FIELD OF THE INVENTION
The invention pertains to a modular switch for vehicles. More particularly, the present
invention relates to an improved modular switch comprising overlapping circuit for
current flow between the contact terminals in both single and dual circuit.
BACKGROUND OF THE INVENTION
Conventionally available switch with butt contact design generally comprises more
number of parts which are made of plastic and metallic. The more number of part
leads to overall more complex functionality. Also the conventional design are being
manufactured with number of processes such as soldering, orbital riveting, flaring,
insert moulding which ultimately results in high cost of the switch.
The conventional designs with butt contact are having single point continuity.
Therefore, the current flow through this single point gradually causes the deterioration
at the contact point and finally the failure of the switch.
As shown in figure 1(a) and (b), conventional switch comprises a no. of parts as knob,
housing, cover, insert, torsion spring, terminals, pin, rivet, steel ball, spring etc. The
moving part (knob) and fixed part (housing) carries mechanism through which current
flows when operated. In available switches, current flows through various parts such
as terminals, pin, torsion spring & knob insert, fixed rivet etc. Hence more voltage
drop due to complex or large circuit in conventional switch.
Further, the current flow continuity breaks in the circuit because of the fact that the
current flows through maximum number of parts. These conventional switches do not
have covered construction thereof. Therefore, there are chances of accumulating
insulating materials (such as dust) between the contact areas. Lastly, the switches are
easily affected by dirt and corrosion and hence, their life is short.
In conventional butt contact type design, when knob with moving contact is pressed to
make contact with fixed contact all the force applied by the user on the knob is
directly transferred to the contacts since they also act as a stopper for the switch
resulting in wear and tear and deformation of contacts.
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Thus, there is a need to provide an improved modular switch which overcomes one or
more of the aforesaid disadvantages.
OBJECTIVES OF THE PRESENT INVENTION
The main objective of the present invention is to overcome at least one of the above
shortcomings.
Another objective of the present invention is to provide an improved modular switch.
Still another objective of the present invention is to provide a modular switch
comprising overlapping circuit for current flow between the contact terminals in both
single and dual circuit.
Yet another objective of the present invention is to provide a modular switch having
controlled contact force.
SUMMARY OF THE PRESENT INVENTION
The present invention provides an improved modular switch comprising knob, at least
a moving contact, a main spring and one or more auxiliary springs, plurality of fixed
contacts or terminals. The modular switch of present invention consist butt contact
design. The modular switch of the present invention comprises lesser number of parts.
Hence, the functioning of the switch is simple and easy. The modular switch of the
present invention is provided with butt contact overlapping continuity instead of
single point contact design. By pressing the knob by the user, the moving contact
makes contact with provided terminals. The modular switch is being operable with
controlled force with the help of spring. A stopper wall is provided in the switch to
resist the knob by over-pressing after having its full travel. The assembly of modular
switch of the present invention is a completely covered structure which provides
protection from the dirt and dust. Also the manufacturing of the modular switch
includes lesser number of processes. Therefore, the overall cost can be reduced
effectively.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention itself, together with features and 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
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described, by way of example only, with reference to the accompanied drawings in
which:
FIGURE 1(a) and 1(b) show an exploded and assembled view of a conventional
switch;
FIGURE 2(a) and 2(b) show an exploded and assembled view of modular switch in
accordance with the present invention;
FIGURE 3 shows knob of the modular switch according to an embodiment of the
present invention;
FIGURE 4 shows housing of the modular switch according to an embodiment of the
present invention;
FIGURE 5 shows cover of the modular switch according to an embodiment of the
present invention; and
FIGURE 6 shows various metallic parts of the modular switch according to an
embodiment of the present invention.
FIGURE 7 shows different operational conditions of the modular switch according to
an embodiment of the present invention.
FIGURE 8 and 9 show the modular switch for dual circuit according to an
embodiment of the present invention.
Skilled artisans will appreciate that elements in the drawings are illustrated for
simplicity and have not necessarily been drawn to scale. For example, the dimensions
of some of the elements in the drawings may be exaggerated relative to other elements
to help to improve understanding of embodiments of the present invention.
DESCRIPTION OF THE PRESENT INVENTION
While the invention is susceptible to various modifications and alternative forms,
specific embodiment thereof has been shown by way of example in the drawings and
will be described in detail below. It should be understood, however that it is not
intended to limit the invention to the particular forms disclosed, but on the contrary,
the invention is to cover all modifications, equivalents, and alternative falling within
the spirit and the scope of the invention as defined by the appended claims.
Before describing in detail embodiments it may be observed that the novelty and
inventive step that are in accordance with the present invention reside in the
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construction of the structure for assisting in assembling of modular switch,
accordingly, the drawings are showing only those specific details that are pertinent to
understanding the embodiments of the present invention so as not to obscure the
disclosure with details that will be readily apparent to those of ordinary skill in the art
having benefit of the description herein.
The terms “comprises”, “comprising”, or any other variations thereof, are intended to
cover a non-exclusive inclusion, such that a setup, device that comprises a list of
components does not include only those components but may include other
components not expressly listed or inherent to such setup or device. In other words,
one or more elements in the 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.
Accordingly present invention provides a modular switch for a vehicle comprising a
housing, a cover for covering the said housing from one side, a pivot provided at inner
surface of housing at predetermined location, at least a pair of fixed contacts or
terminals i.e. first and second terminals disposed in the housing at an intermediate
surface, a main spring mounted on the pivot, at least an auxiliary spring disposed
between the moving contact and the knob, a knob pivotaly mounted in the housing on
the said pivot, at least a moving contact disposed on inner surface of the said knob at
predetermined location actuation of thereof with the help of main spring makes or
breaks the contact with the fixed terminals for making and breaking the circuit.
In one aspect of the present invention, the said fixed terminals are provided with flat
surface.
In one more aspect of the present, invention the said fixed terminals are placed coplaner
and in proximity to each other in the housing at the intermediate surface.
Another aspect of the present invention, the moving contact is mounted in the housing
such that upon application of force on knob, the moving contact makes contact with
the first and second terminals.
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Still another aspect of the present invention, the moving contact is provided with a
curved surface having predetermined length so as to make contact with first and
second terminals.
Yet another aspect of the present invention, the circuit is made when the moving
contact comes in contact with first and second terminals simultaneously.
Another aspect of the present invention, the said housing is provided with one or more
stopper elements to stop the movement of knob in the housing at predetermined
locations.
Still another aspect of the present invention, the pivot is protruded from inner surface
of housing at its middle wall at predetermined location.
The present invention provides a modular switch for a vehicle. Referring to figure 2-
9, which show various parts of the modular switch of the present invention and views
thereof, it can be observed that the same comprises:
Knob – 100;
Housing – 200;
Cover – 300;
Ball- plunger – 2;
Moving contact – 4;
Fixed Terminal – 5;
Main spring – 6;
Auxiliary spring – 7;
Pivot hole in knob – 101;
Casing in knob to accommodate moving contact – 102;
Protruded flat portion on knob – 103;
Pivot – 201;
Spring stopper – 202;
Panel lock – 203;
Intermediate surface for mounting of fixed terminals – 204;
Water protecting rib – 205;
Knob stopper – 206;
Drain hole – 207;
Cover lock – 301;
Connector lock – 302;
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Pivot point – 303.
Accordingly the present invention provides a modular switch comprising a housing, a
cover for housing, a knob, at least a pair of fixed contacts or terminals, a moving
contact, a main spring and at an auxiliary spring.
Referring figures 2 to 5, the housing comprises three side walls i.e. middle wall and
two side walls i.e. first and second side walls joined to the ends of middle wall. The
first side wall comprises a spring stopper on its inner surface at predetermined
location. A pivot is provided with middle wall and adjacent to first side wall at
predetermined location. The pivot is integrated with the housing according to an
embodiment of the present invention. At least a panel lock is being provided on outer
surface of side walls. The second side wall is provided with a knob stopper. This knob
stopper is made of a flat horizontal extended surface provided at the upper edge of the
second side wall. The bottom of the said knob stopper engages with edge of knob so
as to lock the position of knob as shown in figure 2(b). The housing is provided with
an intermediate surface for mounting of pair fixed contacts or terminal. The said pair
of fixed terminals comprises a first and second terminal. The middle surface is
provided with an inclined surface at its bottom edge and adjacent to second side wall.
A cover for covering the open side of housing is being provided as shown in figures
2(a), 2(c) and 5. The said cover (300) comprises a wall and a bottom surface. The
cover comprises wall(s) in conformity with walls of housing so as to form a cover
housing-knob assembly completely. The said cover is provided with one or more
cover locks and a pivot point at predetermined location. The cover engages with the
housing by means of cover lock. An inclined surface is provided with bottom surface
of the cover at predetermined location. The said inclined surface comprises one or
more connector locks. When cover lock of cover engages with the housing, the said
inclined surface of cover also engages with the inclined surface of housing with the
help of connector locks. The housing and cover are provided with a rectangular
groove along with inclined extended surfaces at bottom so as to create a small
opening at the bottom of the hosing-cover assembly. Referring to figures 4 and 5, the
housing comprises a water protecting rib and a drain hole.
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Referring figures 2(a) and 2(b), the knob is pivotably mounted on housing on the said
pivot. Referring to figure 3, the knob comprises pivot hole on its legs, at least a casing
for moving contact and a protruded flat portion at predetermined location at its bottom
edge. The protruded flat portion acts as stopper in released condition of knob as
shown in figure 2(b). The pivot hole is provided to accommodate the pivot integrated
in housing. The knob is mounted on the said pivot with a main spring provided
between pivot holes of the knob. The knob is able to move pivotally with respect to
the pivot. Upon movement of knob, the spring stopper acts as stopper for main spring
as shown in figure 2(b). The casing is provided in knob to accommodate a moving
contact. The moving contact and an auxiliary spring is snap locked with casing. A
main spring is disposed on the pivot so as to provide a controlled pivotal movement to
knob by means of resilience force of the main spring. The said knob comprises with
one or more casing on its inner surface. The casing is provided to accommodate a
moving contact. At least one auxiliary spring is disposed between the said moving
contact and the casing. The said auxiliary spring provides resilient force upon the
moving contact. This force helps the moving contact to apply controlled pressure on
fixed contacts or terminals. Upon application of force on knob by user, the knob
moves pivotaly, consequently the moving contacts makes contact with fixed contact.
The circuit is made to allow flow of current through the circuit elements. Upon
release of force or pressure from knob by the user, the knob will tend to move back to
its original position. During this movement, the edge of knob engages with the flat
surface of bottom of knob stopper.
Referring figures 6(a) and 6 (b), the fixed contacts or terminals are inserted moulded
at intermediate surface of the housing of the modular switch and after that both
terminal are separated by trimming process in such a way that in working condition
moving contact act as a contact bridge which connects both the terminals as shown in
figure 7(b) and 7(c). One of the terminal acts as a negative and other acts as a positive
terminal. Both the fixed contacts i.e. first and second contacts are placed in coplanar
manner and in proximity to each other. Therefore, when the moving contact is pressed
and touches both the terminals, the required circuit is established and current flow
takes place. On releasing the pressure from the knob, moving contact moves apart
from the terminals and both the terminals are no more in connection through moving
contact, as shown in figure 7(a). Hence, the established circuit breaks and no current
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flows through the terminals according to an embodiment of the present invention as
shown in figure 7(a). The surfaces of both the terminals may deteriorate at the point of
contact and may become non-flat surface after a period of service. Therefore, the
moving contact has been provided with a curve-shaped bottom surface according to
an embodiment of the present invention as shown in figure 6(c). As the moving
contact has curve-shaped bottom surface and houses with a spring, therefore the
moving contact connects both the terminals even in deteriorated and non-flat
condition as shown in figure 7(c).
According to an embodiment of the present invention, in dual circuit, the modular
switch comprises a knob, a main spring, two moving contacts, two pairs of terminals
i.e. two first terminals and two second terminal and at least two auxiliary spring as
shown in figures 8 and 9. In dual circuit, as shown in figure- 8 two spring loaded
moving contacts are assembled within knob at predetermined locations. The main
spring is assembled within the space provided in knob to achieve dual position. A
pivot in housing/knob is used for angular swivel movement of knob. Two pairs of
terminals i.e. four terminals used to make dual circuit. Two terminals are for output
signal and two terminals are for input signal. According to an embodiment of the
present invention one terminal, which is common for both circuit, can also be used for
input signal. At least one moving contact is always in contact with two terminals (one
output and one/ common input terminal) when knob is in released position. When
knob is pressed, other moving contact makes contact with other two terminals (one
output and one/ common input terminal), as shown in figure 8(a) and 8(b). An angular
portion is provided on the adjacent wall of the housing. The angular portion acting as
stopper to restrict the overpressing of knob.
As shown in figure 9 two spring loaded moving contacts are assembled within knob.
A spring loaded ball/ plunger is assembled within knob, which is guided in detent
provided in housing to achieve dual position. The pivot in housing/ knob is used for
angular swivel movement of knob.
The operation of modular switch of the present invention is being controlled by
contact force with the help of auxiliary springs. The spring is housed with the moving
contact. When the knob is pressed, moving contact makes a contact with both
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terminals at a certain travel and just before the full travel of the knob. After the
making of contact, and for the full travel of the knob, the angular portion acts as
stopper for the knob. Therefore, the force generated by the overpressing of the knob
by the user after making of contact is controlled by the spring. Further force generated
after the full travel is transferred to the stopper and not the moving contact.
The foregoing description has described only a few of the many possible
implementations of the present invention. Thus, the description is given only by way
of illustration and nothing contained in this section should be construed to limit the
scope of the invention.
ADVANTAGES OF THE PRESENT INVENTION
The main advantage of the present invention is to provide a modular switch in which
current flows between both the terminals thorough moving contact.
Another advantage of the present invention is to provide the moving contact with a
curve-shaped bottom surface which enables the connection between moving contact
and both terminals even in deteriorated and non-flat condition.
Still another advantage of the present invention is to provide the modular switch with
lesser number of part which results in simple and easy functioning.
Further advantage of the present invention is to provide the modular switch with
circuit where minimal voltage drop will take place which improves the quality and
reliability of the modular switch.
Further more advantage of the present invention is to provide a modular switch which
can be manufactured with lesser number of manufacturing processes which ultimately
results in reduction in effective cost of modular switch.
Another advantage of the present invention is to provide a modular switch with
controlled contact force type design upon application of force on the knob by user.
Yet another advantage of the present invention is to provide a completely covered
modular switch facilitating the safety from dust and dirt.
The inventors have been working to develop the invention, so that advantage can
be achieved in an economical, practical, and facile manner. While preferred
aspects and example configurations have been shown and described, it is to be
understood that various further modifications and additional configurations will
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be apparent to those skilled in the art. It is intended that the specific embodiments
and configurations herein disclosed are illustrative of the preferred nature of the
invention, and should not be interpreted as limitations on the scope of the invention.

We claim:
1. A modular switch for a vehicle comprising:
a housing (200);
a cover (300) for covering the said housing from one side;
a pivot (201) provided at inner surface of housing at predetermined location;
at least a pair of fixed contacts or terminals (5) i.e. first and second terminals
disposed in the housing at an intermediate surface (204);
a main spring (6) mounted on the pivot;
a knob pivotaly mounted in the housing on the said pivot;
at least a moving contact (4) disposed on inner surface of the said knob at
predetermined location actuation of thereof with the help of main spring (6)
makes or breaks the contact with the fixed terminals (5) for making and
breaking the circuit and
at least an auxiliary spring (7) disposed between the moving contact (4) and
the knob (100).
2. The switch as claimed in claim 1, wherein the said fixed terminals are
provided with flat surface.
3. The switch as claimed in claim 1, wherein the said fixed terminals are placed
co-planer and in proximity to each other in the housing at the intermediate
surface.
4. The switch as claimed in claim 1, wherein the moving contact is mounted in
the housing such that upon application of force on knob, the moving contact
makes contact with the first and second terminals.
5. The switch as claimed in claim 1, wherein the moving contact is provided with
a curved surface having predetermined length so as to make contact with first
and second terminals.
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6. The switch as claimed in claim 1, wherein the circuit is made when the
moving contact comes in contact with first and second terminals
simultaneously.
7. The switch as claimed in claim 1, wherein the said housing is provided with
one or more stopper elements to stop the movement of knob in the housing at
predetermined locations.
8. The switch as claimed in claim 1, wherein the pivot is protruded from inner
surface of housing at its middle wall at predetermined location.