned to control it. 
   Thus, a need exists for an improved seat switch assembly that does not include exposed switch contacts. Additionally, a need exists for a seat switch assembly with a lower mounting profile than existing seat switch assemblies. Further, a need exists for a fail-safe seat switch assembly. 
   SUMMARY OF THE INVENTION 
   Certain embodiments of the present invention provide a switch assembly that includes a base, a flat spring, a switch, and an actuating member. The base includes a central channel. The flat spring may be pivotally secured to a portion of the base. The switch is proximate the flat spring, and is configured to selectively open and close a circuit, such as an ignition circuit for a vehicle. 
   The actuating member is positioned through the central channel and abuts the flat spring. The actuating member is configured to be engaged toward the flat spring in order to activate the switch, wherein movement of the actuating member in a first direction causes the flat spring to move in a second direction into the switch to activate the switch. When the actuating member is disengaged, the flat spring returns to an at-rest position in which the flat spring moves into a deactivation position with respect to the switch. The first direction may be perpendicular to the second direction. For example, vertical movement of the actuating member may cause a portion of flat spring to move horizontally into the switch. 
   The flat spring may include an elongated beam integrally connected to a post which is, in turn, integrally connected to a bent clip. A distal tip of the elongated beam may be secured to a portion of the base. For example, the distal tip may be pinched, sandwiched, or otherwise trapped between a portion of the base and another structure, such as a cover. The bent clip may be secured to another portion of the base. The elongated beam bows in the first direction when engaged by the actuating member, thereby causing the post to rotate or otherwise deflect in the second direction into the switch. The elongated beam may taper toward the tip. 
   The switch assembly may also include a first cover secured to the base. The switch may be sealingly secured within a switch chamber defined between the base and the first cover. 
   The actuating member may include s a second cover secured to a washer. A coil spring may be positioned between the second cover and the base. The washer may include a central protuberance connected to a circumferential flap that is pivotally biased into the base. For example, the circumferential flap may be pivotally biased into interior edges of the base that define the central channel. 
   Certain embodiments of the present invention also provide a switch assembly that includes a base having a central channel, a first cover secured to the base, and a switch configured to selectively open and close an activation circuit. The switch may be completely disposed between the base and the first cover. The switch assembly may also include a spring member secured to a portion of the base, and an actuating member positioned through the central channel and abutting the spring member. The actuating member is configured to be engaged toward the spring member in order to urge a portion of the spring member into abutment with the switch, thereby activating the switch. 
   Certain embodiments of the present invention provide a switch assembly may be configured to be positioned within a seat of a vehicle. The switch assembly operates to activate operation of the vehicle when an operator is seated. Further, the switch assembly operates to deactivate operation of the vehicle when the operator dismounts from the seat 

   
     BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS 
       FIG. 1  illustrates an isometric bottom view of a seat switch assembly according to an embodiment of the present invention. 
       FIG. 2  illustrates an isometric cross-sectional internal view of a seat switch assembly according to an embodiment of the present invention. 
       FIG. 3  illustrates an isometric top view of a flat spring according to an embodiment of the present invention. 
       FIG. 4  illustrates a side view of a flat spring in a non-deflected position according to an embodiment of the present invention. 
       FIG. 5  illustrates a side view of a flat spring in a deflected position according to an embodiment of the present invention. 
   

   Before the embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including” and “comprising” and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items and equivalents thereof. 
   DETAILED DESCRIPTION OF THE INVENTION 
     FIG. 1  illustrates an isometric bottom view of a seat switch assembly  10  according to an embodiment of the present invention. The seat switch assembly  10  is configured to be positioned within a vehicle seat and connected to an ignition circuit of the vehicle. The switch assembly  10  may be used with various vehicles and machines that are configured to be controlled by an operator. 
   The seat switch assembly  10  includes a base  12  secured to a bottom cover  14 . The base  12  may snapably secure to the bottom cover  14  through beams  16  that snapably secure to, or within, reciprocal features, such as slots or channels  18 , formed in the bottom cover  14 . Optionally, the base  12  may secure to the bottom cover  14  through latches, clasps, screws, bolts, bonding, glue, and the like. 
   A top cover or button  20  is also secured to the base  16 , as discussed with respect to  FIG. 2  below. A coil spring  22  is disposed between an underside of the top cover  20  and a top surface of the base  12 . 
     FIG. 2  illustrates an isometric cross-sectional internal view of a seat switch assembly  10 . A mid-section of the bottom cover  14  downwardly protrudes to form a basin  23 . A switch chamber  24  is defined between the base  12  and one end of the bottom cover  14 . A spring chamber  26  is also defined between the base  12  and the bottom cover  14  and is adjacent the switch chamber  24 . As shown in  FIG. 2 , the spring chamber  26  may span the distance of the basin  23 . Additionally, a tip chamber  28  is defined between the base  12  and the bottom cover  14  and is distally located from the switch chamber  24 . Thus, the switch chamber  24  is located on one side of the spring chamber  26 , while the tip chamber  28  is located on the other side of the spring chamber  26 . While the base  12  and the bottom cover  14  are shown as two separate components, the base  12  and the bottom cover  14  may, optionally, be integrally formed as a single unit. 
   A switch  30  is secured within the switch chamber  24 . The switch  30  may be sealed within the switch chamber  24  by the base  12  and the bottom cover  14 . Thus, the switch  30  may be completely within the seat switch assembly  10  such that no portion of the switch  30  extends out of the seat switch assembly  10 . The switch  30  includes an electrical input  32  configured to be connected to an electrical wire, contact, or the like of an ignition circuit of a vehicle. 
     FIG. 3  illustrates an isometric top view of a flat spring  34  according to an embodiment of the present invention. The flat spring  34  includes a horizontal elongated beam  36  integrally connected to an upright beam or post  38 . An upper end of the upright beam  38  is, in turn, integrally connected to a downwardly bent clip  40 . 
   As shown in  FIG. 3 , the elongated beam  36  tapers toward a tip  42 . Thus, the distal portion  44  of the beam  36  may bow and flex easier than the proximal portion  46  of the beam  36  that is closer to the upright beam  38 . Because the proximal portion  46  includes more material than the distal portion  44 , the proximal portion  46  is stiffer than the distal portion  44 . 
   Referring again to  FIG. 2 , the bent clip  40  is secured over a top surface of a ledge  47  (or other such support point) of an interior support wall  48  of the base  12 . A downwardly angled groove  49 , which provides a clearance  51  for a small degree of rotation about the ledge  47 , may be formed in the ledge  47 . That is, the short clearance area  51  may exist between a distal end  51  of the bent clip  40  and the groove  49  of the ledge  47  to allow for the bent clip  40  to pivotally deflect about the ledge  47 , which serves as a pivot point. The bent clip  40  is secured into the groove  49  so that a portion of the bent clip  40  abuts the ledge  47 , while a clearance area exists between the ledge  47  and the distal tip of the bent clip  40 . The downward cant of the bent clip  40  ensures that the bent clip  40  remains secured to the support wall  48 . Additionally, the coil spring  22  may abut into the bent clip  40 , thereby exerting a compressive force into the bent clip  40 . The force exerted into the bent clip  40  by the coil spring  22  may also serve to maintain the position of the bent clip  40  with respect to the ledge  47  and against the vertical wall  50  due to a short offset between the ledge  47  and the point of contact of the coil spring  22 . 
   In the deactivated position, the upright beam  38  conforms to a lateral surface  50  of the support wall  48  of the base  12 . As mentioned above, the flat spring  34  is secured to the support wall  48  by way of the bent clip  40  securing to or over the ledge  47  and being trapped under the coil spring  22 . The upright beam  38  does not, however, fasten to the lateral surface  50  of the support wall  48 . Instead, the upright beam  38  overlays the lateral surface  50 . A lower end  52  of the upright beam  38  is positioned between the lateral surface  50  of the support wall  48  and the switch  30 . 
   The elongated beam  36  of the flat spring  34  spans between the interior support wall  48  through the spring chamber  26  to an interior support wall  54  of the base  12  located opposite the support wall  48 . The support walls  48  and  54  are part of a circumferential support wall structure that defines a central channel  56  through the base  12 . 
   The distal end  44  of the beam  36  is restrained between the support wall  50  and an upper ridge  58  of the basin  23 . The tip  42  of the flat spring  34  extends into the tip chamber  28 . 
   The top cover  20  includes an upper wall  60  having downwardly curved outer edges  62 . As shown in  FIG. 2 , the coil spring  22  is positioned underneath the top cover  20  and the ledge  47 . A retaining wall  63  upwardly extends from the base  12  and surrounds a circumference of the coil spring  22 . The retaining wall  63  ensures that the coil spring  22  does not shift with respect to the base  12 . Additionally, the curved edges  62  of the top cover  22  ensure that the coil spring  22  does not eject from the top cover  22 . A column  64  downwardly extends from the top cover  20 . A washer channel  66  is formed through the column  64 . 
   A washer  68  securely fastens to the top cover  20  through the washer channel  66 . The top cover  20  and the washer  68  form an actuation member configured to move into the flat spring  34 . The washer  68  includes a semi-spherical central protuberance  70  integrally connected to a circumferential flange  72  that outwardly extends from the protuberance  70 . A central column  74  upwardly extends from the protuberance  70  and is securely positioned within the washer channel  66 . A fastener  76 , such as a screw or bolt, is used to securely fasten the top cover  20  to the washer  68 . Alternatively, the washer  68  and the top cover  20  may be integrally formed as a single unit. 
   The top cover  20  is secured to the base  12  by way of the circumferential flange  72  of the washer  68  being compressively sandwiched underneath the ledge  47  of the interior support walls  48  and  54 . The flat spring  34  exerts a resistive force into the protuberance  70  of the washer  68  in the direction of arrow A that pushes the washer  68  in the same direction. Thus, the flange  72  is forced into an underside of the ledge  47 . 
   The coil spring  22  is positioned between an underside of the top cover  20  and a top surface of the ledge  47  that surrounds the central channel  56  formed through the base  12 . The coil spring  22  exerts a resistive force into the top cover  20  in the direction of arrow A, and a resistive force into the ledge  47  in the direction of arrow A′. 
   In operation, when an operator engages the top cover  20 , such as by sitting on a vehicle seat, the top cover  20  moves down in the direction of arrow A′, thereby compressing the coil spring  22  between the top cover  20  and the ledge  47  of the base  12 . As the top cover  20  moves in the direction of arrow A′, the protuberance  70  is forced downward into the elongated beam  36  of the flat spring  34 . The movement of the protuberance  70  into the beam  36  downwardly bows the beam  36 . The basin  23  of the bottom cover  14  provides adequate space for the beam  36  to bow. As the beam  36  downwardly bows, the upright beam  38  laterally swings in the direction of arrow B about the pivot point defined between the ledge  47  and the bent clip  40 . The upright beam  38  is thus moved into an activation contact  80  of the switch  30 . Engagement of the activation contact  80  activates the switch  30  to complete an ignition circuit. Thus, the machinery, such as a lawn mower, may be activated. 
   If force is exerted into the top cover  20  in an angled direction, such as shown by arrow C, the protuberance  70  still moves downwardly into the flat spring  34  in the direction of arrow A′. In this situation, the top cover  20  may exert an angled force with respect to the base  12 . However, the force is transferred to the washer  68 , and the circumferential flange  72  pivots with respect to the ledge  47  to counteract the angled force, thereby ensuring that the protuberance  70  is downwardly directed toward the center of the beam  36  in the direction of arrow A′. Thus the switch assembly  10  transmits the motion of the top cover  20  to the switch  30  from any angle of actuation. 
     FIG. 4  illustrates a simplified side view of the flat spring  34  in a non-deflected position according to an embodiment of the present invention. In this position, the elongated beam  36  is substantially straight and horizontal. Also, the upright beam  38  is substantially straight and vertical. 
     FIG. 5  illustrates a simplified side view of the flat spring  34  in a deflected position according to an embodiment of the present invention. When force is applied to the elongated beam  36 , such as through the washer  68  (shown in  FIG. 3 ), in the direction of arrow A′, the elongated beam  36  downwardly bows, thereby forcing the upright beam to swing sideways about the ledge  47 , which acts as a pivot point, in the direction of arrow B. The upright beam  38  pivotally deflects in the direction of arrow B about the pivot point defined by the ledge  47  due to the moment arm defined by the contact point of the protuberance  70  (shown in  FIG. 2 ) and the bent clip  40  over the ledge  70 . 
   As shown in  FIG. 5 , the tip  42  of the flat spring  34  is restrained or otherwise contained between the interior support wall  54  of the base  12  (shown in  FIG. 2 ) and the upper ridge  58  of the basis  23  (shown in  FIG. 2 ). Because the flat spring  34  is resilient, when the flat spring  34  bows or otherwise deflects, the restrained tip  42  exerts a resistive force that tends to bring the flat spring  34  back to its at-rest position. That is, the pivoting nature of the tip  42  exerts a pulling force into the flat spring  34  that tends to flatten the beam  36  and move the beam  38  in the direction of B′. Thus, when force is no longer applied to the flat spring  34  in the direction of arrow A′, the force exerted by the restrained tip  42  flexes the flat spring  34  back to its at-rest position, in which the upright beam  38  does not exert an activating force into the switch  30  (shown in  FIG. 3 ). As such, the flat spring  34  provides a fail-safe mechanism that ensures the ignition circuit is disconnected when an activating force is no longer applied to the seat switch assembly  10  (shown in  FIGS. 1-2 ). 
   Referring to  FIGS. 3-5 , because the beam  36  tapers toward the tip  42 , the distal portion  44  is allowed to deflect more than the proximal portion  46 . The net effect of increasing bowing toward the tip  42  imparts a more immediate and direct sideway displacement in the direction of arrow B due to the deflection and resultant force of the distal portion  44  being transferred to the stiffer proximal portion  46 . While the stiffer proximal portion  46  does not deflect or bow as much the tapered distal portion  44 , the proximal portion  46  quickly and efficiently transfers the lateral movement component of the distal portion  44  to the upright beam  38 , which responsively rotates in the direction of arrow B. Thus, engagement of the top cover  20  (shown in  FIGS. 1 and 2 ) is quickly and efficiently transferred to the switch  30  (shown in  FIG. 2 ). 
   Referring to  FIGS. 1-5 , when force is no longer applied to the top cover  20  in the direction of arrow A′, the flat spring  34 , because it is resilient, returns to its original position. Thus, the elongated beam  36  flattens out, and the upright beam  38  moves away from the switch  30 , thereby disconnecting the ignition circuit. As the elongated beam  36  flattens out, it exerts an upwardly directed force into the protuberance  70  in the direction of arrow A. The force exerted into the protuberance  70  moves the washer  68 , and therefore the top cover  20  in the direction of arrow A. At the same time, the coil spring  22  decompresses and pushes the top cover  20 , and therefore the washer  68 , in the direction of arrow A. Thus, the flat spring  34  no longer exerts an activating force into the switch  30 , and the top cover  20  is moved back into a disengaged position. 
   Thus, embodiments of the present invention provide an improved seat switch assembly that does not include exposed switch contacts. As shown in  FIG. 2 , for example, the switch  30  is completely disposed within the seat switch assembly  10 . Thus, the switch  30  is protected from foreign objects, substances and contaminants. 
   Additionally, embodiments of the present invention provide a seat switch assembly with a lower mounting profile than existing seat switch assemblies. Because the switch  30  is laterally disposed within the assembly  10 , the vertical profile of the assembly  10  is relatively small. 
   Further, embodiments of the present invention provide a fail-safe seat switch assembly. When force is no longer applied to the top cover  20 , the resilient flat spring  34 , as described above, flexes or springs back to an at-rest position in which the switch  30  is no longer engaged. 
   While various spatial terms, such as front, rear, upper, bottom, lower, mid, lateral, horizontal, vertical, and the like may used to describe embodiments of the present invention, it is understood that such terms are merely used with respect to the orientations shown in the drawings. The orientations may be inverted, rotated, or otherwise changed, such that a front portion is a rear portion, and vice versa, horizontal becomes vertical, and the like. 
   Variations and modifications of the foregoing are within the scope of the present invention. It is understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text and/or drawings. All of these different combinations constitute various alternative aspects of the present invention. The embodiments described herein explain the best modes known for practicing the invention and will enable others skilled in the art to utilize the invention. The claims are to be construed to include alternative embodiments to the extent permitted by the prior art. 
   Various features of the invention are set forth in the following claims.