TECHNICAL FIELD

[001] This invention relates to a unique enclosure for a light dimmer controller, the kind of which utilises a digital rotary encoder wherein the rotation of the metal shaft of the digital rotary encoder provides for a generatable signal indicative of a request of a user to increase or decrease light brightness of the lamp under the control of the light dimmer controller and wherein the axial movement of the metal shaft of the digital rotary encoder provides a generatable signal indicative of a request of the user to turn on, off or program functional settings for the lamp under the control of the light dimmer controller.

[002] More particularly this invention relates to such an enclosure arrangement referenced above wherein any potentially electrical live parts of the light dimmer controller when mounted to the electrical wall plate are inaccessible by a user or operator of the dimmer.

BACKGROUND ART DISCUSSION

[003] Light dimmer controllers utilising digital rotary shaft encoders include a metal actuating shaft which is classifiable or definable potentially as a live part which means that under the laws, regulation and/or Industry Standards of many countries this requires that such parts are not to be accessible by a user once the light dimmer controller has been mounted to the electrical wall plate for operability in the control of the related lamp associated with the dimmer.

[004] For the most part conventional electrical wall plates could either be a single or multi piece arrangement including a large external face or frame with a small cut-out to which the enclosure for the light dimmer controller would be physically mounted allowing a portion of the shaft to protrude out therefrom wherein a user operable control knob would be attachable to that protruding portion of the shaft. [005] Digital rotary encoders rely upon metal actuating shafts because while the portion of the metal shaft available to the external operable control knob may be of a significant enough diameter to absorb inherent mechanical stresses associated with the operability of the control knob placed upon it by the user, that part of the metal shaft that enters the digital rotary encoder has a significantly reduced diameter and accordingly if one was to rely upon a shaft made from a material with safe electrical insulating properties, such as plastic, the structural integrity of such material from a mechanical stress point of view may be in adequate hence the requirement to rely upon a metal actuating shaft for the digital rotary encoder.

[006] Presenting a portion of the metal actuating shaft externally from the electrical wall plate making the metal shaft accessible to a user would be unacceptable, again as introduced above, as the metal actuating shaft is definable as a live part and therefore no such parts should be accessible to the user if the requisite and associated laws, regulations and/or Industrial Standards are to be adhered to.

[007] Still further, it also needs to be recognised that the user operable control knob may in some instances need to be replaced without necessarily having to replace a pre-existing mounted electrical wall plate with the light dimmer controller connected thereto.

[008] Therefore there remains the need for potential user accessibility to a portion of the shaft protruding out from the enclosure arrangement of the dimmer light controller when mounted to the electrical wall plate but not at the expense of exposing the user to 'electrical live parts'.

[009] Accordingly it is an object of this invention to provide for an enclosure arrangement for a light dimmer controller utilising a metal actuating shaft of a digital rotary encoder wherein the metal shaft is insulated such that a user of the light dimmer controller when mounted to the electrical wall plate will have no accessibility to any electrically live parts of the light dimmer controller. [010] Further objects and advantages of the invention will become apparent from a complete reading of this specification.

SUMMARY OF THE INVENTION

In one form of the invention there is provided a light dimmer controller mountable to an electrical wall plate, said arrangement including: a main longitudinal body wherein a light dimmer controller including a digital rotary encoder having a metal shaft is supportable therein said main longitudinal body, wherein the metal shaft of the digital rotary encoder is characterised that upon rotation of said metal shaft provides for a generatable signal indicative of a request of a user to increase or decrease light brightness of a lamp under control of said light dimmer controller and wherein axial movement of said metal shaft provides a generatable signal indicative of a request of the user to turn off, on or programmable functional settings of the lamp under the control of said light dimmer controller; an insulator cap adapted to be fastenably configurable about a portion of said metal shaft of the digital rotary encoder, said insulator cap characterised with an external contoured profile for frictional fixed attachment of a user operable control knob for rotation and/or axial movability of said digital rotary encoder metal shaft by the user when said user engages said user operable control knob; a retaining member mounted internally within at least a partially closed distal end of the main longitudinal body, wherein the at least partially closed distal end of the main longitudinal body is at an electrical wall plate engaging end of said main longitudinal body, said retaining member including an aperture which when the light dimmer controller is supported therein said main longitudinal body, said insulator cap fastenably configured about the portion of said metal shaft is protrudable out therefrom said aperture of the retaining member to provide to the user an electrically insulated access to the external contoured profile of the insulator cap for the user to attach the user operable control knob and maintain electrical insulation from the metal shaft for the user during subsequent rotation or axial movement of the user operable control knob by the user.

[01 1] In preference the retaining member includes a generally circular shaped aperture.

[012] In preference the insulator cap has a larger diameter at an open end relative to a diameter at an opposite end such that the larger diameter at the open end of said insulator cap allows said insulator cap to be retained within the main longitudinal body of the enclosure as the portion of the metal shaft covered by the insulator cap protrudes out through the generally circular shaped aperture of the retaining member.

[013] Advantageously as that portion of the metal actuating shaft that protrudes out from the mounted electrical wall plate to which the user operable control knob is attachable thereto is completely encapsulated by the insulator cap no 'electrical live part' is accessible by the user despite the fact that the user will be able to, as required, attach their own or replace an existing operable control knob.

[014] In preference the open end of the insulator cap includes a generally lateral skirt or rim.

[015] In preference the retaining member includes a raised shouldered platform of a configuration to match the aperture at a closed end at the wall engaging end of the main longitudinal body, wherein the raised platform or surface of the retaining member includes or defines the generally circular aperture to which the user engageable end of the insulator cap encapsulating the portion of the metal shaft is protrudable out therefrom.

[016] Advantageously, the raised shouldered platform as it extends out from the main longitudinal body is able to firstly present the requisite aperture shape for the insulator cap to pass there through to completely encapsulate appropriately that portion of the metal shaft protruding out from the light dimmer controller but at the same time as the retaining member is mounted internally within the main longitudinal body and the raised platform portion extends out from the closed end of the main longitudinal body provides a means in which when the shaft is axially moved in as a user pushes down on the operable control knob for example to turn on, off or program functional settings for the lamp under the control of the light dimmer controller, this degree of axial movement is restricted, that if the operable control knob is pushed by the user with excessive force that force will be supported without damage against the internal workings of the digital rotary encoder as the operable knob is prevented from further axial movement by the abutment between the operable control knob and the raised shouldered platform of the retaining member protruding out from the end of the main longitudinal body of the enclosure

arrangement.

[017] As will be discussed in greater detail shortly hereafter in relation to further preferred embodiments, this gap created by the shouldered platform between the user operable control knob and the closed end of the enclosure arrangement which is engaging the wall plate, will also allow a gap such that any lighting within the light dimmer controller will be able to spill out under the knob even when the knob has been operably pushed in by the user in cases as introduced above.

[018] In preference the insulator cap is shaped generally as a hexagonal prism with six uniform and regular longitudinal side peripheral faces with the top of the hexagonal prism slightly truncated and/or distorted with a flat surface to provide a reduced diameter of the top face when compared with a diameter of the base and/or open end of the insulator cap.

[019] As introduced above, the differences in diameter between the top face or base face of the generally tapered or distorted hexagonal prism allows for the insulator cap to pass through the aperture of the retaining member initially so it can protrude out from the main longitudinal body of the enclosure but then be prevented from any further extension thereout by the interference or abutting engagement with the rim of the aperture of the retaining member up against the side or base of the insulator cap. [020] In preference each longitudinal face or at least a proportion of said faces, of the generally distorted hexagonal shaped prism of the insulator cap includes a longitudinal raised rib, preferably made of resilient plastic.

[021] In preference the user operable control knob includes an internal column having a hollow chamber with a defined shape so as to have a corresponding configuration with the external longitudinal face of the insulator cap so that the user operable control knob and the insulator cap can be joined together through an interference fit and/or frictional mating.

[022] In preference the internal defined hollow column or chamber of the operable control knob includes a matching distorted slightly hexagonal prism configuration with internal slots so that the faces of the hexagonal prism of the internal column of the user operable control knob may have an interference or frictional mating relationship with the corresponding faces of the general hexagonal prism shape of the insulator cap wherein the raised longitudinal ribs on the respective faces of the hexagonal prism of the insulator cap are restable or nestable therein the defined slots provided for by the internal column or chamber of the user operable control knob.

[023] In preference the insulator cap has an internal cross sectional infill along its longitudinal length which defines a hollow portion and at least one solid portion.

[024] An advantage of such an arrangement is that rather than having a completely hollow internal infill of the insulator cap by selectively moulding into the arrangement an internal moulded slots, ridges or abutments will allow the insulator cap to frictionally fit or mate with more than just a single kind of metal actuating shaft of differing digital rotary encoders.

[025] As is to be expected, if one was to have an interference type fit between the insulator cap and the metal actuating shaft without the requirement of any additional fastening components such as a screw or rivet, there would be the need therefore to be able to have the internal configuration of the insulator cap moulded in such a way so that it can present internal sides and/or abutments for the metal shaft to be pressed up and encapsulated thereabout in a resilient fit.

[026] In preference the main longitudinal body is made of transparent material, preferably transparent plastic.

[027] In preference the insulator cap is made of transparent material, preferably transparent plastic.

[028] In preference the retaining member is made of transparent material, preferably transparent plastic.

[029] Advantageously, through the use of transparent material, indicator lights used by the light dimmer controller will be able to pass out through the transparent plastic to be visible from the front of the enclosure either beside or behind the user operable control knob when such an operable control knob is attached to the insulator cap which is extended out from the main longitudinal body of the enclosure when mounted to the electrical wall plate.

[030] Advantageously, this enclosure arrangement will allow the replacement of the traditional potentiometer in a light dimmer controller with a digital rotary encoder requiring the use of a metal actuating shaft without creating any issues that may fall foul of laws, regulations and Industrial standards wherein electrically "live parts" must not be able to be accessed by the user, including such metal shafts.

[031] The unique use of the insulator cap provides a barrier between the metal actuating shaft and although a user will be in a position to apply their own or swap the user operable control knob which will operate the metal actuating shaft, such an activity however will not involve making any contact with the metal actuating shaft per se, as the metal shaft is appropriately encapsulated and inaccessible to the user through the use of the insulator cap. [032] The momentary action push switch, attached to the metal actuating shaft as the digital rotary encoder mechanism requires the provision for a small axial movement to activate the switch for this enclosure arrangement avoids the

transmitting of excessive axial forces exerted by the user on the operable control knob thereby preventing any damage to the fragile components of the light dimmer controller through the unique use of the raised shouldered platform of the retaining member mounted internally within the main longitudinal body of the enclosure arrangement at the wall engaging end.

[033] This slightly raised shouldered platform, while limiting any potential excessive axial forces exerted by the user of the operable control knob, also prevents the user operable control knob from being pressed down entirely upon the end of the main longitudinal body or the front face of the electrical wall plate, providing a slight gap through which visual indicator light or illumination will be able to still pass from the inside of the enclosure arrangement containing the light dimmer controller to the outside.

[034] Accordingly in its preferred embodiments the enclosure arrangement of this invention will be able to provide transparency within the material used to allow light from an indicator to pass through from the inside of the enclosure to the outside to be observed by a user all with the ability to be able to use a metal actuating shaft which is protected by the unique insulator cap thereby not exposing any 'live electrical parts' to the user.

[035] As introduced above, the internal moulding or contouring of the insulator cap is configured so that when encapsulating the metal actuating shaft of the digital rotary encoder it is adapted for a tight frictional fit to avoid rotation or any translation and to allow at least two different shafts to be through an interference fit engaged frictionally within the internal contouring of the insulator cap.

[036] Through the inventive use of the slightly truncated hexagonal pyramid shape this will allow the user to attach the operable control knob in any one of six rotational positions instead of the single allowed rotational position as required to fit the single "flat" operable control knob of conventional arrangements. This freedom of being able to easily position the user operable control knob about the hexagonal shape of the insulator cap rather than the restricted configuration provided by a conventional arrangement is possible because the absolute rotational position of the operable control knob rotated by the user conveys no information for the light dimmer controller utilising a digital rotary encoder which contrasts with the use of

conventional potentiometers where this is not the case.

[037] Advantageously through the use of the longitudinal raised ridges on each of the longitudinal side faces of the insulator cap facilitates locking the user operable control knob with the insulator cap as the ridges are resiliently pressured into position within the slots in the underside of the operable control knob.

[038] In order now to describe the invention in greater detail a series of preferred embodiments will be presented with the assistance of the following illustrations and accompany text.

BRIEF DESCRIPTION OF THE DRAWINGS

[039] Figure 1 is a front perspective view of the insulator cap of the enclosure arrangement in a preferred embodiment of the invention.

[040] Figure 2 is a perspective top view of Figure 1.

[041] Figure 3 is a perspective internal view looking into the insulator cap shown in Figure 1.

[042] Figure 4 is a perspective view of the retaining member mountable internally within the main longitudinal body of the enclosure arrangement in a preferred embodiment of the invention.

[043] Figure 5 is the same retaining member shown in Figure 4 but from an underside perspective view. [044] Figure 6 is a perspective view of the main longitudinal body of the enclosure arrangement wherein a light dimmer controller is supportable therein in a preferred embodiment of the invention.

[045] Figure 7 is an underside perspective view of a user operable control knob fixably attachable to an insulator cap of the enclosure arrangement in a preferred embodiment of the invention.

[046] Figure 8 is a part cut away perspective view of the enclosure arrangement with a light dimmer control arrangement enclosed therein in a preferred embodiment of the invention.

[047] Figure 9 is a part cross sectional view showing the upper part of the closure engagement with a light dimmer controller supported therein the enclosure

arrangement in a preferred embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

[048] Referring now to the drawings in greater detail.

[049] Figures 1 , 2 and 3 show a preferred embodiment of the insulator cap (10) which has a generally longitudinal hexagonal slightly distorted overall configuration wherein the diameter of the top surface (12) and its hexagonal side top edges (13) presenting the relevant longitudinal hexagonal side faces (15) running along the length of the insulator cap (10) is smaller compared to the diameter at the opposite end where the skirting or rim (16) extends around the periphery at the base of the insulator cap (10).

[050] The hexagonal shape makes it easy to attach on the user operable control knob (34) shown in Figure 7 as the user operable control knob (34) includes an underside internal column (35) with a hollow chamber which has on its internal sides (36) the corresponding hexagonal shape (37) along with a degree of inherent resiliency at least partly brought about by the gap (38). [051] The user operable control knob (34) also can include slots (39) that allow the raised ribs or ridged sections (17) of the insulator cap to form an interference fixable attachment when the user operable control knob (34) and the insulator cap are brought together.

[052] Internally the insulator cap (10) has a molded profile which provides sections of hollowness but also molded abutments so as to allow an interference or frictional fixable engagement between the insulator cap (10) and the metal actuating shaft of the digital rotary encoder which forms part of the light dimmer controller.

[053] The insulator cap (10) has an internal profiled internal configuration (20) that provides for spacing (19).

[054] In the preferred embodiment this is not a waste of spacing but is simply an alternative internal configuration so that an actuating metal shaft of another digital rotary encoder which has a different design than the one shown in Figure 9 can also be incorporated and encapsulated by the same insulator cap (10).

[055] Rather than having a completely hollow insulator cap which would potentially only allow for a mated interference fit with a single design of a metal actuating shaft of a digital rotary encoder, as introduced above this invention acknowledges the requirement that by designing different internal profiles of the insulating cap (10) this provides contoured abutments and openings which will allow metal shafts of other digital rotary encoders to also be attachable to the insulator cap without necessarily any separate fixing arrangement such as with a screw or the like.

[056] Figures 4 and 5 show the retaining member (22) which includes the main base plate (24) mountable tabs (25) on each of the respective corners, the raised shoulder (26) which has a generally square configuration of dimensions comparable to the opening (32) made available on the main longitudinal body (30) of the enclosure arrangement as best seen in figure 6. At the electrical wall plate engaging end of the main longitudinal body (30) shown generally as (33) the closed end surface (31 ) defines an opening (32) which matches the configuration of the square shaped edge (27) of the retaining member (22) so that the raised shoulder (26) is able to protrude out therefrom the opening (32) of the main longitudinal body (30).

[057] The raised shoulder (26) provides for the upper platform or surface (28) of the retaining member (22) which then defines the aperture (29) which is of a comparable diameter or dimension to the insulator cap (10) such that due to the slight tapering or distortion of the cylindrical based hexagonal shape of the insulator cap (10) the top (12) of the insulator cap is able to pass its way there through the circular aperture (29) of the retaining member (22) but the base of the insulator cap (10) will be prevented from extending out there from the aperture (29).

[058] As best seen in Figure 8, the retaining member (22) is mounted to a printed circuit board (43) associated with the digital rotary encoder of the light dimmer controller supported in the main longitudinal body (30) of the enclosure arrangement.

[059] Is is not a restriction of the invention that the retaining member (22) needs only to be mounted to the printed circuit board (43) but as shown in this arrangement the mounting to the printed circuit-board (43) allows the raised shoulder portion (26) of the retaining member (22), as introduced above, to be able to extend out there from the main longitudinal body (30) closed end (31 ) through the square opening (32) wherein that square opening (32) (best seen in figure 6) matches with the square configuration of the raised shoulder (26) portion of the retaining member (22) so that the top surface (28) of the retaining member (22) then provides for the generally circular aperture through which the insulator cap (10) can pass there through until the base of the insulator cap (10) prevents the insulator cap (10) from completely extending out beyond that top surface (28) of the retaining member (22).

[060] While not necessarily shown in the illustrations, the insulator cap (10), retaining member (22) and the main longitudinal body (30) of the enclosure arrangement can all be made of transparent plastic such that in instances where there is illumination within the enclosure arrangement, this illumination is able to pass through the plastic to be visible from the front of the dimmer, either beside or behind the user operable knob (34). [061] In the arrangement shown in Figure 8 there would be an available gap (50) where illumination will be able to spill out between that area confined by the user operable control knob (34) and the electrical wall plate (not shown) when the light dimmer arrangement within the enclosure arrangement is mounted thereto.

[062] As introduced above, the travel of the actuating metal shaft (41 ) of the digital rotary encoder as part of the overall dimmer light controller (40), will preferably have the inward travel on the encoder of the order of 0.5mm and with the arrangement presented when the operable control knob (34) is pushed in by a user even with excessive force, that force will be supported without damage and that the operable control knob can also be stopped by the raised shoulder (26) of the retaining member (22) which will also maintain the gap (50) to allow the spill out of illumination as referred to above.

[063] As best seen in Figure 9, the metal shaft (41) is able to be pushed up for an interference fit shown by way of (42a) and (42b) to be encapsulated and fastenably held to the insulator cap (10).

[064] As best illustrated in Figure 8 if a user wished to change the user operable control knob (34) and pull the knob (34) off the insulator cap (10), as the metal shaft (41 ) is completely encapsulated by the insulator cap (10) there is still no opportunity for a user to be able to access in any way electrically live parts of the dimmer light controller.