A wallbox dimmer switch includes an actuator mounting frame having a platform portion that is receivable in a rectangular wallplate opening having standard toggle-type dimensions. The dimmer switch includes a pushbutton actuator for a switch and an adjacently located dimmer actuator that extend substantially parallel to a first side of the platform portion. The pushbutton actuator includes a user-engageable portion having an outer surface of which at least the end portions are defined by a portion of a substantially prolate spheroid for minimization of undesirable coupling between the adjacent actuators during actuation by a user. The switch may also include an actuator for an airgap switch extending through the platform portion and an array of indicator lights that are displayed through openings extending to an actuator-presentation surface of the platform portion.

Wallbox dimmer switch having side-by-side pushbutton and dimmer actuators

A pressure sensitive control device having a housing made up of a plurality of housing members, a diaphragm, a bistable snap-disc, a switch and an actuator. The snap-disc moves from one configuration to another upon application of pressure over a predetermined amount to drive the actuator which moves the switch from its normal operating position, which can be either closed or open, to a tripped position, which is opposite its normal operating position. Two adjacent housing members, which support the snap-disc and switch, respectively, are formed with cooperating spacers which allow the spacing of these housing members to be continuously varied over a small range of adjustment to allow the switch point of the control device to be adjusted after partial assembly of the control device. The diaphragm and some of the housing members may be subassembled for testing the components of the control device prior to complete assembly. The switch is initially formed as one piece and electrically halved after subassembly with one of the housing members. A housing member which is formed for connection to an electrical control circuit to which the control device is to be attached is modular and can be replaced with similar housing members which are configured for connection to different types of mating electrical connectors associated with different control circuits. Methods of assembly are also enclosed.

Method of assembling a pressure responsive control device

An element protector control for protecting the electrically powered heating element of a kettle against overheating has primary and secondary (or back-up) modes of operation The primary protection mode utilizes a dished, snap-acting bimetal which is oriented so that the side of the bimetal which is convex when the blade is cold faces the heating element head, and the bimetal is sprung against a flat rear surface of the element head so that the bimetal in its cold condition flattens against the element head The bimetal determines the condition of a pair of switching contacts provided in the control The bimetal is mounted in a carrier which is spring biassed towards the element head and, for providing the secondary protection mode, the carrier is formed of a thermoplastics material so that in the event of failure of the primary protection in an overtemperature situation so that the element temperature continues to rise, the carrier will collapse towards the element head, and the collapse of the carrier is arranged to disconnect the control from its power supply terminals

Thermal control units

A thermally activated electrical interrupt device incorporates a thermally activated portion engaging with an electrical interrupt portion. The thermally activated material expands when heated, causing an interrupt control rod to open an electrical contact. When the interrupt device is placed into an interrupt state, a reset mechanism maintains the interrupt control rod in the interrupt state until specifically reset. An actuating shaft is in operational communication with at least one electrical contact. The actuating shaft is maintained in a thermal monitoring position until an interrupt control rod is moved via a thermally expanding material and engages with the actuating shaft, releasing it from the thermal monitoring position. The actuating shaft is projected via a biasing member to cause a change in state of the electrical contact. The actuating shaft remains in the interrupt state until the user resets the switch.

Thermally activated electrical interrupt switch

A method of manufacturing a compact switch includes steps of (a) forming a base by insert molding on terminal members such that terminal pins of the terminal members are extended downward through the base when the terminal members, one of which has a bimetallic plate-fixing portion and another of which has engaging grooves to be engaged with a movable spring member, are punched in a hoop member; (b) fixing a bimetallic plate to the fixing portion of the one terminal member, a fixed contact being attached to a free end of the bimetallic plate which is displaced when temperature of the bimetallic plate is raised; (c) bringing a movable spring member into engagement with the engaging grooves of the other terminal member, a movable contact to be faced to the fixed contact being attached to a free end of the movable spring member; (d) bringing a lower end portion of a push button member into engagement with the movable spring member; (e) cutting the terminal pins at predetermined positions from a lead frame of the hoop member and accommodating in a housing a switch unit thus formed by the steps (a) to (d) to enable automated manufacturing process of the compact switch.

Method of manufacturing a compact switch

An electrical switch construction having a housing carrying a fixed contact and a snap blade having a contact to be snapped relative to the fixed contact as the blade is moved relative to the housing to provide a switching function with the fixed contact. A generally C-shaped actuator has opposed ends disposed on opposite sides of the blade, one end of the actuator being interconnected to the blade to cause snap movement thereof upon movement of that one end of the actuator in one direction relative to the housing. A compression spring is disposed between that one end of the actuator and the housing to tend to oppose movement of that one end of the actuator in that one direction. A motion transmitting arrangement is carried by the housing and is operatively associated with the other end of the actuator whereby movement of the other end of the actuator toward the blade by the motion transmitting means in the one direction causes an initial flexure of the actuator between the ends thereof before the one end is moved sufficiently in that one direction to cause the blade to snap relative to the housing.

Electrical switch construction and method of making the same

A control unit having a condition selector, an electrical switch having an actuator unit provided with an adjustable movement differential, a condition responsive device for actuating the switch when the condition responsive device senses certain conditions selected by the selector, and a lever arrangement carried by the unit and being operatively associated with the actuator unit of the switch and the device whereby the device can actuate the switch by the lever arrangement, the lever arrangement having a first adjustable lever operatively interconnected to the selector and acting as a main range lever. The first lever is operatively interconnected to the condition responsive device and to the actuator unit of the switch. The lever arrangement has a second adjustable lever operatively interconnected to the selector and to the actuator unit of the switch for adjusting the movement differential of the actuator unit of the switch.

Werner R. Bauer

Papers

Electrical switch construction and method of making the same

Control unit and electrical switch construction therefor and methods of making such a control unit and electrical switch construction