Abstract:
An electrical rocker paddle switch assembly having a switch housing; a manually movable rocker paddle coupled to the housing; an actuator having a first end and a second end, the actuator being attached to the rocker paddle at the first end and the second end configured to activate a switch in response to a corresponding movement of the rocker paddle; a bored member having a first end that is attached to an underside of the rocker paddle near a pivot axis of the rocker paddle, and a second end that has an opening configured to retain a roller member and allow a portion of the roller member to extend beyond an end of the bored member, the bored member extending in a substantially perpendicular direction from the rocker paddle. A spring and a ball are configured to be retained in the bored member, the spring configured in the bored member to urge the ball towards the opening. A detent member is formed along a bottom of the housing, the detent member being configured to contact the ball when a force is exerted on the rocker paddle, the detent member being further configured to retain the rocker paddle in a pre-determined position corresponding to the force that is exerted on the rocker paddle when the rocker paddle reaches an end position in a direction of movement.

Description:
BACKGROUND 
   1. Field 
   The disclosed embodiments relate to improvements in switch-actuating and dimmer control devices for controlling electrical power applied to a load, in particular, a load which is adapted to operate at different power levels, such as electrical lamps, fans, etc. 
   2. Brief Description of Related Developments 
   A wide variety of switch actuators are commercially available for controlling the switching of power between a power source and an electrical load. Many of these actuators either incorporate or are otherwise combined with a device for varying the level of power applied to the load, hereinafter referred to as a “dimming” device or “dimmer.” To enhance the appearance of the switch and dimmer actuators (which are often independent members), especially those intended for use in the home, it is known to surround or “frame” the actuators with a rectangular bezel. The bezel housing is usually attached to a “yoke” or “strap” which, in addition to functioning as the means by which the switch/dimmer is connected to a conventional wall box, sometimes serves as a platform for supporting the switch and/or dimmer components. 
   Such devices can comprise a relatively large, rectangularly shaped switch/dimmer actuator which is supported and surrounded by a rectangular bezel. The bezel, which is made of plastic, is releasably connected to a mounting plate by a plurality of resilient tabs which engage apertures in the mounting plate. The switch/dimmer can be of the “capacitance” type, comprising solid state touch-sensitive circuitry for controlling the light level. The switch/dimmer actuator is generally made of metal and is immovably positioned within the bezel frame. One touch of the actuator by the user&#39;s finger causes the switch to turn on or off, depending on its original state. Touching and holding the actuator acts to vary the power level applied to the load. When the dimmer is off, one touch restores the power to the load at the same level at which the dimmer was last touched. 
   SUMMARY 
   The aspects of the disclosed embodiments are directed to an electrical rocker paddle switch assembly. In one embodiment the assembly comprises a switch housing; a manually movable rocker paddle coupled to the housing; an actuator having a first end and a second end, the actuator being attached to the rocker paddle at the first end and the second end configured to activate a switch in response to a corresponding movement of the rocker paddle; a bored member having a first end that is attached to an underside of the rocker paddle near a pivot axis of the rocker paddle, and a second end that has an opening configured to retain a roller member and allow a portion of the roller member to extend beyond an end of the bored member, the bored member extending in a substantially perpendicular direction from the rocker paddle. A spring and a ball are configured to be retained in the bored member, the spring configured in the bored member to urge the ball towards the opening. A detent member is formed along a bottom of the housing, the detent member being configured to contact the ball when a force is exerted on the rocker paddle, the detent member being further configured to retain the rocker paddle in a pre-determined position corresponding to the force that is exerted on the rocker paddle when the rocker paddle reaches an end position in a direction of movement. 
   The invention and its various advantages will be better understood from the ensuing detailed description of preferred embodiments, reference being made to the accompanying drawings in which like reference characters denote like parts. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIGS. 1A-1C  are perspective, front and side plan views of a wall switch embodying the present invention. 
       FIG. 2  is an exploded view of the wall switch of  FIGS. 1A-1C , showing the various elements of one embodiment of the invention and their relationship to other parts of the wall switch. 
       FIGS. 3A and 3B  are side views of a bezel assembly including aspects of the disclosed embodiments. 
       FIG. 4  is a plan view of the one embodiment of the mounting plate of  FIG. 2 , illustrating internal details. 
       FIG. 5  is a circuit diagram of one embodiment of the electronics of the invention. 
       FIG. 6A  is a bottom view of one embodiment of the paddle assembly of  FIG. 2 . 
       FIG. 6B  is an elevational view of one embodiment of the bezel assembly. 
   

   DETAILED DESCRIPTION OF THE EMBODIMENTS 
   Referring to  FIGS. 1A-1C , one example of an electrical switch and dimmer device  100  incorporating aspects of the disclosed embodiments is illustrated. In one embodiment the device  100  includes a backcover  102 , and a bezel assembly  104  which includes a switch-actuating paddle  106 . Bezel assembly  104  comprises a bezel housing  108  having a rectangular outer shape adapted to be received in a corresponding opening in a faceplate (not shown). In one embodiment, the bezel housing  108  is adapted to be connected or coupled, such as by a snap connection, to a mounting plate  120 . 
   In one embodiment, a sidewall  110  of bezel housing  108  is provided with a slot  112  for receiving and guiding a dimmer actuator  114 , shown as a small tab or push slide  116 , of a dimmer device  232 , shown in  FIG. 2 . 
   The various components of the switch and dimmer device  100  are illustrated in  FIG. 2 . 
   The mounting plate shown in  FIG. 2  can include threaded openings  222  by which a conventional faceplate may be attached by screws in the usual manner. Alternatively, a snap-on faceplate, which mounts to mounting plate  220  without screws, may be used. Mounting plate  220  can also includes openings  224  by which the entire switch and dimmer device may be rigidly connected to a conventional wall box (not shown). The mounting plate  220  can support a component plate or platform  230  on which may be mounted the electrical and/or electronic circuitry, such as that normally associated with a dimming device  232 . The component plate  230  can also support a switch  234  that is actuated by paddle  202 , as will be described in greater detail below. 
   The mounting plate  220  also includes a rectilinear slot  226  formed therein. The manually-manipulatable dimming actuator  228  operates through slot  226  to engage a slidably mounted member  236 , whose position determines the variable resistance comprising the dimming device  232 . The sliding movement of the actuator  228  controls the position of member  236  and the power level applied to the load. 
   As shown in  FIG. 2 , the bezel assembly  210  may be attached to the mounting plate  220  in any conventional manner. In one embodiment, the bezel assembly  210  is molded as a single plastic piece and is provided with integral resilient tabs  212  which snap into corresponding openings  221  in mounting plate  220 . Similarly, component plate  230  can be formed as a single plastic piece and is provided with integral resilient tabs (not shown) which snap into corresponding openings in the mounting plate  220 . In the example shown in  FIG. 2 , rivets  223  are used in conjunction with bushings  225  and corresponding receiving holes to secure the component plate  230  to the mounting plate  220 . 
   The switch  234  is activated by tab  204  of paddle  202 . The tab  204  projects through a corresponding opening  227  in mounting plate  220 . The bezel assembly  210  is also provided with an opening in order to accommodate the tab  204 . 
   The bezel assembly  210  has a peripheral wall  214  that extends around substantially the entire periphery of the bezel assembly  210 . The oppositely-facing inner surfaces of opposing wall portions  214 A and  214 B are a pair of axle receivers  216 , which together define a pivot axis  218 . A pair of stub axles  206  are found on the sides of the paddle  202 , that engage respective axle receivers and allow the paddle  202  to pivot about the axis  218 . 
   The paddle  202  is pivotably mounted on stub axles  206  for pivotable movement about axis  218 . The bezel assembly  210  has on its inner surface  214 A and  214 B a pair of semicircular recesses for pivotably receiving stub axles  206  therein. A pair of limit stops  208  are provided to limit the pivoting movement of paddle  202  to a range between first and second positions corresponding to first and second switch states. In one embodiment, the limit stops comprise rubber assemblies to provide quiet operation of the switch assembly. 
   In one embodiment, the paddle  202  is also provided on its inner surface with a spring receiver or cylinder  203  for receiving and retaining spring  205 . The cylinder  203  is located substantially at a midpoint of the paddle  202 , in-line with the pivot assembly  206 . One end of the spring  205  is urged against an underside surface of the paddle  202 . The other end of the spring  205  is urged against, coupled to, or in contact with a spherical or roller mechanism  207 , also referred to herein as a ball. The roller mechanism  207  is retained or captured in an open end, or hole  203   a , of the cylinder  203  as shown in  FIG. 3A . In one embodiment, the roller mechanism  207  comprises a steel ball. In alternate embodiments, the roller mechanism  207  can comprise any suitable material that provides durability and free movement of the roller mechanism. Preferably, the roller mechanism  207  does not have any seams that might interfere with movement or rotation of the roller mechanism against a surface, or prevent an object from moving or sliding along a surface of the roller mechanism  207 . Although the aspects of the disclosed embodiments will be described herein with respect to a spherical roller mechanism, such as a steel ball, in alternate embodiments, any suitable shape can be used that allows for rotational movement, such as for example a cylindrical shape. 
   In one embodiment, the spring  205  and steel ball  207  are located within a bored cylinder  203  that is positioned in approximately the middle area of the paddle  202  and bezel assembly  210  as shown in  FIG. 2 . The metal sphere or ball  207  is retained within the bored cylinder  203  against the pressure of the spring  205 . As shown in  FIG. 3A , a portion of the ball  207  protrudes past an end portion or hole  303   a  of the cylinder  203 . The ball  207  falls partially into the hole in the cylinder  203  under the pressure of the spring  205 , with the spring  205  holding the ball  207  in this position. The ball  207  is configured to move upwards, or back into region  303   b  of the cylinder  203 , when a force is exerted against the ball  207 . As shown in  FIGS. 3A and 3B , in one embodiment, an inner area of region  303   b  of the cylinder  203  is bored slightly wider to accommodate the size of the ball  207 . Thus, the ball  207  can only travel a pre-determined distance back into the bore  303   b  of the cylinder  203  when pressure is exerted on it. 
   The paddle assembly  202 , in combination with the spring  205  and ball  207  assemblies form an actuation mechanism of the dimmer switch  234 . Referring to  FIGS. 3A and 3B , the pressure of the spring  205  against the ball  207  will hold the paddle assembly in one of two positions. As shown in  FIGS. 3A and 3B , detent  302  is formed at the bottom of the receiver  215 , substantially in-line with the pivot axis assembly  218 . In one embodiment, the detent  302  has a triangular shape. As shown in  FIGS. 3A and 3B , the side faces of the detent  302  can be angled against the direction of rotation of the paddle  202  about the axis  218 . 
   For example, when force F 1  is exerted on end  201 A of paddle  202  to move end  201 A into the position shown in  FIG. 3A , the ball  207  will be urged against, or rest against the corresponding angled side face of detent  302 . As described earlier, in this position, the tab  204  is urged against the micro-active switch inner side. 
   The force exerted by spring  205  on ball  207  will hold the position of the paddle  202  as shown in  FIG. 3A  until a force that exceeds a pre-determined force is exerted on the other end,  201 B, of the paddle  202 . From the original position of paddle  202  shown in  FIG. 3A , when force F 2  is exerted on the paddle end  201 B, the paddle  202  will rotate about the axis  218  to the position shown in  FIG. 3B . As pressure F 2  is applied and the paddle  202  rotates about the axis  218 , the detent  302  will be urged against the ball  207 . The force F 2  must be sufficient to push ball  207  back into the cylinder  203 , compressing spring  207 , and allowing the paddle  202  to rotate to the position shown in  FIG. 3B . When the position of the ball  207  has rotated past the detent  302 , the pressure of the spring  205  urges the ball  207  back into the hole  303   a  in the cylinder  203 . The size or area of the bore of the region  303   b  also allows the ball  207  to spin or rotate to provide a smooth switching action of the paddle  202 . 
   When the ball  207  moves past the apex of the detent  302 , the force of the ball  207  against the detent  302  will hold or lock the paddle in the corresponding position. In one embodiment, the angle of movement of the paddle  202  and ball  207  is in the range of approximately 5 to 20 degrees. In the preferred embodiment, the range is approximately 9 degrees. Although the detent  302  shown in  FIGS. 3A and 3B  comprises a triangular shape, in alternate embodiments, any suitable shape can be used that will push against and retain the ball  207  in the respective positions shown in  FIGS. 3A and 3B . The aspects of the disclosed embodiments provide a fluent and quiet action of the paddle  202  when the paddle  202  is moved from one position to the other. 
   The paddle  202  may be of any suitable shape as long as paddle  202  has two opposite ends  201 A and  201 B, each of which can be actuated by a user. The ends  210 A and  201 B permit a user to manually apply pressure to paddle  202  to cause it to pivot about axis  218 . The outer surface of paddle  202  may be substantially planar, or may be in the form of flat angularly-disposed planes which intersect at the center of paddle  202 . In one embodiment, the paddle  202  comprises a thermoplastic material.  FIG. 6A  illustrates one embodiment of the bottom side of the paddle  202 . 
   In one embodiment, the device  100  can include a night-light feature. In this embodiment, low voltage is applied to lamp  231  through wires in a conventional manner. Luminous energy from the lamp  231  is directed through an opening in mounting plate  220  and a corresponding opening in a floor of the bezel assembly  210 . Upon striking the inner surface of paddle  202 , this luminous energy is reflected toward the bezel floor. After multiple reflections between the bezel floor and the inner surface of the paddle, the reflected luminous energy exits the bezel assembly through a clearance space between the outer edges of paddle  202 , and the inside edges of bezel assembly  210 , including the inner wall surfaces  214 A and  214 B. To facilitate such multiple reflections, especially in the case where the paddle material is opaque or light-absorbing, it is preferred that the paddle and bezel floor surfaces which receive light from the lamp be provided with a diffuse, reflective material or tape. The diffuse surface operates to scatter the incident light, thereby providing a more uniform light level about the paddle periphery. 
   To connect paddle  202 , spring receiver  203  and spring  205  to bezel housing  210 , paddle  202  is oriented with its inner surface facing the floor of the bezel housing  210 . Spring  205  is inserted into the recess  215 . One end of spring  205  engages the ball  207  and the other end of spring  205  is placed in or on the spring receiver  203 . This compresses spring  205  with sufficient force to retain stub axle  206  in the receivers  216 . 
   Operation of the assembled device  100  will now be described with respect to  FIG. 1A . To actuate the wall switch  100 , the outwardly protruding paddle end  111  is depressed by a user. Depression of end  111  causes paddle  106  to pivotably rotate about axis  218  of  FIG. 2 . Pressure or force on one end of paddle  106  causes the detent  302  of  FIGS. 3A and 3   b  to press against the ball  207 , which causes the spring  205  to constrict. The ball  207  rolls from one side of the detent  302  to the other side, and the paddle  202  is at a resting state in that position. When end  201 A of paddle  202  is pressed, the tab  204  actuates the microswitch  234 , which applies power to the load, which in one application can comprise a light. To vary the level of electrical current applied by the switch  234  to the load, dimmer actuator  116  manually slides within slot  112  formed in bezel sidewall  110 . Movement of the dimmer actuator  116  controls the position of member  236  of  FIG. 2 , which in turn, varies the resistance of the variable resistor or dimmer device  232 . 
   It should be understood that many modifications to the various parts of the invention may be made without departing therefrom. For example, any style or type of wall plate may be used with the invention, and microswitch  234  is not the only type of switch that may be actuated by paddle  202 . Moreover, microswitch  234  need not be directly actuated by tab  204  on paddle  202 , but may be directly actuated by an intermediate mechanism or linkage. Also, while a paddle-type actuator is particularly preferred, a similarly shaped push-button-type actuator could be used. In this case, the bezel housing would support the actuator for movement perpendicular to the plane of bezel wall surface  214  and a spring would bias the actuator to an “out” position, in which tab  204  would not operate to depress the switch plunger on switch  234 . 
   Referring to  FIG. 4 , one embodiment of the component plate  230  of  FIG. 2  is illustrated. In one embodiment, the components on the component plate  403  include lead  401 , inductor  402 , switch  404 , resistor  405 , neon lamp  406 , silicon controlled rectifier  407 , bilateral diode  408 , capacitor  409 , moveable potentiometer  410 , lead  411 , capacitor  412  and lead  413 . An exemplary schematic diagram illustrating the interconnections of the described components in accordance with the disclosed embodiments is shown in  FIG. 5 . 
   The compact construction of the electrical switch and dimmer device assembly of the disclosed embodiments provides a simple and room saving arrangement of assemblies on the component plate  403  (printed circuit board), which leaves a larger area between the mounting plate  220  and the component plate  230  shown in  FIG. 2 . This larger area can provide for greater heat dissipation from the assembly of components that are mounted on the component plate  403 . 
   In one embodiment, the silicon controlled rectifier  407  is mounted in such a fashion on the mounting plate  230  that provides room for heat output and dissipation, which ensure stable power. In one embodiment, as shown in  FIG. 2 , a heatsink of the silicon controlled rectifier can be coupled to the mounting plate  220  to provide heat dissipation. According to tests, sample results of which are detailed below, the dimmer switch assembly of the disclosed embodiments can maintain a 700 W power factor, whether configured as 1-gang, 2-gang or 3-gang assembly. The ability of this tightly configured component assembly to adequately dissipate heat allows the silicon controlled rectifier  407 , together with the other components, to function in a controlled and specific manner. 
   The switch assembly of the disclosed embodiments can be configured as a single pole device, a three-way device, a single pole lighted device, a three-way lighted device, a magnetic low voltage single pole device, a magnetic low voltage three way device, a magnetic low voltage single pole lighted device or a magnetic low voltage three-way lighted device. Each of these devices and be configured in 1-gang, 2-gang and 3-gang arrangements. 
   The following is a comparison of the measured power factor of the dimmer device of the disclosed embodiments versus other dimmers in the market: 
   
     
       
             
             
             
           
             
             
             
             
           
         
             
                 
                 
             
             
                 
                 
               Other dimmer 
             
             
                 
               Our dimmer 
               in market 
             
             
                 
                 
             
           
           
             
                 
             
           
        
         
             
                 
               1 gang 
               700 W 
               600 W 
             
             
                 
               2 gang 
               700 W 
               500 W↓ 
             
             
                 
               3 gang 
               700 W 
               400 W↓ 
             
             
                 
                 
             
           
        
       
     
   
   The heat that is generated from the component assembly  403  during operation, and in particular the silicon controlled rectifier  407 , is easily dissipated in the dimmer switch device of the disclosed embodiments, and which allows the dimmer switch device to provide a more stable function. Other devices require larger areas to provide adequate heat dissipation. The unique structure of the component assembly  403  and the mounting of the silicon controlled rectifier  407  provide advantages not seen or realized in the art. 
   The aspects of the disclosed embodiments provide an actuation mechanism for a dimmer assembly, which can include a thermoplastic paddle. A spring with a steel ball is placed in a cylinder construction in the middle of the cover plate and provides the actuator for the dimmer switch. When the paddle is pushed, the tab on the paddle will actuate the micro-active switch on the inner side. Rubber assemblies on the inner side of the paddle can assure long term operation. The internal structure of the dimmer assembly provides compact construction, with simple and space saving arrangements. This helps in the dissipation of heat generated internally and helps to provide a more stable and constant power factor.