Electrical resistors – Mechanically variable – Movable contact electrically adjustable over length of...
Reexamination Certificate
1999-10-01
2001-07-10
Easthom, Karl D. (Department: 2832)
Electrical resistors
Mechanically variable
Movable contact electrically adjustable over length of...
C338S197000, C338S199000, C338S153000
Reexamination Certificate
active
06259351
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates to an electrical control box for easy convertibility between multiple modes of operation. More specifically, it relates to a dimmer switch which uses the same back body, PC board, and strap-heat sink but allows adaptation for either toggle switch or slide switch operation.
BACKGROUND OF THE INVENTION
Although the simple binary toggle switch is still the primary lighting control device in most homes due to cost, dimmers and other new lighting controls are often preferred for handling many lighting tasks more efficiently. By controlling the intensity of the light according to needed or desired parameters, dimmers reduce wasted electricity, saving money and natural resources. A dimmer permits lowered or raised light levels so that they are appropriate to the need. For example, a bathroom dimmer can be set to a low setting for restful light when bathing or napping, then raised to a higher intensity setting to apply makeup.
Most dimmers today are solid-state devices. They actually switch off and on very rapidly—120 times per second. Because the human eye integrates, it perceives the light as a product of how long the current is in the “off” and “on” cycles.
Dimmers save money. First, they significantly cut wasted energy by using only the amount of electricity needed. When a light is dimmed 25%, a dimmer saves about 20% of the electricity required. When dimmed by 50%, it saves 40% of the electricity. Second, a dimmer greatly extends lamp life because it reduces strain on the filament. When dimmed 25%, a lamp lasts 4 times longer than it would at full power, and dimmed by 50%, it will last as much as 20 times longer.
No special wiring is needed for a dimmer—it may replace any conventional light switch, but there are specially-rated dimmers for fluorescent or low-voltage lighting and fans. Dimmers must be selected with ratings to handle the type and load of fixtures it will control.
Dimmers may be operated with a toggle, a dial, a slide, a paddle switch, a touch-pad or electronic button; some types integrate two or more of these methods to handle different tasks. Whereas in a binary toggle switch the switch simply moves between an on and an off position, in dimmer switch applications the toggle switch is movable between multiple operative positions.
Prior art dimmer switches include those which operate with the toggle switch and those which operate with a slide switch. A known prior art device incorporates a PC board. The planar extension of the PC board is perpendicular to the planar extension of the face plate.
There is a need for a dimmer electrical control box which is capable of being adapted for use with a toggle switch or a sliding switch which utilizes a common PC board in the electrical control box to promote versatility. There is also a need for a dimmer electrical control box where manufacturing costs are reduced by enabling the use of common components for two different products, one using a toggle switch and one using a sliding switch.
Also, it is desirable for an electrical control box to use screw terminals as this facilitates hook up to external wiring. Prior art devices have instead relied on leads coming out of the electrical control box.
SUMMARY OF THE INVENTION
The present invention relates to an electrical control box that is easily assembled with a toggle switch or a slide switch. The electrical control boxes of this invention employ the same back body, the same PC board and accompanying components, and the same strap-heat sink, but are adaptable to accommodate either a slide dimmer switch or a toggle dimmer switch.
An objective of the present invention is to provide a large surface heat sink which allows a triac to be mounted with the other discrete components on the circuit board of the box instead of far removed from the circuit board, thus avoiding the need for long lead lines. This permits PC board mounting which is parallel to the face plate. Additionally, this permits using screw terminals with pressure plates and does not rely upon lead wires coming out of the electrical control box as in various prior art devices.
This invention relates to an electrical control box for dimmer operation having a slide potentiometer and adapted to use either a slide switch or a toggle operatively coupled to the slide potentiometer. This invention permits a triac to be mounted with short lead lines onto the circuit board inside the electrical control box assembly. The configuration of the present invention yields a compact and versatile device.
According to various embodiments, this invention provides an electrical lighting dimmer device, comprising: a back body; a circuit board supported by the back body; a potentiometer connected to the circuit board; a link actuator operably connected to the potentiometer; and a metal strap comprising a planar surface and a ground flap that extends from the strap planar surface and is in electrical connection with a ground terminal mounted on the back body, wherein the link actuator is connectable to both a lever arm of a toggle switch and a bar of a slide switch. Manufacturing costs are reduced in that the same back body, circuit board, metal strap and link actuator may be employed to manufacture either a toggle operated dimmer switch or a slide operated dimmer switch.
According to other embodiments, this invention provides an electrical lighting dimmer device, comprising: a slide potentiometer; a link actuator operably connected to the slide potentiometer and including a pin; and a lever arm comprising a pivot point, a longitudinal aperture in a lower portion of the lever arm below the pivot point in which the link actuator pin is received, and a toggle switch connected to an upper portion of the lever arm above the pivot point; wherein arcuate movement of the toggle switch is translated to linear movement of the link actuator. Additionally, the invention relates to a lighting control device comprising: a back body including a back surface, side walls extending from the back surface, and an open front face; a circuit board supported on interior surfaces of the back body side walls, the circuit board having a major planar surface that is essentially parallel to the back body back surface and a potentiometer mounted thereon, the circuit board and potentiometer providing a signal to control intensity of light; and a link actuator connecting the potentiometer to a dimmer switch. This type of link actuator, and orientation of the circuit board, facilitates the device accommodating either a toggle or slide switch.
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Bryndzia Michael R.
Burke Andrea
Radosavljevic Dejan
Easthom Karl D.
Pass & Seymour, Inc.
Wall Marjama & Bilinski
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