A two-piece rocker assembly having an inner rocker and an outer rocker, the inner rocker being snap-fit into the outer rocker via a connection between at least one flange and at least one latch beam. In certain embodiments, a locking member is added to the two-piece rocker assembly.

FIELD OF THE INVENTION

The invention generally relates to electrical switches and more specifically relates to a two-piece rocker assembly for use in a rocker switch.

BACKGROUND OF THE INVENTION

Rocker switches are used as electrical switches in industry, domestically and in automobiles, boats and airplanes, for example. Because of their wide application and large scale manufacture, the unit price of rocker switches is relatively low. There are applications in which it is useful to take advantage of the low unit cost of rocker switches, and where it is desirable to enhance them.

Various rocker switch assemblies are known in the prior art. Rocker switch assemblies are made from a standard switch base, and a rocker assembly is typically mounted onto the switch base via a bracket, which is in turn mounted on the switch base. The rocker switch assemblies include protrusions that allow the rocker switch assembly to rock and pivot with respect to the bracket.

In the prior art, rocker switch assemblies have suffered from various deficiencies. Such deficiencies include the rocker switch not being aesthetically pleasing. Other deficiencies include various problems associated with rocker switches, such as the rocker switches not being easy to produce, and having various problems regarding the fit of the rocker assembly on the bracket and switch base, the fit being a result of poor manufacturing and production techniques. Other problems of prior art designs that include locks on rocker switches involve the lock on the rocker assembly falling out or becoming stuck, whereby the lock is prone to failure as it becomes stuck in use and fails over time due to poor manufacturing.

Prior art rocker switch assemblies have typically been made using a 2-step molding process, which requires expensive tooling and requires a step of overmolding, or molding two pieces onto one another to create the rocker switch assembly.

The 2-step molding process of the prior art has significant disadvantages as a 2-step molding process often results in shrinkage problems from overmolding, which results in production issues whereby components of the rocker switch assemblies do not fit correctly together.

As can be seen, a need exists to provide a rocker switch and rocker assembly that overcomes the disadvantages of the prior art.

SUMMARY OF THE INVENTION

Accordingly, it is an object of the invention to provide for a two-piece rocker switch assembly (rocker assembly) that overcomes the disadvantages of the prior art. It is another object of the invention to provide a two-piece rocker assembly that is easy and inexpensive to produce.

These and other objects of the invention are achieved by providing a rocker switch comprising: a switch base; a bracket mounted on the switch base; and a rocker assembly mounted on the bracket, the rocker assembly able to pivot on the bracket, the rocker assembly including: an outer rocker having an interior body, the interior body of the outer rocker having at least one retention member; and an inner rocker having at least one latch beam that engages the at least one retention member to allow the inner rocker to be secured within the inner body of the outer rocker, the inner rocker being snap-fit within the outer rocker.

In certain embodiments, the outer rocker has four retention members and the inner rocker has four latch beams, wherein each of the four retention members are correspondingly engaged with one of the four latch beams to secure the inner rocker within the inner body of the outer rocker.

In certain embodiments, the inner rocker is secured to the outer rocker by snap-fitting the inner rocker within the inner body of the outer rocker, such that the snap-fitting occurs during assembly of the rocker switch.

In certain embodiments, the inner rocker has a body having a substantially rectangular shape and at least one opening within the body.

In certain embodiments, each of the four latch beams are located at each corner of the rectangular shape of the inner rocker and the four latch beams are each angled in a plane away from the body of the inner rocker. In certain embodiments, the four latch beams are angled approximately 45 degrees from the body of the inner rocker. In other embodiments, the four latch beams can be angled less than or greater than 45 degrees from the body of the inner rocker.

In certain embodiments, the inner rocker has a stem, the stem engaged with the switch base.

In certain embodiments, the at least one latch beam is snapped in underneath the retention member, such that the at least one beam is held in place by the retention member securing the inner rocker within the inner body of the outer rocker.

In certain embodiments, the outer rocker has at least one guide, the at least one guide able to locate and retain the inner rocker within the inner body of the outer rocker.

In certain embodiments, the inner rocker has at least one horizontal flange, the at least one horizontal flange able to engage with the at least one guide to retain the inner rocker within the outer rocker.

In certain embodiments, the outer rocker has four guides and the inner rocker has four horizontal flanges, the four guides engaged with the four horizontal flanges to retain the inner rocker within the outer rocker.

In certain embodiments, the inner rocker has four external flanges, the four external flanges engaged with the four guides to secure the inner rocker within the outer rocker.

In certain embodiments, the outer rocker has a window.

In certain embodiments, the rocker assembly includes a locking member, the locking member having a body located within a pocket between the inner rocker and the outer rocker.

In certain embodiments, the locking member is slidable within the pocket between the inner rocker and the outer rocker, wherein the locking member includes a sliding surface for sliding the locking member along a surface of the inner rocker.

In certain embodiments, the locking member includes a spring, the spring providing a force against the locking member sliding along the surface of the inner rocker.

In certain embodiments, the inner rocker includes a post, the post supporting a first end of the spring to prevent the locking member from sliding along the surface of the inner rocker and keeping the locking member in a closed position.

In certain embodiments, the locking member has a center hole for housing a second end of the spring, the spring being contained in a compressed state between the center hole of the locking member and the post located on the inner rocker.

In certain embodiments, the locking member includes locking features on the locking member, the locking features able to engage with corresponding locking features on the switch bracket.

In certain embodiments, the locking member has flanges on either side of the locking member, the flanges being captured in the pocket formed between the outer rocker and the inner rocker, the flanges being retained on the sliding surface for sliding the locking member along the surface of the inner rocker.

Other objects of the invention are achieved by providing a method for manufacturing a rocker switch, the method comprising the steps of: providing a switch base; mounting a bracket on the switch base; providing a rocker assembly including an outer rocker having at least one retention member and an inner rocker having at least one latch beam; snap-fitting the inner rocker within the outer rocker, so that the at least one latch beam is snap-fit within the at least one retention member to secure the inner rocker within the outer rocker; and mounting the rocker assembly on the bracket.

In certain embodiments, the method further comprises providing a locking member and placing the locking member between the outer rocker and inner rocker prior to snap-fitting the inner rocker within the outer rocker, so that the locking member is held in a pocket between the outer rocker and inner rocker.

In certain embodiments, the inner rocker and the outer rocker are manufactured separately. In certain embodiments, the inner rocker and the outer rocker are not manufactured via a 2-step molding process, but instead are manufactured separately and are snap-fit together during assembly.

Other objects of the invention are achieved by providing a rocker switch comprising: a switch base; a bracket mounted on the switch base; and a rocker assembly mounted on the bracket, the rocker assembly able to pivot on the bracket, the rocker assembly including: an outer rocker having four retention members; an inner rocker having four latch beams that each engage one of the four retention members to allow the inner rocker to be secured by the outer rocker; and a locking member, the locking member located with a pocket between the inner rocker and the window of the outer rocker, the locking member including a sliding surface for sliding the locking member along a surface of the inner rocker and a spring providing a force against the locking member sliding along the surface of the inner rocker, such that the locking member is able to move from a locked (engaged) position to an unlocked (disengaged) position by sliding the locking member longitudinally along the sliding surface of the inner rocker, wherein the inner rocker is secured to the outer rocker in a snap-fit manner.

Other objects of the invention and its particular features and advantages will become more apparent from consideration of the following drawings and accompanying detailed description. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is directed to a new two-piece snap-fit rocker assembly for use in a rocker switch where the inner rocker snaps into the outer rocker. This overcomes issues in the prior art, which involves rockers assemblies manufactured by a 2-step over molding process whereby the inner rocker and outer rocker are molded together. The 2-step over molding process often results in shrinkage problems, which results in production issues whereby components of the rocker switch assemblies do not fit correctly together and/or have aesthetical problems. The 2-step over molding process also requires much more expensive tooling.

Turning now in detail to the drawings,FIG. 1is a perspective view of a rocker switch1000of an embodiment of the present invention. Here, the rocker switch1000is shown having a rocker assembly100with a locking member120, the rocker assembly being mounted on bracket110. Bracket110is in turn mounted on a switch base170. The switch base170is a standard switch base and bracket110is a standard switch bracket. However, the rocker assembly100is a new 2-piece snap fit rocker assembly where the inner rocker snaps into the outer rocker (also referred to as a sub-rocker and rocker respectively) and includes a sliding lock120that is captured between the outer rocker and inner rocker.

Referring toFIG. 2, an exploded view of rocker switch1000ofFIG. 1is shown. Rocker switch1000includes outer rocker200having a top surface215and a body218. The outer rocker200is shown having a window210. The body218of the outer rocker200is shown being curved such that the body218has an arc shape. In certain embodiments, the outer rocker200is made of a hard plastic material or an insulating material. In certain embodiments, the outer rocker is a shell or a cap. In certain embodiments, the outer rocker is manufactured as a single piece by using a mold and molding process.

InFIG. 2, the locking member120is shown having ribs220that are ergonomic to suit an operator's finger. The locking member has flanges235and237(shown inFIGS. 2, 5 and 6) that retain the locking member in a cavity between the outer rocker200and the inner rocker140. The locking member also has locking features225and230that mate with corresponding locking features on the switch bracket110.

Also shown inFIG. 2is spring125. In certain embodiments, spring125is a standard compression spring. The spring is used to hold the locking member in place in a locked (engaged) position and when compressed exerts a force to hold the locking member in the locked (engaged) position.

Inner rocker140is also shown inFIG. 2. Inner rocker140has four latch beams240,245,250and255. Latch beams240,245,250and255are shown as each being in a corner of the inner rocker140. Latch beams240,245,250and255are shown as being angled at2planes away from the body140of the inner rocker. In certain embodiments, the latch beams are flexible. In certain embodiments, the inner rocker is made of a hard plastic material or an insulating material. In certain embodiments, the inner rocker is a shell or a cap. In certain embodiments, the inner rocker is manufactured as a single piece by using a mold and molding process.

Inner rocker140also has various features242and244that snap onto the bracket pivot points285and287on the switch bracket110. In certain embodiments, the various features242and244extend away and substantially perpendicularly from the body of the inner rocker140. Inner rocker140is shown having windows252and254, as well as bore256. The purpose of window254is to allow the light path for rocker images. Bore256is used to maintain a more uniform wall thickness. The locking member fits within window252when engaged with inner rocker140. Window252and254allow the inner rocker to have a cavity, so that the inner rocker140is able to pivot along the bracket110. Inner rocker140is shown having a stem260. The stem260engages with the switch actuator. Inner rocker140also has pockets to guide and retain the lock flanges.

Furthermore, inner rocker140also has sliding surface610and620, whereby the locking member120is able to slide on the sliding surface610and620to actuate the lock.

FIG. 2also shows inner rocker140having external flanges262,264,266and268as well as horizontal flanges232,234,236and238. The external flanges and horizontal flanges allow the inner rocker140to be secured within the body of the outer rocker200, as the external flanges262,264,266and268and horizontal flanges232,234,236and238fit with the outer rocker200to position the inner rocker140within the outer rocker200.

In certain embodiments, inner rocker140transmits light for image illumination and can accept paint. In certain embodiments, the inner rocker incorporates features to guide and retain the lock and prevent its extraction.

FIG. 2also has a switch bracket110having an upper surface265. Located on the upper surface is locking feature270that corresponds to flanges225and230of the locking member120. Additional configurations of locking feature270are shown inFIGS. 9A-9H. In certain embodiments, locking feature270may be replaced by one or more locking features of various configurations.

Switch bracket110also has a bore280that receives the stem260. The bore is supported by a support mount275and horizontal protrusions285and287as well as a tapered section290. The horizontal protrusions285and287engage with features242and244to snap onto the inner rocker140onto the switch bracket110. The inner rocker140is mounted on the support mount275and is able to pivot with respect to the support mount275and the tapered section290. In certain embodiments, the tapered section290is hollow, so that a cavity is formed that allows the inner rocker140to pivot along the bracket110. Upon pivoting of the inner rocker, the stem260is able to actuate the switch to turn the switch on and off.

Also shown inFIG. 2is switch base170having a body295and electrical connections150,150′ and150″. As shown there are three electrical connections, though additional or fewer electrical connections may be used in the invention.

FIG. 3is a bottom view of outer rocker200ofFIG. 1.FIG. 3shows the window210of the outer rocker as well as inner surfaces350and355of the outer rocker200.

Also shown are retention members305,310,315and320. The retention members305,310,315and320extend from the outer body218of the outer rocker200, such that the retention members305,310,315and320extend inwardly towards the center of the outer rocker200. In certain embodiments, the retention members305,310,315and320are located in the corners of the outer rocker200. In certain embodiments, the outer rocker200has a rectangular or substantially rectangular shape. In certain embodiments, the outer rocker200has an arc shape. In certain embodiments, the outer rocker200has a rectangular shape with curved edges connecting each of the sides of the outer rocker. In certain embodiments, the retention members305,310,315and320are part of the one-piece design of the outer rocker200. In certain embodiments, the retention members305,310,315and320each have a straight edge so as to mate with the latch members of the inner rocker140.

Outer rocker200also has guides325,330,335and340. The guides have an H-shape or have an open rectangular shape, where one end of the rectangle is open. The guides325,330,335and340are used to retain the inner rocker140within the outer rocker200. In certain embodiments, the guides325,330,335and340provide pressure on the external flanges and horizontal flanges of the inner rocker140to hold and secure the inner rocker140within the outer rocker200. In certain embodiments, crush ribs390and392are provided on the guide surfaces to ensure a tight fit with inner rocker140. Crush ribs390and392may be located on each side of the guides325,330,335and340.

FIG. 4shows a bottom view of the inner rocker140after being snap-fit within the outer rocker200. As shown, the latch beams240,245,250,255correspond to retention members315,305,320and310respectively. The engagement of the four retention members315,305,320and310with the four latch beams240,245,250,255secures inner rocker140within the inner body of the outer rocker200. The latch beams240,245,250,255are snapped in below the retention members315,305,320and310and the force exerted by the retention members315,305,320and310on the latch beams240,245,250,255secures the inner rocker140in place.

Also shown are guides325,330,335and340assisting in retaining and securing the inner rocker140to the outer rocker200. The external flanges262,264,266and268as well as horizontal flanges232,234,236and238allow the inner rocker140to be secured within the body of the outer rocker200, specifically through the engagement with the flanges325,330,335and340of the outer rocker200.

Also shown inFIG. 4is locking member120being placed into the cavity (pocket) between the inner rocker140and outer rocker200, so that the flanges235,237of the locking member120are inside the cavity between the inner rocker140and outer rocker200.

During the production method, the locking member120is placed into the cavity of the inner rocker140and outer rocker200so that the flanges235,237are inside the cavity. The inner rocker140is then snap fit into the outer rocker200. The locking member120is captured in the cavity between the inner rocker140and outer rocker200. In use, the locking member120is able to slide longitudinally within the cavity.

InFIG. 4, the locking member120is held in place by a spring125whereby one end of the spring125is attached to post360on the inner rocker140. The spring125holds the locking member in a locked (engaged) position. If the spring125is actuated by moving the locking member120, the locking member120is moved to an unlocked (disengaged) position, whereby the rocker assembly100is able to pivot along the switch bracket110.

Also shown inFIG. 4are various features242and244that snap the inner rocker140onto the bracket pivot point, allowing the inner rocker140and rocker assembly100to be retained by the switch bracket110.

FIG. 5shows a perspective view of the locking member120. Locking member120has bore420, such that end of the spring125is housed within bore420.FIG. 5also shows flanges235,237, the flanges235,237acting as wings to slide on the sliding surfaces610,620of the inner rocker140.

The locking member also has flanges225and230that correspond to various locking features on the switch bracket110. Locking member120is also shown having inverted bore sections410and415coring for injection molding. Flanges235,237also have vertical sections425,430respectively that allow for capture by the outer rocker140. This is shown more clearly inFIG. 6.

FIG. 6is a cross section view of locking member120held within the rocker assembly100ofFIG. 1.FIG. 6shows the locking member120being held within the outer rocker200and inner rocker140. The flanges235,237having vertical sections425,430respectively are shown being retained by a sliding surface610and620of the inner rocker140. The locking member120is able to slide longitudinally along sliding surfaces610,620to move the locking member120from an unlocked (disengaged) to a locked (engaged) position, and in turn allowing the rocker assembly to pivot and change the switch setting.

Also shown inFIG. 6is the bore420in the locking member120housing one end of the spring125. Latch beams245and240are also shown being retained by retaining members305and315respectively. Also shown are external flanges262and266interacting with the outer rocker200to secure the inner rocker140within the outer rocker200. Further shown are guides325and335used to retain the inner rocker140.

The locking member120and rocker assembly100provides permanent lock retention and prevents inadvertent lock removal during switch operation, which is a problem with some prior art designs.

The actuation locking member120is shown inFIGS. 9A-9F, whereby the locking features225and230mate with the locking features270,270′ and270″ on the switch bracket110. Various embodiments are shown inFIGS. 9A-9Fdemonstrating this engagement. Specifically, the lock down, lock mid and lock up positions are shown in both locked (engaged) and unlocked (disengaged) positions.FIGS. 9A-9Bshow the lock down position,FIGS. 9C-9Dshow the lock mid position andFIGS. 9E-9Fshow the lock up position.

FIG. 9Ashows locking member120in a locked (engaged) lock down position whereby locking features225and230mate with flange902on the locking feature270. Locking feature270has a single finger-like flange902which extends laterally away from the locking feature270to receive the locking feature230.

InFIG. 9A, the locking feature230is shown engaged with and below locking flange902, such that the top surface of flange904interacts with the bottom surface of flange902. In certain embodiments, the flange904is threaded or ribbed for better engagement with finger-like flange902on the locking feature904.

InFIG. 9A, the rocker assembly100is shown being parallel to the switch bracket110. Furthermore, the spring125is shown being held in place via the post360and stop member906as flange235is being held in place on the sliding surface610of the inner rocker in the locked (engaged) position. Furthermore, the rocker assembly100is secured to the switch bracket110via the bracket pivot point285.

FIG. 9Aalso shows the stem260being in the A′ position, whereby the stem is angled to the right. This is the locked (engaged) lock down position whereby the rocker switch1000is turned off and the locking member120is in the locked (engaged) lock down position.

InFIG. 9B, the locking member120is actuated by a movement shown by arrows910and920and is disengaged from the locking feature270. The actuation of the locking member120occurs through a user using force to push the locking member120horizontally to the right (as shown by arrow910) and then the user pushes the outer rocker200down (as shown by arrow920).

By moving the locking member120horizontally, this opens the lock and causes the locking member120to slide longitudinally (horizontally) along the sliding surface610of the inner rocker140to disengage the locking feature230from the locking feature270.

Once the locking feature230is disengaged from the locking feature230, the rocker assembly100is free to be able rock on the switch bracket110, so that the position of the stem moves from the A′ position as the rocker switch1000is actuated. This allows the rocker switch100rock or pivot with respect to the switch bracket110.

FIG. 9Cshows another embodiment of the invention whereby the rocker assembly100is in the lock mid position. InFIG. 9C, locking feature270′ is shown having two finger-like flanges902′.FIG. 9Calso shows the stem being in the B′ position whereby the rocker switch100is not parallel with the switch bracket110, as it is angled up and away from the switch bracket110. The stem is in the B′ position, which causes actuation or partial actuation of the switch. This is the lock mid position.

InFIG. 9C, the rocker assembly100is shown being a locked (engaged) position where the locking member120is spring-biased and locked and engaged in the center groove of the locking feature270′ in the central position. The spring125is shown being held in place via the post360and stop member906as flange235is being held in place on the sliding surface610of the inner rocker. Furthermore, the rocker assembly100is secured to the switch bracket110via the bracket pivot point285.

FIG. 9Dshows the locking feature230disengaged from the center groove between flanges902′ and902′ of the locking feature270′. The disengagement of the locking feature230from the locking feature270′ involves pushing the locking member120horizontally to the right (as shown by arrow930) and pushing the outer rocker200down (as shown by arrow940. This causes the disengagement of the locking features and allows the rocker switch100rock or pivot with respect to the switch bracket110.

FIG. 9Eshows another embodiment of the invention whereby the rocker assembly100is in the lock up position. InFIG. 9E, locking feature270″ is shown having a single finger-like flange902″.FIG. 9Ealso shows the stem being in the C′ position whereby the rocker switch100is not parallel with the switch bracket110, as it is angled up and away from the switch bracket110. The stem is in the C′ position, which causes actuation or partial actuation of the switch. This is the lock up position.

In the lock up position, the rocker switch100is at a greater angle away from the switch bracket than in the lock mid position.

InFIG. 9E, the rocker assembly100is shown being a locked (engaged) position where the locking member120is spring-biased and locked and engaged under the locking feature270″. The spring125is shown being held in place via the post360and stop member906as flange235is being held in place on the sliding surface610of the inner rocker. Furthermore, the rocker assembly100is secured to the switch bracket110via the bracket pivot point285.

InFIG. 9E, locking feature230has a body915having an extension member922/924. Extension member922/924is shown having an upper portion922and a lower portion924. The lower portion924is engaged with the flange902″ on the locking feature270″, such that in the engaged lock up position the lower portion924of the extension member sits on flange902″ and the body915is flush with a surface (top portion908) of the flange902″

Also shown is that locking feature230has flange902″ having a top portion908and bottom portion912. The bottom portion912is engaged with the lower portion924of the extension member when in the locked position. The top portion908is engaged with the body915such that the body915is flush with the top portion908.

FIG. 9Fshows the locking feature230disengaged from the flange902″ of the locking feature270″. The disengagement of the locking feature230from the locking feature270″ involves pushing the locking member120horizontally to the right (as shown by arrow95) and pushing the outer rocker200down (as shown by arrow960). This causes the disengagement of the locking features and allows the rocker switch100rock or pivot with respect to the switch bracket110.

FIG. 9Gshows a cross sectional view of the engagement of the interaction of locking feature230with locking feature270″ shown inFIGS. 9E-9F. InFIG. 9G, locking member120is shown having a locking feature230. Locking feature230has body915and extension member extension member922/924. Extension member922/924is shown having an upper portion922and a lower portion924. As shown, lower portion924has a larger width than upper portion924. The lower portion924is shown being able to engaged with the upper surface912of the bottom portion912of the locking feature230.

FIG. 9Hshows a perspective view of the engagement of the interaction of locking feature230with locking feature270″. Here, the locking feature270″ is shown whereby top portion908extends above the bottom portion912and whereby the locking feature230and locking feature270″ mate with one another through movement of the features along the direction of arrow950. Top portion908fits within a sleeve between flanges924of locking feature230when the locking features are engaged with one another.

In certain embodiments, the primary lock function of locking member120is to prevent inadvertent actuation of the switch (unwanted change of setting). The lock is spring loaded to stay in the desired lock position. The operator pushes the lock button to disengage the locking mechanism from the locking features (locking bracket) to change switch settings. The new design incorporates flanges on either side of the lock that are captured in a pocket formed between the inner rocker140and outer rocker200to prevent inadvertent lock extraction.

In certain embodiments, the locking features270′ may be replaced by a locking feature with additional flanges and/or prongs, such as locking features270and270″ shown in various embodiments of the invention.

FIG. 7is a perspective view of a rocker switch7000of another embodiment of the present invention involving a non-locking rocker assembly700. Here, the rocker switch7000is shown having a rocker assembly700mounted on switch bracket710. Switch bracket710is in turn mounted on a switch base770. The switch base770is a standard switch base and bracket710is a standard switch bracket. However, the rocker assembly100is a new 2-piece snap fit assembly where the inner rocker snaps into the outer rocker.

FIG. 8is an exploded view of the rocker switch7000ofFIG. 7. Referring toFIG. 8, rocker switch7000includes outer rocker800having a top surface815and a body818. The body818of the outer rocker800is curved and has an arc shape. In certain embodiments, the outer rocker800is made of a hard plastic material or an insulating material. In certain embodiments, the outer rocker is a shell or a cap.

Inner rocker740is also shown inFIG. 8and combined with outer rocker800forms rocker assembly700. Inner rocker740has four latch beams840,845,850and855. In certain embodiments, latch beams840,845,850and855are each in a corner of the inner rocker740. In other embodiments, the latch beams840,845,850and855are angled at a plane away from the body of the inner rocker740.

Inner rocker740also has various features842and844to snap onto the bracket pivot point. Inner rocker also has windows852and854, as well as bore856. Window852and854allow the inner rocker to have a cavity, so that the inner rocker740is able to pivot along the switch bracket710. Inner rocker740also has a stem860. The stem860engages with the switch actuator to turn the switch on and off. The inner rocker740also has pockets to guide and retain the lock flanges. Windows852and854can also be used to allow LEDs to illuminate the rocker800.

FIG. 8also has external flanges862,864,866and868as well as horizontal flanges832,834,836and838. The external flanges and horizontal flanges allow the inner rocker740to be secured within the body of the outer rocker800. In certain embodiments, inner rocker740transmits light for image illumination and can accept paint.

FIG. 8also has a switch bracket710having an upper surface865. Switch bracket710also has a bore280that receives the stem860. The bore is supported by a support mount875and vertical protrusions885and887as well as a tapered section890. The inner bracket740is mounted on the support mount875and is able to pivot with respect to the support mount875and the tapered section890. In certain embodiments, the tapered section890is hollow, so that a cavity is formed that allows the inner rocker740to pivot along the bracket710.

Also shown inFIG. 8is switch base870having a body895and electrical connections750,750′ and750″. As shown there are three electrical connections, though additional or fewer electrical connections may be used in the invention.

In certain embodiments of the invention the rocker assembly is a 2-piece snap together rocker/sub-rocker design incorporating self-centering truss like snap latches. The new design is an improvement over the prior art 2-shot over molding process that requires much more expensive tooling.

While the invention has been specifically described in connection with certain specific embodiments thereof, it is to be understood that this is by way of illustration and not of limitation, and that various changes and modifications in form and details may be made thereto, and the scope of the appended claims should be construed as broadly as the prior art will permit.