Rocker-type power-supply switch device

[0002] 1. Field of the Invention

[0003] The present invention relates to a switch, and more particularly, to a seesaw-type power-supply switch.

[0004] 2. Description of the Related Art

[0005] To mount some conventional switches to power supplies, the conventional switches engage an outer case of the power supplies through hooks. These hooks can be made of a flexible material, such as thermoplastic resin. When arc resistance is needed, the switch case can be made of a thermosetting resin. In some designs, the hooks are made of plate materials that connect to the switch case.

[0006] When a thermosetting resin is used, the hook, in some instances, is made separately from the switch case. In these switches, many parts may be needed and these parts may be difficult to assemble. Accordingly, there is a need for an easily assembled switch that has an arc resistance.

[0007] In one aspect of the invention, a switch comprises a first case and a second case. The first case has an accommodating portion that receives a stationary contact and a movable contact. A cover, having a window hole, is supported by a top portion of the first case. An operating lever that includes a portion passing through the window hole operates a movable contact. The movable contact mechanically couples and separates from a stationary contact. At an outside portion of the second case, a hook such as an engaging hook, and a stationary terminal project from the first case. The first case and the cover are received by the second case. In this aspect, the first case and the cover are comprised of an arc resistance resin. The second case is comprised of a thermoplastic resin. Preferably, the second case is more flexible than the first case. Furthermore, the stationary terminal is secured to the second case through a receiving hole by a press fitting. Preferably, the receiving hole passes through an inside bottom portion of the first case.

[0008] In a second aspect, a contact section, which comprises the stationary contact and the movable contact, is enclosed by the first case and the cover. An outside surface of the first case and an inside surface of the second case comprise a preventing means. A recess formed within an outside side surface of the first case, and a protrusion projecting from the inside surface of the second case preferably comprise the preventing means.

[0009] In another aspect, the switch comprises a protruding step which is positioned near an inside bottom surface of the second case. The protruding step is disposed near a hole configured to receive the stationary terminal. Preferably, a through hole passes through the inside bottom portion of the first case. The through hole is positioned to receive the protruding step. In this aspect, the stationary terminal is positioned within the switch by bringing a bottom surface portion of the stationary terminal into contact with the protruding step. In another aspect, the first case and the second case is positioned by fitting the protruding step through the through hole.

[0010] FIG. 1 is a front view of an embodiment of the invention.

[0011] FIG. 2 is a side view of FIG. 1.

[0012] FIG. 3 is a sectional view taken along lines III—III of FIG. 2.

[0013] FIG. 4 is a sectional view taken along line IV—IV of FIG. 2.

[0014] FIG. 5 is a plan view of a second case.

[0015] FIG. 6 is a front view of the second case.

[0016] FIG. 7 is a plan view of a first case.

[0017] FIG. 8 is a front view of the first case.

[0018] FIG. 9 is a plan view of a cover.

[0019] FIG. 10 is a front view of the cover.

[0020] FIG. 11 is a plan view of an operating lever.

[0021] FIG. 12 is a front view of the operating lever.

[0022] Referring to FIGS. 1-12, a first case 1 is comprised of an insulating material, that preferably includes a plastifiable PPS (polyphenylene sulfide) having an arc resistance and a thermosetting resin such as unsaturated polyester. Preferably, the plastifiable PPS has a high arc resistance.

[0023] The first case 1 includes an open topside. As shown in FIG. 7, preferably an interior portion of the first case 1 is separated into two accommodating portions 1band 1cby an insulating wall 1a. A pair of substantially rectangular slot-shaped receiving holes 1dare positioned near the corners of the first case 1. The substantially rectangular slot-shaped receiving holes 1dare configured to receive stationary terminals 5 and 6 that are shown in FIG. 3. The stationary terminals 5 and 6 are positioned in an interior bottom portion of the accommodation portions 1band 1c. Preferably, the substantially rectangular slot-shaped receiving holes 1dare positioned across from each other. A pair of substantially rectangular or polygon shape through holes 1eare formed adjacent to each through hole 1d. These pairs of receiving holes 1dand through holes 1eare preferably positioned across from each other. As partially shown in FIG. 4, protruding steps 3bpass through and engage the inner peripheral surfaces of the corresponding through holes 1e.

[0024] As shown in FIG. 7, preferably, a recess 1fis formed in an outer surface end of the first case I. The recess 1fis configured to receive a protrusion 3c(as shown in FIG. 5) which comprises an arc formed within an inside surface of the second case 3. In this embodiment, when the protrusion 3cand recess 1fare not in alignment, the first case 1 does not seat within the second case 3. This misalignment prevents the first case 1 from being properly coupled to the second case 3. Preferably, this misalignment is easily identified.

[0025] Preferably, a cover 2 (as shown in FIG. 9) comprises an insulating material such as a plastifiable PPS (polyphenylene sulfide) having an arc resistance and a thermosetting resin such as unsaturated polyester. Preferably, the cover 2 has a substantially multisided shape and an open bottom side. As shown in FIG. 9, a pair of cross-shaped window holes 2apass through the cover 2. An actuating portion 4bof an operating lever 4 shown in FIG. 12, passes through the pair of window holes 2a.

[0026] The cover 2 engages a top wall portion of the first case 1 to conceal the open portion of the first case 1. The first case 1 and the cover 2 are preferably configured to cover a contact section that comprises first and second stationary contacts 5aand 6a, respectively, and a movable contact 7 as shown in FIG. 3. In this embodiment, the contact section of the switch is protected by the cover 2 and the first case 1, which preferably comprises resins having high arc resistances.

[0027] Preferably, the second case 3 is made of an insulating material, such as polyacetals and polyamides, which are thermoplastic resins that are more flexible than the first case 1. Preferably, the second case 3 has a substantially parallelepiped shape having an open top side, as shown in FIG. 6. Two pairs of slot-shaped or polygonal shaped holes 3afor receiving the stationary terminals 5 and 6 pass through an inner bottom surface of the second case 3 shown in FIG. 5. The holes 3aare positioned across from each other. Two pairs of substantially rectangular or polygon shaped protruding steps 3bare formed near the holes 3a. The protruding steps 3bare positioned across from each other, and preferably pass through and engage the corresponding through holes 1eof the first case 1. In this embodiment, the height of the protruding steps 3bare preferably slightly greater than the depths of the through holes 1e. The preferred heights of the protruding step 3bensure that the protruding steps 3bpass through the corresponding through holes 1e. Preferably, the dimensions of the protruding step 3ballows the stationary terminals 5 and 6 that are secured to the holes 3aof the second case 3 to couple the protruding steps 3b. Accordingly, the stationary terminals 5 and 6 are mechanically coupled to the second case. Preferably, the protrusion 3cof the second case 3 is configured to engage the recess 1fof the first case 1. Preferably, the protrusion 3cis a unitary part of a side surface within the open portion of the second case 3. The protrusion 3cengages the recess 1fwhen the first case 1 is properly received by the second case 3. Preferably, the configuration of the outside surface of the first case 1 and the inside surface of the second case 3 prevents an improper assembly of the switch. If the first case 1 is improperly inserted within the second case 3, the recess 1fand the protrusion 3cwill not engage each other and the first case 1 will not substantially seat within the second case 3. Accordingly, when the first case 1 has not been properly inserted within the second case 3, a misalignment is easily detected. The structure that prevents the first case 1 from being improperly inserted within the second case 3 is not limited to a recess and a protrusion because many other suitable structures may also be used.

[0028] As shown in FIG. 6, a hook, such as a preferred snap engaging hook 3d, for example, is a unitary part of or couples to a side or a front surface of the exterior of the second case 3. Preferably, the hook 3dis made of a thin-plate material that terminates at ends coupled to or joined to the exterior surface of the second case 3. Preferably, the hook 3dis flexible, and encloses a substantially triangular or polygonal-shaped opening. The hook is preferably configured to snappingly engage devices, such as electronic devices.

[0029] As shown in FIG. 6, presser grooves 3fare positioned in the lower end of a front exterior surface of the second case 3. As shown in FIG. 1, the presser grooves 3fare configured to press and inwardly bend dislodging-preventing pawls 5cand 6cafter the stationary terminals 5 and 6 have been inserted through the holes 3ato prevent the stationary terminals 5 and 6 from becoming dislodged from the second case 3. Pawls 5cand 6c(shown in FIG. 3) are formed on the bottom surface of the second case 3. The pawls 5cand 6care disposed in a row that is coupled with the presser grooves 3f.

[0030] As partially shown in FIG. 1, preferably, holes 3g, which rotatably support shafts 4cof the operating lever 4, are formed near the top end of the second surface of the outside of the second case 3. Preferably, operating lever 4 is made of an insulating material, such as synthetic resin. As partially shown in FIG. 12, preferably, the operating lever 4 comprises a substantially planar operating portion 4a, a rod-shaped actuating portion 4b, which couples to the lower surface of the operating portion 4a, and a pair of the shafts 4cwhich oppose each other near the center of a side surface of the operating lever 4. Preferably, the actuating portion 4b(shown in FIG. 12) is received by the pair of window holes 2aof the cover 2 (shown in FIG. 9). Preferably, shafts 4care received by the holes 3gand are supported by the second case 3 through which the holes 3gpass or partially pass through (shown in FIG. 1).

[0031] Preferably, a pair of the stationary terminals 5 and 6 are disposed near the inside bottom portions of the first and second cases 1 and 3. Preferably, the pair of stationary terminals 5 and 6 are made of electrically conductive materials, and are substantially L-shaped. The first stationary contact 5a, with which a rotary contact portion 7aof the movable contact 7 engages, is preferably positioned near the top surface of the stationary terminal 5. The second stationary contact 6ais preferably positioned near the top surface of the stationary contact 6. In this preferred embodiment, the stationary contact 6ais normally coupled to contact portion 7b.

[0032] The preferred dimensions of the receiving holes 1dof the first case 1 are preferably greater than the widths of the stationary terminals 5 and 6. The preferred dimensions of the holes 3aof the second case 3 are preferably slightly smaller than the receiving holes 1d. Ends of the stationary terminals 5 and 6 at sides opposite to the corresponding stationary contacts 5aand 6a, respectively, pass through the receiving holes 1dof the first case 1. The ends of the stationary terminals 5 and 6 pass through the holes 3aof the second case 3 to press-fit and secure the first and second stationary contacts 5aand 6a, respectively, to the first and second cases 1 and 3.

[0033] As shown in FIG. 3, preferably cutaway portions 5band 6bpass through the centers of the stationary terminals 5 and 6. The dislodging-preventing pawls 5cand 6care received by the cutaway portions 5band 6b, respectively. The pawls 5cand 6care disposed near the corresponding presser grooves 3fof the second case 3 shown in FIG. 6. The pawls 5cand 6care pressed, and are inwardly bent to engage the presser grooves 3f(shown in FIG. 1) and thereby prevent the stationary terminals 5 and 6 from becoming dislodged from the second case 3.

[0034] Referring now to FIG. 3, preferably, the movable contact 7 comprises an electrically conductive material. The rotary contact portion 7awhich contacts and separates from the first stationary contact 5ais formed at a first end of the movable contact 7. The contact portion 7bwhich contacts the second stationary contact 6ais formed at a second end of the movable contact 7. Preferably, a coil spring 8 rotatably biases the movable contact 7 as shown in FIG. 3. Preferably, the coil spring 8 is disposed near the center of the movable contact 7. As lever 4 is depressed, the actuating portion 4bof the operating lever 4 preferably biases and rotates the coil spring 8, causing the movable contact 7 to rotate about the contact portion 7blike a fulcrum.

[0035] To assemble the preferred switch, the first case 1 is inserted into the second case 3. Preferably, the first case 1 is inserted into the bottom portion of the second case 3 such that the protrusion 3cengages the recess 1f. Preferably, the protruding step 3bof the second case 3 is received by the through holes 1eof the first case 1 (shown in FIG. 4). Preferably the stationary terminals 5 and 6 are press-fit or inserted into holes 3aof the second case 3 and through the receiving holes 1dof the first case 1 (partially shown in FIG. 4). Through this engagement, the stationary terminals 5 and 6 are secured to the first and second cases 1 and 3, respectively. Preferably, the stationary terminals 5 and 6 are secured to the second case 3 through a pressing jig. Preferably the pressing jig presses and bends the dislodging-preventing pawl 5cof the stationary terminal 5 and the dislodging-preventing pawl 6cof the stationary terminal 6.

[0036] Preferably, the movable contact 7 is disposed above the stationary terminals 5 and 6. In this embodiment, when the contact portion 7bis coupled or in contact with the second stationary contact 6a, the cover 2 is coupled to the top portion of the first case 1, which is inserted within and secured to the second case 3. The actuating portion 4bof the operating lever 4 is inserted through the window holes 2aof the cover 2. Preferably an end of the actuating portion 4bis in contact with the coil spring 8 which is disposed on the movable contact 7 when shafts 4cof the operating lever 4 engage the holes 3gof the second case.

[0037] According to the preferred embodiment, the switch device comprises a first case 1 and a second case 3. The first case 1 encloses the contacts 5a,6a,and 7 within the first case 1. The cover 2 protects and seals the contacts 5a,6a,and 7 from contaminants. Preferably, the engaging hook 3dand the stationary terminals 5 and 6 project from the second case which encloses the first case 1 and the cover 2. Preferably, the first case 1 and the cover 2 are made of resins having a high arc resistance.

[0038] Preferably, the second case 3 is made of a thermoplastic resin that is more flexible than the first case 1. The stationary terminals 5 and 6 are secured to the second case 3 by passing the stationary terminals 5 and 6 through the receiving holes 1dwhich pass through the inside bottom portion of the first case 1.

[0039] Preferably, the second case 3 is made of a thermoplastic resin. The thermoplastic resin preferably provides arc resistance between the contacts, and forms the engaging hook 3d. Preferably terminals 5 and 6 are secured to the first and second cases 1 and 3, respectively, making it unnecessary to separately bond terminals 5 & 6 to one or more cases using an adhesive. Moreover, to provide satisfactory arc resistance, the second case is preferably made of a thermosetting resin having a high arc resistance. Accordingly, the engaging hook 3d, in the preferred embodiment need not be made of a separate plate material.

[0040] Preferably, the first case 1 comprises accommodating portions 1band 1cin which the first and second stationary contacts 5aand 6a, respectively, and the movable contact 7 are disposed. Preferably, the snap engaging hook 3dis a unitary part of or is coupled to the second case 3. The stationary terminals 5 and 6 project from the corresponding first and second stationary contacts 5aand 6a, respectively. The second case 3 preferably encloses the first case 1 and the cover 2. Preferably, the first case 1 and the cover 2 are made of resins having an arc resistance, and the second case 3 is made of a more flexible resin than the first case 1.

[0041] In the preferred embodiment, the stationary terminals 5 and 6 are press-fitted to the second case 3. The stationary terminals 5 and 6 pass through the receiving holes 1dthat pass through the inner bottom portion of the first case 1. Preferably, a high arc resistance between the contacts is maintained. The stationary terminals 5 and 6 can be press-fitted to both the first and second cases 2 and 3. The preferred first and second case 2 and 3, respectively, and stationary terminals 5 and 6 make it unnecessary to separately bond the stationary terminals 5 and 6 to both the cases 2 and 3 using an adhesive. The contact section, which comprises the first and second stationary contacts 5aand 6a, respectively, and the movable contact 7, may be enclosed by the first case 1 and the cover 2 which are made of resins having high arc resistances.

[0042] An outside surface of the first case 1 and an inside surface of the second case 3 may include a preventing means. Preferably the preventing means prevents assembly in such a manner that the first case 1 is improperly inserted into the second case 3. In a preferred embodiment, the preventing means comprises a recess 1fwhich is provided on the outside surface of the first case 1, and a protrusion 3cwhich is positioned on the inner surface of the second case 3. In this preferred embodiment, the recess 1fand the protrusion 3care positioned on the sides of the respective first case 1 and second case 3 having the shortest lengths of each respective case. The preventing means can be integrally coupled with or a unitary part of the first and second cases 1 and 3. When the first case 1 is improperly inserted into the second case 3, the recess and the protrusion 3care not aligned and thus, do not engage each other. This improper assembly can be easily detected because the first case 1 does not substantially seat within the second case 2.

[0043] The switch device may further comprise protruding steps 3bthat are positioned on the inner bottom surface of the second case 3. The protruding steps 3bare preferably disposed near the holes 3athat receive the stationary terminals 5 and 6 and project upward from the inner bottom surface of the second case 3. Through holes 1e,passing through the inner bottom portion of the first case 1, receive the protruding steps 3b.In the preferred switch device, the stationary terminals 5 and 6 may be positioned by bringing bottom surface portions of the stationary terminals 5 and 6 into contact with the protruding steps 3b.Preferably, the stationary terminals 5 and 6 are received and secured to the holes 3aof the second case 3. The first case 1 and the second case 3 may be positioned by fitting the protruding steps 3bwithin the through holes 1e.Accordingly, the cases 1 and 3 can be easily aligned, and the receiving holes 3aand 1ecan be easily aligned.

[0044] While various embodiments of the invention have been described, it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible that are within the scope of this invention. Accordingly, the invention is not to be restricted except in light of the attached claims and their equivalents.