Control devices having independently suspended buttons for controlled actuation

• US 10,181,385 B2
• Filed: 04/20/2016
• Issued: 01/15/2019
• Est. Priority Date: 04/20/2015
• Status: Active Grant

• Current Assignee: Lutron Electronics Company Incorporated (Lutron Electronics)
• Original Assignee: Lutron Electronics Company Incorporated (Lutron Electronics)
• Inventors: Bhate, Nikhil Vithal, Destremps, Rich, Harrison, James, Jennings, Jason Edward, Mace, Eric Jonathan, Phillips, Stephen
• Primary Examiner(s): Jimenez, Anthony R.
• Application Number:
  US15/134,299
• Publication Number:
  US 20160307714A1
• Time in Patent Office: 1,000 Days
• Field of Search: 200 5 A
• CPC Class Codes: H01H 13/70 having a plurality of operating members associated with different sets of contacts, e.g. keyboard mounting together a plurality of independent switches H02B
• CPC Class Codes: H01H 13/83 characterised by legends, e.g. Braille, liquid crystal displays, light emitting or optical elements
• CPC Class Codes: H01H 13/84 characterised by ergonomic functions, e.g. for miniature keyboards; characterised by operational sensory functions, e.g. sound feedback legends H01H13/83
• CPC Class Codes: H01H 2209/006 Force isolators
• CPC Class Codes: H01H 2215/006 Only mechanical function
• CPC Class Codes: H01H 2215/012 Positioning of individual dome
• CPC Class Codes: H01H 2215/018 unstressed in open position of switch
• CPC Class Codes: H01H 2219/002 replaceable; adaptable
• CPC Class Codes: H01H 2219/04 Attachments; Connections
• CPC Class Codes: H01H 2219/06 Reflector
• CPC Class Codes: H01H 2219/062 Light conductor
• CPC Class Codes: H01H 2221/05 Force concentrator; Actuating dimple
• CPC Class Codes: H01H 2223/0345 with keys positioned directly next to each other without an intermediate bezel or frame
• CPC Class Codes: H01H 2227/018 Printed contacts; Metal foil
• CPC Class Codes: H01H 2227/026 Separate dome contact
• CPC Class Codes: H01H 2229/022 Modular assembly
• CPC Class Codes: H01H 2231/052 Selectors, e.g. dimmers
• CPC Class Codes: H01H 2233/04 captured between assembled parts of support
• CPC Class Codes: H01H 2235/018 Spring seat

Abstract

A control device includes a button assembly having one or more buttons and a button carrier that includes a plurality of resilient, independently deflectable spring arms. The control device may be configured as a wall-mounted keypad to control a load control device, or as a thermostat to control a temperature regulation appliance. The button carrier may be configured to prevent interference between the buttons during operation of the control device. The button assembly may be captured between a faceplate of the control device and a housing that is attached to a rear side of the faceplate. The control device may include one or more button retainers that are attached to the buttons and that are configured to align respective outer surfaces of the buttons relative to each other, and relative to the faceplate of the control device, when the buttons are in respective rest positions.

Claims

1. A control device configured for use in a load control system that controls an amount of power delivered to an electrical load, the control device comprising:

a faceplate that defines an opening that extends therethrough;

a button assembly that includes at least two buttons, a button carrier to which the at least two buttons are attached, the at least two buttons configured to be received within the opening of the faceplate; and

a control module that includes;

a printed circuit board (PCB) having at least two pairs of electrical contacts, each pair of electrical contacts configured to be electrically connected together in response to an actuation of a respective one of the at least two buttons;

at least two electrical shorting pads, each electrical shorting pad corresponding to a respective one of the at least two buttons;

at least one lighting element that is configured to illuminate an inner surface of at least one of the at least two buttons; and

a light guide assembly that is configured to disperse light emitted by the at least one lighting element, the light guide assembly including a carrier layer that has the at least two electrical shorting pads attached thereto,

wherein each pair of electrical contacts comprises an open circuit pad on the PCB, each open circuit pad corresponding to one of the at least two electrical shorting pads, and

wherein the control module is configured to be attached to the faceplate such that the button assembly is captured by, and floats between, the faceplate and the control module.

2. The control device of claim 1, wherein the button assembly further comprises a light blocker that is configured to block at least a portion of the light emitted by the at least one lighting element.

3. The control device of claim 2, wherein the light blocker includes at least one translucent region that is configured to permit light emitted from the at least one lighting element to illuminate the inner surface of one of the at least two buttons, and further includes an opaque region that is configured to block light emitted from the at least one lighting element from illuminating a gap between the at least two buttons.

4. The control device of claim 1, wherein the light guide assembly further includes a light guide film layer that is disposed adjacent to the carrier layer.

5. The control device of claim 4, wherein the light guide assembly further includes a spacer layer that is attached to a rear surface of the carrier layer, the spacer layer defining at least one opening that is aligned with the at least two electrical shorting pads.

6. The control device of claim 4, wherein the light guide assembly further includes at least two force concentrators that are disposed between the carrier layer and the light guide film layer, wherein each of the at least two force concentrators is aligned with a corresponding one of the at least two buttons.

7. The control device of claim 4, wherein the light guide film layer includes a first region that disperses light emitted by the at least one lighting element behind a first one of the at least two buttons, and a second region that disperses light emitted by the at least one lighting element behind a second one of the at least two buttons.

8. The control device of claim 7, wherein the at least one lighting element comprises:

a first light emitting diode that is disposed near a side of the first one of the at least two buttons; and

a second light emitting diode that is disposed near a side of the second one of the at least two buttons.

9. The control device of claim 7, wherein the at least one lighting element comprises:

a first pair of light emitting diodes that are disposed near opposed sides of the first one of the at least two buttons; and

a second pair of light emitting diodes that are disposed near opposed sides of the second one of the at least two buttons.

10. The control device of claim 9, wherein the first and second pairs of light emitting diodes are mounted to a surface of the PCB.

11. The control device of claim 9, wherein the light guide assembly further includes a first reflector strip that is disposed along a first side of the light guide film layer, and a second reflector strip that is disposed along an opposed second side of the light guide film layer.

12. The control device of claim 1, wherein the button assembly further comprises a deflectable return member that is configured to bias one of the at least two buttons from a depressed position to a rest position.

13. The control device of claim 12, wherein the deflectable return member comprises a pair of resilient contact domes, each contact dome corresponding to one of the at least two buttons, wherein each resilient contact dome is configured to collapse when a corresponding one of the at least two buttons is operated to the depressed position, and to resiliently bias the corresponding one of the at least two buttons to the rest position when operation of the corresponding one of the at least two buttons is ceased.

14. The control device of claim 13, wherein each contact dome defines an actuator that abuts an inner surface of a corresponding one of the at least two buttons when the corresponding one of the at least two buttons is in the rest position.

15. A control device configured for use in a load control system that controls an amount of power delivered to an electrical load, the control device comprising:

a faceplate that defines an opening that extends therethrough;

a button assembly that includes at least two buttons and a button carrier to which the at least two buttons are attached, the at least two buttons configured to be received within the opening of the faceplate;

a control module that includes a printed circuit board (PCB) having at least two pairs of electrical contacts, each pair of electrical contacts configured to be electrically connected together in response to an actuation of a respective one of the at least two buttons; and

an adapter that is configured to be mounted to a structure,

wherein the adapter and the faceplate are configured such that the faceplate is removably attachable to the adapter, and

wherein the control module is configured to be attached to the faceplate such that the button assembly is captured by, and floats between, the faceplate and the control module.

16. A control device configured for use in a load control system that controls an amount of power delivered to an electrical load, the control device comprising:

a faceplate that defines an opening that extends therethrough;

a button assembly that includes at least two buttons and a button carrier to which the at least two buttons are attached, the at least two buttons configured to be received within the opening of the faceplate; and

a control module that includes a printed circuit board (PCB) having at least two pairs of electrical contacts, each pair of electrical contacts configured to be electrically connected together in response to an actuation of a respective one of the at least two buttons,

wherein the control module is configured to be attached to the faceplate such that the button assembly is captured by, and floats between, the faceplate and the control module, and

wherein when the button assembly is captured between the control module and the faceplate, the button carrier is not constrained from moving along a direction that extends parallel to a front surface of the faceplate such that the at least two buttons are moveable between opposed inner surfaces of the opening.

17. The control device of claim 16, wherein the control module further includes at least two electrical shorting pads, each electrical shorting pad corresponding to a respective one of the at least two buttons.

18. The control device of claim 17, wherein each pair of electrical contacts comprises an open circuit pad on the PCB, each open circuit pad corresponding to one of the at least two electrical shorting pads.

19. The control device of claim 18, wherein the control module further comprises at least one lighting element that is configured to illuminate an inner surface of at least one of the at least two buttons.

20. The control device of claim 19, wherein the button assembly further comprises a light guide assembly that is configured to disperse light emitted by the at least one lighting element, the light guide assembly including a carrier layer that has the at least two electrical shorting pads attached thereto.

21. The control device of claim 16, wherein each button of the at least two buttons of the button assembly defines four corners along a perimeter of the button and the button carrier includes a plurality of resilient, independently deflectable spring arms, wherein the at least two buttons are attached to the button carrier such that a corner of each of the at least two buttons is suspended by a corresponding one of the deflectable spring arms.

22. The control device of claim 21, wherein the plurality of deflectable spring arms are configured to prevent interference between the at least two buttons during independent operation of the at least two buttons, and during simultaneous operation of the at least two buttons.

23. The control device of claim 21, wherein the button carrier is further configured to support the at least two buttons in a linear array.

24. The control device of claim 16, wherein the control module further includes a housing that is configured to receive the PCB, and that is further configured to capture the button assembly.

25. The control device of claim 24, wherein the control module is configured to be attached to the faceplate by securing the housing to a rear side of the faceplate with screws.

26. The control device of claim 25, wherein the housing is configured to floatingly support the button assembly.

27. The control device of claim 16, wherein when the button assembly is captured between the control module and the faceplate, the button carrier is constrained from moving along a direction that extends perpendicular to a front surface of the faceplate.

28. A control device configured for use in a load control system that controls an amount of power delivered to an electrical load, the control device comprising:

a faceplate that defines an opening that extends therethrough;

a button assembly that includes at least two buttons and a button carrier to which the at least two buttons are attached, the at least two buttons configured to be received within the opening of the faceplate; and

a housing that is configured to be attached to a rear side of the faceplate such that the button assembly is captured between the faceplate and the housing,

wherein when the button assembly is captured between the faceplate and the housing, the button carrier is constrained from moving along a direction that extends perpendicular to a front surface of the faceplate, and is moveable along a direction that extends parallel to the front surface of the faceplate between opposed sides of the opening.

29. The control device of claim 28, further comprising:

an adapter that is configured to be mounted to a structure,

wherein the adapter and the faceplate are configured such that the faceplate is removably attachable to the adapter.

30. The control device of claim 28, further comprising:

a printed circuit board (PCB) that is configured to be received in a void of the housing, the PCB having at least two open circuit pads, each open circuit pad configured to be electrically shorted in response to an actuation of a respective one of the at least two buttons.

31. The control device of claim 28, wherein the button carrier is configured to prevent interference between the at least two buttons during independent operation of the at least two buttons, and during simultaneous operation of the at least two buttons.

32. A control device configured for use with a temperature regulation appliance, the control device comprising:

a button assembly that includes at least two buttons and a button carrier to which the at least two buttons are attached;

a printed circuit board (PCB) having at least two pairs of electrical contacts, each pair of electrical contacts configured to be electrically connected together in response to an actuation of a respective one of the at least two buttons; and

at least two button retainers, the at least two button retainers configured to, when the at least two buttons are in respective rest positions, abut a rear surface of the PCB such that respective outer surfaces of the at least two buttons are aligned relative to each other,

wherein the PCB defines a plurality of apertures that extend therethrough, and wherein each of the at least two buttons includes two pairs of posts that extend in a rearward direction from the button, each post configured to extend through one of the plurality of apertures and to attach to a corresponding one of the at least two button retainers.

33. The control device of claim 32, wherein the button assembly further comprises at least two deflectable return members, each return member configured to bias a corresponding one of the at least two buttons from a depressed position to a rest position.

34. The control device of claim 32, wherein the button carrier includes at least two button frames and at least one resilient, independently deflectable spring arm that connects the at least two button frames, wherein each of the at least two buttons is attached to a corresponding one of the at least two button frames.