Rocker paddle switch with articulated cam driver

• US 7,122,754 B2
• Filed: 12/22/2005
• Issued: 10/17/2006
• Est. Priority Date: 07/25/2003
• Status: Active Grant

• Current Assignee: Leviton Manufacturing Company Incorporated
• Original Assignee: Leviton Manufacturing Company Incorporated
• Inventors: Tufano, Anthony, Endres, Paul, Oddsen, Dennis A., Kurek, Stephen R.
• Primary Examiner(s): LEE, KYUNG S
• Application Number:
  US11/315,062
• Publication Number:
  US 20060108211A1
• Time in Patent Office: 299 Days
• Field of Search: 200/339, 200523-524, 200/553, 200/547, 200541-542, 200/329, 200/563, 200557-558, 200/17.R
• US Class Current: 200/339
• CPC Class Codes: H01H 19/635 Contacts actuated by rectilinearly-movable member linked to operating part, e.g. by pin and slot
• CPC Class Codes: H01H 21/025 Light-emitting indicators
• CPC Class Codes: H01H 21/245 the contact returning to its original state upon the next application of operating force
• CPC Class Codes: H02G 3/14 Fastening of cover or lid to box

Abstract

There is disclosed a paddle switch operated by pushing on the lower portion of a rocker paddle to turn the switch “on” or “off”. The lower edge of the paddle pivots in and out about its upper edge. The switch includes articulated driver means coupled to be driven by the rocker paddle. When the rocker paddle is pushed in, it urges the articulated driver means to rotate a cam means in a first, clock wise direction, or a second, counter clock wise direction. Alternate rotation of the cam drives a slider member having a cam follower back and forth along a linear axis. A shaped leaf spring cooperates with the cam follower to assist in the movement of the slider and determines its rest positions. An indicator such as an LED is used to indicate the state of conduction of the switch. When the rocker paddle is released, it is biased by a spring to pivot back to its initial position. The rocker paddle of the switch is not located within a frame and has a surface along its vertical axis of positive first differential and zero second differential, comprised of a combination of splines which extend between points of varying distances from a datum plane. This surface has zero second differential when the rate of height increase of individual splines is constant.

Claims

1. A switch comprising:

a housing;

a rocker paddle pivotally coupled to said housing to assume a first depressed position when subjected to an external force and a second at rest position when not subjected to an external force;

cam means adapted to alternately rotate in a first direction and a second opposite direction;

articulated cam driver means coupled to be driven by said rocker paddle to urge said cam means to rotate in said first or said second direction;

slider means coupled to be moved alternately in a first and a second opposite linear direction by rotation of said cam means;

bumper support member coupled to said slider means to cushion the stopping of the slider means at the end of its travel in said first and second direction by contacting stops coupled to said housing;

a stationary contact and a movable contact coupled to said switch housing, said movable contact biased to contact said stationary contact and urged by said slider means to break contact with said stationary contact; and

a leaf spring within said housing to assist said slider means to move in said first and second directions.

2. The switch of claim 1 wherein said articulated cam driver means comprises:

a first member adapted to be coupled to said housing;

a second member slidably coupled within said first member;

spring means; and

an actuator interposed between said second member and said spring means wherein said second member is urged to move in a first direction to engage said cam means when the rocker paddle is subjected to an external force and in a second opposite direction out of engagement with the cam means by said spring means when said rocker paddle is not subjected to an external force.

3. The switch of claim 2 wherein said second member is held slidably captive within said first member.

4. The switch of claim 3 wherein said actuator is a shaft.

5. The switch of claim 3 wherein said actuator is a shaft having a first end for engaging said cam means and a second end having a collar for engaging both an end of said spring and said second member.

6. The switch of claim 5 comprising

a clearance opening located between said first member and said cam means for receiving said shaft.

7. The switch of claim 6 wherein said clearance opening is elongated.

8. The switch of claim 7 wherein said elongated opening has a long dimension along the length of the switch and a short dimension along the width of the switch.

9. The switch of claim 7 wherein said elongated clearance opening is rectangular.

10. The switch of claim 2 further comprising a ground/mounting strap attached to said housing, said ground/mounting strap providing a cradle like support for holding said switch to a wall box.

11. The switch of claim 10 wherein said ground/mounting strap is made of sheet metal.

12. The switch of claim 1 wherein said articulated cam driver means comprises:

a cylindrical member coupled to said housing having a first opening at one end and a second opening at the other end;

a plunger slidably coupled to move into said cylindrical member when said rocker paddle is subjected to an external force;

an actuator driven by said plunger to rotate said cam means as said plunger is moved into said cylindrical member; and

a spring coupled to urge said actuator and said plunger to urge said rocker paddle to move to its second at rest position when said paddle is not subjected to an external force.

13. The switch of claim 1, wherein the slider means comprises a tapered opening for receiving said cam means where rotation of said cam means causes said slider means to move said movable contact.

14. The switch of claim 1, wherein said housing further comprises a base having separate chambers for receiving said slider means and said leaf spring.

15. The switch of claim 14 wherein the chamber for housing said leaf spring has a length greater than that of said leaf spring such that the ends of said spring are not constrained.

16. The switch of claim 14 further comprising a window in the rocker paddle to pass light from illumination means in said housing.

17. The switch of claim 16 wherein said illumination means comprises an LED.

18. The switch of claim 14 further comprising front and rear wire clamp means for wire conductors mounted to said housing and coupled to the stationary contact and the movable contact.

19. The switch of claim 1 comprising:

a surface along the length of said paddle of positive first differential comprised of a combination of splines drawn between points of varying distances from a datum plane.

20. The switch of claim 19 wherein said paddle along its length has a surface of zero second differential comprised of splines drawn between points of varying distance from a datum plane when the rate of height increase of the individual splines is constant.

21. The switch of claim 19 wherein said paddle along its width has a surface of a positive first differential and negative second differential, comprised of a combination of splines drawn between points of varying distances from the datum plane.

22. The switch of claim 19 wherein said paddle along its length has a surface of positive first differential, comprised of splines drawn between points of varying distance from a datum plane and, along its width a surface of a positive first differential and negative second differential, comprised of a combination of splines drawn between points of varying distances from the datum plane.

23. The switch of claim 22 wherein said paddle along its length has a surface of zero second differential comprised of splines drawn between points of varying distances from a datum plane when the rate of height increase of the individual splines is constant.

24. The switch of claim 19 wherein the paddle is not within a frame.