DESC:FORM 2
THE PATENTS ACT, 1970
(39 OF 1970)
&
THE PATENT RULES, 2003

COMPLETE SPECIFICATION
(See section 10, rule 13)

Title of the invention:
A SWITCHING MECHANISM IN AUTOMOBILES

APPLICANT:
VARROC ENGINEERING LIMITED
An Indian entity having address as:
L-4, MIDC Waluj, Aurangabad-431136,
Maharashtra, India

The following specification particularly describes the invention and the manner in which it is to be performed.

TECHNICAL FIELD
Present disclosure generally relates to a field of automobiles. Particularly, but not exclusively, the present disclosure relates to handlebar switch or control switch in automobiles.
BACKGROUND
Presently, the handlebar of two-wheeler or three-wheeler automobiles includes numerous handlebar switches/control switches that are mounted on the handlebar switch/switchgear assembly. These switches consist of horn module, headlight module, blinker, or winker module, pass or passing module, start module, engine kill module, hazard module, and the like.
Fig.1 illustrates a butt-type switch module which is actuated using a compression spring made of Phosphor Bronze. The switch module includes two rivets that are biased from each other and present at each end of the spring. When the spring is compressed, the rivets come in contact with each other, thereby completing the circuit and forming an electrical connection.
However, the heat generated by the above switching mechanism leads to formation of micro-weld on the surface of the compression spring and the compression spring gets set after finite number of endurance cycles. Thus, the above-mentioned factors results in failure of the switch and limited number of endurance cycles.
One solution to above mentioned drawbacks is butt-type switch module which is actuated using a torsion spring. The switch module includes two rivets in an arrangement with the torsion spring and when the torsion spring is compressed the rivets come in contact with each other, thereby completing the circuit and forming an electrical connection. However, the torsion spring switching mechanism can only be used in angular moving switches.
Therefore, there exists a need in the art to provide a system which overcomes the above-mentioned problems and to provide a linear motion switch having high endurance cycles and increased life.
SUMMARY
The present disclosure overcomes one or more shortcomings of the prior art and provides additional advantages discussed throughout the present disclosure. Additional features and advantages are realized through the techniques of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered a part of the claimed disclosure.
In one non limiting embodiment a switch may be disclosed. The switch may comprise a panel with a cavity, a knob disposed and protruding out of the cavity, a housing assembled below the panel. Further, the housing may comprise a cover assembly and a terminal assembly, wherein the cover assembly comprises a cover with a base plate, wherein base plate is enabled with a hole, wherein a fixed contact is housed in the hole of the base plate. Further, the terminal assembly may comprise a moving terminal and a moving contact may be connected to a first end of the moving terminal, and wherein a second end of the moving terminal may be inserted into the fixed terminal along with a torsion spring. Further, the torsion spring may be configured to engage with the moving terminal to bias the moving contact away from the fixed contact. Further, a pivot axis of the moving terminal may be oriented orthogonally to the direction of pressing of the knob. Further, the knob may be configured to engage with the moving terminal on pressing of the knob, thereby engaging the moving contact with the fixed contact.
In another embodiment an implementation of the switch is disclosed. In this implementation the housing may comprise a drain hole. The drain hole may be configured to avoid water accumulation in the contact area. Further, the depth of the drain hole may be increased in Z direction at least by 6 mm. Further, as per design calculations, and the type of application and required size of the switch, depth of the drain hole may be varied. Further, the drain hole may have an oblong shape. Further, a water drain may be provided to remove water accumulated in the fixed terminal area depth of the water drain. Further, the switch may have chamfer on the drain hole. The chamfer may be provided completely or partially on the drain hole area to ease the water flow towards the drain hole.
The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
The features, nature, and advantages of the present disclosure will become more apparent from the detailed description set forth below when taken in conjunction with the drawings in which like reference characters identify correspondingly throughout. Some embodiments of system and/or methods in accordance with embodiments of the present subject matter are now described, by way of example only, and with reference to the accompanying figures, in which:
Fig. 1 illustrates a prior art butt type switch actuation using compression spring;
Fig. 2 illustrates an exploded view of the switch 200, in accordance with an embodiment of the present disclosure;
Fig. 3 illustrates a sectional view 300 of a switch 200, in accordance with an embodiment of the present disclosure;
Fig. 4 illustrates an assembled view 400 of a switch 200 in automobiles, in accordance with an embodiment of the present disclosure;
Fig. 5 illustrates an implementation 500 of switch 200, in accordance with another embodiment of the present disclosure;
Fig. 6 illustrates a bottom view 600 of switch 200, in accordance with another embodiment of the present disclosure;
Fig. 7 illustrates a sectional view 700 of switch 200, in accordance with another embodiment of the present disclosure;
Fig. 8 illustrates a sectional view 800 of switch 200, in accordance with another embodiment of the present disclosure; and
Fig. 9 illustrates a sectional view 900 of switch 200, in accordance with another embodiment of the present disclosure.
It should be appreciated by those skilled in the art that any block diagram herein represents conceptual views of illustrative systems embodying the principles of the present subject matter. Similarly, it will be appreciated that any flow charts, flow diagrams and the like represent various processes which may be substantially represented in computer readable medium and executed by a computer or processor, whether or not such computer or processor is explicitly shown.

DETAILED DESCRIPTION
The terms “comprise”, “comprising”, “include(s)”, or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a setup, system or method that comprises a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such setup or system or method. In other words, one or more elements in a system or apparatus proceeded by “comprises… a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or apparatus.
In the following detailed description of the embodiments of the disclosure, reference is made to the accompanying drawings that form a part hereof, and in which are shown by way of illustration specific embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, and it is to be understood that other embodiments may be utilized and that changes may be made without departing from the scope of the present disclosure. The following description is, therefore, not to be taken in a limiting sense.
Fig. 2 illustrates an exploded view of the switch 200, in accordance with an embodiment of the present disclosure. In an embodiment of the present disclosure, the switch 200 may comprise a panel 201, a knob 202, a compression spring 203, a moving terminal 204, a moving contact 205, a torsion spring 206, a plurality of insulating washers 207 and 209 and a fixed contact 208, a cover 210, a pivot 211, a circlip 212, mounting screws 213, a fixed terminal 214, and a housing 215.
In one embodiment a switch 200 is disclosed. The switch 200 may comprise the panel 201 with a cavity 201-a. Further, the knob 202 may be disposed and protruding out of the cavity 201-a. Further, the housing 215 may be assembled below the panel 201. The housing 215 along with the knob 202 is inserted into the panel 201 such that the housing 215 is completely covered by the panel 201. Further, the housing 215 comprises a cover assembly 20 and a terminal assembly 21. The terminal assembly 21 may be inserted and fixed inside the housing 215. The housing 215 may be then closed with the cover assembly 20. Further, the housing 215, the terminal assembly 21 and the cover assembly 20 together form an enclosed assembly. Further, the cover assembly 20 may comprise the cover 210 with the base plate 210-a. Further, the base plate 210-a may be enabled with a hole 210-b. Further, the fixed contact 208 may be housed in the hole 210-b of the base plate 210-a. Further, the terminal assembly 21 may comprise the moving terminal 204. Further, the moving contact 205 may be connected to a first end of the moving terminal 204 and a second end of the moving terminal 204 may be inserted into the fixed terminal 214 along with the torsion spring 206. Further, the torsion spring 206 may be configured to engage with the moving terminal 204 to bias the moving contact 205 away from the fixed contact 208. Further, a pivot axis of the moving terminal 204 may be oriented orthogonally to the direction of pressing of the knob 202. Further, the knob 202 may be configured to engage with the moving terminal 204 on pressing of the knob 202, thereby engaging the moving contact 205 with the fixed contact 208. Further, the moving terminal 204 may move around the axis of pivot 211 if a force greater than the torsion spring force is applied on the first end of the moving terminal 204.
In one embodiment, the knob 202 may have a butt-type shape. The butt type shape allows ease of operation and can be used for multiplicity of applications. Further, butt type shape is easy to locate on vehicle handlebar.
In one embodiment, the moving terminal 204 may be arranged below the knob 202. Further, a vertical axis Y2 of the moving contact 205 may be offset to a vertical axis Y1 of the knob 202, thereby reducing the force required to displace the moving contact 205 to connect with the fixed contact 208. Further, the moving terminal 204 may be configured to translate a linear motion of the knob 202 to an angular displacement of the torsion spring 206.
In another embodiment, the moving terminal 204 may be an elongated arm. Further, the moving contact 205 may be fixed at the first end of the moving terminal 204 and the second end of the moving terminal 204 may be inserted into the fixed terminal 214 along with the torsion spring 206.
Further, in another embodiment, the torsion spring 206 may comprise a fixed end 206-a and a moving end 206-b. Further, the fixed end 206-a may be fixed in a notch 217 in the housing 215 and the moving end 206-b may be inserted into a notch provided on the moving terminal 204. Further, the torsion spring 206 may be connected to the fixed terminal 214 using a pivot pin 211 and a circlip 212.
Further, insulating washers 207, 209 may be placed at the periphery of the hole 208-a to insulate the fixed contact 208 from the base plate 210-a.
In one embodiment, the knob 202 may comprise a first leg 216 and a second leg 217. Further, the first leg 216 may be longer than the second leg 217. Further, the first leg 216 and the second leg 217 may be inserted into a pair of holes (215-a, 215-b) present at the top of the hosing 215. Further, the first leg 216 may be in contact with the moving terminal 204. Further, upon pressing of the knob 202, the first leg 216 may be configured to press the moving terminal 204, thereby shifting the moving contact 205 towards the fixed contact 208.
The terminal assembly 21 may be inserted and fixed inside the housing 215. The housing 215 may be then closed with the cover assembly 20. The housing 215, the terminal assembly 21 and the cover assembly 20 may together form an enclosed assembly. The housing 215 along with the knob 202 may be inserted into the panel 201 such that the housing 215 may be completely covered by the panel 201 and the knob 202 comes out of the hole present in the panel 201.
In one embodiment, the moving contact 205 and the fixed contact 208 may be made of bimetallic material or any other combination of the conductive materials.
In another embodiment, the moving contact 205 and the fixed contact 208 may be rivets, bolts, screws, or any other suitable contact mechanism. Further, the pivot 211 may use a pivot pin, bolt, rivet, or any other suitable mechanism to move the moving terminal 204.
Fig. 3 illustrates a sectional view 300 of a switch 200, in accordance with an embodiment of the present disclosure.
In an embodiment of the present disclosure, the switch 200 may comprise a panel 201, a knob 202, a compression spring 203, a moving terminal 204, a moving contact 205, a torsion spring 206, a plurality of insulating washers 207 and a fixed contact 208, a cover 210, a pivot 211, a circlip (not shown), mounting screws (not shown), a fixed terminal 214, and a housing 215. The above components may have a similar connection as discussed in above embodiments.
The knob 202 may be mounted on the top of the housing 215 using the compression spring 203. The knob 202 may have a fixed range of motion between the panel 201 and the housing 215. The knob 202 includes two legs having different length inserted into the holes (215a, 215b) present at the top of the housing 215, when the knob 202 is mounted on the housing 215.
The terminal assembly 21 and the cover assembly 20 may be inserted inside the housing 215 such that the fixed contact 208 connected to the moving terminal 204 is placed at a specific elevation below the moving contact 205 attached to the base of the cover 210 and the leg 216 of the knob 202 may be in contact with the first end of the moving terminal 204. The moving terminal 204 may be configured to translate a linear motion of the knob 202 into an angular displacement of torsion spring 206 to form a closed contact between the moving contact 205 and the fixed contact 208, when the knob 202 is pressed. The closed contact between the moving contact 205 and the fixed contact 208 completes electrical circuit associated with the switch 200. Upon release of the knob 202, the torsion spring 206 and compression spring 203 together push the knob 202 to its resting position. By using two springs, namely the torsion spring 206 and compression spring 203, the chance of failure of the switch 200 is reduced significantly. This is because, the torsion spring 206 and compression spring 203 both push the moving terminal 204 and the knob 202 towards resting position simultaneously. Thus, even if the compression spring 203 fails operate in the desired fashion due to friction between the knob 202 and housing 215, or other failures, the torsion spring 206 compliments the movement of the knob 202 towards the resting position thereby reducing the chances of failure.
In an embodiment of the present disclosure, once the electrical circuit is complete by virtue of the moving contact 205 touching the fixed contact 208, the intended switching operation of a two-wheeler or three-wheeler vehicle is initiated. As soon as the knob 202 is released, the knob 202 is retracted to the resting position thereby biasing the moving contact 205 from the fixed contact, which further results into circuit break and the switching operation of a two-wheeler or three-wheeler vehicle is terminated. In one non-limiting embodiment, the switch 200 may be incorporated in any type of vehicle for performing the switching operations such as but not limited to honking, vehicle powering, ignition, audio alert, and activation or deactivation of the vehicle.
In one non-limiting embodiment of the present disclosure, the switch 200 may be incorporated on a handlebar of a vehicle as a horn switch or an engine start switch. However, the switching operation performed by the switch 200 is not limited to above example and any other switching operation that can be implemented using the switch 200 is well within the scope of the present disclosure.
In an embodiment of the present disclosure, the housing 215 and the knob 201 are made up of electrically non-conductive material, which eliminates the chances of micro-weld formation on the surface of the compression spring 203, thereby avoiding the setting of compression spring 203. Thus, the linear switch facilitates high endurance cycles.
In one non-limiting embodiment, the material used in terminal assembly may be Brass Cu-Zn with 63% Cu and 37% Zn composition and the material using in the housing and cover may be Nylon 6/ Nylon66 with glass filled 30% Grade B3WG6 Ultramid. However, the material used in making the switch 200 is not limited to above example, and any other having similar properties is well within the scope of present disclosure.
Fig. 4 illustrates an assembled view 400 of the switch 200 in automobiles, in accordance with an embodiment of the present disclosure. The knob 202 may be connected at the top of an enclosed assembly formed by the terminal assembly 21, the cover assembly 20 and the housing 215.
Fig. 5 illustrates an implementation 500 of switch 200, in accordance with another embodiment of the present disclosure. In an embodiment, the switch 200 may be implemented on a panel 201 installed on a handlebar of a two-wheeler or a three-wheeler vehicle. The switch 200 may be configured for the applications such as honking, vehicle powering, ignition, audio alert, and activation or deactivation of vehicle operations, when the switch 200 is pressed.
Fig. 6 illustrates an bottom view 600 of the switch 200 is disclosed. In this implementation the housing 215 may comprise a drain hole 601. The drain hole 601 may be configured to avoid water accumulation in the contact area. Further, the depth of the drain hole 601 may be increased in Z direction at least by 6 mm. Further, as per design calculations, and the type of application and required size of the switch 200, depth of the drain hole may be varied. Further, the drain hole 601 may have an oblong shape. Further, a water drain 602 may be provided to remove water accumulated in the fixed terminal 214 area depth of the water drain 602, 802.
Fig. 7 illustrates a sectional view 700 of the switch 200. The switch 200 may have chamfer 701 on the drain hole 601. The chamfer 701 is provided completely or partially on the drain hole 601 periphery to ease the water flow towards the drain hole 601.
Fig. 8 illustrates a sectional view 800 of the switch 200. Further, the illustration 800 provides another view of the chamfer 701 and the water drain 602.
Fig. 9 illustrates a sectional view 900 of the switch 200. In the implementation 900, the fixed terminal 214 may be guided with a housing wall 901. Further, the length of the housing wall 901 may be increased at least up to 4.5 mm. The housing wall 901 may be configured to completely fix the moment of the fixed terminal 214 in X- direction or in longitudinal direction along X-X.
The illustrated steps are set out to explain the exemplary embodiments shown, and it should be anticipated that ongoing technological development will change the manner in which particular functions are performed. These examples are presented herein for purposes of illustration, and not limitation. Further, the boundaries of the functional building blocks have been arbitrarily defined herein for the convenience of the description. Alternative boundaries can be defined so long as the specified functions and relationships thereof are appropriately performed. Alternatives (including equivalents, extensions, variations, deviations, etc., of those described herein) will be apparent to persons skilled in the relevant art(s) based on the teachings contained herein. Such alternatives fall within the scope and spirit of the disclosed embodiments.
ADVANTAGES OF THE PRESENT DISCLOSURE
Exemplary embodiments discussed above may provide certain advantages. Though not required to practice aspects of the disclosure, these advantages may include those provided by the following features.
In an embodiment, the housing and the knob 202 of the switch 200 are made up of electrically non-conductive material, which eliminates the chances of micro-weld formation on the surface of the compression spring.
In an embodiment, the present disclosure avoids the setting of compression spring.
In an embodiment, the switch of the present disclosure facilitates high endurance cycles.
,CLAIMS:I/ WE CLAIM:

1. A switch (200) comprising:
a panel (201) with a cavity (201-a);
a knob (202) disposed and protruding out of the cavity (201-a);
a housing (215) assembled below the panel (201), wherein the housing (215) comprising a cover assembly (20) and a terminal assembly (21), wherein the cover assembly (20) comprises a cover 210 with a base plate (210-a), wherein the base plate (210-a) is enabled with a hole (210-b), wherein a fixed contact (208) is housed in the hole (210-b) of the base plate (210-a);
characterized in that,
the terminal assembly (21) comprising:
a moving terminal (204), wherein a moving contact (205) is connected to a first end of the moving terminal (204), and wherein a second end of the moving terminal (204) is inserted into a fixed terminal (214) along with a torsion spring (206), wherein the torsion spring (206) is configured to engage with the moving terminal (204) to bias the moving contact (205) away from the fixed contact (208), wherein a pivot axis of the moving terminal (204) is oriented orthogonally to the direction of pressing of the knob (202), wherein the knob (202) is configured to engage with the moving terminal (204) on pressing of the knob (202), thereby engaging the moving contact (205) with the fixed contact (208).

2. The switch (200) as claimed in claim 1, wherein the moving terminal (204) is arranged below the knob (202), and wherein the moving terminal (204) is configured to translate a linear motion of the knob (202) to an angular displacement of the torsion spring (206).

3. The switch (200) as claimed in claim 1, wherein a vertical axis (Y2) of the moving contact (205) is offset to a vertical axis (Y1) of the knob (202), thereby reducing the force required to displace the moving contact (205) to connect with the fixed contact (208).

4. The switch (200) as claimed in claim 1, wherein the moving terminal (204) is an elongated arm, wherein the moving contact (205) is fixed at the first end of the moving terminal (204), and wherein the second end of the moving terminal (204) is inserted into the fixed terminal (214) along with the torsion spring (206).

5. The switch (200) as claimed in claim 1, wherein the torsion spring (206) comprises a fixed end (206-a) and a moving end (206-b), wherein the fixed end (206-a) is fixed in a notch (217) in the housing (215), wherein the moving end (206-b) is inserted into a notch provided on the moving terminal (204), and wherein the torsion spring (206) is connected to the fixed terminal (214) using a pivot pin (211) and a circlip (212).

6. The switch (200) as claimed in claim 1, wherein insulating washers (207, 209) are place at the periphery of the hole (208-a) to insulate the fixed contact (208) from the base plate (210-a).

7. The switch (200) as claimed in claim 1, wherein the knob (202) comprises a first leg (216) and a second leg (217), wherein the first leg (216) is longer than the second leg (217), wherein the first leg (216) and the second leg (217) are inserted into a pair of holes (215-a, 215-b) present at the top of the hosing (215), wherein the first leg (216) is in contact with the moving terminal (204), and wherein upon pressing of the knob (202), the first leg (216) is configured to press the moving terminal (204), thereby shifting the moving contact (205) towards the fixed contact (208).

8. The switch (200) as claimed in claim 1, wherein a compression spring (203) is enabled between the knob (202) and the housing (215), wherein the compression spring (203) is configured to bias the knob (202) away from the moving terminal (204), and wherein the torsion spring (206) and the compression spring (203) are electrically isolated from each other to avoid short circuit.

9. The switch (200) as claimed in claim 1, wherein the housing (215) comprise a drain hole (601) to avoid water accumulation at a contact area, wherein the contact area is formed between the fixed contact (208) and the moving contact (205), wherein a chamfer (701) is provided throughout the inner circumference of the drain hole (601) area to ease the water flow form the drain hole (601), wherein the housing (215) comprises a water drain (602) is provided to remove water accumulated around the fixed terminal (214) and the pivot (211), and wherein the housing (215) comprises a housing wall (901) configured to fix the movement of the fixed terminal (214) in longitudinal direction X-X.

10. The switch (200) as claimed in claim 1, wherein an electrical circuit is complete when the moving contact (205) and the fixed contact (208) touch each other, and wherein the electric circuit corresponds to at least one of operations of honking, vehicle powering, ignition, audio alert, and activation or deactivation of vehicle operations.

Dated this 23rd day of June 2022

Priyank Gupta
Agent for the Applicant
IN/PA-1454