Abstract:
An electrical device is disclosed for use in a wall box having a series of buttons that can either be rocker buttons or push buttons. These buttons can be supported by springboards formed integral with a support board. The springboards are for biasing the series of buttons. Much of the device is housed within a housing formed at a first end by a body and a second end by a strap coupled to the housing. The strap extends beyond the body, wherein this strap can be used to dissipate heat from the device. Inside of the housing can be at least one circuit board which has switches, which can be used to receive instructions from a plurality of buttons. In one embodiment, a plurality of light pipes are adapted so that they are housed at least partially inside of these buttons. At least one portion of the light pipe can be formed as a shaft and adapted to extend out from this housing and down to a light emitter disposed on the circuit board. In at least one embodiment, this light pipe can also include at least one actuator which is used to contact an associated springboard when a button is acted on. This movement causes the springboard to contact an actuator on a TAC switch which then results in an associated set of instructions being sent to the circuit board.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    The invention relates to a compact and efficiently designed electrical control device having buttons for allowing a user to control different electrical devices. To support these buttons, there is a spring board to bias these buttons in a particular direction. 
         [0002]    In the past, spring boards that have been used to support either rocker mechanisms or push buttons have been made from a metallic material which may result in these spring boards being formed as separate from a support board supporting these spring boards. In addition, the use of metallic material for these spring boards can result in unnecessary interference when using an antenna enclosed within a wall mounted electrical device but disposed adjacent to these spring boards. Furthermore, previous designs of electrical devices have been cumbersome because different elements such as light pipes and buttons were not coupled together in a space saving manner. 
       SUMMARY OF THE INVENTION 
       [0003]    One embodiment relates to an electrical device for use in a wall box having a series of springboards formed integral with a support board. The springboards are for biasing a series of buttons which can be in the form of either rocker buttons or push buttons. At least one of these buttons can have an associated light. While any type of light could be used, one example of a light can be in the form of a light pipe which can be used to feed light from a light emitter such as a LED light. 
         [0004]    One of the benefits of the invention is that if a springboard is formed integral with a support board or a rack, this reduces complexity in assembly and can also reduce manufacturing cost. 
         [0005]    If a light is incorporated into a button or switch, this can result in a more simple design and installation as well as a reduction in manufacturing and tooling costs. 
         [0006]    The integration of the light into an associated switch or button, such as a push button or a rocker button, results in the creation of an instant indicator for these buttons. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]    Other objects and features of the present invention will become apparent from the following detailed description considered in connection with the accompanying drawings. It should be understood, however, that the drawings are designed for the purpose of illustration only and not as a definition of the limits of the invention. 
           [0008]    In the drawings, wherein similar reference characters denote similar elements throughout the several views: 
           [0009]      FIG. 1  discloses an exploded perspective view of a first embodiment; 
           [0010]      FIG. 2A  is a perspective view of a button shown in  FIG. 1 ; 
           [0011]      FIG. 2B  discloses a perspective view of a light pipe shown in  FIG. 1 ; 
           [0012]      FIG. 2C  shows a side view of a light pipe and button combination; 
           [0013]      FIG. 2D  shows a bottom view of a light pipe and button combination; 
           [0014]      FIG. 2E  shows a bottom view of another button; 
           [0015]      FIG. 3A  discloses a perspective view of a support board shown in  FIG. 1 ; 
           [0016]      FIG. 3B  shows a bottom view of the support board shown in  FIG. 3A ; 
           [0017]      FIG. 4  shows a perspective view of a first and a second circuit board shown in  FIG. 1 ; 
           [0018]      FIG. 5A  discloses a perspective view of a strap and antenna wire holder shown in  FIG. 1 ; 
           [0019]      FIG. 5B  shows a perspective view of the assembled device; 
           [0020]      FIG. 6  is an exploded perspective view of another embodiment; 
           [0021]      FIG. 7A  is a perspective view of the series of buttons shown in  FIG. 6 ; 
           [0022]      FIG. 7B  is a side view of a button and lightpipe combination; 
           [0023]      FIG. 7C  is a bottom view of a button and lightpipe combination; 
           [0024]      FIG. 7D  is a front perspective view of an additional button shown in  FIG. 6 ; 
           [0025]      FIG. 8A  is a perspective view of the support board shown in  FIG. 6 ; 
           [0026]      FIG. 8B  is a back perspective view of the support board shown in  FIG. 8A ; 
           [0027]      FIG. 9  Is a perspective view of the circuit boards shown in  FIG. 6 ; 
           [0028]      FIG. 10A  is a perspective view of the strap and an antenna wire holder as shown in  FIG. 6 ; and 
           [0029]      FIG. 10B  is a perspective view of the assembled device. 
       
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
       [0030]    Referring to the drawings,  FIG. 1  discloses an exploded perspective view of the first embodiment  10 . This embodiment includes a plurality of buttons  20  which can be coupled to a plurality of lights, which can be in the form of light emitting elements or light pipes  30  which can be coupled to a frame  40 . Frame  40  can be coupled to strap  60  which is secured to body  95  via screws  50 . Disposed below the strap  60  is a support board  70  which supports a plurality of springboards above a plurality of contacts on a circuit board  80 . There is also an additional power circuit board  90  which is coupled at one end to a power input such as a contact  92  and feeds power into circuit board  80 . When strap  60  is screwed into body  95 , strap  60  covers support board  70 , and circuit boards  80  and  90  enclosing these elements in a housing. 
         [0031]    Buttons  20  can be in the form of any usable buttons but in this embodiment are shown as rocker buttons. This series of buttons includes a first button  22 , a second button  24 , a third button  26 , and a fourth button  28 . There is also an additional controller button  29  which differs from the series of buttons  20  in that this controller button  29  does not accept the light pipe. Button  22  is shown in greater detail in  FIG. 2A . For example, button  22  includes a first section  22 . 1  which is angled, and a second section  22 . 2  which is angled, wherein each of these sections is joined together to form a slightly angled V-shaped button. There is a rocker hinge or axle  22 . 3  disposed opposite the front faces of button  22 . In addition, an opening  22 . 4  is disposed in button  22  which is designed to allow a section of a light pipe to shine therethrough. Button  22  can also contain therein a foil strip  22 . 8  (See  FIG. 2C ) designed to block the emission of light through this button. This button  22  is designed similar to buttons  24 ,  26 , and  28  such that these buttons all have the same components. 
         [0032]    A series of light pipes  30  is shown as light pipes  32 ,  34 ,  36  and  38 . One of these light pipes  32  is shown in greater detail in  FIG. 2B . For example, light pipe  32  includes a first emitting section  32 . 1  and a second emitting section  32 . 2 . Disposed between these two emitting sections is a cut out where light which extends up from a shaft  32 . 6  relays to either emitting section  32 . 1  or  32 . 2 . Light then flows into section  32 . 1  and also flows into the additional components  32 . 3 ,  32 . 4 , and  32 . 5 . Section  32 . 3  acts as an actuator which then contacts an associated spring board element at the free end of this spring board element to move this spring board element down thereby contacting the associated actuator element on circuit board  80 . Section  32 . 4  includes an extending member which extends through opening  22 . 4  in button  22 . In this case, each light pipe has this extending section which extends through the associated opening in the associated connected button. Disposed opposite actuator  32 . 3  is another actuator  32 . 8  (See also  FIGS. 2C and 2D ) which extends down to contact an associated springboard when a button is pushed in that direction. There are also extending elements  32 . 5  and  32 . 7  which extend out from second emitting section  32 . 2 . These extending elements are for snugly fitting the light pipe inside an underside region of button  22 . 
         [0033]      FIG. 2E  discloses an underside view of button  29 . Button  29  is in the form of a non-lightpipe receiving button which has a translucent opening  29 . 1  for receiving infrared (IR) transmissions. Because button  29  does not receive a light pipe having actuators, button  29  includes its own set of actuators  29 . 2  and  29 . 3  formed therein. 
         [0034]      FIG. 3A , shows a support board  70  which includes an integral series of spring boards or associated springboard sections which are formed in a one piece manner with a frame  71 . Frame  71 , is supported in the housing by a series of legs  73 . This frame is for supporting a series of spring board sections which in this view, includes a least two spring boards thereby allowing a rocker button to rock back and forth in at least two directions or remain at rest in the center position. For example, there is a series of springboard sections  110 ,  120 ,  130  and  140  each having at least two spring board elements. First springboard section  110  includes springboards  111  and  116 . Second springboard section  120  includes springboards  121  and  126 . Third springboard section  130  includes springboards  131  and  136 . Fourth springboard section includes springboards  141  and  146 . 
         [0035]    While these springboard sections can be formed in any manner, and even formed different from each other, in this embodiment, each of these springboard sections are substantially identical to each other. Therefore, only first springboard section  110  will be discussed in detail. For example, first springboard section  110  includes a first springboard element  111 , and a second springboard element  116  which can be used to bias the light pipe or light body section  32  into a balanced center position. By rocking button  22  either to the left or to the right, this movement causes the associated actuator elements  32 . 3  and  32 . 8  to act on the associated springboards  111  or  116 . Springboard  111  includes a first section  111 . 1  which is formed as a molded spring section coupled to frame  71 . Springboard element  111  also includes a free end  111 . 2  which is shown curved in a substantially L-shaped manner and extends to a free end. Pressing down on free end  111 . 2  causes curved section  111 . 1  to bend and compress thereby causing free end  111 . 2  to move down. This can be caused for example, by pressing down on a section of a button such as section  22 . 1  of button  22  which thereby presses down on the left section of a light pipe  32 . 1  which then presses down on associated actuator  32 . 3 . This movement then causes free end  111 . 1  to move down thereby driving an actuator section  111 . 3  into an associated actuator on switch  182  (see  FIG. 4 ). 
         [0036]    Springboards  151  and  156  can be formed in a similar manner to the springboards shown in springboard sections  110 - 140 , however, in this embodiment these springboards  151  and  156  are designed differently than the springboards in springboard sections  110 - 140 . For example, these springboards have a more pronounced L-shaped section which creates a larger spaced opening between springboards  151  and  156 . In addition, as shown in  FIG. 3B  an underside view of springboard  151  shows a first curved flexure section  151 . 1  which leads to an extended region  151 . 2 . Coupled to region of  151 . 2  is a contact section  151 . 3 . Similarly, spring board  156  also includes a first curved connection section  156 . 1 , a second free curved end  156 . 2  as well as a contact section  156 . 3 . The relatively wider opening created by these springboards is designed to allow infrared light to pass therethrough. 
         [0037]    These two springboards are for contacting with contacts  189  and  190  shown in  FIG. 4 .  FIG. 4  discloses a perspective view of circuit boards  80  and  90 . Circuit board  80  includes a series of switches which can be in the form of any available switches. One type of switch used could be a TAC switch. Switches  181 ,  182 ,  183 ,  184 ,  185 ,  186 ,  187 ,  198 ,  189 ,  190  are shown and are all disposed on circuit board  80  and adapted to work with other components on circuit board  80 . Each of these switches can be formed different from each other, however in this embodiment, each of these switches are formed in a substantially similar manner. For example, switches  181  and  182  are described in greater detail, however the description of each of these switches will be sufficient to describe any of the other switches. For example switches  181 , and  182  each have a switch body  181 . 2 , and  182 . 2  respectively. Each of these switch bodies is fastened to circuit board  80 . In addition, switch bodies  181 . 2  and  182 . 2  each have associated actuator elements  181 . 1  or  182 . 1  respectively. 
         [0038]    When actuator elements  181 . 1  or  182 . 1  are contacted by an associated contact such as by contact elements  111 . 3  or  116 . 3 , this sends a signal into circuit board  80  to activate a set of instructions associated with either of these switches. In addition, circuit board  80  has a series of light emitters such as light emitters  191 ,  194 ,  196 , and  198 . These light emitters can be in the form of a light emitting diode or LED, which can then emit light up through a light pipe such as light pipe  32  for eventual display in an associated button such as emitting through hole  22 . 4  in button  22 . 
         [0039]      FIG. 5A  shows a perspective view of strap  60  having an antenna holder  62  coupled thereto. Antenna holders  62  can be coupled thereto as a dielectric element which can be snapped in to strap  60  thereby shielding antenna  100  from unnecessary interference with strap  60 . Antenna  100  is coupled to circuit board  80  and can be fed up from circuit board  80  to antenna holder  62 . 
         [0040]      FIG. 5B  shows a perspective view of the assembled device wherein strap  60  is coupled to housing  95  while antenna  100  as well as antenna holder  62  are disposed beneath a frame  40 . Frame  40  can essentially be snapped into strap  60  via a series of catches  42  which can snap into associated holes  64  in strap  60 . Frame  40  also contains a plurality of axle supports  46  which support associated axles such as axle  22 . 3 . In this way, a button such as button  22  can rest on these axle supports  46  and thereby rock back and forth in frame  40 . Frame  40  can be removed from strap  60  by simply pressing laterally in a forceful manner to unclip catches  42 . 
         [0041]    In this way, different colored faceplates or frames can be attached and matched with frame  40  to create a multi-changeable facade. 
         [0042]    This type of design can be used in many different ways. One example is that this design can be used as a zone controller wherein each button  22 ,  24 ,  26 , and  28  can act as an on-off switch for different lights in a room or different electrical devices in a room, or different electrical components in different rooms. A zone controller can be a user interface with multiple switches such as rocker buttons acting as on-off switches with each switch being coupled to a particular load. Since these buttons all act as rocker buttons, these buttons then can be used to separately turn on or off these different electrical components. 
         [0043]      FIG. 6  discloses a perspective view of a second embodiment of the invention. This view shows face plates or frame  210  which can be used to support a plurality of buttons  220  as well as an additional rocker button  229 . These buttons can be fit into the frame and an associated strap  230  wherein strap  230  can be secured to a back cover  295  via screws  240 . Disposed below strap  230  is a support board  250 . Support board  250  is for supporting a plurality of springboards above a plurality of associated switches on a circuit board, such as circuit boards  270  and  290 . Circuit board  270  includes plurality of contacts and a plurality of light emitters. Circuit board  290  functions as a power circuit board having an associated contact  292  for receiving power from a power line and then feeds this power into circuit board  270 . Once strap  230  is secured to cover  295  via screws  240 , support board  250  as well as circuit boards  270  and  290  are disposed in a housing formed by back cover  295  and between strap  230  and cover  295 . 
         [0044]      FIG. 7A  discloses a perspective view of button series  220 . Button series  220  includes a plurality of buttons such as buttons  222 ,  224 ,  226 , and  228 . Each of these buttons includes an opening  222 . 1 ,  224 . 1 ,  226 . 1 , and  228 . 1  respectively wherein these openings are designed to allow light to flow there-through from an associated light pipe. For example, in this view, button  228  includes a light pipe  227  coupled thereto and extending below button  228 . Each of these buttons to  222 ,  224 ,  226 , and  228  are the form of pushbuttons which can be pushed in a singular direction as opposed to rocker buttons disclosed in the previous embodiment, which can be moved in at least two different directions via a rocking motion. In this case, there can also be a design that includes different combinations of push buttons and rocker buttons as well. 
         [0045]      FIG. 7B  is a side view of a button and lightpipe combination. These lightpipes are similar to the lightpipe  32  disclosed above. For example, lightpipe  227  includes a shaft  227 . 1 , actuator elements  227 . 2  and  227 . 3  as well as extending elements  227 . 4  (See  FIG. 7C ) which allow this lightpipe to be snapped into button  228 . In addition, disposed inside of this button is a strip of foil  231  which is shown by the dotted line. This strip of foil is designed to keep light from flowing out of button  228 , and instead out of hole  228 . 1 .  FIG. 7C  is a bottom view of button  228  and the associated lightpipe  227  showing shaft  227 . 1  and extending elements  227 . 4 . 
         [0046]      FIG. 7D  shows button  229  is in the form of a rocker button. Rocker button  229  includes a first section  229 . 1 , and a second section  229 . 2  wherein each of these sections angles up in a substantially V-shaped manner. There can be an optional third section  229 . 3  which is in the form of a window for receiving IR signals into the housing. These IR signals can then be received by an IR receiver  299  coupled to circuit board  270 . In addition, a support forming a hinge  229 . 4  is coupled to the side opposite the face of this rocker button. This hinge allows this button to move back and forth to activate two different actuators disposed on circuit board  270 . 
         [0047]      FIG. 8A  discloses a perspective view of support board or frame  250  which supports a plurality of springboards coupled thereto. For example, a series of springboards  252 ,  254 ,  256 , and  258  are all each coupled to frame  251  or support board  250 . Support board  250  includes a frame  251  and legs  253 . These legs  253  support this support board above the adjacent circuit boards. These springboards can be formed in any useful manner and may be formed differently from each other. In this embodiment, springboard  252  is substantially identical to springboards  254 ,  256 , and  258 . Therefore the description of springboard  252  applies to these other boards  254 - 258 . 
         [0048]    For example, spring board  252  (See  FIG. 8B ) includes a base section  252 . 1  which connects at a first end to main body  251 . At this connection end is a curved section which forms an associated spring region such as a leaf spring. This section is curved because it provides greater flexure for the device by having a longer top surface area in tension than the underside in compression. 
         [0049]    Spring board  252  has an opposite free end  252 . 3  which is movable when pressed on. At a central region of spring board  252 , is a support column  252 . 2  which has an associated hole. Support column  252  is designed to receive an associated light pipe such as light pipe  227  which fits therein and extends into an associated light emitter. 
         [0050]    As shown in  FIG. 8B , the free end of spring board  252  includes a contact element or button  252 . 4 . This contact button can be used to contact an associated actuator on a switch on a circuit board  270 . 
         [0051]    A set of rocker springboards  260  is also coupled to support board  250 . For example, first rocker springboard  262  includes a first connected end  262 . 1  and a second free end  262 . 2 . First connected end  262 . 1  has a curved section which allows this springboard to form a high quality leaf spring thereby flexing and bending back up to support an associated rocker button. There is also an additional spring board  264  which is formed as a complementary springboard, to support an associated rocker button such as rocker button  229 . Springboard  264  includes a first connected section  264 . 1  which is formed in a curved manner thereby creating a flexing leaf spring wherein this springboard also has an associated free end  264 . 2 .  FIG. 8B  shows the opposite sides of these spring boards showing associated contact elements  262 . 3  and  264 . 3  which can be used to selectively contact actuators  280 . 1  and  282 . 1  (See  FIG. 9 ). 
         [0052]      FIG. 9  shows a perspective view of circuit boards  270  and  290 . Circuit board  270  includes a plurality of switches  272 ,  274 ,  276 ,  278 ,  280 , and  282 . Each of these switches includes an associated actuator  272 . 1 ,  274 . 1 ,  276 . 1 ,  278 . 1 ,  280 . 1 , and  282 . 1 , wherein each of these actuators are associated with a contact base  272 . 2 ,  274 . 2 ,  276 . 2 ,  278 . 2 ,  280 . 2 , and  282 . 2 . These bases are secured to circuit board  270 . In addition, plurality of light emitters are also coupled to circuit board  270 . For example, there is shown light emitters  273 ,  275 ,  277 , and  279 . These light emitters can be in the form of any known lights, such as an LED type emitter. As discussed above, these associated contact elements such as contact elements  252 . 4 ,  262 . 3  or  264 . 3  can contact an associated actuator such as  272 . 1 ,  274 . 1 ,  276 . 1 ,  278 . 1 ,  280 . 1  or  282 . This type of contact sends a signal into circuit board  270  which includes a set of instructions thereby actuating an associated set of commands which have been programmed to respond to a contact of an associated contact element. 
         [0053]      FIG. 10A  disclose a perspective view of strap  230  which has an antenna holder  232  coupled thereto. Antenna holder  232  is in the form of a dielectric material which is used to shield antenna  300  from unnecessary effects from a metal strap  230 . Antenna  300  is coupled to circuit board  280 . 
         [0054]    Once this device is fully assembled, antenna  300  is disposed beneath frame  230 , but is disposed outside of a housing formed by strap  230  and cover  295 . Similar to the first embodiment, frame  210  can be snapped into strap  230 , wherein catch  212  can be snapped into snap holes  232 . 
         [0055]    In addition, frame  210  can be easily removed from strap  230  by simply laterally pressing on frame  210  to release catches  212  (See  FIG. 6 ) from strap holes  232 . For example, in this case, a user could use a screwdriver to laterally press on frame  210  and use a flat head of the screwdriver to pull underneath frame  210  to pop it out from strap  230 . That user could then replace this frame with a different colored frame to provide a substantially easily adaptable display for a user. This device once assembled can be used as a scene controller wherein each of the push buttons  222 ,  224 ,  226 , and  228  can be used to set for example, dimmer settings on a light or series of lights in a room. Other uses for these buttons are possible as well. 
         [0056]    Both of these embodiments show rocker or push buttons associated with a wireless based system having an antenna and infrared receivers. Both of these embodiments can be used with the design of a wireless system disclosed in U.S. patent application Ser. No. 11/559,646, filed on Nov. 14, 2006, the disclosure of which is hereby incorporated herein by reference in its entirety. 
         [0057]    Alternatively, these embodiments can be incorporated into non wireless systems as well. 
         [0058]    With the incorporation of a light into an associated button such as buttons  22 ,  24 ,  26 , or  28  or buttons  222 ,  224 ,  226 , or  228 , this results in these buttons having an indicator. For example, these lights could be used as nightlights which can be used to guide a user to these buttons. Alternatively, these lights could illuminate when a particular button is pushed. For example, if a push button is pushed in, or a rocker button is rocked towards and activation position, the associated light could illuminate thereby indicating to a user that a particular switch has been activated. 
         [0059]    Rocker buttons  22 ,  24 ,  26 , and  28  and their associated switches on the associated circuit board such as circuit board  80 , form rocker switches. These rocker switches can be used as on-off switches, or as level setting switches. For example, if a rocker switch is set as an on-off switch, then a user could for example, push an associated rocker switch to a left position, thereby turning on an electrical load and also turning on an associated light in the button. Alternatively, pushing this switch to a right position would turn an associated load off. 
         [0060]    If the rocker switch is a level setting switch, then a push in a particular direction such as to a left position could be used to increase the intensity of power in a load such as increasing a level of a light connected to an associated controller. Alternatively by pushing this rocker switch in an opposite direction, this could be used to reduce the intensity of power to this load. 
         [0061]    Alternatively, a push button which is shown by way of example as buttons  222 ,  224 ,  226 , and  228  and their associated switches which are disposed on circuit board  270  are combined to form push button switches. Each push button switch can be designed as either an on-off switch, or a level setting switch as well. For example, when a user pushes a push button, if that push button is associated with an on-off switch, then a first push will turn that switch to an on position, thereby turning an associated light on, while a second push could be used to turn that switch off. Alternatively, each push button can be associated with a different level as well. For example, a first push button such as push button  222  can be associated with a switch for setting an associated load such as a light at a first level of illumination. A second push button such as push button  224  can be associated with a switch for setting an associated load such as a light at a second level of illumination. When a user pushes that associated push button, the associated level is set and a light associated with that button is turned on. 
         [0062]    Buttons  29  and  229  can be used as universal switches. For example, in at least one embodiment, button  29  which is positioned to act on switches  189  and  190  can be used as a level setting switch. In this case, the level setting switch would set the intensity level for all of the loads turned on by their associated switches associated with buttons  22 ,  24 ,  26  and  28 . Button  229  could also be used in a similar manner with associated switches associated with buttons  222 ,  224 ,  226 , and  228 . 
         [0063]    In at least one embodiment, push buttons  222 ,  224 ,  226 , and  228  are in the form of level setting push buttons, wherein button  229  is in the form of an on off switch turning on or off associated loads which can then be set in terms of intensity by push buttons,  222 ,  224 ,  226  and  228 . 
         [0064]    Different combinations of these push buttons and rocker buttons are possible, and can be used to create a scene controller or a zone controller. As described generally above, a zone controller comprises a plurality of buttons representing switches, wherein each switch is for controlling an associated load. Generally, with a scene controller, a button or plurality of buttons can represent switches for controlling multiple downstream loads. 
         [0065]    Accordingly, while a few embodiments of the present invention have been shown and described, it is to be understood that many changes and modifications may be made thereunto without departing from the spirit and scope of the invention as defined in the appended claims.