Modular Wall-Mounted Electrical Control Device

Abstract

A family of wall-mounted electrical fixtures, both for lighting control and electrical power or signal delivery, having a modular design. Said modular design predominately isolating those components that are directly connected to in-wall wiring within a wall-mounted base and low-voltage control and communication components, such as sensors, user-interface elements, programmable logic and wireless communication modules, within an aesthetically-appealing, easily-detachable faceplate assembly.

Claims

1. An electrical fixture for direct mounting in a wall or receptacle box, comprising of at least two modules releasably retained together by cooperating latches, the modules comprising: a. a power module attached to the wall or receptacle box comprising: i. an electrical main connection point for connecting the power module to an electrical main; ii. a flange covering the wall opening or electrical receptacle box opening to prevent exposure to live electrical mains connections; iii. an electrical connection point for connecting the power module to a removable user interface module; iv. cooperating mechanical latches for physically retaining a user interface module to said power module; and v. electronic components for regulating electrical main power delivery to fixture-controlled loads and for delivering power to a user interface module; and b. a user interface module, sized to removably attach to a power module while the power module remains installed and in use without removing or disassembling the power module and comprising: i. a primary utility device disposed along the user interface module's primary surface; ii. a means of controlling said primary utility device either by physical interaction, or wireless communication, with control elements disposed on or within said user interface module; iii. electronic components for receiving control signals and delivering said signals to a connected power module or networked electrical fixture; iv. an electrical connection point for connecting the user interface module to a cooperating electrical connection point on a power module suitable for transmission of power and communication signals; and v. cooperating mechanical latches for physically connecting to a power module.

2. The modular electrical fixture of claim 1 wherein the power module contains an AC-DC power converter for producing a DC voltage suitable for powering a user interface module from connected AC electrical mains.

3. The modular electrical fixture of claim 1 wherein the power module contains elements for switching on/off one, or more, connected electrical loads.

4. The modular electrical fixture of claim 1 wherein the power module contains electronic components for measuring the power consumption of connected electrical loads and communicating said measurements to a connected user interface module.

5. The modular electrical fixture of claim 1 wherein the power module contains one or more lights that illuminate when the user interface module is detached as a visual indicator that the power module remains connected to energized electrical mains.

6. The modular electrical fixture of claim 1 wherein the user interface module includes lights that may serve as a backlight, night light or communicate device status signals.

7. The modular electrical fixture of claim 6 wherein the user interface module includes at least one motion sensor such that user interface module lights illuminate in response to user presence detection.

8. The modular electrical fixture of claim 1 wherein the user interface module includes wireless communication electronics enabling remote control of said user interface module and facilitating wireless communication with nearby networked devices.

9. The modular electrical fixture of claim 8 wherein the user interface module includes temperature and/or humidity sensing electronics for monitoring ambient conditions and wirelessly communicating those ambient conditions to a thermostat or equivalent climate control device.

10. The modular electrical fixture of claim 1 wherein the primary utility device disposed on the user interface module is a light switch.

11. The user interface module of claim 10 wherein the light switch is a dimmable light switch.

12. The user interface module of claim 11 wherein light dimming may be controlled by a touch sensitive region on the user interface module.

13. The user interface module of claim 11 wherein light dimming may be controlled by a rotary dial disposed on the user interface module's primary surface.

14. The user interface module of claim 13 wherein the rotary dial for controlling dimming level is magnetically coupled to the user interface module's primary surface and may be detached and used to remotely control light dimming by communicating wirelessly with its parent user interface module.

15. The user interface module of claim 11 wherein light dimming intensity is displayed by a light bar illuminated proportionally to light dimming level.

16. The user interface module of claim 11 wherein an ambient light sensor is incorporated within the user interface module's electronics such that light dimming level may be adjusted automatically in response to changes in ambient light level to maintain a constant light intensity in the vicinity of the user interface module.

17. The user interface of claim 11 wherein a realtime clock is included in the user interface module's electronics such that light intensity may be adjusted automatically in response to time of day.

18. The modular electrical fixture of claim 1 wherein the primary utility device disposed on the user interface module is an electrical receptacle or duplex electrical receptacle.

19. The user interface module of claim 18 wherein load detection components are included within the user interface module's electronics such that the electrical receptacle disposed on the user interface module's primary surface is only electrically energized with AC mains voltage if a qualified electrical load is inserted into the receptacle and not powered otherwise.

20. The modular electrical fixture of claim 1 wherein the primary utility device disposed on the user interface module is a cable, telephone, or network connection port or a plurality thereof.

21. The modular electrical fixture of claim 1 wherein the primary utility device disposed on the user interface module is a thermostat or equivalent climate control device.

22. The modular electrical fixture of claim 1 wherein the primary utility device disposed on the user interface module is a LCD, or equivalent, screen.

23. The modular electrical fixture of claim 1 wherein the primary utility device disposed on the user interface module is a wireless network signal repeater.

24. The modular electrical fixture of claim 1 wherein the user interface module may have customizable aesthetic elements for coordinating with home décor and wall paint colors.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Embodiments of the present invention will now be described, by way of example only, with reference to the attached Figures, wherein:

[0022] FIG. 1 is a first exploded perspective view of an embodiment fashioned as a lighting control switch;

[0023] FIG. 2 is a front perspective view of the wall-mounted base of FIG. 1, partially sectioned to reveal internal components;

[0024] FIG. 3 is an exploded rear perspective view of the wall-mounted base of FIG. 1;

[0025] FIG. 4 is another view thereof with rear cover removed to reveal internal components;

[0026] FIG. 5 is an exploded front perspective view of the faceplate assembly of FIG. 1;

[0027] FIG. 6 is an exploded rear perspective view thereof;

[0028] FIG. 7 is an exploded front perspective view of the button assembly of FIG. 1;

[0029] FIG. 8 is a front perspective view of the electronics assembly of the faceplate component of FIG. 1;

[0030] FIG. 9 is a rear perspective view thereof;

[0031] FIG. 10 illustrates an exemplary alternate embodiment of FIG. 1 incorporating an alternative style of faceplate assembly wherein a button is fashioned as an integral part of a front housing component, rather than a separate component;

[0032] FIG. 11 illustrates an exemplary alternate embodiment of FIG. 1 incorporating an alternative rotary button style;

[0033] FIG. 12 illustrates an exemplary alternative embodiment of the present invention wherein the described wall-mounted electrical control is fashioned as a duplex electrical receptacle.

DETAILED DESCRIPTION

[0034] The present invention is directed to a modular wall-mounted electrical control, fashioned as either an electrical switch or receptacle and fitting within a standard electrical receptacle box.

[0035] Reference is made below to specific elements, numbered in accordance with the attached figures of one embodiment and several variations of that embodiment. The discussion below should be taken to be exemplary in nature and not as limiting of the scope of the present invention. The scope of the present invention is defined in the claims and should not be considered as limited by the implementation details described below, which as one skilled in the art will appreciate, can be modified by replacing or rearranging elements with equivalent functional or aesthetic elements.

[0036] An example of a first embodiment of a modular wall-mounted electrical control in accordance with the present invention is shown in FIG. 1. The modular wall-mounted electrical control 100 generally comprises a wall-mounted base 110 and a detachable faceplate assembly 120.

[0037] According to various embodiments, the wall-mounted base 110 compromises an outer enclosure, consisting of a front 200 and a rear 210 housing, an electronics assembly 220 and an electrical interface 230 for connecting to existing wiring within a building structure's walls as illustrated in FIG. 2.

[0038] Front housing 200 may be formed as, or incorporate features of, a wall plate with mechanical interfaces 240 such that it may be secured to a wall-mounted electrical outlet box, in place of a standard wall plate, with screws 250 similarly to the manner in which a typical wall plate is installed over an outlet box. Front housing 200 may be sized to fully cover the opening of a wall-mounted electrical outlet box to which it is secured to shield users from any exposed high-voltage wires and connections that may be present within said outlet box. Furthermore, front housing 200 may be fashioned to include faceplate mechanical interfaces 260 and electrical interfaces 270 for securing and powering, respectively, detachable faceplate assembly 120.

[0039] Rear housing 210 may fully enclose all, or most, internal components of wall-mounted base assembly 110 and may be attached to front housing 200 with screws 300 (as illustrated in FIG. 3) or other removable or irremovable attachment means including, but not limited to, bolts, rivets or alternative mechanical fasteners, heat stakes, snap fits, interference fitting features, ultrasonic welds, laser welds or adhesive. Said rear housing 210 is sized to fit within a standard electrical outlet box and is typically fully concealed within the wall once wall-mounted base assembly 110 is securing to an electrical outlet box or wall.

[0040] Both front 200 and rear 210 housings are typically fabricated from an electrically-insulating material, such as a thermoplastic or thermoset material compatible with relevant electrical and consumer product safety requirements as may be applicable in each geographic region of use. Alternate materials of construction are also possible, including metals, woods, ceramics, stone, concrete, glass and composite materials provided they do not create electrical short circuits, expose potentially dangerous electrical voltages to end users, or pose any potential fire, or other, hazards that may preclude them from meeting applicable electrical or fire safety standards.

[0041] Electronics assembly 220 is mounted within the enclosure formed by front housing 200 and rear housing 210. Electronics assembly 220 comprises a printed circuit board 400 sized to fit within said enclosure, which may incorporate mounting features 410 for securing to either the front housing 200 or rear housing 210, electrical interface components 230 (which extend through rear housing 210) for electrically connecting to existing wiring within a building structure's walls and electronic components 420, which are electrically connected to electrical traces on printed circuit board 400 so as to create functional electrical circuits as depicted in FIG. 4.

[0042] Mounting features 410 on printed circuit board 400 may include, but are not limited to, holes, slots or board edge geometry to which screws, bolts, rivets, alignment pins, heat stakes, snap fits, or interference fitting features may mate with, or dedicated regions on printed circuit board 400 suitable for establishing an ultrasonic weld, laser weld or adhesive bond. Mating features to those found on printed circuit board 400 may be included on either front housing 200 or rear housing 210 such that the printed circuit board 400 may be secured within wall-mounted base 110 once assembled.

[0043] Electrical interface components 230 may comprise wires connected on one end to printed circuit board 400 and free hanging, protruding through rear housing 210, on the other end such that they may be connected to existing building wiring by splicing or with the use or wire nuts, or equivalent connectors, or may comprise mechanical connectors directly attached to printed circuit board 400 such as screw terminals, spring-loaded connectors, push-in connectors, or posts, which protrude, or are accessible through, rear housing 210, to which building wiring may be directly connected without the use of intermediary wires.

[0044] Electronic components 420 typically comprise at least one load switching component 430, an alternating current to direct current (AC/DC) power converter 440 and a low voltage electrical connector 270 for interfacing with detachable faceplate assembly 120.

[0045] Load switching component 430 may comprise one, or more, physical switches, mechanical relays, solid state relays, transistors, of alternative electrical components and circuitry capable of connecting and disconnecting AC line voltage to a connected load at the rated current of said connected load. In embodiments wherein wall-mounted electrical control 100 is a switch, load switching component 430 may connect and disconnect power to one, or more, wired electrical circuits, such as those powering room lighting or electrical receptacles, while in embodiments wherein wall-mounted electrical control 100 is a receptacle, load switching components 430 may be used for connecting and disconnecting power to individual receptacle outlets of said wall-mounted electrical control 100.

[0046] AC/DC converter 440 may comprise an integrated circuit component, or a collection of components forming a suitable power conversion circuit, of which numerous topologies and designs are well-known to those skilled in the art. AC/DC converter 440 generates a low-voltage (typically less than 60V) direct current (DC) output, which may commonly include, but is not limited to, 24V, 12V, 10V, 6V, 5V, 3.3V, 3V or other voltage as may be required to power and/or communicate with low-voltage DC integrated circuit components chosen for any particular embodiment of the present invention. The low-voltage DC output from AC/DC converter 440 may be directed to power components on printed circuit board 400 such as LEDs, LCD displays, sensors (touch, motion, sound, light, temperature, humidity, electrical current, power, etc.), sound-generating devices, relays, switches, microcontrollers, wireless communication modules, or the like, and/or may be directed to faceplate electrical interface 270 for powering components within detachable faceplate assembly 120.

[0047] Faceplate electrical interface 270 serves as the primary low-voltage power and communication interface between wall-mounted base 110 and detachable faceplate assembly 120. Faceplate electrical interface 270 may comprise a multi-pin connector such as a fixed pin header, spring pin array, spring-loaded connector, exposed contact pads on printed circuit board 400, or the like. Independent contacts on electrical interface 270 may be used to transmit power from wall-mounted base 110 to detachable faceplate 120, signals from sensors or control electronics within wall-mounted base 110 to detachable faceplate 120 or signals from sensors or control electronics within faceplate 120 to wall-mounted base 110, such as may be required to actuate load-switching component 430 on printed circuit board 400 within base 110 from a remote signal originating in detachable faceplate 120.

[0048] Detachable faceplate assembly 120 may be fashioned in numerous distinct forms. In one embodiment of the present invention, detachable faceplate assembly 120 may be fashioned as a switch for turning on/off connected electrical loads including, but not limited to, lights or connected electrical receptacles. In said embodiment, detachable faceplate assembly 120 comprises a front housing 500, button assembly 510, rear housing 520 and electronics assembly 530 as illustrated in FIG. 5.

[0049] Front housing 500 serves as the key aesthetic element of the present invention's industrial design and as such can be customized to achieve multiple different appearances. It may be fabricated from thermoplastic or thermoset materials similar to materials traditionally used on conventional wall-mounted electrical controls or may be fabricated from more unconventional materials including, but not limited to, metals, woods, ceramics, stone, concrete, glass and composite materials provided they do not create electrical short circuits, expose potentially dangerous electrical voltages to end users, or pose any potential fire, or other, hazards that may preclude them from meeting applicable electrical or fire safety standards. Front housing 500 may also be painted or stained to match the décor of the room within which wall-mounted electrical control 100 is installed.

[0050] Rear housing 520 may fully enclose all, or most, internal components of faceplate assembly 120 and may be attached to front housing 500 with screws 600 (as illustrated in FIG. 6), or other removable or irremovable attachment means including, but not limited to, bolts, rivets or alternative mechanical fasteners, heat stakes, snap fits, interference fitting features, ultrasonic welds, laser welds or adhesive. Rear housing 520 incorporates complementary mechanical interface features 610 and electrical interface features 620 to those found on front housing 200 of wall-mounted base 110 for enabling the detachable faceplate assembly 120 to be attached to, and electrically powered by and communicate with, wall-mounted base 110. Mechanical interface features 610 are fashioned such that they engage with mechanical interface features 260 on wall-mounted base front housing 200 without the use of any tools by using snap fitting features including, but not limited to, spring-actuated detents, magnetic couplings, friction fit features, or the like. Electrical interface features 620 are fashioned such they inherently engage with mating electrical interface features 270 on wall-mounted base front housing 200 when mechanical interface features 610 are engaged with mechanical interface features 260 and automatically disengage when the detachable faceplate assembly 120 is mechanically disengaged from wall-mounted base 110. Rear housing 520 may be fabricated from similar materials of construction as front housing 500, although rear housing 520 may not necessarily require the same level of aesthetic attention since it is often concealed once attached to wall-mounted base 110 in many embodiments.

[0051] Button assembly 510 serves as the primary physical user interface to wall-mounted electrical control 100. Although numerous embodiments are possible, in typical embodiments, one example of which is illustrated in FIG. 7, button assembly 510 comprises a physical button 700 and one, or more, indicator light assemblies 710.

[0052] Physical button 700 may be fabricated from any of the materials that front housing 500 may be fabricated, although it is not a requirement that it be fabricated from the same material as front housing 500 in any particular embodiment. Physical button 700 may be pressure-sensitive, touch-sensitive and/or proximity-sensitive and electrically coupled with electronics assembly 530 such that physical button presses, touches, or gestures performed on, or in close proximity to, the button may be converted into electrical signals and recognized as interactions. Said interactions may include a momentary button press, rapid double-tap, press-and-hold, sliding gesture and others, which electronics assembly 530 may be configured to recognize.

[0053] Indicator light assembly 710 on button assembly 510 comprises one, or more, printed circuit board 720, populated with light-emitting components 730, such as a single LED, a series of LEDs or LCD, OLED, or similar, displays, which may provide backlighting and visual status indication such as whether an electrical control is on or off or, in embodiments wherein wall-mounted electrical control 100 is a dimmable light switch, may illuminate proportionally to controlled lighting intensity. In some embodiments, sensors 740 such as ambient light, proximity, touch, motion, sound or others may also be disposed on indicator light assembly 710 as additional sources of input signals to electronics assembly 530 for determining appropriate responses as electronics assembly 530 may be configured to recognize.

[0054] Electronics assembly 530 is mounted within the enclosure formed by front housing 500 and rear housing 520. Electronics assembly 530 comprises at least one printed circuit board 800 sized to fit within said enclosure, which may incorporate mounting features 810 for securing to either the front housing 500 or rear housing 520, electronic components 820, which are electrically connected to electrical traces on printed circuit board 800 so as to create functional electrical circuits and an electrical interface 900 to wall-mounted base, as depicted in FIG. 8 and FIG. 9.

[0055] Mounting features 810 on printed circuit board 800 may include, but are not limited to, holes, slots or board edge geometry to which screws, bolts, rivets, alignment pins, heat stakes, snap fits, or interference fitting features may mate with, or dedicated regions on printed circuit board 800 suitable for establishing an ultrasonic weld, laser weld or adhesive bond similar to mounting features previously described for mounting electronics assembly 220 into wall-mounted base 110 housing. Mating features to those found on printed circuit board 800 may be disposed on either front housing 500 or rear housing 520 such that the printed circuit board 800 may be secured within detachable faceplate 120 once assembled.

[0056] Electronic components 820 typically comprise a microcontroller or programmable logic component 830, a wireless communication module 840 and miscellaneous components and circuitry for powering and interfacing with sensors 850, such as motion, ambient light, sound, proximity or others as may be integrated into electronics assembly 530, and user interface components 910, such as LEDs, LCDs, sound generating devices, and the like. Programmable logic component 830 and wireless communication module 840 may be distinct integrated circuit components or comprise a single system-on-chip (SOC) component capable of performing both functions. Programmable logic component 830 is responsible for storing default behavioural configuration settings and responses, wireless pairing information, security, and user-configurable device settings while wireless communication module 840 enables transmission of control and communication signals between a programming device, such as a smartphone, tablet, laptop, desktop computer or purpose-built programming device and the electrical control device 100 or between multiple electrical control devices 100 that have been configured to communicate with each other.

[0057] Examples of user-configurable device settings that may be stored in programmable logic component 830 and modified via wireless communication module 840 include, but are not limited to: [0058] Device identification settings such as name, location, serial number, and the like; [0059] Security information such as password, known devices allowed to modify device settings, and/or known wireless networks or devices which have been granted access to communicate with, control, or be controlled by said device; [0060] Device electrical load control, backlight and button indicator light behaviours in response to sensor inputs, such as motion or sound detection, ambient light level and/or time of day; [0061] Device electrical load control, backlight and button indicator light behaviours in response to user interactions with button 510 such as single-tap, rapid double-tap, press-and-hold, sliding gestures, or the like, in addition to sensor inputs such as motion or sound detection, ambient light level and/or time of day.

[0062] In certain embodiments, electronics assembly 530 may also include onboard energy storage components 920, such as a rechargeable battery or capacitor, or energy harvesting components such that electronics assembly 530 may continue to be powered even when faceplate assembly 120 is detached from wall-mounted base 110 or in the event of a power failure at wall-mounted base 110. Energy storage components 920 enable configuring device settings when faceplate assembly 120 is detached from wall-mounted base 110, such as at the point of purchase before the device is unboxed or installed, and/or allows faceplate backlight and button lighting and sensor components to continue operating to provide emergency lighting in a power outage situation.

[0063] Electrical interface 900 serves as the mating half of faceplate electrical interface 270 on wall-mounted base 110 and is the primary low-voltage power and communication interface between wall-mounted base 110 and detachable faceplate assembly 120. Electrical interface 900 may comprise a multi-pin connector such as a fixed pin header, spring pin array, spring-loaded connector, or solder pads on printed circuit board 800, which may be contacted by a spring-loaded connector on mating faceplate electrical interface 270. Independent pins or pads on electrical interface 900 may be used to transmit power from wall-mounted base 110 to detachable faceplate 120, signals from sensors or control electronics within wall-mounted base 110 to detachable faceplate 120 or signals from sensors or control electronics within faceplate 120 to wall-mounted base 110.

[0064] Additional embodiments of the present invention are shown in FIGS. 10-12. FIGS. 10 and 11 illustrate alternative embodiments of faceplate assembly 120 of an electrical switch wherein button assembly 510 is fashioned as an integral part of front housing 500 in FIG. 10 and as a rotary knob in FIG. 11.

[0065] FIG. 12 illustrates an embodiment wherein wall-mounted electrical control 100 is fashioned as an electrical receptacle instead of a switch. In said embodiment, the components and functionality described above are directed towards a receptacle. All functionality previously described is preserved in said embodiment, with load switching components 430 on electronics assembly 220 of wall-mounted base 110 configured to control power to each of the two electrical outlets 1200 of the illustrated duplex receptacle rather than switching an external electrical circuit as is the case in embodiments wherein the wall-mounted control is fashioned as an electrical switch. Embodiments such as that illustrated in FIG. 12 may also include additional receptacle-specific control electronics such as a ground fault circuit interrupter (GFCI) and arc fault circuit interrupter (AFCI) components and/or be configured such that load switching components 430 automatically turn themselves “on” or “off” as qualified electrical loads are inserted or removed, respectively, from each receptacle, such that receptacles are de-energized when not in use to minimize the risk of electrical shock.

[0066] Additionally, embodiments such as that illustrated in FIG. 12 may be directed towards auxiliary receptacle applications wherein electrical outlets 1200 may be replaced by auxiliary receptacles for typical household services such as telephone, cable television, internet, or the like. Said embodiments do not require load switching components 430 as may be the case in switch and electrical receptacle embodiments, but may be desirable to coordinate the aesthetic appearance of all wall-mounted fixtures in a home or office. In said embodiments, light-emitting components 730 on indicator light assembly 710 may serve as status indicator symbols, such as illuminating when a telephone is ringing, and/or serve as nightlights in the dark.

[0067] Although the present invention has been described in relation to particular embodiments thereof, many other variations and modifications and other uses will become apparent to those skilled in the art. For example, according to various embodiments, the button, AC electrical receptacles, or auxiliary receptacles, could instead be replaced by a decorative lighting element, digital display, or other similar devices as would typically be wall-mounted within a structure. It is preferred, therefore, that the present invention be limited not by the specific embodiments disclosed herein, but only by the appended claims.