Abstract:
In a modular switch panel assembly, a switch cover with an aperture and a switch button having a button portion and an integral mounting portion are provided. The mounting portion comprises at least first and second spring members protruding laterally of and at opposite sides of the button portion. Each of the spring members has a meandering path shape and has one end integral with the button portion and an opposite end attached to the switch cover such that the button portion extends through the aperture. A printed circuit board has a switch, and is attached to the switch cover such that the switch is adjacent to a bottom surface of the switch button.

Description:
BACKGROUND 
       [0001]    Switch panels are known having one or more switches activated by respective switch buttons mounted in a panel to be used in conjunction with a multiplex electronic control system, such as in recreational vehicles (RV vehicles) in the RV industry. The known switch panel is designed to have a unique nomenclature for each button. The nomenclature is printed on each button or on labels placed on the buttons to indicate the button function. The button can also be back lit by means of LEDs located below or behind the button on a printed circuit board (PCB) on which the switch is located. 
       SUMMARY 
       [0002]    It is an object to improve upon the existing switch panel such that it has improved switch button activation characteristics and a modular design which will allow convenient expansion from a single button to multiple buttons depending on the PCB and switch cover configuration used. 
         [0003]    In a modular switch panel assembly, a switch cover with an aperture and a switch button having a button portion and an integral mounting portion are provided. The mounting portion comprises at least first and second spring members protruding laterally of and at opposite sides of the button portion. Each of the spring members has a meandering path shape and has one end integral with the button portion and an opposite end attached to the switch cover such that the button portion extends through the aperture. A printed circuit board has a switch, and is attached to the switch cover such that the switch is adjacent to a bottom surface of the switch button. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0004]      FIG. 1  is a front perspective view of a modular switch panel assembly of one exemplary embodiment mounted to a mounting surface; 
           [0005]      FIG. 2  is a blow up perspective view of the switch panel assembly of  FIG. 1 ; 
           [0006]      FIG. 3  is a cross-sectional view of the fully assembled switch panel assembly of  FIG. 2  with the cross-section being taken along line III-III of  FIG. 2 ; 
           [0007]      FIG. 4  is a fragmentary perspective view of a first assembly step of a first sub-assembly of the switch panel assembly of  FIG. 2 ; 
           [0008]      FIG. 5  is a fragmentary perspective view of a second assembly step for the first sub-assembly of the switch panel assembly of  FIG. 2 ; 
           [0009]      FIG. 6  is a top perspective view of the first sub-assembly being mounted to a mounting surface; 
           [0010]      FIG. 7  is a perspective view of one of a plurality of switch buttons shown in the switch panel assembly of  FIG. 2 ; 
           [0011]      FIG. 8  is a fragmentary bottom plan view showing one of the switch buttons mounted to a switch cover to form a second sub-assembly of the switch panel assembly of  FIG. 2 ; 
           [0012]      FIG. 9  is a cross-sectional fragmentary side view along line IX-IX in  FIG. 11  with the second sub-assembly mounted to the first sub-assembly; 
           [0013]      FIG. 10  is a perspective end view of the switch panel assembly of  FIG. 2  illustrating two switch cover slots formed as a cross; 
           [0014]      FIG. 11  is the same fragmentary perspective end view as in  FIG. 10  but with the switch cover shown transparent for ease of viewing; 
           [0015]      FIG. 12  is a perspective view of a second alternate embodiment of a modular switch panel assembly; 
           [0016]      FIG. 13  is an exploded perspective view of the modular switch panel assembly of  FIG. 12 ; 
           [0017]      FIG. 14  is a cross-sectional perspective side view taken along section line XIV-XIV in  FIG. 13 ; and 
           [0018]      FIG. 15  is a front plan view of a switch cover with integrated switch button employed in the switch panel assembly of  FIGS. 12 and 13 . 
       
    
    
     DESCRIPTION OF EXEMPLARY EMBODIMENTS 
       [0019]    For purposes of promoting an understanding of the principles of the invention, reference will now be made to the preferred exemplary embodiments/best mode illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, and such alterations and further modifications in the illustrated embodiments and such further applications of the principles of the invention as illustrated as would normally occur to one skilled in the art to which the invention relates are included herein. 
         [0020]      FIG. 1  shows in perspective a modular switch panel assembly  10  according to one exemplary embodiment. Four switch buttons  12 - 15  are illustrated mounted to a switch cover  16 . The switch panel assembly  10  is mounted to a mounting surface  11  as described hereafter. 
         [0021]    As shown in  FIG. 1 , respective nomenclature indicia  12 A- 15 A are provided on the face of the respective switch buttons  12 - 15 . The indicia shown are for use of the switch panel assembly in an RV vehicle although many other uses of the switch panel assembly may be employed for other electronic control-systems. The button can be backlit by means of an LED located below the respective buttons on the printed circuit board described hereafter. Also as further described hereafter, the switch panel assembly is a modular design that can be expanded from a single button to multiple buttons depending on the PCB and switch cover configuration used. For example 2, 4, and 6 button configurations may be employed depending on the application. 
         [0022]    The indicia  12 A- 15 A may be a stick on label applied to the face of the switch button or alternatively may be engraved or printed on the face of the switch button. 
         [0023]    As shown in the exploded perspective view of  FIG. 2 , the modular switch panel assembly  10  has the switch cover  16  provided with respective rectangular apertures  17 - 20  for receiving the respective switch buttons  12 - 15 . Although rectangular apertures and rectangular switch buttons are illustrated the switch buttons could be of other shapes such as round. One end wall  16 A of the cover  16  has a first switch cover slot  21  and an orthogonal second switch cover slot  22  which together form the shape of a cross. Each of these slots is for purpose of receiving a tool such as flat head screw driver for pushing on a retainer spring finger  23  of a PCB retainer  24  described in greater detail hereafter. A similar retainer  26  with a respective second retainer spring finger  25  lies opposite the first PCB retainer  24 . Similarly an additional switch cover slot  27  and corresponding additional orthogonal slot  28  forming a cross are provided at the opposite end of the cover  16  as shown in dash lines. 
         [0024]    The switch cover  16  has a downwardly extending apron formed by end walls  16 A and  16 B and sidewalls  16 C and  16 D. 
         [0025]    The switch buttons  12 - 15  each have, as explained for switch button  12 , a button portion  12 A and a mounting portion  12 B which is integral with the button portion  12 A. The switch button  12  may be a single plastic molding although other structures may be employed such as 1 or 2 piece, or made of metal. The switch buttons engaged with the switch cover  16  forms a switch cover sub-assembly  29 . 
         [0026]    As also shown in  FIG. 2 , a PCB sub-assembly  30  is formed from a PCB  31  and the first and second PCB retainers  24  and  26 . Respective switches  32 - 35  are mounted to the PCB  31  such as by soldering at terminal leads thereof to the PCB. The switches may be push button switches, although other types of switches may be employed. Of course other mounting methods may be employed. The switches  32 - 35  each comprise, as shown for the switch  32 , a spring loaded push button portion  32 A received in a switch body portion  32 B. The push button switches may be momentary contact upon pushing of the push button portion into the body portion, or may be a toggle action wherein with a first push the switch is on and with a second push the switch is off. The switches  32 - 35  may be single pole or multi-pole switches. The modular switch panel assembly  10  comprises the two sub-assemblies—the switch cover sub-assembly  29  and the PCB sub-assembly  30 . 
         [0027]      FIG. 3  shows a cross-sectional view of the assembled switch panel assembly along section line III-III shown in  FIG. 2 . The mounting of the switch buttons such as  12  by use of ribs  51 A, B, C and  52 A, B, C will be explained hereinafter in connection with  FIG. 8 . 
         [0028]      FIG. 4  shows a first step and  FIG. 5  shows a second step of a procedure for assembling the PCB retainer  26  to one end of the PCB  31 . First a boss  36  of retainer  26  is inserted into a hole  37  of PCB  31 . The retainer  26  is then rotated about boss  36  towards the end of the PCB  31 , this allowing another boss  38  of retainer  26  to snap into the hole  39  on the other side of the PCB so that the retainer  26  is then captured at the end of the PCB  31 . In this configuration note that holes  44  and  45  and  42  and  43  are aligned for receiving respective mounting screws as described hereafter. Similarly the other retainer  24  at the opposite end of the PCB  31  is captured by the opposite end of the PCB  31 . Further note cut-out  40  and extension  41  moving from a non-engaged position in  FIG. 4  to an engaged position in  FIG. 5 . 
         [0029]      FIG. 6  illustrates mounting of the PCB sub-assembly  30  onto the mounting surface  11  by use of four screws  42 A- 42 D at the four corners of the PCB  31  and passing through respective aligned holes such as  42 ,  43  and  44 ,  45  shown in dash lines in  FIG. 6 , and aligned holes  90 ,  91  and  92 ,  93  also shown in dash lines in  FIG. 6 . 
         [0030]    Assembly of the switch cover sub-assembly  29  is explained by reference to  FIGS. 7 and 8 . As shown in  FIG. 7 , the switch button  12  mounting portion  12 B has first and second spring members comprising respective springy mounting tabs  55  and  56  at opposite ends of the mounting portion  12 B. Springy mounting tab  55  is formed of a mounting tab portion  55 B attached by first and second S-shaped spring portions  55 A and  55 C to a main body  57  of the mounting portion  12 B. Similarly springy mounting tab  56  has a mounting tab portion  56 B flanked by and attached to the main body  57  by respective S-shaped spring portions  56 A and  56 C. As shown in  FIG. 8  and also in the cross sectional view of  FIG. 3 , three engagement ribs  51 A,  51 B, and  51 C spaced apart and parallel to each other extend from an inner surface of the side wall  16 C and engage with the mounting tab portion  55 B. Similarly on the opposite side engagement ribs  52 A,  52 B, and  52 C extend from the side wall  16 D and engage with the mounting tab portion  56 B. An open region  54  is defined within springy mounting tab  55  and an open region  80  is defined within springy mounting tab  56 . 
         [0031]    As shown in  FIGS. 3, 7, 8, and 9 , and particularly  FIG. 9 , the button portion  12 A has a peripheral lip  12 AA which surrounds a central raised portion of the switch button  12 . This lip, prior to pushing the push button  12 , is held by the mounting springy tabs  55  and  56  in contact with an inner surface  16 E of the top portion of the cover  16 . 
         [0032]    With the aforementioned structure, the switch buttons  12 - 15  are snapped into place by use of the engagement ribs located on each side of the cover that create a ledge for the springy mounting tabs such that the springy mounting tabs are retained between the ribs and the inner surface  16 E of the top portion of the cover  16 . 
         [0033]    The springy mounting tabs  55  and  56  have multiple functions. The first function is to retain the button in the switch cover and the second function is to act as a spring member that returns the button to its start position after the button has been actuated. As a result of the springy connection between the switch cover and the button, the process of actuation of the button is such that no matter where the user pushes on the button, it always results in the actuation of the respective button switch. The function for each button, as previously described, can be printed directly on the face of each button in the switch panel assembly or an indicia label may be applied on each button face. This allows for complete system functional flexibility. 
         [0034]    With respect to  FIGS. 2, 9, 10, and 11  the assembly of the switch cover sub-assembly  29  to the PCB sub-assembly  30  will now be described. A tip  23 A of the retainer spring finger  23  is placed through the switch cover slot  21  and then the switch cover sub-assembly  29  is swung down such that at the opposite end the tip  25 A of the retainer spring finger  25  snaps into place through the respective switch cover slot  27 . Release of the two sub-assemblies from each other is accomplished by insertion of a flat head screw driver through the slot  21 , for example, to push on the tip  23 A of the retainer spring finger  23 , or alternatively the screw driver is inserted through the orthogonal slot  22  to disengage tip  23 A as an alternate way of pushing out the tip  23 A of the retainer spring finger  23 . Of course the two sub-assemblies may also be released by pushing through the opposite end slots  27  or  28 . 
         [0035]    The modular switch panel assembly of the one exemplary embodiment is a unique design which accomplishes the following features:
       The switch buttons are mounted and retained by the cover and not affixed to the button switch itself. A result of this configuration is the ability of the switch panel assembly to absorb manufacturing tolerances between components and at the same time provide reliable and consistent functionality and feel to the end user.   Regardless of where the user pushes on the switch button it always results in the actuation of the button switch.   The springy mounting tabs of the switch button provide retention of the button to the switch cover and also provide the spring force required to return the button to its start position.   The retainer spring fingers of the respective PCB retainers provide the method of attaching the PCB sub-assembly to the switch cover sub-assembly and also allow for easy installation and removal of the switch cover sub-assembly.   The method of attaching the PCB retainer to the PCB requires no fasteners, yet it is securely affixed to the PCB.   Although the one current exemplary embodiment is a rectangular switch button, the switch button can be a number of configurations—for example round, square, oval, etc.   Switch button function can be printed or applied as a label directly on the face of each switch button in the switch panel assembly to allow for complete system functional flexibility.   During mounting of the PCB sub-assembly, the cover sub-assembly is not attached to the PCB sub-assembly and therefore is not likely to be damaged.   In the event the user decides to replace a switch button or change the nomenclature configuration in the cover sub-assembly, the user can simply push the old switch button out and insert a new switch button or reconfigure the switch button location. The reason this is possible is due to the springy mounting tabs on each side of the switch button. The act of pushing the switch button out of the cover results in no damage to the switch button in any way and therefore the switch button can be reused or relocated.   The design offers design flexibility with respect to different configurations—for example number of switch buttons, and/or different text in different locations.   The switch cover can be molded in different colors and may also have different finishes depending on customer requirements.       
 
         [0047]    An alternate exemplary embodiment of the modular switch panel assembly will now be described with reference to drawing  FIGS. 12 through 15 . Here the alternate embodiment switch panel assembly  57  is illustrated in a front perspective view in  FIG. 12  and exploded view in  FIG. 13  mounted to a mounting surface  70 . A switch cover  58  is provided which further comprises a recessed front face  58 A receiving a cover label  59  having an aperture  60  through which a switch button  61  protrudes. Indicia  62  are provided on the cover label  59 , such as for describing a switching function of the switch button  61  of the switch panel assembly. Although only one switch button  61  is shown, additional switch buttons may be provided. 
         [0048]    A PCB  63  having a switch  64  mounted thereon is attached to a rear surface of the switch cover such as by screws  65 A,  65 B received in screw holes  66 A,  66 B in the cover. The switch  64  may be a push button switch, although other switch designs may be employed. 
         [0049]    The PCB  63  together with the switch cover  58  and cover label  59  form an assembly or module  67  when assembled. This modular assembly  67  is mounted to the mounting surface  70  having a cut-out  71  by use of mounting screws  72 A,  72 B received in screw holes  73 A,  73 B. As previously described, the push button switch  64  may be momentary contact or a toggle action and can have one pole or multiple poles. 
         [0050]    As shown in the cross-sectional perspective view of  FIG. 14 , LEDs  81 A,  81 B may be provided on the PCB to back light the switch cover  58 . As also shown in  FIG. 14 , the push button switch  64  has a spring loaded push button portion  64 A received in a switch body portion  64 B. The bottom of a button portion  61 A of switch button  61  contacts the top of the push button portion  64 A when the switch button  61  is depressed. 
         [0051]    The switch button portion  61 A has a rectangular skirt  61 AA having a leading end which contacts the top of the PCB  63 , stopping downward motion of the switch button  61 . 
         [0052]    As shown in  FIG. 15 , the cut-out region  74  in the switch cover  58  is provided for receiving the switch button  61 . At four corners of the button portion  61 A are provided respective S-shaped spring portions  75 ,  76 ,  77 , and  78  as spring members and comprising an integral mounting portion  61 B of the switch button. For the S-shaped spring portion  75 , for example, one end attaches to a side wall  74 A of cut-out region  74  and an opposite end connects to an outside surface of the rectangular skirt  61 AA near a corner of the switch button main body portion  61 A. These S-shaped spring portions are integral with the button portion  61 A and all may be formed of plastic. 
         [0053]    Thus with the aforementioned described design, the switch button is an integral molded portion of the overall switch cover and interacts with the switch button on the circuit board. The spring members as spring portions are integrated with the button portion of the switch button and allows the switch button to move when pressed. 
         [0054]    When the switch button is engaged, for example, the LED indicators may back-light the panel as previously described. 
         [0055]    To prevent light bleeding through the aperture, there is a light wall added to the back of the panel that is included in the molding process. 
         [0056]    Although preferred exemplary embodiments are shown and described in detail in the drawings and in the preceding specification, they should be viewed as purely exemplary and not as limiting the invention. It is noted that only preferred exemplary embodiments are shown and described, and all variations and modifications that presently or in the future lie within the protective scope of the invention should be protected.