Rocker switch

An electrical switch (10) includes first and second spaced contacts (52, 56), and a rocking contact (80) having first and second arms (90, 92) in electrical contact with each other. A support (60) supports the rocking contact (80) for rocking movement in opposite first and second directions. The first arm (90) moves into engagement with the first contact (52) when the rocking contact (80) rocks in the first direction, and the second arm (92) moves into engagement with the second contact (56) when the rocking contact (80) rocks in the second direction. The switch (10) includes a member (20, 36) which pivots to effect rocking movement of the rocking contact (80) in the first and second directions. The member (20, 36) pivots in one direction a first distance to cause the first arm (90) to engage the first contact (52) and pivots in the one direction a second distance beyond the first distance to cause the first arm to slide on the first contact.

BACKGROUND OF THE INVENTION
 1. Technical Field
 The present invention relates to an electrical switch.
 2. Description of the Prior Art
 Vehicles with electric power devices, such as windows, typically have a
 control system with several individual switches. Each switch has a
 manually engageable lever pivotable to actuate the device.
 One known window switch structure is described in U.S. Pat. No. 5,598,918.
 The switch includes an actuator which is manually pivotable in opposite
 directions to engage and close electrical contacts for energizing the
 motor. The switch also includes an electrical contact which is rocked by
 the pivoting actuator to close a set of contacts in the switch. The
 electrical contact is made from metal.
 SUMMARY OF THE INVENTION
 The present invention is an electrical switch comprising spaced first and
 second contacts, and a rocking contact having first and second arms in
 electrical contact with each other. A support supports the rocking contact
 for rocking movement in opposite first and second directions. The first
 arm moves into engagement with the first contact when the rocking
 conactrocks in the first direction, and the second arm moves into
 engagement with the second contact when the rocking contact rocks in the
 second direction. The switch includes a member which pivots to effect
 rocking movement of the rocking contact in the first and second
 directions. The member pivots in one direction a first distance to cause
 the first arm to engage the first contact and pivots in the one direction
 a second distance beyond the first distance to cause the first arm to
 slide on the first contact.

DESCRIPTION OF A PREFERRED EMBODIMENT OF THE INVENTION
 The present invention relates to an electrical switch for controlling a
 device on a vehicle. The device may be any device on a vehicle, such as a
 window, a seat, a mirror, or the like. The specific embodiment of the
 invention described below relates to a power window. It should be
 understood that the switch of the present invention may control a device
 other than a window.
 The present invention is also applicable to various switch constructions.
 As representative of the present invention, FIG. 1 illustrates a switch
 assembly 10. The switch assembly 10 controls operation of an electric
 motor indicated schematically at 11 (FIGS. 2-5) for raising and lowering a
 vehicle window (not shown). The electric motor 11 is a DC motor capable of
 bi-directional rotation.
 The switch assembly 10 is generally of the type shown in U.S. Pat. No.
 5,598,918, the disclosure of which is herein incorporated by reference.
 The switch assembly 10 includes a base 12, first and second rocker
 switches 14 and 16, and a lever 20 for actuating the rocker switches.
 The base 12 of the switch assembly 10 is mounted to a printed circuit board
 30 or an electrical buss system, not shown. A group of metal switch
 terminals (described below) protrude from the base 12 of the switch 10 and
 through corresponding holes in the printed circuit board 30 or electrical
 buss system to connect the switch assembly with the electric motor 11 for
 controlling operation of the motor and thereby of the window.
 The lever 20 is supported by the base 12 for pivotal movement relative to
 the base about an axis 32. The lever is biased as described below to a
 centered or neutral position as illustrated in FIGS. 2 and 3. The lever 20
 is pivotable about the axis 32 in opposite directions from the centered
 position. When the lever 20 is pivoted in a first direction (as shown in
 FIGS. 4, 5 and 5A) from the centered position, the first rocker switch 14
 is actuated to energize the motor to move the window down. When the lever
 20 is pivoted in a second, opposite, direction (not shown) from the
 centered position, the second rocker switch 16 is actuated to energize the
 motor for rotation in the opposite direction to move the window up. The
 structure and operation of the first rocker switch 14 are described as
 exemplary. The structure and operation of the second rocker switch 16 are
 similar to that of the first rocker switch 14 and therefore are not
 described.
 The lever 20 (FIG. 3) has a cylindrical bore 34 in which are received a pin
 36 and a spring 38 for biasing the pin outwardly of the lever. The pin 36
 has an outer end surface 40. The outer end surface 40 has a selected,
 predetermined contour. In the illustrated embodiment, the outer end
 surface 40 has a spherical or convex contour.
 The first rocker switch 14 includes a B+ terminal 50, a ground terminal 54,
 and a motor terminal 58 that are secured in the base. The B+ terminal 50
 is connected to B+ and has a flat upper end surface or first contact 52.
 The ground terminal 54 is connected to ground and has a flat upper end
 surface or second contact 56.
 The motor terminal 58 is connected to the motor 11. The motor terminal 58
 is disposed between the B+ terminal 50 and the ground terminal 54. The
 first rocker switch 14 includes a moving contact assembly 70. The motor
 terminal 58 has an upper end portion that serves as a support 60 such as a
 fulcrum or pivot stand for the moving contact assembly 70.
 The moving contact assembly 70 includes an electrical connector or rocking
 contact 80, made from metal, that is insert molded with a plastic body
 portion 110 of the moving contact assembly. Alternatively, the contact 80
 could be bonded to the body portion 110.
 The rocking contact 80 is made from a single piece of resilient,
 electrically conductive material, preferably metal. A preferred material
 is a copper alloy having high tensile strength.
 The rocking contact 80 has a central portion 82. The central portion 82 has
 an open U-shape including a base leg 84 and two side legs 86 and 88. The
 side legs 86 and 88 extend upward and outward from the base leg 84.
 The rocking contact 80 has first and second arms 90 and 92 which extend
 outward from the central portion 82 of the rocking contact. Because the
 rocking contact 80 is made as one piece from metal, the first and second
 arms 90 and 92 of the rocking contact are in electrical contact with each
 other as well as with the central portion 82 of the rocking contact.
 The first arm 90 of the rocking contact 80 has a relatively short inner
 portion 94 which extends from the first side leg 86 in a direction
 parallel to the base leg 84. A relatively long outer portion 96 of the
 first arm 90 extends from the inner portion 94, at a slight angle downward
 from the inner portion. The outer end of the first arm 90 is deformed to
 form a part-spherical first contact pad at 98. Alternatively, a highly
 conductive metal formed into a sphere may be the first contact pad 98.
 The second arm 92 of the rocking contact 80 has a relatively short inner
 portion 100 which extends from the second side leg 88 in a direction
 parallel to the base leg 84. A relatively long outer portion 102 of the
 second arm 92 extends from the inner portion 100, at a slight angle
 downward from the inner portion. The material of the second arm 92 is
 deformed downward to form a part-spherical first second contact pad 104 at
 the outer end of the second arm. Alternatively, a highly conductive metal
 formed into a sphere may be the second contact pad 104.
 The plastic body portion 110 of the moving contact assembly is molded
 around the central portion 82 of the rocking contact 80. Alternatively,
 the plastic body portion 110 could be bonded to the central portion 82.
 The plastic body 110 has a first surface 112 which has a concave contour.
 The first surface 112 is presented upward toward the lever 20. Thus, the
 first surface 112 on the plastic body 110 is presented toward the outer
 end surface 40 of the pin 36. The metal side leg 86 of the rocking contact
 80 is exposed, through the plastic body portion 110, for electrical
 contact with the pivot stand 60.
 The spring biased pin 36 applies a downward force to urge the moving
 contact assembly 70 downwardly into engagement with the pivot stand 60.
 The outer end surface 40 on the pin 36 engages the first surface 112 on
 the plastic body portion 110 of the moving contact assembly 70. The metal
 side leg 86 of the rocking first contact 80 engages the metal pivot stand
 60 to make electrical contact. The pivot stand 60 supports the moving
 contact assembly 70 for rocking movement in opposite first and second
 directions, as controlled by the lever 20.
 The lever 20 is initially in the centered or neutral position, as
 illustrated in FIG. 3. When the lever 20 is in the neutral position, the
 rocker switches 14 and 16 are not actuated and are not providing
 electrical power to the motor. Specifically, the contact pad 104 of the
 second arm 92 of the rocking contact 80 engages the ground terminal 54 and
 as a result the electric motor 11 is not actuated to move the window down.
 Similarly, the first arm (not shown) of the second rocker switch 16
 engages its associated ground terminal and so the motor 11 is not actuated
 to move the window up.
 When the lever 20 is pivoted a first distance to a first actuating
 position, as illustrated in FIG. 4, the force of the lever is transmitted
 through the pin 36 into the moving contact assembly 70. The outer end
 surface 40 of the pin 36 slides along the first surface 112 of the plastic
 body portion 110 of the moving contact assembly 70. The moving contact
 assembly 70 rocks about the pivot stand 60, to the position shown in FIG.
 4.
 In this position, the contact pad 98 on the first arm 90 of the rocking
 contact 80 engages the contact surface 52 on the B+ terminal 50. This
 engagement electrically connects the B+ terminal 50 with the motor
 terminal 58 through the rocking contact 80. At the same time, the second
 arm 92 of the rocking contact 80 moves out of engagement with the ground
 terminal 54. The motor 11 is energized to move the window down.
 The lever 20 can also be pivoted somewhat farther in the same direction to
 a second actuating position. The second actuating position of the lever 20
 causes the first arm 90 of the rocking contact 80 to be deformed and
 applies an outwardly directed force to the contact pad 98. The contact pad
 98 slides outward over the contact surface 52 on the B+ terminal 50, by
 the distance marked 120 in FIG. 5A. As this sliding movement occurs, the
 contact pad 98 and the contact surface 52 are "wiped" to clean them, as
 illustrated in FIGS. 5 and 5A.
 It is preferred that this additional pivoting action takes place every time
 the rocker switch 14 is actuated. In one embodiment, for example, the
 lever 20 is pivoted about seven degrees to make electrical contact. An
 additional eleven degrees of pivotal movement results in the wiping
 action. This is the full range of movement of the lever 20.
 When the manually applied force on the lever 20 is released, the parts of
 the switch assembly 10 return to the neutral condition shown in FIG. 3.
 To move the window upward, the lever 20 is pivoted in a second direction
 opposite the first direction, that is, counterclockwise as viewed in FIG.
 3. The second rocker switch 16 (FIG. 1) is actuated and the motor is
 operated in an opposite direction of rotation to move the window upward.
 The structure and operation of the second rocker switch 16 are similar to
 those of the first rocker switch 14 and therefore are not described.
 Each one of the first and second arms 90 and 92 of the rocking contact 80
 is selectively bendable to determine the pressure of the engagement
 between the arm and its associated terminal. Specifically, the first arm
 90 includes a bendable portion 95 at the intersection between the inner
 portion 94 and the outer portion 96. If the outer portion 96 is bent
 farther downward from the inner portion 94, then the pressure of the first
 contact pad 98 on the B+ terminal 50 is increased. Conversely, if the
 outer portion 96 is bent farther upward from the inner portion 94, then
 the pressure of the first contact pad 98 on the B+ terminal 50 is
 decreased.
 The sliding movement of the outer end surface 40 of the pin 36, along the
 first surface 112 on the moving contact assembly 70, provides a tactile
 feel to the person moving the lever 20. This tactile feel is controlled by
 the contour of the surfaces 40 and 112. The contour of either or both of
 these surfaces 40 and 112 can be changed to provide a different tactile
 feel. The contour of the first surface 112 on the plastic body portion 110
 of the moving contact assembly 70 can be changed simply by molding the
 plastic body portion with a different contour. This change can be made
 without affecting the configuration or operation of the metal portion of
 the moving contact assembly 70, that is, the rocking contact 80. Thus, it
 is possible to provide a different tactile feel for different switches 10
 of the present invention, simply by molding the plastic body portion 110
 of the moving contact assembly 70 with a different contour.
 The switch assembly 10 also includes two dome switches 130 and 132 (FIG. 2)
 for holding the motor 11 actuated in an automatic operation mode. The
 operation of these dome switches 130 and 132 is the same as the operation
 of the dome switches described in U.S. Pat. No. 5,598,918 and is not,
 therefore, described further herein.
 From the above description of the invention, those skilled in the art will
 perceive improvements, changes and modifications in the invention. Such
 improvements, changes and modifications within the skill of the art are
 intended to be covered by the appended claims.