Traditional-opening dimmer switch having a multi-functional button

• US 20070216318A1
• Filed: 03/16/2007
• Published: 09/20/2007
• Est. Priority Date: 03/17/2006
• Status: Active Grant

• Current Assignee: Lutron Technology Company LLC
• Original Assignee: Lutron Electronics Company Incorporated (Lutron Electronics)
• Inventors: Altonen, Gregory, Chambers, Samuel, Mace, Eric, Ochs, Matthew, Rollo, Louis
• Granted Patent: US 7,837,344 B2
• Time in Patent Office: Days
• US Class Current: 315/209.R
• CPC Class Codes: G02B 6/0001 specially adapted for lighting devices or systems lighting or signalling on vehicles using light guides B60Q1/00; lighting devices for vehicle dashboards B60Q3/10; lighting devices for vehicle interior using light guides B60Q3/62; lighting devices mounted on the vehicle rear part using light guides F21S43/235; measuring arrangements having light conducting pointers G01D13/265; illumination of liquid crystal displays G02F1/1336; illuminated signs G09F13/00
• CPC Class Codes: G02B 6/0068 Arrangements of plural sources, e.g. multi-colour light sources
• CPC Class Codes: H01H 13/023 Light-emitting indicators for multi-layer switches H01H13/83
• CPC Class Codes: H01H 15/102 comprising cam devices
• CPC Class Codes: H01H 2013/026 with two or more independent lighting elements located inside the push button switch that illuminate separate zones of push buttons
• CPC Class Codes: H01H 3/0213 Combined operation of electric switch and variable impedance, e.g. resistor, capacitor H01H9/061 takes precedence
• CPC Class Codes: H05B 39/044 continuously H05B39/042 takes precedence
• CPC Class Codes: Y02B 20/00 Energy efficient lighting technologies, e.g. halogen lamps or gas discharge lamps

Abstract

A load control device, for controlling the amount of power delivered to a electrical load from an AC power source, comprises a user interface adapted to be received in an opening of a traditional-style faceplate and providing a plurality of functionalities on a single control button. A transitory actuation of the control button controls the power delivered to the load. Pulling the control button away from the load control device actuates an air-gap switch to provide an air-gap break in the electrical connection between the source and the load. A linear array of status indicators is provided on a front surface of the control button and displays a visual representation of the amount of power being delivered to the load. A plurality of light pipes are provided inside the control button to conduct the light from a plurality of light-emitting diodes to the front surface of the control button.

Claims

1. A control structure for controlling the power to be applied to an electrical system from an AC power source, said control structure comprising:

a cover plate defining a rectangular opening therein, said rectangular opening having a length and a width;

a first rectangular depressible control button coupleable to said electrical system to turn said system on and off, said first button disposed adjacent one side of the length of said rectangular opening in said cover plate, said first button filling said length of said rectangular opening and about one-half the width of said rectangular opening in said cover plate;

a second rectangular depressible power-increase button coupleable to said electrical system to increase the power applied to said electrical system;

a third depressible rectangular power-decrease button coupleable to said electrical system to decrease the power applied to said electrical system, said second and third buttons being arranged lengthwise adjacent one another within the remaining half of the width of said rectangular opening in said cover plate and extending for said length of said rectangular opening, whereby said first, second, and third buttons fill the full area of said rectangular opening in said cover plate; and

a support frame supporting said first, second, and third buttons.

2. The control structure of claim 1, which further comprises:

a narrow slot centrally disposed along at least a portion of the length of said first button; and

a linear illumination array disposed along the length of said narrow slot, said linear illumination array being energizable from said electrical system to produce a visual output along its length related to the amount of power transmitted to said electrical system in response to an actuation of either of said second or third buttons.

3. The control structure of claim 2, wherein said linear illumination array comprises a plurality of light-conducting pipes each having one end terminating within said slot and spaced along the length of said slot, and a second end coupled to respective ones of an array of light-emitting diodes disposed on a circuit board beneath said cover plate.

4. The control structure of claim 3, wherein the surfaces of said first, second, and third buttons extend through said rectangular opening in said cover plate and beyond the surface of said cover plate for convenient access by a user.

5. The control structure of claim 4, wherein said rectangular opening in said cover plate has a length greater than its width.

6. The control structure of claim 5, wherein said rectangular opening in said cover plate has a length of about 0.925 inch and a width of about 0.401 inch.

7. The control structure of claim 4, wherein said surfaces of said second and third buttons define a single continuous appearance surface having a positive curvature above the plane of said cover plate.

8. The control structure of claim 4, wherein at least the length-wise edges of said surfaces of said first, second, and third buttons are chamfered.

9. The control structure of claim 2, wherein said electrical system is one of a dimmable lighting load or motor control.

10. The control structure of claim 2, further comprising:

an air-gap switch in series with said electrical system, said air-gap switch connected to said first button;

wherein said first button is operable to be manually pressed in one direction toward the surface of said cover plate and pulled away in a second direction above said cover plate, said air-gap switch operable to close when said first button is moved in said first direction and open when said first button is moved in said second direction.

11. The control structure of claim 1, further comprising:

a thin shroud integral with and extending from said support frame and into the peripheral sides of said rectangular opening in said cover plate, the walls of said shroud being disposed between said rectangular opening in said cover plate and the laterally outermost side surfaces of said first, second, and third buttons, the top surfaces of said first and second buttons, and the bottom surfaces of said first and third buttons, so as to prevent the binding of said first, second, and third buttons due to a planar displacement of said cover plate relative to said frame.

12. The control structure of claim 11, wherein the surfaces of said first, second, and third buttons extend through said rectangular opening in said cover plate and beyond the surface of said cover plate for convenient access by a user.

13. The control structure of claim 12, wherein said surfaces of said second and third buttons define a single continuous appearance surface having a positive curvature above the plane of said cover plate.

14. The control structure of claim 13, wherein at least the length-wise edges of the surfaces of said first, second, and third buttons are chamfered.

15. The control structure of claim 11, further comprising:

a narrow slot centrally disposed along at least a portion of the length of said first button; and

a linear illumination array disposed along the length of said narrow slot and visible from the front surface of said cover plate, said linear illumination array being energizable from said electrical system to produce a visual output along its length related to the amount of power transmitted to said electrical system in response to actuations of either of said second or third buttons.

16. The control structure of claim 15, wherein said linear illumination array comprises a plurality of light-conducting pipes each having one end terminating within said slot and spaced along the length of said slot, and a second end coupled to respective ones of an array of light-emitting diodes disposed on a circuit board beneath said cover plate.

17. The control structure of claim 11, wherein said rectangular opening in said cover plate has a length greater than its width.

18. The control structure of claim 17, wherein said rectangular opening in said cover plate has a length of about 0.925 inch and a width of about 0.401 inch.

19. The control structure of claim 1, wherein said electrical system is one of a dimmable lighting load or motor control.

20. The control structure of claim 1, further comprising:

an air-gap switch in series with said electrical system, said air-gap switch connected to said first button;

wherein said first button is operable to be manually pressed in one direction toward the surface of said cover plate and pulled away in a second direction above said cover plate, said air-gap switch operable to close when said first button is moved in said first direction and open when said first button is moved in said second direction.

21. A control structure for controlling the power to be applied to an electrical system, said control structure comprising:

a cover plate which contains a rectangular opening therein;

a support frame supporting a rectangular control button which is coupleable to said electrical system and manually movable for toggling said electrical system on and off in response to operation of said rectangular control button;

a power control actuator fixed relative to said cover plate and coupleable to and manually operable to control the power applied to said electrical system; and

a linear illumination array disposed along the center of the surface of said rectangular control button and electrically energized from said electrical system to produce a visual output along its length which is related to the amount of power transmitted to said electrical system in response to an actuation of said power control actuator.

22. The control structure of claim 21, wherein said surface of said rectangular pushbutton contains a slot, and said linear illumination array comprises a plurality of light-conducting pipes each having one end terminating within said slot and spaced along the length of said slot, and a second end coupled to respective ones of an array of light-emitting diodes disposed on a circuit board disposed beneath said cover plate.

23. The control structure of claim 21, wherein said electrical system is one of a dimmable lighting load or motor control.

24. The control structure of claim 21, wherein said rectangular opening in said cover plate has a length greater than its width.

25. The control structure of claim 21, further comprising:

an air-gap switch in series with said electrical system, said air-gap switch connected to said control button;

wherein said control button is manually operable to be pressed in one direction toward the surface of said cover plate and pulled away in a second direction above said cover plate, said control button operable to close said air-gap switch when moved in said first direction and to open said air-gap switch when moved in said second direction.

26. A control button for controlling a variable output power system and for indicating a power level of said power system, said control button comprising:

a rectangular front operating surface which is operable by a user;

an elongated hollow light-conducting body;

a central elongated illumination display in said rectangular front surface, said central elongated illumination display bisecting the surface thereof;

wherein said control button is coupleable to said electrical system for switching said electrical system on and off responsive to operations thereof, and said illumination display is illuminated at given locations along the length thereof to display the scale value of the actual power level of said power system.

27. The control button of claim 26, wherein said light-conducting body comprises a plurality of light-conducting pipes each having one end terminating at said rectangular front surface and spaced along the length of said rectangular surface, and a second end coupled to respective ones of an array of light-emitting diodes, said light-conducing pipes being mounted within said hollow body.

28. The control button of claim 27, wherein said operating surface has a central slot extending along its length and extending from the interior of said hollow body, one end of each of said light-conducting pipes disposed within said central slot.

29. The control button of claim 27, wherein said control button is operable to be connected to an air-gap switch, said air-gap switch adapted to be coupled in series with said electrical system;

and

further wherein said control button is operable to be pressed in a first direction and pulled in a second direction, said control button operable to close said air-gap switch when moved in said first direction and to open said air-gap switch when moved in said second direction.

30. The control button of claim 26, wherein said hollow light-conducting body comprises a molded plastic body.

31. A load control device for controlling and indicating the amount of power delivered to a load from a source of AC power, said load control device comprising:

an actuator having a front surface operable by a user; and

a linear array of power level status indicators located on said front surface of said actuator and coupleable to said load to indicate the amount of power delivered to said load;

wherein said load control device is operable to control and indicate to said user the amount of power delivered to said load in response to an actuation of said actuator.

32. The load control device of claim 31, wherein said actuator contains a slot therethrough and said linear array of status indicators are disposed in said slot.

33. The load control device of claim 32, wherein said linear array of status indicator comprises a plurality of light-emitting diodes coupled to said load and energizable by respective levels of the power applied to said load and a light pipe having one end surface disposed adjacent said light-emitting diodes and a second end surface disposed in and along said slot.

34. The load control device of claim 33, further comprising:

a lens disposed in said slot and in communication with said one end surface of said light pipes.

35. The load control device of claim 33, wherein said light pipe comprises a plurality of separate parallel light-conducting pipes associated with respective ones of said light-emitting diodes.

36. A control structure for controlling the power to be applied to an electrical system, said control structure comprising:

a cover plate which contains a rectangular opening therein, said rectangular opening having a length and a width;

a first rectangular depressible control button coupled to said electrical system to turn said system on and off, said first button disposed adjacent one side of the length of said rectangular opening in said cover plate, said first button filling said length of said rectangular opening and about one half the width of said rectangular opening in said cover plate;

a second rectangular depressible power-increase button coupled to said electrical system to increase the power applied to said electrical system;

a third depressible rectangular power-decrease button coupled to said electrical system to decrease the power applied to said electrical system, said second and third buttons being stacked atop one another within the remaining half of the width said rectangular opening in said cover plate and extending for said length of said rectangular opening, whereby said first, second and third buttons fill the full surface of said rectangular opening in said cover plate;

a support frame supporting said first, second, and third buttons;

an air-gap switch connected in series with said electrical system; and

an operating mechanism connected between said air-gap switch and said first button, said operating mechanism including a centrally pivoted lever having a first end coupled to said air-gap switch and a second end connected to said first button, whereby the pressing in of said first button toward said cover plate closes said air-gap switch and the pulling out of said first button away from said cover plate opens said air-gap switch.

37. The control structure of claim 36, wherein said electrical system is one of a dimmable lighting load or motor control.

38. The control structure of claim 36, wherein said rectangular opening in said cover plate has a length greater than its width.

39. The control structure of claim 36, wherein said rectangular opening in said cover plate has a length of about 0.925 inch and a width of about 0.401 inch.

40. The control structure of claim 36, wherein the length-wise edges of said second and third buttons are chamfered.

41. An operating mechanism for an air-gap switch in a wall-mounted load control device for controlling the power delivered from an AC power source to an electrical load, said air-gap switch adapted to be coupled in series between said AC power source and said electrical load, said air-gap switch comprising a flexible switch leaf contact movable into and out of engagement with a cooperating contact and biased toward engagement with said cooperating contact, said operating mechanism comprising:

a push-pull button slidably mounted in a support and extending beyond an outer surface of said load control device, said push-pull button operable to be pressed inward or pulled outward by a user;

a centrally pivoted lever having a first end coupled to said push-pull button and a second end; and

a cam connected to said second end of said lever, said cam being movable to separate said leaf spring contact from its said cooperating contact when push-pull button is pulled out by said user and to permit said leaf spring contact to press into contact with said cooperating contact when said push-pull button is pushed in by said user.

42. The operating mechanism of claim 41, further comprising:

a toggle linkage and spring connected between said cam and said leaf spring contact for toggling said leaf spring contact into and out of contact with said cooperating contact in response to the operation of said push-pull button.

43. The operating mechanism of claim 42, wherein said air-gap switch and operating mechanism are mounted on a yoke of said load control device, said push-pull button being slidably mounted in said yoke.

44. The operating mechanism of claim 43, wherein said load control device is adapted to have a cover plate fixed to said yoke, said cover plate having a rectangular opening, said push-pull button extending through said opening for operation by said user.

45. The operating mechanism of claim 44, further comprising:

variable power control operator means fixed to said yoke and having a power control button extending through said cover plate for adjusting the power delivered to said load between said on and off conditions.

46. A control structure for an electrical circuit for controlling the power to be applied to an electrical system from an AC power source, said control structure comprising:

a toggle button having a rectangular hollow plastic body with a translucent outer top surface;

a support structure for supporting said toggle button for linear motion between first and second positions related to switch on and switch off positions;

a light pipe structure supported within said hollow plastic body of said toggle button, said light pipe structure having a first end surface facing the interior surface of said translucent outer top surface and a second end surface opposite to said first end surface;

at least one light-emitting diode facing said second end surface for illuminating said second end surface whereby the light illumination on said second end surface is conducted to said first end surface to illuminate said translucent outer top surface; and

a circuit for energizing said at least one light-emitting diode when said electrical circuit is off.

47. The control structure of claim 46, wherein said light pipe comprises a plurality of spaced pipes which merge together at said first end surface of said light pipe.

48. The control structure of claim 47, wherein each of said spaced pipes have a bottom end, and one of a plurality of light-emitting diodes is disposed adjacent each of said bottom ends.

49. The control structure of claim 47, wherein each of said pipes merge with one another over a concave curvature selected to increase the uniformity of illumination of said first end surface.

50. A load control device for controlling the amount of power delivered to an electrical load from an AC power source, said load control device comprising:

a controllably conductive device operable to be coupled in series electrical connection between said AC power source and said electrical load, said controllably conductive device having a control input for controlling said controllably conductive device between a non-conductive state and a conductive state;

an air-gap switch coupled in series electrical connection with said controllably conductive device, said air-gap switch operable to electrically connect said AC power source and said electrical load through said controllably conductive device when said air-gap switch is in a closed state and operable to provide an air-gap break between said AC power source and said electrical load when said air-gap switch is in an open state;

a controller operatively coupled to said control input of said controllably conductive device for controlling said controllably conductive device between said non-conductive state and said conductive state;

a control actuator adapted to be provided in an opening of a traditional-style faceplate and to extend beyond a front surface of said faceplate, said controller operable to control the amount of power delivered to said electrical load in response to an actuation of said control actuator, said control actuator further coupled to said air-gap switch to control said air-gap switch between said closed state and said open state; and

a visual display provided on a front surface of said actuator, said controller operable to control said visual display to display a representation of the amount of power being delivered to said electrical load.

51. The load control device of claim 50, wherein said visual display comprises a linear array of status indicators.

52. The load control device of claim 51, further comprising:

a plurality of light sources mounted inside said load control device; and

a plurality of light pipes received within said control actuator, said light pipes operable to conduct the light from each of said plurality of light sources to said front surface of said actuator.

53. The load control device of claim 52, wherein said visual display further comprises a status indicator lens provided on said front surface of said actuator.

54. The load control device of claim 53, wherein each light pipe is operable to conduct the light from one of said light sources to provide a point of illumination on said status indicator lens.

55. The load control device of claim 54, wherein the light from each of said light sources is diffused around said point of illumination on said status indicator lens.

56. The load control device of claim 50, further comprising:

an air-gap shaft operable to move along a first axis of travel, said shaft operable to contact said air-gap switch to cause said air-gap switch to enter said open state; and

an air-gap lever coupled to said control actuator and said air-gap shaft, such that said air-gap shaft is operable to contact said air-gap switch when said control actuator is pulled away from said load control device.

57. The load control device of claim 56, wherein said control actuator is operable to move along a second axis of travel parallel to and offset in a longitudinal direction from said first axis of travel.

58. The load control device of claim 57, wherein said second axis of travel is offset in both a longitudinal direction and a lateral direction from said first axis of travel.

59. The load control device of claim 56, wherein said air-gap shaft is operable to separate first and second electrical contacts of said air-gap switch.

60. The load control device of claim 50, further comprising:

a raise actuator, said controller operable to increase the amount of power delivered to said electrical load in response to an actuation of said raise actuator;

a lower actuator, said controller operable to decrease the amount of power delivered to said electrical load in response to an actuation of said lower actuator;

wherein said control actuator, said raise actuator, and said lower actuator are adapted to be provided together in said opening of said traditional-style faceplate.

61. The load control device of claim 60, further comprising:

a frame surrounding said control actuator, said raise actuator, and said lower actuator, said frame adapted to fit within said opening of said traditional-style faceplate.

62. The load control device of claim 50, wherein said controllably conductive device comprises a bidirectional semiconductor switch.

63. The load control device of claim 50, wherein said controller comprises a microprocessor.

64. A load control device for controlling the amount of power delivered to an electrical load from an AC power source, said load control device comprising:

an actuator having a front surface and adapted to be provided in an opening of a traditional-style faceplate; and

a linear array of status indicators located on said front surface of said actuator;

wherein said load control device is operable to control the amount of power delivered to said load in response to an actuation of said actuator.

65. The load control device of claim 64, further comprising:

a plurality of light sources mounted inside said load control device; and

a plurality of light pipes received within said actuator, said light pipes operable to conduct the light from each of said plurality of light sources to said front surface of said actuator.

66. The load control device of claim 65, wherein said visual display further comprises a status indicator lens provided on said front surface of said actuator.

67. The load control device of claim 66, wherein said light pipes are coupled to said status indicator lens via a plurality of rounds.

68. A light pipe structure for conducting light from a plurality of discrete sources, said light pipe structure comprising:

a continuous front surface;

a plurality of light pipes coupled to said continuous front surface, such that said light pipes are each operable to conduct the light from one of said discrete sources to the front surface;

wherein the light pipe structure provides optical coupling between said light pipes to provide a diffusion of the light from said discrete sources at said front surface.

69. The light pipe structure of claim 68, wherein said light pipes are coupled to said front surface via a plurality of rounds.

70. The light pipe structure of claim 68, wherein said front surface is curved.

71. The light pipe structure of claim 68, wherein said continuous front surface comprises a status indicator lens.

72. The light pipe structure of claim 71, wherein said light pipes are received in a control actuator of a load control device such that said status indicator lens is provided at a front surface of said control actuator.

73. An air-gap switch assembly comprising:

first and second switch contacts electrically connected in a closed state;

an air-gap shaft operable to move along a first axis of travel, said shaft operable to cause said air-gap switch to enter an open state in which said switch contacts are not electrically connected; and

an air-gap actuator operable to move along a second axis of travel, which is displaced in an orthogonal direction from said first axis of travel, the air-gap shaft coupled to said actuator such that said air-gap shaft is operable to move along said first axis of travel when the actuator is moved along said second axis of travel.

74. The air-gap switch assembly of claim 73, wherein said air-gap shaft is operable to contact said second electrical contact to move said second electrical contact away from said first electrical contact.

75. The air-gap switch assembly of claim 74, further comprising:

an air-gap lever coupled to said air-gap actuator and said air-gap shaft, such that said air-gap shaft is operable to contact said air-gap switch when said control actuator is pulled away from said load control device.

76. The air-gap switch assembly of claim 73, wherein said second axis of travel is parallel to and offset in a longitudinal direction from said first axis of travel.

77. The air-gap switch assembly of claim 73, wherein said second axis of travel is parallel to and offset in both a longitudinal direction and a lateral direction from said first axis of travel.

78. A load control device for controlling the amount of power delivered to an electrical load from an AC power source, said load control device comprising:

a controllably conductive device operable to be coupled in series electrical connection between said AC power source and the electrical load, said controllably conductive device having a control input for controlling said controllably conductive device between a non-conductive state and a conductive state;

an air-gap switch coupled in series electrical connection with said controllably conductive device and operable to be coupled in series electrical connection between said AC power source and said electrical load, said air-gap switch operable to electrically connect said AC power source and said electrical load through said controllably conductive device when said air-gap switch is in a closed state and operable to provide an air-gap break between said AC power source and said electrical load when said air-gap switch is in an open state;

a controller operatively coupled to said control input of said controllably conductive device for controlling said controllably conductive device between said non-conductive state and said conductive state; and

a control actuator adapted to be provided in an opening of a traditional-style faceplate and to extend beyond a front surface of said faceplate, said controller operable to control the amount of power delivered to said electrical load in response to a first actuation of said control actuator, said control actuator further coupled to said air-gap switch to control said air-gap switch between said closed state and said open state in response to a second actuation of said control actuator, said second actuation characterized by a greater force and a greater displacement of said control actuator than said first actuation.