Abstract:
A switch apparatus having an integrated flasher relay for activation and deactivation of a hazard signaling system particularly for use in automotive vehicles. The actuator has an integral flasher relay that moves with the actuator through the activation and deactivation operations. The switch is also provided with a detent utilizing a roller for releasably locking the actuator in a predetermined position.

Description:
FIELD OF THE INVENTION 
     The present invention relates to pushbutton switch assemblies, particularly pushbutton switches used in interior automotive signal and accessory applications and more particularly to automotive pushbutton hazard switches. 
     BACKGROUND OF THE INVENTION 
     Interior automotive switches have typically comprised an assembly including a switch housing, terminal, a pushbutton actuator, conductive extensions and a relay. The relay is typically composed of a relay module mounted to a circuit board. 
     Prior art hazard switch assemblies included a stationary flasher relay requiring a separate protective outer shell protecting it from the elements and damage. The relay circuit board was typically soldered to the conductive extensions for contact with the terminal upon activation. 
     Prior art pushbutton switches have also utilized detent mechanisms whereby upon force and movement of the pushbutton, the button would temporarily lock in an intermediate position typically activating a signal or accessory, for example, turning on an automobile&#39;s hazard lights. Prior art detent mechanisms have included guides in the form of roller pins, spherical balls and wires which were guided by a track. 
     Prior art pushbutton hazard switches as described above were problematic due to the complexity of the designs, the quantity of components and the spacial and structural relationships between the individual components. A problem often encountered was the requirement to solder the relay circuit board to the conductive extensions or alternatively to the terminals which is costly, inefficient and effectively a permanent connection whereby if a failure occurred in manufacturing or in the field of either of the soldered components, the entire assembly would have to be discarded. 
     Further, prior art hazard switches have included an illumination bulb on either the circuit board or on the shell whereby activation of the switch would illuminate the bulb, and through a translucent film on the exterior of the pushbutton, provide an operator a visual flashing indicator that the hazard lights or accessories were engaged and functioning. For ease of identification of the hazard switch in the vehicle, some prior art switches had the bulb continuously illuminated while the vehicle&#39;s instrument panel lights and/or exterior headlamps were illuminated. Under the latter design, a problem was encountered that due to the stationary nature of the relay and bulb, the intensity of the bulb through the translucent film, and thus the visual indicator, would vary depending on whether the pushbutton was in the engaged or disengaged position. 
     In addition, prior art detent mechanisms using guides in the form of pins, spheres and wires experienced undesirable feel characteristics due to binding and cocking of the guide in the track throughout travel of the pushbutton. 
     Consequently, it would be desirable to provide a switch improving the problematic conditions in prior art pushbutton hazard switches and to provide a switch that is inexpensive, facilitates manufacturing, assembly and service, and effectively activates the hazard signal while providing a visual indication of the signal status to the operator. It would also be desirable to provide a smooth, positive feeling detent for activating and deactivating the switch. 
     SUMMARY OF THE INVENTION 
     The inventive switch comprises a housing assembly or housing having a terminal mounted thereon and an actuator assembly or actuator having an integrated flasher relay therein whereby the actuator is slidingly displaced and moves along the housing placing the actuator in contact with the terminal thereby activating or deactivating the flasher relay. 
     In a preferred aspect of the invention, the actuator assembly includes a casing and a detachable pushbutton. The casing further has a cavity and a track within the cavity which slidingly receives the circuit board of the flasher relay. The pushbutton attaches to the casing and substantially surrounds the relay. This arrangement combines the advantages of a relay that moves with the pushbutton, allows accessibility of the relay, and affords protection of the relay from damage in use. 
     In another preferred aspect of the invention, the actuator further includes an insert that is integrally molded in the casing. The insert provides a conductive electrical connection between the circuit board and the terminal. This arrangement has the advantage of eliminating inefficient and costly solder connections through an electrical connection between the flasher relay and the insert. 
     In an additional preferred aspect of the invention, the flasher relay further includes an illuminatable device which is mounted to the circuit board adjacent the pushbutton. This arrangement has the advantage of the illuminatable device remaining a constant distance from the indicator lens of the pushbutton. 
     In a preferred aspect of the invention, the housing and the actuator assembly have slidably interconnecting guides and rails providing for sliding engagement of the actuator assembly in the housing. This provides for smooth and positive movement of the actuator. 
     In another preferred aspect of the invention, the switch includes a detent for releasably locking the actuator in a predetermined position relative to the terminal. The detent includes a roller having an inner and an outer shoulder separated by a hub. The roller further includes a pin extending outwardly from the outer shoulder opposite the hub. The roller is slidingly engaged in the actuator casing and the pin is guided by a track in the housing. This arrangement provides for smooth movement and positive locking of the actuator relative to the terminal. 
     These and other features and advantages of the invention will be apparent upon reading the following specification which, along with the drawings, describes and discloses preferred and alternative embodiments of the invention in detail. 
    
    
     BRIEF DESCRIPTION OF THE DRAWING 
     The description herein makes reference to the accompanying drawings wherein like reference numerals refer to like parts throughout the several views, and wherein: 
     FIG. 1 is a cut away, bottom view of the switch showing the actuator assembly installed in the housing assembly; 
     FIG. 2 is an exploded view of the actuator assembly; 
     FIG. 3 is a partial perspective view of the actuator assembly showing the flasher relay and detent roller in an installed position; 
     FIG. 4 is a partial top view of the actuator assembly showing the flasher relay and detent roller in an installed position; 
     FIG. 5 is a partial exploded view of the actuator insert with the casing removed and the flasher relay circuit board; 
     FIG. 6 is an exploded view of the housing assembly; 
     FIG. 7 is a cut away, bottom view of the housing assembly; 
     FIG. 8 is an end view of the pushbutton; 
     FIG. 9 is a cut away, side view of the pushbutton; and 
     FIG. 10 is a perspective view of the detent roller. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring to FIGS. 1,  2  and  6 , a switch assembly  10  with an integrated flasher relay is illustrated. Assembly  10  is comprised of an actuator assembly  12  and a housing assembly  100 . The actuator assembly  12  is composed of a button  14  having a face  16  and a visual indicator lens  18 . The button  14  includes a hollow casing cap  20  integrally formed therein. As seen in FIGS. 8 and 9, the cap  20  has upper guide rails  22  and side guide rails  24  along the length of the cap. The cap  20  further includes offset apertures  26  and ribs  28  having closed slots  30 , each slot  30  having a rearward stop  32 . The button  14  also has a pair of offset recesses  34  on the outside of ribs  28 . The button  14  is preferably made from an injection moldable polymer but may be made from other like materials. 
     Referring to FIGS. 2 and 3, the actuator assembly  12  includes a casing  40 . Casing  40  is a four-sided polygon having a cavity  42 . The casing  40  has a pair of spring projections with tapered hook ends  44  integrally molded therein. Upon attachment of the casing  40  to button  14 , the projections  44  releasingly snap to the casing cap  20  through apertures  26  thereby abutting casing  40  to cap  20 . As best seen in FIGS. 2 and 3, casing  40  includes a like pair of upper guide rails  46  and side guide rails  48  on the adjacent walls. Casing  40  also has a keyhole-shaped, closed slot  50  having a first width  51  of greater distance than a second width  52  as shown in FIGS. 3 and 4. Referring to FIGS. 2-4, casing  40  also comprises a biasing member seat  53  adjacent the slot  50  and a track  54  within cavity  42 . The casing  40  is preferably made from an injection moldable polymer, but may be made from other like materials. 
     Referring to FIG. 2, the actuator assembly  12  includes a flasher relay assembly  70  having a relay module  74 , an electrical connector portion  76  and an illuminatable device  78  all mounted to a circuit board  72 . The flasher assembly  70  is integrated in the actuator assembly  12  through inserting flasher assembly  70  into casing  40  through engagement of the circuit board  72  and casing track  54  in the orientation shown in FIGS. 2 and 3. Upon attachment of the button  14 , cap  20  substantially surrounds flasher assembly  70  within the cavity  42  and hollow portion of cap  20 . 
     Now referring to FIGS. 2 and 5, actuator assembly  12  further comprises an insert  56  integrally molded with casing  40 . The insert  56  includes leaf extensions  58  having leaf contacts  60 . The leaf contacts  60  are in conductive contact with grid  57 . The grid  57  is in conducting connection with relay contacts  64 . Upon installation of flasher assembly  70  in casing  40 , connector portion  76  slidingly engages relay contacts  64  thereby providing an electrical connection between flasher assembly  70  and leaf extensions  58 . Insert  56  may be made from any electrically conductive material. 
     Referring now to FIG. 10, switch  10  further comprises a detent providing for a two position, on/off operation. The detent includes a roller  90  having an inner shoulder  94  and an outer shoulder  96  separated by an axial hub  92 . Roller  90  has a pin  98  extending outwardly from outer shoulder  96  opposite hub  92 . Shoulders  94  and  96  are preferably circular in shape having diameters less than the first width  51  of slot  50 , but greater than the second width  52  of slot  50  as seen in FIGS. 3 and 4. Roller  90  is inserted into casing  40  prior to installation of flasher relay  70 . As seen in FIGS. 3 and 4, inner shoulder  94  is inserted through first width  51  of keyhole slot  50  and thereafter, roller  90  is positioned into the second, more narrow width  52  thereby preventing the roller  90  from falling in or out of the casing through first width  51 . Upon installation of flasher relay assembly  70  in the casing  40  through track  54 , the roller  90  is prevented from sliding to first width  51  through contact of inner shoulder  94  and circuit board  72 . This prevents the roller from falling out of the casing through slot  50 . 
     Referring to FIG. 6, switch  10  includes a housing assembly  100  consisting of a left housing  101 , a right housing  120  and left and right  114 ,  164  terminals respectively. The left housing  101  has a base wall  102 , side walls  104 , a terminal recess  108 , terminal stops  110  and latches  106  integrally molded therein. 
     Right housing  120  includes a base wall  122  and side walls  124 . Side walls  124  of right housing  120  further include latch apertures  126 , mounting tabs  128  and spring projections  130  all integrally molded therein as shown in FIG.  6 . Side walls  124  further include flanges  132  having studs  134  extending outwardly therefrom and integrally molded therein. Side walls  124  also have guides  140  integrally molded therein. 
     As best seen in FIG. 7, base wall  122  of right housing  120  includes a terminal recess  158 , terminal stops  160  a biasing member seat  156  and a pair of upper guides  138 . Guides  138  and  140  slidingly engage rails  46  and  48  respectively of actuator assembly  12 . It is understood the present invention contemplates that the rails may be molded into the housing and the guides molded in the casing. Base wall  122  further includes a detent track  142  integrally molded therein. Track  142  includes a tapered opening  144 , an elongate portion  146  extending therefrom ending in an enlarged area bifurcated by a catch  152 . Track  142  further includes a first stop  148  and a second stop  150  adjacent the catch  152 . The width of track  142  through middle portion  146  and around catch  152  is slightly greater than the width of pin  98  of detent roller  90 . Left housing  101  and right housings  120  are preferably made from an injection molded polymer, but other like materials may be used. 
     The detent roller inner and outer shoulders  94  and  96  respectively assist the roller  90  in staying in a planar relationship with the casing thereby keeping the pin  98  substantially perpendicular to the casing and aligned with the guide track  142  throughout travel of the actuator assembly  12 . This increased alignment reduces binding of the actuator assembly  12  in the housing assembly  100  and provides a smooth feeling through button  14  for the operator. Roller  90  freely moves within the first width  52  of slot  50  through contact of hub  92  along the casing  40 . 
     Referring to FIG. 6, terminals  114  and  164  include terminal pins  118  and  168 , respectively. Terminals  114  and  164  are made of any common electrically conducting material and are attached to the left  101  and right  120  housings in recesses  108  and  158  respectively through known techniques such as heat staking, adhesive or mechanical fasteners. The terminal stops  110  and  160  prevent movement of the terminals  114  and  164  respectively upon installation of a wiring connector (not shown) over terminal pins  118  and  168 . Subsequent to attachment of terminals  114  and  164  to the left housing  101  and right housing  120  respectively, the left housing  101  is releasably connected to the right housing  120  through engagement of latches  106  through apertures  126  on the right housing  120  thereby forming a closed-walled polygonal housing with a through cavity. 
     Referring now to FIGS. 1 and 7, switch  10  further includes a biasing member  172 , preferably in the form of a compression spring, which is positioned in biasing member seat  156  of right housing  120 . Upon installation of actuator assembly  12  into housing assembly  100 , the opposite end of biasing member  172  is positioned in biasing member seat  53  of casing  40 . The biasing member  172  provides a physical force biasing the actuator assembly  10  away from terminals  114  and  164 . It is understood that devices other than a compression spring may be used to bias the actuator away from the housing. Such other devices may include a tension spring, a leaf spring a conical spring washer or other mechanical resistance devices. 
     Upon installation of the detent roller  90  in the casing  40  and subsequent installation of the flasher assembly  70  in the casing  40 , the pushbutton  14  is attached to the casing as previously described completing actuator assembly  12  as seen in FIG.  7 . Biasing member  172  is positioned in biasing member seat  156  in right housing  120  and extends outwardly therefrom. 
     Actuator assembly  12  is installed into the housing assembly  100  through alignment and sliding engagement of upper rails  46  and side rails  48  of casing  40  with upper guides  138  and side guides  140  of right housing  120  respectively. As depicted in FIGS. 1 and 7, upon further insertion and engagement of actuator  12  within housing  100 , roller  90  is positioned in keyhole slot  50  such that pin  98  contacts and is guided by tapered opening  144  in the right housing  120 . Upon further insertion and engagement of actuator  12  within housing  100 , biasing member  172  contacts biasing member seat  53  of casing  40  thereby providing resistance or bias from further insertion of the actuator toward the terminals. Through additional force exerted on the actuator  12  overcoming the resistance of biasing member  172 , projections  130  on the right housing  120  contact the ribs  28  of button  14 . Additional force applied to the actuator will releasably lock projections  130  through slots  30  in the ribs  28  of button  14 . Studs  134  on flanges  132  will also enter and be guided into recesses  34  of button  14  thereby resisting twisting or torsion of actuator assembly  12  relative to housing assembly  100 . Without additional force applied to the button, the resistance provided by biasing member  172  forces the actuator assembly  12  in a position such that the latches  130  are in abutting engagement with the stops  32  of slots  30  as shown by solid lines in FIG.  1 . This position of the actuator relative to the housing is the non-engaged or “off” position of the switch whereby the flasher relay is not activated and thus not flashing. 
     Referring now to FIGS. 1 and 7, in operation, force is applied to the actuator assembly  12  through the button  14  thereby moving actuator assembly  12  with integrated flasher relay  70  towards terminals  114  and  164  along upper guides  138  and side guides  140 . Pin  98  is guided in detent track  142  and, through guidance of catch  152 , is directed toward and abuts first stop  148  thereby preventing further engagement of actuator  12  in housing  100 . Flanges  132  provide an additional stop preventing further movement of actuator  12  through contact with button  14  shown in phantom in FIG.  1 . As best seen in FIG. 7, upon release of pressure on button  14 , the resistance by biasing member  172  will automatically force actuator assembly  12  away from the terminals. Upon movement of the actuator assembly  12  away from the terminals, pin  98  will abuttingly engage return catch  152  and thereby prevent further movement of actuator  12  away from the terminals while the release of force on button  14  is maintained. Slot  50  allows smooth adjustment of roller  90  to properly seat pin  98  on catch  152 . At this point, leaf extensions  58  are adjacent the contact plates  116  and  166  of terminals  114  and  164  thereby placing in electrical engagement contacts  60  with contact plates  116  and  166  as shown in phantom in FIG.  1 . This position of the actuator  12  whereby the pin  98  is in abutting engagement with catch  152  and the leaf contacts  60  are in electrical contact with contact plates  116  and  166 , defines the active or “on” position of the switch thereby activating the flasher relay and further providing a flashing visual indication through lens  18  by activation of illuminatable device  78 . 
     To deactivate or turn off the flasher relay, pressure is again applied to the actuator assembly  12  through button  14  to overcome the resistance of biasing member  172 . Upon such force, pin  98  is thrust towards the second stop  150  of detent track  142  as best seen in FIG.  7 . Movement of actuator  12  toward the terminal is stopped upon pin  98  contacting second stop  150  of track  142  and through contact of button  14  and flanges  132  as shown in phantom in FIGS. 1 and 7. Upon release of pressure from button  14 , the resistance of biasing member  172  will again bias or force actuator assembly  12  away from the terminals and pin  98  will be biased away from second stop  150 , thrust past catch  152  and will be guided along track  142  toward its original position. Biasing member  172  will bias actuator assembly  12  away from the terminals until latches  130  of right housing  120  abuttingly engage stops  32  of guide slots  30  in button  14 . Such movement will translate leaf contacts  60  from contact plates  116  and  166  thereby deactivating the flasher relay and ceasing flashing of illuminatable device  78  and visual indication of flashing through lens  18 . 
     Reactivation of the flasher relay switch is achieved through again applying pressure to the actuator assembly  12  through button  14  as previously described to complete another cycle.