HK1097090A

HK1097090A - Rocker paddle switch with semi-rigid cam driver

Info

Publication number: HK1097090A
Application number: HK07102037.4A
Authority: HK
Inventors: P．恩德雷斯; S．R．库雷克; A．塔范诺; D．A．奥德森
Original assignee: 立维腾制造有限公司
Priority date: 2003-07-25
Filing date: 2004-07-23
Publication date: 2007-06-15

Description

Rocker paddle switch with semi-rigid cam driver

This application is a continuation of the application filed on 25/7/2003 under serial No. 10/627224.

Technical Field

The present invention relates generally to the field of electrical wiring devices, such as wall-mounted type electrical switches and sockets, and more particularly to a robust electrical wiring device system whose components may be modular and interchangeable, having a substantially unitary hybrid appearance when the modular components are combined with one another. This patent specification describes such a robust system and is identical, in whole or in part, to the claims hereof and/or to several patent applications relating to portions and/or components of such a robust system.

Background

When wiring in an existing building, such as a public place, a commercial place or a residential place, is changed by modifying wiring devices such as switches, sockets or a combination of sockets and switches, it is necessary to open a hole in a wall of the building, install a box in the hole, connect, for example, the box to a vertical stud, and then install the wiring devices in the box. In the new construction, the box is attached to a stud of an open wall and then mounted to the wall resting on the stud, which may be a stone slab having an opening to allow the box to be handled. Conventional wall boxes have pairs of mounting ears for mounting wiring devices to such boxes. After the wiring devices are connected to the various conductors, they are operated to connect each wiring device to a pair of mounting ears of the box using threaded fasteners (sometimes referred to as bolts or screws, these terms being used interchangeably herein). For each wiring device in the box, the process of connecting the wiring device to the various conductors and then connecting the wiring device with the wires to the box is performed. The wall plate is then typically mounted around or over each of the wiring devices in the box.

Typical mounting structures include a single wiring device or a plurality of wiring devices arranged side-by-side in a common box. In mounting arrangements having multiple wiring devices within a common box, the installation of the wall plate is very time consuming. This is because the wall plate for multiple wiring devices provides a separate window for each wiring device. Thus, the wiring devices must be aligned with each other, must be parallel to each other, and must be spaced from each other by a distance determined by the spacing between the openings or windows in the wall plate. Misalignment or positioning problems are often caused by wall boxes being skewed relative to the wall or the wall being uneven. Only after all the wiring devices have been accurately positioned relative to each other can the wall plate be installed around the wiring devices.

One electrical connection device commonly used today is a rocker-type electrical switch, available under the trademark Decora, whose actuating element rotates about a central horizontal axis. The trademark Decora is owned by the assignee of the present invention. To operate such a switch, a rocker switch actuating element is pushed in at the top to supply power to a consumer, such as a lamp, and the rocker switch actuating element is pushed in at the bottom to disconnect power from the consumer. Thus, by arranging two or more rocker switches side by side in a box, the actuating elements of the switches can be brought into opposite positions at any one time. For example, by arranging two rocker switches side-by-side within a box, a portion, referred to as the top edge, associated with the "on state or position" of the actuating element of one switch will be flush with the top surface of the wall plate when in the open position, while the top edge of an adjacent switch will be flush with the bottom surface forming the wall plate opening when in the closed position. If one or each of these switches is a 3-way or 4-way switch, such inside-out positioning of adjacent switches can also occur when both switches are in an open or closed state. This irregular internal and external positioning of adjacent switches, particularly 3-way and 4-way switches, in the user's mind creates operational uncertainty, i.e., when the user subsequently needs to actuate or release less than all of the rocker switches, it is not certain which switch is in the open position and which switch is in the closed position.

What is needed, therefore, is a rocker switch that is always in the same position, i.e., bottom edge out and top edge in, regardless of the conductive state of the switch, i.e., whether open or closed. What is also needed is a switch that is always aligned with one another when the switch is positioned alongside another switch or switches in a common box, regardless of whether they are in an open or closed state.

Disclosure of Invention

The invention discloses an on/off switch which is turned on or off by pushing a lower portion of a rocker plate. The lower edge of the rocker paddle pivots in and out about its top or upper edge. When the switch is in its on or off position, the spring biasing means urges the lower portion of the rocker plate into its out position. The rocker paddle of the switch is not located within a frame and has, along its vertical axis, a surface with a positive first differential and a zero second differential, the surface being made up of a combination of splines extending between points at different distances from a datum plane. The surface has a quadratic differential of zero when the rate of height increase of the individual splines is constant.

A semi-rigid cam driver on the rocker paddle connected to the switch causes a cam to rotate in both a clockwise and counterclockwise direction whenever the rocker paddle is depressed. A slide member having a cam follower is driven back and forth along a straight axis by alternate rotation of the cam. A leaf spring cooperates with the cam follower to assist in moving the slide member and defining its rest positions. An indicator, such as a light emitting diode, is used to indicate the conductive state of the switch.

The foregoing has outlined, rather broadly, a preferred combination of features of the present invention so that those skilled in the art may better understand the detailed description of the invention that follows. Additional features of the invention will be described hereinafter that form the subject of the claims of the invention. Those skilled in the art should appreciate that they can readily use the conception and the specific embodiment disclosed as a basis for designing or modifying other structures for carrying out the same purposes of the present invention without departing from the spirit and scope of the invention in its broadest form.

Drawings

Other aspects, features and advantages of the present invention will become more fully apparent from the following detailed description, the appended claims and the accompanying drawings in which like elements are given like reference numerals.

FIG. 1 is a front perspective view of a switch and wall plate of the prior art;

FIG. 2 is an exploded perspective view of a prior art switch, connection plate and wall plate and box for receiving the prior art device;

fig. 3 is a front perspective view of a switch and wall plate according to the principles of the present invention;

FIG. 4 is a front perspective view of the switch of FIG. 3 showing the grounding/mounting strap and the multi-function clip;

fig. 5 is an exploded view of a connection plate, switch and wall plate according to the principles of the present invention;

fig. 6 is a front view of a receptacle and wall plate according to the principles of the present invention;

FIG. 7 is a front perspective view of the receptacle of FIG. 6 showing the grounding/mounting strap and the multi-function clip;

fig. 8 is an exploded view of a connection plate, receptacle and wall plate according to the principles of the present invention;

FIG. 9 is a front perspective view of an alignment plate for a single wiring device;

FIG. 10 is a perspective view of a grounding/mounting strap for the wiring lug;

FIGS. 11 and 11A are schematic bottom perspective views showing the grounding/mounting strap connected to a switch (FIG. 11) and a receptacle (FIG. 11A);

FIG. 12 is a plan view of a multi-function clip typically attached to the bottom end of a grounding/mounting strap;

FIG. 12A is a side view of the multi-function clip of FIG. 12;

FIG. 13 is a plan view of a multi-function clip typically attached to the top end of a grounding/mounting strap;

FIG. 13A is a cross-sectional view of the multi-function clip of FIG. 13 taken along line A-A;

FIG. 14 is an exploded view of a switch according to the principles of the present invention;

fig. 15 is a schematic perspective view of a base assembly of the switch of fig. 14;

FIG. 16 is an exploded view of the base assembly of FIG. 15;

FIG. 17 is another exploded view of the switch;

FIG. 18 is an exploded view of another part of the switch;

FIG. 19 is an exploded view, partially in section, of the cam driver of the switch;

FIG. 20 is an exploded perspective view of the switch showing the lamp assembly plate;

FIG. 21A is a plan view of a lamp assembly plate;

FIG. 21B is a bottom perspective view of the lamp assembly plate;

FIG. 22 is an exploded perspective view showing the lamp in the rocker paddle of the switch;

FIG. 23 is a perspective view of the lamp tube;

FIG. 24 is a cross-sectional view taken along line 24-24 of FIG. 3;

FIGS. 25A-25C are cross-sectional views taken along lines 25A-25A, 25B-25B, 25C-25C of the rocker plate of FIG. 14;

FIG. 26 is an exploded perspective view of a switch having an alternative cam driver;

FIG. 27 is a cross-sectional view taken along line 24-24 of FIG. 3, wherein the cam-driver is the cam-driver of FIG. 26;

FIG. 28 is an exploded perspective view of a switch having an alternative cam driver;

FIG. 29 is a cross-sectional view taken along line 24-24 of FIG. 3, wherein the cam driver is the cam driver of FIG. 28;

FIG. 30 is a front perspective view of a wall plate for a single wiring device;

fig. 31A-31C are cross-sectional views along lines 31A-31A through 31C-31C of the wall plate of fig. 30;

fig. 32 is a cross-sectional view of the bottom edge of the wall plate taken along line 32A-32A of fig. 30;

fig. 33 is a cross-sectional view of the top edge of the wall plate taken along line 33A-33A of fig. 30;

fig. 34, 34A are schematic views of the top edge of the wall plate of fig. 30 showing the groove and logo structures;

FIG. 35 is an enlarged, fragmentary perspective view of the locking pawl of the multi-function clip engaging the rack of the wall plate;

fig. 36 is an enlarged partial cross-sectional view of the tabs of the wall plate and alignment plate showing how the two components are separated after locking;

FIG. 37 is an exploded perspective view of the box, alignment plate and wall plate for two wiring devices;

FIG. 38 is an exploded view of the alignment plate and wall plate for the three wiring devices;

FIG. 39 is an exploded view of an alignment plate and wall plate for four wiring devices;

FIG. 40 is an exploded view of an alignment plate and wall plate for five wiring devices;

fig. 41 is an exploded view of an alignment plate and a wall plate for six wiring devices.

Detailed Description

Referring to fig. 1, there is shown a front perspective view of a wall electrical switch 18 and wall plate 16 of the "Decora" type as part of a prior art assembly 10. Referring to fig. 2, there is shown an exploded perspective view of the wall box 13, electrical wiring devices such as switch 18, connection plate 30 and wall plate 16 of the prior art device shown in fig. 1. A suitable hole is made in the wall to receive a box 13 for mounting to a peg 15 therein, or to allow a suitable box to be mounted to an adjacent peg or directly to the material of the wall (e.g. gypsum plasterboard). The box 13 is selected to be large enough so that as many wiring devices are desired to be installed in the box, the box can receive as many wiring devices. The box 13 is made of metal or plastic, depending on local legal requirements, with one or more openings in the side or back of the box to allow wires or cables to pass into the interior of the box 13. The cassette 13 has mounting means 19 to allow the cassette to be secured to adjacent pegs 15. The box supports a pair of mounting ears 21 for each wiring device to be mounted in the box. Each mounting lug includes a threaded hole 23 and a mounting screw of a wiring device, such as rocker switch 18 or a socket, is secured in the threaded hole 23. For example, in the usual assembly sequence, the cables are passed through knock-out opening 17 into the interior of the box. The insulation at the end of the cable is stripped and the end of the cable is connected to the body 20 of the switch 18 or to the terminal (junction) at the side or rear of the receptacle. After the cable wires are connected to the terminals on the side or rear of the switch body, the switch is pushed into the box and secured in place with screws (not shown) that pass through clearance openings such as elongated mounting slots 25 and are threaded into openings 23 of mounting ears 21, thereby mounting switch 18 into box 13. The connection plate 30 is then placed around the front of the switch and the connection plate 30 is secured to the switch using the mounting screws 26, which mounting screws 26 pass through the clearance openings 32 in the connection plate and are screwed into the openings 24 formed in the mounting/grounding strap of the wiring device. The connection plate 30 also comprises a main aperture 34, the shape of the main aperture 34 being complementary to the shape of the front of the switch 18 passing through it. The aperture 34 in fig. 1 is rectangular to receive the front of the switch 18 or receptacle. The screw head that passes through the hole 25 of the switch 18 and engages the threaded opening 23 of the mounting ear 21 is larger than the hole 25 so that the switch 18 or socket can be securely held on the box 13 and on a wall surface (not shown). Similarly, the screw head that passes through the hole 32 of the connection plate 30 and engages the threaded opening 24 of the switch's ground strap is larger than the hole 32 so that the connection plate 30 is securely held to the switch 18.

At each end 36, 38 of the connecting plate 30, respectively, there are two pawls 40, 42, which are made as extensions of the connecting plate 30, but which are thinner in section. One end 36 also terminates in an angled leg 48, the angled leg 48 extending at approximately a 45 degree angle relative to the horizontal edge of the end 38 of the wall plate 30, and the end 36 is used to assist in releasing a connected wall plate.

The wall plate 16 is proportioned to fit onto the connection plate 30 and the box 13, a single wiring device such as a rocker switch 18 or a socket is placed into the box 13, and the wall plate is secured to the box 13.

To attach wall plate 16 to attachment plate 30, pawls 40, 42 of attachment plate 30 are configured to engage serrated racks 81 on the inner surfaces of end walls 70, 72 of wall plate 16 when the wall plate is pushed in.

FIG. 3 is a front perspective view of a wiring device, such as switch 110 and wall plate 138, according to the principles of the present invention; FIG. 4 is a front perspective view of the switch 110 of FIG. 3, illustrating the grounding/mounting strap and the multi-function clip; fig. 5 is an exploded view of fig. 3 showing the connection plate, switch and wall plate. Referring to fig. 4 and 5, the switch 110 has an actuator plate 111, which actuator plate 111 is rotatable about an axis at its upper end and is biased by an internal spring element so as to be in the same rest position when in the "open" or "closed" position. Repeated pressing and releasing on the surface of the switch's actuation plate 111 alternately closes and opens a set of contact points located within the switch body, so that the actuation plate alternately connects and disconnects an electrical device, such as a light, from the power source whenever the actuation plate is pressed and released. Thus, whether a group switch is an on-off switch, a three-way switch, or a four-way switch, the top and bottom edges of each switch are always aligned with the top and bottom edges of all other switches in the group switch. An on-off indicator, such as a light 112, is provided in the actuator plate to indicate to the user whether the switch is in the on or off position. For example, when the light 112 is on, the switch is in the off position, and when the light is off, the switch is in the on position. The switch's actuation plate 111 is not within a frame and is complementary in function to the wall plate 138. The actuation plate of the switch has a length-to-width ratio and surface texture that provides a contact surface of increased size that is easier to identify and use.

The switch 110 is attached to a grounding/mounting strap 123. the grounding/mounting strap 123 has ends 122. these ends 122 provide increased surface area for contact with the wall and support for the multi-function clips 130, 151. these multi-function clips 130, 151 are attached to the ends 122 by attachment means such as screws, rivets, spot welding, pressure bonding, TOX process or the like.

Referring to fig. 10, there is shown a perspective view of a grounding/mounting strap 123 for a wiring device such as switch 110. The strap 123 has a base support member 150, the base support member 150 being located between two intermediate support members 152, the two intermediate support members 152 being bent at right angles to the base member 150 and terminating in an outwardly projecting end portion 122. The two intermediate support members 152 and the base support member bracket are securely attached to a wiring device such as switch 110 by rivets, screws or the like 155 (see fig. 11, fig. 11 being a bottom perspective view showing a grounding/mounting strap attached to a switch) that pass through openings 154 in the base support member. A ground terminal 163 is provided for connection to a ground line, the ground terminal 163 projecting outwardly from the ground/mounting strap and having a threaded opening for receiving a screw 125. Each end 122 of the band 123 is rectangular and has two openings 126 and 128. The opening 126 may be circular, oval, square, or rectangular and is a clearance opening for mounting screws 108, which mounting screws 108 may be provided by the wiring device manufacturer for attaching the wiring device to a box. The distance between the centers of the openings 126 in the ends 122 of the ground/mounting strap is equal to the distance between the centers of the openings 23 (see fig. 2) in the mounting ears 21 of the box 13 to allow the mounting screws 108 to mate with the threaded openings 23 and be securely retained. The opening 128 in each end 122 of the belt is a clearance opening for mounting an alignment pin that is part of and is located on an alignment plate. Other openings may be provided in end 122 for attaching and/or aligning a clip to the end of the grounding/mounting strap. The ends 122 are flat rectangular elements that provide an increased area for increased contact with a wall. Referring to fig. 2, fig. 2 shows the very small ends of the prior art grounding/mounting strap where if the scored gasket 31 is removed from the strap, the remaining surface for wall contact is only the material around the opening of the mounting ears 21.

The end 122 of the ground/mounting strap 123 has a width "X" of about 1.563 inches and a depth "Y" of about 0.318 inches. These dimensions are not critical. However, the distance between the edges 129 of the ends 122 of the straps should be no greater than 4.6 inches to allow a wall plate to fit over and cover the grounding/mounting straps. The grounding/mounting strap 123 may be made of sheet metal and secured to the switch using screws, rivets or any convenient fastening means 155. Screw ends 126 are located on either side of the switch body for receiving phase and neutral conductors, not shown.

The multi-function clips 130, 151 are attached to the ends 122 of the ground/mounting strap. The multi-function clip may be made of phosphor bronze, spring brass, spring steel, or similar material. Referring to fig. 12, which shows a schematic plan view of the multi-function clip 130 typically attached to the bottom end of a ground/mounting strap, fig. 12A is a side view of the multi-function clip 130 of fig. 12. The clip 130 is a clip connected to the bottom end 122 of the grounding/mounting strap 123 and has openings 132 and 134. When the clip 130 is attached to the end of the ground/mounting strap, the opening 132 is aligned with the opening 126 of the ground/mounting strap and the opening 134 is aligned with the opening 128 in the end 122 of the ground/mounting strap. Opening 132 is a clearance opening for a threaded fastener such as screw 108, screw 108 being used to connect the wiring device to a box. The opening 132 may be circular, square, oval, or rectangular to allow the threaded fastener to move up and down and to the side so that the fastener can be aligned with the threaded opening in the box when the wiring device is attached to the box.

The opening 134 in the clip 130 is substantially circular and has three inwardly projecting elements 133, the three inwardly projecting elements 133 being bent upwardly towards the surface of the wiring device by an angle of between 10 and 30 degrees. Preferably at a 20 degree angle. The ends of the three projecting members 133 form an opening that is slightly smaller than the outer diameter of the alignment pin 118 on the alignment plate (see fig. 9), and the three projecting members 133 flex or bend upward as the alignment pin enters the opening 134 from the rear. The ends of the projecting elements 133 frictionally engage the alignment pins and securely hold the alignment pins to prevent the alignment pins from being easily disengaged from the multi-function clip. At the end 147 of the clip 130 are locking pawls 140, each of which is slightly longer than one-half inch (one-half of an inch). The end 149 of each locking pawl 140 is bent upwardly at an angle of 20 to 60 degrees and is adapted to engage the toothed rail on the inside surface of the end of the wall plate to securely hold the wall plate (see fig. 35). When the locking pawl 140 is bent upward at an angle of 20 to 60 degrees, preferably about 40 degrees, the end 149 of the locking pawl 140 catches and securely holds the wall plate. The multi-function clip 130 is a clip that performs numerous functions not disclosed in the prior art.

The openings 143 in the multi-function clip can be used to attach the clip to the end of the grounding/mounting strap using, for example, rivets, screws, TOX processes, etc. The opening 145 can be used for alignment purposes when attaching the clip to the end of the strap. The distance between the side edges 154 of the clip should not exceed 1.533 inches in order to allow the clip to be connected to the end of the mounting/grounding strap without extending past the side edges of the strap 123. The clip shown in fig. 12 and 12A is a clip that is attached to the bottom end of the grounding/mounting strap.

Referring to fig. 13, there is shown a schematic plan view of a multi-function clip typically attached to the top end of a grounding/mounting strap. Fig. 13A is a cross-sectional side view of the multi-function clip taken along line a-a in fig. 13. The clip shown in fig. 13 and 13A is similar to the clip shown in fig. 12 and 12A, except that the end 157 of the clip 151 is bent upward and the opening 153 for the threaded fastener has a tab 155 that extends into the opening 153 and is bent at a slight downward angle toward the rear of the switch. The tabs 155 serve to engage and retain the threaded body of the fastener 108 and, in addition, serve to help provide a ground connection between the band and the threaded fastener to ensure the switch is grounded. Because of the use of the clip 130, when the switch is attached to the box, the opening 153 in the clip 151 and the opening 126 in the strap are aligned with each other during assembly to allow the fastening means to be aligned with the threaded opening in the box. The distance between the edges 147 of the clips should not exceed 1.533 inches in order to allow the clips to be connected to the ends of the ground/mounting strap without extending past the side edges of the end 122 of the strap 123.

Referring to fig. 6, there is shown a front view of a receptacle and wall plate in accordance with the principles of the present invention; FIG. 7 is a front perspective view of the receptacle 520 of FIG. 6, showing the grounding/mounting strap and the multi-function clip; fig. 8 is an exploded view of the component of fig. 6 showing the connection plate, the receptacle and the wall plate. Referring to fig. 7 and 8, the receptacles 520 are for 15 amp.125 Volt Ac (VAC) to 20 amp.125 volt ac (not shown), and each individual receptacle has two slot openings 524 and 526 for receiving flat blades of an appropriate plug and a semicircular ground blade opening 528 in accordance with NEMA 5-15R specifications. Opening 526 is larger than opening 524 so that a two-piece plug can only be inserted in one direction to maintain proper electrode connection. The contacts in the larger slots are connected to a neutral conductor (neutral conductor) through which the external metal components of the electrical appliance, such as a toaster, television set, etc., can be grounded by maintaining this proper electrical connection. The semicircular grounding piece prevents the plug from being reversely connected with the socket electrode.

The receptacle 520 is connected to a grounding/mounting strap 123. the grounding/mounting strap 123 has ends 122. these ends 122 provide increased surface area for contact with the wall and support for the multi-function clips 130, 151. these multi-function clips 130, 151 are connected to the ends 122 by connection means such as screws, rivets, spot welding, pressure connections, TOX processes or the like.

Referring to fig. 10, there is shown a perspective view of a grounding/mounting strap 123 for a wiring device such as receptacle 520. The strap 123 has a base support member 150, the base support member 150 being located between two intermediate support members 152, the two intermediate support members 152 being bent at right angles to the base member 150 and terminating in an outwardly projecting end portion 122. The two intermediate support members 152 and the base support member bracket are securely attached to the receptacle 520 by rivets, screws or the like passing through openings 154 in the base support member (see fig. 11A, 11A being a bottom perspective view showing the grounding/mounting strap attached to a receptacle). Ground terminal 163 is for connection to a ground line, the ground terminal 163 projecting outwardly from the ground/mounting strap and having a threaded opening for receiving a screw 125. Each end 122 of the band 123 is rectangular and has two openings 126 and 128. The opening 126 may be circular, oval, square or rectangular and is a clearance opening for mounting screws 108, which mounting screws 108 may be provided by the wiring device manufacturer for attaching the wiring device to the box. The distance between the centers of the openings 126 in the end 122 of the ground/mounting strap is equal to the distance between the centers of the openings 23 (see fig. 2) in the mounting ears 21 of the box 13 to allow the mounting screws 108 to engage the threaded openings 23 and be securely retained by the threaded openings 23. The opening 128 in each end 122 of the tape is a clearance opening for receiving an alignment pin that is part of and located on the alignment plate. Other openings may be provided in end 122 for attaching and/or aligning a clip to the end of the grounding/mounting strap. These ends 122 are flat rectangular elements that provide an increased area for increased contact with the wall surface. Referring to fig. 2, there is shown the relatively small ends of the prior art grounding/mounting strap wherein if the scored gasket 31 is removed from the strap, the remaining surface for contact with the wall is only the material surrounding the opening of the mounting ears 21. The end 122 of the ground/mounting strap 123 has a width "X" of about 1.563 inches and a depth "Y" of about 0.318 inches. These dimensions are not critical. However, the distance between the edges 129 of the ends 122 of the straps should not be greater than 4.6 inches in order to allow the wall plate to fit over and cover the mounting/grounding strap. The grounding/mounting strap 123 may be made of sheet metal and secured to the receptacle using screws, rivets or any convenient fastening means 155. Screw ends 126 on either side of the receptacle body are used to receive phase and neutral conductors, not shown.

The multi-function clips 130, 151 are attached to the ends 122 of the ground/mounting strap. These multi-function clips may be made of phosphor bronze, spring brass, spring steel, or similar materials. Referring to fig. 12, which shows a schematic plan view of the multi-function clip 130 typically attached to the bottom end of a ground/mounting strap, fig. 12A is a side view of the multi-function clip 130 of fig. 12. The clip 130 is a clip connected to the bottom end 122 of the grounding/mounting strap 123 and has openings 132 and 134. When the clip 130 is attached to the end of the ground/mounting strap, the opening 132 is aligned with the opening 126 of the ground/mounting strap and the opening 134 is aligned with the opening 128 in the end 122 of the ground/mounting strap. Opening 132 is a clearance opening for a threaded fastener such as screw 108, screw 108 being used to connect the wiring device to a box. The opening 132 may be circular, square, oval, or rectangular to allow the threaded fastener to move up and down and to the side so that the fastener can be aligned with the threaded opening in the box when the wiring device is attached to the box.

The opening 134 in the clip 130 is substantially circular and has three inwardly projecting elements 133, the three inwardly projecting elements 133 being bent upwardly towards the surface of the wiring device by an angle of between 10 and 30 degrees. Preferably at a 20 degree angle. The ends of the three projecting members 133 form an opening that is slightly smaller than the outer diameter of the alignment pin 118 on the alignment plate (see fig. 9), and the three projecting members 133 flex or bend upward as the alignment pin enters the opening 134 from the rear. The ends of the projecting elements 133 frictionally engage the alignment pins and securely hold the alignment pins to prevent the alignment pins from being easily disengaged from the multi-function clip. At the end 147 of the clip 130 are locking pawls 140, each of which is slightly longer than one-half inch in length. The end 149 of each locking pawl 140 is bent upwardly at an angle of 20 to 60 degrees and is adapted to engage the toothed rail on the inside surface of the end of the wall plate to securely hold the wall plate (see fig. 35). When the locking pawl 140 is bent upward at an angle of 20 to 60 degrees, preferably about 40 degrees, the end 149 of the locking pawl 140 catches and securely holds the wall plate. The multi-function clip 130 is a clip that performs numerous functions not disclosed in the prior art.

Referring to fig. 13, there is shown a schematic plan view of a multi-function clip typically attached to the top end of a grounding/mounting strap. Fig. 13A is a cross-sectional side view of the multi-function clip taken along line a-a in fig. 13. The clip of fig. 13, 13A is attached to the top of the grounding/mounting strap. The clip shown in fig. 13 and 13A is similar to the clip shown in fig. 12 and 12A, except that the end 157 of the clip 151 is bent upward and the opening 153 for the threaded fastener has a tab 155 that extends into the opening 153 and is bent at a slight angle toward the rear of the switch. The tabs 155 serve to engage and retain the threaded body of the fastener 108 and, in addition, serve to help provide a ground connection between the band and the threaded fastener to ensure the switch is grounded. Because of the use of the clip 130, when the switch is attached to the box, the opening 153 in the clip 151 and the opening 126 in the strap are aligned with each other during assembly to allow the fastening means to be aligned with the threaded opening in the box. The distance between the edges 147 of the clip should not exceed 1.522 inches in order to allow the clip to be connected to the end of the ground/mounting strap without extending past the side edges of the end 122 of the strap 123.

Referring to fig. 9, there is shown a front perspective view of the alignment plate 114 of fig. 5 for a single wiring device such as a switch or receptacle. The alignment plate 114 may be made of any suitable material, such as brass, aluminum, cold rolled steel, plastic coated with an electrically conductive material, etc., the alignment plate 114 having a centrally located opening 116, the opening 116 being sized to receive the body of the wiring device. Centrally between the opposed top and bottom ends of opening 116 are two clearance openings 117, each clearance opening 117 opening into or being spaced from opening 116, the two clearance openings 117 being used for mounting screws 108, which mounting screws 108 are used to connect the wiring device, switch or socket and the alignment plate 114 to the box 13. Between the outer edge of each clearance opening 117 and the end 121 of the plate 114 is an alignment pin 118. The clearance opening 117 in the alignment plate 114 may have an open end as shown in fig. 9 or may be an opening completely surrounded by material. When the alignment plate is attached to the ground/mounting strap, the openings 128 in the end 122 of the ground/mounting strap are clearance openings for receiving the alignment pins 118, and the openings 128 are aligned with the openings 134 in the multi-function clips 130, 151. Thus, when the wiring device is attached to the alignment plate, the alignment pins are positioned to enter the openings 134 in the multi-function clips 130, 151 that are attached to the lower and upper ends of the wiring device ground/mounting strap 123. The alignment plate 114 may have two ribs 119 and a downwardly extending tab 120 extending from the bottom edge for assisting in removing the wall plate from around the surface of the wiring device. When alignment plate 114 is attached to the wiring devices, alignment plate 114 covers the box in which the wiring devices are mounted. The alignment plate 114 shown in fig. 9 is for a single wiring device.

The alignment plate 114 helps overcome difficulties encountered in mounting and positioning wiring devices, such as one or more switches, switches and/or receptacles, or one or more receptacles, to the box prior to placing the wall plate around the wiring devices. Prior to installation of the wall plate, various difficulties may be encountered, such as when aligning the wiring devices with one another, positioning the wiring devices parallel to one another, adjusting the spacing between the wiring devices to be equal and uniform, and installing all of the wiring devices flat against the wall. Alignment plate 114 has a single opening and a pair of alignment pins, and these difficulties are overcome by using such alignment plate 114 in conjunction with a multi-function clip. The opening in the alignment plate is sized to receive one or more wiring devices that are positioned side-by-side in a box, and the alignment plate has a pair of alignment pins 118 that hold each wiring device along a plane and precisely position each wiring device relative to each other. Each set of alignment pins on the alignment plate is located on a vertical axis that forms the center of the wiring device, and each wiring device has a multi-function clip at each end of the grounding/mounting strap for frictionally receiving and securely holding the alignment pins on the alignment plate. In assembly, the wiring device is first attached to the alignment plate and the alignment plate, which holds the wiring device securely, is attached to the wall box using mounting screws. A wall plate can then be placed around the wiring device by simply pressing the wall plate toward the wall without any further adjustment, thereby allowing the end 149 of the locking pawl 140 of the multi-function clip to engage the teeth on the inboard end of the wall plate.

In addition to clamping the wall plate to the grounding/mounting strap, the multi-function clip helps overcome the difficulties encountered in mounting and positioning one or more electrical wiring devices to a box so that the wall plate can be quickly and easily placed around the wiring devices and flat against the wall. Each wiring lug according to the present invention has a multi-function clip at each end of the grounding/mounting strap with a plurality of positioning openings 134 for receiving and engaging the alignment pins 118 on the alignment plate 114. When the pins on the alignment plate engage the close clearance locating openings 134 in the multi-function clips, the pins precisely locate each wiring device in all directions, sideways, upwardly and downwardly, and the plate itself also locates the wiring devices along a plane, thereby allowing a wall plate to be positioned around a single wiring device or a group of wiring devices without any initial and subsequent adjustment. Each pair of alignment pins on the alignment plate is located on a substantially vertical axis that precisely defines the center of the wiring lug, however, other alignments may be provided and are within the scope of the present invention. An opening 134 in each multi-function clip receives and securely retains an alignment pin 118. These multi-function clips cooperate with the alignment pins to precisely locate and align all of the wiring devices mounted on the alignment plate. As described below, the alignment plate may be fabricated to receive one or more wiring devices. After the wiring device is attached to the alignment plate, the wiring device is attached to a wall box along with the alignment plate using threaded fasteners, such as screws through openings 132 of the multi-function clip, openings 127 in the ground/mounting strap, and openings 117 of the alignment plate. The alignment plate provides a substantially flat, rigid support for the wiring devices, ensuring that all wiring devices are accurately positioned so that the wall plate can be placed around the wiring devices without any further adjustment.

During assembly, the insulation on the cables in the box is stripped and the cables are connected to the side or rear terminals of a wiring device such as a switch or receptacle. After the cables are connected to the wiring device, the alignment plate is positioned behind the wiring device by threading the wiring device through the openings in the alignment plate. The front surface of the alignment plate is then moved toward the rear surface of the end of the grounding/mounting strap. As the alignment plate moves toward the wiring device, the alignment pins 118 on the alignment plate enter the openings 128 in the strap and the openings 134 in the clips 130. As the alignment pins enter the openings 134, the alignment pins force the upwardly curved protrusions 133 to resiliently move upward and spread apart slightly so that the alignment pins can fully enter the openings 134. The ends of these upwardly bent projections engage and securely hold alignment pins 118 and strongly resist rearward movement and withdrawal of the pins from openings 134. The switch or receptacle, which has been attached to the alignment plate and connected to the cable wires, is then inserted into the box. When the wiring device is inserted into the box, the screw 108 in the opening 132 in the multi-function clip and the clearance opening 117 in the alignment plate are aligned with the opening 23 and screwed into the opening 23, thereby securing both the alignment plate and the wiring device to the box and the wall surface. The screw head that passes through the openings 126 in the ends of the grounding/mounting strap and the openings 132 in the clips in the wiring device is larger than either opening so that the wiring device and the alignment plate 114 can be secured.

At this point, the wall plate is placed over the installed wiring device. It should be noted (see fig. 3, 4, and 5) that when the wiring device is a switch as disclosed herein, the rocker paddle of switch 110 is frameless. It is not within a frame. Thus, the switch must be precisely located within the wall plate to ensure that the rocker plate is free to move and not contact any surface of the wall plate or the side of the adjacent wiring device.

Each multi-function clip 130, 151 contains two side-by-side locking pawls 140. See fig. 12-13A. Each locking pawl 140 is bent downward approximately 40 degrees toward the rear of the wiring device. After the wiring device is attached to the alignment plate, the two locking detents 140 of the multi-function clip at the bottom end of the wiring device ride over the tabs 120 on the alignment plate. The tab 120 (see fig. 36) serves as a tool pivot point so that the wall plate 138 can be easily removed from around a switch or receptacle when the wall plate 138 is attached to an alignment plate. A slot 74 in the lower edge of the wall plate 138 provides access for the insertion of a small flat tool, such as a screwdriver, to facilitate removal of the wall plate from the wiring device.

Wall plate 138 is proportioned to fit end 122 of grounding/mounting strap 123 and the box in which the wiring device is disposed to alignment plate 114. Wall plate 138 is placed around the wiring device and locked into place by pushing the wall plate toward the wiring device until the ends of locking pawls 140 engage the teeth on the inner walls of the top and bottom edges of the wall plate.

Referring to fig. 14-24, the components of the switch and the switch of fig. 3-5 are shown in detail in several views. More specifically, fig. 14 is an exploded view of a switch according to the principles of the present invention; fig. 15 is a schematic perspective view of a base assembly of the switch of fig. 14; FIG. 16 is an exploded view of the base assembly of FIG. 15; FIG. 17 is another exploded view of the switch; FIG. 18 is an exploded view of another part of the switch; FIG. 19 is an exploded view, partially in section, of the cam driver of the switch; FIG. 20 is an exploded perspective view of the switch showing the lamp assembly plate; FIG. 21A is a plan view of a lamp assembly plate; FIG. 21B is a bottom perspective view of the lamp assembly plate; FIG. 22 is an exploded perspective view showing the lamp in the rocker paddle of the switch; FIG. 23 is a perspective view of the lamp tube; fig. 24 is a cross-sectional view taken along line 24-24 of fig. 3.

Referring to FIG. 14, there is shown an exploded view of the base assembly 300 and frame assembly 400 joined together and connected to the rocker paddle 112 to form a single pole switch. Fig. 15 shows a perspective view of the base assembly 300. The base assembly 300 includes a housing member 302, the housing member 302 being formed of an electrically insulating material and having a longitudinal slot 304, the longitudinal slot 304 extending along the length of the housing member 302 and being centrally located between side walls 306, 308 of the housing member 302. The slot 304 is sized to receive a slider 320 (see fig. 16) that slides back and forth within the slot 304. A clearance opening 310 is located in the housing member 302 and beyond each end of the slot 304, the clearance opening 310 for receiving a fastening device 124, such as a rivet, screw or the like, to lock the grounding/mounting strap 123, the base assembly 300 and the frame assembly 400 together. The side wall 308 of the housing member has an opening 309, the opening 309 being adapted to receive a fixed terminal assembly 312; the side wall 306 has an opening 336 for receiving brush terminal assemblies 346, each of which is more fully shown in FIG. 16.

Referring to fig. 16, the fixed terminal 312 is composed of a rectangular plate 313 and a substantially non-yielding contact support wall 314, the support wall 314 being bent at right angles to the rectangular plate and having a contact 316. The fixed terminal 312 is made of a conductive material such as brass. An inverted U-shaped groove 318 in the rectangular plate 313 is a clearance opening for receiving a terminal screw 320, which terminal screw 320 is screwed into a pressure plate 323 located behind the plate 313. In operation, as terminal screw 320 is tightened, the bottom surface of the head of screw 320 and pressure plate 323 move toward each other to clamp rectangular plate 313. The fixed terminal assembly 312 is connected to an electrical conductor by placing a ring of electrical conductor, such as a wire, under the head of the screw 320, or inserting the straight end of the conductor between the pressure plate 323 and the rectangular plate 313, and then tightening the screw 320 to lock the conductor between the plates 313 and 323, or between the plate 313 and the head of the screw 320. Looking at the side walls 308 of the housing member 302, each of the two side edges 311 of the opening 309 includes a vertical slot or rail 315 for receiving and retaining the side edges of the rectangular plate 313. The stationary terminal assembly 312 is seated and retained within the opening 309 of the side wall 308 of the housing member 302 by sliding the rectangular plate 313 of the stationary terminal assembly 312 downwardly into the slot or track 315 in the side edge of the opening 309.

The brush terminal assembly (brush terminal assembly)346 includes a rectangular plate 380 made of a conductive material, such as brass, which rectangular plate 380 supports a yieldable contact support arm 344, which support arm 344 has a contact 317. An inverted U-shaped slot 381 in rectangular plate 380 is a clearance opening for receiving terminal screw 386. Terminal screws 386 are free to pass through clearance openings 381 and thread into pressure plate 388. By tightening the terminal screw 386, the rectangular plate 380 is clamped between the bottom surface of the head of the screw 386 and the pressure plate 388. The brush terminal assembly 346 can be connected to the electrical conductors by placing a coil of wire under the head of the screw or inserting the straight end of the wire between the pressure plate 388 and the rectangular plate 380. By tightening the screw 386, the conductor can be locked between the screw head and the plate 380 or between the plate 380 and the pressure plate 388. Looking at the side walls 306 of the housing member 302, each of the two edges 303 of the opening 384 has a narrow vertical slot or rail 317 for receiving and securing the side edges of the rectangular plate 380. The brush terminal assembly 346 is seated and secured within the opening 384 of the side wall 306 of the housing member 302 by sliding the rectangular plate 380 of the brush terminal assembly down into the slot or track 317 in the edge of the opening 384.

The stationary terminal assembly 312 and the brush terminal assembly 346 are made of electrically conductive material so that an electrical circuit can be formed between the wires connected to the terminal screws 320, 386. Preferably, the conductive members are all made of high levels of good quality conductive material so that large currents, such as 10 or 20 amps, can be carried repeatedly for long periods of time without generating significant heat, without electrical losses, and without excessive arcing. Such materials may include silver alloys for the contacts, beryllium copper for the brush arms, and brass for the remaining conductive components.

Referring to fig. 15 and 16, when slider 320 is positioned within slot 304, slider 320 is free to move back and forth between side walls 319, 321 from one end of the slot to the other end of the slot. One end of the slider 320 has a rectangular funnel-shaped slot opening 322, the slot opening 322 extending completely through the slider and being adapted to receive the cam follower 370 of the cam 366. It should be appreciated that the rectangular funnel-shaped slot opening 322 is not limited to being disposed at one end of the slider, but can be disposed at any convenient location along the slider. A rectangular cam follower 324 projects downwardly from the bottom surface of slider 320 and is located approximately midway between the two ends of the slider. A hold down projection 326 projects upwardly from the top surface of slider 320 and is located approximately midway between the ends of the slider. In addition, a brush end control projection 327 also projects upwardly from the top surface of the slider. The space 329 between the restraining projection 326 and the brush end control projection 327 is for receiving the resilient contact arms 344 of the brush terminal assembly 346. Movement of the slider 320 in the direction "a" causes the projection 327 to press against the contact arm 344 to flex downwardly, thereby moving away from the fixed contact 316. Movement of slider 326 in direction "B" causes projection 327 to move upwardly, which allows contact arm 344 to spring back and allow contact 317 to make electrical contact with contact 316. A cushion support member 328 projects outwardly from the side of slider 320, cushion support member 328 providing support for a rubber O-ring 330. With the slider positioned within the slider receiving slot 304, the O-ring 330 moves back and forth between the stops 332, 334 of the opening 336 in the inner wall 321 (see fig. 15) as the slider is driven from one end of the slot 304 to the other. The O-rings cushion the stopping of slider 320 by contacting stops 332, 334 at the ends of opening 336 in wall 321. The contacts 317 (see fig. 16) of the brush terminal assembly 346 are biased by the spring arms 344 to move upwardly toward the stationary contacts 316. As the slider is moved downwardly, the arm 344 moves the contact 317 towards the contact 316, and to help compensate for some of the upward force exerted by the arm 344, a secondary spring 338 is provided. The assist spring 338 also serves to help balance the feel of the rocker paddle when the switch is operated.

The movable resilient contact arm 344 of the brush terminal assembly 346 is resiliently biased to move the contact 317 upwardly toward the stationary contact 316. Thus, the slider 320 requires a greater force to move the contact 317 on the resilient contact arm 344 out of engagement with the fixed contact 316 than the force required to close the contacts. Referring to fig. 16, a secondary spring 338 is used to help overcome this force. The helper spring 338 is a flat resilient metal strip that is folded about its center at a large radius so as to have two legs 337, 339 that form an inverted V-shape. The inverted V-shaped helper spring 338 fits within a chamber 340 (see fig. 16) at the top of the slot 304 so that the apex of the V is at the top of the slot. As the slider 320 is moved up, the resilient bias of the resilient contact arms 344 helps close the contacts 316, 317. As the slider moves up and the contacts close, end 342 of slider 320 contacts leg 339 of assist spring 338 and urges it toward leg 337. At this time, the assist spring 338 is compressed and biases the slider 320 to move downward. When the contacts 316, 317 are opened, the secondary spring 338 urges the slider downward against the force of the resilient arm 344. Thus, when the resilient contact arm 344 is moved downwardly so that the contacts 316, 317 open, the spring 338 helps overcome the force exerted on the slider by the resilient contact arm 344 of the brush end 346.

Wall 348 has a slot opening 350 at the end of chamber 340, which slot opening 350 allows end 342 of slider 320 to enter chamber 340 to engage leg 339 and move leg 339 toward leg 337 of helper spring 338. Wall 348 helps to retain secondary spring 338 within chamber 340.

As can be seen in fig. 24, the spring chamber 354 is located below the slider receiving slot 304 and opens into the slot 304. The spring chamber 354 is elongated and has a rectangular cross section and houses a flat cam shaped leaf spring 352. The spring chambers 354 may be symmetrically disposed in the center of the switch base 300 and have a support bar 356 at each end for supporting a flat cam shaped leaf spring 352. One end recess 365 is located beyond each support bar 356. The overall length of the chamber 354 is determined by the length of the flat cam leaf spring 352.

The cam shaped leaf spring 352 is made of flat resilient steel sheet, preferably spring steel, and has a shape substantially similar to that shown in fig. 22. The flat cam leaf spring 352 is symmetrical in shape about a central apex 358. Moving along the spring 352 from this apex to the end, the spring has a short downwardly sloping cam portion 359 on each side of the apex 358 which together with the support portion 357 forms a recess 360, 362 on each side of the apex. Support portion 357 is seated on support bar 356 and terminates in a U-shaped outer end 364, the U-shaped outer end 364 being seated in end pocket 365. The apex 358, the rise in the center of the spring, and the short flat cam portions 359 on each side of the apex and engaged by the support portions 357 provide a surface discontinuity for the cam 324 rather than a smooth transition as the cam 324 moves over the apex.

Referring to fig. 16 and 24, the cam 366 is used to move the slider back and forth between its left and right positions, which correspond to the open and closed positions of the switch. The cam 366 has two cylindrical projections 368 that are aligned with one another and extend from both sides to form a shaft support bar that is rotatably received by support bearing openings 378 in the side walls 319, 321 of the slider receiving slot 304. During operation, the cam 366 can rock back and forth in clockwise and counterclockwise directions along an axis defined by the projection 368. Below protrusion 368 and extending downward is cam follower 370, cam follower 370 fitting with minimal clearance into rectangular funnel-shaped slot opening 322 in slider 320. Extending upwardly from the projection 368 is a cam control surface 430, the cam control surface 430 having a first pocket 374 on the left side of the cam and a second pocket 372 on the right side of the cam. Looking at the side view of the cam 366 as shown in FIG. 24, the dimple 372 is located to the right of the rotational axis of the cam and the dimple 374 is located to the left of the rotational axis of the cam. Thus, when the slider is in its right-hand position, application of a downward force on pocket 372 will cause cam follower 370 to rotate in a clockwise direction, causing slider 320 to move to the left. In a similar manner, when the slider is in its left-hand position, application of a downward force on pocket 374 will cause cam follower 370 to rotate in a counterclockwise direction, causing the slider to move to the right. Thus, pressing down on dimple 372 causes the cam to rotate clockwise, thereby causing cam follower 370 to move the slider to the left. Thereafter, pressing down on pocket 374 will cause the cam to rotate counterclockwise, thereby causing the cam follower to move the slider to the right. Alternately pressing on pockets 372 and 374 will cause the slider to move back and forth, initially in one direction, and then in the other direction.

Projecting upwardly from the base member 401 of the frame assembly 400 and made of the same material as the base member are two hook members 396 (see fig. 16 and 18) that engage and rotatably retain mating hook members 418 (see fig. 17) projecting downwardly from the subplate 412 of the rocker plate assembly 398. The frame assembly 400 includes a rectangular clearance opening 402 in the bottom member 401, the clearance opening 402 being aligned with the top of the cam 366 and passing therethrough such that an actuator 405 (see fig. 18 and 19) of the cam driver 431 protrudes to engage and operate the cam 366.

The cam 366 is operated by an articulated cam driver 431 (fig. 19), said articulated cam driver 431 being composed of a cylindrical element 409, a plunger 403, an actuating member 405 and a conical helical spring 407. Each time the plunger 403 moves downwardly, the cam driver 431 engages the cam 366 and drives the cam 366 initially in a clockwise direction and then in a counter-clockwise direction. An open-ended cylindrical member 409 supports two ears 411, each ear 411 having a threaded opening for receiving a retaining member, such as a screw, to secure the member 409 to the frame assembly 400. The member 409 has a first opening 413 at its lower end and a second opening 415 at its upper end. The first opening 413 at the lower end of the cylindrical member 409 is large enough to avoid blocking or snagging the rectangular clearance opening 402 when the member 409 is mounted to the bottom member 401 of the frame assembly 400 and positioned above the opening 402. The cylindrical member 409 supports an internal, inwardly projecting ridge 417, the ridge 417 being located between the first opening 413 and the second opening 415.

Plunger 403 is slidably mounted within member 409. The outer diameter of the plunger 403 is slightly smaller than the diameter of the second opening 415 in the upper end of the cylindrical member 409, allowing the plunger to move up and down within the opening 415 without binding. The plunger 403 has an edge 429 which has an outer, outwardly projecting protuberance 433 at its end. A shoulder 417 in the cylindrical member 409 interengages with a ridge 433 on the plunger 403 to retain the plunger 403 within the member 409.

The actuator 405 supports an elongated rod 421, said actuator 405 can be made of cold rolled steel or plastic with suitable properties, said elongated rod 421 having a wide radius at one end and a first collar 423 and a second collar 425 at the other end. The collar 423 has a diameter smaller than the diameter of the collar 425, and the collar 423 is adapted to frictionally engage the smaller diameter end of the conical spring 407. The end of second collar 425 is disposed within opening 428 of plunger 403 and contacts internal protrusion 427.

The coil spring 407 is conical with its top end wrapped around the collar 423 and frictionally engaging the collar 423, and the diameter of the bottom of the spring 407 is large enough to extend beyond the rectangular clearance opening 402 to avoid interference with the rod 421 as it rotates back and forth in the rectangular clearance opening 402. Opening 402 has a long dimension along the length of the switch and a small dimension along the width of the switch. The small dimension of the opening 402 is slightly larger than the diameter of the stem 421 to allow the stem 421 to move within the opening 402 without binding, and the long dimension of the opening 402 allows the stem 421 to engage and operate the cam 366 without binding.

A small protrusion 406 can be used to engage the lower end of the secondary coil spring 408, the small protrusion 406 extending upward from the base member 401 of the frame assembly 400 and being made of the same material as the base member, the secondary coil spring 408 being provided to urge the rocker plate 112 to its out-turned position. Under normal use conditions, the spring 407 will provide sufficient force to urge the rocker plate 112 away from the frame assembly 400. However, in the event that additional force is desired, an auxiliary spring 408 may be provided. The protrusion 406 has an outer diameter slightly smaller than the inner diameter of the auxiliary coil spring 408 and is adapted to be within one end of the auxiliary coil spring. The upper end of the secondary coil spring 408 is disposed within a recess 410 (see fig. 17) in the daughter board 412 and is held captive within the recess 410. The subplate 412 is secured to the underside of the rocker paddle 112 by gluing, by some plastic protrusion that extends from the underside of the rocker paddle and is folded over after passing through the opening in the subplate, and/or the like.

Referring to FIG. 17, there is shown an exploded perspective view of the base assembly 300, frame assembly 400 and the bottom of rocker plate assembly 398 of a single pole switch. Referring to the frame assembly 400, the frame assembly 400 may be a single piece constructed of a suitable plastic, with two projections 414 projecting from the bottom surface and disposed in contact with the top surface of the shaft support bar formed by the side-by-side cylindrical projections 368 of the cam 366. The projection 414 prevents the cylindrical projection 368 from moving out of the bearing receiving surface in the inner wall of the slider receiving slot. Further, projecting downwardly from the bottom surface of frame assembly 400 is a slider restraining projection 416, which projection 416 slidably contacts projection 326 on slider 320. The projection 416 prevents the slider 320 from being pushed up and out of the slot 304 by the upward force of the cam shaped leaf spring 352 by contact with the projection 326 on the slider 320, the leaf spring 352 pushing up against the rectangular shaped cam follower 324.

A subplate 412 is attached to the underside of the rocker paddle 112, and the subplate 412 is a single piece made of plastic material with two hook-shaped elements 418 projecting downwardly from the bottom surface. The hook-shaped elements 418 are configured to engage hooks 396 on the frame assembly 400. When hooks 418 engage hooks 396, hooks 418 allow the rocker paddle assembly to move toward frame assembly 400 and allow the rocker paddle assembly to move away from frame assembly 400, while hooks 418 also prevent the subplate and attached rocker paddle from separating from frame assembly 400. A downwardly extending ring 410 on the daughter board 412 lines up with the protrusion 406 on the frame assembly to provide a hold for the top of the secondary spring 408 when a secondary spring is applied. The inner diameter of the ring 410 is slightly larger than the outer diameter of the secondary spring to allow the placement of the end of the secondary spring into the ring 410. Two arms 422 project beyond the rear end of the daughter board 412, each arm 422 supporting a circular peg 420, one peg 420 on the outer end of each arm, the two arms 422 being axially aligned with each other to form a common axis (axel). The pegs snap into openings 424 in the frame assembly 400, thereby forming a hinge about which the subplate and rocker paddle 112 rotate relative to the frame and base assembly. The daughter board 412 is secured to the bottom surface of the rocker plate 112 by gluing, by heat bonding, or the like, to form a single assembly.

The switch disclosed herein may have an on-off indicator, such as a light, to indicate when the switch is in its conductive state and when it is in its non-conductive state. This on-off indicator light may have a color or white. In practice, blue lamps are considered to be preferred. Referring to fig. 21A and 21B, the top and bottom of a Printed Circuit Board (PCB) assembled within a frame assembly 400 is shown. On the upper surface of the printed circuit board 430, a resistor 432, a diode 434 and a Light Emitting Diode (LED)436 are provided, which are connected together to a spring terminal 390. Referring to fig. 14, a frame assembly 400 is mounted on top of the base assembly 300 to provide support for the printed circuit board and has openings for spring contacts 390 to project through the frame assembly and contact the plate 313 of the stationary terminal and the plate 380 of the brush terminal assembly 346. The led 436 indicates the conductive state of the switch by being "on" or "off. In operation, the lamp 394 is in an "on" state when the contacts of the switch are open and in an "off" state when the contacts of the switch are closed.

Referring to fig. 23, there is shown a light pipe 440 attached to the underside of the rocker plate (see fig. 22) to optically connect the leds to a window 442 at the lower end of the rocker plate. The end of the tube adjacent the led has a spherical surface for receiving light from the led, and the other end of the tube has a diverging outlet surface which is a window in the edge of the rocker paddle.

Referring to fig. 24, to assemble the switch, the secondary spring 338 is inserted into the end chamber 340, the leaf spring 352 is placed into the spring chamber 354, and the slider 320 is placed into the slot 304. The slider end 342 faces the helper spring 338 and a triangular shaped cam follower 324 projecting from the slider bottom slidably engages the top surface of the leaf spring 352. The protruding cylindrical peg 368 of the cam 366 is placed in the bearing surface opening 378 of the side walls 319, 321 of the slot 304 and the cam follower 370 is mounted in the opening 322 of the slider 320. The stationary terminal 312 is mounted within the opening 309 and the brush terminal assembly 346 is seated within the opening 384. As the brush terminal assembly 346 is placed in position, the resilient contact arms 344 move rearwardly against the force of the resilient arms and are seated within the slots 329, the slots 329 being located between the restraining projection 326 and the resilient contact arm control elements 327 of the slider 320. At this point, all of the various components have been placed in the switch base 300, as shown in the assembled condition of fig. 24.

Referring to the frame assembly 400 and the cam driver 431, the plunger 403 is positioned within the cylindrical member 409 by inserting the plunger 403 into the bottom opening of the cylindrical member 409 until the outwardly extending protuberance 421 of the end of the plunger skirt engages the inwardly projecting protuberance 417 of the plunger. The actuator 405 is then inserted into the plunger through the bottom opening of the cylindrical member 409 until the top surface of the collar 425 contacts the internal protrusion 427, the internal protrusion 427 extending downward from the inner surface of the top of the plunger 403. A conical coil spring 407 is inserted into the bottom opening of the cylindrical member 409 and positioned around the actuator 405 such that the apex of the coil spring is positioned around the collar 423. At this point, the mounted cam drivers 431 are mounted to the bottom element 401 of the frame 400 such that the actuators are mounted to move freely through the elongated holes 402 and align the clearance openings in the frame with the threaded openings in the ears of the cylindrical element.

The frame assembly 400 includes the light emitting diodes, resistors, diodes and contacts 390. now, the frame assembly 400 is placed onto the switch base, a grounding/mounting strap is placed along the bottom and end of the base assembly 300, and screws, drive pins, rivets or the like 124 are used to lock the grounding/mounting strap, switch base assembly and frame assembly together. In the illustrated embodiment, the conical coil spring 407 exerts an upward force on the actuator and plunger to maintain the plunger in the outwardly most extended position. The subplate has a cutout 433 through which the plunger 403 passes to contact the underside of the rocker paddle 112. The top surface of the plunger then contacts the bottom surface of the rocker plate and it is the upward force of the spring 407 that must be overcome when the user operates the switch to bias the rocker plate to its outward position. In some cases, it is desirable to have a switch that requires a greater amount of force to operate. If a greater force is desired, this can be accomplished by a coil spring 429 having a lower end seated on the protrusion 406 on the frame and an upper end seated in the spring pocket 410 of the daughter board. The tabs 420 on the legs 422 snap into openings 424 in the frame assembly 400 to form a hinge to allow the rocker plate assembly 398 and the frame assembly 400 to rotate relative to each other. Rocker assembly 398, with its subplate, is then depressed toward the frame assembly until hook 418 engages hook 396. At this time, the bottom side or bottom of the rocker plate assembly contacts the top surface of the plunger 403, and a pressure is applied by hand to the rocker plate assembly, overcoming the force of the spring 407, to move the rocker plate assembly toward the frame assembly, thereby driving the elongate rod 421 of the actuator 405 downward through the opening 402 into engagement with the cam eccentric surface 372.

Fig. 24 is a cross-sectional view of a single pole switch with the contacts of the switch closed and the switch in a conductive state. The surface of the rocker plate is then pressed and the plunger 421 is pressed to move downward against the force of the spring 407 to contact the ramp 430 of the cam 366 and slide to the right into the pocket 372. Continued squeezing of the rocker paddle causes the actuator 405 to continue moving downward and causes the cam 366 to rotate clockwise about the cylindrical protrusion 368. This causes cam follower 370 to rotate in a clockwise direction, thereby moving slider 320 to the left. As slider 320 moves to the left, triangular shaped cam follower 324 moves out of spring recess 360 and past right support section 359 toward centrally located apex 358 of cam shaped leaf spring 352. As the slider continues to move to the left, triangular shaped cam 324 causes leaf spring 352 to deflect downward as protrusion 326 on slider 320 cooperates with hold-down protrusion 416 to prevent upward movement of slider 320. As the triangular cam 324 moves to the top of the apex 358 of the spring and toward the apex left support section 359, the leaf spring begins to spring back to its original, unpressurized position by moving upward. The leaf spring, through this upward movement, acts on the shaped cam follower 324 to help drive and accelerate the cam follower 324 and slider 320 to the left until the cam follower 324 is seated in the recess 362. At this time, the contacts of the switch are separated from each other. Thus, the cam shaped leaf spring 352, in combination with the cam follower 324, helps move the slider into the left or right recesses 362, 360 to quickly open and close the contacts. The rocker is then depressed and the actuator 405 enters the pocket 374 of the cam, causing the cam to rotate in a counterclockwise direction, which causes the slider to compress the leaf spring as it moves to the right. As the cam follower 324 continues to move to the right and as it passes the apex 358, the compressed leaf spring begins to spring back, returning to its original position. This upward movement of the leaf spring causes the cam follower 324 to move rightward until it reaches the recess 360, at which time the switch contacts are closed. Continued pressing and releasing of the rocker paddle of the switch alternately opens and closes the contacts of the switch. The conduction state of the switch is displayed to the user using light emitted from a light emitting diode, neon lamp or sign lamp connected through the fixing and brush terminal assemblies. When the contacts of the switch are closed, there is no potential difference across the lamp-resistor combination, and therefore the lamp remains dark. When the contacts of the switch are open, there is a potential difference across the lamp-resistor combination and the lamp is lit.

Referring to FIGS. 25A, 25B and 25C, there are shown cross-sectional views of the rocker plate 112 of the switch of FIG. 14. FIG. 25A is a cross-sectional view taken along line A-A of FIG. 14; FIG. 25B is a cross-sectional view taken along line B-B of FIG. 14; fig. 25C is a sectional view taken along line C-C in fig. 14. The width of the rocker paddle is 1.79 inches and the length of the rocker paddle is 2.77 inches. The surface of the rocker paddle has a vertical axis along its length and a horizontal axis along its width, where the surface of the rocker paddle along the vertical axis of the rocker paddle has a profile with a positive first differential (differential) and a second differential of zero when the rate of height increase of the individual splines is constant, consisting of a combination of splines drawn between points at different distances from the datum plane. The horizontal axis has a surface with a contour having a positive first differential and a negative second differential, consisting of a combination of splines drawn between points at different distances from the datum plane. Referring to FIG. 25A, the surface along line A-A lies between two substantially 0.139 inch apart contour boundaries, perpendicular to datum plane A, equally disposed about the true contour with respect to a datum plane. The basic dimensional size and profile tolerances create a tolerance zone to control the shape and size of the surface. The surface has a length of about 2.77 inches. Within this length, a profile is defined by dimensions of about twenty equidistant points spaced about 0.139 inches apart. Each dimension represents the distance of the corresponding point from a reference plane a, which is the flat rear surface of the rocker paddle. From left to right in fig. 25A, these dimensions increase from about 0.277 to about 0.328 inches in the center and then decrease to about 0.278 inches at the right. This gradual change defines a contour of gradually increasing height and then gradually decreasing height, where the points are connected by individual splines. The points are not connected by a single arc and the rate at which the profile height increases is not constant. The rate of height increase of the individual splines decreases from left to right to the center and then increases from the center to the right. Thus, the second derivative of the profile is negative from each end to the center. That is, the difference between the magnitudes of the distances at some points from one end toward the center increases. Thus, from one end to the center, the surface has a profile with a positive first differential and a negative second differential, which is made up of a combination of splines drawn between points at different distances from a datum plane. This depiction basically depicts the rocker plate surfaces along lines A-A, B-B and C-C in FIG. 14.

FIG. 25B shows a cross-sectional view along line B-B of FIG. 14 extending along the horizontal centerline of the rocker plate, which defines a surface having a positive first differential and a substantially negative second differential from one end to the centerline. The second derivative is substantially negative because not all successive points have a constant increment.

FIG. 25C shows a cross-sectional view along line C-C of FIG. 14, extending along a diagonal of the rocker plate, which defines a surface having a positive first differential and a substantially negative second differential from one end to the center line. The second derivative is substantially negative because not all successive points have a constant increment.

FIGS. 25A-25C show the dimensions of the rocker in detail, and therefore, for the sake of brevity, the dimensions shown in FIGS. 25-25C will not be repeated.

Referring to fig. 26, there is shown an exploded view of a switch having another cam driver; fig. 27 is a cross-sectional view taken along line 24-24 of fig. 3, wherein the cam-driver is the cam-driver of fig. 26. In this embodiment, the hinged cam driver 431 shown in FIG. 19 is replaced by a flexible cam driver having a blunt end 600. The flexible cam driver with blunt end 600 is constructed from a flat strip of flexible material, such as spring steel, bent over onto itself in its center and having a large radius, forming blunt end 602 with a diameter that fits within pockets 372, 374 of cam 366. The ends of the flexible cam driver are bent 90 degrees and each end has an opening for receiving a retaining element to connect the flexible cam driver to the daughter board 412. In this embodiment, daughter board 412 does not have cutouts 433, but is continuous to provide support for flexible cam driver 600 and to allow the flexible cam driver to be connected to the daughter board. The cam drivers 600 may be attached to the daughter board using rivets, plastic tabs that protrude from the daughter board, through openings in the ends of the cam drivers, and heat deformed to secure the cam drivers to the daughter board, or any other method. The structure and operation of the switch in the embodiment of figures 26 and 27 is identical in all respects to that of the switch of figures 14-25C, except that a flexible cam drive having a blunt end 600 is used in place of the hinged cam drive 431 shown in figure 19.

Referring to fig. 28, there is shown an exploded view of a switch having another type of cam driver, and fig. 29 is a cross-sectional view taken along line 24-24 of fig. 3, wherein the cam driver is the cam driver shown in fig. 28. In this embodiment, the hinged cam driver 431 shown in FIG. 19 is replaced by a semi-flexible cam driver having a tip portion 700, such as a tightly wound coil spring 700 having a tapered tip 702. In this embodiment, daughter board 412 does not have cutouts 433 but is continuous to provide support for the semi-flexible cam driver 700 and to allow the semi-flexible cam driver to be connected to the daughter board. The sub-plate has a small protrusion extending downward from the bottom of the sub-plate and having such a diameter as to fit snugly into the top end of the tightly wound spring. The tightly wound springs 700 are connected to the daughter board by being placed on the protrusions on the daughter board. The lower end of the tightly wound spring 700 supports a conical tip 702 having a cylindrical rear end with a diameter substantially equal to the inner diameter of the spring 700 and which is inserted into and securely retained by the tightly wound spring. The tip of the tapered tip 702 has a small diameter that allows the tip to fit into the pockets 372 and 374 of the cam 366. The structure and operation of the switch of the embodiment disclosed in fig. 28 and 29 is identical in all respects to the switch disclosed in fig. 14-25C, except that a semi-flexible cam driver having a tip portion is used in place of the hinged cam driver 431 shown in fig. 19.

Referring to fig. 30-35, for a single wiring device, the width of the face of the wiring device is approximately 55% of the width of the wall plate along the horizontal axis and approximately 56% of the length of the wall plate along the vertical axis. When the wiring device is a receptacle, the profile along the width of the receptacle surface is flat in one plane and compound along the length of the receptacle surface and has a constant radius greater than 10 inches and less than 40 inches, with a preferred radius of approximately 30.724 inches. The shape of the socket surface is different from the shape of the switch to enable correct positioning of the inserted plug. When the wiring device is a switch, its surface has a vertical axis along its length and a horizontal axis along its width, wherein the rocker plate surface along its vertical axis has a profile with a positive first differential made up of a combination of splines drawn between points at different distances from the datum plane and a second differential of zero when the rate of height increase of the individual splines is constant. The horizontal axis has a surface with a profile of positive first differential and negative second differential, consisting of a combination of splines drawn between points at different distances from the datum plane. Referring to fig. 30, a front perspective view of a wall plate of a single wiring device is shown. The wall plate is substantially 4.92 inches long by 3.28 inches wide and has a single opening 100 without a partition element for receiving a wiring device, which may be a switch without a frame or a receptacle, both of which are slightly less than 2.82 inches long by 1.83 inches wide to fit within the opening 100. The width of the wall plate can vary depending on how many wiring devices are to be combined, arranged side-by-side. The front surface of the wall plate disclosed herein has a compound or composite profile shape such that the surface of the opening for receiving wiring devices is spaced from the wall a greater distance than the outer edge of the wall plate. Referring to FIG. 31B, a cross-sectional view taken along line 31B-31B of FIG. 30 is shown. Fig. 31A-31C are cross-sectional views along lines 31A-31A through 31C-31C of the wall plate of fig. 30 and along a horizontal midline between a point K at the outer right edge and a point L at the inner edge of the opening for receiving wiring devices. As shown in fig. 31B, the surface is located between two contour boundaries that are substantially 0.002 inches apart, perpendicular to the datum plane a, and uniformly disposed about the true contour with respect to a datum plane. The basic dimensional and contour tolerances create a tolerance zone to control the shape and size of the surface. The width of the surface is about 0.73 inches. Within this width, a contour is defined by the size of approximately ten equidistant points spaced 0.073 inches apart. Each dimension represents the distance of the corresponding point from a reference plane a, which is the (flat) rear surface of the wall plate starting from point K. From left to right, these dimensions increase from about 0.243 inches to about 0.302 inches. When the points are connected by individual splines, the progressively changing dimensions define a contour of progressively increasing height and having a positive first differential. The points are not connected by a single arc and the rate at which the height of the profile increases is not constant. The rate of height increase of the individual splines decreases from left to right and the second derivative of the contour is negative. That is, the difference between the distance dimension of a first point and the distance dimension of a second point is greater than the difference between the distances of the second and third points, and so on. This surface therefore has a contour with a positive first differential and a negative second differential, which is constituted by a spline combination drawn between points at different distances from a datum plane. FIG. 31A is a cross-sectional view taken along line 31A-31A of FIG. 30; FIG. 31B is a cross-sectional view taken along line 31B-31B of FIG. 30; FIG. 31C is a cross-sectional view taken along line 31C-31C of FIG. 30; fig. 31A-C clearly show a cross-sectional view of the wall plate profile along lines 31A-31A, 31B-31B and 31C-31C in fig. 30.

A cross-sectional view along a line 31C-31C (see fig. 31C) extending along the vertical midline of the wall plate defines a surface having a positive first differential and a zero second differential, which is formed by a combination of splines drawn between points at different distances from a datum plane. This profile has a quadratic differential of zero, since the rate of height increase of the individual splines is constant; the difference between any two sequential dot sizes is substantially 0.0037 inches.

The wall plate 138 for a single wiring device shown in fig. 30 includes a number of teeth along the inside top and bottom edges for engaging the ends of the locking pawls 140 of the multi-function clips 130, 151. Referring to fig. 32, fig. 32 is a cross-sectional view of the bottom edge of the wall plate taken along line 32A-32A of fig. 30; fig. 33 is a cross-sectional view of the top edge of the wall plate taken along line 33A-33A in fig. 30. The top outside edge (see fig. 33) has a recessed area, such as a groove, with a floating identification designation, such as a word that identifies a letter, number, and/or symbol of the manufacturer of the device. Referring to fig. 33, a cross-sectional view of the top rail of the wall plate 138 along line E-E of fig. 30 is also shown. Fig. 34, 34A show a portion of the top edge of the wall plate of fig. 30, showing the slot and logo nomenclature. In fig. 34 and 34A, a slot 217 is provided in the top outside edge of the wall plate (see fig. 33). The slot is approximately three-quarters of an inch in length and has a width less than the width of the edge of the rail. As shown in fig. 33, 34, 34A, the slot 217 is a rectangular depression having wall surfaces, which are formed by four walls defining the slot. A floating identification structure, such as the manufacturer's name, "LEVITON," is disposed within the groove or recess. The height of the emerging identification structure may be 0.010 inches, wherein the top surface of the emerging identification structure is substantially flush with the surface of the edge of the wall plate.

When the wiring device of the invention is a switch, the surface of the switch rocker paddle is a continuation of the profile of the wall plate so that their surfaces are complementary to each other. When the wiring device is a receptacle, the profile along the width of the receptacle surface is flat in one plane and compound along the length of the receptacle surface and has a constant radius. The shape of the receptacle surface is different from the shape of the switch to enable correct positioning of the inserted plug. The wall plate has no exposed mounting screws, nor other visible metal elements. When the wall plate is placed around the wiring device, the only parts that are visible are the wall plate 16 and the switch or receptacle. No fastening means, such as screws, are visible for securing the wall plate in place.

To attach the wall plate 138 to the wiring device, the edges of the pawls 140 of the bottom and top clips 130, 151 engage the racks 80 on the inner surfaces of the top and bottom end walls 70 of the wall plate 138. There are two racks on each end wall 70 of the wall plate 138. Each rack 80 has a plurality of toothed teeth 82, each tooth 82 having an angled front face 84 and an angled rear face 86. Referring to fig. 35, fig. 35 is an enlarged perspective view showing the locking pawl of the multi-function clip engaging the rack of the wall plate when the end of the locking pawl 140 engages the angled front surface 84 of a tooth and the pawl is deflected and moves past the tip of the first tooth 82. Once the pawl 140 passes the tip of the tooth 82, it returns to its original position and is located between the angled rear surface 86 of the first tooth 82 and the angled front surface 84 of the second tooth 82. This operation may be repeated as many times as necessary to position the top and bottom ends of the wall plate 138 as close to the wall as possible. Because the rails 80 and pawls 140 are independently operated, the wall plate 138 can be positioned against the wall contour even when the wall is not flat. This ability to position the wall plate to closely follow the contour of the wall is even more pronounced when the wall plate 138 is large, such as a wall plate that is disposed around a plurality of wiring devices.

Referring to fig. 36, an enlarged partial cross-sectional view of the wall plate and the tab of the alignment plate is shown to indicate how the two components can be separated after locking. Once the end of the locking pawl 140 is seated in the valley between the two teeth, it becomes difficult to remove the wall plate 138 from the pawl 140. To assist in removing the wall plate, a slot 74 is provided in the bottom end 70 of the wall plate 138 to allow access to the tab 120. A small flat tool knife, such as a screwdriver blade 76 or the like, can be moved through the slot 74 in the end 70 to contact the outer surface of the tab 120 and the rear wall of the slot 74. The force applied to the tab 120 separates the wall plate 138 from the wiring device by moving the blade 76 using the rear wall of the slot 74 as a fulcrum. Since the tool 76 can apply a significant force to the tab 120, the pawl 140 can be disengaged from the teeth, thereby separating the wiring device from the wall plate.

Referring to fig. 37, there is shown an exploded view of the alignment plate and a wall plate for two wiring devices. There are no dividers or separators in either the wall plate openings or the alignment plate openings to separate the two wiring devices. The two wiring devices can be housed in a double box 160, for example, formed of two single boxes joined by fasteners passing through threaded holes 164 in two connecting ears 166. Alignment plate 114 has a single opening 116, four clearance openings 117 and four alignment pins 170 to receive two wiring devices such as two switches, one receptacle and one switch, or two receptacles.

The wall plate 138 may have four racks 80 on the interior of the top and bottom end walls for receiving four pawls, with two intermediate racks receiving one pawl of each wiring device. There are also two tabs 120, the tabs 120 being accessible through the slots 74 in the end wall 70 of the cover plate 138. Because the pawls 140 are independently operated by their respective racks 80, the wall plate 138 compensates for the lack of flatness of the wall on which the wiring device is mounted.

Referring to fig. 38, there is shown an exploded view of the alignment plate 114 having a single opening 116 and a wall plate 138 for receiving three wiring devices mounted together in three boxes (not shown). The wall plate 138 has a single opening 100 without a dividing or separating element to receive three wiring devices placed side by side and has four sets of racks 80, with each of the two end racks receiving a single pawl and the two middle racks receiving two pawls. Alignment plate 114 has a single opening 116 with no separation or separating elements, three sets of clearance openings 117 and three sets of alignment pins 170 for receiving three wiring devices.

Referring to fig. 39, there is shown an exploded view of an alignment plate 114 having a single opening 116 without a dividing or separating element and a wall plate 138 for receiving four wiring devices mounted together in four boxes (not shown). The wall plate 138 has a single opening 100 without a dividing or separating element for receiving four wiring devices arranged side by side, and the alignment plate 114 has a single opening 116 without a dividing or separating element for receiving four wiring devices arranged side by side.

Fig. 40 is an exploded view of an alignment plate 114 and a wall plate 138, the alignment plate 114 having a single opening 116 without a dividing or separating element, the wall plate 138 having a single opening 100, the opening 100 for receiving five wiring devices mounted together in five boxes (not shown). The single opening 100 in the wall plate 138 has no dividing or separating elements and the alignment plate 114 has a single opening 116 without dividing or separating elements for receiving five wiring devices arranged side-by-side.

Fig. 41 is an exploded view of an alignment plate 114 having a single opening 116 without a dividing or separating element and a wall plate 138 having a single opening 100, the opening 100 for receiving six wiring devices that are mounted together in six boxes (not shown). The single opening 100 in the wall plate 138 has no dividing or separating elements and the alignment plate 114 has a single opening 116 without dividing or separating elements for receiving six wiring devices that are arranged side-by-side.

Each of the wall plates shown in the figures may be made of a conductive or non-conductive material. When the wall plate is made of a non-conductive material, such as plastic, a conductive coating may be sprayed, plated, etc. on the front surface, the back surface, or both the front and back surfaces of the wall plate to provide a conductive path from the wall plate through the alignment plate to the ground. In the case of wall plates attached to wiring devices by means other than the alignment plates shown herein, such as screws or the like, the conductive path from the wall plate to the ground is via said means for attaching the wall plate to the wiring device and/or box.

The present invention contemplates a system wherein a number of electrical wiring devices not expressly described above may be employed without departing from the spirit and legal scope of the present invention.

While there have been described, illustrated and pointed out fundamental novel features of the invention as applied to a preferred embodiment thereof, it will be understood that various omissions and substitutions and changes in the form and details of the devices illustrated, and in their operation, may be made by those skilled in the art without departing from the spirit of the invention.

Claims

1. A switch, comprising:

a housing;

a rocker paddle pivotally connected to said housing such that when subjected to an external force, the rocker paddle is in a first depressed position and when not subjected to an external force, the rocker paddle is in a second rest position;

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

a semi-rigid cam driver having one end connected to be driven by said rocker paddle to cause said cam gear to rotate in either said first or said second direction;

slide means connected to be alternately moved in first and second opposite linear directions by rotation of said cam means;

fixed and movable contacts connected to said switch housing, said movable contact being biased into contact with said fixed contact and urged by said sliding means to break contact with said fixed contact;

a leaf spring located within said housing for assisting movement of said slide in said first and second directions.

2. The switch of claim 1, wherein said semi-rigid cam driver comprises:

a spiral wound element having a conical end and being connected to said housing;

spring means connected to urge said rocker paddle to said second rest position.

3. The switch of claim 2 wherein said conical end of said spirally wound element is positioned to engage said cam means.

4. A switch according to claim 2, including a clearance opening in an element between said rocker paddle and said cam means for receiving said helically wound element.

5. The switch of claim 4, wherein said gap opening is elongated.

6. The switch of claim 5, wherein the elongated opening has a long dimension along a length of the switch and a short dimension along a width of the switch.

7. The switch of claim 5, wherein said elongated gap opening is rectangular.

8. The switch of claim 1, wherein said slider includes a tapered opening for receiving said cam means, wherein rotation of said cam means causes said slider to move said movable contact.

9. The switch of claim 1 wherein said housing further comprises a base having spaced apart cavities for receiving said slider and said leaf spring.

10. The switch of claim 9, wherein the chamber for receiving said leaf spring has a length greater than the length of said leaf spring such that the ends of said leaf spring are not bound.

11. The switch of claim 9, further comprising a window in the rocker paddle to pass light from the illumination means in the housing.

12. The switch of claim 11 wherein said illumination means comprises a light emitting diode.

13. The switch of claim 9, further comprising front and rear wire gripping means for electrical conductors, said wire gripping means being mounted to said housing and connected to the fixed stationary contact and the movable brush contact.

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

15. The switch of claim 14, wherein said grounding/mounting strap is made of sheet metal.

16. A switch, comprising:

a housing;

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

a spirally wound cam driver having a conical end connected to be driven by said rocker paddle to drive said cam means in said first or second direction when said rocker paddle is subjected to an external force;

spring means connected to urge said rocker paddle to its second position;

slide means connected to be alternately moved in first and second opposite directions by said cam means;

fixed and movable contacts connected to said housing, said movable contact being biased into contact with said fixed contact and being urged by said sliding means to break contact with said fixed contact;

a leaf spring located within said housing for assisting movement of said slide in said first and second directions; and

wherein said leaf spring is substantially symmetrical about a central apex and has a relatively short cam portion on each side of said apex, the cam portions extending downwardly from said apex, an upwardly extending member at the end of each short cam portion, the members forming a pocket therebetween; and each upwardly extending member is seated on the support means with the end of each upwardly extending portion beyond the support means being bent downwardly.

17. A switch, comprising:

a housing;

spring means connected to urge said rocker paddle to its second position;

slide means connected to move in first and second opposite directions by said cam means;

a leaf spring located within said housing for assisting movement of said slide in said first and second directions;

wherein said leaf spring is substantially symmetrical about a central apex and has a relatively short cam portion on each side of said apex, the cam portions extending downwardly from said apex, an upwardly extending member at the end of each short cam portion, the members forming a pocket therebetween; and each upwardly extending member is seated on the support means with the end of each upwardly extending portion beyond the support means being bent downwardly; and

the switch housing further includes a switch base having spaced apart cavities for separately receiving the slide and the cam-shaped leaf spring in the cavities.

18. The switch of claim 1, comprising:

a surface along the length of the rocker paddle, the surface having a positive first differential, is formed by a combination of splines drawn between points at different distances from a reference plane.

19. The switch of claim 18 wherein said rocker paddle has a surface along its length having a zero second differential comprised of splines drawn between points at different distances from a datum plane when the rate of height increase of individual splines is constant.

20. The switch of claim 18 wherein said rocker paddle has a surface along its width having a positive first differential and a negative second differential comprised of a combination of splines drawn between points at different distances from a datum plane.

21. The switch of claim 18 wherein said rocker paddle has a surface along its length having a positive first differential comprised of splines drawn between points at different distances from a datum plane and has a surface along its width having a positive first differential and a negative second differential comprised of a combination of splines drawn between points at different distances from a datum plane.

22. The switch of claim 21 wherein said rocker paddle has a surface along its length having a quadratic differential of zero when the rate of height increase of individual splines is constant, the surface consisting of splines drawn between points at different distances from a datum plane.

23. The switch of claim 18, wherein said rocker paddle is not within a frame.

24. The switch of claim 17 wherein said rocker paddle has a surface along its length having a positive first differential comprised of a combination of splines drawn between points at different distances from a datum plane.

25. The switch of claim 24 wherein said rocker paddle has a surface along its length having a second derivative of zero when the rate of height increase of individual splines is constant, the surface being comprised of splines drawn between points at different distances from a datum plane.

26. The switch of claim 24 wherein said rocker paddle has a surface along its width having a positive first differential and a negative second differential comprised of a combination of splines drawn between points at different distances from a datum plane.

27. The switch of claim 24 wherein said rocker paddle has a surface along its length having a positive first differential comprised of splines drawn between points at different distances from a datum plane and has a surface along its width having a positive first differential and a negative second differential comprised of a combination of splines drawn between points at different distances from a datum plane.

28. The switch of claim 27 wherein said rocker paddle has a surface along its length having a second derivative of zero when the rate of height increase of individual splines is constant, the surface being comprised of splines drawn between points at different distances from a datum plane.

29. The switch of claim 24 wherein said rocker paddle is not within a frame.