WO2015122122A1

WO2015122122A1 - Switch module, switch, and switch assembly

Info

Publication number: WO2015122122A1
Application number: PCT/JP2015/000264
Authority: WO
Inventors: Kazuya Baba; Hirohisa Okuno; Hideto TADA; Takashi KUSAGAWA; Katsuya Imai; Toshiyuki Takii
Original assignee: Panasonic Intellectual Property Management Co., Ltd.
Priority date: 2014-02-13
Filing date: 2015-01-21
Publication date: 2015-08-20
Also published as: JP6406594B2; TW201546847A; JP2015153557A

Abstract

A switch module includes a housing, a push-button, a stationary contact and a movable contact. The push-button has an operation face. The housing holds the push-button so as to be movable in a first direction. The stationary and movable contacts are housed in the housing. The movable contact is configured to be switched between in contact with and out of contact with the stationary contact whenever the operation face of the push-button receives a pushing force. The housing includes a body having an opening that crosses the first direction and a cover coupled to the body to cover the opening of the body. Part of a rim of an opening of the body have a protrusion that protrudes in the first direction to cover both the stationary contact and the movable contact as seen from a second direction that is perpendicular to the first direction.

Description

SWITCH MODULE, SWITCH, AND SWITCH ASSEMBLY

The invention relates generally to switch modules, switches, and switch assemblies and, more particularly, to a switch module having a push-button and contacts of which state is switched every time the push-button receives a pushing-force, a switch including the switch module, and a switch assembly including the switch.

There has been known a switch configured so that the state of its contacts is switched whenever an operating handle thereof receives a pushing-force (for example, see JP2004-296230A (hereinafter referred to as "Document 1")). The switch disclosed in Document 1 is a wide handle switch (so-called, a piano handle (type) switch), and has a pivot point positioned on one side thereof. The switch of Document 1 includes the operating handle and a switch body. In the switch body, a stationary contact and a movable contact are housed in a housing that is constituted by a body and a cover.

Incidentally, in such switches, there have been increased demands of decrease of the height of the switch module (the height of the switch body). In other words, demands for decreasing the height of the housing of the switch body have been increased.

In this regard, if the conventional switch module is modified so that the height of the housing is simply decreased, a contact point (a position where the movable contact comes in contact with the stationary contact in the housing) would be placed near a boundary between the body and the cover. That is, the contacts (the stationary contact and the movable contact) would be positioned close to the boundary between the body and the cover. However, it is undesirable that an electric arc resulting from a motion of the contacts takes place near the boundary between the body and cover, and that a distance (insulation distance) between the outside space of the housing and the contacts becomes small due to the boundary between the body and the cover.

Summary

It is an object of the present invention to provide a switch module, a switch and a switch assembly, capable of having improved arc-resistant property and decreasing a size of a housing.

A switch module according to an aspect of the invention includes a housing, a push-button, a stationary contact and a movable contact. The push-button has an operation face. The housing holds the push-button so that the push-button is movable in a first direction. The stationary contact is housed in the housing. The movable contact is housed in the housing. The movable contact is configured to be switched between in contact with and out of contact with the stationary contact in response to a pushing force in the first direction applied onto the operation face of the push-button. The housing includes a body shaped like a case and a cover. The body has an opening that crosses (is perpendicular to) the first direction. The cover is coupled to the body to cover the opening of the body. Part of a rim of the opening of the body has a protrusion that protrudes in the first direction so as to cover both the stationary contact and the movable contact as seen from a second direction that is perpendicular to the first direction.

A switch according to an aspect of the invention includes the switch module and an operating handle. The operating handle is attached to the housing to face the push-button. The operating handle is configured to receive a push operation to transfer a pushing force by the push operation to the push-button.

As switch assembly according to an aspect of the invention includes the switch, an attachment frame and a plate. The attachment frame holds the switch module. The plate has an opening surrounding the operating handle. The plate is disposed on (in front of) the attachment frame.

According to the aspects of the invention, it is possible to improve arc-resistant property and also to decrease a size of a housing.

The figures depict one or more implementation in accordance with the present teaching, by way of example only, not by way of limitations. In the figures, like reference numerals refer to the same or similar elements where:
FIG. 1 is a sectional view of a switch module according to an embodiment. FIG. 2 is a perspective external view of the switch module, an operating handle, an attachment frame and a plate according to the embodiment. FIG. 3 is an exploded perspective view of the switch module according to the embodiment. FIG. 4 is a sectional view of the operating handle attached to the switch module according to the embodiment. FIG. 5 is a sectional view of a switch module according to a variation of the embodiment. FIG. 6 is a view illustrating the switch module according to the embodiment.

A switch module according to an aspect of the invention includes protrusions that are formed at parts of a rim of an opening of a body so as to cover a stationary contact and a movable contact (i.e., so as to hide a stationary contact and a movable contact behind the protrusions). Accordingly, it is possible to achieve both effects of having improved arc-resistant property and decreasing the size of a housing constituted by the body and the cover.

Hereinafter, a switch module 1, a switch 3 including the switch module 1, and a switch assembly 7 including the switch 3, according to the present embodiment, are described with reference to attached drawings.

As shown in FIG. 1, the switch module 1 of the embodiment includes a housing 11, a push-button (a push-button handle) 12, and contacts 13, and is configured so that the state of the contacts 13 is switched whenever the push-button 12 receives a pushing-force of which magnitude is predetermined level or more. As shown in FIG. 2, the switch module 1 constitutes, along with an operating handle 2, the switch 3. In other words, the switch 3 according to the embodiment includes the switch module 1 and the operating handle 2. The operating handle 2 is disposed on the housing 11 to face the push-button 12 and is configured to receive a push operation to transfer a pushing force by the push operation to the push-button 12. The switch 3 according to the embodiment is a wide handle switch (a piano handle (type) switch), and has a pivot point on one side of the switch 3. The switch 3 described in the embodiment is the wide handle switch, but the switch 3 may be a switch other then the wide handle switch.

The switch module 1 is shaped like a substantially rectangular solid as a whole. In the explanation below, unless not specified, a length direction of the switch module 1 is also referred to as a horizontal direction A1, a width direction of the switch module 1 is also referred to as a vertical direction (a second direction) A2, and a direction perpendicular to each of the length and width directions of the switch module 1 (i.e., a height direction of the switch module 1) is also referred to as a front-rear direction (a first direction) A3 (see FIG. 2).

In detail, in the switch module 1, the housing 11 and the push-button 12 are disposed on first and second sides of the first direction A3, respectively. Hereinafter, for simplifying the explanation, the first side of the first direction A3 (upper right in FIG. 2) is also referred to as "rear side", and the second side of the first direction A3 (lower left in FIG. 2) is also referred to as "front side".

The housing 11 is shaped like a case extending in the length direction A1 that is perpendicular to the first direction A3. The push-button 12 is disposed on a front face (a face on the second side of the first direction A3) of the housing 11 on a first side of the length direction A1 (lower right in FIG. 2). Hereinafter, for simplifying the explanation, the first side of the length direction A1 (lower right in FIG. 2) is also referred to as "right side", and a second side of the length direction A1 (upper left in FIG. 2) is also referred to as "left side".

The second direction A2 is perpendicular to each of the first and length directions A3 and A1, and corresponds to the vertical direction in FIG. 2. Hereinafter, for simplifying the explanation, a first side of the second direction A2 (upper side in FIG. 2) is also referred to as "upper side", and a second side of the second direction A2 (lower side in FIG. 2) is also referred to as "lower side".

The switch module 1 of the embodiment will now be explained with reference to FIGS. 1 to 4. However, known components used in conventional switch modules may not be explained in detail herein.

As shown in FIG. 1, the switch module 1 includes the housing 11 and the push-button 12. The switch module 1 further includes, as the contacts 13, a stationary contact 14 and a movable contact 15. As shown in FIG. 3, the switch module 1 further includes an switch piece 41, a first terminal plate 42, a second terminal plate 43, two first locking springs 44, two second locking springs 45, a first release button 46, and a second release button 47. The switch module 1 includes a reversal spring 51, a reversing handle 52, a slide cam 53, and a return spring 54 that constitute a switch mechanism configured to switch the state of the contacts 13 (namely, open and close the contacts 13). The switch module 1 is held by an attachment frame 8 (see FIG. 2) with which the switch module 1 is attached to an installation surface.

As shown in FIG. 3, the housing 11 includes a body 61 and a cover 62. The body 61 is shaped like a case, and has an opening 611. The cover 62 is coupled to the body 61 to cover the opening 611 of the body 61. The housing 11 is shaped like a rectangular solid. In the embodiment, the body 61 is disposed on the rear side (the first side of the first direction A3), and the cover 62 is disposed on the front side (the second side of the first direction A3). The opening 611 of the body 61 is formed in a front face (a face in the second side of the first direction A3) of the body 61.

The housing 11 has an inside space in which the switch piece 41, the first terminal plate 42, the second terminal plate 43, the two first locking springs 44, the two second locking springs 45, the first release button 46, and the second release button 47 are housed.

The body 61 is a synthetic resin molding product. The body 61 is shaped like a case having the opening 611 that crosses (is perpendicular to) the front-rear direction (the first direction) A3. The body 61 integrally includes a bottom wall 612, two side walls 613 facing each other in the width direction (the vertical direction) A2, and two side walls 614 facing each other in the length direction (the horizontal direction) A1. Each of the two side walls 613 extends in the length direction (the horizontal direction) A1. A dimension of the housing 11 in the width direction (the vertical direction) A2 is set to such a dimension that up to three wiring devices each of which has the same size as the switch modules 1 can be attached to the attachment frame 8 (see FIG. 2). That is, the dimension of the housing 11 in the width direction (the vertical direction) A2 is set to be approximately one-third of a dimension in the vertical direction A2 of an opening 81 of the attachment frame 8. A dimension of the housing 11 in the length direction (the horizontal direction) A1 is set to be approximately the same as a dimension in the horizontal direction A1 of the opening 81.

With regard to the body 61, each side wall 613 is provided with two latch projections 615. Regarding each side wall 613, the two latch projections 615 are arranged along the length direction of the housing 11 (the horizontal direction A1). As shown in FIG. 1, two first through-holes 616 and two second through holes 617 each of which allows an electric code to be inserted into are formed in the bottom wall 612. A releasing hole is formed near the two first through-holes 616, and another releasing hole is formed near the two second through-holes 617. A position regulation recess 618 (see FIG. 1) is formed inside the body 61. The position regulation recess 618 includes a V-shape of which the width increases towards the front (towards the second side of the first direction A3).

The cover 62 is a synthetic resin molding product. The cover 62 is shaped like a case having an opening that crosses (is perpendicular to) the front-rear direction (the first direction) A3. As shown in FIG. 3, the cover 62 integrally includes a front wall 621, two side walls 622 facing each other in the width direction (the vertical direction) A2, and two

side walls

623, 624 facing each other in the length direction (the horizontal direction) A1. Each of the two side walls 622 extends in the length direction (the horizontal direction) A1. Regarding the cover 62, each of the two side walls 622 is provided with two latch pieces 625 that extend rearward (to the first side of the first direction A3). Each of the latch pieces 625 has a latch hole 626. By the latch projections 615 engaged with the respective latch holes 626, the body 61 and the cover 62 are assembled together.

A recess 627 is formed in the front wall 621 of the cover 62. The recess 627 is formed of part of the front wall 621 and is set further back than remainder of the front wall 621. The recess 627 is formed in a right part (part on the first side of the length direction A1) of the front wall 621. A through-hole 628 is formed in a bottom of the recess 627 to pierce a bottom wall of the recess 627. A guide groove 630 is formed in a rear part of each of two inner side faces (two side faces in the horizontal direction A1) to extend in the front-rear direction (the first direction) A3. An optically transparent light cover 64 is provided in the front wall 621 of the cover 62. The light cover 64 is attached to a left part (part on the second side of the length direction A1) of the front wall 621. A light source (such as a light-emitting diode) configured to be lit when the contacts 13 (see FIG. 1) are opened (namely, the movable contact 15 is out of contact with the stationary contact 14) is housed in the housing 11, for example. A ray of light from the light source is emitted through the light cover 64. The switch module 1 may be configured so that a light source is lit when the movable contact 15 is out of contact with the stationary contact 14, or that a light source is lit when the movable contact 15 is in contact with the stationary contact 14. Alternatively, the switch module 1 may be configured so that a light source(s) emits different lights according to whether the movable contact 15 is in contact with or out of contact with the stationary contact 14.

Each of the

side walls

623, 624 of the cover 62 has two attachment nails 631 with which the switch module 1 is attached to the attachment frame 8 (see FIG. 2). Two shaft parts 632 for holding the operating handle 2 is provided on the front wall 621 of the cover 62. The two shaft parts 632 are provided on the left part (part on the second side of the length direction A1) of the front wall 621. The light cover 64 is positioned between the two shaft parts 632 in the second direction A2. Two or more (three, in the illustrated example) insertion holes 633 are formed in the front wall 621 of the cover 62. The insertion holes 633 are formed on the left part of the front wall 621 along the second direction A2.

As shown in FIG. 3, the push-button 12 has the operation face 121, and is held by the housing 11 to be movable in the first direction A3. The housing 11 is disposed on the first side of the first direction A3, and the operation face 121 is disposed on the second side of the first direction A3 (with respect to the push-button 12). That is, the push-button 12 is attached to the housing 11 with the operation face 121, which is configured to receive a pushing force in the front-rear direction (the first direction) A3, is placed outside the housing 11. In detail, the push-button 12 is attached to the front wall 621 of the cover 62 so as to be movable in the front-rear direction A3. In summary, the cover 62 has the recess 627 on the second side of the first direction A3 (on the front side thereof), and the push-button 12 is disposed in the recess 627 so that the operation face 121 is located outside the recess 627. The operation face 121 of the push-button 12 is directed to the front (to the second side of the first direction A3). The push-button 12 has a protrusion 122 on each side thereof in the horizontal direction (the length direction) A1. The protrusions 122 that are put in the respective guide grooves 630 of the recess 627 of the cover 62 retain the push-button 12 so that the push-button 12 is movable in the front-rear direction A3.

The first terminal plate 42 includes a link piece 421, two holding pieces 422 and two contact pieces 423. The link piece 421 extends in the second direction A2. The two holding pieces 422 are positioned on the left of the link piece 421, and the two contact pieces 423 are positioned on the right of the link piece 421. The two holding pieces 422 extends rearward (to the first side of the first direction A3) from the respective ends in the second direction A2 of the link piece 421. The two contact pieces 423 extends rearward (to the first side of the first direction A3) from the respective ends in the second direction A2 of the link piece 421. The two holding pieces 422 and the two contact pieces 423 are connected with the link piece 421 so that each of the two holding pieces 422 faces a corresponding one of the two contact pieces 423 in the horizontal direction A1. The first terminal plate 42 further includes a contact holding piece 424 that extends from the link piece 421. The contact holding piece 424 includes a substantially U-shape. The contact holding piece 424 is provided so as to face one of the two contact pieces 423 in the horizontal direction A1.

The second terminal plate 43 includes a link piece 431, two holding pieces 432 and two contact pieces 433. The link piece 431 extends in the second direction A2. The two holding pieces 432 are positioned on the right of the link piece 431, and the two contact pieces 433 are positioned on the left of the link piece 431. The two holding pieces 432 extends rearward (to the first side of the first direction A3) from the respective ends in the second direction A2 of the link piece 431. The two contact pieces 433 extends rearward (to the first side of the first direction A3) from the respective ends in the second direction A2 of the link piece 431. The two holding pieces 432 and the two contact pieces 433 are connected with the link piece 431 so that each of the two holding pieces 432 faces a corresponding one of the two contact pieces 433 in the horizontal direction A1. The second terminal plate 43 further includes a connection piece 434 that extends from the link piece 431. A support piece 435 is formed on a tip of the connection piece 434.

Each of the two first locking springs 44 is formed of an elastic metal plate having electrically-conductive property and shaped like a band of which both ends are bent. Each of the first locking springs 44 is in contact with a corresponding one of the two contact pieces 423 of the first terminal plate 42 and faces a corresponding one of the two holding piece 422 of the first terminal plate 42. Each of the two second locking springs 45 is formed of an elastic metal plate having electrically-conductive property and shaped like a band of which both ends are bent. Each of the second locking springs 45 is in contact with a corresponding one of the two contact pieces 433 of the second terminal plate 43 and faces a corresponding one of the two holding piece 432 of the second terminal plate 43. An electric cord inserted into the body 61 through a first through-hole 616 (see FIG. 1) is held between a first locking spring 44 and a holding piece 422. That is, an end (an end in the first side of the first direction A3; an end in the rear side) of the first locking spring 44 bites a core of the cord to retain the cord, and accordingly the first terminal plate 42 is electrically connected to the electric cord through the first locking spring 44. Similarly, an electric cord inserted into the body 61 through a second through-hole 617 is held between a second locking spring 45 and a holding piece 432. That is, an end (an end in the first side of the first direction A3; an end in the rear side) of the first locking spring 44 bites a core of the cord to retain the cord, and accordingly the second terminal plate 43 is electrically connected to the electric cord through the second locking spring 45.

Each of the first and

second release buttons

46 and 47 is made of thermosetting resin such as urea resin. When the first release button 46 that is located on a back of a release-hole is pressed by an end of a tool such as a minus driver, the first locking springs 44 are deformed to be away from the respective holding pieces 422. Electric cords therefore can be taken out from the first through-holes 616. Similarly, by the second release button 47 being pressed, the second locking springs 45 are deformed to be away from the respective holding pieces 432. Electric cords therefore can be taken out from the second through-holes 617.

Regarding the switch piece 41, as shown in FIG. 1, part of the switch piece 41 is located inside the position regulation recess 618 with a rear edge 411 of the switch piece 41 in contact with the support piece 435. Accordingly, the switch piece 41 is pivotable within a range of the position regulation recess 618 around the rear edge 411 that is in contact with the support piece 435. The switch piece 41 faces the contact holding piece 424 in the horizontal direction A1. As shown in FIG. 3, the switch piece 41 has a spring receiver 412.

As shown in FIG. 1, the stationary contact 14 is housed in the housing 11. In more detail, the stationary contact 14 is provided at an end of the contact holding piece 424.

The movable contact 15 is housed in the housing 11. In more detail, the movable contact 15 is provided on the switch piece 41 at a region facing the stationary contact 14 on the contact holding piece 424. Therefore, the movable contact 15 faces the stationary contact 14 in the horizontal direction A1. The movable contact 15 is positioned on a center in the horizontal direction (the length direction) A1 of the body 61.

The movable contact 15 moves between a position where the movable contact 15 is in contact with the stationary contact 14 (a close position) and a position where the movable contact 15 is out of contact with the stationary contact 14 (an open position) whenever a pushing force is applied to the operation face 121 of the push-button 12. That is, the movable contact 15 is configured to be switched between in contact with and out of contact with the stationary contact 14 whenever the operation face 121 of the push-button 12 receives a pushing force. In more detail, whenever the push-button 12 receives a pushing force, the switch mechanism (described in detail later) is operated so that the switch piece 41 turns to switch the state of the switch module 1 between the state in which the movable contact 15 is in contact with the stationary contact 14 and the state in which the movable contact 15 is out of contact with the stationary contact 14. As a result, the state of the switch module 1 is switched between a state where the first terminal plate 42 and the second terminal plate 43 are electrically connected with each other and a state where the first terminal plate 42 and the second terminal plate 43 are electrically disconnected from each other.

In such a switch module 1, an electric arc may take place when the movable contact 15 is separating from the stationary contact 14. In order to enhance the arc-resistant property (avoid influence of such an electric arc), the body 61 of the embodiment has the characteristic structure described below.

In the body 61 of the embodiment, parts of a rim of the opening 611 of the body 61 have two protrusions 65, as shown in FIGS. 1 and 3. The two protrusions 65 protrude in a direction (the front-rear direction; the first direction A3) along which the operation face 121 of the push-button 12 receives a pushing force so that the protrusions 65 cover the stationary contact 14 and the movable contact 15 as seen from the width direction of the housing 11 (the vertical direction; the second direction A2). In other words, the body 61 of the embodiment has the two protrusions 65 that allow a boundary between the body 61 and the cover 62 to be positioned away from the stationary contact 14 and the movable contact 15.

In detail, each of the two protrusions 65 is contained in part of a corresponding one of the two side walls 613 of the body 61 along the horizontal direction (the length direction) A3. This part of each side wall 613 further protrudes (protrudes frontward, in the embodiment) than remaining part of this side wall 613 in the front-rear direction (the first direction) A3. One of the two protrusions 65 is contained in part of a side wall 613 on the upper side (the first side of the second direction A2), and the other of the two protrusions 65 is contained in part of a side wall 613 on the lower side (the second side of the second direction A2). As described above, the stationary contact 14 and the movable contact 15 are housed in the housing 11 to face each other in the horizontal direction (the length direction) A1. According to the embodiment, as described above, each of the two side walls 613 along the horizontal direction (the length direction) A1 contains a protrusion 65 while the stationary contact 14 and the movable contact 15 are housed in the housing 11.

In further detail, as illustrated in FIG. 6, the body 61 is shaped like a case extending in the length direction A1 that is perpendicular to each of the first and second directions A3 and A2. The body 61 integrally has a center part 66 and side parts 67 on both sides of the center part 66 in the length direction A1. The stationary contact 14 and the movable contact 15 are disposed to face each other in the length direction A1 so as to cross a plane 100 that spreads in the second direction A2 and the length direction A1 and that contains openings 670 of the side parts 67. The openings 670 of the side parts 67 may be parts of (be contained in) the opening 611 of the body 61. The center part 66 has the protrusions 65 to cover the stationary contact 14 and the movable contact 15 as seen from the second direction A2.

Referring back to FIGS. 1 and 3, preferably, the protrusion 65 is positioned between the two latch pieces 625 with the latch projections 615 engaged with the respective latch holes 626. In other words, the protrusion 65 is positioned on a center part in the horizontal direction (the length direction) A1 of the side wall 613.

Each of the two protrusions 65 is shaped like a plate. Each protrusion 65 is formed so that the length thereof in the length direction of the housing 11 (the horizontal direction A1) decreases toward the front (from the bottom part thereof to the top part thereof). The two protrusions 65 face each other in the width direction of the housing 11 (the vertical direction A2). That is, the stationary contact 14 and the movable contact 15 are positioned between the two protrusions 65 in the second direction (the vertical direction) A2.

The body 61 is made of material having a higher fire-resistant property and a higher tracking-resistant property than those of material of the cover 62. Therefore, the protrusion 65 is made of material having a higher fire-resistant property and a higher tracking-resistant property than those of material of the cover 62. The body 61 (containing the protrusion 65) is preferably made of thermosetting resin such as urea resin.

The switch mechanism for the contacts 13 is now explained with reference to FIG. 3. The switch mechanism for the contacts 13 is, as described above, configured to move the movable contact 15 between a position (the close position) where the movable contact 15 is in contact with the stationary contact 14 and a position (the open position) where the movable contact 15 is out of contact with the stationary contact 14. The switch mechanism for the contacts 13 is configured to switch the state of the contacts 13 whenever the push-button 12 is pressed. That is, the switch module 1 includes the switch mechanism that is housed in the housing 11 and that is configured to move the movable contact 15 to switch (to switch the state of the movable contact 15) between in contact with and out of contact with the stationary contact 14 whenever the operation face 121 of the push-button 12 receives a pushing force. As described above, the switch mechanism includes the reversal spring 51, the reversing handle 52, the slide cam 53, and the return spring 54.

The reversal spring 51 is a compression coil spring. The spring receiver 412 of the switch piece 41 is located inside a space in a rear end (an end in the first side of the first direction A3) of the reversal spring 51.

The reversing handle 52 includes a support 521 shaped like a tube having an opening on a rear face thereof. A front end (an end on the second side of the first direction A3) of the reversal spring 51 is placed inside the tube-shaped support 521. A front end (an end on the second side of the first direction A3) of the reversing handle 52 protrudes in the recess 627 of the front wall 621 of the cover 62 through the through-hole 628. Protruding shafts 524 are formed on respective side faces of the reversing handle 52 in intermediate positions in the first direction A3 so as to protrude sideways. The protruding shafts 524 are pivotally supported by shaft supports 629 formed around the through-hole 628. Thus, the reversing handle 52 is attached to the cover 62 so that the reversing handle 52 is free to swing with respect to the cover 62. The reversing handle 52 has two ridges 522, 523 (see FIG. 1). The two

ridges

522, 523 are formed on a front face of the reversing handle 52. The two

ridges

522, 523 protrude from the front face of the cover 62 through the through-holes 628.

The slide cam 53 is made of elastic thermoplastic resin such as polyacetal. When the push-button 12 receives a pushing force, the slide cam 53 slides along a rear face of the push-button 12 (to the right or to the left) in accordance with the position of the reversing handle 52.

The return spring 54 is attached to the rear face of the push-button 12. Ends (ends on the first side of the first direction A3) of return spring pieces 541 of the return spring 54 are elastically in contact with the bottom of the recess 627. The push-button 12 is thus biased (pressed) frontward by the return spring 54.

A behavior of the switch module 1 according to the embodiment is explained with reference to FIG. 1. FIG. 1 shows the switch module 1 in a state where the movable contact 15 is in contact with the stationary contact 14. When the switch module 1 is in the state shown in FIG. 1 and if the push-button 12 is pressed towards the housing 11 while compressing the return spring 54, the slide cam 53 is pressed by the push-button 12 to move rearward (to the first side of the first direction A3). In this time, the slide cam 53 comes in contact with the ridge 522 of the reversing handle 52 to push a left end of the reversing handle 52. The reversing handle 52 thereby turns to the left side (rotates counterclockwise in FIG. 1) while the reversing handle 52 passes through a position where the reversal spring 51 is most compressed. As a result, a spring force applied to the switch piece 41 by the reversal spring 51 is reversed in the horizontal direction A1, and the switch piece 41 is reversed (turns clockwise in FIG. 1) by the spring force. Thereby, the movable contact 15 is separated from the stationary contact 14.

On the other hand, when the switch module 1 is in the state where the movable contact 15 is out of contact with the stationary contact 14 and if the push-button 12 is pressed, the slide cam 53 comes in contact with the (another) ridge 523 of the reversing handle 52 to turn the reversing handle 52 to the right side (rotate clockwise in FIG. 1) while the reversing handle 52 passes through a position where the reversal spring 51 is most compressed. As a result, the spring force applied to the switch piece 41 by the reversal spring 51 is reversed in the horizontal direction A1, and the switch piece 41 is reversed (turns counterclockwise in FIG. 1) by the spring force. Thereby, the movable contact 15 comes in contact with the stationary contact 14.

The operating handle 2 is explained in detail below with reference to FIGS. 2 and 4.

The operating handle 2 is shaped like a rectangular plate having a dimension sufficiently larger than that of the operation face 121 of the push-button 12. Shaft supports are formed on a rear face of the operating handle 2 at positions facing the shaft parts 632 of the switch module 1. The shaft parts 632 are pivotally supported by the shaft supports. The shaft supports hold the shaft parts 632, thereby the operating handle 2 is rotatably supported at one end in the horizontal direction A1 (on a left end) of a front face of the switch module 1. If a right end of the operating handle 2 is pushed rearward (to the first side of the first direction A3), the operating handle 2 rotates around parts (the shaft supports) thereof that are supported by the shaft parts 632 and pushes the push-button 12. The operating handle 2 has two retaining pieces 21 each of which has a nail 22 on a tip thereof. Tips of the retaining pieces 21 of the operating handle 2 are inserted into respective insertion holes 633 of the cover 62 (see FIG. 3). The rotation of the operating handle 2 is restricted at a position where the nails 22 of the retaining pieces 21 are engaged with the respective insertion holes 633.

The operating handle 2 shown in FIG. 5 is used in a case where one switch module 1 is attached to the attachment frame 8. The operating handle 2 has a dimension that is substantially the same as an opening 921 of a plate cover 92 (described later). In a case where two switch modules 1 are attached to the attachment frame 8, operating handles each of which has a dimension that is substantially the same as a half of the opening 921, obtained by dividing the opening 921 at a center in the vertical direction A2, would be used. In a case where three switch modules 1 are attached to the attachment frame 8, operating handles each of which has a dimension that is substantially the same as one-third of the opening 921, obtained by dividing the opening 921 at positions of one-third and two-third in the vertical direction A2, would be used.

The switch assembly 7 including the switch 3 is explained with reference to FIG. 2.

The switch assembly 7 according to the embodiment includes the switch 3 (the switch module 1 and the operating handle 2), the attachment frame 8, and a plate (decorative plate) 9.

The attachment frame 8 is configured to hold the switch module 1. The attachment frame 8 is made of synthetic resin or metal, and is shaped like a rectangular frame. The attachment frame 8 has an opening 81 in which the switch module 1 is placed. The attachment frame 8 includes two first beams 82 and two second beams 83. The two first beams 82 are on opposite sides of the opening 81 in the vertical direction A2. The two second beams 83 are on opposite sides of the opening 81 in the horizontal direction A1. The opening 81 is a space surrounded by the two first beams 82 and the two second beams 83. The opening 81 is shaped like a rectangle, and has a dimension which is substantially the same as total dimensions of three switch modules 1 arranged in the vertical direction A2.

An insertion hole 84 that allows a screw to be inserted into is formed in each first beam 82 in order to fix the first beam 82 to an installation member (such as a wall of a building). A screw hole 85 is also formed in a center part of each first beam 82 in the horizontal direction A1 to be disposed outside of the insertion hole 84 in the vertical direction A2.

Two through-holes 861 are formed in each second beam 83 in a center part in the vertical direction A2. The distance between the two through-holes 861 in each second beam 83 is the same as that between two attachment nails 631 on one side of the switch module 1. Two attachment nails 631 of a switch module 1 located at a center attachment position are to be engaged with the two through-holes 861. Also, two through-

holes

862, 863 are formed in one end part in the vertical direction A2 (upper end part) of each second beam 83. In addition, another two through-

holes

862, 863 are formed in the other end part in the vertical direction A2 (lower end part) of each second beam 83. Two attachment nails 631 of a switch module 1 are to be engaged with the upper-side two through-

holes

862, 863. Also, two attachment nails 631 of a switch module 1 are to be engaged with the lower-side two through-

holes

862, 863. Therefore, a switch module 1 located at the center attachment position is held by the paired two through-holes 861. Also, a switch modules 1 located at an upper attachment position is held by the paired upper-side two through-

holes

862, 863, and a switch modules 1 located at a lower attachment position is held by the paired lower-side two through-

holes

862, 863.

With regard to each second beam 83, a through-hole 864 is further formed between a pair of through-

holes

861 and 863 adjacent in the vertical direction A2 so that a switch module 1 can be held at a position other than the center attachment position, the upper attachment position, and the lower attachment position. In the embodiment, two through-holes 864 are formed in each second beam 83, where one of the two through-holes 864 is formed between an upper-side pair of the through-

holes

861, 863 and the other of them is formed between a lower-side pair of the through-

holes

861, 863. An attachment nail 631 of a switch module 1 is to be engaged with a through-hole 864.

The attachment frame 8 has a step 87 between a front face of a first beam 82 and a front face of a second beam 83 so that the front face of the second beam 83 is set back from the front face of the first beam 82. Therefore, the first and

second beams

82, 83 are formed so that, in a state where the attachment frame 8 is attached to an installation member, parts of the front faces of the second beams 83 where the through-holes 861 to 864 are formed are positioned rear side relative to parts of the front faces of the first beams 82 positioned in front of the installation member.

The plate 9 has an opening surrounding the operating handle 2 and is disposed on the front side (on the second side of the first direction A3) of the attachment frame 8. The plate 9 includes a plate body 91 and the plate cover 92.

The plate body 91 is made of synthetic resin material such as ABS resin, and is shaped like a rectangular frame. The plate body 91 has an opening 911. The plate body 91 has insertion holes 912. The insertion holes 912 are formed at positions corresponding to the screw holes 85 of the attachment frame 8. The plate body 91 can be attached to the attachment frame 8 by attachment screws that pass through insertion holes 912 and are screwed with screw holes 85. The opening 911 overlaps with the opening 81 of the attachment frame 8 in the front-rear direction A3 with the plate body 91 attached to the attachment frame 8. Also, three through-holes 913 are formed in each side beam of the plate body 91 along the vertical direction A2.

The plate cover 92 is detachably attached to the plate body 91 so as to cover the plate body 91. The plate cover 92 is made of synthetic resin material. A rectangular opening 921 is formed in a center of the plate cover 92. Engagement members configured to be engaged with the respective through-holes 913 of the plate body 91 are formed on a rear face of the plate cover 92 at positions corresponding to the through-holes 913.

With this configuration, the switch module 1 is attached to the attachment frame 8, the operating handle 2 is attached to the switch module 1, the plate body 91 is attached to the attachment frame 8, and the plate cover 92 is coupled to the plate body 91. The front face of the operating handle 2 is exposed (protrudes from the plate 9) through the

openings

911, 921 of the plate body 91 and the plate cover 92. Therefore, the operating handle 2 can receive a push operation.

As described above, the switch module 1 according to the embodiment includes the housing 11, the push-button 12, the stationary contact 14 and the movable contact 15. The push-button 12 has the operation face 121. The housing 11 holds the push-button 12 so that the push-button 12 is movable in the first direction A3. The stationary contact 14 is housed in the housing 11. The movable contact 15 is housed in the housing 11. The movable contact 15 is configured to be switched between in contact with and out of contact with the stationary contact 14 whenever the operation face 121 of the push-button 12 receives a pushing force in the first direction A3. The housing 11 includes the body 61 shaped like a case and a cover 62. The body 61 has the opening 611 that crosses (is perpendicular to) the first direction A3. The cover 62 is coupled to the body 61 to cover the opening 611 of the body 61. The parts of the rim of the opening 611 of the body 61 have the protrusions 65 that protrude in the first direction A3 to cover both the stationary contact 14 and the movable contact 15 as seen from the second direction (the vertical direction) A2 that is perpendicular to the first direction A3.

In the switch module 1 of the embodiment, the protrusions 65 are formed at the parts of the rim of the opening 611 of the body 61 so that the protrusions 65 cover the contacts 13 including the stationary contact 14 and the movable contact 15. Accordingly, in the switch module 1 of the embodiment, the boundary between the body 61 and the cover 62 can be positioned away from the contacts 13 while the housing 11 has a decreased height (decreased dimension in the front-rear direction A3). Therefore, in the switch module 1 of the embodiment, it is possible to avoid an electric arc near the boundary and also to give a sufficient distance (insulation distance) between the outside space of the housing 11 and the contacts 13. As a result, it is possible to improve arc-resistant property and also to decrease the size of the housing 11. In addition, in the switch module 1 of the embodiment, it is possible to suppress the leakage of the noise that occurs when the contacts 13 are opened or closed.

In the switch module 1 of the embodiment, due to the protrusions 65 at the parts of the rim of the opening 611 of the body 61, it is possible to suppress the possibility of occurrence of the displacement between the body 61 and the cover 62. In addition, in the switch module 1 of the embodiment, the cover 62 can be easily coupled to the body 61 because the protrusions 65 that are at the parts of the rim of the opening 611 of the body 61 and that protrude relative to remaining part of the rim can be used as a reference.

Preferably, as with the embodiment, the body 61 is made of material having a higher fire-resistant property and a higher tracking-resistant property than those of material of the cover 62.

In the switch module 1 of the embodiment, part of the switch module 1 around a region where an electric arc is to take place can be made of material having a higher fire-resistant property and a higher tracking-resistant property. Accordingly, the arc-resistant property can be further improved.

Preferably, as with the embodiment, the body 61 is made of thermosetting resin.

In the switch module 1 of the embodiment, since the body 61 is made of thermosetting resin, part of the switch module 1 around a region where an electric arc is likely to take place can easily have a higher fire-resistant property and a higher tracking-resistant property. Accordingly, the arc-resistant property is easily improved.

Preferably, as with the embodiment, the housing 11 is shaped like a rectangular solid extending in the length direction A1 that is perpendicular to each of the first and second directions A3 and A2. The stationary contact 14 and the movable contact 15 are housed in the housing 11 to face each other in the length direction A1. A protrusion 65 is contained in part of each side wall 613 of the body 61 along the length direction A1. In each side wall 613, the part containing the protrusion 65 of the side wall 613 further protrudes than remaining part of the side wall 613 in the first direction A3.

In the switch module 1 of the embodiment, the protrusion 65 is provided at the side wall 613 of the body 61 along the length direction (the horizontal direction) A1 so that the part of the side wall 613 further protrudes than the remaining part of the side wall 613. Accordingly, in the switch module 1 of the embodiment, a boundary (a boundary between the side wall 613 the body 61 and the side wall 622 of the cover 62) along the length direction A1, which is positioned closer to the contacts 13 than a boundary (a boundary between the side wall 614 the body 61 and the side wall 624 of the cover 62) along the width direction (the vertical direction A2), can be positioned away from the contacts 13 in the first direction A3. Accordingly, the boundary between the body 61 and the cover 62 can be positioned away from a possible arc which would be formed along the length direction (the horizontal direction) A1, i.e., a direction along which the movable contact 15 moves.

Preferably, as with the embodiment, the body 61 includes two latch projections 615 arranged along the length direction (the horizontal direction) A1 on the side wall 613. The cover 62 includes two latch pieces 625 each of which has a latch hole 626 with which a corresponding one of the two latch projections 615 is engaged. The protrusion 65 is positioned between the two latch pieces 625 in the length direction (the horizontal direction) A1 with the latch projections 615 engaged with the respective latch holes 626.

In the switch module 1 of the embodiment, the protrusion 65 is positioned between the two latch pieces 625 of the cover 62 in a state where the latch projections 615 of the body 61 are engaged with the respective latch holes 626 of the cover 62. Accordingly, in the switch module 1 of the embodiment, it is possible to engage the latch projections 615 with the latch holes 626 as similar to conventional switch modules, regardless of the presence of the protrusion 65 in the body 61.

Preferably, as with the embodiment, the body 61 is shaped like a case extending in the length direction A1 that is perpendicular to each of the first and second directions A3 and A2. The body 61 integrally has a center part 66 and side parts 67 on both sides of the center part 66 in the length direction A1. The stationary contact 14 and the movable contact 15 are disposed to face each other in the length direction A1 so as to cross a plane 100 that contains openings 670 of the side parts 67. The center part 66 has the protrusions 65 to cover (overlap with) the stationary contact 14 and the movable contact 15 as seen from the second direction A2.

In the switch module 1 of the embodiment, the contacts 13 (the stationary contact 14 and the movable contact 15) are disposed so as to cross the plane 100 that contains the openings 670 of the side parts 67. Accordingly, the height (the dimension in the front-rear direction A3) of the housing 11 can be decreased. Furthermore, since the center part 66 contains the protrusions 65, the electric arc that may take place in the contacts 13 can be prevented from leaking outside the housing 11.

Preferably, as with the embodiment, the switch module 1 is configured to be held by the attachment frame 8 that is configured to be attached to an installation surface.

The switch 3 according to the embodiment includes the switch module 1 and the operating handle 2. The operating handle 2 is disposed on the housing 11 to face the push-button 12. The operating handle 2 is configured to receive a push operation to transfer a pushing force by the push operation to the push-button 12.

The switch assembly 7 according to the embodiment includes the switch 3, the attachment frame 8 and the plate 9. The attachment frame 8 holds the switch module 1. The plate 9 has the opening surrounding the operating handle 2 and is attached to the attachment frame 8.

In the embodiment, the switch module 1 is a single-pole switch module, but the switch module 1 is not limited to the single-pole switch module. For example, the switch module 1 may be a three-way switch module as shown in FIG. 5. The switch module 1 shown in FIG. 5 includes, as contacts 13, two stationary contacts 141, 142 and two movable contacts 151, 152. The state of the switch module 1 is switched between a state where the movable contact 151 is in contact with the stationary contact 141 and a state where the movable contact 152 is in contact with the stationary contact 142 whenever a push-button 12 receives a pushing force. Note that, the movable contact 152 is out of contact with the stationary contact 142 when the movable contact 151 is in contact with the stationary contact 141. The movable contact 151 is out of contact with the stationary contact 141 when the movable contact 152 is in contact with the stationary contact 142.

While the foregoing has described what are considered to be the best mode and/or other examples, it is understood that various modifications may be made therein and that the subject matter disclosed herein may be implemented in various forms and examples, and that they may be applied in numerous applications, only some of which have been described herein. It is intended by the following claims to claim any and all modifications and variations that fall within the true scope of the present teachings.

Claims

A switch module comprising:
a push-button having an operation face;
a housing that holds the push-button so that the push-button is movable in a first direction;
a stationary contact housed in the housing; and
a movable contact that is housed in the housing and that is configured to be switched between in contact with and out of contact with the stationary contact whenever the operation face of the push-button receives a pushing force, wherein
the housing comprises:
a body shaped like a case having an opening that crosses the first direction; and
a cover coupled to the body to cover the opening of the body, and
part of a rim of the opening of the body has a protrusion that protrudes in the first direction to cover the stationary contact and the movable contact as seen from a second direction perpendicular to the first direction.
The switch module according to claim 1, wherein the body is made of material having a higher fire-resistant property and a higher tracking-resistant property than those of material of the cover.
The switch module according to claim 2, wherein the body is made of thermosetting resin.
The switch module according to any one of claims 1 to 3, wherein
the housing is shaped like a rectangular solid extending in a length direction that is perpendicular to each of the first and second directions,
the stationary contact and the movable contact are housed in the housing to face each other in the length direction, and
the protrusion is contained in part of a side wall of the body along the length direction, the part of the side wall further protruding than remaining part of the side wall in the first direction.
The switch module according to claim 4, wherein
the body comprises two latch projections arranged along the length direction on the side wall,
the cover comprises two latch pieces each of which has a latch hole with which a corresponding one of the two latch projections is engaged, and
the protrusion is positioned between the two latch pieces in the length direction with the latch projections engaged with the respective latch holes.
The switch module according to any one of claims 1 to 3, wherein
the body is shaped like a case extending in a length direction that is perpendicular to each of the first and second directions, the body integrally having a center part and side parts on both sides of the center part in the length direction,
the stationary contact and the movable contact are disposed to face each other in the length direction so as to cross a plane that contains openings of the side parts, and
the center part has the protrusion to cover the stationary contact and the movable contact as seen from the second direction.
The switch module according to any one of claims 1 to 6, wherein the switch module is configured to be held by an attachment frame that is configured to be attached to an installation surface.
A switch comprising:
the switch module according to any one of claims 1 to 6; and
an operating handle disposed on the housing to face the push-button and configured to receive a push operation to transfer a pushing force by the push operation to the push-button.
A switch assembly comprising:
the switch according to claim 8;
an attachment frame that holds the switch module; and
a plate that has an opening surrounding the operating handle and that is disposed on the attachment frame.