DESC:FIELD OF THE INVENTION

The present disclosure generally relates to switch units. More particularly, the present disclosure relates to a housing member for a switch unit adapted to start and stop an operation of a motor.

BACKGROUND

Conventionally, switch units are used in high-load applications where a switching mechanism is required to control an operation of a motor. However, the switching mechanism in existing switch units may have exposed terminals due to improper design of the housing member. The housing member of the switching mechanism in the switch unit affects the safety and reliability of the switch unit.

The existing housing member can lead to several disadvantages and hazards. Firstly, exposed terminals can be a safety hazard to an operator and/ or a maintenance personnel who may accidentally come into contact with the exposed terminals while working on the switch unit. Electrical shock can occur if the exposed terminals are live and not properly insulated which may result in serious injury or even death.

Secondly, the exposed terminals may also pose a risk to the overall functionality of the switch unit. The exposed terminals can become damaged or corroded over time, leading to electrical faults or failures in the switch unit. This can cause the switch unit to operate improperly or even fail completely, resulting in a loss of productivity and costly repairs.

Additionally, the improper housing member can also cause issues with dust and debris accumulation which can interfere with the operation of the switch unit and lead to overheating, further exacerbating the safety and reliability concerns.

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 and nor is it intended for determining the scope of the invention.

The present disclosure relates to a housing member for a switch unit. The housing member may include a base, a side wall, and a plurality of first receiving members. The side wall extends from the base in an orthogonal orientation. The plurality of first receiving members may be formed on an outer peripheral surface of the side wall. The plurality of first receiving members may be adapted to receive and secure a top cover of the switch unit, such that a sealed connection is formed between the top cover and the housing member.

Further, the present disclosure relates to a switch unit for a motor of a vehicle. The switch unit may include an inner rocker, a top cover, and a housing member. The inner rocker may be adapted to be pivotally moved form and break an electrical connection with the motor. The top cover may be adapted to cover the inner rocker. The housing member may be adapted to accommodate the inner rocker and support the top cover. The housing member may include a base, a side wall, and a plurality of first receiving members. The side wall extends from the base in an orthogonal orientation. The plurality of first receiving members may be formed on an outer peripheral surface of the side wall. The plurality of first receiving members may be adapted to receive and secure a top cover of the switch unit, such that a sealed connection is formed between the top cover and the housing member.

The housing member of the present disclosure ensures that the switching mechanism of the switch unit may be properly sealed from foreign particles such as dust, moisture, and accidental contact, thereby reducing the risk of electrical accidents and increasing the safety of the switch unit. Further, the housing member protects the sub-components of the switch unit from the heat generated by the motor during operation. Moreover, the housing member has a snap-fitting mechanism that securely mounts the spark shield element and the inner rocker inside the switch unit. This secure mounting prevents the spark shield element 103 and the inner rocker from getting dislodged during operation and ensures that the spark shield element and the inner rocker are always in a correct position for optimal performance.

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 with 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 side view of a switch unit for a motor showing internal components of the switch unit, according to an embodiment of the present disclosure;

Figure 1b illustrates a cross-sectional view of the switch unit, according to an embodiment of the present disclosure;

Figure 2 illustrates a side view of a housing member of the switch unit, according to an embodiment of the present disclosure;

Figure 3 illustrates a side view of the housing member depicting an inner rocker coupled with the housing member, according to an embodiment of the present disclosure;

Figure 4 illustrates a top view of the housing member, according to an embodiment of the present disclosure;

Figure 5a illustrates an isometric view of the housing member accommodating a spark shield element, according to an embodiment of the present disclosure;

Figure 5b illustrates a top view of the housing member accommodating a spark shield element, according to an embodiment of the present disclosure; and

Figure 5c illustrates a side view of the housing member accommodating a spark shield element, according to 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. Furthermore, in terms of the construction of the device, a plurality of 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 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 invention belongs. The system and examples provided herein are illustrative only and not intended to be limiting.

For example, the term “some” as used herein may be understood as “none” or “one” or “more than one” or “all.” Therefore, the terms “none,” “one,” “more than one,” “more than one, but not all” or “all” would fall under the definition of “some.” It should be appreciated by a person skilled in the art that the terminology and structure employed herein is for describing, teaching, and illuminating some embodiments and their specific features and elements and therefore, should not be construed to limit, restrict or reduce the spirit and scope of the present disclosure in any way.

For example, any terms used herein such as, “includes,” “comprises,” “has,” “consists,” and similar grammatical variants do not specify an exact limitation or restriction, and certainly do not exclude the possible addition of a plurality of features or elements, unless otherwise stated. Further, such terms must not be taken to exclude the possible removal of the plurality of the listed features and elements, unless otherwise stated, for example, by using the limiting language including, but not limited to, “must comprise” or “needs to include.”

Whether or not a certain feature or element was limited to being used only once, it may still be referred to as “plurality of features” or “plurality of elements” or “at least one feature” or “at least one element.” Furthermore, the use of the terms “plurality of” or “at least one” feature or element do not preclude there being none of that feature or element, unless otherwise specified by limiting language including, but not limited to, “there needs to be plurality of...” or “plurality of elements 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 a person ordinarily skilled 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 of the present disclosure. Some embodiments have been described for the purpose of explaining plurality of the potential ways in which the specific features and/or elements of the proposed disclosure fulfil the requirements of uniqueness, utility, and non-obviousness.

Use of the phrases and/or terms including, 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 other variants thereof do not necessarily refer to the same embodiments. Unless otherwise specified, plurality of particular features and/or elements described in connection with plurality of 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 plurality of features and/or elements may be described herein in the context of only a single embodiment, or in the context of more than one embodiment, or 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 necessarily be taken as limiting factors to the proposed disclosure.

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

Figure 1a illustrates a side view of a switch unit 100 for a motor showing internal components of the switch unit 100, according to an embodiment of the present disclosure. Figure 1b illustrates a cross-sectional view of the switch unit 100, according to an embodiment of the present disclosure. The switch unit 100 may be employed in a motor of a vehicle to start and stop the motor safely. In an embodiment, the switch unit 100 may be embodied as a motor starter, without departing from the scope of the present disclosure. Herein, the switch unit 100 works similarly to a relay, as the switch unit 100 switches ON and OFF the motor.

The switch unit 100 also protects the motor from the impact of overcurrent. Depending on the rating and size of the motor, the switch unit 100 may be available in a variety of ratings and sizes. In addition to preventing the motor from drawing excessive currents, the switch unit 100 switches the necessary power to the motor in a secure manner. In an embodiment, the switch unit 100 may include, but is not limited to, a top cover 101, a rocker arm 102, a spark shield element 103, a moving contact bridge 104, a plurality of rivets 105a and 105b, a housing member 106, a pair of switches, and a bi-metallic circuit breaker assembly.

The inner rocker 102, the plurality of rivets 105a and 105b, and the moving contact bridge 104 work together to start and stop the flow of electric current inside the motor to ensure the safe and reliable operation of the switch unit. The pair of switches may include a first switch and a second switch adapted to actuate to operate the motor in one of an ON state and an OFF state, respectively. Further, the rocker arm may be coupled with the pair of switches. The rocker arm actuates along with the pair of switches to operate the motor.

When either one of the first switch or the second switch may be actuated, then the rocker arm operates to either establish a connection to switch ON the motor or break the connection to switch OFF the motor. Further, the bi-metallic circuit breaker assembly 102 may be adapted to trip the motor, based on heat generated within the switch unit 100 exceeding a threshold heat level.

The top cover 101 may be adapted to be pivotally moved form and break an electrical connection with the motor. In an embodiment, the inner rocker 102 may be formed of a durable and heat-resistant material, such as polymer or ceramic, and is designed to withstand the high temperatures and electrical currents that are present in the switch unit 100.

The plurality of rivets 105a, 105b are small metal pins that are responsible for connecting and disconnecting the power supply to the motor. When the switch unit 100 is activated, the plurality of rivets 105a, 105b connects with each other and allows the electrical current to flow through the motor, causing it to start running.

The moving contact bridge 104 is designed to move back and forth between two fixed contact points, allowing the electrical circuit to be opened or closed as needed. The moving contact bridge 104 may have a rivet 105a from the plurality of rivets 105a, 105b that connects with a fixed rivet 105b from the plurality of rivets 105a, 105b, thereby allowing the electrical current to flow into the motor.

When the switch unit 100 is switched ON, the plurality of rivets 105a, 105b comes in contact with each other that allows the flow of current into the motor. When the plurality of rivets 105a, 105b touch each other, there may be some initial arcing that occurs due to a sudden electrical discharge. The arcing can create high temperatures and ionize air surrounding the plurality of rivets 105a, 105b. Further, the spark shield element 103 may be adapted to protect the sub-components of the switch unit 100 from getting damaged due to an arcing and also prevents an arc residue to deposit onto the sub-components.

The housing member 106 may be adapted to accommodate the components such as inner rocker 102 and support the top cover 101. Further, the housing member 106 provides a shield to the switch unit 100, such that the entry of foreign particles such as moisture or dust, into the switch unit 100 may be prevented. Thus, the housing member 101 provides a provision for easy installation of the components without using fasteners or adhesives. Constructional and functional details of the housing member 101 are explained in the subsequent paragraphs with reference to Figures 2 to 5.

Figure 2 illustrates a side view of a housing member 106 of the switch unit 100, according to an embodiment of the present disclosure. Figure 3 illustrates a side view of the housing member 106 depicting an inner rocker 102 coupled with the housing member 106, according to an embodiment of the present disclosure. Figure 4 illustrates a top view of the housing member 106, according to an embodiment of the present disclosure. Figure 5a illustrates an isometric view of the housing member 106 accommodating a spark shield element 103, according to an embodiment of the present disclosure. Figure 5b illustrates a top view of the housing member 106 accommodating a spark shield element 103, according to an embodiment of the present disclosure. Figure 5c illustrates a side view of the housing member 106 accommodating a spark shield element 103, according to an embodiment of the present disclosure.

Referring to Figures 2 to 5c, the housing member 106 may be constructed to support the components of the switch unit 100. The housing member 106 also provides a certain amount of constraints to enable a smooth operation of the switch unit 100. In an embodiment, the housing member 106 may be formed of a polymeric material, without departing from the scope of the present disclosure. In another embodiment, the housing member 106 may be formed of a metallic material, without departing from the scope of the present disclosure.

The housing member 106 may include a base 202, a side wall 204, and a plurality of first receiving members 206. The side wall 204 extends from the base 202 in an orthogonal orientation.

The plurality of first receiving members 206 may be formed on an outer peripheral surface of the side wall 204. The plurality of first receiving members 206 may be adapted to receive and secure a top cover 101 of the switch unit 100, such that a sealed connection is formed between the top cover 101 and the housing member 106.

In an embodiment, the plurality of first receiving members 206 may be adapted to be engaged with a plurality of first engaging members 208 of the top cover 101, and the engagement of the plurality of first receiving members 206 and plurality of first engaging members 208 forms the sealed connection formed between the top cover 101 and the housing member 106. This prevents the entry of foreign particles into the switch unit 100. Further, this also enables the easy assembly of the top cover 101 and the housing member 106 without implementation of fasteners. Herein, each of the first engaging members 208 has a slot 208a that is complementary to a design of each of the plurality of first receiving members 206.

When the top cover 101 is placed on the housing member 106, each of the plurality of first receiving members 206 on the sides of the housing member 106 fits into the slot 208a provided in each of the first engaging members 208 on the top cover 101. This provides a secure fit between the housing member 106 and top cover 101, preventing them from separating during the operation of the switch unit 100. By securely fastening the top cover 101 to the housing member 106, the exposure of the sub-components of the switch unit 100 is prevented, reducing the risk of electrical shock or other hazards. Additionally, the fastening of the top cover 101 with the housing member 106 helps to prevent the entry of dust, debris, or other contaminants that could damage the sub-components or interfere with the operation of the switch unit 100.
The base 202 may include a cavity 210 adapted to at least partially accommodate and guide an inner rocker 102 of the switch unit 100. The cavity 210 may include a plurality of second receiving members 302 adapted to be engaged with a plurality of second engaging members 301 of the inner rocker 102, such that the sealed connection is formed between the inner rocker 102 and the housing member 106. In an embodiment, the plurality of second engaging members 301 may be embodied as a pair of hinges 301.

The plurality of second receiving members 302 may have a design complementary to the pair of second engaging members 301, which ensures a secure fit and prevents the inner rocker 102 from getting dislodged from an actual position during the operation of the switch unit 100. Further, the pair of second engaging members 301 may be engaged with the plurality of second receiving members 302 in a way that the inner rocker 102 may be able to toggle when required to ensure a smooth switching operation inside the switch unit 100.

The housing member 106 has an input terminal slot 403 and an output terminal slot 401. The input terminal slot 403 accommodates an input terminal. The input terminal has a live input wire to supply electrical current to the motor when the switch unit 100 is turned ON. This means that the input terminal slot 403 is the point at which electrical current enters the switch unit 100.

On the other hand, the output terminal slot 401 accommodates an output terminal. The output terminal has an output live wire. The electrical current reaches the motor through the output live wire when the switch unit 100 is ON. The output live wire is cut off when the switch unit 100 is turned OFF. Additionally, the output terminal slot 401 has a hole 404 that allows electrical wires to be connected to the switch unit 100 through which the electrical current flows into the motor.

As shown in Figures 5a-5c, the spark shield element 103 may be mounted securely inside the switch unit 100 using a snap-fitting mechanism. Herein, the side wall 204 may include a plurality of third receiving members 501 formed on at least on each corner of an inner peripheral surface of the side wall 204 and adapted to be engaged with a plurality of third engaging members of a spark shield element 103 to secure the spark shield element 103 within the housing member 106.

Such engagement ensures a secure fit and prevents a dislodging of the spark shield element 103 from its position. In an embodiment, the plurality of third receiving members 501 may be embodied as a plurality of lugs 501, without departing from the scope of the present disclosure. The snap-fitting mechanism of the housing member 106 enables the spark shield element 103 and the plurality of third receiving members 501 to work together and provide a secure mounting for the spark shield element 103 which ensures that the spark shield element 103 remains in place and effectively prevents arc residues from spreading, thereby enhancing safety and performance of the switch unit 100.

Advantageously, the housing member 106 ensures that the switching mechanism of the switch unit 100 is properly insulated from external factors such as dust, moisture, and accidental contact, thereby reducing the risk of electrical accidents and increasing the safety of the switch unit 100. The housing member 106 also, protects the sub-components of the switch unit 100 from the heat generated by the motor during operation. Further, the housing member 106 has a snap-fitting mechanism that securely mounts the spark shield element 103 and the inner rocker 102 inside the switch unit 100. This secure mounting prevents the spark shield element 103 and the inner rocker 102 from getting dislodged during operation and ensures that the spark shield element 103 and the inner rocker 102 are always in a correct position for optimal performance. The housing member 106 has a simple design that enables an assembly and a disassembly of the switch unit 100 easy which simplifies maintenance and repair tasks of the switch unit 100.

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 housing member (106) for a switch unit (100), comprising:
a base (202);
a side wall (204) extending from the base (202) in an orthogonal orientation; and
a plurality of first receiving members (206) formed on an outer peripheral surface of the side wall (204) and adapted to receive and secure a top cover (101) of the switch unit (100) to form a sealed connection between the top cover (101) and the housing member (106).

2. The housing member (106) as claimed in claim 1, wherein the plurality of first receiving members (206) adapted to be engaged with a plurality of first engaging members (208) of the top cover (101), and the engagement of the plurality of first receiving members (206) and plurality of first engaging members (208) forms the sealed connection formed between the top cover (101) and the housing member (106).

3. The housing member (106) as claimed in claim 1, wherein the base (202) comprises a cavity (210) adapted to at least partially accommodate and guide an inner rocker (102) of the switch unit (100).

4. The housing member (106) as claimed in claim 3, wherein the cavity (210) comprises a plurality of second receiving members (302) adapted to be engaged with a plurality of second engaging members (301) of the inner rocker (102), such that the sealed connection is formed between the inner rocker (102) and the housing member (106).

5. The housing member (106) as claimed in claim 1, wherein the side wall (204) comprises a plurality of third receiving members (501) formed on an inner peripheral surface of the side wall (204) and adapted to be engaged with a plurality of third engaging members of a spark shield element (103) to secure the spark shield element (103) within the housing member (106).

6. A switch unit (100) for a motor of a vehicle, comprising:
an inner rocker (102) adapted to be pivotally moved form and break an electrical connection with the motor;
a top cover (101) adapted to cover the inner rocker (102); and
a housing member (106) adapted to accommodate the inner rocker (102) and support the top cover (101), the housing member (106) comprising:
a base (202);
a side wall (204) extending from the base (202) in an orthogonal orientation; and
a plurality of first receiving members (206) formed on an outer peripheral surface of the side wall (204) and adapted to receive and secure the top cover (101) of the switch unit (100) to forma sealed connection between the top cover (101) and the housing member (106).

7. The switch unit (100) as claimed in claim 6, wherein the plurality of first receiving members (206) adapted to be engaged with a plurality of first engaging members (208) of the top cover (101), and the engagement of the plurality of first receiving members (206) and plurality of first engaging members (208) forms the sealed connection formed between the top cover (101) and the housing member (106).

8. The switch unit (100) as claimed in claim 6, wherein the base (202) comprises cavity (210) adapted to at least partially accommodate and guide the inner rocker (102) of the switch unit (100).

9. The switch unit (100) as claimed in claim 8, wherein the cavity (210) comprises a plurality of second receiving members (302) adapted to be engaged with a plurality of second engaging members (301) of the inner rocker (102), such that the sealed connection is formed between the inner rocker (102) and the housing member (106).

10. The switch unit (100) as claimed in claim 6, wherein the side wall (204) comprises a plurality of third receiving members (501) formed on an inner peripheral surface of the side wall (204) and adapted to be engaged with a plurality of third engaging members of a spark shield element (103) to secure the spark shield element (103) within the housing member (106).