Light Pipe Activated Air Gap Switch for Flush Faceplates
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Solution Overview
Problem
Conventional dimmer switches with air gap switches have a protruding mechanical actuator that is unattractive and space-consuming, limiting the integration of additional features and requiring a separate mechanism for maintenance, which is rarely needed but potentially dangerous due to residual leakage current.
Innovation Solution
An adjustable light pipe assembly that activates an air gap switch, allowing the air gap switch to be hidden within the faceplate and integrated with other features, using a light transmissive channel and cam mechanism to open and close the circuit, providing a smooth, uncluttered surface and enabling remote operation through IR sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional plastic pull-down switch is used for the air gap mechanism, then the air gap switch can be implemented to disconnect power, but the actuator protrudes from the faceplate making it unattractive and consuming valuable faceplate space
Solution Approach 1:
The patent replaces the conventional mechanical pull-down switch with an optical system using a light pipe. The light pipe contains an optical cavity with a light source that illuminates a translucent indicator on the faceplate. When the air gap switch is activated, the light pipe's optical properties change, causing the indicator to darken or change appearance, providing visual feedback without requiring a protruding mechanical actuator. This substitutes mechanical protrusion with optical signaling.
Solution Approach 2:
The patent utilizes color or translucency changes in the light pipe indicator to indicate the state of the air gap switch. The indicator portion of the light pipe changes its optical properties (from translucent to opaque, or color change) based on the switch state, providing clear visual feedback while maintaining a flush, attractive faceplate appearance without protruding elements.
2Reliability
If a conventional plastic pull-down switch is used for the air gap mechanism, then the air gap switch can be implemented, but it consumes valuable faceplate space limiting integration of additional features
Solution Approach 1:
The patent replaces the space-consuming mechanical pull-down actuator with a compact optical light pipe system that integrates within the faceplate. The light pipe's internal optical cavity and light source occupy minimal space compared to a protruding mechanical switch, freeing up faceplate area for additional features such as occupancy sensors, night lights, or ambient light detection while maintaining full air gap switch functionality.
3Illumination intensity
If the light pipe is made transparent to allow light transmission, then light can pass through for indication, but the internal cam mechanism and contacts cannot be effectively shielded from external light
Solution Approach 1:
The patent employs a nested structure where the cam mechanism and electrical contacts are housed within an internal cavity of the light pipe assembly. The light pipe wall acts as an intermediate layer between the internal components and the external environment. The cavity is positioned such that the cam and contacts are shielded from direct external light exposure, while the light pipe material allows sufficient light transmission for indicator visibility. This nested arrangement protects sensitive internal components from light interference while maintaining optical functionality.
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
The solution allows for a compact, aesthetically pleasing dimmer switch that safely disconnects power for maintenance while integrating multiple features, enhancing user satisfaction and compliance with evolving electrical codes and consumer preferences.
Implementation Method 1
a light pipe that can be configured to move in a substantially orthogonal direction from the outer surface of the faceplate
Implementation Method 2
The light pipe can include a first end and a second distal end. In the first position, the first end of the light pipe can be positioned along the outer surface of the faceplate
Data Source
AI summary
An electrical switch device includes a housing, faceplate, and a light pipe assembly that includes a light transmissive channel, a position stop, and a cam. The device also includes an air gap switch having a movable contact assembly and a stationary contact assembly. The movable contact assembly includes a cam follower that engages the cam of the light pipe assembly. The light pipe assembly is configured to pulled outward from the outer surface of the faceplate. Movement of the light pipe assembly cause the cam follower of the movable contact assembly to move along the cam and separate the movable contact from the stationary contact, shorting the circuit. Pushing the light pipe assembly in a direction back into the faceplate causes the cam follower to move in the opposite direction along the cam and allows the movable contact to engage the stationary contact and close the circuit.