Abstract:
The present invention is directed to a device for controlling electrical power provided to at least one electrical load. The actuator retainer housing includes a toggle actuator disposed adjacent to a variable control actuator in a side-by-side arrangement within the actuator retainer housing with no framing or support structure disposed therebetween. The variable control actuator includes a rotatable axial variable control mounting structure coupled to the actuator retainer housing. The axial toggle mounting structure and the axial variable control mounting structure are substantially parallel to a central latitudinal axis. An electronic control circuit is coupled to the plurality of control terminals and the modular switch actuation assembly. The electronic control circuit is configured to respond to actuations of the toggle actuator and/or the variable control actuator.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates generally to lighting control, and particularly to toggle switch and variable actuator control mechanism. 
     2. Technical Background 
     A toggle switch in combination with a variable actuator control mechanism, e.g., a dimmer, is a device that controls a load with two separate actuators. One of these is a single pole single throw (SPST) switch or a single pole double throw (SPDT) switch. The SPST is an ON-OFF switch that may be connected to a single electrical load or multiple loads in parallel. The SPDT switch may be employed to switch between two loads, i.e., when one load is ON, the other load is OFF, and vice-versa. Two SPDT switches may be employed in combination to control a single load from two separate locations. In each of these examples, a load, such as a lighting device, is either ON or OFF. In addition to the toggle switch, many consumers often prefer a control mechanism that includes a variable actuator control mechanism configured to efficiently control the amount of power being provided to the a, e.g., the intensity of the emitted light. The user may adjust the variable actuator control mechanism setting as needed or as desired. Some variable actuator control mechanisms include automatic variable actuator controls that adjust the light intensity based on ambient light conditions. 
     A variable actuator control mechanism, such as a dimmer, may be implemented using an RC control circuit in combination with a thyristor such as a TRIAC. The TRIAC is a bidirectional electronic switch that is configured to conduct current in either direction when it is turned ON. The TRIAC may be turned ON by applying a positive or a negative voltage to the TRIAC gate. The TRIAC is a very convenient way to control the amount of AC power consumed by the lighting device because the TRIAC may be turned ON and OFF in response to a pulsed signal applied to the gate. In practice, the ON/OFF cycle of the TRIAC is often controlled by an RC circuit. The resistor portion of the RC circuit is typically implemented using a potentiometer. A potentiometer is a resistor with a sliding contact that forms an adjustable resistance value. The potentiometer is employed by the user to adjust the value of the resistance to thereby change the RC time constant of the RC circuit. Thus, when 60 Hz AC power is applied to the RC circuit, the RC time constant is adjusted via the potentiometer to adjust the duty cycle of the control signal applied to the gate of the TRIAC. When the duty cycle is relatively low, the TRIAC is ON for a relatively small portion of the AC cycle and the light is relatively dim. When the duty cycle is relatively high, the TRIAC is ON for a relatively long portion of the AC cycle and the light appears to be relatively bright. In addition to lighting control circuits, TRIACs may also be employed in speed control circuits for electric motors (e.g., electric fans) and other appliances. 
     One of the issues of concern to variable actuator control mechanism designers relates to the thermal energy generated by the electrical components of the device. The TRIAC, in particular, generates a significant amount of heat. This concern is exacerbated in toggle switch and variable actuator control mechanisms that include the switch control and variable actuator control within a standard NEMA No. 1 cover plate opening i.e., 0.925″ (minimum) high by 0.401″ (minimum) wide, because the electrical components tend to be disposed within a central region of the device housing. One common technique for mitigating the thermal energy generated by the components is to mount the TRIAC on a heat sink/ground plane. While the heat sinking of the TRIAC improves the thermal performance of the device, the side of the TRIAC opposite the heat sink is not thermally isolated from the interior of the device housing. What is needed, therefore, is a toggle switch/variable actuator control combination switch designed for a standard NEMA No. 1 cover plate opening that more effectively isolates the TRIAC from the device interior and spatially separates the electrical components to obtain improved thermal performance. 
     Another issue that is of concern relates to the costs associated with the toggle dimmer assembly. In state of the art devices, the front body member typically includes a framed portion that accommodates both the toggle switch and the dimmer actuator. The toggle actuator and the dimmer actuator are typically fabricated as separate pieces that extend through their respective framing slots and mate with their respective interfaces on the circuit board. One drawback to this approach relates to the time associated with assembling the various and disparate pieces (including the actuator pieces, the interface pieces, etc.). Thus, what is needed is a modular switching assembly that easily incorporates the various pieces of the toggle dimmer assembly such that the entire modular assembly may be snapped in place on the printed circuit board. This approach saves time and therefore money. 
     SUMMARY OF THE INVENTION 
     The present invention addresses the needs described above by providing a modular switching assembly that includes a toggle switch/variable actuator control combination switch that addresses the needs described above. 
     One aspect of the present invention is directed to a device for controlling electrical power provided to at least one electrical load. The device is configured to be mountable in a wall box and covered by a wall plate having a wall plate opening disposed in a substantially central portion of the wall plate. The device has a device housing including a front body member coupled to a back body member. The front body member includes a front major surface including a front major surface opening disposed at a substantially central portion thereof in substantial alignment with the wall plate opening. The front major surface opening is characterized by at least one longitudinal side and at least one latitudinal side. The back body member includes a plurality of control terminals. A modular switch actuation assembly includes an actuator retainer housing coupled to the device housing. The actuator retainer housing includes a toggle actuator disposed adjacent to a variable control actuator in a side-by-side arrangement within the actuator retainer housing with no framing or support structure disposed therebetween. The toggle actuator and the variable control actuator extend through the front major surface opening. The variable control actuator includes a control surface disposed adjacent a substantial portion of the at least one longitudinal side. The toggle actuator includes a rotatable axial toggle mounting structure coupled to the actuator retainer housing. The variable control actuator includes a rotatable axial variable control mounting structure coupled to the actuator retainer housing. The axial toggle mounting structure and the axial variable control mounting structure are substantially parallel to a central latitudinal axis. The actuator retainer housing includes a stopping portion configured to limit a rotational movement of the toggle actuator between a first predefined position and a second predefined position. An electronic control circuit is coupled to the plurality of control terminals and the modular switch actuation assembly. The electronic control circuit is configured to respond to actuations of the toggle actuator and/or the variable control actuator. 
     In another aspect, the present invention is directed to a device for controlling electrical power provided to at least one electrical load, the device being configured to be mountable in a wall box and covered by a wall plate having a wall plate opening disposed in a substantially central portion of the wall plate. The device includes a device housing characterized by a longitudinal axis and a latitudinal axis. The device housing includes a front body member coupled to a back body member. The front body member includes a front major surface having a front major surface opening disposed at a substantially central portion thereof in substantial alignment with the wall plate opening. The back body member includes a plurality of control terminals. A modular switch actuation assembly includes an actuator retainer housing having at least one mounting structure configured to be coupled to the device housing. The actuator retainer housing also includes a toggle actuator disposed adjacent to a variable control actuator in a side-by-side arrangement extending through the front major surface opening. The actuator retainer housing is substantially bisected by the longitudinal axis. The toggle actuator includes an axial toggle mounting structure coupled to the actuator retainer housing and the variable control actuator including an axial variable control mounting structure coupled to the actuator retainer housing. The axial toggle mounting structure and the axial variable control mounting structure are substantially parallel to the latitudinal axis. The actuator retainer housing includes a stopping portion configured to limit a rotational movement of the toggle actuator between a first predefined position and a second predefined position. An electronic control circuit includes a variable impedance control element coupled to the variable control actuator by a linkage mechanism. The linkage element converting a variable control actuator motion into a linear variable impedance control motion. The variable impedance control element being configured to control the electrical power provided to the at least one load via the variable control actuator. The variable impedance control element is disposed in a first lateral portion of the device housing and characterized by a first major axis that is parallel to and off-set from the longitudinal axis by the linkage mechanism. 
     In yet another aspect, the present invention is directed to a device for adjustably controlling electrical power to at least one electrical load, the device being configured to be mountable in a wall box and covered by a wall plate having a single substantially central wall plate opening. The device includes a device housing characterized by a longitudinal axis and a latitudinal axis. The device housing includes a front body member coupled to a back body member. The front body member includes a front major surface including a front major surface opening disposed at a substantially central portion thereof in substantial alignment with the wall plate opening. The back body member includes a plurality of control terminals. A printed circuit board member includes an electronic control circuit. The electronic control circuit includes a slide potentiometer offset from the longitudinal axis and disposed along a first lateral edge of the printed circuit board member. The electronic control circuit includes a switch contact arrangement offset from the longitudinal axis and disposed along a second lateral edge of the printed circuit board member opposite the first lateral edge. The printed circuit board member includes a board opening disposed between the slide potentiometer and the switch contact arrangement. An electronic power regulator is coupled to the electronic control circuit and disposed in a vented region of the front body member. The vented region including a thermal isolation barrier between the electronic power regulator and the printed circuit board. An actuator retainer housing includes a lower housing portion disposed in the board opening and coupled to the printed circuit board member. The actuator retainer housing also includes a switching device disposed adjacent to a variable rotary control actuator in a side-by-side arrangement extending through the front major surface opening. The switching device includes a switch actuator operatively coupled to the switch contact arrangement. The switching device is configured to move the switch actuator between a first switch position and a second switch position. The variable rotary control actuator including a linkage member configured to convert a variable rotary control actuator movement into a slide actuation of the slide potentiometer. 
     Additional features and advantages of the invention will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the invention as described herein, including the detailed description which follows, the claims, as well as the appended drawings. 
     It is to be understood that both the foregoing general description and the following detailed description are merely exemplary of the invention, and are intended to provide an overview or framework for understanding the nature and character of the invention as it is claimed. The accompanying drawings are included to provide a further understanding of the invention, and are incorporated in and constitute a part of this specification. The drawings illustrate various embodiments of the invention and together with the description serve to explain the principles and operation of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a half-frame toggle switch and variable actuator control mechanism with a cover plate in accordance with an embodiment of the present invention; 
         FIG. 2  is a perspective view of the half-frame toggle switch and variable actuator control mechanism depicted in  FIG. 1  without the cover plate; 
         FIG. 3  is a perspective view of a frameless toggle switch and variable actuator control mechanism with a cover plate in accordance with another embodiment of the present invention; 
         FIG. 4  is a perspective view of the frameless toggle switch and variable actuator control mechanism depicted in  FIG. 3  without the cover plate; 
         FIG. 5  is a perspective view of a frameless toggle switch and variable actuator control mechanism with a cover plate in accordance with another embodiment of the present invention; 
         FIG. 6  is a perspective view of the frameless toggle switch and variable actuator control mechanism depicted in  FIG. 5  without the cover plate; 
         FIG. 7  is an exploded view of the toggle switch and variable actuator control mechanism depicted in  FIGS. 1 and 2 ; 
         FIG. 8  is an exploded view of the toggle switch and variable actuator control mechanism depicted in  FIGS. 5 and 6 ; 
         FIG. 9  is an exploded view of the toggle switch and variable actuator control mechanism and printed circuit board in accordance with the embodiments of either  FIG. 1  or  FIG. 3 ; 
         FIGS. 10A-10B  are various views of the actuator retainer and printed circuit board in accordance with the embodiments of either  FIG. 1  or  FIG. 3 ; 
         FIGS. 11A-11D  are exploded and perspective views of the toggle switch and variable actuator in relation to the actuator retainer member; 
         FIGS. 12A-12E  are perspective views of the variable actuator, variable actuator linkage and potentiometer at various potentiometer settings; 
         FIGS. 13A-13E  are side views of the variable actuator, variable actuator linkage and potentiometer at the various potentiometer settings shown in  FIGS. 12A-12E ; 
         FIGS. 14A-14C  are cross-sectional views illustrating the assembly of the modular switch actuation assembly and the separator in accordance with the present invention; 
         FIG. 15  is a schematic view of a circuit for a toggle switch and a variable actuator control in accordance with an embodiment of the invention; 
         FIG. 16  is a schematic view of a circuit for a toggle switch and a variable actuator control in accordance with another embodiment of the invention; 
         FIG. 17  is a schematic view of a circuit for a toggle switch and a variable actuator control in accordance with yet another embodiment of the invention; 
         FIG. 18  is a schematic view of a circuit for a toggle switch and a variable actuator control in accordance with yet another embodiment of the invention; 
         FIG. 19  is a schematic view of a circuit for a toggle switch and a variable actuator control in accordance with yet another embodiment of the invention; 
         FIG. 20  is a schematic view of a circuit for a toggle switch and a variable actuator control in accordance with another embodiment of the invention; 
         FIGS. 21A-21C  are perspective views of the variable actuator, variable actuator linkage and slide switch in accordance with another embodiment of the present invention; 
         FIGS. 22A-22C  are alternate perspective views of the variable actuator and slide switch depicted in  FIGS. 21A-21C ; and 
         FIG. 23  is a detail view of the separator structure depicted in  FIGS. 22A-22C . 
     
    
    
     DETAILED DESCRIPTION 
     Reference will now be made in detail to the present exemplary embodiments of the invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts. An exemplary embodiment of the toggle switch and variable actuator control device of the present invention is shown in  FIG. 1 , and is designated generally throughout by reference numeral  10 . 
     As embodied herein, and depicted in  FIG. 1 , a perspective view of a half-frame toggle switch and variable actuator control device  10  with a cover plate  1  in accordance with an embodiment of the present invention is disclosed. The cover plate  1  includes a standard NEMA No. 1 opening  3 . Thus, the dimensions of opening  3  are substantially equal to about 0.925″×0.401″. The toggle switch  12  and the rotary variable actuator  14  extend through the wall plate opening  3  such that they are accessible to a user. In this embodiment, a separator member  30  (not shown in FIG.  1 ) includes a half-frame that extends around the toggle switch  12  and not around the rotary variable actuator  14 . Those of ordinary skill in the art will understand that when the load is a light, the rotary variable actuator  14  will be implemented as a dimmer control. 
     Referring to  FIG. 2 , a perspective view of the half-frame toggle switch and variable actuator control device  10  depicted in  FIG. 1  without the cover plate  1  is disclosed. The heat sink  20 , serving as a front cover, includes wall box mounting holes  200  at either end thereof. Closer to the center, the heat sink  20  also includes recessed wall plate fastening holes  202  at either end thereof. The ground terminal post  22  (not shown in this view) is attached to heat sink  20  by rivet  220 . TRIAC  24  (also not shown in this view) is attached to heat sink  20  by rivet  240 . The heat sink  20  includes a raised portion  26  that formed a variable actuator link recess underneath heat sink  20 . The heat sink  20  also includes an irregularly shaped opening  28 . Separator  30  includes a registration edge  34  that substantially conforms to opening  28  and aligns the separator  30  with heat sink  20 . The half-frame  32  extends from a planar front surface of separator  30  within the boundary formed by registration edge  34 . Separator  30  also includes an opening  38  that provides access to the toggle switch  12  and the rotary actuator  14 . 
     The separator  30  is also shown underneath heat sink  20  and includes a latch  36  that mates with back body snap  62 . The back body  60  also provides access to various wiring terminals. For example, ground screw terminal  2  is employed to terminate the ground wire to the ground terminal post  22  (not shown in this view). Line hot screw terminal  4  is used to terminate the line hot conductor. If the present invention is configured as a SPDT switch, the other side of the device  10  (not shown in this view) will include two traveler terminals  6  which, of course, are used to terminate traveler wires in a lighting circuit. 
     As noted above, those of ordinary skill in the art will understand that an SPDT switch may be employed in various types of circuit arrangements. For example, an SPDT switch may be used to switch between two loads, i.e., when one load is ON, the other load is OFF, and vice-versa. Two SPDT switches may be employed in combination to control a single load from two separate locations. Of course, if one of the traveler terminals in left unconnected, the SPDT will function as a SPST switch and can be used to turn the electrical load between the ON and OFF positions. Those of ordinary skill in the art will understand that when the load is a light, the rotary variable actuator  14  will be implemented as a dimmer control. 
     As embodied herein and depicted in  FIG. 3 , a perspective view of a frameless toggle switch and variable actuator control device  10  with a cover plate  1  in accordance with another embodiment of the present invention is disclosed. The cover plate  1  includes a standard NEMA No. 1 opening  3 . The minimum dimensions, therefore, are about 0.925 inches by 0.401 inches or thereabout. The area occupied by the No. 1 opening is less than or equal to about 0.5 inches square. The toggle switch  12  and the rotary variable actuator  14  extend through the wall plate opening  3  such that they are accessible to a user. In this embodiment, the separator member  30  does not include a frame member. 
     Referring to  FIG. 4 , a perspective view of the frameless toggle switch and variable actuator control device  10  depicted in  FIG. 3  without the cover plate  1  is disclosed. All of the features depicted in  FIG. 2 , and their corresponding reference numerals, are identical in  FIG. 4  with the exception that the separator  30  embodiment of  FIG. 4  does not include a half-frame  32 . Reference is made to U.S. Design patent application Nos. 29/352,130 and 29/352,132, both of which were filed on Dec. 17, 2009, which are incorporated herein by reference as though fully set forth in their entirety, for a more detailed explanation of various design features of the toggle actuator  12 , rotary actuator  14  and frameless or half-framed separator  30 . 
     Referring to  FIG. 5 , a perspective view of a frameless toggle variable actuator switch  10  with a cover plate  1  in accordance with another embodiment of the present invention is disclosed. The cover plate  1  again includes a standard NEMA No. 1 opening  3 . The toggle switch  12  and the rotary variable actuator  14  extend through the wall plate opening  3  such that they are accessible to a user. Once again, in this embodiment, the separator member  30  does not include a frame member. 
       FIG. 6  is a perspective view of the frameless toggle variable actuator switch depicted in  FIG. 5  without the cover plate. All of the features depicted in  FIGS. 2 and 4 , and their corresponding reference numerals, are almost identical in  FIG. 6 . Like  FIG. 4 , the separator  30  embodiment of  FIG. 6  is frameless. The embodiment depicted in  FIG. 6  differs from the previous embodiments in two other respects. First, the heat sink  20  includes removable tab members  23 . The heat sink  20  in this embodiment is configured for a relatively higher power handling (e.g., 700 W vis á vis 1100 W) and the related heat dissipation. The other difference relates to the presence of the preset variable actuator control  540 . One will immediately note that the preset variable actuator control  540  is hidden behind cover plate  1  in  FIG. 5 . The preset variable actuator control  540 , as its name suggests, allows a user to manually preset the low end of the variable actuator control. If the variable actuator control is a dimmer, the preset variable actuator control  540  will preset the low end of the light intensity such that dimmer actuator  14  may vary the light intensity from the preset low end intensity to the maximum intensity provided by the lighting. Once the preset level is set, the user may install the cover plate  1  such that the preset variable actuator control  540  is hidden. 
     Referring to  FIG. 7 , an exploded view of the toggle variable actuator switch device  10  depicted in  FIG. 1  is disclosed. Again, the heat sink  20  includes wall box mounting holes  200 , ground terminal rivet  220 , and TRIAC rivet  240 . The heat sink  20  includes a raised portion  26  that formed a variable actuator link recess underneath heat sink  20 . The heat sink  20  also includes an irregularly shaped opening  28  that registers and aligns with separator  30 . A ground terminal  22  is mounted to the underside of the heat sink  20  by rivet  220 . TRIAC  24  is also mounted to the underside of the heat sink via rivet  240 . As those of ordinary skill in the art will appreciate, the TRIAC  24  is one example of an electronic power regulator used to control the amount of AC power consumed by an electrical load. 
     As described above, separator member  30  includes a half-frame  32 , a registration member  34 , a latch  36  and an opening  38 . Separator  30  also includes a pocket  33  that is configured to accommodate TRIAC  24 . The pocket  33  includes a vented portion  330  formed in the side wall of separator  30 . The vented pocket  33  provides a thermal barrier between the TRIAC  24  and the printed circuit board assembly  50 . In particular, there is a pocket floor (not shown) that is disposed between the TRIAC  24  and the circuit board assembly  50  when the device  10  is assembled. 
     The toggle switch  12  and the rotary variable actuator  14  are disposed in an modular actuator retainer assembly  40  that snaps into printed circuit board  500  in a manner that will be subsequently explained. 
     The printed circuit board assembly  50  includes various components mounted on a printed circuit board  500  that also provides electrical circuit traces that electrically interconnect the various components. The modular actuator retainer assembly  40  is configured to be mounted within a central opening  52  formed in a central portion of circuit board  500 . A slide potentiometer  54  is disposed on one side of opening  52  along a lateral edge of circuit board  500 . A linkage element  142  is connected to the slide portion of the slide potentiometer. The linkage element  142  couples to another linkage element (not shown in this view) disposed on the rotary variable actuator  14 . Switch traveler contacts  56  are disposed on the opposite side of opening  52  along the opposing lateral edge of circuit board  500 . In the example embodiment of  FIG. 5 , there are two travelers  56  disposed on the underside of printed circuit board  500  and are accessible to toggle switch actuators  122  via slots  560  formed in printed circuit board  500 . Each of the two travelers is connected to a corresponding traveler terminal  6  via printed circuit board connections. One of the travelers is connected to the line hot terminal  4  depending on the state of toggle switch  12 . A toroidal choke  58  is connected to the circuit board  500  at one end thereof and is cantilevered in the manner shown under opening  52 . 
     The printed circuit board assembly  50  is inserted into the back body member  60  such that the terminals  2 ,  4 ,  6  are accessible via the recessed portions  64 . The back body snap  62  mates with the latch  36  of the separator  30 . 
     As embodied herein and depicted in  FIG. 8 , an exploded view of the toggle switch and variable actuator control mechanism depicted in  FIGS. 5 and 6  is disclosed. The embodiment depicted in  FIG. 8  is quite similar to the embodiment shown in  FIG. 7 . Thus, the description provided herein omits repetitive features. As noted above, the heat sink  20  in this embodiment is configured for a relatively higher power handling and the related heat dissipation. The heat sink  20  includes tabs  23  that may be removed by the installer. The separator  30  shown in this view is frameless. The modular switch actuation assembly  40  is identical to that depicted in the previous drawings. This embodiment also depicts the preset variable actuator control  540  in relation to variable actuator  54  and printed circuit board  500 . When device  10  is assembled, the preset variable actuator control  540  extends though opening  39  in separator  30  and opening  280  in heat sink  20  such that it is accessible to the user before the cover plate  1  is installed (See  FIGS. 5 and 6 ). The choke coil  58  in this embodiment is relatively more robust than the choke coil shown in  FIG. 7  because it must handle the higher currents associated with the higher power rating (e.g., 1100 W). 
       FIG. 9  is an exploded detail view of the modular actuator retainer assembly  40  and printed circuit board assembly  50  in accordance with the embodiments of either  FIG. 1  or  FIG. 3 . Note that modular actuator retainer assembly  40  includes snap elements  400  disposed in the upper body portion  42 . The snap elements  400  are configured to be inserted into openings  502  in the printed circuit board  500 . Thus, the lower body portion  46  of the modular switch actuation assembly  40  is inserted into opening  52  and extends under the printed circuit board  500  in a manner that is described in more detail below. 
       FIGS. 10A-10B  are various views of the actuator retainer and printed circuit board in accordance with the embodiments of either  FIG. 1  or  FIG. 3 .  FIG. 10A  shows the modular actuator retainer assembly  40  without the toggle switch  12  or the rotary variable actuator  14 . The upper actuator retainer portion  42  includes a trunnion lock  420  and a trunnion slot  422  that engage trunnions integrally formed on either side of the toggle switch  12 . The trunnions, of course, are small cylindrical projections on either side of the toggle switch  12  that define a switch axis of rotation upon which toggle switch  12  pivots in response to user actuation. The upper actuator retainer portion  42  also includes upper portion snap elements  424  on either end thereof. The upper portion snap elements  424  mate with a portion of the separator member  30  during assembly, in a manner that will be described in more detail below. The modular actuator retainer assembly  40  also includes a lower actuator retainer portion  46  that is inserted into the central opening  52  of printed circuit board  500  and extends below the printed circuit board  500  when the snap elements  400  are inserted into openings  502 . The lower actuator retainer portion  46  includes a choke stand-off portion  48  that extends therefrom. The choke stand-off  48  prevents the toroidal choke  58  from interfering with rotary variable actuator  14 . 
       FIG. 10B  is a cross-sectional view of the printed circuit board  500  along a central longitudinal axis with the printed circuit board  500 . As the lower actuator retainer portion  46  is inserted into opening  52 , the choke stand-off member  48  is seen to be in substantial alignment with a vertical axis that includes the trunnion lock  420 , the trunnion slot  422 , and a switch spring retainer portion  460  formed in the interior of the lower actuator retainer portion  46 . The switch spring retainer portion  460  will be described in more detail below in conjunction with a detailed description of the toggle switch  12 . 
     Referring to  FIG. 11A-11D , exploded views of the toggle switch  12  and the rotary variable actuator  14  in relation to the modular actuator retainer assembly  40  are disclosed.  FIG. 11A  shows toggle switch  12  in relation to the actuator retainer  40 . In particular, toggle switch  12  includes a trunnion  120  that mates with trunnion lock  420 . Trunnion  120  includes toggle switch actuators  122  extending from an underside portion of the trunnion  120  at a location outboard of where trunnion  120  mates with trunnion lock  420 . Toggle switch  12  also includes a relatively short trunnion  124  that is configured to be inserted into trunnion slot  422 . As noted previously, trunnion  120  and trunnion  124  are cylindrical elements that define the axis of rotation of the toggle switch  12 . As switch  12  rotates between the double-throw switch positions, the actuators  12  move accordingly.  FIG. 11B  is a perspective view of  FIG. 11A  that shows the toggle switch  12  within the modular actuator retainer assembly  40 . 
       FIG. 11A  also shows a shaft  440  that includes an end stop  442 . These elements are disposed in a side-by-side relationship with trunnion slot  422  and are employed to seat the rotary variable actuator  14  within the modular actuator retainer assembly  40  alongside the toggle switch  12 . Thus, the toggle switch  12  is separated from the rotary variable actuator  14  only by the relatively thin width of the trunnion slot  422 . 
       FIG. 11C  is an exploded view that shows the rotary variable actuator  14  in relation to the actuator retainer  40 . As an initial point, the rotary variable actuator  14  is not fully circular; the solid portion of the rotary variable actuator  14  constitutes a reflex angle, i.e., an angle greater than 180 degrees. The cutaway portion of the variable actuator  14 , therefore, forms an obtuse angle (i.e., between 90 and 180 degrees). Thus, the sum of the reflex angle and the obtuse angle must equal 360 degrees. The cutaway portion of the variable actuator  14  represents both a cost and a space savings. The cutaway portion reduces the size of the variable actuator  14 . This feature results in a modular actuator retainer assembly  40  with a reduced profile. In turn, the overall device thickness is reduced. The spatial savings results material savings which reduces costs. 
     The rotary variable actuator  14  includes a linkage portion  140  that mates with the previously described linkage portion  142  to actuate the slide potentiometer  54 . The rotary variable actuator  14  also includes a snap pocket  144  that is configured to mate with the barrel trunnion  440 . The rotary variable actuator  14  is prevented from slipping off the end of the shaft  440  by the end stop  442 . Finally, the rotary variable actuator  14  includes a serrated portion  146  that provides the user with a tactile surface when adjusting the rotary variable actuator  14 .  FIG. 11D  is a perspective view of  FIG. 11C  that shows the rotary variable actuator  14  assembled within the modular actuator retainer assembly  40 . 
     Referring to  FIGS. 12A-12E , perspective views of the variable actuator  14 , variable actuator linkage  142  and potentiometer  54  at various potentiometer settings are disclosed. In particular, these views illustrate the relationship between the angular rotation amount (A) and the linear displacement (X) of potentiometer  54 .  FIGS. 13  A- 13  E are side views of the variable actuator, variable actuator linkage and potentiometer at the various potentiometer settings shown in  FIGS. 12A-12E . Note that variable actuator linkage member  140  is disposed within a pocket formed within the H-shaped linkage member  142 . The H-shaped linkage member  142  is disposed on the slide portion of the slide potentiometer  54 . As the variable actuator  14  is rotated clockwise, the linkage member  140  also rotates such that linkage member  142  moves from left-to-right along the slide potentiometer  54 . Thus,  FIGS. 12A and 13A  show the linkages ( 140 ,  142 ) at the farthest counter-clockwise position of the rotary variable actuator  14 . This position, of course, corresponds to the lowest potentiometer  54  setting. In each successive Figure, the rotary variable actuator  14  is moved incrementally in the clockwise direction to move the slide potentiometer incrementally rightward until the slide potentiometer  54  is at its maximum setting in  FIGS. 12E and 13E . 
       FIGS. 14A-14C  show various cross-sectional views that illustrate the assembly of the modular switch actuation assembly  40 .  FIG. 14A  is an exploded cross-sectional view of the actuator retainer and variable actuator disposed within the half-framed separator member  30  depicted in  FIG. 1 . The choke stand-off member  48  is shown at the very top of the drawings. As noted above, the choke stand-off  48  prevents the toroidal choke  58  (not shown in this view) from interfering with rotary variable actuator  14 . Thus, the toroidal choke  52  is disposed between the choke stand-off member  48  and the rear inside major surface of the back body  60 . The actuator retainer is shown with the rotary variable actuator  14  attached thereto. The toggle switch  12  is omitted for the sake of clarity. The separator  30  includes retainer guide members  300  which mate with the snap elements  420  of the upper actuator retainer portion  42 . 
       FIG. 14B  is a cross-sectional view of the modular actuator retainer assembly  40  that shows the snap elements  420  mated with the retainer guide members  300 .  FIG. 14B  omits both the toggle switch  12  and the rotary variable actuator  14  for the sake of clarity of illustration. Taken together,  FIGS. 14A and 14B  illustrate the assembly of the modular actuator retainer assembly  40  within the separator member  30 . The only difference between this embodiment and the embodiment depicted in  FIG. 3  is that the embodiment of  FIG. 3  does not include a frame  32  around the toggle switch  12  and the rotary variable actuator  14 . 
       FIG. 14C  is a cross-sectional view of the actuator retainer, toggle switch and variable actuator disposed within the half-framed separator member depicted in  FIG. 1 . Like  FIG. 14B ,  FIG. 14C  is a cross-sectional view of the modular actuator retainer assembly  40  that shows the snap elements  420  mated with the retainer guide members  300 . Essentially,  FIG. 14C  shows a fully assembled actuator retainer whereas  FIG. 14B  does not include any components. Thus, the switch spring retainer portion  460 , which is formed in the interior of the lower actuator retainer portion  46 , is coupled to the toggle switch spring  16  at one end thereof. The other end of the spring  16  is connected to a bottom portion of the toggle switch. Thus, when a user toggles from a first switch position to a second switch position, spring element  16  applies a force that causes the toggle switch  12  to snap into the appropriate switch position. The handle portion of toggle switch  12  extends though the half-frame  32  and is accessible by the user. 
     As embodied herein and depicted in  FIG. 15 , a schematic view of a circuit for a toggle switch and a variable actuator control in accordance with an embodiment of the invention is disclosed. The dashed line indicates the portion of the schematic  100  that is disposed within device  10 . Line hot terminal is connected to the source of AC power (V 1 ). Traveler terminals  6  are connected to the traveler wires that extend from wall switch S 2 . Switch S 2  is also connected to the source of AC power (V 1 ) to complete the circuit. The traveler terminals  6  are also connected to the toggle switch  12  which turns device  10  ON/OFF. 
     Circuit  100  includes an RLC circuit that includes choke coil  58  in combination with resistor  582  and capacitor  584 . The RLC circuit is configured to prevent device  10  from propagating electrical noise generated by TRIAC Q 1  back towards AC source V 1  and the electrical distribution system. 
     An RC circuit formed by resistor  102  and capacitor  104  is employed as a voltage regulation filter that substantially eliminates spurious high frequency noise from being transmitted to the variable actuator timing circuit  108 . As those skilled in the art will appreciate, high frequency noise could be improperly interpreted by timing circuit  108  as an AC signal phase angle corresponding to the time to turn ON. By filtering out high frequency noise, the RC circuit helps maintain the proper timing of circuit  100 . The variable actuator circuit  108  includes current limiting resistor  106  coupled to an RC circuit that includes potentiometer  54  and capacitor  542 . The resistance of the RC circuit is the parallel resistance of potentiometer  54  and calibration resistor  539 . The calibration resistor  539  is installed during manufacturing and ensures that the load emits some illumination at the lowest setting of the potentiometer (this corresponds to potentiometer  54  being set at its maximum resistance.) In any event, the charging time of capacitor  542  is equal to the RC time constant of the RC timing circuit  108 . Thus, the resistance of potentiometer  54  determines the RC time constant. When the capacitor  542  is charged to the breakover voltage of DIAC  240 , the DIAC  240  will conduct to turn TRIAC  24  ON for a predetermined portion of the AC half-cycle. In other words, circuit  100  is able to vary the amount of power provided to the load by altering the duty cycle of the AC half cycle. Subsequent to TRIAC  24  turning ON, the voltage at capacitor  542  is zeroed such that DIAC  240  and TRIAC  24  turn on at about the same phase angle for both the positive and negative half cycles. Although the switching device is shown as a TRIAC, those skilled in the art that other switching devices may be employed such as bi-polar transistors, MOSFETS, gate turn-off thyristors, and SCRs. 
     As embodied herein and depicted in  FIG. 16 , a schematic view of a circuit for a toggle switch and a variable actuator control in accordance with another embodiment of the invention is disclosed. The dashed line indicates the portion of the schematic  100  that is disposed within device  10 . The schematic of  FIG. 16  is almost identical to the schematic of  FIG. 15 . Thus, for sake of brevity, only the differences between the two circuits will be discussed. The circuit  100  of  FIG. 16  is directed to a low voltage lighting load application. Load L represents, e.g., a track lighting installation that includes a transformer T that has a primary P and a secondary S. The 120 VAC provided by AC voltage source is converted by the transformer T such that a low voltage power supply is provided to the transformer load, e.g. 12 V, for powering a low voltage light (LVL). Because of the variability associated with the load LVL, the calibration resistor  539  is implemented using preset variable control actuator  540  (trim potentiometer  540 ) that provides a variable low end adjustment. 
     As embodied herein and depicted in  FIG. 17 , a schematic view of a circuit for a toggle switch and a variable actuator control in accordance with yet another embodiment of the invention is disclosed. The dashed line indicates the portion of the schematic  100  that is disposed within device  10 . Line neutral terminal  4  is connected to the source of AC power (V 1 ). Traveler terminals  6  are connected to the traveler wires that extend from wall switch S 2 . Switch S 2  is also connected to the source of AC power (V 1 ) to complete the circuit. The layout of schematic of  FIG. 17  is almost identical to the layout of schematic of  FIG. 15  and, therefore, the description of identical circuitry is omitted for the sake of brevity.  FIG. 17  is a relatively high power handling circuit of the type depicted in  FIGS. 5 and 6 . Thus, the choke coil of the RLC circuit includes coil  58  in combination with coil  580 , which is disposed in parallel with resistor  582 . Reference is made to U.S. Pat. No. 6,188,214, which is incorporated herein by reference as though fully set forth in its entirety, for a more detailed explanation of the choke coil circuit implementation. The value of certain resistors may also be adjusted in light of the higher currents associated with the embodiment of  FIG. 17 . 
     As embodied herein and depicted in  FIG. 18 , a schematic view of a circuit for a toggle switch and a variable actuator control in accordance with yet another embodiment of the invention is disclosed. The dashed line indicates the portion of the schematic  100  that is disposed within device  10 . The circuit of  FIG. 18  is a relatively high power handling version of the circuit depicted in  FIG. 16 . The description of similar or identical circuitry, therefore, is omitted for the sake of brevity. Again, the choke coil of the RLC circuit includes coil  58  in combination with coil  580 , which is disposed in parallel with resistor  582 . Reference is made to U.S. Pat. No. 6,188,214, which is again incorporated herein by reference as though fully set forth in its entirety, for a more detailed explanation of the choke coil circuit implementation. The value of certain resistors may also be adjusted in light of the higher currents associated with the embodiment of  FIG. 18 . 
     As embodied herein and depicted in  FIG. 19 , a schematic view of a circuit for a toggle switch and a variable actuator control in accordance with yet another embodiment of the invention is disclosed. In this embodiment, the circuit  200  is a toggle switch and a dehummer variable fan speed control for the electric fan load (F). Circuit  200  includes slide switch  54  in combination with capacitive circuit  210  and capacitive circuit  220 . The slide switch S 1  includes a glider disposed in a switch housing that is mounted on the printed circuit board  500 . The switch  54  includes dual contact springs on the bottom of the glider that interact with two rows of contacts. Each contact spring makes contact between adjacent contacts in the same row as the contact spring. Reference is made to U.S. Pat. No. 6,841,749, which is incorporated herein by reference as though fully set forth in its entirety, for a more detailed explanation of the slide switch  54  for the fan control circuit  200 . Referring to schematic circuit  200 , the glider  545  is shown on switch  54  at a low speed switch position S 1 - 1  by a solid line, at a medium speed switch position S 1 - 2  by a dashed line, and at a high speed switch position by a dotted line. At switch position S 1 - 1 , the contacts  1 ,  3  and  2 ,  4  are connected by the glider  545 . Because contacts  1 ,  2  are not used, only capacitor circuit  210  is connected between line neutral terminal  4  and toggle switch  12 . The inductive reactance of the fan and the capacitive reactance of the circuit form a voltage divider. The switch circuit  54  varies the capacitance of the circuit when the switch is in different positions. In switch position S 1 - 2 , contacts  3 ,  5  and  4 ,  6  are connected by the glider  545 . Capacitor circuit  220  is disposed in parallel with capacitor circuit  210 . Trace  202  is connected to contact  5  and thus to contact  3  by way of glider  545  when at position S 1 - 2 . Contact  3 , as noted above, is connected to filter circuit  210 . Thus, there is a reduced impedance between line neutral terminal  4  and toggle switch  43  and the fan speed is increased at position S 1 - 2 . When the glider position is moved to position S 1 - 3 , contacts  5 , 7  and  6 , 8  are connected. Since contacts  202  are shorted together by trace  202 , contacts  7  and  8  are shorted together and the fan speed is at full power. 
     As embodied herein and depicted in  FIG. 20 , a schematic view of a circuit for a toggle switch and a variable actuator control in accordance with another embodiment of the invention is disclosed. In this embodiment, the load includes a fluorescent light ballast configured to power a fluorescent light. The layout of circuit  300  is similar to the previous embodiments. The choke coil of the RLC circuit includes coil  58  which is disposed in series with resistors  582 . As noted above, this circuit prevents noise generated by TRIAC  24  from propagating back into the electrical distribution system. The voltage regulation circuit includes resistor  302  and DIAC  304 . This circuit is different from the voltage regulator circuits disclosed in the previous embodiments. Because the circuit  300  is designed for a fluorescent ballast load, DIAC  304  is employed instead of a capacitor because it is more robust noise filter. The fluorescent light load is more susceptible to voltage variations. DIAC  304  clamps the voltage at 60 V. The variable actuator circuitry  308  is more complicated than the circuitry employed in previous embodiments. Again, resistor  306  is a current limiting resistor. 
     The variable actuator circuitry  308  has four resistive components including user potentiometer  54  and trim potentiometer  540 . Trim potentiometer  540  is disposed in parallel with resistor  542  and is employed by the user to adjust the low end setting of the dimmer. As shown in  FIGS. 5 and 6 , preset variable control actuator (trim potentiometer)  540  is hidden by wall plate  1 . Calibration resistor  544  is carefully selected during manufacturing such that the lowest setting of the trim potentiometer  540  results in a minimum low level illumination of the florescent light. Thus, resistor  544  sets the absolute lowest dimmer setting, i.e., when potentiometer  54  and trim potentiometer  540  are at their lowest adjustment settings. 
     Circuit  300  includes a starting circuit  310  that is not included in any of the previous embodiments. Starting circuit  310  is disposed in parallel with the variable actuator circuitry  308  and is configured to shunt current around the actuator circuit  308  to DIAC  240  at start-up. Essentially, the ballast presents a high impedance to TRIAC  24  and, therefore, TRIAC  24  would not turn ON if not for the starting circuit  310 . By turning DIAC  240  and TRIAC  24  ON at full output, the charging current through capacitor C 10  becomes great enough for TRIAC  24  to turn ON. The fluorescent light will turn ON within 8-10 AC line cycles. As soon as the fluorescent light illuminates, there will be enough load current to keep TRIAC  24  ON. In state of the art fluorescent dimmers, a mechanical solution is employed to address the “mechanical” fluorescent ballast starting solution. In other words, one must turn the light ON using the full-power setting of the dimmer and adjust the dimmer to a desired setting thereafter. The present invention eliminates the mechanical fluorescent ballast starting solution and replaces it with an electronic starter circuit that allows the user to preset the florescent light at a desired intensity. 
     In particular, starting circuit  310  includes circuit  312  and circuit  314 . Circuit  312  shunts current to DIAC  240  during the positive half-cycles of AC power, whereas circuit  314  shunts current to DIAC  240  during the negative half cycles of AC power. Thus, circuits  312  and  314  alternate between half-cycles of AC power until capacitors C 3  and C 4  are fully charged. Due to the charging, DIAC  240  is turned ON early in each AC half cycle so TRIAC  24  is ON at full power. Due to the fact that it takes longer than 8-10 AC line cycles for the capacitors to fully charge, circuits  312  and  314  assure that the fluorescent light will illuminate. Capacitors C 3  and C 4  eventually charge fully at which point circuits  312  and  314  have little or no affect on TRIAC  24 . Instead, the actuator circuit  308  begins to fire DIAC  240  at the phase angle setting dictated by variable actuation circuit  308  in the manner previously described. When line voltage is turned off by switch by S 2  (if provided) or switch  12 , resistors R 9  and R 10 , respectively, will bleed (discharge) capacitors C 3  and C 4  within a relatively short period of time (e.g., about a half-second). This assures that circuits  312  and  314  will be ready to restart the electronic ballast load when line voltage is restored. 
     The output circuit comprising DIAC  240  and TRIAC  24  includes a resistor  242  that is connected to the gate of TRIAC  24 . Once DIAC  240  is OFF, resistor  242  bleeds current away from the gate of TRIAC  24  to guarantee its turn-off. TRIAC  24  may be referred to as a “sensitive gate TRIAC” meaning that it is capable of turning ON at low values of load current. 
     Referring to  FIGS. 21A-21C , perspective views of the variable actuator, variable actuator linkage and slide switch in accordance with another embodiment of the present invention are disclosed. This embodiment corresponds to the toggle switch and variable fan speed control disclosed in  FIG. 19  and the associated text.  FIGS. 21A-21C  show the toggle switch  12  and the rotary actuator  14  disposed in the modular switch assembly  40 . The modular switch assembly is mounted within the printed circuit board in the manner previously described. The rotary actuator  14  mates with the slide switch  55  (S 1 ). The slide switch  55  includes a slide actuator member  550  disposed over a lower slide body  553  which is also mounted on the printed circuit board  500 . The slide actuator member includes an opening that accommodates a switch button  551  and a notch  552  that accommodates the linkage portion  140  therein. When the rotary actuator  14  is rotated by the user, the linkage portion  140  pulls the slide actuator member  550  in the direction indicated by the arrow such that switch button  551  moves the internal switch slider contacts from the LOW switch position to a higher speed switch position. In  FIG. 21B , the slide switch  55  is shown in the MED fan speed position.  FIG. 21C  shows the slide switch  55  in the HIGH fan speed position. Thus, the linkage portion  140  converts the rotational movement of the rotary actuator  14  into a linear actuation motion of slide switch  55 . Although three stepped switch positions are shown in  FIG. 21 , the invention is not to be limited to any particular number of positions. 
     The slide switch  55  also includes a flexible arm  554  which includes detents  556 ,  558  disposed on either end thereof. The function of the flexible arm  554  and detents  556 ,  558  is described below. 
     Those skilled in the art will understand that in this embodiment, the rotary actuator  14  is moved in discrete increments that correspond to the fan speed positions of the fan speed switch  55 . In one alternate embodiment, these discrete positions may be discovered by the user through trial and error. In other words, as the rotary actuator  14  is incremented, the user will notice the speed of the fan changing. In another alternate embodiment, portions of the serrated surface  146  are removed and human readable indicia are printed or formed on the smoothed surface of dial  146  to indicate the fan speed position. For example, the letter “L” would be indicative of LOW, “M” for MEDIUM and “H” for HIGH. As noted herein, the switch speed is not limited to only three discrete positions. In such cases, numerical indicia (e.g., 1, 2, 3, 4, and 5) may be used to indicate the discrete position. Of course, other suitable indicia may be employed, such as combinations of colors or alphanumerics. 
       FIGS. 22A-22C  are alternate perspective views of the variable actuator  14  and slide switch  55  depicted in  FIGS. 21A-21C . These drawings show the rotary actuator  14  within the opening  38  of the separator  30 . The separator member  30  includes four cammed stop elements  35 . The cammed stop elements are divided into two pairs of stop elements  35 . The leftward pair of stop elements  35  are configured to engage the detent  556  and the rightward pair of stop elements  35  are configured to engage the detent  558 . Thus, the combination of the detents  556 ,  558  and the cammed stop elements  35  are used to resist any movement of the slide switch  55  away from the S 1 - 1 , S 1 - 2  and S 1 - 3  positions. See  FIG. 19 . 
       FIG. 22A  corresponds to the LOW fan speed position shown in  FIG. 21A . Detent  556  is disposed on the outboard side of the leftward pair of stop elements. Detent  558 , on the other hand, is disposed on the inboard side of the rightward pair of stop elements.  FIG. 22B  corresponds to the MED fan speed position depicted in  FIG. 21B . Note that detent  556  is disposed between the leftward pair of stop elements and detent  558  is disposed between the rightward pair of stop elements  35 .  FIG. 22C  corresponds to the HIGH fan speed position shown in  FIG. 21C . Detent  556  is disposed on the inboard side of the leftward pair of stop elements. Detent  558 , on the other hand, is disposed on the outboard side of the rightward pair of stop elements and adjacent to the end stop feature  350  protruding from the interior side of separator  30 . 
       FIG. 23  is a detail view of the separator structure depicted in  FIG. 22B . This view clearly shows the position of detent  556  between the leftward pair of stop elements as well as the position of detent  558  between the rightward pair of stop elements  35 . The linkage mechanism  140  is also shown within the notch  552 . The depth of the notch  552  allows the linkage portion  140  to move up and down with the movement of the rotary actuator  140 . 
     All references, including publications, patent applications, and patents, cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein. 
     The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. The term “connected” is to be construed as partly or wholly contained within, attached to, or joined together, even if there is something intervening. 
     The recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. 
     All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate embodiments of the invention and does not impose a limitation on the scope of the invention unless otherwise claimed. 
     No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention. 
     It will be apparent to those skilled in the art that various modifications and variations can be made to the present invention without departing from the spirit and scope of the invention. There is no intention to limit the invention to the specific form or forms disclosed, but on the contrary, the intention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention, as defined in the appended claims. Thus, it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.