Multi-function electrical switch assembly

A multi-function electrical switch assembly has body sections defining therebetween a chamber containing spaced fixed electrical contacts and spaced moveable electrical contacts carried by a plunger member which is resiliently restrained from moving the moveable contacts toward the fixed electrical contacts; a second set of electrical terminals are defined by a fixed terminal connected to a moveable deflectable arm carrying a first contact which, upon such arm being sufficiently deflected by the plunger, engages a cooperating second fixed contact.

BACKGROUND OF THE INVENTION 
The prior art has proposed various forms of normally open electrical switch 
assemblies; however, such have not been found to satisfy a great number of 
application requirements. For example, especially where relatively high 
electrical currents are to be experienced in the switch itself, any slow 
movement of one moveable electrical contact toward another will quickly 
result in deterioration of such electrical contacts because of electrical 
arcing which will take place between such contacts as they experience slow 
relative motion therebetween. 
Attempts to, in turn, cause rapid motion of such moveable contacts as by 
the employment of manually actuated cam means have not proven to be 
satisfactory because, aside from the increased cost of such cams, the 
motion of the cam is still, in the main, directly dependent upon the rate 
of speed at which manual actuation is performed. 
Other attempts at creating switch assemblies wherein a snap action is 
introduced into the movement of such moveable contacts have, to a 
functional degree, succeeded; however, such arrangements have usually 
required sensitive over-center type tripping mechanisms or other 
relatively complex and costly mechanisms. Further, in such prior art 
snap-acting switch assemblies it is usually impossible to attain such a 
snap-action movement when the total permissible travel of the related 
actuating member is very short. 
Further, the prior art has failed to provide, in the same switch assembly, 
means for both affecting a snap-action switching function as well as 
additional switching functions not requiring a snap-action. 
Accordingly, the invention as herein disclosed and described is primarily 
directed to the solution of the above as well as other related problems. 
SUMMARY OF THE INVENTION 
According to the invention, an electric switch assembly comprises at least 
first and second relatively fixed electrical conductor means spaced from 
each other, third electrical conductor means normally operatively secured 
to said first but spaced from said second electrical conductor means, 
resiliant restraining means operatively connected to said third electrical 
conductor means spaced from said first and second electrical conductor 
means, fourth and fifth fixed spaced electrical contact means adapted for 
cooperative engagement with respective sixth and seventh moveable 
electrical contact means, and actuator means effective for moving said 
sixth and seventh contact means toward said fourth and fifth contact means 
and for creating a force against said resilient restraining means so as to 
cause said third electrical conductor means to move toward said second 
electrical conductor means and thereby complete an electrical circuit 
across said first and second electrical conductor means and said fourth 
and fifth contact means. 
Various general and specific objects and advantages of the invention will 
become apparent when reference is made to the following detailed 
description considered in conjunction with the accompanying drawings.

DESCRIPTION OF THE PREFERRED EMBODIMENTS 
Referring now in greater detail to the drawings, FIGS. 1 and 2 illustrate a 
switch assembly 10, constructed in accordance with the teachings of the 
invention, as comprising first and second housing sections 12 and 14, 
preferably of electrically nonconductive material, which, when assembled, 
generally define a chamber 16 therebetween. 
A plunger-like actuating member 18, preferably formed of electrically 
non-conductive material, has a first stem portion 20 slidably received as 
within a guide passageway 22 formed in housing section 12 and a second 
relatively enlarged cylindrical portion 24 slidably received within a 
cooperating cylindrical chamber or recess 26 also formed in housing or 
body section 12. Preferably, stem portion 20 has its longitudinal sides 
flatted, as for example, to be of square cross-section as shown in FIG. 9, 
in order to have such flat sides cooperate with juxtaposed squared sides 
of aperture 22. The enlarged portion 24 is preferably provided with an 
annular peripheral groove or recess 28 which, in turn, receives an annular 
seal 30 which, in fact, may be of the O-ring type. Seal 30 functions to 
seal the inner spaces of the switch assembly 10 from the ambient 
atmosphere. 
A relatively enlarged chamber 32 accepts a compression spring 34 which has 
one end operatively seated against surface 36 of transverse wall portion 
38 and has its other end operatively seated against axial end surface 40 
of cylindrical enlargement 24. Near the inner-most end 42 of stem 18 is 
formed an annular groove or recess 44 which receives a C-like retainer or 
abutment member 46 effective to serve as an abutment or stop in 
cooperation with surface 48 of wall portion 38. As spring 34 normally 
urges plunger member 18 to the left, as viewed in FIG. 1, abutment or stop 
means 46 limits the left-ward movement of plunger 18. 
An extension 50, carried by plunger means 18, has a free end 52 which is 
operatively received within a recess 54 formed within a cap or button-like 
member 56. Preferably, cap member 56 is formed of material having a 
noticeable degree of resilient deflection whereby an internally formed 
annular detent ring portion 58, and the body portion of cap 56 thereabout, 
can undergo resilient deflection during assembly of the cap 56 to 
extension 50 and eventually enabling such ring 58 to be received with the 
annular recess 60 formed generally peripherally in extension 50. 
The shank portion of body section 12 is preferably threaded as at 62 as for 
threadable engagement with cooperating nuts 64 and 66 between which a 
lock-type washer 68 may be situated. Nuts 64 and 66 may be employed for 
retaining the entire switch assembly 10 to a suitable related support 
structure as, for example, fragmentarily illustrated at 70. 
Generally, as can be seen, when the actuating means 56 is engaged and 
pressed generally inwardly toward the remaining portion of the switch 
assembly 10, plunger means 18, against the resilient resistance of spring 
34, is moved further inwardly (towards the right as viewed in FIGS. 1 and 
2) moving end 42 correspondingly. When the actuating means 56 is released, 
spring 34 serves to return plunger means 18 and actuating means 56 to the 
position shown in FIGS. 1 and 2 with abutment 46 functioning as a stop 
means to determine the left-ward most position of plunger means 18. 
FIGS. 5 and 6 illustrate a modification of the invention. All elements in 
FIGS. 5 and 6 which are like or similar to those of FIGS. 1-4 are 
identified with like reference numbers provided with a suffix "a". 
In FIGS. 5 and 6, a generally tubular retainer 72, preferably of somewhat 
resiliently deflectable plastic material such as, for example, 
polypropylene, is closely received within cylindrical recess 26a and 
retained therein as by an annular peripherally formed ring portion 74, 
carried by retainer 72, cooperatively engaging annular recess 76a formed 
in the surface of cylindrical opening 26a. 
Retainer 72 has an inner cylindrical surface 78 which, at the upper end (as 
viewed in FIGS. 5 and 6) thereof, blend into a spherical surface 80 
through which a generally conical aperture 82 is formed. 
The upper end of plunger means 18a is provided with an enlarged section or 
body 84, operatively engaged by the lower-disposed spring 34a, which has 
an outer generally cylindrical and segmented surface as defined by 
cylindrical surface portions 86 and 88 slidably received within containing 
cylindrical surface 78. As also shown in FIG. 11, the body portion 84 is 
provided with an upwardly extending generally centrally situated guide 
portion 90 having flatted sides 92 and 94 and a generally radiused contour 
96. Sides or surfaces 92 and 94 extend as to join the segmented 
cylindrical surface section 88. Further, inclined surfaces or ramp means 
98 and 100, formed on opposite sides of guide portion 90, are adapted for 
cooperative engagement with respective cam portions 102 and 104 carried by 
lever or actuating means 106. 
Lever means 106 has its body portion 108 formed as to have a generally 
spherical surface 110, adapted for cooperation with inner spherical 
surface 80 of retainer 72, which, when viewed as in FIG. 12, may have a 
generally circular projected outer configuration. As also shown in FIG. 
12, a slot-like clearance or opening is provided generally medially so as 
to have the opposed side walls 112 and 114 thereof adapted for respective 
juxtaposition to sides or wall surfaces 94 and 92 of plunger means 18a 
while simultaneously receiving, within such clearance, guide portion 90. 
When lever means 106 is assembled as shown, spring 34a normally urges 
plunger means 18a generally outwardly (upwardly as viewed in FIGS. 5 and 
6) causing lever means 106 to be urged generally counter-clockwise by 
virtue of ramp surfaces 98 and 100 urging cam portions or legs 102 and 104 
generally to the right while spherical surface 110 of lever body 108 
correspondingly rotates within spherical surface 80 of retainer 72. In the 
normal or un-actuated state, the elements would assume respective 
positions as generally depicted in FIG. 5. 
When plunger means 18a is to be depressed, the actuating means or lever 106 
handle portion 116 is rotated from the position depicted in FIG. 5 towards 
the position depicted in FIG. 6. By so doing, the contacting or edge 
surfaces 118 and 120 of cam legs or portions 104 and 102 respectively 
react against inclined surfaces 100 and 98 causing plunger means 18a to be 
displaced downwardly. In the embodiment of FIGS. 5 and 6, the relative 
angle of the ramp surfaces 98 and 100, the force of spring 34a, the 
coefficient of friction and the overall geometry is preferably such as to 
result in spring 34a moving plunger means 18a and lever or actuating means 
106 back to the position depicted in FIG. 5 whenever handle portion 116 is 
released. 
FIGS. 7 and 8 illustrate a further modification of the invention. Those 
elements in FIGS. 7 and 8 which are like or similar to those of FIGS. 1-6 
are identified with like reference numbers provided with a suffix "b". In 
comparing FIGS. 7 and 8 respectively to FIGS. 5 and 6, it can be seen that 
in the arrangement of FIGS. 7 and 8, the ramps or inclined surfaces each 
have a notch or step-like portion 122 formed therein and located such as 
to respectively receive the edge surfaces 118b and 120b of cam legs 104b 
and 102b when the actuating means 106b has attained an actuated position 
as generally depicted in FIG. 8. With the respective elements in their 
FIG. 8 positions, the line of force developed by spring 34b is such as to 
lock-in the cam legs 102b and 104b within notches 122 thereby precluding 
the automatic return to the FIG. 7 position of plunger means 18b upon 
release of actuating means 106b. Such return to the FIG. 7 position is 
attained only after the actuating means or lever 106b has been first 
manually actuated sufficiently to move cam legs 102b and 104b out of 
respective detent recesses 122. 
FIGS. 13, 14, 15 and 16 illustrate a further modification of the invention. 
Those elements in FIGS. 13, 14, 15 and 16 which are like or similar to 
those of FIGS. 1-12 are identified with like reference numerals provided 
with a suffix "C". In comparing, for example, FIGS. 13 and 15 to FIGS. 7 
and 8 it can be seen that the most significant difference is that body 84c 
has opposed ramp or cam surfaces 300 and 302 as well as opposed ramp or 
cam surfaces 304 and 306 with such pairs of opposed surfaces being 
disposed generally on opposite sides of the centrally situated guide 
portion 90c. 
As shown in FIGS. 13 and 16, for example, actuating means 106c is provided 
with laterally spaced legs 308 and 310 which respectively have edges 312, 
314 and 316, 318 accommodated and received by the surfaces 300, 302 and 
304, 306. When the actuating means 106c is in a null or neutral position 
as illustrated in FIGS. 13, edges 312, 314, 316 and 318 are respectively 
juxtaposed to surfaces 300, 302, 304 and 306. However, as portion 116c of 
actuating means 106c is pivotally actuated to the right or left as shown 
in FIG. 14, the apex 320 of edges 312, 314 and apex 322 of edges 316, 318 
respectively engage surfaces 302 and 306 and forcibly axially displace 
body 84c against the resilient resistance of spring 34c. If after lever 
portion 166c has been rotated to the left as shown in FIG. 14, lever 116c 
is released, spring 34c will move plunger means 18c and body 84 upwardly 
causing the actuating means 106c to again assume the position depicted in 
FIG. 13, thereby providing a momentary quality or characteristic to the 
overall switch assembly. 
However, if lever 116c is pivotally actuated a sufficient distance to the 
right as depicted in fantom line in FIG. 14, apexes 320 and 322 will, 
after respectively engaging surfaces 300 and 304 as to thereby axially 
displace body portion 84c, engage notch or step-like portions 324 and 326 
formed generally into surfaces 300 and 304, respectively. If the lever 
portion 166c of actuating means 106c is then released, plunger means 18c 
and body portion 84c will remain in an actuated position because the then 
geometry of the respective elements is maintained by virtue of spring 34c 
tending to further rotate lever 116c of actuating means 106c in the 
clockwise direction which is prevented by the abutting engagement between 
lever portion 116c and wall of aperture 82c. In order to again have the 
elements return to the neutral position depicted by FIG. 13, the lever 
116c must first be manually actuated as to remove apexes 320 and 322 from 
detents or notches 324 and 326 at which event, spring 34c will be able to 
return the cooperating elements to the FIG. 13 positions. 
Referring now again to FIGS. 1 and 2, as well as to the other remaining 
Figures, body or housing section 14 is shown as carrying four electrical 
terminals 124, 126, 128 and 130 which, in the preferred form, have 
threaded externally situated shank portions. The body portions 132, 134, 
136 and 138 of the respective terminals may be either pressed in or molded 
with housing section 14 as to be retained thereby. The flanges 140, 142, 
144 and 146 prevent such terminals from being pushed inwardly of the 
switch assembly while generally longitudinally extending flatted surfaces, 
typically shown at 148, prevent rotation of the terminals with respect to 
housing section 14. 
Terminal 124 has an inwardly extending post-like connecting portion 150, 
terminal 130 has an inwardly directed contact portion 152 while terminals 
126 and 128 respectively have inwardly directed contact portions 154 and 
156. 
A switch contact-carrying arm 158 is shown as having its one end 160 
situated atop a mounting surface 162, of housing 14, and suitably secured 
to post 150 as by, preferably, soldering. A cooperating aperture 164 
permits the reception therethrough of post 150. The remaining portion of 
resiliently deflectable contact-carrying arm or conductor 158, which may 
be formed of, for example, beryllium copper, is illustrated in a generally 
cantilevered condition with respect to mounting surface 162. The other 
swingable end 166 of arm conductor 158 has an electrical contact 168 
suitably affixed thereto so as to be in general juxtaposition with but 
spaced from fixed contact 152. 
Generally intermediate mounting surface 162 and contact 152, a 
pedestal-like body portion 170 is formed with a generally planar abutment 
surface 172 as well as an integrally formed upstanding extension or 
support 174 which has a slot 176 formed therein and adapted to receive a 
flange or tab 178 of a U-shaped spring 180 as well as a spring retainer 
182 of generally L-shaped configuration with the foot portion thereof 
serving to engage the underside of the flange 178 and thereby generally 
pivotally retain the spring 180 in slot 176. 
As is best seen in FIG. 10, end portions 160 and 166 are relatively wide 
and interconnected by a relatively narrow intermediate body portion 184. 
Preferably end 160 is closely received within a notched-out portion 186 
which serves to automatically properly locate the arm 158 during assembly. 
The end portion 166 has a generally rectangular cut-out or aperture 188 
formed therein and adapted to receive, therethrough, the spring perch or 
support 174. An integrally formed finger-like portion 190 extends 
generally into the aperture 188 and is adapted to be received within a 
cooperating aperture 192 formed in one leg 194 of U-shaped spring 180 
which has its other leg 196 carrying the flange or tab 178. 
With reference to FIGS. 1 and 10, it can be seen that when the switch 
assembly 10 is in a normal condition, that is, with plunger means 18 in 
the position shown, leg 194 of spring 180 contained and generally confined 
within opening 188 is resiliently deflected toward the other leg 196 as 
well as the spring perch 174. 
As can best be seen in FIGS. 1 and 3, body or housing section 14 is 
basically of cup-shaped configuration having an end or bottom wall 200 
with an integrally formed annular or cylindrical side wall 202. In the 
preferred form, additional strengthening ribs or rib configurations 204, 
206, 208 and 210 are formed integrally with and externally of end wall 
200. Further, as shown in FIG. 10 and partly shown in FIG. 1, in the 
preferred embodiment, a plurality of generally axially extending grooves 
or recesses 212, 214, 216 and 218 are formed in the inner surface of wall 
200 as to be spaced from each other and adapted to respectively receive 
therein locating pins or extensions 220, 222, 224 and 226 which are 
preferably formed integrally with housing or body section 12. 
Referring in greater detail to FIGS. 1, 2 and 4, in the preferred 
embodiment a second electrically conductive member 228 is shown as having 
a generally medially disposed aperture 230 for tightly engaging surface 
portion 232 of plunger means 18 as to thereby be retained thereto. Member 
228, which may be formed of, for example, beryllium copper, is a generally 
resiliently deflectable leaf contact means having a centrally disposed 
body portion 234 and integrally formed legs or arms 236 and 238 extending 
angularly and radially therefrom with such arms 236 and 238 respectively 
having contact portions 240 and 242 at the ends thereof. The leaf-like 
contact means 228 is so positioned as to have contact portions 240 and 242 
generally juxtaposed to contacts 156 and 154, respectively. 
OPERATION OF THE INVENTION 
As generally indicated in FIG. 3, terminal 124 may be electrically 
connected via conductor means 244 to a suitable related source of 
electrical potential 246 which, in turn, may also be electrically 
connected as by conductor means 248 to, for example, lamp or other 
suitable indicia indicator means 250 which is normally in an unenergized 
state except when associated condition responsive means, as at 252, in 
response to sensing the attainment of a preselected operating condition, 
function to close the circuit through means 250, conductor 254 and to 
ground. As shown, the indicia indicator means 250 is also electrically 
connected via conductor means 256, in parallel to conductor 254, to switch 
terminal 126. 
Terminal 130 may be electrically connected as by conductor means 258 to 
related main electrical load means 260 while terminal 128 is shown 
connected to ground potential as by conductor means 262. By way of 
example, load means 260 may be an electrical starter system for an 
internal combustion engine. 
In the normal condition of the switch assembly, the various elements 
comprising switch assembly 10 (or 10a or 10b) would assume positions as 
depicted in FIGS. 1 and 2 (or FIGS. 5 and 2 or FIGS. 7 and 2). At this 
time the resilient force of the somewhat pre-loaded U-shaped spring 180 
causes the contact member 158 and end 166 to ssume a position which 
results in the lowest possible preload to exist in U-shaped spring 180. 
This, of course, causes member 158 to assume a position substantially as 
depicted in FIG. 1 with the result that the upper movable contact 168, 
carried by end 166, is held away from lower fixed electrical contact 152. 
In this condition, the electrical circuit through terminals 124 and 130 is 
open. 
Further, with the elements in the positions shown in FIGS. 1 and 2, the 
spring contact means 228 is also held as to keep movable contact portions 
240 and 242 respectively away from cooperating fixed contacts 156 and 154. 
Therefore, under such condition, the electrical circuit between terminals 
128 and 126 is also open. 
When it is desired that the switch assembly complete or close an electrical 
circuit, or circuits, therethrough, switch actuator means 56, 106 and 106b 
are actuated, as previously described, causing plunger means 18 to move 
against the resilient resistance of spring 34 and generally inwardly of 
the switch assembly towards cantilevered contact means 158. When the end 
42 of electrically non-conductive plunger means 18 reaches contact arm 158 
and continues to move thereagainst, the portion 184 or arm 158, which is 
resiliently deflectable, starts to move toward surface 172 of pedestal 
portion 170 in a somewhat bowed configuration. That is, the initial force 
applied by plunger means end 42 is not sufficient to overcome the 
resilient resistance of U-shaped spring 180 which must experience a degree 
of increased deflection before it will permit downward movement (to the 
right as viewed in FIG. 1) of the end portion 166 and contact 168 carried 
thereby. 
Accordingly, as plunger means end 42 continues to exert an increased 
downward force against the medial portion 184 of arm 158 causing it to bow 
to a greater extent, the U-shaped spring 180 experiences two-directional 
resulting force components. One of such components causes leg 194 to be 
further deflected toward opposed leg 196 while the other force component 
is generally parallel to the direction of movement of plunger means 18 
tending to move or deflect the U-shaped spring 180 generally towards wall 
200 of body or housing section 14. When such force components become 
sufficiently great, the U-shaped spring 180 in effect snaps toward wall 
200 (while still exhibiting a slight upward resilient force) causing 
plunger means end 42 to hold arm portion 184 against abutment surface 172 
while, simultaneously, movable contact 168 is snapped down against fixed 
contact 152 of terminal 130 thereby completing an electrical circuit as 
from terminal 124, through post 150, contact arm 158, contact 168, contact 
152 and terminal 130. 
Of course, when the external force applied to the actuating means is 
removed, both the resilience of contact arm 158 and any existing 
resilience of spring 180 cause contact arm 158 including movable contact 
168 to again move upwardly (toward the left as viewed in FIG. 1) assuming 
a position as generally depicted in FIG. 1. 
When the plunger means 18 is actuated downwardly (to the right as viewed in 
FIG. 1) as hereinbefore described, it should be apparent that leaf-type 
contact means 228 is also moved in the same direction and towards 
engagement with fixed contacts 156 and 154. In the preferred embodiment of 
the invention, the distance that plunger means 18 has to move in order to 
achieve operative engagement between contact portion 240 and contact 156 
or between contact portion 242 and contact 154 is substantially less than 
the distance which plunger means 18 must move in order to cause 
cantilevered arm contact means 158 to snap-over and attain operative 
engagement as between movable contact 168 and fixed contact 152. 
In any even, when operative engagement of contact portions 240 and 242 is 
respectively made with fixed contacts 156 and 154 a circuit is completed 
as from terminal 128, through leaf contact means 228 and to terminal 126. 
It should be apparent that if after such operative engagement is attained 
plunger means 18 continues to move to the right as viewed in FIGS. 1 and 
2, that legs 236 and 238 will be forcibly moved or deflected generally 
radially outwardly causing contact portions 240 and 242 to, during such 
movement, wipe across the surfaces of fixed contacts 156 and 154 thereby 
serving to continually clean such surfaces and assure the removal 
therefrom (as well as from the contact) portions 240 and 242) of any 
deposits or impurities which might otherwise exhibit a deleterious effect 
on the flow of current as between cooperating engaging contacts. 
If the switch assembly were employed in the environment of FIG. 3, the 
initial movement of plunger means 18 causing the circuit from terminal 126 
to terminal 128 to be closed, would cause test energization of indicia 
indicator means 250 to determine whether such warning means 250 was 
operative. Further movement of plunger means 18 would close the circuit as 
between terminals 124 and 130 causing energization of the load means 260. 
Of course, as already apparent, the switch means of the invention is of a 
momentary type in that releasing the actuating means causes the automatic 
return of the elements as to, for example, that shown in FIGS. 1 and 2. 
This is true with the exception of the modification of FIGS. 7 and 8 
wherein, if the actuating means 106b is moved sufficiently, the elements 
will not return to their original normal positions unless first such 
actuating means 106b is manually moved from the locked detent position of 
FIG. 8. 
In the preferred embodiment, the housing sections are formed of plastic 
materials such as, for example, polypropylene. Although body or housing 
sections 12 and 14 may be secured to each other by any suitable means, as 
for example mechanically by screws or such, or adhesively by suitable 
cementing means, in the preferred embodiment, housing sections 12 and 14 
are heat fused to each other along the juxtaposed abutting surfaces 
therebetween. In order to enhance such fusion, a bead-like annular ring 
protuberance may be initially formed on, for example, body section 12 as 
generally depicted, fragmentarily, by fantom lines at 270 of FIG. 2. Such 
a protuberance would serve to localize the heating and enhance fusion as 
between housing sections 12 and 14. 
Although only one preferred embodiment and selected modifications of the 
invention have been disclosed and described, it is apparent that other 
embodiments and modifications of the invention are possible within the 
scope of the appended claims.