Power control device for an electrical load

• US 7,416,310 B1
• Filed: 01/30/2006
• Issued: 08/26/2008
• Est. Priority Date: 12/02/2003
• Status: Expired due to Fees

• Current Assignee: Pass And Seymour Incorporated (Legrand SA)
• Original Assignee: Pass And Seymour Incorporated (Legrand SA)
• Inventors: Savicki, Gerald R. Jr.
• Primary Examiner(s): Husar; Stephen F.
• Assistant Examiner(s): Neils; Peggy A.
• Application Number:
  US11/343,101
• Time in Patent Office: 939 Days
• Field of Search: 362/85, 362/95, 362/800, 362/373, 200/330, 200/331, 200/18, 200/310, 200/313, 200/317, 439/490
• US Class Current: 362/95
• CPC Class Codes: H01H 11/0006 for converting electric switches H01H13/564 takes precedence
• CPC Class Codes: H01H 15/025 Light-emitting indicators
• CPC Class Codes: H01H 23/025 Light-emitting indicators
• 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: H01H 9/0271 structurally combining a switch and an electronic component for relays H01H50/021
• CPC Class Codes: H01H 9/162 Means to facilitate removal or replacement of light-emitting elements
• CPC Class Codes: H01H 9/182 Illumination of the symbols or distinguishing marks H01H9/181 takes precedence
• CPC Class Codes: H01R 13/70 with built-in switch
• CPC Class Codes: H01R 13/7175 Light emitting diodes (LEDs)
• CPC Class Codes: H01R 2103/00 Two poles
• CPC Class Codes: H01R 24/76 with sockets, clips or analogous contacts and secured to apparatus or structure, e.g. to a wall

Abstract

The present invention is directed to a device for adjustably providing power to at least one electrical load. The device includes a body member. A plurality of terminals are configured to be coupled to a source of the power. A power control circuit is disposed in the body member and coupled between the plurality of terminals and the at least one electrical load. The power control circuit includes at least one variable control mechanism coupled to at least one series pass element. The at least one series pass element is configured to provide power to the at least one electrical load in accordance with the at least one variable control mechanism setting. A frameless front cover member is connected to the body member and has a raised rectangular form factor substantially corresponding to a standard wall plate opening. The frameless front cover assembly has a plurality of switch mechanisms including at least one first switch mechanism coupled to the at least one variable control mechanism and at least one second switch mechanism actuatable without interference from the standard wall plate. The at least one first switch mechanism and the at least one second switch mechanism are characterized by a transverse dimension substantially equal to the transverse dimension of the standard wall plate opening.

Claims

1. A device for adjustably providing power to at least one electrical load, the device comprising:

a body member;

a plurality of terminals configured to be coupled to a source of the power and at least one load;

a power control circuit disposed in the body member and coupled between the plurality of terminals and the at least one electrical load, the power control circuit including at least one variable control mechanism coupled to at least one series pass element, the at least one series pass element being configured to provide power to the at least one electrical load in accordance with the at least one variable control mechanism setting; and

a frameless front cover assembly connected to the body member and having a raised rectangular form factor substantially corresponding to a standard wall plate opening, the frameless front cover assembly comprising a plurality of switch mechanisms including at least one first switch mechanism coupled to the at least one variable control mechanism and at least one second switch mechanism actuatable without interference from the standard wall plate, the at least one first switch mechanism and the at least one second switch mechanism being characterized by a transverse dimension substantially equal to the transverse dimension of the standard wall plate opening.

2. The device of claim 1, wherein the at least one first switch mechanism includes at least one user variable slide switch assembly configured to adjust the variable control mechanism.

3. The device of claim 2, wherein the at least one user variable slide switch assembly includes at least one control switch mechanism actuatable between an OPEN position and CLOSED position at a predetermined adjustment position of the at least one user variable slide switch.

4. The device of claim 3, wherein the at least one control switch mechanism is either a single-pole single-throw switch or single-pole double-throw switch.

5. The device of claim 2, wherein the user variable slide switch assembly includes a continuously variable switch.

6. The device of claim 2, wherein the user variable slide switch assembly includes a multi-position switch.

7. The device of claim 2, wherein the at least one user variable slide switch assembly is characterized by a longitudinal dimension substantially equal to the longitudinal dimension of the standard wall plate opening.

8. The device of claim 2, wherein the frameless front cover assembly further comprises a modular lamp assembly coupled to the user variable slide switch assembly, the at least one user variable slide switch assembly and the modular lamp assembly in combination being characterized by a longitudinal dimension substantially equal to the longitudinal dimension of the standard wall plate opening.

9. The device of claim 1, wherein the at least one second switch mechanism includes either a single-pole single-throw switch or single-pole double-throw switch.

10. The device of claim 1, wherein the at least one second switch mechanism includes a preset switch coupled to the at least one first switch mechanism, the preset switch being configured to turn the at least one first switch mechanism between an ON state and an OFF state.

11. The device of claim 1, wherein the at least one first switch mechanism and the at least one second switch mechanism in combination are characterized by a longitudinal dimension substantially equal to the longitudinal dimension of the standard wall plate opening.

12. The device of claim 1, wherein the frameless front cover assembly further comprises a modular lamp assembly coupled to the at least one first switch mechanism, the modular lamp assembly being disposed in longitudinal alignment with the at least one first switch mechanism and the at least one second switch mechanism, such that the at least one first switch mechanism, the at least one second switch mechanism and the modular lamp assembly in combination are characterized by a longitudinal dimension substantially equal to the longitudinal dimension of the standard wall plate opening.

13. The device of claim 1, wherein the at least one variable control mechanism includes a control circuit coupled to the series pass element, the control circuit being configured to cycle the series pass element between an ON position and an OFF position a predetermined number of times during each AC cycle in accordance with the at least one adjustable switching mechanism switch setting.

14. The device of claim 13, wherein the control circuit includes an RFI noise suppression circuit.

15. The device of claim 12, wherein the RFI noise suppression circuit includes at least one inductor and at least one capacitor.

16. The device of claim 1, further comprising at least one surge suppression device.

17. The device of claim 1, wherein the at least one series pass element includes a solid state device.

18. The device of claim 17, wherein the solid state device includes a thyristor.

19. The device of claim 17, wherein the solid state device includes a triac.

20. The device of claim 1, wherein the at least one variable control mechanism includes a continuously variable potentiometer.

21. The device of claim 1, wherein the at least one variable control mechanism includes a multiple position switch element configured to drive the series pass element between multiple discrete power settings.

22. The device of claim 21, wherein the multiple position switch element is configured to switch between a plurality of capacitors when driving the series pass element between multiple discrete power settings.

23. The device of claim 1, wherein the plurality of terminals include screw terminals.

24. The device of claim 1, wherein the plurality of terminals include wire terminals.

25. The device of claim 1, wherein the at least one variable control mechanism includes a plurality of switching mechanisms and the at least one series pass element includes a plurality of series pass elements.

26. The device of claim 1, wherein the at least one second switch mechanism includes at least one preset switch coupled in series with the at least one series-pass element.

27. The device of claim 1, wherein the at least one second switch mechanism includes at least one general purpose switch configured to control at least one load.

28. The device of claim 1, wherein the at least one electrical load includes a fan motor.

29. The device of claim 1, wherein the at least one electrical load includes a lamp.

30. The device of claim 1, wherein the frameless front cover assembly further comprises either a modular lamp assembly or an interchangeable blank member having a form factor substantially similar to the modular lamp assembly form factor.

31. The device of claim 30, wherein the modular lamp assembly includes a locator light.

32. The device of claim 30, wherein the modular lamp assembly includes a pilot light.

33. The device of claim 30, wherein the modular lamp assembly includes a night light.

34. The device of claim 1, further comprising a mounting member disposed between the frameless front cover assembly and the body member, the distance between a rear surface of the mounting member and a major surface of the rear body member is approximately 1.20 inches or less.

35. The device of claim 34, wherein the mounting member is a planar heat sink.

36. The device of claim 35, wherein the planar heat sink includes a central portion configured to accommodate the frameless front cover assembly and segmented tabs disposed on the periphery of the central portion.

37. The device of claim 1, wherein the front cover assembly further comprises a receptacle.

38. A device for adjustably providing power to at least one electrical load, the device comprising:

a body member;

a plurality of terminals configured to be coupled to a source of the power and at least one load;

a power control circuit disposed in the body member and coupled between the plurality of terminals and the at least one electrical load, the power control circuit including at least one variable control mechanism coupled to at least one series pass element, the at least one series pass element being configured to provide power to the at least one electrical load in accordance with the at least one variable control mechanism setting;

a frameless front cover assembly connected to the body member, the frameless front cover assembly including at least one switch mechanism coupled to the at least one variable control mechanism, the frameless front cover assembly having a raised rectangular form factor substantially corresponding to a standard wall plate opening, the frameless front cover assembly being characterized by a transverse dimension substantially equal to the transverse dimension of the standard wall plate opening; and

a modular lamp assembly disposed in longitudinal alignment with the frameless front cover assembly, the modular lamp assembly being dimensionally characterized by the transverse dimension, the modular lamp assembly and the frameless front cover assembly in combination being dimensionally characterized by a longitudinal dimension substantially equal to the longitudinal dimension of the standard wall plate opening.

39. A device for adjustably providing power to at least one electrical load, the device comprising:

a body member;

a plurality of terminals configured to be coupled to a source of the power and at least one load;

a power control circuit disposed in the body member and coupled between the plurality of terminals and the at least one electrical load, the power control circuit including at least one variable control mechanism coupled to at least one series pass element, the at least one series pass element being configured to provide power to the at least one electrical load in accordance with the at least one variable control mechanism setting;

a frameless front cover assembly connected to the body member and having a raised rectangular form factor substantially corresponding to a standard wall plate opening, the frameless front cover assembly comprising a plurality of switch mechanisms including at least one first switch mechanism coupled to the at least one variable control mechanism and at least one second switch mechanism actuatable without interference from the standard wall plate, the at least one first switch mechanism and the at least one second switch mechanism being characterized by a transverse dimension substantially equal to the transverse dimension of the standard wall plate opening; and

a modular lamp assembly disposed in longitudinal alignment with the frameless front cover assembly, the modular lamp assembly being dimensionally characterized by the transverse dimension, the modular lamp assembly and the frameless front cover assembly in combination being dimensionally characterized by a longitudinal dimension substantially equal to the longitudinal dimension of the standard wall plate opening.