DESC:FIELD OF THE INVENTION

The present disclosure generally relates to switch assemblies. More particularly, the present disclosure relates to a switch assembly having an array of switch units such that each switch unit includes an ON panel, an OFF panel, and a rocker arm.

BACKGROUND

An electrical switch assembly is a device used to start and stop an electrical circuit by permitting or preventing electricity transmission through the switch assembly. Conventionally, the switch assembly includes two switch units for controlling electrical transmission to one or more connected devices. To increase the number of controllable devices for a switch assembly, the number of switch units must be increased. The increased number of switch units results in increased space requirements. This means the size of the frame and other components of the switch assembly may be increased resulting in increased manufacturing or tooling costs. Moreover, the components of the switch assembly may have to be redesigned thereby resulting in increased overall costs for the end consumer.

Therefore, in view of the above-mentioned problems, there is a need to provide an improved switch assembly that can eliminate one or more of the above-mentioned problems associated with the existing switch assemblies.

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 is it intended for determining the scope of the invention.

In an embodiment of the present disclosure, an electric switch, is disclosed. The electric switch includes a housing and a plurality of switch units disposed in the housing. Further, each switch unit of the plurality of switch units comprises a pair of terminals disposed in the housing and adapted to receive a pair of electrical wires, wherein each terminal of the plurality of terminals includes a fixed contact. In addition, the switch unit includes a movable contact pivotably disposed in the housing, wherein the movable contact is adapted to abut a terminal of the pair of terminals, and adapted to pivot to make selective contact with another terminal of the pair of terminals. Furthermore, the electric switch includes a rocker unit pivotably disposed in the housing over the fixed contact, wherein the and adapted to pivot the fixed contact to toggle the switch between an OFF condition and an ON condition. Finally, the electric switch includes a pair of panels pivotably disposed in the housing over the rocker unit, the pair of panels comprising an OFF panel adapted to pivot the rocker unit to put the switch in the OFF condition and an ON panel adapted to pivot the rocker unit to put the switch in the ON condition.

In another embodiment, an electric switch assembly is disclosed. The electric switch assembly includes a base plate having a central opening and a pair of cover plates disposed on the base plate on either side of the central opening. Further, the electric switch assembly includes a plurality of electric switches installed in the central opening, wherein each of the plurality of electric switch includes a housing and a plurality of switch units disposed in the housing. Further, each switch unit of the plurality of switch units comprises a pair of terminals disposed in the housing and adapted to receive a pair of electrical wires, wherein each terminal of the plurality of terminals includes a fixed contact. In addition, the switch unit includes a fixed contact pivotably disposed in the housing, wherein the fixed contact is adapted to abut a terminal of the pair of terminals, and adapted to pivot to make selective contact with another terminal of the pair of terminals. Furthermore, the electric switch includes a rocker unit pivotably disposed in the housing over the fixed contact, wherein the and adapted to pivot the fixed contact to toggle the switch between an OFF condition and the ON condition. Finally, the electric switch includes a pair of panels pivotably disposed in the housing over the rocker unit, the pair of panels comprising an OFF panel adapted to pivot the rocker unit to put the switch in the OFF condition and an ON panel adapted to pivot the rocker unit to put the switch in the ON condition.

The electrical switch of the present disclosure includes multiple switch units in the same form factor as a conventional electrical switch thereby allowing a greater number of electric switches thereby increasing the capability of the electric switch assembly.

To further clarify the advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof, which is 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 invention 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 1A illustrates a perspective view of an electric switch assembly, in accordance with one or more embodiments of the present disclosure;
Figure 1B illustrates an exploded view of various components of the electric switch assembly shown in Figure 1A, in accordance with one or more embodiments of the present disclosure.
Figure 2A illustrates an exploded view of an electric switch having two one-way switch units, in accordance with one or more embodiments of the present disclosure;
Figure 2B illustrates an assembled view of the electric switch having two one-way switch units, in accordance with one or more embodiments of the present disclosure;
Figure 3A illustrates an exploded view of an electric switch two two-way switch units, in accordance with one or more embodiments of the present disclosure; and
Figure 3B illustrates an assembled view of the electric switch two two-way switch units, in accordance with one or more embodiments 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 skill 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 no embodiments or one embodiment or several embodiments or to all embodiments. Accordingly, the term “some embodiments” is defined as meaning “no embodiment, or 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 spirit and 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 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” or “one or more elements” or “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 ordinary skills 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 fulfill 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 alternate embodiment,” “one embodiment,” “an embodiment,” “multiple embodiments,” “some embodiments,” “other embodiments,” “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 features and/or elements 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.

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

Figure 1A illustrates a perspective view of an electric switch assembly 200, in accordance with one or more embodiments of the present disclosure. Figure 2B illustrates an exploded view of the electric switch assembly 200 shown in Figure 1A, in accordance with one or more embodiments of the present disclosure. The electric switch assembly 200 may be adapted to be installed in an electric box embedded in a wall. The electric switch assembly 200 may be designed to allow connection with various electrical connections to control a plurality of electrical devices/appliances. The electric switch assembly 200 may have the same size and shape as a conventional switch assembly but may include a plurality of electrical switches, also commonly known as gangs. The capability of the electrical switch assembly 200 may allow for a greater number of electrical connections.

The electric switch assembly 200, disclosed herein, includes a base plate 202 that may have an opening 204. In addition, the electric switch assembly 200 may include a pair of cover plates 206 disposed on the base plate on either side of the central opening 202. Further, each cover plate 206 may be flush with opposing edges of the base plate 202. In one example, the base plate 202 may include peripheral walls 201a, 201b extending orthogonally from the edges. In one example, the electric switch assembly 200 may include a plurality of electrical switches 100 disposed in the central opening 202. The details of the electrical switch 100 will be provided in the following paragraphs.

Figure 2A illustrates an exploded view of the electrical switch 100 having two one-way switch units 300, in accordance with one or more embodiments of the present disclosure. Figure 2B illustrates an assembled view of the electrical switch 100 having two one-way switch units 300, in accordance with one or more embodiments of the present disclosure.

The electrical switch 100 may include a housing 102 that may accommodate various components of the electrical switch 100. The housing 102 can be made as a single-piece injection molded body. The housing 102 may be designed in such a way that the housing 102 may accommodate the pair of switch units 300. In other words, the switch units 300 and 200 may have a single common housing 102. Although the present illustration shows two switch units 300, a greater number of switch units can be incorporated into the same housing 102. The housing 102 may include a pair of end walls 102-1 formed on opposite ends of the housing 102. In addition, the housing 102 may include a plurality of side walls 102-2 formed on longitudinal sides of the housing 102. In the illustrated example, the housing 102 may include a total of four side walls 102-2.

As mentioned before, the electrical switch 100 may include a plurality of switch units 300. Further, each of the plurality of switch units 300 includes various components. For instance, the switch unit 300 may include a pair of terminals 107 that may be disposed in a cavity inside the housing 102. In one example, each terminal 107 may be rivet pillars and may include provisions to allow the coupling of an electric wire thereto. Accordingly, the pair of terminals 107 may be adapted to receive a pair of electrical wires. Further, each terminal 107 may include a fixed contact 107-1.

Further, the switch unit 300 may include a moving contact 105 disposed above the pair of terminals 107. The moving contact 105 may be made of a single-piece metallic strip that may be bent/stamped into a predefined shape. The moving contact 105 may include a first section that may permanently abut the fixed contact 107-1 of a terminal 107 of the pair of terminals 107, and a second section that may selectively abut the fixed contact 107-1 of another terminal 107 of the pair of terminals 107 to open/close the electrical circuit.

In one example, the switch unit 300 may include a spark shield 106 disposed around the moving contact 105. The spark shield 106, as the name suggests, may be adapted to contain an electric arc generated during the engagement/disengagement of the movable contact 105 with the fixed contact 107-1. The spark shield 106 may include a hollow body with a slab at a center thereof to allow mounting of the movable contact 105. In one example, the movable contact 105 is pivotably mounted, such that the movable contact 105 may flex to selectively abut the fixed contact 107-1. Further, the spark shield 106 may aid the movement of the moving contact 105 therein such that the spark shield 106 is adapted to prevent an electrical fault in the switch unit 300.

Positioned above the movable contact 105 is a rocker unit that actuates the movable contact to open/close the circuit. The rocket unit may include a rocker arm 103 and a plunger 104. The rocker arm 103 may be pivotably mounted to the housing 102 and may be capable of performing see-saw motion. Further, the plunger 104 may be adapted to bend the second section of the movable contact 105 to open/close the electric circuit.

In an example, the rocker arm 103 may be disposed on a rocker hinge to facilitate a seesaw-like movement of the rocker arm 103. The rocker arm 103 is adapted to move in an alternating upward and downward direction about the rocker hinge like the movement of a seesaw. The rocker arm 103 may engage with the plunger 104 via springs. Moreover, the plunger 104 may protrude downward relative to the rocker arm 103. The plunger 104 may be adapted to be in contact with a middle portion of the moving contact 105.

The rocker arm 103 is adapted to alternatively perform a see-saw motion in an upward direction and a downward direction on receipt of force from the ON panel 101-1 and/or the OFF panel 101-2 to achieve the switch ON condition and/or the switch OFF condition respectively. In an embodiment, the moving contact 105 is positioned below the rocker arm 103 and adapted to move corresponding to the rocking movement of the rocker arm 103. In an embodiment, the moving contact 105 may be a one-way moving contact 105. The plunger 104, upon actuation by the rocker arm 103, may be adapted to toggle the switch unit 300 between the switch ON condition and the switch OFF condition and vice versa. The switch unit 300 also includes the spark shield 106 positioned below the rocker arm 103.

In one example, the switch unit 300 may also include a pair of panels, namely an ON panel 101-1 and an OFF panel 101-2. The ON panel 101-1 may adapted to achieve a switch ON condition of the switch unit 300 on application of a downward force thereon. On the other hand, The OFF panel 101-2 is adapted to achieve a switch OFF condition of the switch unit 300 on application of a downward force thereon. In one example, the OFF panel 101-2 may be positioned side to the ON panel 101-1 such that the ON panel 101-1 and the OFF panel 101-2, and the pair of end walls 102-1 collectively form a flat surface. The ON panel 101-1 and the OFF panel 101-2 may pivot independently of each other. Such an arrangement does away a need for a long single-piece rocker arm thereby making the switch unit 300 compact. As a result, the overall length of the switch unit 300 is reduced thereby allowing the packing of multiple switch units 300 in a single gang setup. In one example, a single electric switch may accommodate up to four switch units 300 while keeping the form factor the same as a conventional single gang.

In another example, the rocker arm 103 may have a central axis eccentrically aligned with respect to a center line between the ON panel 101-1 and the OFF panel 101-2. This means the central axis of the rocker arm 103 is offset relative to the center line between the ON panel 101-1 and the OFF panel 101-2. This feature of the rocker arm 103 ensures optimum usage of space and allows a greater number of switch units 300 to be accommodated.

Although not shown, the switch unit 300 includes a first return spring sandwiched between the rocker arm 103 and the ON panel 101-1 such that the first return spring is adapted to push the ON panel 101-1 back into an original position thereof on receipt of force from the ON panel 101-1. This means in the ON condition and the OFF condition, the ON panel 101-1 remains flat and forms a flat surface with the OFF panel 101-2.

Similarly, a second return spring (not shown) is positioned between the rocker arm 103 and the OFF panel 101-2. The second return spring is adapted to push the OFF panel 101-2 back into an original position thereof on receipt of force from the OFF panel 101-2. This means in the ON condition and the OFF condition, the OFF panel 101-2 remains flat and forms a flush surface with the OFF panel 101-2.

The switch unit 300 may also include a visual indicator unit 109 adapted to illuminate to indicate the switch ON condition of the switch unit 300. In an embodiment, the visual indicator unit 109 may include a Light Emitting Diode (LED) 109-1 disposed in the spark shield, such that a portion of the LED 109-1 protrudes through a cut-out section in the rocker arm 103. In addition, the visual indicator unit 109 may include a reflector 109-2 disposed on the rocker arm 103 of the rocker unit. The reflector 109-2 may be made of an optical grade material having a 45-degree angle surface such that the light reflects on the 45-degree angle surface and travels to the visual indicator unit 109 for providing ON/OFF indication.

During the operation, the ON panel 101-1 is adapted to achieve a switch ON condition of the switch unit 300 on application of a downward force thereon. In an embodiment, the OFF panel 101-2 is positioned in a vertical orientation relative to the ON panel 101-1. Moreover, the OFF panel 101-2 is adapted to achieve a switch OFF condition of the switch unit 300 on application of a downward force thereon. The rocker arm 103 has a central axis eccentrically aligned with a center line between the ON panel 101-1 and the OFF panel 101-2. Moreover, the rocker arm 103 is adapted to alternatively pivot in an upward direction and a downward direction on receipt of force from one of the ON panel 101-1 and the OFF panel 101-2 to achieve the switch ON condition and/or the switch OFF condition respectively. The at least two side plates 206 are adapted to be removably coupled to opposing edges (201a, 201b of the base plate 202, such that the array of switch units 300 are disposed in a space defined between the at least two side plates 206.

Figure 3A illustrates an exploded view of an electric switch 100 having two two-way switch units 400, in accordance with one or more embodiments of the present disclosure whereas Figure 3B illustrates an assembled view of the electric switch 100 having two two-way switch units 400, in accordance with one or more embodiments of the present disclosure. A majority of components of the electric switch 100 are identical to the corresponding components shown in Figures 2A and 2B and hence not repeated for the sake of brevity. The components different from the electric switch 100 include a third terminal 302 and a moving contact 304. The switch units 400 may be a two-way switch and therefore include an additional third terminal 302. Further, the moving contact 304 may include a third section that may selectively abut the third terminal 302. In one example, the moving contact 304 is designed in such a way the moving contact with make a permanent connection with one of the terminals 107 and will alternatively make contact with the other terminal 107-1 and the third terminal 302.

According to the present disclosure, the electric switch 300, and 400 have a form factor that allows for accommodating multiple units with the electrical switch 100. Such an arrangement allows for accommodating a greater number of electrical controls with a small size. As a result, the overall size of the electrical switch assembly 200 may be reduced. In one example, the electrical switch assembly 200 may allow for up to six switch unit 300 whereas the conventional switch assembly may only allow for up to two switch units. Moreover, the ON panel 101-1 the OFF panel 101-2, and the pair of cover plates form a flush surface that not only enhances the aesthetic of the electric switch assembly 200, but also prevents ingress of dust into the electric switch assembly 200.

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. An electric switch (100) comprising:
a housing (102);
a plurality of switch units (300, 400) disposed in the housing (102), wherein each switch unit (300, 400) of the plurality of switch units (300, 400) comprises:
a pair of terminals (107) disposed in the housing (102) and adapted to receive a pair of electrical wires, wherein each terminal (107) of the plurality of terminals (107) includes a fixed contact (107-1);
a moving contact (105, 304) pivotably disposed in the housing (102), wherein the moving contact (105, 304) is adapted to abut a terminal (107) of the pair of terminals (107), and adapted to pivot to make selective contact with another terminal (107) of the pair of terminals (107);
a rocker unit pivotably disposed in the housing (102) over the movable contact (105, 304), wherein the rocker unit is adapted to pivot the movable contact (105, 304) to toggle the switch between an OFF condition and an ON condition; and
a pair of panels pivotably disposed in the housing (102) over the rocker unit, the pair of panels comprising an OFF panel (101-2) adapted to pivot rocker unit to put the switch in the OFF condition and an ON panel (101-1) adapted to pivot rocker unit to put the switch in the ON condition.

2. The electric switch (100) as claimed in claim 1, wherein the pivoting of the OFF panel (101-2) and the ON panel (101-1) are independent of each other.

3. The electric switch (100) as claimed in claim 1, wherein each switch unit (300, 400) comprises a spark shield disposed in the housing (102) and positioned around the pair of contact

4. The electric switch (100) as claimed in claim 1, wherein the housing (102) comprises:
a pair of end walls formed on opposite ends of the housing (102); and
a plurality of side walls formed on longitudinal sides of the housing (102), wherein each side wall of the pair of side walls includes a pair of pivoting adapted to receive a mounting hole of adjacent OFF panel (101-2) and ON panel (101-1).

5. The electric switch (100) as claimed in claim 1, wherein each switch unit (400) comprises a third terminal (302), and wherein the moving contact (105, 304) is adapted to adapted to pivot to make contact alternatively with the third terminal (107) and the other terminal (107) of the pair of terminals (107).

6. The electric switch (100) as claimed in claim 1, wherein each switch unit (300, 400) comprises a plurality of spring sandwiched between the rocker unit with the OFF panel (101-2) and the ON panel (101-1), wherein the plurality of springs is adapted to push respective OFF panel (101-2) and ON panel (101-1) to respective home position.

7. The electric switch (100) as claimed in claim 1, wherein each switch unit (300, 400) comprises:
a Light Emitting Diode (LED) (109-1) disposed in a cut-out section in the rocker, such that a portion of the LED (109-1) protrude from the cut-out section, wherein the LED is indicative of ON condition of the switch unit; and
a reflector (109-2) disposed on the rocker unit at angle of 45 degrees and adapted to reflect light from the LED (109-1) towards a diffuser on the ON panel (101-1).

8. The electric switch (100) as claimed in claim 1, wherein the ON panel (101-1), the OFF panel (101-2), and edges of the pair of end walls form a flat surface.

9. An electric switch (100) assembly (200) comprising:
a base plate having a central opening;
a pair of cover plates disposed on the base plate on either side of the central opening; and
a plurality of electric switches (100) installed in the central opening, wherein each of the plurality of electric switch (100) comprising:
a housing (102);
a plurality of switch units (300, 400) dispose in the housing (102), wherein each switch unit (300, 400) of the plurality of switch units (300, 400) comprises:
a pair of terminals (107) disposed in the housing (102) and adapted to receive a pair of electrical wires, wherein each terminal (107) of the plurality of terminals (107) includes a fixed contact (107-1);
a movable contact (105, 304) pivotably disposed in the housing (102), wherein the movable contact (105, 304) is adapted to abut a terminal (107) of the pair of terminals (107), and adapted to pivot to make selective contact with another terminal (107) of the pair of terminals (107);
a rocker unit pivotably disposed in the housing (102) over the movable contact (105, 304), wherein the and adapted to pivot the movable contact (105, 304) to toggle the switch between an OFF condition and an ON condition; and
a pair of panels pivotably disposed in the housing (102) over the rocker unit, the pair of panels comprising an OFF panel (101-2) adapted to pivot the rocker unit to put the switch in the OFF condition and an ON panel (101-1) adapted to pivot the rocker unit to put the switch in the ON condition.

10. The electric switch (100) assembly (200) as claimed in claim 9, wherein the ON panel (101-1) the OFF panel (101-2), and the pair of cover plates forms a flush surface.