AC powered remote device

Abstract

The technology described herein relates to an electrical wiring device powered by AC mains, such as a smart switch or dimmer, for wireless control of an electrical load. The device includes a power circuit on a first PCB to convert AC to DC, and an RF switch circuit on a second PCB capable of wireless communication. An actuator facilitates initiation of a wireless command. A partition physically isolates live voltage elements for improved user safety. The device requires no battery maintenance, supports uninterrupted operation, and is suitable for residential, commercial, and hospitality environments.

Description

[0001] Cross-reference to related applications

[0002] This application relates to and claims priority to U.S. Provisional Patent Application Serial No. 63 / 737,953, filed December 23, 2024, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This disclosure relates to electrical wiring devices, and more particularly to smart switches and dimmers powered by AC mains for wireless management of electrical loads. Background Technology

[0004] As those skilled in the art will understand, smart switches, dimmers, and sensors are increasingly used in residential and commercial environments to enable wireless control of lighting and other electrical loads. These devices typically utilize wireless communication protocols, including ZigBee, Bluetooth, and Wi-Fi, to interact directly with central controllers, hubs, or smart devices. A common method for powering such devices is to use batteries, which allow for flexible installation without requiring a direct connection to AC mains power.

[0005] However, this reliance on battery power presents several challenges. Battery-powered smart switches require regular maintenance to replace or recharge the battery, which can be particularly burdensome in environments with many such devices, such as hotels, offices, or hospitals. The need for frequent battery replacements increases operating costs, and if the battery runs out before maintenance begins, it can cause the device to shut down. Furthermore, to extend battery life, these devices typically enter a low-power sleep mode when not in use. While this extends battery life, it can lead to delayed response times, communication interruptions, or temporary loss of connectivity to wireless networks, especially if the device is not frequently activated to maintain pairing or receive updates.

[0006] Therefore, improved solutions are needed to address the maintenance, reliability, and performance limitations associated with battery-powered smart electrical wiring devices, while maintaining compatibility with existing installation standards and wireless communication protocols. Furthermore, user safety for smart devices needs to be ensured, as removing the front cover and hardwiring the smart device to AC mains could expose users to hazardous voltages. Summary of the Invention

[0007] According to one aspect, an electrical wiring device for installation within an electrical concealed junction box includes: a power circuit disposed on a first printed circuit board connected to AC mains power and outputting a DC power signal, wherein the first printed circuit board is positioned within a rear body of the electrical wiring device; an RF switch circuit for providing wireless commands to a smart device disposed on a second printed circuit board, the RF switch circuit being powered by the DC power signal; an actuator mechanically communicating with the RF switch circuit to initiate wireless control of a remote electrical load; and a separator located between the first and second printed circuit boards, the separator being configured to physically isolate charged voltage elements of the first printed circuit board and configured to prevent user contact with the electrical wiring device when its front cover is removed.

[0008] In one example, the separator is a grounding strip.

[0009] In one example, the separator is a splitter.

[0010] In one example, the electrical wiring arrangement also includes a pair of wires that extend through the separator to transmit the DC power signal from the power supply circuit to the RF switching circuit.

[0011] In one example, the electrical wiring arrangement also includes pairs of wires that extend around the separator to transmit the DC power signal from the power supply circuit to the RF switching circuit.

[0012] In one example, the power supply circuit is an isolated power supply circuit.

[0013] In one example, the isolated power supply circuit includes a flyback converter having a transformer for isolating the DC power signal.

[0014] In one example, the RF switching circuit is also configured to reduce the voltage of the DC power signal.

[0015] In one example, the RF switch circuit does not employ a sleep mode that requires "wake-up" for updates.

[0016] In one example, the RF switch circuit is configured to communicate with at least one connected device to prevent the at least one connected device from unpairing with the RF switch circuit.

[0017] In one example, the RF switch circuit is configured to communicate via at least one wireless protocol selected from a group consisting of ZigBee, Bluetooth, and Wi-Fi.

[0018] In one example, the actuator includes a rocker arm lever that is fitted into the trimming ring in a manner that allows rotational movement.

[0019] In one example, the actuator also includes a dimmer slider connected to the rocker arm dial for adjusting the brightness level of a remote electrical load.

[0020] In one example, the actuator includes at least one button configured to transmit predefined lighting control commands to the smart device.

[0021] In one example, the actuator includes a motion sensor configured to detect occupancy and generate a control input signal for the RF switching circuit.

[0022] In one example, the actuator is connected to a trimming ring, wherein the trimming element includes a tab that is positioned and sized to fit under a wall panel during installation, the tab preventing the trimming ring from detaching from the electrical wiring device.

[0023] In one example, the actuator is connected to a trimming ring, which is fastened to the separator by screws to prevent the trimming ring from detaching from the electrical wiring device. Attached Figure Description

[0024] Figure 1A This is an exploded perspective view of an exemplary electrical wiring installation.

[0025] Figure 1B This is an exploded perspective view of an exemplary electrical wiring installation.

[0026] Figure 2A This is an exploded perspective view of an exemplary electrical wiring installation.

[0027] Figure 2B This is an exploded perspective view of an exemplary electrical wiring installation.

[0028] Figure 3 This is a schematic diagram of an example isolated power supply. Detailed Implementation

[0029] This disclosure addresses the limitations of battery-powered RF switches by providing a switch directly powered by AC mains while incorporating safety and performance features. The device includes power circuitry on a first printed circuit board (PCB) for converting AC power to a suitable DC voltage, and RF switching circuitry on a second PCB for wireless communication using protocols such as ZigBee, Bluetooth, or Wi-Fi. Power can be isolated for further user safety. Physical separators (such as grounding strips or delimiters) are positioned between the two PCBs to isolate live voltage components, ensuring user safety by preventing contact with high-voltage components when removing the device's front cover. This architecture eliminates the need for battery maintenance, enabling continuous operation without interruption due to battery depletion or sleep mode. Furthermore, the device maintains uninterrupted communication with connected systems, preventing unpairing or connection loss. By addressing both the performance and safety challenges of existing solutions, this disclosure provides a robust, reliable, and user-friendly alternative for the wireless control of electrical loads.

[0030] Figure 1A-Figure 1B An example of an electrical wiring device 100 with RF control capability is depicted. As shown, the electrical wiring device 100 includes an RF control PCB 102 on which an RF switch circuit 104 is disposed for providing wireless commands to a smart device. The wireless command signal can be transmitted via any wireless protocol / technology, including but not limited to protocols based on the ZigBee standard, Bluetooth technology, and / or Wi-Fi technology. Pairing of the electrical wiring device 100 with a remote device can be accomplished via known methods. It should be understood that communication with the remote device can be conducted through direct communication or through one or more intermediate devices (such as through a mesh network or hub), and includes communication via the cloud. Electrical switch and dimmer circuits, transceivers, and remote operation of switches via protocols such as ZigBee, Bluetooth, and Wi-Fi are known in the art, and any suitable smart switch circuit can be used.

[0031] The electrical wiring arrangement may further include actuators for operating RF switching circuits. For example... Figure 1A As shown, the actuators are implemented as a toggle 106 and a dimmer toggle 108, i.e., toggles with sliders, to achieve the dimming feature. However, it should be understood that any suitable actuator can be used. For example, the actuator may optionally include a button for achieving local / external features or for achieving various preset lighting features. In other examples, the actuator may be a motion detector or a wave or touch switch. Other actuators are shown, for example, in US2022 / 0246372 entitled “Battery powered devices,” which is incorporated herein by reference in its entirety.

[0032] In the example shown, the toggle 106 is disposed in a trimming ring 110 for supporting the toggle 106 and for covering (e.g., enclosing) the RF control PCB 102. Here, the trimming ring 110 includes features for allowing the toggle 106 to swing back and forth in response to a user pressing the toggle 106.

[0033] The RF switching circuit 104 is powered by a power supply circuit 114 disposed on a PCB (represented as AC PCB 116). For safety reasons, the power supply circuit 114 is an isolated power supply. Any suitable power supply circuit topology can be used to convert AC power from AC mains (e.g., 120 V, 60 Hz) into a voltage suitable for powering the RF switching circuit. Figure 3 An example of a suitable power supply is described. AC mains power supplies power to the power circuit 114 via termination 118. Termination 118 may include termination screw 120 for connecting the live wire from the junction box.

[0034] As shown in the example of Figure 1, the AC PCB 116 is separated from the RF control PCB 102 by a grounding strip 122, which is sized and designed to be fitted into a junction box. The grounding strip 122 also provides a degree of protection to the user, preventing the user installing electrical wiring from coming into contact with higher voltage AC mains power input to the AC PCB 116.

[0035] Pairs of wires 128 may extend through or around the grounding strip 122 to connect the AC PCB 116 to the RF control PCB 102. Additionally, the AC PCB 116 may be disposed within the rear body 126 together with the trim ring 110 and the grounding strip 122 to provide complete enclosure of the device 100.

[0036] Figure 1B It shows Figure 1A Another example. Aside from the tab feature 130, this example is similar to... Figure 1A Similarly, the tab features are positioned and sized to fit under the wall panel, preventing the user from pulling the trim ring away from the wall panel and potentially exposing the internal structure, including higher voltage components.

[0037] Figure 2A An alternative example is provided: electrical wiring device 100-2 (including splitter 126, but excluding grounding strip) for separating RF control PCB 102 from AC PCB 116. Figure 2AExamples also include different actuator examples, such as a single-point press dial 106-2 with a dimmer dial 108, requiring a trim piece 110-2 with front features to accommodate the dial 106-2. The back features of the ground strip 122 and the splitter 126 can be configured to accept a battery in an alternative example of the AC PCB 116, thus providing manufacturing flexibility and the ability to reuse components between battery-powered and power-powered versions of the device. Common features between Figures 1 and 2 are given the same reference numerals.

[0038] Figure 2B An alternative example, electrical wiring device 100-3, is depicted. Except for the inclusion of screws, this example is similar to... Figure 2A Similarly, the screw is inserted into the hole 134 in the trim ring 110-2 and engages with the threaded hole 136 in the separator 124. (In another example, the trim ring may also include a threaded hole.) Once the screw 132 is inserted, easy removal of the trim ring 110-2 is prevented, thereby protecting the internal structure of the electrical wiring assembly 100-3 and the user from the risk of electric shock. Figure 2B Compared to Figure 2A Inverted to better show holes 134 and 136.

[0039] Figure 3 An exemplary suitable power supply circuit 300 that can be implemented on an AC PCB 116 is shown. As shown in the figure, Figure 3 It is a flyback converter, comprising transformer T1 and diode D2, and controlled by flyback controller U1 via pin 4. Other aspects of power supply 300 will be understood by those skilled in the art and will only be briefly described. On the primary side, full-bridge rectifier D1 converts the input AC mains signal into a high-voltage DC signal. The converted DC signal is input to a low-pass Pi filter, which includes inductor FB1 and capacitors C1 and C2, to remove high-frequency EMI components. The flyback converter down-converts the voltage based on the number of turns in the primary and secondary windings of T1 and the drive signal provided by U1. On the secondary side, a buffer circuit including resistor R5 and capacitor C5 suppresses ringing. Output smoothing capacitors C6 and C7 smooth the output voltage to eliminate ripple from the output of diode D2. This output is +5V, which can be input to linear regulator U2 and output smoothing capacitor C9 to provide a +3.3V DC signal to output terminals W1 and W2.

[0040] Because transformer T1 wirelessly transmits power (from the primary winding to the secondary winding of T1), power supply 300 is an isolated power supply. Using an isolated power supply means that when the user opens the front cover, they will not come into contact with any part of the circuit connected to the live wire or any termination, thus reducing the risk of electric shock.

[0041] It should be understood that some quantities that convert the input voltage to a suitable value can be performed on circuitry located on the RF control PCB, thus allocating the function of providing power to the RF switching circuitry. For example, the linear regulator U2 and the smoothing capacitor C9 can be located on the RF control PCB 102 to perform the final step of converting the voltage to the value used by the RF control PCB 102.

[0042] Wired smart dimmers offer several advantages over similar battery-powered devices. First, using a wired power source eliminates the need for battery replacements. Since these switches are frequently used in hospitality settings such as hotels, battery maintenance can be difficult to manage. Furthermore, to conserve power, battery-powered devices often enter sleep mode when not in use for extended periods. This requires periodic "wake-ups" to determine if a system update is needed. This is unnecessary in the wired devices shown in Figures 1 and 2 and described herein. Additionally, the wired design improves conductivity. If the wireless system does not "hear" the paired device for a period of time, it can unpair it. By continuously supplying power to the RF switching circuitry, the wired device can communicate with the wireless system to maintain pairing.

[0043] It should be understood that the values ​​used above are merely representative values, and other values ​​may also conform to the spirit and intent of this disclosure.

[0044] Although several inventive embodiments have been described and illustrated herein with reference to certain exemplary embodiments, those skilled in the art will readily conceive of various other devices and / or structures for performing functions and / or obtaining results and / or one or more advantages described herein, and each such variation and / or modification is considered to be within the scope of the inventive embodiments described herein (and those skilled in the art will understand that various changes in detail may be made without departing from the spirit and scope of the invention as defined by the claims supported by the written description and drawings). More generally, those skilled in the art will readily understand that all parameters, dimensions, materials, and configurations described herein are exemplary, and actual parameters, dimensions, materials, and / or configurations will depend on one or more specific applications of the teachings used in this invention. Those skilled in the art will recognize, or be able to determine, many equivalents of the particular inventive embodiments described herein using only conventional experimentation. Therefore, it should be understood that the above embodiments are given by way of example only and within the scope of the appended claims and their equivalents; inventive embodiments can be practiced in ways different from the specific description and claims. Furthermore, in the case of describing exemplary embodiments with reference to a specific number of elements, it should be understood that exemplary embodiments may be implemented using fewer or more elements.

[0045] All references cited in this article, including publications, patent applications and patents, are incorporated herein by reference to the same extent that each reference individually and specifically indicates that it is incorporated by reference and fully elaborated in this article.

[0046] All definitions used and defined herein should be understood as controlling dictionary definitions, definitions in referenced and incorporated literature, and / or the general meaning of the defined terms.

[0047] In the context of describing this invention (especially in the context of the appended claims), the use of the terms “a” and “an,” as well as “the” and similar indicative words, should be interpreted to cover both singular and plural forms, unless otherwise expressly stated herein or clearly contradicted by the context. Unless otherwise expressly stated, the terms “comprising,” “having,” “including,” and “containing” should be interpreted as open-ended terms (i.e., meaning “including, but not limited to,”). The term “connected” should be interpreted as being partially or wholly contained in, attached to, or combined with, even if there is interference.

[0048] As used in the specification and claims, the phrase "at least one" in relation to a list of one or more elements should be understood to mean at least one element selected from any one or more elements in the list of elements, but does not necessarily include at least one of each element specifically listed in the list of elements, and does not exclude any combination of elements in the list of elements. This definition also allows for the optional presence of elements other than those specifically identified in the list of elements referred to by the phrase "at least one," regardless of their relation to those specifically identified elements. Thus, as a non-limiting example, "at least one of A and B" (or equivalently, "at least one of A or B," or equivalently, "at least one of A and / or B") in one embodiment may refer to at least one, optionally including more than one A, with no B (and optionally including elements other than B); in another embodiment, at least one, optionally including more than one B, with no A (and optionally including elements other than A); in yet another embodiment, at least one, optionally including more than one A, and at least one, optionally including more than one B (and optionally including other elements), etc.

[0049] It should also be understood that, unless the contrary is explicitly stated, in any method claimed herein that includes more than one step or action, the order of the steps or actions of the method is not necessarily limited to the order in which the steps or actions of the method are described.

[0050] As used throughout the specification and claims, approximate language can be used to modify any quantity representation, allowing for variation without altering its underlying function. Therefore, values ​​modified by one or more terms such as "approximately" and "substantially" are not limited to specified precise values. In at least some cases, approximate language can correspond to the precision of the instrument used to measure the value. In this document and throughout the specification and claims, scope limitations can be combined and / or interchanged; such scopes are defined and include all subscopes contained herein, unless otherwise indicated by context or language.

[0051] Unless otherwise expressly stated herein, the description of the range of values ​​herein is intended only as a shorthand for each individual value falling within that range, and each individual value is incorporated into the specification as if it were described separately herein.

[0052] Unless otherwise expressly stated herein or clearly contradicted by the context, all methods described herein can be performed in any suitable order. The use of any and all examples or exemplary language (e.g., "for example") provided herein is merely for the purpose of better illustrating embodiments of the invention and is not intended to limit the scope of the invention, unless otherwise expressly stated.

[0053] No language in this specification should be construed as indicating that any unclaimed element is essential to the practice of this invention.

[0054] In the claims and the foregoing description, all transitional phrases, such as “comprising,” “including,” “carrying,” “having,” “containing,” “involving,” “holding,” “consisting of,” etc., should be understood as open-ended, meaning including but not limited to. According to Section 2111.03 of the U.S. Patent Examination Procedure Manual, only the transitional phrases “consisting of” and “substantially consisting of” are closed or semi-closed transitional phrases, respectively.

[0055] It will be apparent to those skilled in the art that various modifications and alterations can be made to this invention without departing from its spirit and scope. The invention is not intended to be limited to the one or more specific forms disclosed; rather, it is intended to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention as defined in the appended claims. Therefore, this invention is intended to cover modifications and alterations to the invention, provided they fall within the scope of the appended claims and their equivalents.

Claims

1. An electrical wiring device for installation in an electrical concealed junction box, the electrical wiring device comprising: A power circuit is disposed on a first printed circuit board, the power circuit being connected to AC mains power and outputting a DC power signal, wherein the first printed circuit board is positioned within the rear body of the electrical wiring device; An RF switch circuit for providing wireless commands to a smart device disposed on a second printed circuit board, the RF switch circuit being powered by the DC power signal; An actuator, which mechanically communicates with the RF switching circuit, to initiate wireless control of a remote electrical load; and A separator, located between the first printed circuit board and the second printed circuit board, is configured to physically isolate the charged voltage elements of the first printed circuit board and to prevent user contact with the electrical wiring device when the front cover is removed.

2. The apparatus according to claim 1, wherein, The separator is a grounding strip.

3. The apparatus according to claim 1, wherein, The separator is a splitter.

4. The apparatus of claim 1 further includes a pair of wires extending through the separator to transmit the DC power signal from the power supply circuit to the RF switching circuit.

5. The apparatus of claim 1 further comprises a pair of wires extending around the separator to transmit the DC power signal from the power supply circuit to the RF switching circuit.

6. The apparatus according to claim 1, wherein, The power supply circuit is an isolated power supply circuit.

7. The apparatus according to claim 6, wherein, The isolated power supply circuit includes a flyback converter having a transformer for isolating the DC power signal.

8. The apparatus according to claim 1, wherein, The RF switching circuit is also configured to reduce the voltage of the DC power signal.

9. The apparatus according to claim 1, wherein, The RF switch circuit does not employ a sleep mode that requires "wake-up" for updates.

10. The apparatus according to claim 1, wherein, The RF switch circuit is configured to communicate with at least one connected device to prevent the at least one connected device from unpairing with the RF switch circuit.

11. The apparatus according to claim 1, wherein, The RF switch circuit is configured to communicate via at least one wireless protocol selected from the group consisting of ZigBee, Bluetooth, and Wi-Fi.

12. The apparatus according to claim 1, wherein, The actuator includes a rocker arm lever that is mounted in the trimming ring in a manner that allows rotational movement.

13. The apparatus according to claim 12, wherein, The actuator also includes a dimmer slider connected to the rocker arm dial for adjusting the brightness level of the remote electrical load.

14. The apparatus according to claim 1, wherein, The actuator includes at least one button configured to transmit predefined lighting control commands to the smart device.

15. The apparatus according to claim 1, wherein, The actuator includes a motion sensor configured to detect occupancy and generate a control input signal for the RF switching circuit.

16. The apparatus according to claim 1, wherein, The actuator is connected to the trimming ring, wherein the trimming element includes a tab that is positioned and sized to fit under the wall panel during installation, the tab preventing the trimming ring from detaching from the electrical wiring device.

17. The apparatus according to claim 1, wherein, The actuator is connected to the trimming ring, which is fastened to the separator by screws to prevent the trimming ring from detaching from the electrical wiring device.

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