Patent Publication Number: US-9431192-B2

Title: Actuator biased by a horizontal member

Description:
FIELD OF THE DISCLOSURE 
     The present disclosure relates generally to an electrical wiring device and, more particularly, relates to a switch actuator assembly for activating a switch in an electrical wiring device. 
     DESCRIPTION OF THE RELATED ART 
     Electrical wiring devices, such as switches, dimmer switches, etc., typically include a spring mechanism to actuate the switching component. When a user pushes an actuator on a wiring device, the spring mechanism is typically configured so that the spring mechanism is displaced along its longitudinal axis. However, this type of design has disadvantages because there is limited space in a wiring device, and a spring mechanism configured to be displaced along its longitudinal axis takes up valuable space and requires substantial depth in the wiring device to accommodate the movement of the spring mechanism. In addition, a design with the spring mechanism displaced along its longitudinal axis typically requires other components to be included in the wiring device, such as a lever mechanism, which takes up additional space and increases manufacturing costs. These types of designs are particularly disadvantageous in interchangeable color change kits that typically include the mechanism components in the rocker-frame assembly, which is separate from the rest of the electrical device. 
     It would be desirable for a wiring device to have an actuator biased by a component that is not displaced along its longitudinal axis. This would allow for the overall depth of the wiring device to decrease without compromising the balanced “feel” by the user when pressing the actuator. In addition, the number of unique parts required for manufacturing wiring devices would decrease, which would also reduce manufacturing complexity and costs, including inventory costs, labor costs, molding costs, etc. 
     SUMMARY OF THE DISCLOSURE 
     A switch actuator assembly for activating a switch in an electrical wiring device is disclosed. The switch actuator assembly preferably includes a frame having a peripheral wall, a rocker, first and second resilient member supports, a tab having a contact surface, and a resilient member. The first and second resilient member supports may extend from opposite sides of either the frame or the rocker, and the tab may extend from the other of the frame or the rocker. The first and second resilient member supports are preferably arranged and configured to be in registered alignment with respect to one another to form an axis. The resilient member preferably includes a first end, a second end, and a middle portion. A longitudinal axis of the resilient member may be defined between the first and second ends. The first and second ends are preferably configured to engage the first and second resilient member supports respectively, and the middle portion is preferably configured to interact with the tab. In use, the rocker is preferably pivotally mounted to the frame and configured to rotate between a first position and a second position. The contact surface of the tab preferably deflects the resilient member in a direction that is perpendicular to the longitudinal axis of the resilient member when the rocker is in the first position and the second position. 
     In a second, alternate embodiment of a switch actuator assembly for activating a switch in an electrical wiring device, the switch actuator assembly preferably includes a frame, a rocker, and a resilient member. The frame preferably includes first and second frame mounting members, a bottom wall, and first and second trunnions. The first and second frame mounting members preferably extend from the bottom wall, and the first and second trunnions are parallel to the bottom wall and project inwardly. The rocker preferably includes a bottom surface, a tab, and first and second sides. The tab preferably includes first and second surfaces, and the tab preferably extends from the bottom surface of the rocker. The first and second sides of the rocker preferably include first and second rocker mounting members respectively. The first and second rocker mounting members are preferably arranged and configured to pivotally mount to the first and second frame mounting members respectively. The resilient member preferably includes first and second ends and a bearing surface. A longitudinal axis of the resilient member may be defined between the first and second ends. The first and second ends are preferably configured to engage the first and second trunnions respectively, and the bearing surface is preferably arranged and configured to interact with the tab of the rocker. In use, the rocker is preferably adapted and configured to pivotally rotate between a first position and a second position. The first surface of the tab preferably deflects the bearing surface of the resilient member when the rocker is in the first position, and the second surface of the tab preferably deflects the bearing surface of the resilient member when the rocker is in the second position. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S) 
       One or more aspects of the present invention are particularly pointed out and distinctly claimed as examples in the claims at the conclusion of the specification. The foregoing and other objects, features, and advantages of the present invention may be more readily understood by one skilled in the art with reference being had to the following detailed description of several embodiments thereof, taken in conjunction with the accompanying drawings wherein like elements are designated by identical reference numerals throughout the several views, and in which: 
         FIG. 1  is a perspective view of an exemplary embodiment of an electrical wiring device; 
         FIG. 2A  is a perspective view of an exemplary embodiment of a rocker-frame assembly and a slide switch; 
         FIG. 2B  is an exploded view of the rocker-frame assembly and the slide switch of  FIG. 2A ; 
         FIG. 2C  is a front view of the rocker-frame assembly and the slide switch of  FIG. 2A ; 
         FIG. 2D  is a sectional view of the rocker-frame assembly of  FIG. 2C  in a first position taken along section line A-A; 
         FIG. 2E  is a sectional view of the rocker-frame assembly of  FIG. 2C  in a second position taken along section line A-A; 
         FIG. 2F  is a bottom view of the rocker-frame assembly and the slide switch of  FIG. 2A ; 
         FIG. 3A  is a front view of a rocker of the rocker-frame assembly of  FIG. 2A ; 
         FIG. 3B  is a bottom view of the rocker of  FIG. 3A ; 
         FIG. 3C  is a sectional view of the rocker of  FIG. 3B  taken along section line B-B; 
         FIG. 4A  is perspective view of a frame of the rocker-frame assembly and the slide switch of  FIG. 2A ; 
         FIG. 4B  is a top view of the frame and the slide switch of  FIG. 4A ; 
         FIG. 5  is a side view of a spring of the rocker-frame assembly of  FIG. 2A ; 
         FIG. 6A  is a perspective view of the slide switch, a frame and a spring of the rocker-frame assembly of  FIG. 2A ; 
         FIG. 6B  is a top view of the slide switch, the frame and the spring of  FIG. 6A ; 
         FIG. 7  is a perspective view of the electrical device of  FIG. 1 , with the rocker-frame assembly removed; 
         FIG. 8A  is a top view of an exemplary embodiment of a frame and a wire of the rocker-frame assembly; and 
         FIG. 8B  is a perspective view of the frame and the wire of the rocker-frame assembly of  FIG. 8A . 
     
    
    
     DETAILED DESCRIPTION 
     The present disclosure describes an apparatus, assembly and method for an electrical wiring device having an actuator (e.g., a rocker) biased by a resilient member. Embodiments will be described below while referencing the accompanying figures. The accompanying figures are merely examples and are not intended to limit the scope of the present disclosure. 
       FIG. 1  illustrates an exemplary embodiment of an electrical wiring device  90 . As shown, the electrical wiring device  90  may include a rocker  10 , a base  85 , a frame  40 , and a yoke  95 . In addition, the electrical wiring device  90  may include a switch  99  and a front housing  105  (see  FIG. 7 ). The switch  99  is adapted and configured for turning power “on”/“off” to an electrical load. In some embodiments, the electrical wiring device  90  may also include an optional slide potentiometer or slide switch  80  for dimmer and motor load control applications. In use, the rocker  10  is movable through a range of travel, for example, from a first position (see  FIG. 2D ) and a second position (see  FIG. 2E ). The first position of the rocker  10  corresponds to the “off” position of the electrical wiring device  90 ; while the second position of the rocker  10  corresponds to the “on” position of the electrical wiring device  90 . As will be described in more detail below, when the rocker  10  is in the second position, the rocker  10  is pressing down on the switch  99 , thereby actuating the switch  99  and turning the power “on”; and, when the rocker  10  is in the first position, the rocker is not pressing down on or actuating the switch, and thus the power is “off.” However, it will be understood by one of ordinary skill in the art that in other embodiments, such as embodiments that include a three-way switch, the “on” and “off” status with respect to the rocker position may change. 
     According to one aspect of the present invention, the electrical wiring device  90  preferably includes a resilient member to impart a force on the rocker  10 , biasing the rocker  10  through a range of travel, for example, from the first position and the second position. More preferably, the resilient member extends horizontally across the electrical wiring device  90  (e.g., along a minor axis of the rocker  10 ). The resilient member may be any resilient member or material that can apply a biasing force now or hereafter known in the art including a spring, a wire (as shown in  FIG. 8A ), a rubber piece, a plastic piece, and the like. Preferably, as best shown in  FIG. 2A , the resilient member is a coil spring. 
     As will be described in greater detail below, the rocker  10 , the frame  40 , the resilient member, and the optional slide potentiometer or slide switch  80  for dimmer and motor load control applications may be incorporated into a rocker-frame assembly  5  so that the rocker-frame assembly  5  is removable from the base  85 . In this manner, the rocker-frame assembly  5  may be provided as an interchangeable color changing kit that enables an installer or end user to easily change the color of the visible portions of the device  90  to coordinate with changes in the building décor or occupant preferences. Alternatively, as will be appreciated by one of ordinary skill in the art, the rocker  10  may be permanently coupled to the base  85 . 
     Referring to  FIGS. 2A-2F , an exemplary embodiment of the rocker-frame assembly  5  will now be described. As previously mentioned, the rocker-frame assembly  5  may include a rocker  10 , a frame  40 , and a resilient member, such as the spring  70 . In some embodiments, the rocker-frame assembly  5  may also include an optional slide potentiometer or slide switch  80  for dimmer and motor load control applications. As will be described in further detail below, the rocker-frame assembly  5  uses the buckling resistance of the spring  70  to impart a force on the rocker  10 , biasing the rocker  10  in a first position and a second position. The first position of the rocker-frame assembly  5  corresponds to the “off” position of the switch  99 ; and, the second position of the rocker-frame assembly  5  corresponds to the “on” position of the switch  99 . 
     As shown in  FIGS. 2A-2F and 3A-3C , the rocker  10  may include a first end  15 , a second end  17 , a top surface  11 , and a bottom surface  13 . The rocker  10  may also include a tab  18  and an arm  26 . The tab  18  and the arm  26  may extend from the bottom surface  13  of the rocker  10 . More specifically, the tab  18  may extend from the bottom surface  13  of the first end  15  of the rocker  10 , and the arm  26  may extend from the bottom surface  13  of the second end  17  of the rocker  10 . However, in other embodiments, the tab may extend from the bottom surface of the second end of the rocker, and the arm may extend from the bottom surface of the first end of the rocker. 
     The tab  18  may include a contact surface  21  having a first surface  20  and a second surface  22 . As will be described in greater detail below, the first and second surfaces  20 ,  22  are preferably angled relative to a planar surface E-E, which is substantially parallel to a longitudinal axis Y′ of the resilient member or spring  70  (see  FIGS. 3C and 5-6B ). In one exemplary embodiment, the angle of the first surface  20  is preferably 62 degrees, and the angle of the second surface  22  is preferably 46 degrees. However, it will be understood by one of ordinary skill in the art that these quantified angles are merely examples, and the first surface  20  and/or the second surface  22  may be of a different angle with respect to the planar surface E-E. 
     In addition, the rocker  10  may include first and second pins  12 ,  14 . The first and second pins  12 ,  14  may project from opposite sides  30 ,  32  of the rocker  10 , and define a pivot axis  19 . The top surface  11  of the rocker  10  is configured to be pressed by a user to change the position of the rocker  10 . As shown, the top surface  11  is positioned at an inward angle towards the pivot axis. However, in other embodiments, any other suitable shape, contour, dimensions, angles, surfaces, etc. may be used for functional and/or aesthetic reasons. 
     As shown in  FIGS. 2A-F  and  4 A-B, the frame  40  may include a bottom wall  41  and a peripheral wall  43  extending around the frame  40 . The frame  40  may also include first and second slots  42 ,  44  positioned on opposite sides  45 ,  47  of the frame  40 , and adapted and configured to receive the first and second pins  12 ,  14  of the rocker  10 . 
     The frame  40  may also include first and second openings  62 ,  64  that are formed in the bottom wall  41 . As will be described in more detail below, the first opening  62  is adapted and configured to be in registered alignment with and accommodate the tab  18  of the rocker  10  to allow the tab  18  to extend at least partially through the first opening  62  when the rocker  10  is in the first position; and, the second opening  64  is adapted and configured to be in registered alignment with and accommodate the arm  26  of the rocker  10  and the switch  99  of the electrical device  90  (see  FIG. 7 ). 
     The frame  40  preferably includes first and second resilient member supports  60 ,  65 . The first and second resilient member supports  60 ,  65  may be arranged and configured to be in registered alignment with respect to one another to form an axis. In the embodiment of  FIG. 4A-B , the first and second resilient member supports  60 ,  65  may include first and second support members  55 ,  57  and first and second trunnions  56 ,  58 , respectively. The support members  55 ,  57  may extend from the bottom wall  41 , and the first and second trunnions  56 ,  58  may extend from oppositely-facing inner surfaces of the first and second support members  55 ,  57 , respectively. In use, the resilient member supports  60 ,  65  are positioned on opposite sides of the first opening  62  of the frame  40 , and may be fixed. As will be described in more detail below, the first and second resilient member supports  60 ,  65  are each adapted and configured to receive an end  72 ,  74  of the spring  70  (see  FIG. 6A-B ). It will be understood by one of ordinary skill in the art that the resilient member supports may be any feature or component that is configured to support the resilient member. For example, in other embodiments, the resilient member supports may extend from the peripheral wall or sides of the frame. In other alternate embodiments, the resilient member supports may extend from the rocker. 
     The frame  40  may also include a hinge  54  extending from the bottom wall  41  thereof and positioned at one end  49  of the frame  40 . The hinge  54  may include first and second feet  66 ,  68  that are positioned on opposite sides  45 ,  47  of the frame  40 , respectively. Furthermore, the frame  40  may include first and second snaps  46 ,  48  extending from the bottom wall  41  and/or the peripheral wall  43 , on opposite sides  45 ,  47  of the frame  40 , respectively. The first and second snaps  46 ,  48  may each include a latch portion  50 ,  52 , respectively. As will be described in more detail below, the hinge  54 , feet  66 ,  68  and snaps  46 ,  48  are adapted and configured to engage with the front housing  105  of the electrical wiring device  90  to secure the rocker-frame assembly  5  to the electrical wiring device  90  (see  FIGS. 1 and 7 ). 
     As shown in  FIGS. 5 and 6A -B, the spring  70  may include a first end  72 , a second end  74 , and a middle portion  76 . The spring  70  may have a longitudinal axis Y′ defined between the first and second ends  72 ,  74 . The first end  72  of the spring  70  may be adapted and configured to be positioned around the first trunnion  56 , and the second end  74  of the spring  70  may be adapted and configured to be positioned around the second trunnion  58 . When the spring  70  is engaged with the first and second trunnions  56 ,  58 , the first and second ends  72 ,  74  of the spring  70  are fixed against translation along an axis that is perpendicular to the longitudinal axis Y′ of the spring  70 , and positioned horizontally in the frame  40  so that it is substantially parallel to the pivot axis  19 . In a preferred embodiment, the middle portion  76  may include a bearing surface  78 , in which at least a portion of the spring coils are in a close or contacting relationship. Preferably, at least two adjacent, successive coils are in a close or contacting relationship. As will be described in more detail below, the bearing surface  78  is adapted and configured to engage the tab  18  of the rocker  10 . The spring  70  may be any spring now or hereafter known in the art including a coil spring, a compression spring, and the like. 
     To assemble the rocker-frame assembly  5 , the first and second ends  72 ,  74  of the spring  70  are coupled to the first and second trunnions  56 ,  58 , respectively. Furthermore, the first and second pins  12 ,  14  of the rocker are received by the first and second slots  42 ,  44  of the frame  40 , respectively, thereby enabling the rocker  10  to pivot within the frame  40  about the pivot axis  19 . In other embodiments, the rocker may include first and second rocker mounting members that extend from the first and second sides of the rocker, respectively; and, the frame may include first and second frame mounting members that extend from the bottom wall and/or the peripheral wall. The first and second rocker mounting members may be arranged and configured to pivotally mount to the first and second frame mounting members respectively. The first and second rocker mounting members may include first and second pins respectively, the first and second pins defining a pivot axis. In addition, the first and second frame mounting members may include first and second slots respectively, the first and second slots arranged and configured to receive the first and second pins. 
     In use, the rocker  10  may pivotally rotate about the pivot axis  19  through a range of travel, for example, from a first position (see  FIG. 2D ) to a second position (see  FIG. 2E ). When the rocker  10  is in the first position, the switch  99  (see  FIG. 7 ) is “off.” More specifically, in the first position or “off”, the arm  26  of the rocker  10  is in registered alignment with the switch  99  and the opening  64  of the frame  40 , but the arm  26  is not pressing down on the switch  99 . When the rocker  10  is in the second position, the switch  99  is “on.” More specifically, in the second position or “on”, the arm  26  of the rocker  10  is in registered alignment with the switch  99  and the opening  64  of the frame  40 , and the arm  26  is pressing down on the switch  99  to thereby actuate the switch  99 . 
     As shown in  FIGS. 2D-E , when the rocker  10  is rotated about the pivot axis  19 , the contact surface  21  of the tab  18  rides against the bearing surface  78  of the spring  70 . More specifically, when the rocker  10  is in the first position (i.e. a user presses the first end  15  of the rocker  10 ), the first surface  20  of the tab  18  is in contact with the bearing surface  78  of the spring  70 ; and, the tab  18  displaces the spring  70  forward towards the direction of the pivot axis  19  and upward towards the direction of the bottom surface  13  of the rocker  10 . Thus, the spring  70  is deflected perpendicular to its longitudinal axis Y′ towards the direction of the pivot axis  19  when the rocker  10  is in the first position. When the rocker  10  is in the second position (i.e. a user presses the second end  17  of the rocker  10 ), the second surface  22  of the tab  18  is in contact with the bearing surface  78  of the spring  70 ; and, the tab  18  displaces the spring  70  forward towards the direction of the pivot axis  19  and downward towards the direction of the opening  62  of the frame  40 . Thus, the spring  70  is deflected perpendicular to its longitudinal axis Y′ downward towards the direction of the opening  62  when the rocker  10  is in the second position. 
     In both the first and second positions, the tab  18  applies force on the spring  70 , displacing or bending the spring  70  so that the spring  70  follows the path of an arc; and, the buckling resistance of the spring  70  imparts a force on the rocker  10 . That is, the spring  70  provides a biasing force to keep the rocker  10  in the first or second position until a user applies pressure to an end  15 ,  17  of the rocker  10 , causing the rocker  10  to pivot about the pivot axis  19  to the other respective first or second position. 
     As shown in  FIGS. 3A-C , the angle of the first surface  20  of the tab  18  is preferably 62 degrees relative to planar surface E-E, and the angle of the second surface  22  of the tab  18  is preferably 46 degrees relative to planar surface E-E. These examples of quantified angles of the first and second surfaces  20 ,  22  provide a balance so that the rocker  10  may be switched from the first position to the second position (and vice versa), with the user applying the same amount of force for each position. However, it will be understood by one of ordinary skill in the art that these quantified angles above are merely examples, and the first surface  20  and/or the second surface  22  may be of a different angle with respect to the planar surface E-E, as long as the angles are not perpendicular to the plane E-E. It will also be understood by one of ordinary skill in the art that the angles of the first and second surfaces may be dependent on the geometry of the tab. 
     In the exemplary embodiment described above, the tab  18  extends from the rocker  10 , and the frame  40  is adapted and configured to engage with the spring  70  via the first and second support members  55 ,  57  and the first and second trunnions  56 ,  58 . However, it will be understood by one of ordinary skill in the art that in other embodiments, the tab may extend from the frame; and, the first and second resilient member supports, and/or any other attachment feature or component that is adapted and configured to receive an end of the spring, may extend from the rocker. For example, the first and second resilient member supports may extend from the bottom surface of the rocker, the first and second sides of the rocker, etc. 
     The frame  40  may be attached to the electrical wiring device  90  in any convenient manner. As previously mentioned, in the exemplary embodiment shown in  FIGS. 2A-F ,  4 A-B,  6 A-B, and  7 , the hinge  54  may be aligned with an opening  92  formed in the front housing  105 , and the feet  66 ,  68  of the hinge  54  may be positioned within respective openings  96 ,  98  formed in the front housing  105  (see  FIG. 7 ). The rocker-frame assembly  5  may be pivoted to the installed position. The first and second snaps  46 ,  48  of the frame  40  may pass through openings  91 ,  93  of the front housing  105  so that the latch portions  50 ,  52  snap into the respective openings  91 ,  93 . 
     In the exemplary embodiment described above, the spring  70  is positioned horizontally between the rocker  10  and the frame  40 , wherein the first and second ends  72 ,  74  of the spring  70  are held in place by the first and second trunnions  56 ,  58  respectively so that the spring  70  may not be displaced along its longitudinal axis Y′, and the first and second ends  72 ,  74  are prevented from translating toward or away from the bottom surface  13  of the rocker  10 . Thus, the overall depth of the rocker-frame assembly  5  may be minimized because extra space is not needed for the spring  70  to be displaced along its longitudinal axis and/or for the first and second ends  72 ,  74  of the spring  70  to translate. A decrease in overall depth of the rocker-frame assembly  5  may be ideal for applications, such as but not limited to, interchangeable color change kits that enable an installer or end user to easily change the color of the visible portions of the device to coordinate with changes in the building decor or occupant preferences. 
     In addition, in the exemplary embodiment described above, a slide potentiometer or slide switch  80  is positioned in the frame  40  adjacent the rocker  10 . However, it will be understood by one of ordinary skill in the art that in other embodiments, the electrical wiring device may not include a slide potentiometer or slide switch, or may include a slide potentiometer or slide switch but of a different shape, size, etc. Furthermore, in other embodiments, the slide potentiometer or slide switch may be in a different position or configuration on the device, such as but not limited to, being positioned within the rocker. Furthermore, in other embodiments, the incorporation of a horizontally aligned spring according to the description herein may be employed in switching of a dimmer or any other electrical wiring device. 
     A method for assembling an electrical device  90  will now be described. The spring  70  is positioned on the frame  40  as described in detail above. The first end  72  of the spring  70  may pass over the first trunnion  56  of the frame  40 , and the second end  74  of the spring  70  may pass over the second trunnion  58  of the frame  40 . The rocker  10  may be pivotally attached or mounted to the frame  40  to enable the tab  18  on the rocker  10  to deflect the spring  70  perpendicular to a longitudinal axis of the spring  70  when the rocker  10  is in a first position and a second position. The first and second slots  42 ,  44  on the frame  40  are adapted and configured to receive the first and second pins  12 ,  14  on the rocker  10 . 
     To attach the rocker-frame assembly  5  to the front housing  105 , the user aligns a hinge  54  on the frame  40  with the opening  92  on the front housing  105 , and inserts the first and second feet  66 ,  68  and the hinge  54  on the frame  40  into the openings  92 ,  96 ,  98  on the front housing  105 , respectively. The user may then pivot the rocker-frame assembly  5  into the installed position by inserting the first and second snaps  46 ,  48  of the frame  40  into the openings  91 ,  93  on the front housing  105  that are adapted and configured to be aligned with the snaps  46 ,  48  until the latches  50 ,  52  on the snaps  46 ,  48  engage the openings  91 ,  93  to hold the rocker-frame assembly  5  in the installed position. 
     Referring to  FIG. 8A-B , in another exemplary embodiment, the resilient member of the electrical wiring device may be a wire  270 . The wire  270  may include a first end  272 , a second end  274 , and a middle portion  276 . The first end  272  is adapted and configured to be positioned between a bottom wall  241  of the frame  240  and a first support member  255  that extends from the bottom wall  241 . The second end  274  of the wire  270  is adapted and configured to be positioned between the bottom wall  241  of the frame  240  and a second support member  257  that extends from the bottom wall  241 . The wire  270  is positioned in the frame  240  so that the wire  270  is stationary, and the middle portion  276  is substantially parallel to the pivot axis  219 . 
     While certain embodiments of the disclosure have been described herein, it is not intended that the disclosure be limited thereto, as it is intended that the disclosure be as broad in scope as the art will allow and that the specification be read likewise. Therefore, the above description should not be construed as limiting, but merely as exemplifications of particular embodiments. Those skilled in the art will envision additional modifications, features, and advantages within the scope and spirit of the claims appended hereto.