Patent ID: 12191070

DETAILED DESCRIPTION

FIG.1depicts an example load control system100that may include one or more components capable of wireless communication with each other. For example, the load control system100may include a load control device102and one or more components (e.g., sensors, remote control units, etc.) configured to wirelessly communicate with the load control device102, for example to control one or more functions of the load control device102.

The load control device102may be electrically connected between an alternating-current (AC) power source104and an electrical load106. The load control device102may be operable to control an amount of power delivered from the AC source104to the load106. The load106may be a lighting load, for example, or any other electrical load.

The load control device102may be, for example, an electronic switch or a dimmer switch. The load control device102may include a controllably conductive device coupled in series electrical connection between the AC source104and the load106for controlling an amount of power delivered from the AC source104to the load106. For example, the controllably conductive device may include one or more semiconductor power devices, such as, a thyristor (e.g., a triac), a field-effect transistor (FET) in a rectifier bridge, two FETs in anti-series connection, one or more insulated-gate bipolar junction transistors (IGBTs), or any suitable bidirectional semiconductor switch. The load control device102may be connected to the AC source104by a first wire108, to the load106by a second wire110, and to an electrical path between the load106and a neutral side of the AC source104by a third wire112. The first wire108may be referred to as a hot wire, the second wire110may be referred to as a switched-hot or dimmed-hot wire, and the third wire112may be referred to as a neutral wire. In this regard, the illustrated load control device102may be referred to as a three-wire load control device. However it should be appreciated that the load control system100is not limited to a three-wire load control device, and that the load control system100can alternatively employ a two-wire load control device that does not require a connection to the neutral side of the AC source104.

The controllably conductive device (not shown) may operate in respective non-conductive and conductive states within respective portions of each half cycle of an AC waveform provided by the AC source104. The controllably conductive device may be switched between the non-conductive and conductive states, respectively, in response to a triggering signal. In a forward phase-control system, generation of a triggering signal may be synchronized with an AC line voltage supplied by the AC source104such that the triggering signal is generated at a certain time after a zero-crossing is detected. A zero-crossing may be the time at which an AC supply voltage of the AC source104transitions from positive to negative polarity, or from negative to positive polarity, at the beginning of each half-cycle. Responsive to the triggering signal, a gate of the controllably conductive device may be energized, causing the controllably conductive device to operate in the conductive state for the remainder of the AC half cycle.

During the time interval between the zero-crossing and the gate triggering, the controllably conductive device may operate in the non-conductive state. When the controllably conductive device is operating in the non-conductive state, effectively no power is supplied to the load106. The load control device102may be configured to allow for alteration of the time interval, such as in response to adjustment of a user-operable control (e.g., a dimming knob or a slider) or in response to changes in a dimming level signal. Altering the time interval between the zero crossing and the gate triggering (and, thereby affecting the conduction angle of the controllably conductive device) affects the amount of power delivered to the load106. See, for example, commonly-assigned U.S. Pat. No. 5,430,356, entitled “Programmable Lighting Control System With Normalized Dimming For Different Light Sources,” which is incorporated herein by reference in its entirety. Thus, the controllably conductive device may be switched to affect the AC voltage waveform provided to the load106, thereby controlling the power delivered to the load106.

The load control device102may be configured for wireless communication and the load control system100may include one or more remote control devices configured to wirelessly communicate with and remotely control the load control device102. In this regard, the load control device102may be referred to as a wireless load control device. For example, the load control system100may include an occupancy sensor114, a daylight sensor116, or a remote control118, such as a remote keypad, for example. Each of the occupancy sensor114, the daylight sensor116, and the remote control unit118may be configured to wirelessly communicate with the load control device102over respective wireless communication links to control one or more functions of the load control device102. For example, the occupancy sensor114, the daylight sensor116, and the remote control118may each transmit radio-frequency (RF) signals120to the load control device102. The wireless communication links may be the same or different, and may include one or more of a Clear Connect RF link, a WiFi link, a cellular wireless link, a Bluetooth link, a ZigBee® link, for example.

FIG.2is an exploded view of the load control device102. The load control device102may include a number of components, including a faceplate assembly130, a button assembly140, a yoke300, a cradle150, an antenna400, a printed circuit board (PCB)170, a rear cover180, and one or more fasteners for securing one or more of the components of the load control device102in an assembled configuration, for example screws190for securing the yoke300to the rear cover180.

The illustrated rear cover180has a substantially rectangular shape defined by an upper wall181, a lower wall182that is spaced from the upper wall181along a longitudinal direction L, opposed side walls183that are spaced apart from each other along a lateral direction A that extends substantially perpendicular with respect to the longitudinal direction L, and a rear wall184. The rear cover180may define an open front end185that is spaced from the rear wall along a transverse direction T that extends substantially perpendicular to both the longitudinal direction L and the lateral direction A. It should be appreciated that the while the lateral and transverse directions L, T are oriented substantially toward the right or left and the longitudinal direction L is oriented substantially up or down, that the orientation of the load control device102may vary during use.

The upper wall181, lower wall182, side walls183, and rear wall184of the rear cover180may define a cavity186that extends into the front end185of the rear cover180along the transverse direction T. The cavity186may be sized to at least partially enclose one or more components of the load control device102when the load control device102is assembled, and may operate to protect one or more components of the load control device102. The illustrated rear cover180includes four receptacles187located proximate to respective intersections of the upper and lower walls181,182with the side walls183. The receptacles187may be configured to receive fasteners used to secure one or more components of the load control device102in an assembled configuration. For example, inner surfaces of the receptacles187may be threaded so as to engage with corresponding threads of the screws190.

The illustrated PCB170includes a substrate body that defines a first surface170aof the PCB170and an opposed second surface170bof the PCB170that is spaced from the first surface170aalong the transverse direction T. The substrate body may be sized such that the PCB170may be received in the cavity186of the rear cover180. For example, the PCB may have an upper end171, an opposed lower end172that is spaced from the upper end171along the longitudinal direction L and first and second opposed sides173spaced apart from each other along the lateral direction A. A spacing of the upper end171from the lower end172along the longitudinal direction L may be shorter than a spacing between respective inner surfaces of the upper and lower walls181,182of the rear cover180along the longitudinal direction L, and a spacing from one side173to the other along the lateral direction A may be shorter than a spacing between respective inner surfaces of the side walls183of the rear cover180along the lateral direction A.

Electrical components may be attached (e.g., mounted) to one or both of the first and second surfaces170a,170band placed in electrical communication with electrical circuits defined on the first and second surfaces170a,170bof the PCB170and/or in a body of the PCB. For example, a plurality of switches174that may be operated to control one or more functions of the load control device102may be mounted on the first surface170aof the PCB170. An RF communication circuit (not shown) may be mounted to the PCB170. The RF communication circuit may include an RF transmitter, an RF receiver, and/or an RF transceiver. The RF communication circuit may be operable to transmit and receive RF signals at a communication frequency (e.g., communication frequency f RF) for controlling one or more functions of the load control device102.

The faceplate assembly130may have any suitable shape, such as the illustrated substantially flat, rectangular shape. The faceplate assembly130may include an adapter131and a faceplate132. The adapter131may be configured to be attached to the yoke300and the faceplate132may be configured to be releasably attached to the adapter131, for example as described in commonly-assigned U.S. Pat. No. 4,835,343, entitled “Two Piece Face Plate For Wall Box Mounted Device,” which is incorporated herein by reference in its entirety. The components of the faceplate assembly130, for example the adapter131and the faceplate132, may be made of any suitable material, for example metal or plastic. The faceplate assembly130(e.g., the adapter131and the faceplate132) may define an opening133that extends through the faceplate assembly130along a direction that is substantially parallel to the transverse direction T. The opening133may be sized to receive at least a portion of the button assembly140when the faceplate assembly130is attached to the yoke300. It should be appreciated that the load control device102is not limited to the illustrated faceplate assembly130, and that the load control device102may employ any suitable faceplate, or no faceplate, as desired.

FIGS.3A-3Cdepict an example yoke300that may be used, for example, with the load control device102. The yoke300may be made of any suitable material, such as metal. The yoke300may include a plate member302that defines an upper end302a, an opposed lower end302bthat is spaced from the upper end302aalong the longitudinal direction L, opposed first and second sides302c,302dthat are spaced from each other along the lateral direction A, an outer surface302e, and an inner surface302fthat is spaced from the outer surface302ealong the transverse direction T. The outer and inner surfaces302e,302fof the plate member302may be planar surfaces that are substantially coplanar with a plane defined by the longitudinal direction L and the lateral directions A.

The plate member302may have a section of material removed therefrom so as to define an opening304sized to receive one or more components of the load control device102, for example the opening304may be sized to receive at least a portion of the cradle150therein. The opening304extends into the second side302dof the plate member302. The plate member302may at least partially define a perimeter306of the opening304.

The perimeter306of the illustrated opening304includes an upper portion306a, a lower portion306b, a side portion306c, first and second offset portions306d,306e, and third and fourth offset portions306f,306g. The upper portion306aextends substantially parallel to the lateral direction A, is spaced from the upper end302aalong the longitudinal direction L, and is located nearer the upper end302athan the lower end302b. The lower portion306bextends substantially parallel to the lateral direction A, is spaced from the lower end302balong the longitudinal direction L, and is located nearer the lower end302bthan the upper end302a. The side portion306cextends substantially parallel to the longitudinal direction L, is spaced from the first side302calong the lateral direction A, and is located nearer the first side302cthan the second side302d.

The first and second offset portions306d,306eare angularly offset relative to both the longitudinal and lateral directions L, A, and extend between the upper and side portions306a,306cand the lower and side portions306b,306c, respectively. The third and fourth offset portions306f,306gare angularly offset relative to both the longitudinal and lateral directions L, A, and extend from the second side302dto respective ends of the upper and lower portions306a,306bthat are nearest the second side302d, such that the opening304is narrowed along the longitudinal direction L between the second side302dand the upper and lower portions306a,306bof the perimeter306. The plate member302is closed at the first side302cand is at least partially open at the second side302d, such that the plate member302, and more generally the yoke300, is substantially “C” shaped. It should be appreciated that the opening304of the plate member302is not limited to the illustrated geometry, and that the plate member302may alternatively define any other suitable opening geometry, for instance an opening having a perimeter with closed sides spaced from one another along the lateral direction A.

The third and fourth offset portions306f,306gmay operate to guide one or more components into a received position within the opening304. As shown, the third and fourth offset portions306f,306gmay operate to guide at least a portion of the cradle150into an inserted position in the opening304if the cradle150is disposed into an inserted position within the opening304along a direction from that is substantially parallel to the lateral direction A (e.g., right to left inFIG.3B).

The plate member302may define one or more attachment members configured to allow a shorting member to be attached to the yoke300, as described elsewhere herein. The illustrated plate member302defines a pair of opposed channels309that are recessed in the outer surface302eof the plate member302, proximate the upper and lower ends302a,302b, respectively. The illustrated channels309are sized to at least partially receive respective ends of a shorting wire314, for example as depicted inFIGS.6A-6B.

The yoke300may include one or more tab members that may be configured to facilitate attachment of the load control device102to a suitable receptacle, for example a single gang electrical wallbox. The yoke300may include an upper tab member308athat extends upward from the upper end302aof the plate member302along the longitudinal direction L and an opposed lower tab member308bthat extends downward from the lower end302bof the plate member302along the longitudinal direction L. One or both of the upper and lower tab members308a,308bmay be substantially coplanar relative to the plate member302and may be offset from the plate member302along the transverse direction T, for example offset forward from the outer surface302e, such that the plate member302is recessed along the transverse direction T relative to the upper and lower tab members308a,308b. The upper and lower tab members308a,308bmay be integral, for example monolithic, with the plate member302or may be separate from the plate member302and attached thereto.

One or more of the plate member302, the upper tab member308a, and the lower tab member308bmay define respective apertures (e.g., apertures301,303,305,307) that extend there through, for example along a direction that extends substantially parallel to the transverse direction T. The apertures301in the upper tab member308aand the lower tab member308bmay be sized to receive screws to attach the yoke300to an electrical wallbox, which may be made of, for example, metal or plastic. The apertures303in the upper tab member308aand the lower tab member308bmay be sized to receive screws that may also be received in complementary apertures of one or more components of the faceplate assembly130to attach the faceplate to the yoke300. One or more of the apertures305,307may be sized to at least partially receive one or more components of the load control device102or respective attachment members supported by the one or more components, for example the screws190, one or more attachment members of the button assembly140, or one or more attachment members of the cradle150, as described elsewhere herein.

The yoke300may include one or more flange members that may be oriented so as to be angularly offset relative to the plate member302. For example, the illustrated yoke300includes a flange member310located along the first side302cof the plate member302that extends inwardly relative to inner surface302f. The illustrated flange member310may be defined in a plane that is angularly offset with respect to the plane of the plate member302, for example substantially normal with respect to the plate member302.

The flange member310may define a base310athat extends along at least a portion of the plate member302, an inner edge310bthat is spaced from the base310a, and opposed upper and lower edges310c,310dthat extend from the base310ato the inner edge310band may be spaced from one another, for example along the longitudinal direction L. The flange member310may further define a first, outer surface310eand an opposed second, inner surface310fthat is spaced from the outer surface310e, for example along the lateral direction A.

The outer surface310emay be spaced from the first side302cof the plate member302by a distance D1along the lateral direction A such that the flange member310is received in the rear cover180when the yoke300is in an assembled position relative to the rear cover180. For example, the outer surface310emay be spaced from the first side302cof the plate member302such that the distance D1is approximately equal to (e.g., slightly shorter than) a thickness of a corresponding side wall183of the rear cover180. The inner edge310bof the flange member310may be spaced from the base310aby a distance D2along the transverse direction T such that the inner edge310bextends substantially to the rear wall184of the rear cover180when the yoke300is attached to the rear cover180. The base310a, inner edge310b, and the upper and lower edges310c,310dmay define a perimeter of the flange member310.

The base310aof the illustrated flange member310extends along a portion of the first side302cof the plate member302between the upper and lower ends302a,302band the inner edge310bextends substantially parallel to the longitudinal direction L. The upper and lower edges310c,310dhave respective first portions and second portions. The first portions extend between the base310aand the second portions, and are angularly offset with respect to each other and with respect to the transverse direction T, such that the flange member310is tapered between the base310aand the second portions. The second portions extend substantially parallel to the transverse direction T between the first portions and the inner edge310b.

The flange member310may be configured to enable the attachment of one or more electrical components of the load control device102, for example to enable the attachment of one or more semiconductor power devices (e.g., controllably conductive devices, such as triacs, FETs, or the like) to the flange member310rather than to the PCB170(e.g., the first or second surfaces170a,170bof the PCB170). The flange member310may define one or more apertures312configured to receive respective fasteners of one or more electrical components that are mounted to the flange member310. The one or more apertures312may extend through the flange member310, for example along a direction that is substantially normal to the outer and inner surfaces310e,310f. For example, the illustrated flange member310defines four apertures312that are substantially aligned with one another along the longitudinal direction L.

The illustrated apertures312allow the mounting of up to four semiconductor power devices (e.g., four triacs) to the flange member310. A semiconductor power device may be secured to the flange member310using a select one of the apertures312and may be electrically connected to the PCB170, for example by soldering the semiconductor power device to one or more electrical circuits defined on the second surface170bof the PCB170. With the yoke300in an assembled position relative to the rear cover180, one or more semiconductor power devices attached to the flange member310may be enclosed by the rear cover180and the plate member302of the yoke300, such that the semiconductor power devices are housed within the load control device102. One or more semiconductor power devices may be attached to the flange member310in desired positions, for example using one or more of the apertures312. In this regard, the load control device102may be configured to house a variable number of semiconductor power devices.

Mounting one or more semiconductor power devices to the flange member310rather than to the yoke300, allows for flexibility and modularity in configuring the load control device102in accordance with different applications (e.g., configurations). Moreover, if fewer than four semiconductor power devices are specified for a particular configuration of the load control device102(e.g., a load control device102having one triac), any one of the four apertures312may be selected for use in securing the triac.

The flange member310may dissipate heat generated by one or more semiconductor power devices secured to the flange member310. For example, heat generated by a semiconductor power device secured to the flange member310may be conducted into the flange member310and through the plate member302to one or both of the upper and lower tab members308a,308b.

The flange member310may be integral, for example monolithic, with the plate member302or may be separate from the plate member302and attached thereto. For example, the flange member310, the upper and lower tab members308a,308b, and the plate member302may be monolithic, such that the yoke300may be made from a single piece of material. The yoke300may be stamped from a piece of a substantially flat piece of sheet metal. The upper and lower tab members308a,308band the flange member310may be formed by bending respective portions of the sheet metal. Apertures of the yoke300, for instance the apertures312, may be punched, drilled, or otherwise defined in the sheet metal of the yoke300, for example before the upper and lower tab members308a,308band the flange member310are bent into position.

It should be appreciated that if the flange member310is sized to be substantially equal to or smaller in size than the opening304, that at least a portion of the material removed from a first yoke to define the opening thereof may define the flange member310of an adjacent, successive second yoke. In this regard, it can be said that the flange member of the first yoke is nested in the opening of the second yoke with regards to a manufacturing process that produces the first and second yokes (e.g., a stamping process). It should further be appreciated that the flange member310is not limited to the illustrated geometry, and that the flange member can be alternatively constructed with any suitable geometry. It should further still be appreciated that the yoke300is not limited to a single flange member as illustrated, and that the yoke300may include any suitable number of flange members in the same or different locations relative to the plate member302, as desired.

FIGS.4A-4Cdepict an example yoke350that may be used, for example, with the load control device102, for example in the place of the yoke300. The yoke350may be made of any suitable material, such as metal. The yoke350may include a plate member352that defines an upper end352a, an opposed lower end352bthat is spaced from the upper end352aalong the longitudinal direction L, opposed first and second sides352c,352dthat are spaced from each other along the lateral direction A, an outer surface352e, and an inner surface352fthat is spaced from the outer surface352ealong the transverse direction T. The outer and inner surfaces352e,352fof the plate member352may be planar surfaces that are substantially coplanar with a plane defined by the longitudinal direction L and the lateral directions A.

The plate member352may have a section of material removed therefrom so as to define an opening354sized to receive one or more components of the load control device102, for example the opening354may be sized to receive at least a portion of the cradle150therein. The opening354extends through the plate member352along the transverse direction T. The plate member302may at least partially define a perimeter356of the opening354. The cradle150may be inserted into the opening354, along a direction substantially parallel to the transverse direction T, for example.

The perimeter356of the illustrated opening354includes an upper portion356a, a lower portion356b, a first side portion356c, first and second offset portions356d,356e, and a second side portion356f. The upper portion356aextends substantially parallel to the lateral direction A, is spaced from the upper end352aalong the longitudinal direction L, and is located nearer the upper end352athan the lower end352b. The lower portion356bextends substantially parallel to the lateral direction A, is spaced from the lower end352balong the longitudinal direction L, and is located nearer the lower end352bthan the upper end352a. The first side portion356cextends substantially parallel to the longitudinal direction L, is spaced from the first side352calong the lateral direction A, and is located nearer the first side352cthan the second side352d. The second side portion356fextends substantially parallel to the longitudinal direction L, is spaced from the second side352dalong the lateral direction A, and is located nearer the second side352dthan the first side352c.

The first and second offset portions356d,356eare angularly offset relative to both the longitudinal and lateral directions L, A, and extend between the upper and first side portions356a,356cand the lower and first side portions356b,356c, respectively. It should be appreciated that the opening354of the plate member302is not limited to the illustrated geometry, and that the plate member352may alternatively define any other suitable opening geometry.

The yoke350may include one or more tab members that may be configured to facilitate attachment of the load control device102to a suitable receptacle, for example a single gang electrical box. The yoke350may include an upper tab member358athat extends upward from the upper end352aof the plate member352along the longitudinal direction L and an opposed lower tab member358bthat extends downward from the lower end352bof the plate member352along the longitudinal direction L. One or both of the upper and lower tab members358a,358bmay be substantially coplanar relative to the plate member352and may be offset from the plate member352along the transverse direction T, for example offset forward from the outer surface352e, such that the plate member352is recessed along the transverse direction T relative to the upper and lower tab members358a,358b. The upper and lower tab members358a,358bmay be integral, for example monolithic, with the plate member352or may be separate from the plate member352and attached thereto.

One or more of the plate member352, the upper tab member358a, and the lower tab member358bmay define respective apertures (e.g., apertures351,353,355,357) that extend there through, for example along a direction that extends substantially parallel to the transverse direction T. The apertures351in the upper tab member358aand the lower tab member358bmay be sized to receive screws to attach the yoke350to an electrical wallbox, which may be made of, for example, metal or plastic. The apertures353in the upper tab member358aand the lower tab member358bmay be sized to receive screws that may also be received in complementary apertures of one or more components of the faceplate assembly130to attach the faceplate to the yoke350. One or more of the apertures355,357may be sized to at least partially receive one or more components of the load control device102or respective attachment members supported by the one or more components, for example the screws190, one or more attachment members of the button assembly140, or one or more attachment members of the cradle150.

The yoke350may include one or more flange members that may be oriented so as to be angularly offset relative to the plate member352. For example, the illustrated yoke350includes a flange member360located along the first side352cof the plate member352that extends inwardly relative to inner surface352f. The illustrated flange member360may be defined in a plane that is angularly offset with respect to the plane of the plate member352, for example substantially normal with respect to the plate member352.

The flange member360may define a base360athat extends along at least a portion of the plate member352, an inner edge360bthat is spaced from the base360a, and opposed upper and lower edges360c,360dthat extend from the base360ato the inner edge360band may be spaced from one another, for example along the longitudinal direction L. The flange member360may further define a first, outer surface360eand an opposed second, inner surface360fthat is spaced from the outer surface360e, for example along the lateral direction A.

The outer surface360emay be spaced from the first side352cof the plate member352a distance D3along the lateral direction A such that the flange member360is received in the rear cover180when the yoke350is in an assembled position relative to the rear cover180. For example, the outer surface360emay be spaced from the first side352cof the plate member352such that the distance D3is approximately equal to (e.g., slightly shorter than) a thickness of a corresponding side wall183of the rear cover180. The inner edge360bof the flange member360may be spaced from the base360aa distance D4along the transverse direction T such that the inner edge360bextends substantially to the rear wall184of the rear cover180when the yoke350is attached to the rear cover180. The base360a, inner edge360b, and the upper and lower edges360c,360dmay define a perimeter of the flange member360.

The base360aof the illustrated flange member360extends along a portion of the first side352cof the plate member352between the upper and lower ends352a,352band the inner edge360bextends substantially parallel to the longitudinal direction L. The upper and lower edges360c,360dhave respective first portions and second portions. The first portions extend between the base360aand the second portions, and are angularly offset with respect to each other and with respect to the transverse direction T, such that the flange member360is tapered between the base360aand the second portions. The second portions extend substantially parallel to the transverse direction T between the first portions and the inner edge360b.

The flange member360may be configured to enable the attachment of one or more electrical components of the load control device102, for example to enable the attachment of one or more semiconductor power devices (e.g., controllably conductive devices, such as triacs, FETs, or the like) to the flange member360rather than to the PCB170(e.g., the first or second surfaces170a,170bof the PCB170). The flange member360may define one or more apertures362configured to receive respective fasteners of one or more electrical components that are mounted to the flange member360. The one or more apertures362may extend through the flange member360, for example along a direction that is substantially normal to the outer and inner surfaces360e,360f. For example, the illustrated flange member360defines four apertures362that are substantially aligned with one another along the longitudinal direction L.

The illustrated apertures362allow the mounting of up to four semiconductor power devices (e.g., four triacs) to the flange member360. A semiconductor power device may be secured to the flange member360using a select one of the apertures362and may be electrically connected to the PCB170, for example by soldering the semiconductor power device to one or more electrical circuits defined on the second surface170bof the PCB170. With the yoke350in an assembled position relative to the rear cover180, semiconductor power devices attached to the flange member360may be enclosed by the rear cover180and the plate member352of the yoke350, such that the semiconductor power devices are housed within the load control device102. One or more semiconductor power devices may be attached to the flange member360in desired positions, for example using one or more of the apertures362. In this regard, the load control device102may be configured to house a variable number of semiconductor power devices.

Mounting one or more semiconductor power devices to the flange member360rather than to the yoke350, allows for flexibility and modularity in configuring the load control device102in accordance with different applications (e.g., configurations). Moreover, if fewer than four semiconductor power devices are specified for a particular configuration of the load control device102(e.g., a load control device102having one triac), any one of the four apertures362may be selected for use in securing the triac.

The flange member360may dissipate heat generated by one or more semiconductor power devices secured to the flange member360. For example, heat generated by a semiconductor power device secured to the flange member360may be conducted into the flange member360and through the plate member352to one or both of the upper and lower tab members358a,358b.

The flange member360may be integral, for example monolithic, with the plate member352or may be separate from the plate member352and attached thereto. For example, the flange member360, the upper and lower tab members358a,358b, and the plate member352may be monolithic, such that the yoke350may be made from a single piece of material. The yoke350may be stamped from a piece of a substantially flat piece of sheet metal. The upper and lower tab members358a,358band the flange member360may be formed by bending respective portions of the sheet metal. Apertures of the yoke350, for instance the apertures352, may be punched, drilled, or otherwise defined in the sheet metal of the yoke350, for example before the upper and lower tab members358a,358band the flange member360are bent into position.

FIGS.5A-5Cdepict an example antenna400that may be used by the load control device102for wireless communication, for example for wireless communication between the load control device102and one or more components of the load control system (e.g., the occupancy sensor114, the daylight sensor116, the remote control unit118, etc.). The antenna may be made of any suitable material, such as metal. The antenna400may be made from a length of wire having a first end402that is configured to be attached to the PCB170and a free second end404. The first end402may be attached to the PCB170, for instance may by soldering the first end402to a corresponding electrical contact disposed on the first surface170aof the PCB170, so as to place the antenna400in electrical communication with the PCB170.

The antenna400may be configured as a formed monopole antenna (e.g., a bent or articulated monopole antenna) having two loops, including a first, inner loop406(e.g., an inner bend) and a second, outer loop408(e.g., an outer bend) that at least partially surrounds the inner loop406, including the second end404. The shape of the antenna400, including the inner and outer loops406,408may be defined by a number of distinct sections. For example, the illustrated antenna400includes a first section410that extends from the first end402along a direction that is substantially parallel to the transverse direction T to a first bend412. The first section410may define a length L1along the transverse direction T such that the inner and outer loops406,408are spaced a predetermined distance from the first surface170aof the PCB170.

The outer loop408may begin with the first bend412. The first bend412is approximately ninety degrees. A second section414of the antenna extends upward from the first bend412along a direction that is substantially parallel to the longitudinal direction L to a second bend416. The second bend416is approximately ninety degrees. A third section418of the antenna400extends from the second bend416along a direction that is substantially parallel to the lateral direction A to a third bend420. The third bend420is approximately forty five degrees. A relatively short fourth section422extends along a direction that is angularly offset with respect to both the lateral direction A and the transverse direction T, between the third bend420and a fourth bend424. The fourth bend424is approximately forty five degrees. A fifth section426extends downward from the fourth bend424along a direction that is substantially parallel to the longitudinal direction L to a fifth bend428, such that the fifth section426is substantially parallel to the second section414. The fifth bend428is approximately forty five degrees. A relatively short sixth section430extends along a direction that is angularly offset with respect to both the lateral direction A and the transverse direction T, from the fifth bend428to a sixth bend432. The sixth bend432is approximately forty five degrees. A seventh section434of the antenna400extends from the sixth bend432along a direction that is substantially parallel to the lateral direction A to a seventh bend436, where the outer loop408may end. The seventh section434is substantially parallel to and shorter than the third section418.

The inner loop406may begin with the seventh bend436. The seventh bend436is approximately ninety degrees. An eighth section438extends upward from the seventh bend436along a direction that is substantially parallel to the longitudinal direction L to an eighth bend440, such that the eighth section438is substantially parallel to both the second section414and the fifth section426. The eighth bend440is approximately ninety degrees. A ninth section442extends from the eighth bend440along a direction that is substantially parallel to the lateral direction A to a ninth bend444. The ninth bend444is approximately ninety degrees. The ninth section442is substantially parallel to and shorter than the seventh section434. A tenth section446extends downward from the ninth bend444along a direction that is substantially parallel to the longitudinal direction L to the second end404, such that the tenth section446is substantially parallel to the second section414, the fifth section426, and the eighth section438.

The outer loop408of the antenna400may have a first height H1defined by the third section418and the seventh section434, and a first width W1defined by the second section414and the fifth section426. The inner loop406of the antenna400has a second height H2defined by the seventh bend436and the ninth section442and a second width W2defined by the eighth section438and the tenth section446. The second height H2may be shorter than the first height H1and the second width W2may be narrower than the first width W1, such that the inner loop406is defined substantially within the outer loop408and may be said to be at least partially enclosed by the outer loop408.

Wireless communication performance of the antenna400(e.g., a tuned frequency of the antenna) was found to be tunable in accordance with structural characteristics of the antenna400, including one or more of the following: an overall length of the wire of the antenna400(e.g., as defined by the first end402and the second end404; spacing between adjacent segments of the inner and outer loops406,408; a spacing between the inner and outer loops406,408of the antenna400and the outer surface302eof the plate member302, as described elsewhere herein; and respective locations and angles of the bends. A desired level of wireless communication performance was achieved when the second section414is spaced a distance D5from the eighth section438along the lateral direction A, the eighth section438is spaced a distance D6from the tenth section446along the lateral direction A, the tenth section446is spaced a distance D7from the fifth section426along the lateral direction A, the third section418is spaced from the ninth section442a distance D8along the longitudinal direction L, and the second end404is spaced from the seventh section434a distance D9along the longitudinal direction L, wherein D5is longer than both D6and D7, respectively, but shorter than a sum of D6and D7, and wherein D8is approximately equal to, for example slightly shorter than, D9.

Both the inner and outer loops406,408may be substantially coplanar relative to each other and substantially coplanar with respect to a plane defined by the longitudinal direction L and the lateral direction A. It should be appreciated that the antenna400of the load control device102is not limited to the illustrated geometry, and that the antenna400may be alternatively constructed. The antenna may alternatively define more or fewer segments, more or fewer bends of the same or different angles, more or fewer loops that may or may not partially enclose one another, loops defined in planes that are partially or completely noncoplanar with respect to each other, and so on, for example to accommodate different button configurations.

FIGS.6A-6Ddepict an example partial assembly of the load control device102, with the yoke300. The yoke300and the antenna400are depicted in assembled positions relative to each other. Other components of an assembled load control device102, for example as depicted inFIG.2, are omitted fromFIGS.6A-6Din order to more clearly illustrate the location and orientation of the antenna400with respect to the yoke300in an assembled load control device102. In an assembled load control device102, the antenna400may be at least partially supported in its installed position relative to the yoke300by one or both of a physical connection established between the first end402and the PCB170(e.g., a solder joint) and one or more physical connections established between the antenna400and the cradle150, as described elsewhere herein.

In an assembled position relative to the yoke300, one or more portions of the antenna400, such as respective sections and bends of the outer loop408, may be spaced from corresponding portions of the perimeter306of the opening304along the lateral direction A and/or the longitudinal direction L. With the first end402of the antenna400attached to the PCB170and the PCB170and the yoke300attached to the rear cover180, at least a portion of the first section410of the antenna may protrude through the opening304of the plate member302, such that the inner and outer loops406,408of the antenna400are spaced from the outer surface302eof the plate member302a distance D10. The distance D10was found to be an important characteristic in tuning the antenna400to achieve the desired level of wireless communication performance of the load control device102.

The load control device102may be mounted to a metal or plastic wallbox and one or more components of the faceplate assembly130(e.g., the adapter131and the faceplate132) may be made of metal or plastic. The load control device102may be configure such that an impedance of the antenna400, and thus a transmission and/or a reception range of the antenna400may be substantially consistent over various installation conditions. When the load control device102is installed in a metal wallbox or with a faceplate assembly130made of metal, electric fields produced when the antenna400is transmitting may cause current to flow through the metal wallbox and/or through the metal faceplate assembly in a loop.

However, when the load control device102is installed in a plastic wallbox and with a faceplate assembly130made of plastic, the current may not flow in a loop, for example because of the opening304. To account for such a condition, the load control device102may include an electrically conductive shorting member, for example an electrically conductive shorting wire314that may be attached to the yoke300(e.g., to the plate member302) so as to complete a “ring” around the opening304, such that current is able to flow in a loop through the yoke300, for example when the antenna400is transmitting. Respective portions of the shorting wire314may be disposed into corresponding ones of the channels309and secured therein (e.g., using solder).

FIGS.7A and7Billustrate current flow around the yoke300without and with a shorting member installed. The shorting wire314illustrated inFIGS.6A and6Bis replaced with an electrically conductive shorting strap316. It was found that the shorting wire314and the shorting strap316may be used interchangeably with the yoke300to achieve substantially the same effect with regards to current flow around the yoke300. The illustrated shorting strap316may be secured to the plate member302, for example, via screws190that also secure one or more of the yoke300, the cradle150, and the PCB170to the rear cover180.

When the load control device102does not include a shorting member and is installed in a plastic wallbox with a faceplate assembly130made of plastic, current flow through the yoke300(e.g., through the plate member302) is disrupted, as illustrated by the flow path602shown inFIG.7A. When a shorting member, for example the shorting strap316, is attached to the plate member302, as depicted inFIG.7B, current flow through the yoke300(e.g., through the plate member302) is not disrupted, as illustrated by the flow path604. This may also be the case when the load control device102does not include a shorting member and is installed in a metal wallbox or with a faceplate assembly130made of metal. Therefore, the shorting member may ensure that current may flow through the yoke300(e.g., by establishing the flow path604) and that the impedance of the antenna400remains relatively constant independent of a type of wallbox to which the load control device102, with the yoke300, is mounted and/or a type of faceplate attached to the load control device102.FIG.7Cillustrates an example current flow through the yoke350. As shown, the current flow through the yoke350(e.g., through the plate member352) is not disrupted, as illustrated by the flow path606. The impedance of the antenna400, when used with the yoke305, may remain relatively constant independent of a type of wallbox to which the load control device102, with the yoke350, is mounted and/or a type of faceplate attached to the load control device102.

The tolerances of the electrical components of the RF communication circuit mounted to the PCB170may also affect the wireless communication performance of the antenna400by causing the communication frequency f RF to move away from the tuned frequency of the antenna400. However, the structure of the antenna400provides a low Q-factor, such that slight changes in the communication frequency f RF do not greatly affect the magnitude of the RF signals transmitted by the RF communication circuit (i.e., the antenna has a relatively flat gain curve). Therefore, the antenna400may not need to be fine-tuned during manufacturing of the load control device102(e.g., to bring the communication frequency f RF back towards the tuned frequency of the antenna400), and the RF communication circuit may be operable to more consistently transmit the RF signals in a variety of installations (e.g., with plastic or metal wallboxes or with plastic or metal faceplate assemblies).

Referring now toFIGS.8A-8B and9A-9C, the PCB170may include one or more switches174that are mounted to the first surface170aof the PCB170and are electrically connected to corresponding electrical circuits of the PCB170, such that activation of a select one of the one or more switches174may control one or more functions of the load control device102. The illustrated PCB170has five switches disposed on the first surface170aof the PCB170, including a first switch174a, a second switch174b, a third switch174c, a fourth switch174d, and a fifth switch174e.

The button assembly140may include a frame142that may define any suitable shape, such as substantially rectangular. The frame142may be configured to support one or more buttons144that may be depressed to control corresponding functions of the load control device102when the button assembly140. The frame142of the illustrated button assembly140supports five buttons144, including a first button144a, a second button144b, a third button144c, a fourth button144d, and a fifth button144e. Each of the buttons144may be depressed to activate a corresponding switch174on the PCB170, as described elsewhere herein.

The button assembly140may include one or more attachment members configured to engage with complementary engagement members of one or more other components of the load control device102, such that the button assembly140may be supported independently of the yoke300. For example, the button assembly140may have one or more attachment members designed to engage with complementary engagement members of the cradle150, for example such that the button assembly is supported directly by the cradle150. If the button assembly140is supported independently of the yoke300, deformation of the button assembly140that may cause one or more of the buttons144to fail to operate properly (e.g., deformation of the frame142) may be mitigated. The button assembly140may include one or more attachment members, for example one or more resilient cantilevered latches146and one or more rigid posts148, that are configured to be received by complementary engagement members of the cradle150, as described elsewhere herein. The illustrated button assembly may include three latches146(only two are depicted) and two posts148that extend inward from the frame142along a direction that is substantially parallel to the transverse direction T.

The cradle150includes a base152that may have any suitable shape, such as the illustrated substantially rectangular, plate shape. The base152defines an upper end152a, an opposed lower end152bthat is spaced from the upper end152aalong the longitudinal direction L, opposed first and second sides152c,152dthat are spaced from each other along the lateral direction A, and opposed outer and inner surfaces152e,152fthat are spaced from each other along the transverse direction T. The base152may define a channel151along the second side152dthat is configured to receive at least a portion of the antenna shorting wire314. Opposed ends of the channel151may substantially align with the channels309defined by the yoke300when the cradle150is attached to the yoke300.

A spacing of the upper end152afrom the lower end152balong the longitudinal direction L may be substantially equal to a spacing from the upper end302aof the plate member302of the yoke300to the lower end302balong the longitudinal direction L, and a spacing from the first side152to the second side152dalong the lateral direction A may be substantially equal to a spacing from the second side302dto the inner surface310fof the flange member310along the lateral direction A. The outer surface152eof the base152may be configured to contact at least a portion of the inner surface302fof the plate member302when the cradle150and the yoke300are in an assembled position relative to each other.

The cradle150may include one or more walls154that extend rearward from the inner surface152fof the base152, for example along a direction substantially parallel to the transverse direction T. For example, the cradle150may include walls154that, in combination with the base152, define a protective enclosure over electrical components attached to the first surface170aof the PCB170, such as the switches174. The walls154may include one or more attachment members, such as posts (not shown), that may be received in press fit engagement in corresponding apertures defined in the substrate body of the PCB170(e.g., through the substrate body along the transverse direction T), so as to secure the PCB170to the cradle150. One or more portions of the first surface170aof the PCB170may abut corresponding edges of the walls154when the PCB170is attached to the cradle150.

The cradle150may include a projection156that extends forward from the outer surface152eof the base152. The projection156may have any suitable shape. The projection156may include a front wall158that defines an outer perimeter of the projection156and a perimeter wall160that extends from the front wall158to the outer surface152eof the base152along substantially an entirety of the outer perimeter of the front wall158. The front wall158and the perimeter wall160may define a cavity configured to at least partially receive the antenna400, as described elsewhere herein.

The perimeter wall160of the illustrated projection156defines an upper section160athat extends along the lateral direction A, a lower section160bthat extends along the lateral direction A and is spaced from the upper section160aalong the longitudinal direction L, opposed first and second side sections160c,160dthat are spaced from each other along the lateral direction A, a first angled section160ethat is angularly offset with respect to both the longitudinal direction L and the lateral direction A and extends from the upper section160ato the first side section160c, and a second angled section160fthat is angularly offset with respect to both the longitudinal direction L and the lateral direction A and extends from the lower section160bto the first side section160c.

As shown, the perimeter wall160substantially conforms to the shape of the opening304in the plate member302of the yoke300, such that when the cradle150is attached to the yoke300, the upper and lower sections160a,160b, the first side sections160c, and the first and second angled sections160e,160f, fit closely to corresponding portions of the perimeter306of the opening304and the projection156protrudes forward from the opening304along the transverse direction T. The perimeter wall160substantially conforms to the shape of the opening354in the plate member352of the yoke350, such that when the cradle150is attached to the yoke350, the upper and lower sections160a,160b, the first side sections160c, and the first and second angled sections160e,160f, fit closely to corresponding portions of the perimeter356of the opening354and the projection156protrudes forward from the opening354along the transverse direction T.

The cradle150may include one or more activation members configured to transmit a force applied to a button144of the button assembly140to a corresponding switch174of the PCB170. For example, the illustrated cradle150includes five cantilevered button paddles162defined in the front wall158of the projection156. Each button paddle162has a base end161that is anchored in the front wall158and an opposed free end163that is movable, for example along the transverse direction T, with respect to the base end161.

The free end163of each of the illustrated button paddles162supports a post164that extends rearward from the free end163along the transverse direction T and is configured to activate a corresponding switch174disposed on the PCB. When a button144of the button assembly140is depressed, a portion of the button144will make contact with a corresponding button paddle162and cause the button paddle162to be biased inward along the transverse direction T, such that the post164of the button paddle causes a corresponding switch174disposed on the PCB170to be activated.

The illustrated cradle150has five button paddles162defined in the front wall158. A first button paddle162ais defined proximate the upper section160aof the perimeter wall160. The base end161of the first button paddle162ais located proximate an intersection of the upper section160aand the second side section160d. The free end163of the first button paddle162ais spaced from the base end161along the lateral direction A and is substantially aligned with the base end161along the longitudinal direction L. The first button paddle162ais configured to be biased inwardly by the first button144a, thereby activating the first switch174a.

A second button paddle162bis defined proximate to the lower section160bof the perimeter wall160. The base end161of the second button paddle162bis located proximate an intersection of the lower section160band the second side section160d. The free end163of the second button paddle162bis spaced from the base end161along the lateral direction A and is substantially aligned with the base end161along the longitudinal direction L. The second button paddle162bis configured to be biased inwardly by the second button144b, thereby activating the second switch174b.

A third button paddle162cis defined proximate the first side section160cof the perimeter wall160. The base end161of the third button paddle162cis located nearer the lower section160bof the perimeter wall160than the upper section160a. The free end163of the third button paddle162cis spaced from the base end161along the longitudinal direction L and is substantially aligned with the base end161along the lateral direction A. The third button paddle162cis configured to be biased inwardly by the third button144c, thereby activating the third switch174c.

A fourth button paddle162dis defined proximate the second side section160dof the perimeter wall160. The base end161of the fourth button paddle162dis located nearer the upper section160aof the perimeter wall160than the lower section160b. The free end163of the fourth button paddle162dis spaced from the base end161along both the longitudinal direction L and the lateral direction A. The fourth button paddle162dis configured to be biased inwardly by the fourth button144d, thereby activating the fourth switch174d.

A fifth button paddle162eis defined between the third and fourth button paddles162c,162d. The base end161of the fifth button paddle162eis located nearer the upper section160aof the perimeter wall160than the lower section160b. The free end163of the fifth button paddle162eis spaced from the base end161along the longitudinal direction L and is substantially aligned with the base end161along the lateral direction A. The fifth button paddle162eis configured to be biased inwardly by the fifth button144e, thereby activating the fifth switch174e.

The cradle150may function with button assemblies other than the illustrated button assembly140, such as button assemblies having more or fewer buttons than the button assembly140. For example, a first alternative button assembly140′ that may be used with the cradle150is illustrated inFIG.9B. The button assembly140′ may be constructed substantially similarly to the button assembly140, but with only four buttons, including a first button144a′ that operates similarly to the first button144a, a second button144b′ that operates similarly to the second button144b, a third button144c′ that operates similarly to the third button144c, and a fourth button144d′ that operates similarly to the fourth button144d.

A second alternative button assembly140″ that may be used with the cradle150is illustrated inFIG.9C. The button assembly140″ may be constructed substantially similarly to the button assembly140and the button assembly140′, but with only three buttons, including a first button144a″ that operates similarly to the first button144a, a second button144b″ that operates similarly to the second button144b, and a third button144c′ that operates similarly to the fifth button144e. In this regard, the cradle150may accommodate a plurality of button configurations. Accordingly, the load control device102may be configured with a plurality of different button configurations.

The cradle150allows for flexibility and modularity in configuring the load control device102. For example, a button assembly (e.g., the button assembly140,140′,140″, etc.) may be selected for use with the cradle150based, for example, upon a desired number of functions of the load control device102that will be controlled by the buttons of the button assembly. It should be appreciated that the load control device102is not limited to the button assemblies illustrated inFIGS.9A-9C, and that button assemblies with more or fewer buttons may be constructed for use with the cradle150.

The cradle150may be configured to receive at least a portion of the antenna400. The outer and inner loops408,406of the antenna400may be received in the cavity of the projection156such that the outer and inner loops408,406do not interfere with operation of any of the button paddles162. For example, the outer and inner loops408,406of the antenna400may be disposed in spaces between the posts164of the button paddles162, as illustrated inFIG.8B.

The antenna400may be attached to an inner surface of the front wall158of the projection156. For example, the outer and inner loops408,406of the antenna400may be attached to the inner surface of the front wall158at one or more locations using a bonding agent. The projection156may include an antenna support member (not shown) that extends inward from the inner surface of the front wall158along the transverse direction T. The antenna support member may extend, for example, from the inner surface of the front wall158to the first surface170aof the PCB170when the PCB170is attached to the cradle150. The antenna support member may at least partially enclose a portion of the antenna400that it supports, for example the first section410of the antenna400.

The cradle150may include one or more sets of attachment members configured to allow the cradle150to be attached to one or more other components of the load control device102. For example, the cradle may include a first set of attachment members configured to engage with complementary attachment members of the button assembly140to secure the cradle150and the button assembly140to one another. The cradle150may include a second set of attachment members configured to engage with the yoke300to secure the cradle150to the yoke300.

The first set of attachment members includes three apertures166that extend through the base152of the cradle150along a direction that is substantially parallel to the transverse direction T. Each aperture166may be configured to received and releasably engage with a corresponding latch146of the button assembly140. The first set of attachment members includes a pair of silos168that extend forward from the outer surface152eof the base152along the transverse direction T. Each silo168may be configured to receive a corresponding post148of the button assembly140in press fit engagement. The button assembly140may be attached to the cradle150by aligning the latches146with the apertures166and the posts148are aligned with the silos168, and then biasing the cradle150and the button assembly140toward one another along the transverse direction T until each latch146snaps into an engaged positions within a respective one of the apertures166.

The second set of attachment members includes resilient cantilevered latches169that extend forward from the outer surface152eof the base152along the transverse direction T. Each latch169may be configured to be received in and releasably engage with a corresponding aperture307defined in the yoke300. The cradle150may be attached to the yoke300by aligning the latches169with corresponding apertures307and then biasing the cradle150and the yoke300toward one another along the transverse direction T until each latch169snaps into an engaged positions within a respective one of the apertures307. It should be appreciated that the cradle150is not limited to the illustrated first and second sets of attachment members, and that the cradle150may include any suitable attachment members to facilitate securing the cradle to one or both of the button assembly140and the yoke300, or to another component of the load control device102.

The cradle150may be configured to ease insertion of the cradle150into an inserted position within the opening304of the yoke300along a direction from that is substantially parallel to the lateral direction A (e.g., right to left inFIG.3B). The cradle150may be alternatively constructed without the silos168and the latches169, such that portions of the outer surface152eof the base152, for example a first portion at least partially bordered by the upper section160aand first angled section160eof the perimeter wall160and the upper end152aand first side152cof the base152and a second portion at least partially bordered by the lower section160band second angled section160fof the perimeter wall160and the lower end152band first side152cof the base152, are substantially smooth. When the cradle150is so constructed, the outer surface152eof the base152of the cradle150may abut and may slide along the inner surface302fof the plate member302of the yoke300as the cradle150is inserted into the opening304of the yoke300along a direction from that is substantially parallel to the lateral direction A.

Referring now toFIGS.10A-10B and11A-11B, the faceplate assembly130may be configured to enhance one more wireless communication performance characteristics of the load control device102.FIG.11Adepicts an example of wireless communication of the load control device102if the adapter131and the faceplate132of the faceplate assembly130are made of an electrically insulative material, for example plastic. In this configuration, the antenna400may provide the load control device102with a first wireless transmission range.

The faceplate130may be configured to extend the wireless communication range of the load control device102, for example beyond the first wireless communication range associated with the example configuration ofFIG.11A. In this regard, the faceplate assembly130may be referred to as a range extending faceplate assembly.

FIG.10Aillustrates a faceplate assembly130that includes an adapter131and a faceplate132that are both made of an electrically insulative material, such as plastic. The adapter131includes a first pair of apertures134aand a second pair of apertures134bthat extend through the adapter131along a direction that is substantially parallel to the transverse direction T. The first pair of apertures134ais located such that each aperture134asubstantially aligns with a corresponding aperture303of the yoke300when the adapter131is attached to the yoke300. The second pair of apertures134bis located such that each aperture134bsubstantially aligns with a corresponding aperture301of the yoke300when the adapter131is attached to the yoke300. The illustrated faceplate assembly130includes a pair of screws135that may be disposed in the apertures134aand screwed into the apertures303of the yoke300so as to attach the adapter131to the yoke300. The screws135may be made of an electrically conductive material, such as metal. As described elsewhere herein, the faceplate132may be configured to attach to the adapter131, for example once the adapter131is secured to the yoke300.

The illustrated faceplate assembly130may further include an electrically conductive member136that is configured to be attached to the adapter131such that the electrically conductive member136is spaced from the yoke300along the transverse direction T when the adapter131is attached to the yoke300. The conductive member136may be made of any suitable electrically conductive material, such as metal. The conductive member136may comprise a metallic label affixed to the adapter131.

The electrically conductive member136may have any suitable shape, such as the illustrated substantially plate like shape. The illustrated electrically conductive member136defines any opening137that is sized to be larger than the opening133defined by the adapter131and the faceplate132. The opening137may define an inner perimeter of the electrically conductive member136that is spaced from one or more portions of a perimeter defined by the opening133when the electrically conductive member136is attached to the adapter131. The illustrated electrically conductive member136is sized so as to be enclosed within the faceplate assembly130(e.g., covered by the faceplate132). The illustrated electrically conductive member136may be attached to an outer surface131aof the adapter131. However, the electrically conductive member136is not limited to attachment to the outer surface131a. For example, the electrically conductive member136may be attached to an inner surface of the adapter131, embedded within the adapter131, or otherwise attached supported by the adapter131or faceplate132as desired.

The electrically conductive member136may be configured to be placed in electrical communication with the yoke300. For example, the electrically conductive member136may define a pair of apertures138,139that are located such that each aperture substantially aligns with corresponding apertures134a,303of the adapter131and the yoke300, respectively, when the electrically conductive member136is attached to the adapter131and the adapter131is attached to the yoke300. A first, upper aperture138of the pair may be sized such that a first metal screw135disposed in the upper aperture138and driven into a corresponding aperture134aof the yoke300will place the electrically conductive member136in electrical communication with the yoke300. A second, lower aperture139of the pair may be sized to be larger than the upper aperture138, such that when a second metal screw135is disposed in the lower aperture139and driven into a corresponding aperture134aof the yoke300, the second metal screw135will not make contact with the electrically conductive member136, and thus will not place the electrically conductive member136in electrical communication with the yoke300. When the electrically conductive member136and the adapter131are attached to the yoke300in this manner, the faceplate assembly130, in particular the electrically conductive member136, may operate as a patch antenna that may cooperate with the antenna400, for example as depicted inFIG.11B, to provide the load control device102with a second wireless transmission range that is broader than the first wireless transmission range.

Referring now toFIG.12, an alternative faceplate assembly1130is illustrated. Elements of the faceplate assembly1130labeled with reference numerals that refer to like elements of the faceplate assembly130, incremented by1000, may be assumed to be substantially the same as those of the faceplate assembly130, unless otherwise described herein. The faceplate assembly1130may include an electrically conductive member1136(e.g., a decorative metal surface) that is configured to be attached to the faceplate1132, for example an outer surface of the faceplate1132. The electrically conductive member1136may be configured to be placed in electrical communication with the yoke300at one end (e.g., at only one end) of the yoke300, as shown inFIG.12. For example, the illustrated electrically conductive member1136includes a post1136a(e.g., a tab or “finger”) that is configured to abut a metal screw135used to secure the adapter1131to the yoke300, such that the electrically conductive member1136is placed in electrical communication with the yoke300when the faceplate1132is attached to the adapter1131. The faceplate1132may define an aperture1132athat extends through the faceplate1132along a direction that is substantially parallel to the transverse direction T and is sized to receive the post1136awhen the electrically conductive member1136is attached to the faceplate1132.

Referring now toFIGS.13-15, the load control device102is not limited to the range extending faceplate assemblies130,1130. For example, the load control device102may be alternatively configured with a one piece faceplate1230that may be configured to operate as a range extending faceplate. The faceplate1230may define an opening1233that may be sized substantially the same as the opening133of the faceplate assembly130, for example. The faceplate1230may define one or more apertures configured to receive fasteners in order to attach the faceplate1230to the yoke300. For example, the faceplate1230may include a pair of apertures1234that extend through the faceplate1230along a direction that is substantially parallel to the transverse direction T and are configured to receive screws1235that attach the faceplate1230to the yoke300.

FIG.14illustrates a one piece range extending faceplate1230that is made of metal and attached to the yoke300using a first electrically conductive screw1235athat may be made of an electrically conductive material (e.g., metal) and a second electrically insulative screw1235bthat may be made of an electrically insulative material (e.g., plastic). The faceplate1230may be placed in electrical communication with the yoke300via the first electrically conductive screw1235a, such that the faceplate1230operates as a patch antenna that may cooperate with the antenna400, for example as depicted inFIG.11B, to provide the load control device102with a second wireless transmission range that is broader than the first wireless transmission range.

FIG.15illustrates an alternative one piece range extending faceplate1230′ that is made of metal and attached to the yoke300using two electrically insulative screws1235bthat may be made of an electrically insulative material (e.g., plastic). The faceplate1230′ is constructed substantially the same as the faceplate1230, including an opening1233′ and two apertures1234′ configured to receive the screws1235b, but further includes a silo1230a′ that extends from an inner surface of the faceplate1230′ along a direction that is substantially parallel to the transverse direction T and that is configured to at least partially receive a respective one of the electrically insulative screws1235b. The silo1230a′ may define a length along the transverse direction T such that a free end of the silo1230a′ abuts at least a portion of the yoke300when the faceplate1230′ is attached to the yoke300, thereby placing the faceplate1230′ in electrical communication with the yoke300. The silo1230a′ may be made of an electrically conducive material, such as metal. The silo1230a′ and faceplate1230′ may be monolithic, and may be made of the same metal.