Abstract:
A switch for adjusting a plurality of states of a load is provided having a large paddle actuator for adjusting a first state of a lightning load and incorporating an integrated rocker switch for adjusting a second state of a lighting load. The switch also comprises a concealed air-gap switch for disconnecting the switch from line phase when the paddle actuator is placed in a disconnect position and connecting the switch to line phase when the paddle actuator is placed in a connect position.

Description:
[0001]     This application claims the benefit of the filing date of a provisional application having Ser. No. 60/618,028, which was filed on Oct. 12, 2004. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     1. Field of the Invention  
         [0003]     The present invention relates to a switch device used to control electrical systems and/or devices.  
         [0004]     2. Background of the Invention  
         [0005]     Switches and controls for electrical systems and devices have been developed that control more than one state of an electrical load or device. While it is now commonplace for devices to control a plurality of states, such as the ON/OFF/DIM/BRIGHT state of a lighting load, the integration of multiple control features in a single device typically requires more complicated manufacturing processes to accommodate the different features. It is desirable, therefore to produce an integrated control device that is simple to manufacture and less expensive to produce.  
       SUMMARY OF THE INVENTION  
       [0006]     The present invention is directed to an integrated dimmer switch having a sub-frame that permits simplified manufacturing and incorporating a concealed power switch. The switch has multiple functions and is capable of controlling the status (e.g. ON/OFF/DIM/BRIGHT) state of an electrical load (e.g. lighting load) connected to the switch and is also capable of disconnecting electrical power phase from the switch by actuating a concealed power switch within the integrated switch device. The switch is characterized by relatively large “paddle” actuator incorporating a dimmer switch along an outer edge of the paddle. The dimmer comprises a rocker assembly to facilitate the control of the status of the load connected to the integrated switch and the power switch is activated or deactivated by placing the paddle actuator in one of two positions. 
     
    
     BRIEF DESCRIPTION OF THE DRAWING  
       [0007]     The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention.  
         [0008]     In the Drawings:  
         [0009]      FIG. 1  depicts a dimmer switch in accordance with the present invention;  
         [0010]      FIG. 2  depicts a housing for the switch of  FIG. 1 ;  
         [0011]      FIG. 3  depicts a dimmer actuator for the switch of  FIG. 1 ;  
         [0012]      FIG. 4  details an actuating portion of an actuator for the switch of  FIG. 1 ;  
         [0013]      FIG. 5  depicts a circuit board used in the present invention;  
         [0014]      FIG. 6  details actuation of an power/disengagement switch used in the present invention;  
         [0015]      FIG. 7  details actuation of a micro-switch in accordance with the present invention;  
         [0016]      FIG. 8  details an actuator used in the present invention;  
         [0017]      FIG. 9  depicts the switch of the present invention with the power switch engaged; and  
         [0018]      FIG. 10  depicts the dimmer switch of the present invention with the power switch disengaged.  
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0019]     The dimmer switch of the present invention is characterized by a large paddle actuator having an intensity actuator embedded within its surface. The paddle actuator is biased to a rest position by a first leaf spring formed in a sub-panel below the paddle. A user may press the paddle to overcome the bias and cause the paddle to rotate about a first pivot to a stressed position wherein a ON/OFF switch is actuated. When the paddle is released it returns to the rest position. Thus, the ON/OFF switch is actuated only momentarily; the paddle does not alternate between an ON position and an OFF position; the paddle has a stressed position and an unstressed position.  
         [0020]     Similarly, an intensity actuator can rock about a second pivot. The intensity actuator is biased to a rest position by leaf springs formed in the sub-panel. These springs operate to prevent rotation of the intensity actuator about the second pivot in either a clockwise or counter-clockwise direction respectively. A user may press the intensity actuator to overcome the bias of one or the other of the leaf springs to decrease or increase intensity. When the intensity actuator is released, it returns to its rest position. The intensity actuator is located within an opening of the paddle actuator and operates independently of the paddle actuator. The Paddle actuator of the switch of the present invention can also be rotated about the second pivot to a position that actuates a power (an air-gap) switch concealed within the switch.  
         [0021]     Referring now to  FIG. 1 , depicted therein is a switch  10  of the present invention comprising a housing  104 , housing cover  102  and paddle actuator  100 . The paddle actuator  100  has an opening  112  through which a light pipe  111  and a rocker switch  108  extend. Light pipe  111  has legs  111 A,  111 B,  111 C and  111 D. The bottom edge of paddle actuator  100  incorporates a locking tab (not shown) beneath light  114 . Light  114  can be implemented with an LED (Light Emitting Diode). The switch  10  is adapted to be installed in conjunction with a faceplate  106  to permit installation of the switch  10  to a wall or other mounting surface.  
         [0022]     Referring now to  FIGS. 2 and 3 , depicted therein are a top perspective view of housing cover  102  showing the orientation of rocker switch  108 . As shown in  FIG. 2 , housing cover  102  has leaf springs  236 ,  138 ,  140  and light pipe  111  formed as an integral part of the housing cover  102 . Housing cover  102  also has axle wells  144  and  146  formed within it in which axles  110 B of the paddle actuator  100  shown in  FIG. 4 , are positioned to snap fit into wells  144  and  146 , thus coupling the paddle actuator  100  to the housing cover  102 . Still referring to  FIG. 2 , light pipe  111  rises vertically from the surface of housing cover  102  and has a peg  142 A extending perpendicularly therefrom. Rocker  108  has an opening through which peg  142 A extends when rocker  108  is mounted onto the light pipe  111 . Rocker  108  mounted such that it engages with leaf springs  138  and  140  when rotated about peg  142 A in a clockwise direction or a counterclockwise direction, respectively.  
         [0023]      FIG. 3  shows the interaction of the rocker  108  with leaf springs  138  and  140 . As depicted therein, directly positioned on a circuit board underneath leaf springs  138  and  140  are micro switches  134  and  136  which have corresponding spring loaded plungers  134 A and  136 A respectively. When rocker  108  is depressed so as to rotate in a clockwise direction, it engages leaf spring  138  which in turn pushes down on spring loaded plunger  136 A of micro-switch  136  thus activating the microswitch. Upon release of rocker  108 , the leaf spring  138  recoils back to its original position allowing the plunger  136 A of micro-switch  136  to spring back to its original position. Similarly, when rocker  108  is depressed (in the direction show by arrow  152 ) so as to rotate in a counterclockwise direction, it engages leaf spring  140  which in turn pushes down on spring loaded plunger  134 A of micro-switch  134  thus activating the micro-switch. Upon release of rocker  108 , leaf spring  140  recoils back to its original position. The perpendicular peg  142 A of light pipe  111 , leaf springs  138  and  140 , light pipe  111  and micro-switches  136  and  134  constitute a rocker switch arrangement which, when activated, can be used to control the intensity of a light or the relevant speed of a fan or any other similar electrical device and/or system connected to the switch of the present invention.  
         [0024]     Referring now to  FIG. 4 , depicted therein is a perspective view of the back of paddle actuator  100  shown in  FIG. 1 . As depicted therein, integrally formed on the rear of paddle actuator  100  is power switch actuator tab  410 . Note that the power switch (not shown) can be implemented with an air gap switch or any other switch that is able to disconnect a power line from one side of a switch or other device. Hereinafter the power switch will be referred to as an air gap switch. It will be readily understood that the power switch can be implemented with other types of switches and is not limited to the an air-gap switch. Formed on actuator  410  are axles  110 B and air gap switch actuating tab  110 A. Also formed on paddle actuator  100  are switch actuating tab  113 A and paddle locking tab  113 . Paddle locking tab  113  further comprises shaped guide surfaces  113 B and  113 C respectively.  
         [0025]     Referring now to  FIG. 5 , depicted therein is a printed circuit board  131  Certain elements of printed circuit board  131  are located to engage with corresponding elements of paddle actuator  100  of  FIG. 1  and housing cover  102  of  FIG. 2  wherein when assembled, housing cover  102  is sandwiched between paddle actuator  100  and printed circuit board  131 . The sub assembly comprising paddle actuator  100 , housing cover  102  and circuit board  131  are installed to housing  104  to complete the switch  10  of  FIG. 1 . As shown in  FIG. 5 , circuit board  131  comprises micro-switch  132  having a spring-loaded plunger  132 A. The power switch implemented with the preferred embodiment is an air-gap switch  148  having a spring loaded lever  148 A and is mounted on another printed circuit board (not shown) located underneath printed circuit board  131 . Air gap switch  148  extends through a cut out in printed circuit board  131  as shown. Micro-switches  134  and  136  and their corresponding spring-loaded plungers  134 A and  136 A are located on circuit board  131  and placed to correspond to the placement of leaf springs  138  and  140  of  FIG. 2  respectively. LEDs  538 ,  540 ,  542 ,  544  and  546  are placed to correspond to the locations of the legs of light pipe  111  such that when housing cover  102  and circuit board  131  are cooperatively assembled, each of LEDs  538 ,  540 , 542 ,  544  and  546  are located directly beneath a corresponding leg of light pipe  111 .  
         [0026]     Referring back to  FIG. 2 , the housing cover  102  has an opening  248  through which the actuator tab  110 A of the air gap actuator  410  (See  FIG. 4 ) extends to engage with air gap switch  148  when cover  102  is mated with paddle actuator  100  and circuit board  131 .  
         [0027]      FIG. 6  details a portion of the switch of the present invention and shows the cooperative assembly of cover paddle  100 , housing cover  102  and printed circuit board  131  with respect to the actuation of air gap switch  148 . As depicted therein, when paddle actuator  100 , housing cover  102  and circuit board  131  are cooperatively assembled the air gap actuating tab  110 A of air gap actuator  410  extends through opening  248  of housing cover  102  and makes contact with spring-loaded lever  148 A of air gap switch  148 . In operation of the switch  10  of the present invention, pressing paddle actuator  100  in the direction shown by arrow  153  in and thereby actuator  410  in the direction of the arrow establishes positive contact between actuator tab  110 A and lever  148 A, opens the air gap switch  148  and interrupts connection of the switch  10  to line phase (not shown) or electric power. Similarly, paddle actuator  100 , and in turn, cover actuator  410  can be pulled from lever  148 A in a direction opposite of that shown by arrow  153  thereby allowing lever  148 A to close air-gap switch  148 , thereby connecting switch  10  to line phase.  
         [0028]     The operation of the air-gap switch can be the reverse of the above description; that is when the paddle is depressed, the air-gap switch connects the power line (not shown) to the switch of the present invention and when paddle  100  is pulled, the air-gap switch disconnects the power from the switch  10  of the present invention.  
         [0029]     When paddle actuator  100 , housing cover  102  and circuit board  131  are cooperatively assembled, paddle actuator  100  pivots along axles  110 B which are snap-fit into wells  144  and  146 . This arrangement brings actuating tab  113 A into resilient contact with leaf spring  236  formed in housing cover  102  see  FIGS. 2, 4 , and  7 . Located directly beneath the point of resilient contact between tab  113 A and leaf spring  236  is micro-switch  132  and spring loaded plunger  132 A; this arrangement is depicted in  FIG. 7 . Referring to  FIG. 7 , if paddle actuator  100  is depressed in the direction shown by arrow  155 , the bias in leaf spring  236  is overcome and leaf spring  236  is brought into contact with plunger  132 A of micro-switch  132 . In operation of the switch  10  shown in  FIG. 1  this action changes the state of a load connected to switch  10  from OFF to on or vice-versa.  
         [0030]     Referring now to  FIG. 8 , depicted therein is a detail of a portion of paddle actuator  100 . As shown in  FIG. 4 , paddle actuator  100  comprises actuator tab  113 A, locking tab  113  and surfaces  113 B and  113 C.  FIG. 8  is a detail of actuator tab  113 A, tab  113  and surfaces  113 B and  113 C. As shown un  FIG. 7 , actuator  113 A engages spring  236  to actuate switch  132 . As shown in  FIG. 8 , adjacent to actuator  113 A is locking surface  113 C. With reference to  FIG. 9  when cover  100  is in the rest position locking surface  11   3 C and tab  113  are inserted in opening  123  (See  FIG. 2 ) of housing cover  102  whereby locking surface  113 C resiliently engages tab  124  of cover  102  (see  FIG. 2 ) to retain cover  100  in place for normal switch operation. The sloping ramp configuration of locking surface  113 C permits retraction of tab  113  and surface  113 C from opening  123  when sufficient force is applied to the bottom portion of cover  100 , as shown in  FIG. 10 . Still referring to  FIG. 10 , when the bottom portion of cover  100  is pulled in the direction of the arrow by a user, it disengages surface  113 C from tab  124  and rotates cover  100  upward and pivots the top portion of cover  100  around axles  110 B. The pivot action permits air-gap actuator  410  (see  FIG. 6 ) to contact lever  148 A of air-gap switch  148  and thereby disengaging line phase from switch  10  as described above in the discussion of  FIG. 6 . The extent to which cover  100  can be pulled out is restricted by the extent to which the upper extent of cover  100  can rotate with respect to housing  102  i.e., when the upper part of cover  100  comes into contact with the upper portion of housing  102  cover  100  cannot rotate any further.  
         [0031]     While there have been shown and described and pointed out the fundamental novel features of the invention as applied to the preferred embodiment, as it presently contemplated for carrying them out, it will be understood that various omissions and substitutions and changes of the form and details of the device illustrated and in its operation may be made by those skilled in the art, without departing from the spirit of the invention.