The present invention generally relates to a switch assembly for a vehicle, and particularly, to a fuel cut-off switch assembly provided in a fuel inlet housing of the vehicle to control an ignition of an engine of the vehicle.

Background:

Generally, a vehicle includes a fuel inlet opening to provide/feed fuel to the vehicle. Further, the fuel inlet opening is provided with a door, so that any moisture or liquid content other than the fuel may not mix-up with the fuel. Further, it is necessary to turn-off the engine of vehicle while refueling the vehicle, to avoid any accidents. Sometimes the driver may not turn-off the engine while refueling the vehicle, which leads to a serious threat to the vehicle and a fuel station. To counter such issues, a fuel cut-off switch is introduced in the fuel inlet opening. Such switch may provide signal to an Electronic Control Unit (ECU) of the vehicle to turn-off the ignition of the engine.

Conventional fuel cut-off switch may include a body/housing provided with first contacts electrically connected to the ECU, and a second contact adapted to touch to the metal contact. The body is a semi-closed part, and an insulator may close the opened side of the body upon placing the contacts inside the body. Here, the second contact is provided in the body in such way that the second contact may get contact with the first contacts when the door of the fuel inlet is closed. In other words, the opening/closing of the door of the fuel inlet may affect movement of the second contact provided in the switch. As the insulator is connected to the body from a side to enclose the insulator, some holes/gaps are detrimentally formed between the insulator and the body. Such gaps may allow water/moisture or any liquid inside the body of the switch, which leads to malfunction of the switch. As a result, the switch may malfunction and may lead to any accidents. As the insulator is separately assembled to the body from a side of the body, the assembling-time of the switch may increase.

Accordingly, there remains a need for a cut-off switch configured to stop ignition of a vehicle while refueling the vehicle. Further, there remains another need for a design of a switch that restricts entering of water into the switch, thereby avoiding malfunctioning of the switch. Furthermore, there remains another need for a design of a switch that increases service life of the switch.

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 nor intended to determine the scope of the invention.

In an embodiment of the present disclosure, a switch assembly for a vehicle is disclosed. The switch assembly includes a housing, an insulator, a holder, and a cover. The housing includes a bottom portion and a top portion provided with at least one slot. Further, the insulator is received in the housing and adapted to be coupled to an inner surface of the top portion of the housing. The insulator includes at least one terminal pin, and at least one engaging member formed on a first surface of the insulator. Here, the engaging member is adapted to couple with the slot formed on the top portion of the housing to couple the insulator with the housing. Further, a holder is movably received in the top portion of the housing such that the holder is juxtaposed to the insulator and adapted to move relative to the insulator. Further, the holder includes a metal contact adapted to be in contact with the terminal pin when the holder moves towards the bottom portion of the housing, and the cover is adapted to encapsulate the top portion of the housing.

To further clarify the 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:

Fig. 1 illustrates a schematic view of a switch assembly for a vehicle, in accordance with an embodiment of the present invention;

Fig. 2 illustrates a schematic view of a housing of the switch assembly of Fig. 1;

Figs. 3-5 illustrate cross-sectional views of the switch assembly of Fig. 1 depicting various components of the switch assembly;

Fig. 6 illustrates a perspective view of the housing encapsulated by a cover of Fig. 1;

Fig. 7 illustrates an exploded view of the switch assembly of Fig. 1; and

Fig. 8 illustrates a schematic view of a position of the switch assembly in the vehicle, in accordance with an embodiment of the preset invention.

Further, skilled artisans will appreciate that elements in the drawings are illustrated for simplicity and may not have 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.

The term “some” as used herein is defined as “none, or one, or more than one, or all.” Accordingly, the terms “none,” “one,” “more than one,” “more than one, but not all” or “all” would all fall under the definition of “some.” The term “some embodiments” may refer to no embodiments or to one embodiment or to several embodiments or to all embodiments. Accordingly, the term “some embodiments” is defined as meaning “no embodiment, or one embodiment, or more than one embodiment, or all embodiments.”

The terminology and structure employed herein is for describing, teaching and illuminating some embodiments and their specific features and elements and does not limit, restrict or reduce the spirit and scope of the claims or their equivalents.

More specifically, any terms used herein such as but not limited to “includes,” “comprises,” “has,” “consists,” and grammatical variants thereof do NOT specify an exact limitation or restriction and certainly do NOT exclude the possible addition of one or more features or elements, unless otherwise stated, and furthermore must NOT be taken to exclude the possible removal of one or more of the listed features and elements, unless otherwise stated with the limiting language “MUST comprise” or “NEEDS TO include.”

Whether or not a certain feature or element was limited to being used only once, either way it may still be referred to as “one or more features” or “one or more elements” or “at least one feature” or “at least one element.” Furthermore, the use of the terms “one or more” or “at least one” feature or element do NOT preclude there being none of that feature or element, unless otherwise specified by limiting language such as “there NEEDS to be one or more . . . ” or “one or more element is REQUIRED.”

Unless otherwise defined, all terms, and especially any technical and/or scientific terms, used herein may be taken to have the same meaning as commonly understood by one having an ordinary skill in the art.

Reference is made herein to some “embodiments.” It should be understood that an embodiment is an example of a possible implementation of any features and/or elements presented in the attached claims. Some embodiments have been described for the purpose of illuminating one or more of the potential ways in which the specific features and/or elements of the attached claims fulfil the requirements of uniqueness, utility, and non-obviousness.

Use of the phrases and/or terms such as but not limited to “a first embodiment,” “a further embodiment,” “an alternate embodiment,” “one embodiment,” “an embodiment,” “multiple embodiments,” “some embodiments,” “other embodiments,” “further embodiment”, “furthermore embodiment”, “additional embodiment” or variants thereof do NOT necessarily refer to the same embodiments. Unless otherwise specified, one or more particular features and/or elements described in connection with one or more embodiments may be found in one embodiment, or may be found in more than one embodiment, or may be found in all embodiments, or may be found in no embodiments. Although one or more features and/or elements may be described herein in the context of only a single embodiment, or alternatively in the context of more than one embodiment, or further alternatively in the context of all embodiments, the features and/or elements may instead be provided separately or in any appropriate combination or not at all. Conversely, any feature and/or element described in the context of separate embodiments may alternatively be realized as existing together in the context of a single embodiment.

Any particular and all details set forth herein are used in the context of some embodiments and therefore should NOT be necessarily taken as limiting factors to the attached claims. The attached claims and their legal equivalents can be realized in the context of embodiments other than the ones used as illustrative examples in the description below.

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

Fig. 1 illustrates a schematic view of a switch assembly 100 for a vehicle, in accordance with an embodiment of the present invention. Here, the switch assembly 100 can be a cut-off switch configured to control ignition of the vehicle. In one example, the switch assembly 100 may be a fuel cut-off switch configured to control the ignition of the vehicle when the switch assembly 100 is activated. Further, the switch assembly 100, hereinafter referred to as switch 100, includes a primary housing 102, also referred to as a housing, a cover 112 and a secondary housing 116. In one example, the cover 112 may be a rubber cover adapted to encapsulate at least a part of a top portion of the housing 102 and the secondary housing 116 provided at a bottom portion of the housing 102. The switch 100 may be provided in a fuel inlet of the vehicle, so that the switch 100 may control the ignition of the vehicle depending on a position of a door of the fuel inlet. Particularly, the switch 100 may be disposed in the fuel inlet in such a way that opening/closing of the door of the fuel inlet may activate/deactivate the switch 100.

Fig. 2 illustrates a schematic view of the housing 102 of the switch 100 of Fig. 1. As described, the housing 102 may include the bottom portion 104 and the top portion 106 provided with at least one slot 106A. The cover 112 is adapted to enclose the top portion 106 of the housing 102, so that water or any foreign particles may not enter the housing 102. The housing 102 may include a locking part 102A adapted to engage with a foot portion of the cover 112. As shown in Fig. 2, the locking part 102A is protruded part formed on an outer surface of the top portion 106 of the housing 102. Here, the housing 102 can be a rectangular housing. The foot portion of the cover 112 is adapted to be coupled with the locking part 102A of the housing 102, so that the cover 112is firmly connected to the housing 102. Similarly, the housing 102A may include an extended part 102B connected to the bottom portion 104. Here, the extended part 102B may receive the secondary housing 116. In one example, the extended part 102B is designed in such a way that the extended part 102B can be received in the secondary housing 116. Further, the geometry and features of the housing 102 and cover 112 are described with respect to forthcoming figures.

Figs. 3-5 illustrate cross-sectional views of the switch 100 of Fig. 1 depicting various components of the switch 100. As described, the switch 100 includes the housing 102, the cover 112, and the secondary housing 116. In addition to that, the switch 100 further includes an insulator 108 received in the housing 102, and a holder 110 slidably received in the housing 102. Here, Fig. 3 illustrates a cross-sectional view of the switch 100 depicting placement of the insulator 108 and the holder 110. Further, the insulator 108 is adapted to be coupled to an inner surface of the top portion 106 of the housing 102. The insulator 108 further includes at least one terminal pin 202 and at least one engaging member 204 formed on a first surface of the insulator 108 as shown in Fig. 4.

Here, Fig. 4 illustrates a detailed cross-sectional view of the switch 100 depicting a locking arrangement of the insulator 108 with the housing 102. As described, the engaging member 204 is adapted to couple with the slot 106A formed on the top portion 106 of the housing 102. In one example, the engaging member 204 can be a snap-fit assembly adapted to deform while assembling the insulator 108 into the housing 102. Upon assembling, the engaging member 204 engages with the slot 106A formed in the housing 102 as shown in the detailed view of Fig. 4. Further, the terminal pin 202 may be extended from the top portion 106 to the bottom portion 104 of the housing 102. As shown in Fig. 3, the terminal pin 202 may be protruded out from the bottom portion 104 of the housing 102 and received in the secondary housing 116. In one example, the terminal pin 202 is imprinted into or partially encapsulated by the insulator 108. Further, the terminal pin 202 is formed along a length of the insulator 108 and protruded out from the bottom portion 104 of the housing 102.

Further, the holder 110 is movably received in the housing 102, particularly, the holder is slidably received in the top portion 106 of the housing 102 and juxtaposed to the insulator 108. Further, the holder 110 is adapted to move relative to the insulator 108 inside the housing 102. The the holder 110 includes a metal contact 206 adapted to be in contact with the terminal pin 202 when the holder 110 moves towards the bottom portion 104 of the housing 102. As explained, the holder 110 is a plastic part provided with a tension-loaded member 114 to move back the holder 100 to the top portion 106 of the housing 102. Here, the tension-loaded member 114 may be a spring that enables the relative movement of the holder 110 with respect to the insulator 108. The holder 110 may be offset to the insulator 108 so that the holder 110 can move relative to the insulator 108. In this example, the insulator 108 may be coupled with one wall of the housing 102, and the holder 110 may be slidably coupled to the opposite wall of the housing 102.

Referring to Fig. 5, the bottom portion 104 of the housing 102 may include a base 302 and an opening 304. Here, the terminal pin 202 may protrudes out from the bottom portion 104 of the housing 102 through the opening 304. Further, the tension-loaded member 114 is disposed between the base 302 of the housing 102 and an end of the holder 110, so that the tension-loaded member 114 can push the holder 110 towards the top portion 106 of the housing 102. Generally, the holder 110 may be in contact to the door of the fuel inlet through the cover 112, so that the movement, i.e., opening or closing, of the door may enable the holder 110 to move relative to the insulator 108. As a result, the metal contact 206 provided in the holder 110 may get in contact with the terminal pin 202 provided in the insulator 108, thereby triggering a signal to an electronic control unit of the vehicle to stop/start ignition of the vehicle.

Further, the insulator 108 further includes a protrusion 310 formed on a second surface of the insulator 108 and operatively in contact with the end of the holder 110. The protrusion 310 is formed on a surface of the insulator 108 that is opposite to the surface on which the engaging member 204 is formed. Here, the protrusion 310 is provided in the insulator 108 operatively in contact with the end of the holder 110, so that the holder 110 may not move towards the base 302 of the housing 102 beyond a threshold distance. Also, the protrusion 310 restricts the holder 110 inside the housing 102 so that the holder 110 may not pop-out from the top portion 106 of the housing 102 due to the expansion force of the tension-loaded member 114.

Further, the holder 110 includes a top part 312 formed on a top end of the holder 110 and protruded out from the top portion 106 of the housing 102. The top part 312 of the holder 110 may be in contact with a coupling part 314 of the cover 112. Here, the top part 312 and the coupling part 314 are complementary to each other, thereby any force acting on the coupling part 314 of the cover 112 may be transferred to the top part 312 of the holder 110. Further, the coupling part 314 may be in contact with the door of the fuel inlet of the vehicle. As the cover 112 made of rubber, it is flexible enough to enable movement of the top part 312 of the holder 110 without toping out from the top portion 106 of the housing 102. As a result, any foreign liquid may not enter the housing 102 and function of the switch 100 is not affected.

Fig. 6 illustrates a perspective view of the housing 102 encapsulated by the cover 112 of Fig. 1. As explained above, the slot 106A is provided on the top portion 106 of the housing 102 and the cover 112 is received on the housing 102 in such a way that the cover 112 fluidically isolate the slot 106A from the foreign liquids. Further, the housing 102 is made as a single component and adapted to receive the insulator 108 and the holder 110. Here, the slot 106A formed on the top portion 106 is necessary to couple the insulator 108 to the housing 102. As explained, the cover 112 may close the slot 106A formed on the top portion 106 and close the top end of the housing 102. Here, the insulator 108 and the holder 110 are disposed through the top end of the housing 102. Upon assembling the insulator 108 and the holder 110, the cover 112 is disposed on the top end of the housing 102, so that the housing 102 can be waterproof. Therefore, malfunction of the switch 100 can be avoided.

Fig. 7 illustrates an exploded view of the switch 100 of Fig. 1. Initially, the insulator 108 is received in the housing 102, so that the engaging member 204 can be engaged to the slot 106A formed in the housing 102. Here, the terminal pin 202 is provided in the insulator 108. Thereafter, the tension-loaded member 114 received in the base 302 of the housing 102. Upon that, the holder 110 with the metal contact 206 is received in the housing 102 in such a way that the holder 110 slides in the housing 102. To enable sliding of holder 110 in the housing 102, a pair of grooves 306 and a paid of ribs 308 are provided in the switch 100. Here, the pair of ribs 308 are complementary to and received in the pair of grooves 306. Particularly, the pair of grooves 306 is formed in the housing 102 and the pair of ribs 308 is formed on lateral sides of the holder 110. The pair of ribs 308 is adapted to be received in the pair of grooves 306 such that the pair of ribs 306 is adapted to move linearly in the pair of grooves 306, thereby enabling relative movement of the holder 110 with respect to the insulator 108.

As shown in Figs 3 and 7, the metal contact 206 is protruded out from the holder 110 in such way that the metal contact 206 may get contact with the terminal pin 202 when the holder 110 is slide towards the base 302 of the housing 102. For example, the metal contact 206 may be in contact with the terminal pin 202 when the door of the fuel inlet is closed. Thereafter, the terminal pin 202 is electrically connected to the ECU of the vehicle and the ECU may maintain the ignition of the vehicle. In case the door of the fuel inlet is open, the holder 110 of the switch 100 may move towards the top portion 106 of the housing 102, thereby disconnecting the contact between the metal contact 206 and the terminal pin 202. Further, the terminal pin 202 may stop transferring any signal to the ECU. Thereafter, the ECU may stop the ignition/fuel flowing to the engine of the vehicle.

Further, the extended portion 102B of the housing 102 is adapted to be received in the secondary housing 116. Here, the secondary housing 116 may include an electrical conductor configured to connect the terminal pin 202 to the ECU. As explained, the terminal pin 202 may be extended till the secondary housing 116 through the opening 304 formed in the extended portion 102A of the housing 102. Further, the secondary housing 116 is filled with a PU filling (Polyurethane Foam), so that the water or any foreign liquid may not enter the housing 102 through the secondary housing 116.

Fig. 8 illustrates a schematic view of a position of the switch 100 in the vehicle, in accordance with an embodiment of the preset invention. Here, the switch 100 is disposed in the fuel inlet 800, in such way the coupling part 314 of the switch can be in contact with the door 8002. In this example, the door 802, also referred to as fuel door, is an open condition. Hence, the switch 100 may trigger the ECU to turn off the ignition/fuel of the vehicle, thereby avoiding any accidents. Also, the switch 100 is provided with the cover 112 to encapsulate the housing 102. Therefore, the water or any foreign liquid may not enter the housing 102 of the switch 100, thereby avoiding malfunction of the switch 100 and increasing service life of the switch 100.

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.

We Claim:

1. A switch assembly (100) for a vehicle, comprising:
a housing (102) having a bottom portion (104) and a top portion (106) having at least one slot (106A);
an insulator (108) received in the housing (102) and adapted to be coupled to an inner surface of the top portion (106) of the housing (102), the insulator (108) comprising:
at least one terminal pin (202); and
at least one engaging member (204) formed on a first surface of the insulator (108) and adapted to couple with the slot (106A) of the top portion (106) of the housing (102) to couple the insulator (108) with the housing (102);
a holder (110) movably received in the top portion (106) of the housing (102) such that the holder (110) is juxtaposed to the insulator (108) and adapted to move relative to the insulator (108), the holder (110) comprising a metal contact (206) adapted to be in contact with the terminal pin (202) when the holder (110) moves towards the bottom portion (104) of the housing (102); and
a cover (112) adapted to encapsulate the top portion (106) of the housing (102).

2. The switch assembly (100) as claimed in claim 1, wherein the terminal pin (202) is formed along a length of the insulator (108) and protruding out from the bottom portion (104) of the housing (102).

3. The switch assembly (100) as claimed in claim 2, wherein the bottom portion (104) of the housing (102) comprising a base (302) and an opening (304), wherein the terminal pin (202) protrudes out from the bottom portion (104) through the opening (304).

4. The switch assembly (100) as claimed in claim 3, comprising a tension-loaded member (114) provided between an end of the holder (110) and the base (302) of the bottom portion (104) of the housing (102).

5. The switch assembly (100) as claimed in claim 4, comprising:
a pair of grooves (306) formed on opposite inner surfaces of the housing (102); and
a pair of ribs (308) formed on lateral sides of the holder (110) and adapted to be received in the pair of grooves (306) such that the pair of ribs (306) is adapted to move linearly in the pair of grooves (306).

6. The switch assembly (100) as claimed in claim 4, wherein the insulator (108) comprising a protrusion (310) formed on a second surface of the insulator (108) and operatively in contact with the end of the holder (110).

7. The switch assembly (100) as claimed in claim 1, wherein the holder (110) comprising a top part (312) protruding out from the top portion (106) of the housing (102).

8. The switch assembly (100) as claimed in claim 7, wherein the cover (112) comprising a coupling part (314) complementary to and in contact with the top part (312) of the holder (110), wherein the coupling part (314) is adapted to be in contact with a fuel door of the vehicle.

9. The switch assembly (100) as claimed in claim 4, comprising a secondary housing (116) formed below the bottom portion (104) of the housing (102), wherein the secondary housing (116) is filled with a PU filling.

10. The switch assembly (100) as claimed in claim 9, wherein an end of the terminal pin (202) is adapted to be received in the secondary housing (116) and is electrically connected to an electronic control unit of the vehicle.