Abstract:
A power switch including a contact configured to selectively electrically connect a line input to a load output, a switch configured to selectively control the contract, and an indicator. The contact has a closed position in which the line input is electrically connected to the load output, and an open position in which the line input is not electrically connected to the load output. The switch has an on position wherein the contact is controlled to be in the closed position, and an off position wherein the contact is controlled to be in the open position. The indicator provides a normal on status, a normal off status, and an error on status.

Description:
RELATED APPLICATIONS 
       [0001]    The present applications relates to U.S. Provisional Patent Application No. 62/358,931, filed on Jul. 6, 2016, and U.S. Provisional Patent Application No. 62/450,142, filed on Jan.25, 2017. The entire contents, both of which, are hereby incorporated by reference. 
     
    
     FIELD 
       [0002]    Embodiments relate to a power switch and an enclosure for the same. 
       SUMMARY 
       [0003]    Power switches selectively electrically connect a line power to a load. Typically, power switches include a user-switch having an ON position and an OFF position. When the user-switch in is the ON position line power is provided to the load. When the user-switch is in the OFF position line power is not provided to the load. However, such power switches fail to notify the user when there is an error, such as but not limited to, when line power is being provided to the load but the user-switch is in the OFF position. Such a situation may occur when one or more contacts of the power switch are welded together. 
         [0004]    Accordingly, in one embodiment, the application provides a power switch including a line input configured to receive a line voltage, a load output configured to output the line voltage, a contact configured to selectively electrically connect the line input to the load output, a switch configured to selectively control the contract between the open position and the closed position, and an indicator. The contact has a closed position in which the line input is electrically connected to the load output, and an open position in which the line input is not electrically connected to the load output. The switch has an on position wherein the contact is controlled to be in the closed position, and an off position wherein the contact is controlled to be in the open position. The indicator provides a normal on status wherein the indicator is activate when the switch is in the on position and the contact is in the closed position, a normal off status wherein the indicator is inactive when the switch is in the off position and the contact is in the open position, and an error on status wherein the indicator is active when the switch is in the off position and the contact is in the closed position. 
         [0005]    In another embodiment the application provides a power switch including a housing, and indicator, and an indicator lens. The housing includes a rear portion and a front cover coupled to the rear portion. The indicator is supported by the front cover, the indicator is configured to provide an indication of the power switch. The indicator lens is positioned between the indicator and the front cover. 
         [0006]    In another embodiment, the application provides a power switch including a housing and a mounting foot. The mounting foot is configured to secure the housing to a surface. The mounting foot includes a molding and an insert contained within the molding. 
         [0007]    In another embodiment, the application provides a power switch housing including a front cover and a rear housing. The front cover includes a retainer configured to captivate a fastener. In some embodiments the fastener includes a groove and a threaded portion. The rear housing is configured to be coupled to the front cover via the fastener. 
         [0008]    Other aspects of the application will become apparent by consideration of the detailed description and accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]      FIG. 1A  illustrates a front view of a power switch enclosure according to some embodiments of the application. 
           [0010]      FIG. 1B  illustrates a front view of a power switch enclosure with a front cover removed according to some embodiments of the application. 
           [0011]      FIG. 2  illustrates a front view of the power switch enclosure of  FIG. 1  with a front cover removed according to some embodiments of the application. 
           [0012]      FIG. 3  illustrates a fastener of the power switch enclosure of  FIG. 1  according to some embodiments of the application. 
           [0013]      FIG. 4  illustrates the fastener of  FIG. 3  captivated at a front fastener location of the front cover of the power switch enclosure of  FIG. 1  according to some embodiments of the application. 
           [0014]      FIG. 5  illustrates the fastener of  FIG. 3  captivated at a front fastener location of the front cover of the power switch enclosure of  FIG. 1  according to another embodiment of the application. 
           [0015]      FIGS. 6A &amp; 6B  illustrate a cutaway view of the fastener of  FIG. 3  captivated at a front fastener location of the front cover of the power switch enclosure of  FIG. 1  according to some embodiments of the application. 
           [0016]      FIG. 7A  illustrates a perspective view of an insert of a mounting foot of the power switch enclosure of  FIG. 1  according to some embodiments of the application. 
           [0017]      FIG. 7B  illustrates a perspective view of a mounting foot of the power switch enclosure of  FIG. 1  according to some embodiments of the application. 
           [0018]      FIG. 8  illustrates a front view of a mount foot according to another embodiment of the application. 
           [0019]      FIG. 9  illustrates a perspective view of the mounting foot of  FIG. 8  coupled to a housing of the power switch enclosure of  FIG. 1  according to some embodiments of the application. 
           [0020]      FIG. 10  illustrates a perspective view of the power switch enclosure of  FIG. 1  coupled to a surface via the mounting foot of  FIG. 8  according to some embodiments of the application. 
           [0021]      FIG. 11  illustrates an indicator of the power switch enclosure of  FIG. 1  according to some embodiments of the application. 
           [0022]      FIG. 12  illustrates a circuit diagram of the indicator of  FIG. 11  electrically coupled to a switch of the power switch enclosure of  FIG. 1  according to some embodiments of the application. 
           [0023]      FIG. 13  illustrates a perspective view of a male tab of the power switch enclosure of  FIG. 1  according to some embodiments of the application. 
           [0024]      FIG. 14  illustrates a circuit diagram of the indicator of  FIG. 11  according to some embodiments of the application. 
           [0025]      FIG. 15  illustrates an indicator lens of the power switch enclosure of  FIG. 1  according to some embodiments of the application. 
           [0026]      FIG. 16  illustrates the indicator lens of  FIG. 15  and a rear portion of a front cover of the power switch enclosure of  FIG. 1  according to some embodiments of the application. 
           [0027]      FIG. 17  illustrates the indicator lens of  FIG. 15  coupled to a rear portion of a front cover of the power switch enclosure of  FIG. 1  according to some embodiments of the application. 
           [0028]      FIG. 18  illustrates a gasket coupled to the indicator lens of  FIG. 15  according to some embodiments of the application. 
           [0029]      FIG. 19  illustrates a rear view of the housing including the indicator lens of  FIG. 15  according to some embodiments of the application. 
           [0030]      FIG. 20  illustrates a gasket and a front cover according to another embodiment of the application. 
           [0031]      FIG. 21  illustrates the gasket of  FIG. 19  coupled to the front cover according to some embodiments of the application. 
           [0032]      FIG. 22  illustrates an indicator lens coupled to the gasket and front cover of  FIGS. 19 and 20  according to some embodiments of the application. 
           [0033]      FIGS. 23A-23D  illustrate various statuses provided by the indicator of  FIG. 11  according to some embodiments of the application. 
           [0034]      FIG. 24  illustrates a front view of a power switch enclosure according to another embodiment of the application. 
           [0035]      FIG. 25A  illustrates a front view of a housing of the power switch enclosure of  FIG. 23  according to some embodiments of the application. 
           [0036]      FIG. 25B  illustrates a rear view of the housing of the power switch enclosure of  FIG. 23  according to some embodiments of the application. 
       
    
    
     DETAILED DESCRIPTION 
       [0037]    Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. 
         [0038]      FIG. 1A  illustrates a front view of a power switch enclosure  100  according to some embodiments of the application. The power switch enclosure  100  is configured to selectively control and electrical connection between line power to a load. In some embodiments, the load is a motor, such as but not limited to, an alternating-current (AC) motor or a direct-current (DC) motor. In some embodiments, the power switch enclosure  100  is configured to provide a line power having a voltage within a range of approximately 120 VAC to approximately 600 VAC and a maximum current of approximately 600 mA. The power switch enclosure  100  includes an enclosure, or housing,  105 , a user-switch  120 , and an indicator  125 . In some embodiments, the housing  105  may be formed of an insulating material, such as but not limited to, a plastic material. In other embodiments, the housing  105  may be formed of a metallic material, such as but not limited to, stainless steel. Although illustrated as having a rectangular shape, in other embodiments, such as illustrated in  FIG. 1B , the housing  105  may have a circular, semi-circular, or sloped shape. 
         [0039]      FIG. 2  illustrates the power switch enclosure  100  with a front cover  200  of the housing  105  removed from a rear portion  205  of the housing  105 . The front cover  200  is connected to the rear portion  205  via one or more fasteners  300  ( FIG. 3 ) at one or more front fastener locations  210  and one or more rear fastener locations  215 . In some embodiments, the front cover  200  is selectively removable from the rear portion  205 . In such an embodiment, the front cover  200  is replaceable. In some embodiments, the front cover  200  may be a replacement cover on a pre-existing power switch enclosure. 
         [0040]      FIG. 3  illustrates a fastener  300  according to one embodiment of the application. The fastener  300  includes a fastener head  305 , a threaded portion  310 , and a groove  315 .  FIG. 4  illustrates the fastener  300  captivated at the front fastener location  210  of the front cover  200  according to an embodiment of the application. In such an embodiment, the fastener  300  is captivated by a retainer  320 . In the illustrated embodiment, the retainer  320  is a retaining ring. In such an embodiment, the retainer  320  may be formed of metal. The retainer  320  may be coupled to the front cover  200  via a counter bore. The retainer  320  captivates the fastener  300  at the groove  315 . 
         [0041]      FIGS. 5, 6A &amp; 6B  illustrate the fastener  300  captivated at the front fastener location  210  of the front cover  200  according to other embodiments of the application. In such an embodiment, the front cover  200  includes a retainer  400  integrated into the front cover  200 . The retainer  400  captivates the fastener  300  at the groove  315 . 
         [0042]      FIGS. 7A and 7B  illustrate a mounting foot  700  of the power switch enclosure  100  according to some embodiments of the application. The mounting foot  700  may include a molding  705 , an insert  710 , a first mounting aperture  715 , and a second mounting aperture  720 . The molding  705  may be formed of an insulating material, such as but not limited to, a plastic material. The molding  705  is configured to be molded over the insert  710 . The insert  710  may be formed of a rigid material, such as but not limited to a metal (e.g., steel, stainless steel, etc.). In such an embodiment, the insert  710  provides strength and rigidity to the mounting foot  700 , while the molding  705  provides insulation between the power switch enclosure  100  and a surface  750 . In other embodiments, the mounting foot  700  may be formed of a glass-filled plastic, such as but not limited to, a Valox material (for example, Valox 430 PBT). 
         [0043]      FIG. 8  illustrates a mounting foot  700  according to another embodiment of the application. In such an embodiment, the mounting foot  700  further includes a lower portion  755  surrounding the first mounting aperture  715  and an upper portion  760  surrounding the second mounting aperture  720 . The lower portion  755  may have a width of approximately 0.75 in, while the upper portion  760  may have a circumference of approximately 1.0 in. 
         [0044]      FIG. 9  illustrates the mounting foot  700  coupled to the housing  105  of the power switch enclosure  100 . In the illustrated embodiment, the mounting foot  700  is coupled to the rear portion  205  of the housing via a fastener at the first mounting aperture  715 .  FIG. 10  illustrates the power switch enclosure  100  coupled to the surface  750  via one or more mounting feet  700 , according to some embodiments of the application. In the illustrated embodiment, the mounting feet  700  are coupled to the surface  750  via fasteners at the second mounting apertures  720 . In other embodiments, the mounting foot  700  is coupled to the housing  105  via a welding process. 
         [0045]    As illustrated in  FIGS. 1 and 2 , the housing  105  supports the user-switch  120 , the indicator  125 , and an electrical switch  800 . The electrical switch  800  includes a line input  805  and a load output  810 . The line input  805  is configured to electrically connect to the line while the load output  810  is configured to electrically connect to the load. The electrical switch  800  is coupled to the user-switch  120  and configured to be operated by the user-switch  120 . The user-switch  120  includes an ON position and an OFF position. When the user-switch  120  is in the ON position, the electrical switch  800  is also in the ON position and electrically connects the line input  805  to the load output  810 , thus providing line power to the load. When the user-switch  120  is in the OFF position, the electrical switch  800  is also in the OFF position and electrically disconnects the line input  805  from the load output  810 , thus line power is not provided to the load. In some embodiments, the electrical switch  800  includes one or more contacts  815  ( FIG. 12 ) for selectively electrically connecting the line input  805  to the load output  810 . 
         [0046]      FIG. 11  illustrates the indicator  125  according to some embodiments of the application. The indicator  125  provides indication to a user. In the illustrated embodiment, the indicator  125  includes a first line indicator  900   a,  a second line indicator  900   b,  a third line indicator  900   c,  a first load indicator  905   a,  a second load indicator  905   b,  and a third load indicator  905   c.  The line indicators  900   a - 900   c  provide indication to the user that line power is electrically connected to the power switch enclosure  100  via the line input  805 . The load indicators  905   a - 905   c  provide indication to the user that the line power is being provided to the load. In some embodiments, the line indicators  900  and load indicators  905  are light-emitting diodes (LEDs). In other embodiments, the line indicators  900  and load indicators  905  may be audible indicators. 
         [0047]    In the illustrated embodiment, the line power is a three-phase electric power. In such an embodiment, the first line indicator  900   a  and first load indicator  905   a  correspond to a first phase, the second line indicator  900   b  and second load indicator  905   b  correspond to a second phase, and the third line indicator  900   c  and third load indicator  905   c  correspond to a third phase. In other embodiments, the line power may be single-phase. In such an embodiment, the indicator may include only a single line indicator  900  and a single load indicator  905 . 
         [0048]      FIG. 12  illustrates a circuit diagram of the indicator  125  electrically connected to the electrical switch  800  and ground  950 . In the illustrated embodiment, the indicator  125  includes indicator line inputs  950   a,    950   b,    950   c  and indicator load inputs  955   a,    955   b,    955   c.  The indicator line inputs  950   a,    950   b,    950   c  are electrically connected to the electric switch  800  at the line inputs  805   a,    805   b,    805   c  and the indicator load inputs  955   a,    955   b,    955   c  are electrical connected to the electric switch  800  at the load outputs  810   a,    810   b,    810   c.  As discussed above, the electric switch  800  includes contacts  815   a,    815   b,    815   c  for selectively electrically connecting the line inputs  805   a,    805   b,    805   c  to the load output  810   a,    810   b,    810   c.    
         [0049]      FIG. 13  illustrates a male tab  960  according to one or more embodiments of the application. In some embodiments, the indicator  125  (e.g., indicator line inputs  950   a,    950   b,    950   c  and indicator load inputs  955   a,    955   b,    955   c ) is electrically connected to the electrical switch  800  (e.g., the line inputs  805   a,    805   b,    805   c  and the load output  810   a,    810   b,    810   c ) and ground  950  via one or more male tabs  960 . In such an embodiment, the male tabs  960  are configured to allow electrical connection of the high-power electrical switch  800  to the relatively low-power indicator  125 . In some embodiments, the male tabs  960  are Rockwell® Sta-Kon 187 series tabs. In other embodiments, in lieu of male tabs  960 , the power switch enclosure  100  includes one or more female tabs, or female disconnects, configured to operate in a similar manner as male tabs  960 . 
         [0050]      FIG. 14  illustrates a circuit diagram of the indicator  125  according to some embodiments of the application. In the illustrated embodiment, the line input  805  includes line terminals  1005   a,    1005   b,  and  1005   c,  while the load output  810  includes load terminals  1010   a ,  1010   b,  and  1010   c.  In other embodiments, the line power may be single-phase. In such an embodiment, the circuit diagram  1000  includes a single line terminal  1005  and a single load terminal  1010 . The line terminals  1005   a - 1005   c  are each electrically connected in a series-type configuration to resistors R 1  and R 2 , diodes D 1 , and the respective line indicators  900   a - 900   c . The load terminals  1010   a - 1010   c  are each electrically connected in a series-type configured to resistors R 3  and R 4 , diodes D 2 , and the respective load indicators  905   a - 905   c.  In some embodiments, resistors R 1 , R 2 , R 3  and R 4  are configured to handle approximately 1 W of power. Additionally, in some embodiments, diodes D 1  and D 2  are IN4007 type diodes. 
         [0051]      FIGS. 15-19  illustrate an indicator lens  1100  according to some embodiments of the application. The indicator lens  1100  is configured to protect the indicator  125 , as well as other internal circuitry of the power switch enclosure  100 , from external elements. In some embodiments, the indicator lens  1100  may be formed of a clear plastic materials. In other embodiments, the indicator lens  1110  may be formed of a glass material. In the illustrated embodiment, the indicator lens  1100  includes line indicator lenses  1105   a,    1105   b,  and  1105   c , load indicator lenses  1110   a,    1110   b,  and  1110   c,  one or more mounting apertures  1115 , and one or indicator mounts  1120 . 
         [0052]    As illustrated, the indicator lens  1100  is configured to couple to the front cover  200  of the housing  105  and the indicator  125 . In the illustrated embodiment, the indicator lens  1100  is coupled to the front cover  200  via the one or more mounting apertures  1115  ( FIG. 15 ) and one or more fasteners  1117  ( FIG. 19 ). In some embodiments, the one or more fasteners  1117  are screws. Additionally, in the illustrated embodiment, the indicator lens  1100  is coupled to the indicator  125  via the one or more indicator mounts  1120 . 
         [0053]    As illustrated, in some embodiments, a gasket  1125  may be configured to connect the indicator lens  1100  to the front cover  200 . In such an embodiment, the gasket  1125  may include gasket apertures  1130  configured to receive line indicator lenses  1105   a - 1105   c  and load indicator lenses  1110   a - 1110   c.  The gasket  1125  provides additional protection of the indicator  125  and internal circuitry of the power switch enclosure  100  from external elements. Once the indicator lens  1100  is coupled to the front cover  200  and the indicator  125 , the line indicators  900   a - 900   c  and the load indicators  905   a - 905   c  are visible through indicator apertures  1135  of the front cover  200  and the line indicator lenses  1105   a - 1105   c  and load indicator lenses  1110   a - 1110   c  of the indicator lens  1100 . In some embodiments, the gasket  1125  may be formed of a rubber material. In other embodiments, the gasket  1125  is an adhesive tape. In such an embodiment, the adhesive tape may be a double-sided adhesive tape, such as but not limited to, 3M® VHB Adhesive Tape. Additionally, in such an embodiment, the gasket  1125  may be configured to secure the indicator lens  1100  to the front cover  200 . In some embodiments, the indicator lens  1100  and the gasket  1125  are configured to provide a 4× enclosure rating for the power switch enclosure  100 . 
         [0054]      FIGS. 19-21  illustrate the gasket  1125  being coupled to the front cover  200  according to another embodiment of the application. In such an embodiment, the front cover  200  includes one or more studs  1200 . In some embodiments, the studs  1200  are coupled to the front cover  200 , such as by, for example, one or more welds. Furthermore, in some embodiments, the studs  1200  may be threaded. As illustrated in  FIG. 20 , the gasket  1125  is secured to the front cover  200  by fasteners  1205 . As illustrated in  FIG. 21 , the indicator lens  1100  may then be coupled to the gasket  1125 . 
         [0055]      FIGS. 22A-22D  illustrate various indications of the indicator  125  and user-switch  120 .  FIG. 22A  illustrates a no-power status. When the no-power status is indicated, no line power is being received at the line input  805 , therefore no line indicators  900  (e.g.,  900   a - 900   c ) are illuminated and no load indicators  905  (e.g.,  905   a - 905   c ) are illuminated. During the no-power status, the user-switch  120  could also be in the ON position, but since no line power is received at the line input  805 , no indicators are illuminated and no line power is provided to the load. Furthermore, the no-power status may indicate phase failures, for example, by only indicating one or two of the line indicator  900   a - 900   c.    
         [0056]      FIG. 22B  illustrates a normal OFF status. When the normal OFF status is indicated, line power is received at the line input  805 , however the line power is not being delivered to the load. When in the normal OFF status, the user-switch is in the OFF position, line indicators  900  are illuminated, and load indicators  905  are not illuminated. 
         [0057]      FIG. 22C  illustrates a normal ON status. When the normal ON status is indicated, line power is received at the line input and line power is being delivered to the load. When in the normal ON status, the user-switch is in the ON position, line indicators  900  are illuminated, and load indicators  905  are illuminated. 
         [0058]      FIG. 22D  illustrates an error status. When the error status is indicated, line power is received at the line input and the user-switch is in the OFF position, however line power is being delivered to the load. In some embodiments, the error status indicates that one or more contacts have welded or another error condition exists. When in the error status, the user-switch is in the OFF position, line indicators  900  are illuminated, and load indicators  905  are illuminated. Although illustrated as having all line indicators  900  and load indicators  905  being indicated, an error condition may exist when one or more load indicators  905  are illuminated. 
         [0059]      FIGS. 23, 24A, and 24B  illustrate a power switch enclosure  1300  according to another embodiment of the application. In some embodiments, the power switch enclosure  1300  is substantially similar to, and includes substantially similar components as, power switch enclosure  100 . For example, the power switch enclosure  1300  includes an aperture  1305  configured to receive the user-switch  120  and the indicator  125 . Additionally, the power switch enclosure  1300  may further include a second user-switch  1310 . The second user-switch  1310  may be a low-powered auxiliary switch configured to selectively control power to an auxiliary device and/or equipment. In some embodiments, the second user-switch  1310  is a jog switch having two or more positions. 
         [0060]    Thus, the invention provides, among other things, a power switch enclosure providing indication to a user. Various features and advantages of the invention are set forth in the following claims.