The present disclosure relates to switch assemblies and more particularly relates to a switch assembly for a head lamp leveling device of a vehicle.

BACKGROUND

Switch assemblies are employed to selectively close and open an electrical or electronic circuit. Switch assemblies are employed in a vehicle to allow a vehicle’s occupant to operate various electrical components in the, such as headlight light, air conditioner, among other examples. Conventionally, switch assemblies have been designed in varieties of fashion to duly comply with the requirement of the advanced devices, circuits, and appliances. Such conventional switch assemblies include rotary knobs, toggling buttons, lever switches, push buttons, and the like. Such conventional switch assemblies include head light switches, headlamp leveling switches, switch knobs, rotary switch.

Particularly, in headlamp leveling switches in vehicles, rotary knobs have been designed to operate in a fashion to actuate a circuit or a printed circuit board to adjust a cut-offline of the headlamp, for instance to change the area of illuminated region ahead of the vehicle. In such headlamp leveling switches, rotary knobs are provided to lower and raise the level of the headlamps through switching by scrolling the rotary knobs from an upper state to a lower state and multiple midway positions therebetween.

Furthermore, the conventional rotary knobs for headlamp leveling switches are provided with a rotary knob protruding outward from a slot of a casing of the headlamp leveling switches. The rotary knob is housed in a housing with a cut out to allow the rotary knob to protrude from the opening for access to the occupant. Further, the rotary knobs are manufactured as a hollow component so that the rotary knob can be coupled to the underneath circuit. Conventionally, the rotary knobs, owing to its shape forms creates gaps between the rotary knob and the edges of the opening. The gaps cause unwanted entry of dust and water droplet that may hamper the operation of the rotary knob. One way to mitigate this issue is to raise the edges of the opening to cover the gap. However, raising the edges not only increase the material used to manufacture the switch assembly but also lowers the aesthetic appeal of the switch assembly. Moreover, redesigning the opening of the housing warrants manufacture of new molding die which is cost intensive task.

Therefore, in light of foregoing discussions, there is a need to overcome the limitations/drawbacks of the conventional switches and 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 and nor is it intended for determining the scope of the invention.

The present disclosure provides a switch assembly with a knob for a for a head lamp leveling device of a vehicle. The knob is a two-piece assembly of a rotary knob that is operable by an operator and a contact holder that toggles a plurality of positions. The rotary knob has side walls that prevents formation of gaps while the contact holder is positioned in such a that the rotary knob remains flush with a top surface of the assembly.

In an embodiment, a switch assembly is disclosed which includes a body having a casing with a slot. The switch assembly also includes a holder disposed within the body and includes an internal gear profile at a base of the holder. Further, the rotary knob disposed within the slot of body and adapted to rotate with respect to the slot and toggle through a plurality of positions when scrolled. The switch assembly also includes a contact holder locked with the rotary knob by a locking member. The contact holder includes a pawl adapted to travel along the internal gear profile to toggle through the plurality of positions. In an operation, the rotary knob is rotated and thereby the pawl of the contact holder travels along the internal gear profile to toggle through the plurality of positions to regulate light projection on the road illuminated from headlamps of the vehicle. Furthermore, the rotary knob is provided with a pair of side walls extending orthogonally from edges of the outer curved surface with a shaft traversed at the center of the pair of side walls.

Embodiments of the present disclosure addresses the abovementioned problems in the conventional devices and enables to provide the switch assembly with an effectively designed rotary knob and the contact holder locked with the rotary knob. Moreover, the present disclosure eliminates the limitations of the conventional switch assemblies with rotary knobs and provides effective design with the effectively designed rotary knob and the contact holder. The rotary knob and the contact holder as described herein may be prepared using injection molding that reduces the manufacturing cost and reduces the complexity in assembling of the switch assembly.

To further clarify 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 an exploded view of the switch assembly, according to an embodiment of the present disclosure;
Figure 1B illustrates a perspective view of the switch assembly, according to an embodiment of the present disclosure;
Figure 1C illustrates a sectional view of a switch assembly taken along lines X-X of Figure 1B, according to an embodiment of the present disclosure;
Figure 2A illustrates a top perspective view of the rotary knob, according to an embodiment of the present disclosure;
Figure 2B illustrates a bottom perspective view of the rotary knob, according to an embodiment of the present disclosure;
Figure 2C illustrates a side view of the rotary knob, according to an embodiment of the present disclosure;
Figure 3A illustrates a left side view of the contact holder, according to an embodiment of the present disclosure;
Figure 3B illustrates a bottom perspective view of the contact holder, according to an embodiment of the present disclosure; and
Figure 3C illustrates a right-side view of the contact holder, 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, 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 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 one or more features or elements, unless otherwise stated. Further, such terms must not be taken to exclude the possible removal of one or more 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 “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 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 one or more...” or “one or more 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 one or more 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, 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 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.

For the sake of clarity, the first digit of a reference numeral of each component of the present disclosure is indicative of the Figure number, in which the corresponding component is shown. For example, reference numerals starting with digit “1” are shown at least in Figure 1. Similarly, reference numerals starting with digit “2” are shown at least in Figure 2.

In an embodiment of the present disclosure, a switch assembly for a for a head lamp leveling device of a vehicle is disclosed. The switch assembly is provided with a rotary knob disposed within a slot of a body of the switch assembly and adapted to rotate with respect to the slot and toggle through a plurality of positions. Furthermore, the switch assembly also includes a contact holder locked with the rotary knob by a locking member. The contact holder includes a pawl adapted to engage with the internal gear profile for switching through the plurality of positions. Notably, the switch assembly is effectively designed with the rotary knob and the contact holder detachably attached to each other. The rotary knob and the contact holder are manufactured using injection molding and/or mass molding techniques that results in mass production with reduced input cost due to simpler design. Furthermore, the rotary knob and the contact holder are manufactured separately and then conjoined together using the locking member using a lock pin adapted to fit inside a lock-featured notch at a base of each side wall of the rotary knob, to lock the contact holder and the rotary knob.

Figures 1A to 1C illustrates different views of a switch assembly 100, according to an embodiment of the present disclosure. Specifically, Figure 1A illustrates an exploded view of the switch assembly 100. Further, Figure 1B illustrates a perspective view of the switch assembly 100 and Figure 1C illustrates a sectional view of a switch assembly 100 taken along lines X-X in Figure 1B. The switch assembly 100 includes a body 102 with a casing 104 having a slot 106. The switch assembly 100 also includes a holder 108 including an internal gear profile 110, a rotary knob 112, a plurality of positions 114, a contact holder 116 including a locking member 118 and a pawl 120 with a hemispherical tip 136. The switch assembly 100 also includes a printed circuit board 140 and a rear cover 142 coupled to the body 102 and adapted to secure the holder 116 and the body 102. The switch assembly 100 also includes the printed circuit board 140 and a rear cover 142 coupled to the body 102 and adapted to secure the holder 116 and the body 102. In an embodiment, the printed circuit board 140 is configured to receive switching inputs in response to the travel of the pawl 120 along the internal gear profile 110 (as shown in Figure 1A) of the holder 116 based on the scroll of the rotary knob 112.

Throughout the present disclosure, the term “switch assembly” as used herein refers to switch sockets, switching devices and the like deployed in head lamp levelling devices of vehicles to regulate incident light on roads projected from head lamps. Furthermore, the switch assembly 100 is adapted to control headlight leveling mechanism to shift the projection of light on the road and/or oncoming vehicles. Moreover, the switch assembly 100 are designed with the plurality of positions 114 on the casing 104 to indicate a level of projection of light on the road. In an example the switch assembly 100 may be manufactured using a plastic material, a PVC material and the like.

In one example, the body 102 as used herein refers to a frame adapted to provide support to the switch 100 while operating between plurality of positions 114. As shown in the Figure 1A, the body 102 includes four walls with an open top and an open base. In an example, the body 104 is in a cuboidal shape. However, the body 102 may include shapes such as cubic shape, cylindrical shape, and the like. The casing 104 as used herein refers to a cover or a housing mounted on the body 102 to receive the rotary knob 112 inside the slot 106. The slot 106 as used herein is a carved out opening adapted to arrange the rotary knob 112 withing a width of the slot 106. The rotary knob 112 is produced in a size to include no gaps when inserted within the slot 106 and mounted therebetween. In an example, the body 102 and the casing 104 may be manufactured using a plastic material, a PVC material, and the like.

According to one embodiment, the switch assembly 100 includes the holder 108 disposed within the body 102 and including an internal gear profile 110 at a base of the holder 108. The holder 108 as used herein refers to a receptacle or a socket that provided support to the body 102 and mounted withing the body 102. Furthermore, the holder 108 also enable a mounting of the casing 104 thereon to receive the rotary knob 112 within the slot 106. The holder 108 extends from a base of the casing 104 to a proximal length of the body 102. The holder 108 includes the gear profile 110 provided at the base of the holder 108 and adapted to allow a travelling of the rotary knob 112 thereon, when the rotary knob 112 is rotated manually. In an example the holder 108 may be manufactured using a plastic material, a PVC material, and the like. gear profile 110 includes teeth on a top surface that engages with the rotary knob 112 to allow the travelling of the rotary knob 112 thereon.

As mentioned before, the rotary knob 112 disposed within the slot 106 of body 102 and adapted to rotate with respect to the slot 106 and toggle through a plurality of positions 114, shown as markings ‘3’, ‘2’, ‘1’ when scrolled. The rotary knob 112 as used herein refers to an actuator, an activator and the like that is configured to rotate with respect to the slot 106 and toggle through a plurality of positions 114. In an embodiment, the rotary knob 112 protrudes from the slot 106 of the body 102 and adapted to fit within the slot 106 of the body 102. Specifically, as shown in Figure 1B, the rotary knob 112 cross fits within the width of the slot 106 of the body 102 to cover the entire slot 106 and protrudes to a height of a diameter of the rotary knob 112 above the casing 104.

According to an embodiment, the contact holder 116 locked with the rotary knob 112 by a locking member 118, wherein the contact holder 116 includes a pawl 120 adapted to travel along the internal gear profile 110 to toggle through the plurality of positions 114. The contact holder 116 as used herein refers to a supporting element that is locked with the rotary knob 112 by a locking member 118 to support the rotary knob 112 to travel along the internal gear profile 110 to toggle through the plurality of positions 114. The contact holder 116 is coupled to a base of the rotary knob 112 to enable a movement of the pawl 120 on the internal gear profile 110 to toggle through the plurality of positions 114, when the rotary knob 112 is rotated from the top.

In an embodiment, the rotary knob 112 and contact holder 108 are manufactured using injection molding techniques. The rotary knob 112 and contact holder 108 are prepared separately using molding techniques such as injection molding and/or mass molding. Furthermore, the rotary knob 112 and contact holder 108 are manufactured separately to reduce the material wastage that is occurred when the rotary knob 112 and contact holder 108 are integral and manufactured as unibody. Details of the rotary knob 112 and the contact holder 116 is described here in subsequent embodiments.

Figure 2A illustrates a top perspective view of the rotary knob 112, according to an embodiment of the present disclosure. Figure 2B illustrates a bottom perspective view of the rotary knob 112, according to an embodiment of the present disclosure. Figure 2C illustrates a side view of the rotary knob 112, according to an embodiment of the present disclosure.

The rotary knob 112 includes knurls 122 at an outer curved surface 124 that are adapted to receive inputs from a user. The rotary knob 112 is provided with beads shaped grip at the outer curved surface 124 to enable grip when the rotary knob 112 is rotated manually. Furthermore, the rotary knob 112 includes a hollow semi-circular drum 126 including a pair of side walls 130 extending orthogonally from edges of the outer curved surface 124 with a shaft 132 traversed at the center of the pair of side walls 130. The rotary knob 112 is formed with the hollow semi-circular drum 126 extends orthogonally from the edges of the outer curved surface 124 to be formed using injection molding. In an embodiment, each of the side wall 130 includes a lock-featured notch 132 at a base of each side wall 128. The lock-featured notch 132 is a notch piercing provided herein to lock the rotary knob 112 with the contact holder 116 (as shown in Figure 1A). Furthermore, the lock-featured notch 132 is also provided with side notches 133 (as shown in Figure 2C) to allow an extension of a diameter of the lock-featured notch 132 while locking the rotary knob 112 with the contact holder 116.

Figure 3A illustrates a left side view of the contact holder 116, according to an embodiment of the present disclosure. Figure 3B illustrates a bottom perspective view of the contact holder 116, according to an embodiment of the present disclosure. Figure 3C illustrates a right-side view of the contact holder 116, according to an embodiment of the present disclosure.

The contact holder 116 includes a hemispherical tip 136 (as shown in Figure 1A) attached to a distal end 138 of the pawl 120 and adapted to roll on the internal gear profile 110 when the rotary knob 112 is scrolled. The pawl 120 as used herein is a cylindrical element provided with the hemispherical tip 136 inscribed within the base of the contact holder 116. Furthermore, hemispherical tip 136 is configured to engage with the teeth of the internal gear profile 110 of the holder 108 (as shown in Figure 1A). In an example, the pawl 120 is adapted to roll upon the internal gear profile 110 when a user scrolls the rotary knob 112 (as shown in Figure 1A and 2A).

In an embodiment, the locking member 116 includes a lock pin 134 adapted to fit inside the lock-featured notch 132 (as shown in Figure 2A, 2B and specifically in Figure 2C) to lock the contact holder 114 and the rotary knob 112 (as shown in Figure 1A). The lock pin 134 refers to a cylindrical protrusion extending from the surface of the contact holder 114 to lock the lock the contact holder 114 and the rotary knob 112. The lock pin 134 is press fitted inside the lock-featured notch 132. Furthermore, the lock-featured notch 132 is adjustable and allows an insertion of the lock pin 134 therein.

Embodiments of the present disclosure provide the switch assembly 100 having the rotary knob 112 locked with the contact holder 116. Furthermore, the rotary knob 112 locked and the contact holder 116 are manufactured separately to reduce the manufacturing cost. Notably, the rotary knob 112 and the contact holder 116 are prepared using injection molding techniques and/or plastic molding techniques. The switch assembly 100 as described herein may be included but not limited to the head lamp levelling devices and can be utilized with various switches and switching assemblies.

While specific language has been used to describe the present disclosure, 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.

We Claim:

1. A switch assembly (100) comprising:
a body (102) with a casing (104) having a slot (106);
a holder (108) disposed within the body (102) and comprising an internal gear profile (110) at a base of the holder (108);
a rotary knob (112) disposed within the slot (106) of body (102), and adapted to rotate with respect to the slot (106) and toggle through a plurality of positions (114) when scrolled; and
a contact holder (116) locked with the rotary knob (112) by a locking member (118), wherein the contact holder (114) includes a pawl (120) adapted to travel along the internal gear profile (110) to toggle through the plurality of positions (114).

2. The switch assembly (100) as claimed in claim 1, wherein the rotary knob (112) includes knurls (122) at an outer curved surface (124) that are adapted to receive inputs from a user.

3. The switch assembly (100) as claimed in claim 2, wherein the rotary knob (112) includes a hollow semi-circular drum (126) including a pair of side walls (128) extending orthogonally from edges of the outer curved surface (124) with a shaft (130) traversed at the centre of the pair of side walls (128).

4. The switch assembly (100) as claimed in claim 3, wherein each of the side wall (128) includes a lock-featured notch (132) at a base of each side wall (128).

5. The switch assembly (100) as claimed in claim 4, wherein the locking member (116) includes a lock pin (134) adapted to fit inside the lock-featured notch (132) to lock the contact holder (114) and the rotary knob (112).

6. The switch assembly (100) as claimed in claim 1, wherein the rotary knob (112) protrudes from the slot (106) of the body (102) and adapted to fit within the slot (106) of the body (102).

7. The switch assembly (100) as claimed in claim 1, wherein the contact holder (114) includes a hemispherical tip (136) attached to a distal end (138) of the pawl (120) and adapted to roll on the internal gear profile (110) when the rotary knob (112) is scrolled.

8. The switch assembly (100) as claimed in claim 1, comprising a printed circuit board (140) to receive switching inputs in response to the travel of the pawl (120) along the internal gear profile (110) of the holder (116) based on the scroll of the rotary knob (112).

9. The switch assembly (100) as claimed in claim 1, wherein the rotary knob (112) and contact holder (116) are manufactured using injection moulding techniques.

10. The switch assembly (100) as claimed in claim 1, comprising a rear cover (142) coupled to the body (102) and adapted to secure the holder (108) and the body (102).