WO2015164926A1

WO2015164926A1 - A switch assembly

Info

Publication number: WO2015164926A1
Application number: PCT/AU2015/050207
Authority: WO
Inventors: Kevin Woodbine
Original assignee: Harness Master Wiring Systems Pty Ltd
Priority date: 2014-05-01
Filing date: 2015-04-30
Publication date: 2015-11-05
Also published as: AU2014202383A1

Abstract

A switch assembly (100) suitable for operating electrically powered devices on vehicles and to be located in an aperture (95) of a panel (90), the switch assembly (100) including a switch (30) housing electrical components, an adapter (20) configured to be detachably mounted on the switch (30) and in said aperture (95), and a control (10) for operating the switch (30).

Description

A SWITCH ASSEMBLY

FIELD OF THE INVENTION

[0001 ] The present invention relates to a switch assembly, and particularly but not exclusively to a switch assembly suitable for operating electrically powered devices on vehicles.

BACKGROUND TO THE INVENTION

[0002] Switches are used to control operation of various electrically powered devices, such as on vehicles. Some examples of electrically powered devices are sirens, light beacons, air compressors, and after-market accessories such as halogen lamps. Vehicle dashboards and associated control panels are usually provided with apertures into which such switches are to be installed. Such apertures may be located inside or outside the vehicle's cabin.

[0003] The size and shape of apertures for switches of a particular vehicle model are generally standardized. For example, all vehicles built by an Original Equipment Manufacturer (OEM) of vehicles during a particular period have identically sized apertures for switches. However, the size and shape of apertures for switches vary according to vehicle model and manufacturer. For example, apertures for switches provided in one make or model of vehicle are generally of different dimensions to those of another manufacturer or vehicle model.

[0004] This variation in aperture dimensions necessitates vehicle service stations to stock a range of switches suitable for each vehicle model. Increasing stocks increases costs, and makes stock control and ordering more complex, especially when a model or trim level of vehicle is deleted. [0005] Vehicle service stations have the choice between purchasing

expensive OEM switches or cheaper replacement switches. OEM switches can be difficult to source, particularly for older vehicle models. If an OEM switch is not readily available, the installer may have to wait for weeks or months for delivery from overseas.

[0006] Replacement, non-original switches (after-market switches) are generally of lower quality. Such replacement non-original switches also often do not fit correctly in the aperture, being either a loose fit (risking the switch falling out of the dashboard or panel) or a tight fit (requiring re-sizing of the aperture).

[0007] The problem of sourcing and stocking a specific switch is particularly severe when the installer is after a particular type of switch such as a rocker switch or a push switch, with a particular symbol on the button such as driving light or hazard light.

[0008] It is an object of the present invention to address the aforementioned problems by providing a switch assembly designed to suit more than one aperture size.

SUMMARY OF THE INVENTION

[0009] An aspect of the present invention provides a switch assembly suitable for operating electrically powered devices on vehicles and to be located in an aperture of a panel, the switch assembly including a switch housing electrical components, an adapter configured to be detachably mounted on the switch and in said aperture, and a control for operating the switch.

[0010] By having a detachably mountable adapter, a single switch can be used for various aperture sizes. There is no need for stocking switches to suit each aperture size. [001 1 ] In use, an installer selects an adapter which suits a particular aperture. Just by having a selection of adapters, the installer can use the switch having the main electrical components for a number of aperture sizes.

[0012] The adapters are, for example, injection moulded plastic components. The adapters are a lot less expensive than a switch. Therefore, the cost of stocking switches to suit various aperture dimensions is reduced.

[0013] An adapter is preferably of moulded plastic without any electrical components. Therefore, it is lot cheaper than the actual switch.

[0014] The switch assembly may include a first engaging means for releaseably attaching the adapter to the switch. Preferably, the first engaging means includes at least one protrusion on the switch engageable with at least one receiving portion on the adapter. Further preferably, the protrusion or the receiving portion is flexible to allow disengagement.

[0015] The switch assembly may include a second engaging means for releaseably attaching the adapter to said aperture. Preferably, the second engaging means includes at least one lug on the adapter engageable with the aperture. Preferably, the lug is flexible to allow disengagement.

[0016] The control may be at least partially mounted on the adapter.

[0017] The control may have a stem, in use, the stem is inserted in the switch to operate electrical contacts.

[0018] Preferably, the control is sized to suit said aperture.

[0019] The control may be a rocker, toggle or a push button. [0020] The switch assembly may include at least one non-opaque member detachably mounted on the control, in use, the non-opaque member is illuminated by a light on the switch. Preferably, the switch assembly has two non-opaque members detachably mounted on the control and spaced from each other.

[0021 ] The switch is preferably rated for at least 7 amps.

[0022] The adapter may be selected from a plurality of adapters, each adapter is configured to be mounted on the switch and in a different aperture, and wherein the selected adapter is mountable in said aperture.

[0023] The control may be selected from a plurality of controls, each control is configured to suit a different aperture, and wherein the selected control is suited to said aperture.

[0024] A further aspect of the present invention provides a method of installing a switch assembly for operating electrically powered devices in an aperture of a panel including the steps of:

connecting a switch housing electrical components to the device, mounting an adapter on the switch,

mounting the adapter in said aperture, and

mounting an control to operate the switch on the adapter.

[0025] The method may further include the step of selecting the adapter from a plurality of adapters, each adapter is configured to be mounted on the switch and in a different aperture, and wherein the selected adapter is mountable in said aperture.

[0026] The method may further include the step of selecting the control from a plurality of controls, each control is configured to suit a different aperture, and wherein the selected control is suited to said aperture. [0027] A further aspect of the present invention provides switch assembly kit for installing a switch assembly in an aperture of a panel, the kit including: a switch housing electrical components, at least one adapter configured to be detachably mounted on the switch and in said aperture, and at least one control to operate the switch.

[0028] The kit may include a plurality of adapters, each adapter is configured to be mounted on the switch and in a different aperture.

[0029] The kit may also include a plurality of controls, each control is configured to suit a different aperture.

[0030] The kit may also include a plurality of non-opaque members

detachably mountable on the control, each non-opaque member having a marking, in use, a non-opaque member is illuminated by a light on the switch.

[0031 ] Other objects, features and desirable characteristics of the switch assembly of the subject invention will be readily apparent from the accompanying drawings and description.

BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Figure 1 illustrates an isometric view of a switch assembly according to one embodiment of the present invention.

[0033] Figure 2 illustrates a side view of the switch assembly of figure 1 .

[0034] Figure 3 illustrates a front view of the switch assembly of figure 1 .

[0035] Figure 4 illustrates a top view of a control and two non-opaque members of the switch assembly of figure 1 . [0036] Figure 5 is a photograph of a vehicle panel having various size apertures for switches.

[0037] Figure 6 is a photograph of a prototype switch assembly and a panel according to another embodiment of the present invention.

DESCRIPTION OF PREFERRED EMBODIMENT

[0038] Referring to figures 1 to 3, there is provided a switch assembly 100 including a switch 30, an adapter 20 and a control 10. The switch 30 houses all electrical components of the switch including those required to break the current and complete the current. The primary function of the adapter 20 is to make the switch 30 suitable to be mounted in a particular aperture (for example, aperture 95 seen in figure 5). The adapter 20 is detachably mounted on the switch 30 and suited to be detachably mounted in a particular aperture. The control 10 is used to operate the switch 30.

[0039] In order to mount the adapter 20 on the switch 30, there is provided a first engaging means. The first engaging means includes protrusions 32 on the switch assembly 30 and corresponding receiving portions 22 on the adapter 20. There are two protrusions 32 and two receiving portions 22 located on opposite sides of the respective components. The receiving portions 22 are rectangular through holes. The protrusions 32 are wedge shaped. The portion of the adapter 20 on which the receiving portions 22 are located is flexible.

[0040] When the adapter 20 is slid over the switch 30, the portion of the adapter 20 having the receiving portions 22 flexes outward because of the force exerted by the protrusions 32. When the adapter 20 is slid further over the switch 30, the protrusions 32 slip into the receiving portions 22 causing the portion of the adapter 20 having the receiving portions 22 flexes inward. Once the protrusions 32 are in the receiving portions 22, the adapter 20 is locked on to the switch 30. The adapter 20 clips on to the switch 30. In order to detach the adapter 20 from the switch 30, manual force is applied to flex the adapter and push the

protrusions 32 out of the receiving portions 22.

[0041 ] In order to mount the adapter 20 in an aperture 95 (example of an aperture 95 is seen figure 5), there is provided a second engaging means. The second engaging means includes (a) two lugs 24 which are able to engage with portions of the aperture 95 and (b) four guiding portions 26 to snugly fit the adapter in the aperture 95. The adapter 20 is designed to suit a particular aperture 95.

[0042] The two lugs 24 are on opposite sides of the adapter 20. The two lugs 24 are flexible to provide spring action. Each lug 24 is an elongate member extending beyond the guiding portions 26. At the end of each lug 24 is an outward protrusion which engages with the aperture 95 to lock the adapter 20 on the aperture 95.

[0043] The peripheral dimensions of the adapter 20 correspond to a particular aperture 95. A guiding portion 26 is provided at each corner of the adapter 20. The guiding portions 26 are elongate. The guiding portions 26 act as a guide when inserting the adapter 20 into an aperture 95.

[0044] When the adapter 20 is pushed into an aperture 95, the lugs 24 spring inward the adapter 20. When the adapter 20 is pushed further, the outward protrusions of the lugs 24 engage with the edge of the aperture 95. The adapter 20 clips on to the aperture 95. In this state, the adapter 20 is locked on to the aperture 95. In order to release the adapter 20 from the aperture 95, the lugs 24 are pushed inward the adapter 20 to disengage the lugs 24 from the aperture 95, simultaneously the adapter 20 is pushed out of the aperture 95.

[0045] In order to save costs of stocking several switches for various aperture dimensions, a service station could stock switches 30 and adapters 20 as per the present invention. The service station will only need to stock a few switches 30 and multiple adapters 20. Cost of stocking multiple adapters 20 is expected to be much lower than cost of stocking multiple switches (some of which may never be used). Therefore, the burden of inventory cost is expected to be reduced.

[0046] The multiple adapters 10 stocked by a service station are suited to be detachably mounted on a switch 30 and configured to suit various apertures 95. The adapters 20 are interchangeable for a number of switches 30. The outer size and the second engaging means of the adapters 20 are varied as per various apertures 95. For example, the same switch 30 may be used with an adapter 20 suited to fit aperture 95 of Toyota Landcruiser or a different adapter 20 suited to fit aperture 95 of Toyota Prado.

[0047] The control 10 is a rocker having three positions e.g. ON-OFF-ON. Alternatively, the rocker 10 may be a simple toggle with just two positions ON- OFF. Further alternatively, the control 10 may be a push-button. The control 10 is sized such that it is at least partially mounted on the outer edge of an adapter 20. The outer proportions of the control 10 are suited to a particular aperture 95 such that the control 10 occupies most of the aperture 95. The control 10 has a stem 12. When the control 10 is mounted on the adapter 20, the stem 12 is inserted in the switch 30 to operate the contacts inside the switch 30.

[0048] Referring to figures 1 and 4, the switch 30 has two LED lights 34 located on a side facing the control 10. The adapter 20 has a central opening to allow lights from the housing to be transmitted to the back of control 10. The control 10 has two non-opaque members 14 fitted in two through holes in the control 10. The two non-opaque members 14 correspond to the two lights 34. The control 10 is made of opaque material so that, in use, when the LED lights are lit just the non-opaque members are seen illuminated. The LED lights 34 are useable on 12V dc (suitable for cars) or 24 V dc current (suitable for trucks).

[0049] The non-opaque members are detachably attached to the control 10. Each non-opaque member is provided with a projection so that the non-opaque members 14 can be push-fitted from the rear of the control 10. The non-opaque members are retained in the control 10 by the projections.

[0050] The non-opaque members 14 may be a coloured translucent plastic through which some light can pass in order to illuminate the non-opaque members 14. Colour of the non-opaque members 14 is chosen as per the function of the switch, for example red for warning light switch, yellow for light beacon switch etc. A marking may be put on the non-opaque members by way of printing, embossing, sticker, etc. The making may be to indicate the

purpose/function of the switch assembly 100. Alternatively, the marking may be custom e.g. logo of a company. Further alternatively, the marking may be a combination of a company logo and function of the switch.

[0051 ] Alike adapters 20, controls 10 and non-opaque members 14 are also very low cost items compared to the cost of switches described in the background section. Therefore, service stations could stock several controls for various size apertures and type of operation. Non-opaque members can be standardised for all controls by having identically sized through holes on each control, that is the non-opaque member's size does not change depend on switch aperture's 95 dimension. Service stations could stock non-opaque members 14 of the various colours and having various markings.

[0052] The switch 30 is sturdily built and is rated for at least 7 amps.

Generally in vehicles, voltage available is low. Therefore, unless the switch 30 is able to handle high amperage, relays are required to operate certain devices through the switch 30. Relays add cost and complexity to the installation of the electric device. A 7 amp switch 30 is found to be capable of handling most after- market accessories that would be run from an additional switch.

[0053] Referring to figure 6, the prototype seen in this photograph largely resembles the embodiment described earlier. Therefore, the following description is limited to the distinct features seen in figure 6. [0054] At one end, wires 40 from the power supply and to the electrical device are connected to the switch 30. At the other end, wires 40 are terminated at two sealed connectors 45. Sealed connectors 45 are suitable when the switch 30 is being installed outside the cabin of the vehicle where the connection is at a higher risk of being damaged. Alternatively, unsealed connectors may be provided where the switch 30 is to be installed inside the cabin of the vehicle. An alternative vehicle panel 90 having switch apertures 95 is also seen. The outer two apertures 95 of the vehicle panel 90, seen in figure 6, are fitted with covers (not switches).

[0055] In order to install the switch assembly 100 in an aperture 95, the following steps are followed:

• Select an adapter 20 suitable for the particular aperture 95

• Select an control 10 suitable for the adapter 20

• Install desired non-opaque members 14 in the control 10

• Mount the control 10 on the adapter 20

• Connect the connectors 45 to the power source and the electrical device (wires 40 between the switch 30 and the connectors 45 are pre-installed)

• Pull the switch 30 through the rear of the aperture 95

• Mount the adapter 20 on the switch 30

• Mount the adapter 20 in the aperture 95

[0056] Sequence of steps of above method may be varied.

[0057] To make the solution even more practical, the present invention may be provided in switch assembly kits. Such kits could include:

• A switch 30 (pre-connected to wires 40 and connectors 45)

• A number of adapters 20 to suit various aperture sizes

• A number of controls 10 to suit various adaptors 20

• A number of non-opaque members 14 having various markings and/or of various colours. [0058] Such kits would be particularly useful at service stations which install electrically powered devices/accessories on vehicles of various makes. Also, kits would be useful at mine sites where switches often need replacing and the equipment/vehicles are from various manufacturers.

[0059] ALTERNATIVE EMBODIMENTS

[0060] It is possible to provide the adapter 20 and the control 10 as one unit suited for a particular aperture 95. This will reduce the universality of the switch assembly 100. Particularly, the switch assembly 100 would then be limited to a particular type of control. However, such two part switch 100 would also have the advantage of the present invention, which is being able to suit different aperture dimensions.

[0061 ] It is envisaged that the second engaging means, that is the portion of the adapter 20 which engages with the aperture 95, is adjustable to suit a range of aperture sizes. For example, the lugs 24 and/or the guiding portions 26 could be extended inward or outward to the adapter 20 such that the size of the adapter 20 is varied to suit a particular aperture. Therefore, stocks of adapter 20 would also reduce. Equally, the control 10 may also be re-sizable to reduce stocks of controls 10.

[0062] Any one or both non-opaque members 14 may be replaced with opaque member(s) if no illumination of the controls is desired. The non-opaque member(s) 14 may be partially opaque. REFERENCE NUMBER TABLE

No. Feature

10 Control

12 Stem

14 Non-opaque member

20 Adapter

22 Receiving portion

24 Lug

26 Guiding portion

30 Switch

32 Protrusion

34 Light

40 Wires

45 Connector

90 Panel

95 Aperture

100 Switch assembly

Claims

THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS:

1 . A switch assembly suitable for operating electrically powered devices on vehicles and to be located in an aperture of a panel, the switch assembly including a switch housing electrical components, an adapter configured to be detachably mounted on the switch and in said aperture, and a control for operating the switch.

2. A switch assembly according to claim 1 , including a first engaging means for releaseably attaching the adapter to the switch.

3. A switch assembly according to claim 2, wherein the first engaging means includes at least one protrusion on the switch engageable with at least one receiving portion on the adapter.

4. A switch assembly according to claim 3, wherein the protrusion or the receiving portion is flexible to allow disengagement.

5. A switch assembly according to any one of the preceding claims, including a second engaging means for releaseably attaching the adapter to said aperture.

6. A switch assembly according to claim 5, wherein the second engaging means includes at least one lug on the adapter engageable with the aperture.

7. A switch assembly according to claim 6, wherein the lug is flexible to allow disengagement.

8. A switch assembly according to any one of claims 5 to 7, wherein the second engaging means includes elongate guiding portions to guide the adapter in said aperture.

9. A switch assembly according to any one of the preceding claims, wherein the control is at least partially mounted on the adapter.

10. A switch assembly according to any one of the preceding claims, wherein the control has a stem, in use, the stem is inserted in the switch to operate electrical contacts.

1 1 . A switch assembly according to any one of the preceding claims, wherein the control is sized to suit said aperture.

12. A switch assembly according to any one of the preceding claims, wherein the control is a rocker, toggle or a push button.

13. A switch assembly according to any one of the preceding claims, including at least one non-opaque member detachably mounted on the control, in use, the non-opaque member is illuminated by a light on the switch.

14. A switch assembly according to claim 13, including two non-opaque members detachably mounted on the control and spaced from each other.

15. A switch assembly according to any one of the preceding claims, wherein the switch is rated for at least 7 amps.

16. A switch assembly according to any one of the preceding claims, wherein the adapter is selected from a plurality of adapters, each adapter is configured to be mounted on the switch and in a different aperture, and wherein the selected adapter is mountable in said aperture.

17. A switch assembly according to any one of the preceding claims, wherein the control is selected from a plurality of controls, each control is configured to suit a different aperture, and wherein the selected control is suited to said aperture.

18. A method of installing a switch assembly for operating electrically powered devices in an aperture of a panel including the steps of:

mounting the adapter in said aperture, and

mounting a control to operate the switch on the adapter.

19. A method according to claim 18, further including the step of selecting the adapter from a plurality of adapters, each adapter is configured to be mounted on the switch and in a different aperture, and wherein the selected adapter is mountable in said aperture.

20. A method according to claim 18 or 19, further including the step of selecting the control from a plurality of controls, each control is configured to suit a different aperture, and wherein the selected control is suited to said aperture.

21 . A switch kit for installing a switch assembly in an aperture of a panel, the kit including: a switch housing electrical components, at least one adapter configured to be detachably mounted on the switch and in said aperture, and at least one control to operate the switch.

22. A kit according to claim 20, including a plurality of adapters, each adapter is configured to be mounted on the switch and in a different aperture.

23. A kit according to claim 20 or 21 , including a plurality of controls, each control is configured to suit a different aperture.

24. A kit according to any one of claims 20 to 22, including a plurality of nonopaque members detachably mountable on the control, each non-opaque member having a different marking, in use, a non-opaque member is illuminated by a light on the switch.