DESC:TECHNICAL FIELD

The present disclosure relates to electrical switching devices. More particularly, the present disclosure relates to a dual ampere switch assembly applicable for household appliances and automotive applications. The dual ampere switch assembly can be designed compact in size suitable for operating at high ampere ratings, which are useful, particularly for automobiles such as two-wheeled vehicles.

BACKGROUND

The information in this section merely provides background information related to the present disclosure and may not constitute prior art(s) for the present disclosure.

The design of switches for vehicles, household appliances, and other high-current applications is crucial, as the design must be selected based on the switches ability to safely handle high currents while providing reliable control over powerful electrical components. The types of switches used for high amperage in various applications can differ based on the specific needs and electrical requirements of each device.

Vehicles, particularly the two-wheeled vehicles are widely used around the world due to their efficiency and manoeuvrability in traffic. The two-wheeled vehicles are typically equipped with switch assemblies that control various electrical components, including lighting devices, signal indicators, and horns. The switch assembly includes one or more actuation mechanisms designed to activate or deactivate these components while ensuring the rider's safety and enhancing the overall riding experience.
Currently, the switch assemblies face several challenges related to their space requirements and the one or more actuation mechanisms. Further, the installation of switch assemblies and the actuation mechanisms require a significant space which increases the space requirement of each switch assembly. For example, several switch assemblies are required to be installed in a vehicle to control various functions associated with different applications, which requires more space for installation. As such, if the size of each switch assembly is large as in the case of existing switch assemblies, the total space requirement for all the switch assemblies is also increased. Therefore, a switch assembly having reduced space requirements is desirable.

Another drawback of the existing switch assemblies is the generation of arc discharge before engagement or just after disengagement of contact points within the switch assemblies. For example, when the switch assembly is used for opening and closing a large current, arc discharge occurs between a movable contact portion and a fixed terminal at the time of switching between a conduction state and a non-conduction state (insulation state). The occurrence of the arc discharge can cause wear of the movable contact portion or the fixed terminal. Therefore, considering these challenges, an actuation mechanism that enhances durability without compromising ergonomics or increasing costs is therefore desirable.

Accordingly, in view of the above-mentioned problems, it is desirable to provide a switch assembly that can eliminate the issues associated with the existing art.

The drawbacks/difficulties/disadvantages/limitations of the conventional techniques explained in the background section are just for exemplary purposes and the disclosure would never limit its scope only such limitations. A person skilled in the art would understand that this disclosure and below mentioned description may also solve other problems or overcome the other drawbacks/disadvantages of the conventional arts which are not explicitly captured above.

SUMMARY

This summary is provided to introduce a selection of concepts, in a simplified format, that are further described in the detailed description of the invention. This summary is neither intended to identify key or essential inventive concepts of the invention nor intended to determine the scope of the invention.

In an embodiment of the present disclosure, a dual ampere switch assembly comprising a housing, a base assembly, an actuation unit, and a movable connection member is disclosed. The base assembly is coupled to the housing, the base assembly comprising a pair of terminals, each electrically coupled to a respective fixed connection member. Each of the pair of fixed connection members has a predefined profile to enable the contact surface ideal for high ampere current transfer. Further, the movable connection member slidably disposed in the housing and adapted to slide upon actuation from the actuation unit to make selective contact with the fixed connection member. The movable connection member includes a pair of ends adapted to make multiple contacts with the surface of the pair of fixed connection members.

According to the present disclosure, the compact design of the dual ampere switch assembly ensures that the overall packaging size is reduced thereby minimizing the space requirements of the switch. Further, the dual ampere switch assembly can operate at high ampere ratings as well thus making the dual ampere switch assembly adaptable in nature. Moreover, the dual ampere switch assembly includes the movable connection member of a cylindrical geometry which allows for a different region of the movable connection member to make contact with the fixed connection member thus reducing the chances of wear and tear. Furthermore, due to the biasing forces of the second spring, the contact between the movable connection member and the fixed connection member is smooth which further ensures a reduction in arc discharge.

To further clarify the advantages and features of the present disclosure, a more particular description of the invention will be rendered by reference to specific embodiments thereof, which are illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail in the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:

Figure 1 illustrates an exploded view of a dual ampere switch assembly with a support member, in accordance with an embodiment of the present disclosure;
Figure 2 illustrates an exploded view of the dual ampere switch assembly, in accordance with an embodiment of the present disclosure;
Figure 3 illustrates an assembled view of the dual ampere switch assembly, in accordance with an embodiment of the present disclosure;
Figure 4 illustrates a cut-sectional view of the dual ampere switch assembly along axis A-A’ in Figure 3, in accordance with an embodiment of the present disclosure;
Figure 5 illustrates a perspective view of a base assembly in the dual ampere switch assembly, in accordance with an embodiment of the present disclosure;
Figure 6 illustrates a front view of a fixed connection member of the base assembly, in accordance with an embodiment of the present disclosure;
Figure 7(a) illustrates a side view of the dual ampere switch assembly in an open configuration, in accordance with an embodiment of the present disclosure; and
Figure 7(b) illustrates a side view of the dual ampere switch assembly in a closed configuration, in accordance with an embodiment of the present disclosure.

Further, skilled artisans will appreciate that elements in the drawings are illustrated for simplicity and may not have necessarily been drawn to scale. For example, the flow charts illustrate the method in terms of the most prominent steps involved to help to improve understanding of aspects of the present invention. Furthermore, in terms of the construction of the device, one or more components of the device may have been represented in the drawings by conventional symbols, and the drawings may show only those specific details that are pertinent to understanding the embodiments of the present invention so as not to obscure the drawings with details that will be readily apparent to those of ordinary skilled in the art having the benefit of the description herein.

DETAILED DESCRIPTION OF FIGURES

For the purpose of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated system, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skilled in the art to which this invention belongs. The system, methods, and examples provided herein are illustrative only and not intended to be limiting.

The term “some” as used herein is defined as “none, or one, or more than one, or all.” Accordingly, the terms “none,” “one,” “more than one,” “more than one, but not all” or “all” would all fall under the definition of “some.” The term “some embodiments” may refer to one embodiment or to several embodiments or to all embodiments. Accordingly, the term “some embodiments” is defined as meaning “one embodiment, or more than one embodiment, or all embodiments.”

The terminology and structure employed herein are for describing, teaching and illuminating some embodiments and their specific features and elements and do not limit, restrict or reduce the scope of the claims or their equivalents.

More specifically, any terms used herein such as but not limited to “includes,” “comprises,” “has,” “consists,” and grammatical variants thereof do NOT specify an exact limitation or restriction and certainly do NOT exclude the possible addition of one or more features or elements, unless otherwise stated, and furthermore must NOT be taken to exclude the possible removal of one or more of the listed features and elements, unless otherwise stated with the limiting language “MUST comprise” or “NEEDS TO include.”

Whether or not a certain feature or element was limited to being used only once, either way, it may still be referred to as “one or more features” “one or more elements” “at least one feature” or “at least one element.” Furthermore, the use of the terms “one or more” or “at least one” feature or element does NOT preclude there being none of that feature or element, unless otherwise specified by limiting language such as “there NEEDS to be one or more . . . ” or “one or more element is REQUIRED.”

Unless otherwise defined, all terms, and especially any technical and/or scientific terms, used herein may be taken to have the same meaning as commonly understood by one having an ordinary skill in the art.

Reference is made herein to some “embodiments.” It should be understood that an embodiment is an example of a possible implementation of any features and/or elements presented in the attached claims. Some embodiments have been described for the purpose of illuminating one or more of the potential ways in which the specific features and/or elements of the attached claims fulfil the requirements of uniqueness, utility, and non-obviousness.

Use of the phrases and/or terms such as but not limited to “a first embodiment,” “a further embodiment,” “an alternative embodiment,” “one embodiment,” “an embodiment,” “multiple embodiments,” “some embodiments,” “other embodiments,” “a further embodiment”, “furthermore embodiment”, “additional embodiment” or variants thereof do NOT necessarily refer to the same embodiments. Unless otherwise specified, one or more particular features and/or elements described in connection with one or more embodiments may be found in one embodiment or may be found in more than one embodiment, or may be found in all embodiments, or may be found in no embodiments. Although one or more features and/or elements may be described herein in the context of only a single embodiment, or alternatively in the context of more than one embodiment, or further alternatively in the context of all embodiments, the features and/or elements may instead be provided separately or in any appropriate combination or not at all. Conversely, any feature and/or element described in the context of separate embodiments may alternatively be realized as existing together in the context of a single embodiment.

Any particular and all details set forth herein are used in the context of some embodiments and therefore should NOT be necessarily taken as limiting factors to the attached claims. The attached claims and their legal equivalents can be realized in the context of embodiments other than the ones used as illustrative examples in the description below.

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The present disclosure provides a dual ampere switch assembly for varying applications, which requires a compact switch capable of operating at high ampere ratings. The dual ampere switch assembly includes housing, a base assembly, an actuation unit, and a movable connection member, which may all be arranged in a compact design to ensure the overall packaging size thereof. The base assembly is configured with a pair of terminals, each electrically coupled to a respective fixed connection member. The pair of fixed connection members, each having a predefined profile to enable the contact surface to be ideal for high ampere current transfer. Therefore, the fixed connection member makes contact with movable connection members at multiple points on the surface. The movable connection member is slidably disposed in the housing and is designed with a pair of ends each adapted to make multiple contacts with the pair of fixed connection members.

Embodiments of the present disclosure will be described below in detail with reference to the accompanying drawings.

Further, skilled artisans will appreciate those elements in the drawings are illustrated for simplicity and may not have necessarily been drawn to scale.

Figure 1 illustrates an exploded view of the dual ampere switch assembly 100 with a support member 108, in accordance with an embodiment of the present disclosure. Figure 2 illustrates an exploded view of the dual ampere switch assembly 100, in accordance with an embodiment of the present disclosure. Figure 3 illustrates an assembled view of the dual ampere switch assembly 100, in accordance with an embodiment of the present disclosure. Figure 4 illustrates a cut-sectional view of the dual ampere switch assembly 100 along axis A-A’ in Figure 3, in accordance with an embodiment of the present disclosure. For the sake of brevity, Figure 1 to Figure 4 have been explained together.

The dual ampere switch assembly 100 may be installed in vehicles, and household appliances which may include but are not limited to microwaves and refrigerators, industrial control systems, automotive components, and medical devices, but more importantly in vehicles, particularly two-wheeled vehicles. The compact size, high sensitivity, and ability to endure a plurality of operation cycles of the dual ampere switch assembly 100, make that essential in safety mechanisms, limit detection, and control systems. Thus, the dual ampere switch assembly 100 may be reliable, efficient, and versatile across a wide range of industries. In the subsequent paragraphs, the dual ampere switch assembly 100 may interchangeably be referred to as the switch assembly 100, without departing from the scope of the present disclosure

In an embodiment, the switch assembly 100 may be embodied as a microswitch. Herein, the microswitch can be an electromechanical switch designed to operate with minimal physical force. Further, the switch assembly 100 is a dual ampere microswitch assembly, which may work at current ratings ranging between 0.1 micro-ampere (mA) and 5 Ampere. The switch assembly 100 may have a snap-action mechanism that may allow the switch assembly 100 to change states quickly and reliably. The switch assembly 100 is commonly used in applications requiring precision, durability, and frequent switching.

The switch assembly 100 may include but is not limited to, base assembly 101, a movable connection member 102, a first spring 103, a plunger 104, a second spring 105, a covering member 106, and a housing 107.

The base assembly 101 may be coupled to the housing 107, where the base assembly 101 may include a pair of terminals 101a, 101b, a fixed connection member 101c, and a second spring 105. In an embodiment, a portion of the base assembly 101 may be made of plastic material or any similar material. The base assembly 101 may be inserted within the housing 107 and the pair of terminals 101a, 101b may protrude outwardly from the housing 107. Further, each of the pair of terminals 101a, 101b are electrically coupled to a respective fixed connection member 101c.

Further, each of the pair of terminals 101a, 101b may be secured in the base assembly 101 using a locking mechanism. In an embodiment, the pair of terminals 101a, 101b of the base assembly 101 may be made of copper material with gold or silver plating or any other similar metallic material. Furthermore, each of the pair of the fixed connection member 101c may have a predefined profile to enable the contact surface adequate for high ampere current transfer. In an embodiment, the fixed connection member 101c of the base assembly 101 may be made of copper material with gold or silver plating or any similar material. The details of the fixed connection member 101c have been discussed in detail later with reference to Figure 5 and Figure 6.

The base assembly 101 and the housing 107 may also include the second spring 105 which may be biased against the plunger 104. Further, the switch assembly 100 may include the support member 108 which may be used to mount the switch assembly 100 onto a fixed mounting location ensuring proper operation and safety.

In one of the embodiments, the support member 108 may include a mount and an epoxy sealant. Herein, the mount may be used to mount the switch assembly 100 onto a handlebar of the two-wheeled vehicle. The support member 108 may be filled with an epoxy-based material for sealing a bottom part of the support member 108 and the base assembly 101 from an external environment thus forming the epoxy sealant.

The actuation unit may be slidably disposed within the housing 107, where the actuation unit may be placed on top of the base assembly 101. The actuation unit may include but is not limited to, the plunger 104, the first spring 103, and the movable connection member 102.

The plunger 104 may include a close end, a bottom portion, and a pair of opposite-facing longitudinal slits along a length of the plunger 104. The plunger 104 may be adapted to receive the moving connection member 102. In an embodiment, the plunger 104 may be made of a plastic material or any similar material. Further, the first spring 103 may be disposed in the plunger 104 and the first spring 103 may be biased against the movable connection member 102. In an embodiment, the first spring 103 and the second spring 105 may be made of stainless steel material or any similar material.

The movable connection member 102 may be slidably disposed in the housing 107 and may be configured to slide upon actuation from the actuation unit to make selective contact with the fixed connection member 101c. In an embodiment, the movable connection member 102 may be made of copper material with gold or silver plating or any similar material. The movable connection member 102 may be manufactured as a cylindrical component, which may include a pair of ends and the pair of ends are adapted to make multiple contacts with the surface of the pair of fixed connection members 101c. The movable connection member 102 may be used to engage with the fixed connection member 101c via the first spring 103.

Additionally, the movable connection member 102 may be engaged with the plunger 104 via the second spring 105. The movable connection member 102 may slide in order to establish a butt contact with the fixed connection member 101c. The butt contact may include the first spring 103 for operation and the second spring 105 to maintain contact pressure between the movable connection member 102 and the fixed connection member 101c. The cylindrical structure of the movable connection member 102 may rotate along a central axis and correspondingly slide on the pair of fixed connection members 101c to avoid the wearing of the movable connection member 102 and the switch assembly 100.

In one of the exemplary embodiments of the present invention, the movable connection member 102 has a circular cross-section, specifically in capsule shape with hemispherical ends connected by a cylindrical middle section. The cylindrical mid-section may contribute an enhanced contact with the fixed connection member 101c of the base assembly 101. The cylindrical outer surface of the movable connection member 102 ensures multiple contact points with the fixed connection member 101c of the base assembly 101.

The provision of the second spring 105 may further ensure that an arc discharge of the switch assembly 100 is reduced since the contact between the movable connection member 102 is smooth. This may be possible due to the biasing force of the second spring 105. The movable connection member 102 is adapted to move from a first position to a second position upon receiving a force on the plunger 104. Similarly, the movable connection member 102 may be adapted to move from the second position to the first position upon receiving a biasing force from the first spring 103 in the absence of the force on the plunger 104.

The covering member 106 may be provided for the top sealing of the switch assembly 100 and may be manufactured of an elastic material such as rubber. The covering member 106 may be disposed in a hole and may be used to cover the top end of the plunger 104. Once assembled, the base assembly 101, the movable connection member 102, the first spring 103, the plunger 104, and the second spring 105 are enclosed within the housing 107. In an embodiment, the housing 107 may be designed such that the housing 107 is easily snap-fitted to an adaptor that is removably fastened to the mounting location on the two-wheeled vehicle. In an embodiment, the housing 107 may be made of plastic material or any similar material.

The housing 107 may include a hole, and the top end of the plunger 104 protrudes from the hole. The hole in the housing 107 may be a circular opening, which may have a diameter greater than that of the plunger 104. The hole allows for the top of the plunger 104 to protrude through the housing, which facilitates the actuation of the switch assembly 100 using the plunger 104. The hole may be covered using the covering member 106 which acts as an outermost surface, which receives the user interaction with the switch assembly 100.

Figure 5 illustrates a perspective view of a base assembly 101 of the switch assembly 100, in accordance with an embodiment of the present disclosure. Figure 6 illustrates a front view of a fixed connection member 101c of the base assembly 101, in accordance with an embodiment of the present disclosure. The base assembly 101 includes the pair of terminals 101a, 101b. The base assembly 101 defines the fixed connection member 101c for receiving the movable connection member 102. Referring to the description of the fixed connection member 101c with reference to Figure 1 to Figure 4, the predefined profile of the pair of fixed connection members 101c is at least one of a V-shaped and a U-shaped profile.

In an embodiment, the fixed connection member 101c may have the U-shaped profile incorporated at a bottom end of the V-shaped profile, thus combining the two profiles. The movable connection member 102 is adapted to be engaged with the fixed connection member 101c via the first spring 103. The provision of the V-shape and the U-shape for the fixed connection member 101c ensures presence of multiple points of contact when the movable connection member 102 is seated within the fixed connection member 101c.

Figure 7a illustrates a side view of the switch assembly 100 in a normally open configuration, in accordance with an embodiment of the present disclosure. Figure 7a shows the OFF position of the switch assembly 100 where the movable connection member 102 may not be in contact with the fixed connection member 101c. As shown in Figure 7a, the covering member 106 has not been used by the user of the two-wheeled vehicle. This further denotes that the first spring 103, the plunger 104, and the second spring 105 have not been actuated which allows the movable contact member 102 to stay undisturbed in an unactuated position. Thus, based on the aforementioned configuration, the switch assembly 100 may be in the OFF state and does not allow for a flow of current.

Figure 7b illustrates a side view of the switch assembly 100 in a normally closed configuration, in accordance with an embodiment of the present disclosure. Figure 7b shows an ON position of the switch assembly 100 where the movable connection member 102 may be in contact with the fixed connection member 101c. As shown in Figure 7b, the covering member 106 has been used by the user to perform at least one function using the two-wheeled vehicle. This further denotes that the first spring 103, the plunger 104, and the second spring 105 have been actuated which allows the movable contact member 102 to be in an actuated position. Upon actuation of the covering member 106, the plunger 104 may be pushed in a downward direction. The actuation of the plunger 104, thus presses the first spring 103 which allows the plunger 104 to make contact with the movable connection member 102. Further, once contact has been established between the plunger 104 and the movable connection member 102, the movable connection member 102 moves downwards, pressing onto the second spring 105 and thus making contact with the fixed connection member 101c. The contact established between the movable connection member 102 and the fixed connection member 101c is a butt contact which allows for a flow of current. Thus, based on the aforementioned configuration, the switch assembly 100 may be in the ON state and allow for the flow of current.

According to this disclosure, the compact design with a limited number of components, the switch assembly 100 ensures the overall packaging size is reduced thereby reducing the space requirements of the switch assembly 100. Further, the switch assembly 100 operates at high ampere ratings as well thus making the switch adaptable in nature. Moreover, the multiple contact points of the switch assembly 100 allow for high ampere current transmission without leakage currents. Furthermore, the switch assembly 100 includes the movable connection member 102 of the cylindrical geometry which allows for a different region of the movable connection member 102 to make contact with the fixed connection member 101c thus reducing the chances of wear and tear. Additionally, due to the biasing forces of the second spring 105, the contact between the movable connection member 102 and the fixed connection member 101c is smooth which further ensures a reduction in arc discharge.

While specific language has been used to describe the present subject matter, any limitations arising on account thereto, are not intended. As would be apparent to a person in the art, various working modifications may be made to the method in order to implement the inventive concept as taught herein. The drawings and the foregoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment.
,CLAIMS:1. A dual ampere switch assembly (100), comprising:
a housing (107);
a base assembly (101) coupled to the housing (107), the base assembly (101) comprising a pair of terminals (101a, 101b) each electrically coupled to a respective fixed connection member (101c), wherein each of the pair of fixed connection member (101c) having a predefined profile to enable the contact surface adequate for high ampere current transfer;
an actuation unit slidably disposed in the housing (107); and
a movable connection member (102) slidably disposed in the housing (107) and configured to slide upon actuation from the actuation unit to make selective contact with the fixed connection member (101c), wherein the movable connection member (102) includes a pair of ends adapted to make multiple contacts with the surface of the pair of fixed connection members (101c).

2. The dual ampere switch assembly (100) as claimed in claim 1, wherein the actuation unit comprises:
a plunger (104) having a close end, a bottom portion, and a pair of opposite facing longitudinal slits along a length of the plunger (104) and adapted to receive the moving connection member (102);
a first spring (103) disposed in the plunger (104) and adapted to bias against the movable connection member (102); and
a second spring (105) disposed between the base member and the housing and adapted to bias against the plunger (104).

3. The dual ampere switch assembly (100) as claimed in claim 1, wherein the housing (107) includes a hole, and the top end of the plunger (104) protrudes from the hole.

4. The dual ampere switch assembly (100) as claimed in claim 3, comprising a covering member (106) disposed in the hole and adapted to cover the top end of the plunger (104).

5. The dual ampere switch assembly (100) as claimed in claim 1, wherein the predefined profile of the pair of fixed connection members (101c) is at least one of a V-shaped and a U-shaped profile.

6. The dual ampere switch assembly (100) as claimed in claim 5, wherein each of the pair of terminals (101a, 101b) is secured to the base assembly by a locking mechanism.

7. The dual ampere switch assembly (100) as claimed in claim 1, wherein the movable connection member (102) is adapted to rotate along a central axis and slide horizontally on the pair of fixed connection members (101c) to avoid wearing of the movable connection member (102).

8. The dual ampere switch assembly (100) as claimed in claim 1, configured to operate in a range of 0.1 micro-ampere (mA) to 5 ampere (A).

9. The dual ampere switch assembly (100) as claimed in claim 1, wherein the dual ampere switch assembly (100) includes a support member (108) adapted to mount the dual ampere switch assembly (100) onto a fixed mounting location.

10. The dual ampere switch assembly (100) as claimed in claim 9, wherein the support member (108) adapted to be filled with an epoxy-based material for sealing a bottom part of the base assembly (101) from an external environment.