# Patent

## Title
Digital multimeter having improved rotary switch assembly

## Abstract

A multimeter includes a case having a rotary selector knob for selecting a multimeter function. A circuit board defining multiple switching terminals thereon is located in the case. A rotary switch assembly is operatively coupled to the selector knob. The rotary switch assembly has a plurality of contact pairs which selectively complete a galvanic connection across predetermined pairs of switching terminals. The rotary switch assembly further includes first and second switch members located in opposition on respective sides of the circuit board. Each of the switch members has at least one of the contact pair.

## Background
CROSS-REFERENCE TO A RELATED APPLICATION
This application is a divisional of copending application Ser. No. 11/893,109, filed Aug. 14, 2007, which is incorporated herein by reference.


BACKGROUND OF THE INVENTION
The present invention relates generally to digital multimeters. More particularly, the invention relates to a digital multimeter having an improved rotary switch assembly.
Digital multimeters (DMMs) function to measure a number of electrical parameters as needed for service, troubleshooting and maintenance. Such parameters may include AC voltage and current, DC voltage and current, resistance and continuity. In some cases, a DMM may measure other parameters such as capacitance and temperature.
A DMM will often be configured as a hand-held unit having a rotary knob by which various functions are selected. A plurality of lead jacks are provided in the case (i.e., housing) of the unit for connection of test leads. The specific jack used may depend on the function that has been selected. An LCD display provides a reading of the tested parameter.
Various electronic components are mounted to a printed circuit board located inside the case of the DMM. A rotary switch having multiple contact pairs may be mounted to the printed circuit board. When the selector knob is rotated by a user, the contact pairs are moved into or out of engagement with pairs of contact terminals located on the surface of the printed circuit board itself. As a result, a galvanic connection between the terminal pairs will be made as necessary for the selected function. The terminal pairs are formed through suitable printed circuit technology as conductive pads on the printed circuit board.
Details regarding the construction and operation of multimeters may be discerned from U.S. Pat. Nos. 7,034,517, 6,466,003 and 6,043,640, incorporated herein by reference.
SUMMARY OF THE INVENTION
According to one aspect, the present invention provides a multimeter comprising a case having a rotary selector knob for selecting a multimeter function. A circuit board defining multiple switching terminals thereon is located in the case. A rotary switch assembly is operatively coupled to the selector knob. The rotary switch assembly has a plurality of contact pairs which selectively complete a galvanic connection across predetermined pairs of switching terminals. The rotary switch assembly further includes first and second switch members located in opposition to one another on respective sides of the circuit board. Each of the switch members has at least one of the contact pairs.
In presently preferred embodiments, the rotary switch assembly includes a shaft interconnecting the first and second switch members. The shaft is configured such that the first switch member and the second switch member are interconnected in a predetermined angular orientation.
Often, it will be desirable for the first switch member to include at least four contact pairs. Similarly, the second switch member may include at least three contact pairs. In addition, the second switch member may also have a nonfunctional sweeper operative to facilitate balance during rotation. For example, the nonfunctional sweeper may include a pair of parallel sweeper members.
Exemplary embodiments may include a detent disc located on an inside surface of the case. In such embodiments, the detent disc may interconnect the selector knob and first switch member for rotation about a common rotational axis. In this regard, the selector knob may include a coupling structure engaging the detent disc such that the selector knob and detent disc rotate together. The detent disc and first switch member may be interconnected via a plurality of drive pins offset from but parallel to the common rotational axis. Preferably, the detent disc and first switch member may each include a visual alignment feature to facilitate assembly.
According to exemplary embodiments, each of the first and second switch members may comprise a support disc in which the contact pairs are carried. The support disc in such embodiments may be formed of a polymeric material. A least one punch-out aperture may be provided in the support disc at which adjacent contact pairs are disconnected.
According to an additional aspect, the present invention provides a method of forming a rotary switch member for use in a multimeter. One step of the method involves providing a unitary metallic element defining a plurality of contact pairs wherein adjacent contact pairs are interconnected by a strip. At least two of the contact pairs are oriented in different directions. Another step involves encapsulating portions of the unitary metallic element with a polymeric material such that end portions of the contact pairs and at least part of each strip remain exposed. A further step of the method involves removing a portion of each strip to prevent galvanic connection between adjacent contact pairs.
Additional aspects of the present invention are provided by a rotary switch assembly for use in an electronic metering device. The assembly comprises a selector knob and a generally planar substrate board having conductive pads thereon defining multiple switching terminals. First and second switch members are located on respective sides of the substrate board. The switch members are operatively connected to the selector knob for rotation about a common rotational axis. Each of the switch members is configured having a support disc formed of a polymeric material in which a plurality of contact pairs are carried. The contact pairs are operative to complete a galvanic connection across predetermined pairs of the switching terminals.
In presently preferred embodiments, the first and second switch members are interconnected via a shaft extending through the substrate board along the common rotational axis. Preferably, the shaft is configured such that the first and second switch members are interconnected in a predetermined angular orientation.
Additional aspects of the present invention are achieved by a rotary switch assembly for use in an electronic metering device. The assembly comprises a selector knob and a generally planar substrate board having conductive pads thereon defining multiple switching terminals. A first switch member, located on the substrate board, has a support disc formed of a polymeric material in which a plurality of contact pairs are carried. The contact pairs of the first switch member are operative to complete a galvanic connection across predetermined pairs of switching terminals. A detent disc interconnects the selector knob and first switch member for rotation about a common rotational axis. The detent disc and first switch member each include a visual alignment feature to facilitate assembly.
Other objects, features and aspects of the present invention are provided by various combinations and subcombinations of the disclosed elements, as well as methods of practicing same, which are discussed in greater detail below.



BRIEF DESCRIPTION OF THE DRAWINGS
A full and enabling disclosure of the present invention, including the best mode thereof, to one of ordinary skill in the art, is set forth more particularly in the remainder of the specification, including reference to the accompanying drawings, in which:
FIG. 1 is a perspective view of a digital multimeter constructed in accordance with the present invention;
FIG. 2 is an exploded view showing various components of the multimeter of FIG. 1;
FIG. 3 is an enlarged exploded view of various components of a rotary switch assembly utilized in the multimeter of FIG. 1;
FIG. 4 is a side elevation showing first and second rotary switch members of the rotary switch assembly as mounted to a circuit board;
FIG. 5 is a plan view of a portion of the circuit board showing various terminal pairs thereon;
FIG. 6 is a plan view of the second rotary switch member showing an outer side thereof (i.e., the side away from the circuit board);
FIG. 7 is a perspective view of the second rotary switch member showing an inner side thereof (i.e., the side mounted toward the circuit board);
FIG. 8 is a perspective view of a unitary metallic element used in producing the second rotary switch member;
FIG. 9 is a plan view of the first rotary switch member showing an outer side thereof;
FIG. 10 is a perspective view of the first rotary switch member showing an inner side thereof;
FIG. 11 is a perspective view of a unitary metallic element used in producing the first rotary switch member;
FIGS. 12-14 are diagrammatic illustrations showing various molding steps that may be used in producing a rotary switch member in accordance with the present invention; and
FIG. 15 is a perspective view showing the rotary switch member as it emerges from the mold in FIG. 14.



Repeat use of reference characters in the present specification and drawings is intended to represent same or analogous features or elements of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
It is to be understood by one of ordinary skill in the art that the present discussion is a description of exemplary embodiments only, and is not intended as limiting the broader aspects of the present invention, which broader aspects are embodied in the exemplary constructions.
FIG. 1 illustrates a digital multimeter (DMM) 10 constructed in accordance with the present invention. Multimeter 10 comprises a housing in the form of a case 12 defining an interior cavity in which various internal components are located. A suitable display, such as a liquid crystal display (LCD), can be viewed through a transparent window 14 located in the top surface of case 12. A plurality of keys (collectively indicated at 16) provide a user interface. As shown, these keys may include directional navigation buttons as indicated at 18. A plurality of jacks for connection of respective test leads are also provided, as collectively indicated at 20.
A rotary selector knob 22 allows the user to select a particular multimeter function. In this case, ten such functions are provided, indicated by respective stop positions in the knob rotation. As one skilled in the art will appreciate, suitable graphics will typically be printed on the top surface of case 12 to indicate the respective function.
Certain additional details about the construction of multimeter 10 can be most easily explained with reference to FIG. 2. In this embodiment, case 12 is preferably formed having top and bottom case members 12a and 12b which together define the interior cavity. Preferably, each of the case members 12a and 12b may be formed of a molded shell of high impact rigid plastic which is at least partially overmolded with a softer polymeric material. The softer material provides a desirable gripping surface. The molded shell of the bottom case member may be opaque, whereas embodiments are contemplated in which the molded shell of the top case member is transparent. An opaque “skin” may be applied to the top case member to cover areas not already covered by the overmold that should not be transparent.
Various electronic components necessary for operation of multimeter 10 are mounted to a circuit board 24 within the interior cavity. Portions of circuit board 24 are covered by a bottom shield 26 and a top shield 28 to reduce the effects of interference on the operation of multimeter 10.
Multimeter 10 includes a rotary switch assembly by which circuit board 24 “knows” the position of selector knob 22. Referring now to FIGS. 2-4, switch assembly 30 in this embodiment includes a first switch member 32 and a second switch member 34 opposed to one another on the top and bottom sides, respectively, of circuit board 24. In this case, switch member 34 includes a shaft 36 extending through an aperture 38 defined in circuit board 24. Shaft 36 is received in a corresponding bore 40 defined in the center of switch element 32.
Preferably, shaft 36 includes a key received in a corresponding keyway defined in bore 40. As a result, switch members 32 and 34 will be situated in the correct angular orientation during the assembly process. In addition, shaft 36 and bore 40 may define a series of flats which further prevent relative rotation between switch members 32 and 34. An appropriate locking feature may be provided having a tendency to maintain the interconnection between switch members 32 and 34 after they are connected together.
A detent mechanism is used to divide rotation of selector knob 22 into discrete increments. As a result, selector knob 22 will remain in the selected position until the user intentionally moves the knob to a new position. In this embodiment, the detent mechanism comprises a detent disc 42 located in a recess 44 defined on the inside surface of case member 12a. Recess 44 defines a series of “teeth” 46 around its circumference. The teeth 46 are engaged by protuberances located at the end of respective springs (such as spring 48 and its protuberance 50) formed as an integral extension of detent disc 42. As one skilled in the art will recognize, the springs urge the respective protuberance into the valley between adjacent teeth 46.
A stop feature is preferably provided to limit rotation of knob 22 in both clockwise and counterclockwise directions. In this case, the stop feature comprises an arcuate groove 52 (FIG. 2) defined in the housing. Groove 52 receives a protrusion 54 (FIG. 3) located on the bottom of selector knob 22. When protrusion 54 gets to the end faces of groove 52, further rotation is prevented.
As shown in FIG. 3, selector knob 22 includes a depending shaft 56 that extends through an aperture 58 defined in case member 12a. Shaft 56 couples selector knob 22 to detent disc 42 such that they rotate together. In addition, detent disc 42 includes a pair of drive pins 60 received in respective drive holes 62 defined in the top of first switch member 32. As a result of this arrangement, rotation of selector knob 22 by a user will rotate detent disc 42, which in turn rotates switch assembly 30. In this embodiment, all of the components rotate around a common rotational axis A. Depending on the configuration of shield 28, an opening, such as circular opening 64, may be necessary to accommodate drive pins 60.
Detent disc 42 and switch member 32 may include visual indicators to ensure proper orientation during assembly. In this case, respective arrows 66 and 68 are provided for this purpose (see FIG. 3). The assembler knows that if the arrows are pointed in a particular direction, all of the rotational components will be oriented correctly with respect to one another.
Referring to FIG. 5, circuit board 24 includes a plurality of switching terminals that are either open (nonconducting) or closed (conducting) depending on the position of switch members 32 and 34. The switching terminals are formed as conductive pads on both planar surfaces of circuit board 24. For example, one position of selector knob 22 may provide a galvanic connection across terminals 70a and 70b. Another position of selector knob 22 may provide a galvanic connection across terminals 72a and 72b. As a result, the function to be performed by multimeter 10 is selected.
Additional details regarding the construction of second switch member 34 can be most easily explained with reference to FIGS. 6 and 7. As shown, switch member 34 comprises a support disc 74 in which a plurality of contact pairs 76a, 76b and 76c are carried. Support disc 74 is preferably formed of a suitable polymeric material such as an acceptable ABS/PC blend.
Contact pairs 78a-c are preferably formed from a suitable metal having the desired conductive and spring-like qualities. For example, presently preferred embodiments of the invention utilize beryllium copper which has been plated with nickel. As shown, each of the contact pairs 78a-c includes a pair of spring-like “fingers,” such as fingers 78a and b, that are connected together at their proximal ends (as indicated at 80). The fingers will contact a respective terminal pad as the switch member is rotated.
In this embodiment, switch member 34 also includes a “nonfunctional” sweeper 82. Sweeper 82 is “nonfunctional” in the sense that it does not serve as a switch armature, but instead functions to provide balance to switch member 34 during rotation. Specifically, sweeper 82 counteracts the upward spring force of contact pair 76a which might otherwise cause switch member 34 to tilt. As will be described in more detail below, contact pairs 76a-c and nonfunctional sweeper 82 may be advantageously formed from a unitary metallic element 84 (FIG. 8).
Referring now to FIGS. 9 and 10, first switch member 32 is also preferably formed having a support disc 86 in which a plurality of contact pairs 88a-d are carried. Like support disc 74, support disc 86 may be formed of a ABS/PC blend, or other suitable polymeric material. Contact pairs 88a-d are preferably produced from nickel-plated beryllium copper or other suitable conductive material. Contact pairs 88a-d may be formed from a unitary metallic element 90 (FIG. 11).
One exemplary process for producing a switch member according to the present invention will now be described with reference to the remaining figures. In this regard, FIGS. 12-14 diagrammatically illustrate a mold in which the support disc may be formed. In this case, the mold is configured to form support disc 86 of first switch member 32. Referring now to FIG. 12, unitary metallic element 90 is placed into a base 92 of the mold. Base 92 will include a suitable fixture ensuring the correct orientation of element 90. For example, element 90 may define a plurality of holes (FIG. 8 shows a similar hole 94 in element 84) that receive aligning pins located in the mold.
After element 90 is placed in the correct orientation, the mold is closed, as shown in FIG. 13. The polymeric material is injected into the mold so as to surround selected regions of unitary metallic element 90 and thereby form support disc 86. Once the polymeric material is suitably hardened, it can be removed from the mold as indicated in FIG. 14.
Referring now to FIG. 15, one skilled in the art will appreciate that all of the contact pairs are connected to one another when the switch member is removed from the mold. To interrupt a galvanic connection between the respective contact pairs, the support discs are provided with a number of punch-out apertures, such as punch-out aperture 96. These apertures expose the connecting strips between adjacent contact pairs so that at least a portion 98 of the strip can be removed. As a result, each of the contact pairs functions as an individual armature in the switch arrangement.
It can thus be seen that the present invention provides a digital multimeter having an improved rotary switch assembly. While preferred embodiments of the invention have been shown and described, modifications and variations may be made thereto by those of ordinary skill in the art without departing from the spirit and scope of the present invention. In addition, it should be understood that aspects of the various embodiments may be interchanged both in whole or in part. Furthermore, those of ordinary skill in the art will appreciate that the foregoing description is by way of example only, and is not intended to be limitative of the invention as further described in the appended claims.

## Claims

1. A rotary switch assembly for use in an electronic metering device, said rotary switch assembly comprising:
a selector knob;
a generally planar substrate board having conductive pads thereon defining multiple switching terminals;
a first switch member located on said substrate board, wherein said first switch member has a support disc formed of a polymeric material in which a plurality of contact pairs are carried, and wherein said contact pairs of said first switch member are operative to complete a galvanic connection across predetermined pairs of said switching terminals; and
a detent disc interconnecting said selector knob and said first switch member for rotation about a common rotational axis,
wherein said detent disc comprises a plurality of springs formed as integral extensions of said detent disc, and
wherein said detent disc and said first switch member each include a visual alignment feature having a directional indicator, and wherein alignment of the directional indicators is indicative of rotational alignment of the detent disc and the first switch member in a correct alignment orientation to facilitate assembly.

2. A multimeter comprising:
a case having a rotary selector knob for selecting a multimeter function;
a circuit board located in said case, said circuit board defining multiple switching terminals thereon; and
a rotary switch assembly operatively coupled to said selector knob, wherein said rotary switch assembly has a plurality of contact pairs that selectively complete a galvanic connection across predetermined pairs of said switching terminals, and wherein said rotary switch assembly further includes first and second switch members located in opposition on respective sides of said circuit board, each of said first and second switch members having at least one of said contact pairs,
wherein said second switch member further includes a nonfunctional sweeper operative to facilitate balance during rotation and configured to not serve as a switch armature.

3. The rotary switch assembly of claim 1, wherein when said visual alignment features are in a predetermined rotational position, said selector knob, said detent disc, and said first and second switch members are in the correct alignment orientation that is proper for said assembly.

4. The rotary switch assembly of claim 1, wherein said visual alignment feature of said detent disc is provided on a surface side of said detent disc facing said first switch member during said assembly.

5. The rotary switch assembly of claim 4, wherein said visual alignment feature of said first switch member extends from a periphery of a circumferential extent of said first switch member.

6. The rotary switch assembly of claim 1, further comprising a second switch member, wherein at least one of said first and second switch members carries an integral shaft coupled to the other of said first and second switch members.

7. The rotary switch assembly of claim 6, wherein said integral shaft is configured such that said first and second switch members are interconnected in a predetermined angular orientation.

8. The rotary switch assembly of claim 1, further comprising a second switch member, wherein said second switch member includes a nonfunctional sweeper operative to facilitate balance during rotation.

9. The multimeter of claim 2, wherein said nonfunctional sweeper is positioned on said second switch member so as to counteract an upward force of one or more of said plurality of contact pairs on said second switch member.

10. The multimeter of claim 2, wherein said nonfunctional sweeper includes a pair of parallel sweeper members.

11. The multimeter of claim 2, further comprising a detent disc located on an inside surface of said case, said detent disc interconnecting said selector knob and said first switch member for rotation about a common rotational axis.

12. The multimeter of claim 11, wherein said detent disc and said first switch member each include a visual alignment feature indicative of rotational alignment of the detent disc and the first switch member to facilitate assembly.

13. The multimeter of claim 12, wherein when said visual alignment features are in a predetermined rotational position, said selector knob, said detent disc, and said first and second switch members are in an orientation proper for said assembly.

14. The multimeter of claim 12, wherein said visual alignment feature of said detent disc is provided on a surface side of said detent disc facing said first switch member during said assembly.

15. The multimeter of claim 14, wherein said visual alignment feature of said first switch member extends from a periphery of a circumferential extent of said first switch member.

16. The multimeter of claim 11, wherein said selector knob includes a coupling structure engaging said detent disc such that said selector knob and said detent disc rotate together.

17. The multimeter of claim 2, wherein at least one of said first and second switch members carries an integral shaft that couples to the other of said first and second switch members.

18. The multimeter of claim 17, wherein said integral shaft is configured such that said first switch member and said second switch member are interconnected in a predetermined angular orientation.

19. The multimeter of claim 2, wherein each of said first and second switch members comprise a support disc in which said plurality of contact pairs are carried, said support disc being formed of a polymeric material.

20. The multimeter of claim 19, wherein each of said support discs defines at least one punch-out aperture at which adjacent contact pairs are disconnected.

21. The rotary switch assembly of claim 1, wherein each of the directional indicators of said visual alignment features comprises a respective directional arrow.

22. The multimeter of claim 2, wherein said nonfunctional sweeper and said at least one contact pair of said second switch member are formed from a unitary metallic element.