Dual Load Control Device with Metal Leaf Springs
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Solution Overview
Problem
Existing electrical switch devices lack the ability to provide both direct control of local electrical loads via wired connections and remote control of multiple loads via wireless RF signaling, with a desire for a dual load switching device that offers independent control of two local loads and uniform tactile feedback.
Innovation Solution
A dual electrical load control device with a housing configured for a single-gang electrical box, featuring first and second switches for direct control and a communications device for wireless control, along with a button frame assembly using metal leaf springs for uniform tactile feedback and a compact RF antenna for wireless messaging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a single-gang electrical box is used to house the control device, then the device occupies less space and is more compact, but it becomes difficult to accommodate multiple switches and wireless communication components independently
Solution Approach 1:
The device is divided into distinct functional modules: first switch module, second switch module, and wireless communication module. Each module is independently positioned within the housing, allowing them to function separately while occupying minimal space collectively. This segmentation enables the compact single-gang design while maintaining independent controllability of multiple loads.
Solution Approach 2:
The control device is designed to perform multiple functions within a single unit: it can control first local load via first switch, second local load via second switch, and remotely controlled load via wireless communication. This multi-functionality allows the device to replace multiple separate devices, reducing overall space requirements while maintaining full functionality.
2Ease of operation
If wide area push buttons are used for tactile feedback, then uniform tactile feeling is achieved across the button surface, but the button structure becomes more complex requiring additional support mechanisms
Solution Approach 1:
Metal leaf springs are used as flexible support elements beneath the wide area push buttons. These thin, flexible springs provide uniform elastic support across the entire button surface, ensuring consistent tactile feedback regardless of where the button is pressed. The flexible nature of the leaf springs allows them to conform to the button's wide surface area while maintaining structural integrity.
Solution Approach 2:
The mechanical properties of the button support system are optimized by selecting appropriate metal leaf spring materials and dimensions. The spring constants and geometric parameters of the leaf springs are carefully chosen to provide the desired tactile feedback characteristics across the wide button surface, achieving uniformity through parameter optimization rather than complex structural design.
3Adaptability or versatility
If independent control of two local loads is provided through wired connections, then direct control capability is enhanced, but the device requires more wiring connections and terminal points
Solution Approach 1:
The control device is designed with dual functionality: it can control local loads through wired connections via two independent switches, and control remote loads through wireless communication. This multi-functionality allows a single device to replace multiple devices, reducing overall wiring complexity in the system while maintaining the capability for independent control of multiple local loads.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables direct and remote control of electrical loads through wired and wireless connections, providing independent control of two local loads and uniform tactile feedback, while maintaining a compact and cost-effective design.
Implementation Method 1
At least one leaf spring is provided that is mounted to the frame base structure, the at least one leaf spring associated with the at least one button to bias the associated button in a first direction
Implementation Method 2
A communications device disposed at least partially within the housing is further provided and configured to wirelessly transmit a control signal to control at least one additional electrical load
Data Source
AI summary
An electrical control device comprising a housing configured to be at least partially mountable within a single-gang electrical box; and including at least first and second switches disposed at least partially within the housing, each the at least first and second switches configured as providing a respective first and second input to the electrical control device and, the electrical control device being configured to be wired to a respective first and a second electrical load. A communications device disposed at least partially within the housing is configured to wirelessly transmit a control signal to control at least one additional electrical load.