FIELD OF THE INVENTION
The present invention relates to a handle-bar switch assembly. In particular, the present invention relates to an improved protective cover for switch module of the handle-bar switch assembly to prevent dirt and other contaminants from damaging the working parts of the switch without adversely effecting the operation of the switch.
BACKGROUND OF THE INVENTION
Generally, switches used in vehicles are exposed to harsh industrial environments which may accelerate the deterioration of the active components of the switch, thereby jeopardizing the good operation of the switch. Therefore, it is desirable to provide a cover around the exposed portion of the switch module in order to protect the interior of the switch module from the entrance of foreign matter such as water, oil and dust.
Conventionally, the switch module was protected by a single protection cover. The single protective covers of the prior art do not always provide a tight and continuous seal around the switch module openings which they are covering. Sometimes, the cover which covers the switch module is uneven or becomes loose over time because of the sealing mechanism employed. Thus, the foreign matter and other contaminants eventually leak behind the cover and damage the switch.
Therefore, the present invention provides an improved protective cover for a switch module and improved sealing mechanism to prevent the entry of the foreign particles inside the switch which may affect the working of the switch.
OBJECT OF THE INVENTION
The primary objective of the present invention is to provide an improved protective cover for a switch module to prevent direct entry of water, dust, grease and other contaminations.
Another objective of the present invention is to provide an improved sealing mechanism for sealing around the opening in a switch module which is housed inside the switch.
Yet another objective of the present invention is to enhance reliability of the switch module.

SUMMARY OF THE INVENTION
The present invention discloses a handle bar switch contact assembly with an improved protective cover for the start module housed inside the switch for preventing the direct entry of the dust, water, foreign particles which affects the inner working parts of the switch. The protective cover of the present invention has an improved sealing mechanism thereby sealing around the start module to provide a tight and continous sealing.
In one embodiment of the present invention, a handle-bar switch contact assembly comprises a upper switch console disposed on the upper part of the said switch contact assembly; a lower switch console disposed on the lower part of the said switch contact assembly, the said lower switch console comprising a switch button, a first cover accommodating a switch module which comprises a fixed contact and a moving contact which is mounted on a metallic bracket; a second cover comprising a lower end and an upper end; said second cover is disposed between the switch module and the first cover thereby housing the switch module to prevent the entry of contaminating particles; and a switch cover attached to the bottom of lower console switch.
In another embodiment of the present invention, the fixed contact of the switch contact assembly is located at the lower end of the second cover and the metallic bracket is pivoted near the upper end of the second cover so that moving contact is disposed near the lower end.
In yet another embodiment of the present invention, the fixed contact the switch contact assembly is disposed on the upper end of the second cover and the metallic bracket is pivoted near the lower end of the second cover so that moving contact is disposed near the upper end.
In still another embodiment of the present invention, the metallic bracket is attached to the switch button.
In another embodiment of the present invention, the said metallic bracket is pivoted under the force of a torsion spring to a pin which is attached to a terminal.
In yet another embodiment of the present invention, the second cover of the switch contact assembly is provided with one or more drain holes disposed at the lower end for draining out the contaminating particles.

In still another embodiment of the present invention, the switch cover is provided with one or more drain holes, said switch cover is attached to the bottom of lower switch console by a fastaning means so that drain holes of the switch cover is aligned with the drain holes of the second cover.
In another embodiment of the present invention, the fastening means is selected from a group comprising of screw, nut-bolts, rivets.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of the present invention are set forth with particularity in the appended claims. The invention itself, together with further features and attended advantages, will become apparent from consideration of the following detailed description, taken in conjunction with the accompanying drawings. One or more embodiments of the present invention are now described, by way of example only, with reference to the accompanied drawings wherein like reference numerals represent like elements and in which:
Figure 1 illustrates the right-hand side switch assembly showing switch button from lever holder side in accordance with one embodiment of the present invention.
Figure 2 illustrates the right-hand side switch assembly showing switch button from grip side in accordance with one embodiment of the present invention.
Figure 3 illustrates the sectional view of right hand side switch assembly of present invention showing double protection provided within switch console and start module to prevent entry of water, dust, grease and other contamination at contact areas according to one embodiment of the present invention.
Figure 4 illustrates the covered start module along with cover from other side according to one embodiment of the present invention.
Figure 5 illustrates another view of the covered start module along with start button according to one embodiment of the present invention.
Figure 6 illustrates a view of the switch assembly showing switch button from the wiring harness side in accordance with another embodiment of the present invention.

Figure 7 illustrates a view of the switch assembly showing switch button from the throttle end in accordance with another embodiment of present invention.
Figure 8 illustrates an exploded side sectional view of switch assembly showing all child parts used for the switch assembly in accordance with another embodiment of the present invention.
Figure 9 illustrates perspective view of switch module in accordance with another embodiment of the present invention.
Figure 10 illustrates a perspective view of switch module along with the cover of the said switch assembly in accordance with another embodiment of the present invention.
DETAILED DESCRIPTION
The present invention relates to a handle-bar switch assembly. In particular, the present invention relates to an improved protective cover for switch module of the handle-bar switch assembly to prevent dirt and other contaminants from damaging the working parts of the switch without adversely effecting the operation of the switch.
Figure 1 illustrates the right-hand side switch assembly showing start button from lever holder side in accordance with one embodiment of the present invention.
Figure 1 illustrates a start module in RH (right-hand side) handle bar switch module according to a preferred embodiment of the present invention. As shown in figure 1 the start switch module is housed inside the housing switch assembly. Due to adverse environmental conditions, the dirt, water, grease or other foreign contaminants enters the switch and damages the working parts of the start switch module thereby affecting the working of the switch. Hence, in the present invention, the start module is provided with a double protective cover which provides enhanced life due to prevention of direct entry of water, dust, grease and other contaminations.
Figure 2 illustrates the right-hand side switch assembly showing start button from grip side in accordance with one embodiment of the present invention.
In one embodiment, the start switch module is housed inside the housing of switch assembly, wherein the start module is provided with an improved cover for protecting the entry

of the foreign contaminants from entering inside thereby preventing malfunctioning of the start switch.
Figure 3 illustrates the sectional view of right hand side switch assembly of present invention. As shown in figure 3, a double protection is provided within lower switch console to prevent entry of water, dust, grease and other contamination at contact areas according to one embodiment of the present invention.
In one embodiment of the present invention, switch contact assembly comprises of an upper switch console (301) and a lower switch console (302). In the present invention, the lower switch console (302) comprises a first protection cover (303) in the form of a protection wall housing the entire switch module. The first protection cover (303) prevents the entry of water, dust, grease, and other contamination inside the start switch module. The first protection cover can be made as integral part of the lower switch console or it can be made as a separate part attached to the lower console. As shown in figure 3, the switch module comprises a fixed contact and a moving contact mounted on a metallic bracket.
Further, the present invention provides a second protection is provided in the form of a protective cover (304) around the wall of switch module, wherein the second cover (304) provided around the start switch module completely prevents the entry of the water, dust, oil or other contamination etc. inside the start switch module. The second cover comprises a lower end and an upper end.
The start switch module comprises two drain holes (306) at the base of lower switch console (302). If the contamination enters inside the start switch module and settles inside the console, drain holes (306) provided inside the start switch module helps in draining out the contamination. The start switch module along with a switch cover (305) is mounted at the bottom of the lower switch console (302). The switch cover (305) can be fastened to the lower console (302) by using a fastening means (307) such a screw, nut and bolt, rivet etc. One or more drain holes is provided in the switch cover located in such a manner so that the drain holes of the switch cover aligned with the drain holes of the second cover.
A start switch button is also positioned on the lower part of the lower switch console (302). The location of pressing the switch button pressing position is shifted downwards and pivot point is shifted upwards with respect to lower switch console (302).

The present design of the protective layer provides a double protection cover (the first protection cover (303) and the second protection cover (304)) over the contact area and prevents entry of water, dust, grease and other contamination and their accumulation. Even, if the water or dust enters inside contact area due to adverse environmental conditions, it will be drained out from bottom due to provision of drain holes (306) at the bottom of the lower switch console (302). The present embodiment will enhance the life cycle of whole switch assembly by providing double protection against contamination including water, dust and grease.
Figure 4 and Figure 5 illustrates a view of the switch assembly with switch module along with cover and switch button respectively according to an embodiment of the present invention.
In another embodiment of the present invention, the fully covered start switch module used for self-start motorcycles is enclosed within lower switch console (302) of the switch contact assembly. Accumulation of dust, grease, water or any other contamination at contact area will prevent the flow of current. Further, if water enters into the start switch module, then chances of module getting short circuit is high. Therefore, the present invention provides a double protection cover which is sealed around the start switch module in such a manner that the cover prevents direct entry of water and dust in the switch.
Figure 6 illustrates a view of the switch assembly showing switch button from the wiring harness side in accordance with another embodiment of the present invention.
In one embodiment, the said illustration is an alternate embodiment of the present invention with respect to Figure 1. As shown in figure 1, the fixed contact is located at the lower end of the second cover and the metallic bracket is pivoted near the upper end of the second cover so that moving contact is disposed near the lower end. In contrast, figure 6 shows a completely shifted view of the assembly of switch module. As shown in figure 6, the fixed contact is disposed on the upper end of the second cover and the metallic bracket is pivoted near the lower end of the second cover so that moving contact is disposed near the upper end. The switch module is housed inside the switch and the location of pressing the switch button pressing position is shifted upwards and pivot point is shifted downwards with respect to lower switch console. The switch-button pressing position is changed so as to increase the reliability of the switch module.

Figure 7 illustrates a view of the switch assembly showing switch button from the throttle end in accordance with another embodiment of present invention.
In one embodiment, the switch assembly illustrates shifted button pressing position with respect to lower switch console. The location of pressing the switch-button pressing position is shifted upwards and pivot point is shifted downwards with respect to lower switch console.
Figure 8 illustrates an exploded side-sectional view of switch assembly showing all child parts used for the switch assembly in accordance of an embodiment of the present invention.
In one embodiment, the switch module comprises a second protection cover (304) accommodating the fixed contact (802), the switch button (308), and a moving contact (801) attached to the switch button (308). The switch button (308) is mounted at the lower end of the lower switch console (302) along with drain holes (306).
The switch contact assembly comprises a metallic bracket attached to the switch button (308). In an embodiment, the metallic bracket is insert molded to the switch button (308) and a moving contact (801) is disposed on the metallic bracket. The switch button (308) is pivoted, under the force of a torsion spring to a pin (805). A terminal (804) which is conductively coupled with the moving contact is also pivoted to the pin (805). The metallic bracket can act as a conductive connection between the moving contact and the terminal. Alternatively, the bracket can be made of a plastic material which has a conductive wire connecting the terminal with the moving contact.
When the switch button is pressed manually, the moving contact (801) moves towards the fixed contact (802) and makes contact with the fixed contact (802). As shown in figures the surface of the contacts are curved so that the moving contact makes a point contact with the fixed contact. When point contact is made between the fixed and the moving contact, a closed circuit is formed thereby allowing the current to flow from the terminal (804) to the pin (805), then to the moving contact (801) via the metallic bracket and finally to the fixed contact (802).
The said sectional view is an alternate embodiment of present invention illustrates shifted pressing position of the switch button (308) with respect to lower switch console (302). Figure 8 reflects shifted moving contact (801) and fixed contact (802) location with respect to switch button (308) for the said assembly. The fixed and the moving contact are positioned higher such that they are protected from water ingression and water accumulation. The said switch module is

fastened or snap fitted with lower switch console (302). The said illustration is alternate embodiment of present Invention with respect to figure 3.
Particularly, the upper end of the second cover is provided with snap fit means so as to connect the second cover with the lower switch console. The lower end of the second cover is provided with an extended portion which has an opening for inserting the fastener for attaching the second cover with the first cover or lower switch console.
Figure 9 and Figure 10 illustrate a perspective view of switch module in accordance with another embodiment of the present invention.
Figure 9 and figure 10 illustrates switch module assembly showing switch button from wiring harness end and throttle end respectively. The said switch module assembly is alternate embodiment of present invention with respect to Figure 4 and Figure 5. The said illustration reflects shifted button pressing position with respect to lower switch console and the cover used for protection against water, dust and other contamination.
ADVANTAGES OF THE INVENTION
The present invention has following advantages:
i) The present invention protects the start switch module from any unwanted entry of
water, oil, dust or contaminations which affects the working parts of the start switch
thereby deteriorating the working of the start switch module, ii) The present invention will enhance the life cycle of whole switch assembly by
providing double protection against contamination including water, dust and grease, iii) The double cover protection provided around the start switch module completely
prevents the entry of contamination, iv) The drain holes provided on the lower switch case drains out the contaminations if it
enters the switching module, v) The higher position of the contacts protects these contacts in case of water ingression
and accumulation inside.
While the particular preferred embodiments of the present invention have been shown and
described, it will be obvious to those skilled in the art that changes and modifications may be
made without departing from the teachings of the invention. It is therefore contemplates that the
present invention cover any and all modifications, variations or equivalents that fall within the
scope of the basic underlying principles disclosed above and claimed herein.

We Claim:
1. A handle-bar switch contact assembly comprising :
(a) a upper switch console disposed on the upper part of the said switch contact assembly;
(b) a lower switch console disposed on the lower part of the said switch contact assembly, the said lower switch console comprising:
(i) a switch button,
(ii) a first cover accommodating a switch module which comprises a fixed contact and a moving contact which is mounted on a metallic bracket;
(iii) a second cover comprising a lower end and an upper end; said second cover is disposed between the switch module and the first cover thereby housing the switch module to prevent the entry of contaminating particles;and
(c) a switch cover attached to the bottom of lower console switch.
2. The switch contact assembly as claimed in claim 1, wherein the fixed contact is located at the lower end of the second cover and the metallic bracket is pivoted near the upper end of the second cover so that moving contact is disposed near the lower end.
3. The switch contact assembly as claimed in claim 1, wherein the fixed contact is disposed on the upper end of the second cover and the metallic bracket is pivoted near the lower end of the second cover so that moving contact is disposed near the upper end.
4. The switch contact assembly as claimed in any of the preceding claims, wherein the metallic bracket is attached to the switch button.
5. The switch contact assembly as claimed in any of the preceding claims, wherein the said metallic bracket is pivoted under the force of a torsion spring to a pin which is attached to a terminal.
6. The switch contact assembly as claimed in any of the preceding claims, wherein the second cover is provided with one or more drain holes disposed at the lower end for draining out the contaminating particles.

7. The switch contact assembly as claimed in any of the preceding claims, wherein the switch cover is provided with one or more drain holes, said switch cover is attached to the bottom of lower switch console by a fastening means so that drain holes of the switch cover is aligned with the drain holes of the second cover.
8. The switch contact assembly as claimed in any of the preceding claims, wherein the fastening means is selected from a group comprising of screw, nut-bolts, rivets.
9. A handle-bar switch contact assembly substantially as herein described with reference to the accompanying drawings.