Patent Description:
The invention relates to a battery switch and, more specifically, to a battery switch for a low-voltage, direct-current (DC) electrical system such as a system found on yachts, recreational vehicles, trucks, and other vehicles.

In vehicle systems, such as, but not limited to, yachts and recreational vehicles, it is advantageous to disconnect electrical power from a bank of batteries (e.g., a DC power supply) to conserve electrical power over an extended period of inactivity. Typically, such DC power supplies are low-voltage (e.g., six-volts, twelve-volts, twenty-four volts, etc.); however, because of the significant power requirements, the DC power supplies may be configured to output a high-current. A battery switch is operable to selectively connect or disconnect the power supply to the vehicle systems.

In one independent embodiment, a switch may generally include a housing; a first terminal supported by the housing and electrically coupled to a power source; a second terminal supported by the housing and electrically coupled to a load; a contact having a first contact end and a second contact end, the contact being operable to be in a closed position, in which the first contact end engages the first terminal and the second contact end engages the second terminal such that the contact electrically connects the first terminal to the second terminal, and an open position, in which the contact does not electrically connect the first terminal and the second terminal; and a biasing member configured to bias the contact towards the first terminal and the second terminal, the biasing member being operable to apply a first biasing force proximate the first contact end and a second biasing force proximate the second connect end.

<CIT> discloses a rotary switch having a plurality of positions.

<CIT> discloses a switching device comprising a manually rotatable card with spaced contact points placed thereon, such card being resiliently urged against spaced contact surfaces for connection to the terminals of different electrical circuits.

<CIT> discloses an electrical changeover switch according to the preamble of claim <NUM>, comprising a housing including connection terminals, a moving contact element for selectively linking chosen connection terminals, and a driving element for driving the contact element, wherein the housing includes a bore in the bottom of which contact surfaces and the connection terminals open out, the moving contact element consisting of a bar forced against the bottom of the bore by an elastic element carried by the driving element which is mounted for rotation in the bore, and radial bosses equipped with ramps regularly distributed at the periphery of the bottom of the bore <NUM>, which the contact element <NUM> crosses by virtue of the drive element opposing the action of the elastic element, the bosses forming components for indexing the changeover switch in its different positions.

According to a first aspect of the present invention, there is provided a switch according to claim <NUM>.

According to a second aspect of the present invention, there is provided a method of assembling a switch, the method comprising the features of claim <NUM>.

Other features of the invention may become apparent by consideration of the detailed description, claims and accompanying drawings.

<FIG> illustrates an exploded view of a switch <NUM> electrically coupled to a power source, such as, but not limited to one or more batteries, and a load to regulate electrical current between the power source and the load. The switch <NUM> is operable in a closed state, in which electrical current passes through the switch <NUM>, and in an open state, in which the electrical current is inhibited to pass through the switch <NUM>.

The switch <NUM> includes a housing <NUM> containing internal components <NUM> with a rotary selector or actuator knob <NUM> coupled to the housing <NUM> and in communication with the internal components <NUM>. The knob <NUM> rotates about an axis X and includes an indicator <NUM> indicating an angular position of the knob <NUM> relative to the housing <NUM>.

The housing <NUM> includes an upper housing <NUM> located adjacent the knob <NUM>, a lower housing <NUM> coupled to the upper housing <NUM>, and a gasket <NUM> (<FIG>) located between the housings <NUM>, <NUM> (<FIG>). The gasket <NUM> inhibits moisture and debris from propagating into and disrupting the internal components <NUM>. In the illustrated embodiment, the knob <NUM> is positioned outside of the housings <NUM>, <NUM>. In other words, the knob <NUM> is located exterior to the housing <NUM>.

With reference to <FIG> and <FIG>, the upper housing <NUM> includes a flange <NUM> extending towards the axis X and along planar sides of the upper housing <NUM>. As discussed in more detail below, the flange <NUM> may be configured to couple the housings <NUM>, <NUM>. With reference to <FIG>, the housing <NUM> may also include a body <NUM> extending from and surrounding the lower housing <NUM>. In other embodiments, the upper housing <NUM> may include indicia (not shown) to be aligned with the indicator <NUM> of the knob <NUM> when the switch <NUM> is in the closed state or the open state.

With reference to <FIG> and <FIG>, the upper housing <NUM> includes a wheel <NUM>. The wheel <NUM> rotates about the axis X in a similar fashion as the knob <NUM>. The knob <NUM> engages the wheel <NUM> such that the knob <NUM> and the wheel <NUM> are non-rotatably coupled while being rotatable together relative to the upper housing <NUM> (i.e., as a user rotates the knob <NUM>, the wheel <NUM> is rotated).

With reference to <FIG> and <FIG>, the lower housing <NUM> includes apertures <NUM> and support features <NUM> extending between the apertures <NUM>. The support features <NUM> extend slightly above the apertures <NUM> towards the upper housing <NUM> along the axis X. In the illustrated embodiment, the support features <NUM> are constructed as curvilinear members. In other embodiments, the support features <NUM> may be differently constructed (e.g., as linear members, combination linear/curvilinear members, etc.).

In addition, the lower housing <NUM> includes protrusions <NUM> extending radially outwardly from the axis X and rails <NUM> connecting adjacent protrusions <NUM>. Each rail <NUM> engages a corresponding flange <NUM> (<FIG>) to couple the housings <NUM>, <NUM> by an interference fit. In other words, fasteners, adhesives, etc. are not required to couple the housings <NUM>, <NUM>. The protrusions <NUM> are sized to engage corners of the upper housing <NUM> with apertures <NUM> formed through the protrusions <NUM> aligning with apertures <NUM> formed through the corners of the upper housing <NUM>, thereby allowing the switch <NUM> to be fixed to a support structure (not shown) via fasteners.

The lower housing <NUM> also has a curved wall <NUM> (<FIG>) extending about the axis X and defining a cavity of the lower housing <NUM>. The curved wall <NUM> defines recesses <NUM> facing inwardly towards the axis X. In the illustrated embodiment, four recesses <NUM> are spaced apart by ninety degrees relative to each other. In other embodiments (not shown), there may be fewer or more recesses <NUM> and/or the recesses <NUM> may be spaced differently relative to each other. In the illustrated embodiment, two opposing recesses <NUM> are positioned adjacent a stop <NUM> with the stop <NUM> projecting towards the axis X (only one stop <NUM> is shown in <FIG>; however, the lower housing <NUM> may include additional stops <NUM>).

The switch <NUM> also includes terminals <NUM> secured within the apertures <NUM> by an interference fit (further illustrated in <FIG>). The terminals <NUM> extend away from the lower housing <NUM> and generally parallel to the axis X (<FIG>). In other embodiments, the terminals <NUM> may extend in a different direction (e.g., generally perpendicular to the axis X). In the illustrated configuration as a battery switch, the terminals <NUM> are electrically couplable to electrically couple the power source to the load through the switch <NUM>.

With reference to <FIG>, the internal components <NUM> include a rotating member <NUM> having a rotating member body <NUM>, a biasing member <NUM>, and a contact <NUM>. The biasing member <NUM> and the contact <NUM> are received in a cavity <NUM> of the rotating member body <NUM> with the cavity <NUM> in a facing relationship with the terminals <NUM>. In particular, the cavity <NUM> includes opposing channels <NUM> that are sized to receive ends <NUM> of the contact <NUM>. In other words, the channels <NUM> receive a portion of a perimeter of the contact <NUM>. The engagement between the ends <NUM> of the contact <NUM> and the channels <NUM> enables the contact <NUM> to rotate with the rotating member <NUM> about the axis X while allowing the contact <NUM> to axial move relative to the rotating member <NUM> parallel to the axis X.

The rotating member body <NUM> further includes resilient fingers <NUM> located on an outer circumference of a portion of the rotating member <NUM>. In the illustrated embodiment, there are two resilient fingers <NUM>; however, in other embodiments (not shown), there may be only one or more than two resilient fingers <NUM>. Each finger <NUM> is biased in a direction generally perpendicular to the axis X to selectively engage a corresponding recess <NUM> in the lower housing <NUM> to provide a detent arrangement. A gasket <NUM> is located between the upper housing <NUM> and the rotating member <NUM> to inhibit moisture and debris from propagating into and disrupting the internal components <NUM>.

In some embodiments, the contact <NUM> is constructed from bar stock material with a cuboid cross section, e.g., a rectangular cross section. As described in more detail below, the length of the contact <NUM> is such that, in the closed state, the contact <NUM> will be in direct contact with both terminals <NUM>. The contact <NUM> may also be constructed from a material having adequate electrical conductivity properties, such as but not limited to, silver, gold, copper, etc..

Additionally, the contact <NUM> may be coated (e.g., electroplated) with a material having electrical conductivity properties. In some embodiments, the coating may have a higher electrical conductivity than the material being coated. For example, a rectangular bar stock of steel may be coated with copper to obtain a desired electrical conductivity.

The biasing member <NUM> is generally located between the contact <NUM> and the rotating member body <NUM> and is configured to force the contact <NUM> against the terminals <NUM>, thereby reducing electrical resistance therebetween. With reference to <FIG>, in some embodiments, the terminals <NUM> include a convex surface <NUM> adjacent the support features <NUM>. In particular, the support features <NUM> are positioned above the convex surfaces <NUM>. The convex surfaces <NUM> facing the contact <NUM> may, for example, allow for lower contact resistance between the terminals <NUM> and the contact <NUM>, provide more thermal mass and heat sinking into cables (not shown) coupling the bank of batteries to the switch <NUM>, etc..

In the illustrated embodiment, the biasing member <NUM> includes a leaf spring which biases the contact <NUM> away from the rotating member <NUM> along the axis X. The biasing member <NUM> may engage the contact <NUM> at one or more points. In the illustrated embodiment, the center of the biasing member engages the rotating member <NUM>, and the opposite ends <NUM>a, <NUM>b of the biasing member <NUM> engage at or proximate the respective ends <NUM>a, <NUM>b of the contact <NUM> that generally align with the convex surfaces <NUM> of the terminals <NUM>a, <NUM>b (<FIG>). As a result, the biasing member <NUM> provides maximum biasing force against the contact <NUM> towards the respective terminal <NUM>a, <NUM>b to ensure adequate contact area therebetween.

The illustrated biasing member <NUM> is operable to apply a biasing force proximate each end <NUM>a, <NUM>b of the contact <NUM>. The first contact end <NUM>a is engageable with the first terminal <NUM>a (e.g., at the apex of the convex surface <NUM>) at a radial distance D<NUM> from the axis X, and the first end <NUM>a of the biasing member <NUM> applies the biasing force to the first contact end <NUM>a at a radial distance D<NUM> greater than the radial distance D<NUM>. Similarly, the second contact end <NUM>b is engageable with the second terminal 62b at a radial distance D<NUM> from the axis, and the second end <NUM>b the biasing member <NUM> applies the biasing force to the second contact end <NUM>b at a radial distance D<NUM> greater than the radial distance D<NUM>.

In the illustrated construction, the radial distance between the axis X and the engagement of the contact ends 85a, 85b with the respective terminals <NUM>a, <NUM>b is approximately the same. Similarly, the radial distance between the axis X and the engagement of the biasing member ends <NUM>a, <NUM>b and the contact <NUM> is approximately the same. In the illustrated construction, the biasing force applied by the end <NUM>a to the contact <NUM> is approximately the same as the biasing force applied by the end <NUM>b to the contact <NUM>.

In other embodiments (not shown), the biasing member <NUM> may include other mechanisms, in addition or as an alternative to the leaf spring, to bias the contact <NUM> away from the rotating member <NUM>/towards the terminals <NUM>. For example, the biasing member <NUM> may include a Belleville washer, wave spring, or the like. In addition, more than one biasing member may be positioned between the contact <NUM> and the rotating member <NUM>.

To assemble the switch <NUM>, the biasing member <NUM> is first positioned within the cavity <NUM>, and then the ends <NUM>a, <NUM>b of the contact <NUM> are received within the corresponding channel <NUM>a, <NUM>b. In the illustrated embodiment, the biasing member <NUM> includes a greater width and a shorter length than the contact <NUM> such that the biasing member <NUM> is received within the cavity <NUM> but is not engaged by the channels <NUM>a, <NUM>b.

The rotating member body <NUM> is received within the cavity defined by the curved wall <NUM> (<FIG>) of the lower housing <NUM> such that the resilient fingers <NUM> engage corresponding recesses <NUM>. As a result of the stops <NUM> positioned adjacent two opposing recesses <NUM>, the rotating member <NUM> is limited in rotational movement relative to the lower housing <NUM> when the resilient fingers <NUM> abut the stops <NUM>. Thus, in some embodiments, the knob <NUM> is pivotable in a limited operational range (e.g., of about ninety degrees) between the closed state and the open state.

Once the rotating member <NUM> is coupled to the lower housing <NUM>, the contact <NUM> is forced against the convex surface <NUM> of both terminals <NUM> via the biasing member <NUM>. The upper housing <NUM> is coupled to the lower housing <NUM> via the interference fit provided by the protrusions <NUM> and the engagement between the flange <NUM> and the rails <NUM>. As the upper housing <NUM> is coupled to the lower housing <NUM>, the connection feature <NUM> of the rotating member <NUM> is received in a portion of the wheel <NUM>. Consequently, the knob <NUM> engages the wheel <NUM> and the rotating member <NUM> so that the knob <NUM>, the wheel <NUM>, and the rotating member <NUM> rotate together.

In some embodiments, the knob <NUM> is removable from the wheel <NUM> for disassembly of the switch <NUM>. In such an embodiment, to remove the knob <NUM> from the wheel <NUM>, the knob <NUM> is rotated past the operational range (e.g., to about one hundred degrees). The wheel <NUM> will remain stationary due to engagement between the rotating member <NUM> and the stops <NUM>, while the knob <NUM> continues to pivot and disengage from the wheel <NUM>.

In operation, the knob <NUM> is pivoted between a closed position (<FIG>) and an open position (<FIG>) corresponding to the closed state and the open state of the switch <NUM>. In the closed state, the contact <NUM> directly engages the convex surfaces <NUM> of the terminals <NUM> to allow current flow from one terminal <NUM> to the other terminal <NUM> via the contact <NUM> (<FIG> and <FIG>). In the closed position, the biasing member <NUM> forces the contact <NUM> into engagement with the terminals <NUM>. Additionally, in the closed position, each resilient finger <NUM> moves into an associated recess <NUM>, providing positive engagement between the rotating member <NUM> and the lower housing <NUM>. The positive engagement indicates that the switch <NUM> is fully oriented in the closed state by temporarily holding the rotating member <NUM> relative to the lower housing <NUM>.

When the open state is desired, the knob <NUM> is pivoted through the operational range (e.g., about ninety degrees) such that the contact <NUM> disengages both terminals <NUM> and directly contacts the support features <NUM> (<FIG>). At the same time, each resilient finger <NUM> moves into an associated recess <NUM>, providing positive engagement between the rotating member <NUM> and the lower housing <NUM>. The positive engagement indicates that the switch <NUM> is fully oriented in the open state by temporarily holding the rotating member <NUM> relative to the lower housing <NUM>. To return to the closed state, the knob <NUM> is rotated in the opposite direction through the operational range (e.g., again, about ninety degrees) to reestablish engagement between the terminals <NUM> and the contact <NUM>.

Claim 1:
A switch (<NUM>) comprising:
a housing (<NUM>);
a first terminal (<NUM>) supported by the housing (<NUM>) and configured to be electrically coupled to a power source;
a second terminal (<NUM>) supported by the housing (<NUM>) and configured to be electrically coupled to a load;
a contact (<NUM>) having a first contact end (<NUM>) and a second contact end (<NUM>), the contact (<NUM>) being operable to be in a closed position, in which the first contact end (<NUM>) engages the first terminal (<NUM>) and the second contact end (<NUM>) engages the second terminal (<NUM>) such that the contact (<NUM>) electrically connects the first terminal (<NUM>) to the second terminal (<NUM>), and an open position, in which the contact (<NUM>) does not electrically connect the first terminal (<NUM>) and the second terminal (<NUM>);
a biasing member (<NUM>) configured to bias the contact (<NUM>) towards the first terminal (<NUM>) and the second terminal (<NUM>); and
a rotating member (<NUM>) rotatably coupled to the housing (<NUM>), the rotating member (<NUM>) including a cavity (<NUM>) configured to receive the biasing member (<NUM>) and the contact (<NUM>), the biasing member being located between the contact (<NUM>) and the rotating member (<NUM>); and
an actuator (<NUM>) operably coupled to the rotating member (<NUM>) to move the contact (<NUM>) between the closed position and the open position;
wherein the contact (<NUM>) is pivotable about an axis (X) between the closed position and the open position;
wherein the contact (<NUM>) and the biasing member (<NUM>) are configured to rotate about the common axis (X) that extends longitudinally through the contact (<NUM>) and the biasing member (<NUM>),
characterized in that the biasing member (<NUM>) is operable to apply a first biasing force proximate the first contact end (<NUM>) and a second biasing force proximate the second contact end (<NUM>).