Dimmer control switch unit

• US 6,815,625 B1
• Filed: 11/07/2003
• Issued: 11/09/2004
• Est. Priority Date: 04/18/2003
• Status: Active Grant

• Current Assignee: Eaton Intelligent Power Limited (Eaton Corporation PLC.)
• Original Assignee: Cooper Wiring Devices Incorporated (Eaton Corporation PLC.)
• Inventors: Gouhl, Erik J., Leopold, Howard S., Novikov, Lenny M.
• Primary Examiner(s): Vu, David
• Application Number:
  US10/703,686
• Publication Number:
  US 20040206616A1
• Time in Patent Office: 368 Days
• Field of Search: 200/296, 200/329, 315/74, 315/75, 315/76
• US Class Current: 200/296
• CPC Class Codes: H05B 39/086 with possibility of remote control

Abstract

A dimmer control system has a communication control loop that connects a master unit in series with a plurality of remote units, and it is superimposed in series on the dimmer load line so as to allow two-way communication between the master unit and remote units without affecting the operation of the load. Communications from the master to the remote units are encoded in loop current fluctuations, whereas communications from any remote to the master unit are encoded in loop voltage fluctuations. The master unit has a switched power supply, for use during normal LOAD ON operation, in tandem with a capacitive power supply, for use during LOAD OFF operation of the control units so as to minimize hum. The master unit power supply circuit provides an output rail voltage comprised of a reference voltage for the load superimposed with a control loop voltage for the voltage drop across the series-connected remote units. The master unit has a POWER OFF detection circuit and a non-volatile memory for storing system status information, so that when power is restored, the system can be restored to its former power level. The switch units are formed with a cover frame mounting a switch plate on a hinge axis allowing ON/OFF movement of an opposing side thereof. An array of LED light pipes is mounted in the switch plate aligned with the hinge axis, in order to minimize displacement of the light pipes during actuator movement.

Claims

1. A power control switch unit for controlling an amount of power delivered to a load, the switch unit having a bottom housing, comprising:

(a) a cover frame mounted over the bottom housing;

(b) a push-button type actuator switch plate mounted for movement in the cover frame, wherein the actuator switch plate has one longitudinal side mounted on a switch hinge axis to a stationary portion of the cover frame, and an opposing side therefrom that is hingedly movable against a spring force for movement by user actuation thereof;

(c) a light indicator display for visually indicating a power level to be delivered to the load, wherein said light indicator display includes an array of openings or lenses formed in the actuator switch plate for terminating a series of light pipes optically connecting a plurality of LEDs on a control circuit board positioned in the bottom housing, and said array of openings or lenses are positioned on the one longitudinal side of the actuator switch plate and aligned with the switch hinge axis, in order to minimize displacement of the light pipe ends from the LEDs on the control circuit board when the actuator switch plate is actuated.

2. A power control switch unit according to claim 1, wherein said light pipes are integral with the actuator switch plate.

3. A power control switch unit according to claim 1, wherein said cover frame has a generally rectangular shape and said actuator switch plate has the one longitudinal side thereof mounted adjacent one longitudinal vertical side of the cover frame.

4. A power control switch unit according to claim 1, further comprising a rocker type switch accessible through the cover frame for actuating power level control circuitry on the control circuit board in order to set power levels in accordance with user input.

5. A power control switch unit according to claim 4, wherein said actuator switch plate has an opposing side from the one longitudinal side formed with a concave curved edge, and the rocker type switch is formed as an oval-shaped rocker switch positioned in curvilinear alignment adjacent to the concave curved edge of the actuator switch plate.

6. A power control switch unit according to claim 1, wherein said array of openings or lenses for the light pipes of the LEDs are aligned in a vertical line, a bottom one thereof is illuminated with a first color and remains lit, and the others are spaced at increasing vertical positions corresponding to a range of power levels and only one is lit at a time with a second color to indicate the user-selected dimmer power level, whereby the bottom one provides a frame of reference and the other lit one shows the user-selected power level in relation to the bottom frame of reference.

7. A power control switch unit according to claim 1, wherein the dimmer control unit can be configured as a master unit or a remote unit.

8. A dimmer control switch unit comprising:

(a) a cover frame mounted over a bottom housing, the cover frame having a generally rectangular shape;

(b) a push-button type actuator switch plate mounted for ON/OFF movement in the cover frame, wherein the actuator switch plate has one longitudinal side mounted on a switch hinge axis to a stationary portion of the cover frame, and an opposing side therefrom that is hingedly movable against a spring force for ON/OFF movement by user actuation thereof;

(c) an UP/DOWN switch also accessible through the cover frame for actuating dimmer control circuitry on a control circuit board positioned in the wall outlet box in order to set dimmer power levels up or down in accordance with user input; and

(d) a power-level light indicator display provided in the switch unit for visually indicating the dimmer power level set in accordance with user input, wherein said power-level light indicator display includes an array of openings or lenses formed in the actuator switch plate for terminating a series of light pipes optically connecting a plurality of LEDs on the control circuit board which are selectively lit in order to provide a visual representation of the dimmer power level set in the dimmer control circuitry, and said array of openings or lenses are positioned on the one longitudinal side of the switch plate and aligned with the switch hinge axis, in order to minimize displacement of the light pipe ends from the LEDs on the control circuit board when the switch plate is actuated for ON/OFF movement.

9. A dimmer control switch unit according to claim 8, wherein said cover frame has a rectangular shape and said actuator switch plate has the one longitudinal vertical side thereof mounted adjacent one longitudinal vertical side of the cover frame.

10. A dimmer control switch unit according to claim 9, wherein said actuator switch plate has an opposing side from the one longitudinal side formed with a concave curved edge, and the UP/DOWN switch is formed as an oval-shaped rocker switch positioned in curvilinear alignment adjacent to the concave curved edge of the actuator switch plate.

11. A dimmer control switch unit according to claim 8, wherein said array of openings or lenses for the light pipes of the LEDs are aligned in a vertical line, a bottom one thereof is illuminated with a first color and remains lit, and the others are spaced at increasing vertical positions corresponding to the range of dimmer power levels and only one is lit at a time with a second color to indicate the user-selected dimmer power level, whereby the bottom one provides a frame of reference and the other lit one shows the user-indicated dimmer power level in relation to the bottom frame of reference.

12. A dimmer control switch unit according to claim 9, wherein the one longitudinal vertical side of the actuator switch plate is hingedly mounted to the cover frame.

13. A dimmer control switch unit according to claim 8, wherein the dimmer control unit can be configured as a master unit or a remote unit.