DESC:Improved Combination-Switch Assembly

FIELD OF THE INVENTION

The present invention relates to combination switches and more particularly, to a combination-switch assembly having a push knob mounted on a lever unit for a vehicle.

BACKGROUND

There are numerous functionalities that a driver of a vehicle can use while driving the vehicle. Such functionalities may include, but are not limited to, wiper operation, defoggers, headlamps operation, indicators, cruise control, and lane watch. Usually, for ease of operation and convenience of the driver, control of these functionalities is provided in a combination switch. The combination switch may be mounted on a steering wheel column of the vehicle. In order to accommodate multiple such functionalities, the combination switch includes a large number of components. Owing to the geometry of such components, assembly of such components to form the combination switch is a tedious and cumbersome task. Consequently, maintenance of the combination switch is also complex and usually requires skilled labor.

Moreover, since contact areas in such conventional combination switches are not completely covered, there exists a possibility of foreign material entering into the combination switch. As a result, functioning of the combination switch may be adversely affected.

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.

In an embodiment of the present disclosure, a combination-switch assembly for a vehicle is disclosed. The combination-switch assembly includes a push knob mounted on a lever unit. The lever unit includes an upper knob region having guiding ribs to accommodate an axial movement of the push knob, and a middle knob region adapted to be locked with a lower knob region. The upper knob region includes a rubber seal insert-molded with the push knob and adapted to restrict an entry of foreign particles into the combination-switch assembly. The upper knob region further includes a rubber contact including a moving contact pill. The upper knob region includes a Printed Circuit Board (PCB) including a fixed contact gold track adapted to be in contact with the moving contact pill of the rubber contact. The upper knob region further includes at least one wire soldered with the PCB to transfer an electrical signal generated when the moving contact pill and the fixed contact gold track come in contact. The push knob is pushed to move axially downward pressing the rubber contact such that the moving contact pill comes into contact with the fixed contact gold track for switching the push knob. Further, the middle knob region includes at least one spring, and at least one steel ball assembled on the at least one spring. The at least one spring and the at least one steel ball operate to provide a rotary function between the upper knob region and the middle knob region.

In another embodiment of the present disclosure, a combination-switch assembly for a vehicle is provided. The combination-switch assembly includes a push knob mounted on a lever unit. The lever unit includes an upper knob region having guiding ribs to accommodate an axial movement of the push knob. The upper knob region is snap-locked with a PCB holder. The upper knob region includes a rubber seal insert-molded with the push knob and adapted to restrict an entry of foreign particles into the combination-switch assembly. The upper knob region further includes a rubber contact including a moving contact pill. The upper knob region includes a PCB including a fixed contact gold track adapted to be in contact with the moving contact pill of the rubber contact. The upper knob region further includes at least one wire soldered with the PCB to transfer an electrical signal generated when the rubber contact and the PCB come in contact. The push knob is pushed to move axially downward pressing the rubber contact such that the moving contact pill comes into contact with the fixed contact gold track for switching the push knob.

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 1 illustrates a schematic view of a conventional combination switch, in accordance with prior art;
Figure 2 illustrates a schematic view of a combination-switch assembly, according to an embodiment of the present disclosure;
Figure 3 illustrates a sectional view of a portion of the combination-switch assembly depicting a push knob, according to an embodiment of the present disclosure;
Figure 4 illustrates a sectional view of a portion of the combination-switch assembly depicting a position of at least one spring and at least one steel ball of a lever unit, according to an embodiment of the present disclosure; and
Figure 5 illustrates a sectional view of a portion of the combination-switch assembly depicting a drain pocket, 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 been necessarily been drawn to scale. For example, the flow charts illustrate the method in terms of the most prominent steps involved to help to improve understanding of aspects of the present invention. Furthermore, in terms of the construction of the device, one or more components of the device may have been represented in the drawings by conventional symbols, and the drawings may show only those specific details that are pertinent to understanding the embodiments of the present invention so as not to obscure the drawings with details that will be readily apparent to those of ordinary skill in the art having benefit of the description herein.

DETAILED DESCRIPTION OF FIGURES

For the purpose of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated system, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skilled in the art to which this invention belongs. The system, methods, and examples provided herein are illustrative only and not intended to be limiting.

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

Figure 1 illustrates a schematic view of a conventional combination switch 100, in accordance with prior art. As illustrated, a large number of components are required to form different units that control different functions provided by the combination switch 100. For example, a rotary operation to operate headlamp lighting is achieved using steel balls and springs. The steel balls and the springs are assembled in a lever light unit 102 that is further snap-locked with a Printed Circuit Board (PCB) holder 104. The lever light unit 102, after an assembly with the PCB holder 104, is further locked with a knob upper 106 to form a single unit.

In another example, a detent profile for a lighting function is formed on a separate part and assembled with a middle portion, also referred to as knob middle 108, of the combination switch 100. The knob middle 108 is fixed to a lower portion, also referred to as knob lower 110, of the combination switch 100, for example, by snap locking. In an example, the conventional combination switch 100 may include a light detent holder 112 for the detent profile.

In yet another example, for a rotary fog function, steel balls and springs are placed in a knob fog unit 114 of the combination switch 100. Further, a detent profile of the knob fog unit 114 is formed on a separate part and assembled with the knob middle 108. In an example, the conventional combination switch 100 may include a fog detent holder 116 for the detent profile. For enabling a fog functionality of the combination switch 100, a fixed contact copper alloy insulator is locked with the knob lower 110, and a moving contact is assembled with the knob fog unit 114. Further, for enabling the fog functionality, two wires are soldered with an insulator to transfer on/off signal to a vehicle.

As may be gathered from above, the conventional combination switches require a large number of parts to achieve push knob functionalities. Further, in existing combination switches, geometries of various parts are complex. Hence, such parts are difficult to manufacture and assemble as well. Moreover, such parts are difficult to maintain and require more efforts and highly skilled person. Consequently, an overall cost, constructional as well as operational, of the existing combination switches is high. In addition, as the contact areas are not completely covered, the foreign material may come in contact with the contact areas. As a result, functioning of the combination switch may get hampered as well.

The present disclosure relates to a push button type switch mounted on a top of a lever in a stalk combination switch. A push knob is guided by ribs provided in a mating part to control its axial movement. A push rod feature is provided in a center of the push knob to achieve desired operational function signals. An output of the push knob received in the form of electrical signals can be used for various functions. Further, the components used in a lever unit are optimized with respect to geometry and a number of parts required to achieve various functions.

Figure 2 illustrates a schematic view of a combination-switch assembly 200, according to an embodiment of the present disclosure. In an embodiment, the combination-switch assembly 200 may be disposed in a steering column of a vehicle. The combination-switch assembly 200 may include a push knob 202 mounted on a lever unit 204.

The lever unit 204 may include an upper knob region 206 having guiding ribs to accommodate an axial movement of the push knob 202, a middle knob region 208 adapted to be locked with a lower knob region 210.

Figure 3 illustrates a sectional view of a portion of the combination-switch assembly 200 depicting the push knob 202 and the upper knob region 206, according to an embodiment of the present disclosure. Referring to Figure 2 and Figure 3, the upper knob region 206 may include a rubber seal 212 insert-molded with the push knob 202. The rubber seal 212 may be adapted to restrict an entry of foreign particles into the combination-switch assembly 200. The foreign particles may include, but are not limited to, dust particles and water. In an embodiment, the rubber seal 212 may restrict the entry of the foreign particles when the push knob 202 is either OFF or in zero position. The upper knob region 206 may further include a rubber contact 242 including a moving contact pill.

The upper knob region 206 may include a Printed Circuit Board (PCB) 214 comprising a fixed contact gold track. The fixed contact gold track may be adapted to be in contact with the moving contact pill of the rubber contact 242. In an embodiment, the moving contact pill may include, but is not limited to, a gold contact pill and a carbon contact pill.

Further, the upper knob region 206 may include at least one wire soldered with the PCB 214 to transfer an electrical signal generated, when the rubber contact 242 and the PCB 214 come in contact with each other. In an embodiment, the push knob 202 may be pushed to move axially downward pressing the rubber contact 242 such that the moving contact pill comes into contact with the fixed contact gold track for switching the push knob 202. In an embodiment, the push knob 202 may be actuated for operating functionalities including, but not limited to, a front washer, a rear washer, a rear wiper, a front defogger, a rear defogger, a cruise control system, a lane watch system, an instrument panel-related functionalities, and an entertainment unit-related functionalities of the vehicle. In an embodiment, the rear wiper and the front wiper may be a single speed or variable speed wiper. Further, the instrument panel-related functionalities may include, but are not limited to, checking average speed, fuel efficiency, distance travelled, and driving time of the vehicle. Similarly, the entertainment unit-related functionalities may include, but are not limited to, Audio control, Bluetooth® connectivity, and phone related functionalities.

In an embodiment, the middle knob region 208 may include at least one spring 216 and at least one steel ball 218 assembled on the at least one spring 216. Figure 4 illustrates a sectional view of a portion of the combination-switch assembly 200 depicting a position of the at least one spring 216 and the at least one steel ball 218, according to an embodiment of the present disclosure. Referring to Figure 2 and Figure 4, in the present embodiment, the middle knob region 208 may include a pair of springs 216 and a pair of steel balls 218 assembled on a corresponding spring. The at least one spring 216 and the at least one steel ball 218 may operate to provide a rotary function between the upper knob region 206 and the middle knob region 208.

Referring to Figure 2, the combination-switch assembly 200 may further include a PCB holder 220 coupled, for example, snap-locked with the upper knob region 206. The PCB holder 220 may be adapted to support the PCB 214 through guided pins. Therefore, the PCB 214 may be mounted on the PCB holder 220, and the rubber contact 242 may be disposed on the PCB 214 to provide on/off signals upon the operation of the push knob 202. The PCB holder 220 may include a detent profile for coupling with the upper knob region 206 for enabling headlamp lighting function of the vehicle.

In an embodiment, the combination-switch assembly 200 may include a knob fog unit 222 assembled with the middle knob region 208. The knob fog unit 222 may further include a moving contact 234. The moving contact 234 may further include silver plating. The combination-switch assembly 200 may also include a fixed contact copper alloy insert-molded with a plastic insulator 238 locked with the lower knob region 210, and at least one wire 240 soldered with the fixed contact copper alloy insulator 238 to transfer ON/OFF signal to the vehicle. In an embodiment, the fixed contact copper alloy may include silver plating. In an embodiment, the PCB 214 having the gold track may replace the fixed contact copper alloy insert-molded with the plastic insulator 238.

In an embodiment, the middle knob region 208 may have a detent profile. Further, the knob fog unit 222 may be assembled with the middle knob region 208. The knob fog unit 222 may include at least one spring 224 and at least one steel ball 226 assembled on the at least one spring 224. In the present embodiment, the knob fog unit 222 may include a pair of springs 224 and a pair of steel balls 226 assembled on a corresponding spring. The at least one spring 224 and the at least one steel ball 226 operate to provide a fog rotary function.

In an embodiment, the combination-switch assembly 200 may include a lever light unit 228 snap-locked with the PCB holder 220. Further, the lever light unit 228 may be locked with the upper knob region 206. The combination-switch assembly 200 may further include an arm light unit 230 locked with the lever light unit 228 to form a single unit.

In an embodiment, the combination-switch assembly 200 may include a cord CP LW 232 connected to the PCB 214, and a knob cover light 236.

In an embodiment, the combination-switch assembly 200 may also include drain pockets formed along a length of the lever unit 204 to drain any foreign material entering into the lever unit 204. Figure 5 illustrates a sectional view of a portion of the combination-switch assembly 200 depicting the drain pocket 502, according to an embodiment of the present disclosure. For the sake of brevity, features of the present disclosure that are already explained in the description of Figure 2, Figure 3, and Figure 4 are not explained in detail in the description of Figure 5.

In an embodiment when the push knob 202 is in the OFF position or the zero position, foreign material may get accumulated in an upper groove. When the push knob 202 is operated to a position other than the OFF position or the zero position, the foreign material may enter into the lever unit 204 of the combination-switch assembly 200, it may flow out of the combination-switch assembly 200 through the drain pockets 502 provided in the lever unit 204.

In an embodiment, an output of the actuation of the push knob 202 may be low current and can directly be used for low current signal-based functionalities. In an embodiment, the combination-switch assembly 200 may include a controller which may assist in providing multiple synchronized outputs of the combination-switch assembly 200.

As would be gathered, the combination-switch assembly 200 of the present disclosure includes less number of components as compared to conventional combination switches. For example, in an embodiment of the present disclosure, the combination-switch assembly 200 includes 17 components in comparison to 20 components of the existing combination switch.

Further, a contact area of the PCB 214 is completely isolated such that probability of entering of foreign particles in the contact area of the push Knob 202 is almost zero. The rubber seal 212 forms a cover for the PCB 214 and also acts as a protection layer to restrict and prevent entry of the foreign material in the PCB contact area. Therefore, the contact area under the push knob 202 is water and dust proof. In an example, a water droplet test is conducted in actual vehicle mounting condition for 4 seconds and with 200ml of water. It was found that water droplets did not enter into the contact area at all. Similarly, a dust particle test is conducted for over 8 hours and it was found that the dust couldn’t enter the contact area due to sealing by the rubber seal 212.

Furthermore, in the combination-switch assembly 200 of the present disclosure, the detent profile is formed on the PCB holder 220 thereby resulting in easy and simple assembly process of the combination-switch assembly 200. Also, the springs 216, 224 and the steel balls 218, 226 are designed such that during the assembly of the lever unit 204, the springs 216, 224 and the steel balls 218, 226 are assembled in an assembly direction and the detent profile is assembled from the above direction and in turn, avoiding the possibility of falling of the steel balls 218, 226. Moreover, owing to less components and easy maintenance, an overall cost of the combination-switch assembly 200 is significantly reduced.

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:WE CLAIM:

1. A combination-switch assembly (200) for a vehicle, the combination-switch assembly (200) comprising:
a push knob (202) mounted on a lever unit (204); and
the lever unit (204) comprising:
an upper knob region (206) having guiding ribs to accommodate an axial movement of the push knob (202), the upper knob region (206) comprising:
a rubber seal (212) insert-molded with the push knob (202) and adapted to restrict an entry of foreign particles into the combination-switch assembly (200);
a rubber contact (242) comprising a moving contact pill;
a Printed Circuit Board (PCB) (214) comprising a fixed contact gold track adapted to be in contact with the moving contact pill of the rubber contact (242); and
at least one wire soldered with the PCB (214) to transfer an electrical signal generated when the moving contact pill and the fixed contact gold track come in contact,
wherein the push knob (202) is pushed to move axially downward pressing the rubber contact (242) such that the moving contact pill comes into contact with the fixed contact gold track for switching the push knob (202); and
a middle knob region (208) adapted to be locked with a lower knob region (210), the middle knob region (208) comprising:
at least one spring (216); and
at least one steel ball (218) assembled on the at least one spring (216), wherein the at least one spring (216) and the at least one steel ball (218) operate to provide a rotary function between the upper knob region (206) and the middle knob region (208).

2. The combination-switch assembly (200) as claimed in claim 1, wherein the push knob (202) is actuated for operating one of a front washer, a rear washer, a rear wiper, a front defogger, a rear defogger, a cruise control system, a lane watch system, an instrument panel-related functionalities, and an entertainment unit-related functionalities in the vehicle.

3. The combination-switch assembly (200) as claimed in claim 1, wherein the moving contact pill is one of a gold contact pill and a carbon contact pill.

4. The combination-switch assembly (200) as claimed in claim 1, further comprising a PCB holder (220) snap-locked with the upper knob region (206) and adapted to support the PCB (214) through guided pins, wherein the PCB holder (220) has a detent profile for coupling with the upper knob region (206) for headlamp lighting function.

5. The combination-switch assembly (200) as claimed in claim 1, further comprising:
a knob fog unit (222) assembled with the middle knob region (208), the knob fog unit (222) comprising a moving contact;
a fixed contact copper alloy insert-molded with a plastic insulator locked with the lower knob region (210); and
at least one wire soldered with the fixed contact copper alloy insulator to transfer ON/OFF signal to the vehicle.

6. The combination-switch assembly (200) as claimed in claim 1, further comprising:
the middle knob region (208) having a detent profile; and
a knob fog unit (222) assembled with the middle knob region (208), the knob fog unit (222) comprising:
at least one spring (224); and
at least one steel ball (226) assembled on the at least one spring (224), wherein the at least one spring (224) and the at least one steel ball (226) operate to provide a fog rotary function.

7. The combination-switch assembly (200) as claimed in claim 1, further comprising:
a lever light unit (228) snap-locked with the PCB holder (220) and locked with the upper knob region (206); and
an arm light unit (230) locked with the lever light unit (228) to form a single unit.

8. The combination-switch assembly (200) as claimed in claim 1, further comprising drain pockets (502) formed along a length of the lever unit (204) to drain any foreign material entering into the lever unit (204).

9. A combination-switch assembly (200) for a vehicle, the combination-switch assembly (200) comprising:
a push knob (202) mounted on a lever unit (204); and
the lever unit (204) comprising:
an upper knob region (206) having guiding ribs to accommodate an axial movement of the push knob (202), and snap-locked with a Printed Circuit Board (PCB) holder (220), the upper knob region (206) comprising:
a rubber seal (212) insert-molded with the push knob (202) and adapted to restrict an entry of foreign particles into the combination-switch assembly (200);
a rubber contact (242)comprising a moving contact pill;
a PCB (214) comprising a fixed contact gold track adapted to be in contact with the moving contact pill of the rubber contact (242); and
at least one wire soldered with the PCB (214) to transfer an electrical signal generated when the rubber contact (242) and the PCB (214) come in contact,
wherein the push knob (202) is pushed to move axially downward pressing the rubber contact (242) such that the moving contact pill comes into contact with the fixed contact gold track for switching the push knob (202).

10. The combination-switch assembly (200) as claimed in claim 9, further comprising:
a middle knob region (208) adapted to be locked with a lower knob region (210), the middle knob region (208) comprising:
at least one spring (216); and
at least one steel ball (218) assembled on the at least one spring (216), wherein the at least one spring (216) and the at least one steel ball (218) operate to provide a rotary function between the upper knob region (206) and the middle knob region (208).