Abstract:
A rotary switch is provided for controlling an attached light string containing a plurality of light colors. By manipulation of the control dial, a specially designed rotary board is rotated to provide electrical connection to the light string according to one of several present color patterns preprogrammed into the rotary board. The discrete rotary switch positions provided by the rotary switch allow for different color signaling patters to be provided at the output leads from the rotary switch so as to power a multicolored light staring with different patterns and create different multicolored effects. One of the discrete rotary switch positions permits the input color patter from an input light string to be passed through the rotary switch so as to provide the same color pattern at the output leads and power a multicolored light string with the same color pattern provided by the input light string.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to and the benefit of U.S. Provisional Patent Application No. 61/685,967 filed Mar. 28, 2012 titled “Rotary Universal Switch” which is incorporated by reference herein in its entirety. 
    
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not applicable. 
     BACKGROUND OF THE DISCLOSURE 
     1. Field of the Invention 
     The invention is directed to a system and method for providing a rotary switch mechanism for use in selecting color patterns to be displayed on an attached light string. 
     2. Description of the Prior Art 
     Low voltage, low power LED light strings are becoming increasingly popular in holiday decorations. One of the complications in arranging light string systems, however, is how to provide independent color control at each light string, or alternatively allow certain pass through functions so that a “follower” light string may follow the color pattern provided by a “leader” light string. In providing such functions, however, financial considerations often drive the commercial support of one or the other “pattern selection modules” since the cost of the lights strings themselves is relatively low. Thus the need exists for an inexpensive color patter selection device used to control light strings, and in particular, holiday light strings. 
     SUMMARY OF THE INVENTION 
     In one particularly preferred embodiment of the present invention, a rotary switch for controlling a light string is provided and includes: an input board for receiving power, the input board conditioning the power to provide output DC power at a pair of output power leads; an output board connected to a light string at a pair of color signal leads; a rotary board having a first side and a second side and disposed between the input board and the output board, the first side of the rotary board facing the input board and having a plurality of concentric annular conductive rings, the concentric annular conductive rings making electrical contact with a pair flexible electrical connectors coupled to the input board and the pair of output power leads, the second side of the rotary board facing the output board and having a plurality of custom electrical connection patterns on the bottom side, the rotary board having electrical conductors extending through the rotary board so as to electrically connect the plurality of concentric annular conductive rings to the plurality of custom electrical connection patterns, the plurality of custom electrical connection patterns making electrical contact with a pair flexible electrical connectors coupled to the output board and the pair of color signal leads; and the rotary switch providing a variable DC power pattern to the light string according to electrical connections made with the plurality of custom electrical connection patterns. Further, the input board may include an AC-to-DC converter for providing the DC power at the pair of output leads. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The accompanying drawings, which are incorporated in and constitute part of this specification, illustrate embodiments of the invention and together with the description, serve to explain the principles of the invention. The embodiments illustrated herein are presently preferred, it being understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown, in which: 
         FIG. 1  shows a cross sectional side view of the rotary switch according to one embodiment of the system and method of the present invention; 
         FIG. 2  shows the upper surface of the input board included in the rotary switch according to one embodiment of the system and method of the present invention; 
         FIG. 3  shows the upper surface of the rotary board included in the rotary switch according to one embodiment of the system and method of the present invention; 
         FIG. 4  shows the lower surface of the rotary board included in the rotary switch according to one embodiment of the system and method of the present invention; 
         FIG. 5  is an overlay showing both the upper and lower surfaces of the rotary board included in the rotary switch according to one embodiment of the system and method of the present invention; 
         FIG. 6  shows the upper surface of the output board included in the rotary switch according to one embodiment of the system and method of the present invention; 
         FIG. 7  shows the upper surface of the input board included in the rotary switch according to one embodiment of the system and method of the present invention; 
         FIG. 8  shows the upper surface of the rotary board included in the rotary switch according to another embodiment of the system and method of the present invention; 
         FIG. 9  shows the lower surface of the rotary board included in the rotary switch according to another embodiment of the system and method of the present invention; 
         FIG. 10  is an overlay showing both the upper and lower surfaces of the rotary board included in the rotary switch according to another embodiment of the system and method of the present invention; 
         FIG. 11  shows the upper surface of the output board included in the rotary switch according to another embodiment of the system and method of the present invention; 
     
    
    
     DETAILED DESCRIPTION 
     To facilitate a clear understanding of the present invention, illustrative examples are provided herein which describe certain aspects of the invention. However, it is to be appreciated that these illustrations are not meant to limit the scope of the invention, and are provided herein to illustrate certain concepts associated with the invention. 
     It is also to be understood that the present invention or portions thereof may be implemented in various forms of hardware, software, firmware, special purpose processors, or a combination thereof. Preferably, the present invention is implemented in hardware possibly containing software as a program tangibly embodied on a program storage device. The program may be uploaded to, and executed by, a machine comprising any suitable architecture. Preferably, the machine is implemented on a computer platform having hardware such as one or more central processing units (CPU), a random access memory (RAM), and input/output (I/O) interface(s). The computer platform also includes an operating system and microinstruction code. The various processes and functions described herein may either be part of the microinstruction code or part of the program (or combination thereof) which is executed via the operating system. In addition, various other peripheral devices may be connected to the computer platform such as an additional data storage device and a printing device. 
     It is to be understood that, because some of the constituent system components and method steps depicted in the accompanying figures are preferably implemented in software, the actual connections between the system components (or the process steps) may differ depending upon the manner in which the present invention is programmed. Specifically, any of the computers or devices may be interconnected using any existing or later-discovered networking technology and may also all be connected through a lager network system, such as a corporate network, metropolitan network or a global network, such as the interne. 
     Those of skill in the art will appreciate that while the description provided below specifically recites multicolored LED light strings, the general teachings of the invention are applicable to other multicolored light string systems using other types of light strings, such as incandescent bulbs, phosphorescent bulbs, luminescent bulbs, and other electric bulbs. It is also understood that other light bulb types and lighting technologies may require modification so as to function properly in connection with the present invention. 
       FIG. 1  shows a cross sectional side view of the rotary switch  10  having a outer casing  15  with a bottom portion  12  containing a knob receiving mount  13  on the inside of the casing. Rotatable knob  20  is provided at the outer casing top  11  and central spindle  23  of rotatable knob  20  is inserted into hole  14  provided in the top portion of casing  15 . The bottom tip of central spindle  23  is inserted into and retained by knob receiving mount  13 . The knob  20  rests on ball bearings  26  which are provided in a groove (not shown) disposed around the circumference of hole  14 . Knob  20  is secured in position by retaining nut  21  which has switch position dents  27  disposed around its outer circumference. Spring or other flexible element  24  slides along the outer circumference of knob  20  as it is rotated and flexibly locks the angular position of the knob  20  and central spindle so as to provide discrete and easily identified registration points during knob rotation as further described below. 
     Input power signal leads  31  and input color signal leads  12  (hidden behind the power signals in  FIG. 1 ) are provided at the right side of the rotary switch casing  15  through opening  18 . These signals are provided as inputs to input board  30  described below. Leaf springs or other flexible electrical connectors (brushes, wires, bands)  38  are mounted to via holes in the input board  30  and provide electrical connection between those vias and the top surface of rotary board  40 . Complementing balancing springs  39  are provided on the other side of the input board  30  and make physical contact at the top surface of rotary board  40  to provide balance to the rotary board during rotational operation. Input board  30  is fixably mounted to the upper surface of the inside portion of casing  15  with mounting pegs  2 . Hole  36  is provided in input board  30  to allow central spindle  23  to pass through the board. Rotary board  40  is mounted to the central spindle  23  by any of a variety of means including the use of a keyed hole in the rotary board. 
     Output color signals leads  62  are provided at the left side of the rotary switch casing  15  through opening  19 . These signals are provided as outputs from the output board  60  described below. Leaf springs or other flexible electrical connectors (brushes, wires, bands)  68  are mounted to via holes in the output board  60  and provide electrical connection between those vias and the bottom surface of rotary board  40 . Complementing balancing springs  69  are provided on the other side of the output board  60 , make physical contact with the bottom surface of rotary board  40  and provide balance to the rotary board during rotational operation. Output board  60  is fixably mounted to the casing  15  and mounting pegs  2  with screws  6 . Output board hole  66  is provided for allowing central spindle  23  to pass through the board. 
       FIG. 2  shows the upper surface of the input board  30 . In one preferred embodiment of the invention, input board  30 , output board  60  and rotary board  40  are printed circuit boards (PCBs) or printed wiring board (PWBs). Two sided PCBs are composed of an electrically insulating material. Deposited on either or both sides of the PCBs are lands  91  which consist of deposited layers of metal. Copper, silver, or any other liquefiable conductor may be used to deposit a land. Vias  91  are holes extending through the PCB that are filled with the liquefiable conductor such that electrical connection is made from one side of the PCB to the other through the vias. Finally, leads or wires may be inserted into open vias to provide electrical connection between the leads and the lands connected to those vias. Input power signal leads  31  and input color signal leads  32  are connected to input board  30  in this manner as shown in  FIG. 2 . Also shown there are mounting holes  37  for securing the input board  30  to the casing  15  and center hole  36  through which the central spindle  23  of knob  20  is disposed. As described in connection with  FIG. 1  above, leaf springs or other flexible electrical connectors (brushes, wires, bands)  38  are mounted to via holes on the input board  30  and are shown as hidden lines since they extend below the bottom surface of the input board. (See  FIG. 1 .) These flexible connectors provide electrical connection between lands  91  downward through input board  30  to the other side where they make contact with the top surface of rotary board  40 . In this manner, input color signal leads  32  are connected to input vias which in turn are electrically coupled to lands  91  and then through the input board with vias to flexible connectors  38 . The two signals provided by the input color signal leads  31  are named F1 and F2 for convenience of identification. Likewise, input power signal leads  31  are connected to input vias which in turn are electrically coupled to AC/DC converter  34  which provides output DC power via additional lands then through the input board with vias to flexible electrical connectors  38 . The two signals provided by the input power signal leads  31  are named DC+ and DC− for convenience of identification. Complementary balancing springs  39  are provided on the other side of the input board  30 , and although not electrically connected to anything, they make physical contact with the top surface of rotary board  40  to provide balance to the rotary board during rotational operation. 
       FIG. 3  shows the upper surface  41  of the rotary board  40  which includes four concentric annular conductive rings or lands  42 ,  44 ,  46 ,  48 . These lands are labeled with the signal labels provided above since each of those electrical signals are available anywhere on the ring on which they are identified. This allows for rotation of the knob  20  and rotary board  40  which maintains contact with flexible conductor  38  so as to continuously provide the indicated signals. Central keyed-hole  47  is provided in rotary board  40  for central spindle  23  to pass through. The keyed hole prevents any slippage as between the rotary board  40  and the central spindle  23  during rotation of the rotary board  40 . 
       FIG. 4  shows the lower surface  43  of the rotary board  40 . Vias  92  are shown which extend the four electrical signals distributed by annular rings  42 ,  44 ,  46  and  48  from the first side  41  to the second side  43  of rotary board and thereafter to lands  91 . Lands  91  are customized and specially designed and deposited with respect to size and geometry so as to make proper electrical connection between the input board  30  and output board  60  as described in connection with  FIG. 5 . Angular position markers  45 , which are not a part of the rotary board  40  per se, indicate four registered stopping positions of the rotary board through the use of attached knob and in connection with spring  24  described above in connection with  FIG. 1 . 
       FIG. 5  shows the lower surface  43  of rotary board  40  with the concentric annular conductive rings  42 ,  44 ,  46 ,  48  of top side  41  superimposed on top of the lands as indicated by hidden lines. Vias  92  provide electrical connection between the two sides such that the following conductive pattern emerges: land  94  distributes DC+ power signaling; lands  95  distribute DC− power signaling; land  96  distributes F1 color control signaling; and land  98  distributes F2 color control signaling. 
     Similar in design to the input board provided in  FIG. 2 ,  FIG. 6  shows the upper surface of the output board  60 . Mounting holes  67  are provided for securing the output board  60  to the casing  15  and center hole  66  is provided through which the central spindle  23  of knob  20  is disposed. Output color signal leads  62  are connected to output board  60  at vias  92 . Lands  91  provide electrical connection between the output color leads and flexible electrical connectors  68  that are coupled to the output board  60  via holes in the output board  60 . These flexible conductors provide electrical connection between those vias and the bottom surface of rotary board  40 . For convenience, the output color signals are identified as DCO 1  and DCO 2 . Complementing balancing springs  69  are provided on the other side of the output board  60  and make physical contact the bottom surface of rotary board  40  to provide balance to the rotary board during rotational operation. 
       FIGS. 1-6  provide a rotary switch mechanism by which a two-color light string may be powered and controlled. Such control may include a bypass or “following” feature. To accommodate this, an electrical connection to the two wires of a two color input LED light string is provided at input color control leads  32 . Similarly, electrical connection to the two wires of a two-color output LED light string is provided at output color control leads  62 . Each of the two color light strings has LED bulbs that include two different colored LEDs that are connected anode-to-cathode. When a positive DC biasing signal is provided to either LED light string, the LEDs within each bulb that are positively biased are triggered. 
     In operation, the rotary switch operates in the following manner. Flexible electrical connectors  38  carry the signals DC+ and DC− provided by the input board as conveyed and conditioned from the input power signal leads  31  and signals F1 and F2 from the input color signal leads  32 . By proper spacing of the rotary board under the springs  38 , these four signals are presented on the four concentric annular lands  42 ,  44 ,  46  and  48  on the top surface  41  of rotary board  40 . Vias distribute these signals to the bottom surface  43  of the rotary board  40  where customized and uniquely constructed lands  94 ,  95 ,  96  and  98  are provided to further distribute the signaling. Realizing that the flexible contacts  68  on the output board are in registered alignment with the outer most annular regions below those providing DC+ and DC− such that the spring and lead carrying signal DCO 1  is under DC+ and the spring and lead carrying signal DCO 2  is under DC−, the final connection map is provided for each of the registered positions  45  as provided below: 
     
       
         
               
               
               
               
               
             
           
               
                   
                   
               
               
                   
                 Angular 
                 Signal 
                 Signal 
                   
               
               
                   
                 position on 
                 provided 
                 provided  
                   
               
               
                   
                 rotary 
                 at 
                 at 
                 Resultant operation of 
               
               
                   
                 board 
                 DCO1 
                 DCO2 
                 downstream light string 
               
               
                   
                   
               
             
             
               
                   
                 A 
                 NONE 
                 NONE 
                 No LEDs lit 
               
               
                   
                 B 
                 DC+ 
                 DC− 
                 Positive bias LEDs lit 
               
               
                   
                 C 
                 DC− 
                 DC+ 
                 Negative bias LEDs lit 
               
               
                   
                 D 
                 F1 
                 F2 
                 Follows input LED light 
               
               
                   
                   
                   
                   
                 string polarity 
               
               
                   
                   
               
             
          
         
       
     
     In this manner, the rotary switch of the present invention may be simply and inexpensively constructed wherein several discrete switch positions are provided on the switch to automatically select a particular predetermined LED light string color pattern, or alternatively allow a “leader” LED light string to drive the color scheme for other “follower” LED light strings through the rotary switch so as to maintain a homogeneous LED light string display. 
     The basic concepts provided above with respect to the control of a two color LED light string with a rotary switch may be extended to more sophisticated LED light strings, for example, those containing 4 or 6 different colored LEDs in each bulb. In a four-colored LED bulb, three color signal leads are required within the light string to activate all four colors. In a six-colored LED bulb, four color signal leads are required within the light string to activate all six colors. A brief description is provided below of rotary controllers to accomplish the above-recited functions for the four color LED lighting systems. Only the differences from the two colored LED system are highlighted with the understanding that common portions of the systems are constructed and operate as described above. 
     First, the rotary switch  10  provided in  FIG. 1  does not require significant modification in order to handle larger LED string systems, which is one of the advantages of present invention over other solutions. In particular and as mentioned above, in a four color LED lighting system three input power color signal leads  132  will be brought from the input light string as inputs color signals to input board  130 .  FIG. 7 . The three input color signal leads result in three springs being needed to convey the color signals F1, F2 and COM to the upper surface  141  of rotary board  140 .  FIG. 8 . These three springs, in combination with the two springs providing input power signals, raise the total to five springs  138  extending beneath input board  130  that provide electrical contact with five annular corresponding lands  142 ,  144 ,  146 ,  148  and  150  on upper surface  141  of rotary board  140 .  FIG. 8 . Again, upper annular regions of electrical connectivity at the upper surface  141  are extended to lower surface  143  with vias  192  where custom, geometrically designed lands  191  are provided to further distribute the five signals to the bottom surface at appropriate contact points corresponding to switch stopping positions  145 .  FIG. 9 . The rotary board  140  showing the overlaid lands  191  and five annular land regions for the four color rotary switch is provided in  FIG. 10 . Realizing that the contact springs  168  on the output board  160 , which are now three in number, are in registered alignment with the outer most annular regions below those providing DC+, DC− and F1 such that the spring and lead carrying signal DCO 1  is under DC+, the spring and lead carrying signal DCO 2  is under DC−, and the spring and lead carrying signal DCO 3  is under DC+. The final connection map is provided for each of the registered positions  145  as provided below: 
     
       
         
               
               
               
               
               
             
           
               
                   
               
               
                 Angular 
                 Signal 
                 Signal 
                 Signal 
                   
               
               
                 position 
                 provided  
                 provided  
                 provided  
                   
               
               
                 on rotary 
                 at 
                 at  
                 at 
                 Resultant operation of 
               
               
                 board 
                 DCO1 
                 DCO2 
                 DCO3 
                 downstream light string 
               
               
                   
               
             
             
               
                 A 
                 NONE 
                 NONE 
                 NONE 
                 No LEDs lit 
               
               
                 B 
                 + 
                   
                 − 
                 DCO1 positively biased 
               
               
                   
                   
                   
                   
                 with respect to DCO3 
               
               
                 C 
                   
                 + 
                 − 
                 DCO2 positively biased 
               
               
                   
                   
                   
                   
                 with respect to DCO3 
               
               
                 D 
                   
                 − 
                 + 
                 DCO3 positively biased 
               
               
                   
                   
                   
                   
                 with respect to DCO2 
               
               
                 E 
                 − 
                   
                 + 
                 DCO3 positively biased 
               
               
                   
                   
                   
                   
                 with respect to DCO1 
               
               
                 F 
                 − 
                 − 
                 + 
                 DCO3 positively biased 
               
               
                   
                   
                   
                   
                 with respect to DCO1 and 
               
               
                   
                   
                   
                   
                 DCO2 
               
               
                 G 
                 + 
                 + 
                 − 
                 DCO1 and DCO2 
               
               
                   
                   
                   
                   
                 positively biased with 
               
               
                   
                   
                   
                   
                 respect to DCO3 
               
               
                 H 
                 F1 
                 F2 
                 COM 
                 Follows input LED light 
               
               
                   
                   
                   
                   
                 string polarity 
               
               
                   
               
             
          
         
       
     
     It should be understood that the ultimate illumination pattern resulting on the four color light string will depend on the construction and arrangement of the four LED light bulbs, their positions on the string etc. For guidance in this regard, the applicant&#39;s copending U.S. patent application directed to an All Holidays Lighting System may be consulted as described in U.S. patent application Ser. No. 13/694,754 entitled Apparatus and Method for Controlling LED Light Strings, filed Dec. 31, 2012. 
     Additional balancing springs  139  and  169  may be provided on input board  130  and output board  160  as desired or required due to the addition of color signal springs. Finally, the four LED light string arrangement may be extended to larger more color divers systems by application of the teachings of this disclosure. 
     It should be appreciated that by simply changing the rotary board with a differently configured rotary board, different interconnection patterns and resultant biases may be achieved to drive light string illumination and/or provide pass-through functionality from a “leader” string. It is also important to note that the input and output boards and most other parts of the rotary switch are identical in construction with only the number of springs and type of rotary board used being changed to significantly change the functionality of the rotary switch. In fact, a single rotary board can be configured to accommodate a plurality of colored light string systems of differing numbers of LED colors all within one unit. 
     Although various embodiments, which incorporate the teachings of the present invention have been shown and described in detail herein, those skilled in the art can readily devise many other varied embodiments that still incorporate these teachings.