FIELD OF INVENTION

The present invention relates to handle bar switch module for two-wheeler motor cycles particularly, the present invention relates to handlebar switch illumination using light guide. BACKGROUND OF THE INVENTION

Two-wheeler handle bar switch includes various modules to perform various functions for smooth and safe driving. These modules include horn, blinker/indicator, dipper, pass, engine start, engine kill and head lamp ON-OFF - Parking. The more frequently used switches are mounted in the Left-Hand handlebar switch (horn, blinker/indicator, dipper and pass) and the less frequently used ones are mounted in the right-hand side (engine start, engine kill and head lamp ON-OFF-Parking).

Each switch is associated with a standard symbol which helps the driver to familiarize with the switches’ function. In most of the conventional two-wheeler vehicles these symbols are printed on the outside surface of the housing. The printing is done by Pad Printing Process. Depressions are etched into a flat plate. These depressions are filled with ink and a smooth silicone pad (silicone is ink repellent) is used to pick up the impression of the depressions which are transferred to an object which is intended to be printed upon with the image of the depressions. This stamp is called“pad” and gave this printing process its name. However, these symbols are not properly visible under low light conditions. The print becomes dull or degraded over a period of extensive use due to various environmental factors such as UV rays, dust, water, salt content in rain water, etc. Recently, illuminated handlebar switches are being developed in which most of the symbols are illuminated from inside by placing illumination source just below the symbols. The symbol insert is prepared by IMD (In Molding Decoration) process. The IMD injection process is a process wherein the symbol printed formed film is placed between the injection mold and the transparent resin film, and then they are integrally bonded with a curing technology. Mostly SMD LEDs (Surface Mount Device) are used as light source. Under each standard symbol, except for the pass symbol, one or two of these LEDs are being used depending upon the size of the symbol to ensure uniform illumination all along the symbols. Since the pass symbol is not visible directly to the rider as it is located at the rear side of LH handlebar switch, it is not required to get it illuminated. These LEDs are controlled by a single control unit known as regulator driver which is either placed outside the switch casings (this increases the wiring cost) or inside the switch casings, generally RH side. In the conventional illumination switches the illumination sources are not protected against vibrations, water, dust, etc., thus leading to lower life period.

481-DEL-2009 has disclosed, in its claim 1 :

“An illuminated handle bar switch module (1) for motorcycle, said switch module (1) comprising: at least one control switch for operating functions of one or more accessories of the motorcycle; said control switch is configured to connect a power source to the accessory of the motorcycle; at least one function symbol insert (2) comprising at least one symbol (3) indicative of the function performed by the said control switch; at least one illumination sub-assembly (5) comprises: a reflector (6) comprising a top surface (9), a bottom surface (10) and side surfaces (11) located adjacent to the said top surface (9) and the bottom surface (10) so as to define a cavity (12); said top surface (9) comprising at least one light transmitting portion; a printed circuit board (PCB) (7) is accommodated in the cavity (12) of the reflector (6) and comprises a surface mounted illumination source (8); the PCB (7) is accommodated in the cavity (12) so that the said at least one light transmitting surface receive light emitted by the said illumination source (8); the bottom surface (10) of the reflector (6) is provided with a bore (17) for extending out connecting wires (18) soldered to PCB (7); the cavity (12) of the reflector (6) has an open end (14) disposed on one of the side surface (11) of the reflector (6) for receiving the PCB (7) inside the reflector (6); the reflector (6) is made of a transparent material and a coating of opaque material is provided on the bottom and side surfaces (10, 11); and the reflector (6) comprises one or more light reflecting surfaces which are located so as to reflect and guide the light beam, received from the illumination source, to the said at least one light transmitting portion which transmits the light beam; a closure plug (19) disposed in the bore for closing the bore (17) and the said closure plug (19) comprises apertures (20) for projecting there through connecting wires (18) for making electrical connections of the said PCB (7) with the power source said at least one illumination sub-assembly (5) located so that the top surface (9) is disposed directly below the said function symbol insert (2) thereby illuminating the symbol (3) disposed on the said insert (2) by light beam transmitted through the light transmitting portion.”

Reflector used in this design of 481 -DEL-2009 is transparent and a coating of opaque material is provided on the bottom and side surfaces; which is difficult for quality control to avoid painting defects on reflector like dust particles, holes, uneven thickness in reflector construction.

Further 481 -DEL-2009 uses multiple LED sources, one reflector containing one LED per symbol; which makes the assembly cumbersome and time taking and also uses more LEDs for illumination. This also increases raw material cost for this type of illuminated switch. Therefore, there is a need for development of an illuminated switch which will overcome the above-mentioned problems.

SUMMARY OF THE INVENTION

This invention discloses a handlebar switch module for an automotive, the switch module comprising homologation symbols (5 to 17) illuminated by an illumination module; wherein, illumination for all homologation symbols located on various locations on the round surface of handlebar switch module is provided by a single source of illumination.

The illumination module comprises an Illumination source located inside an illumination housing (27) closed from all sides except for an opening on one side through Illumination housing cover (28), the opening being connected to one end of pipe of a light guide, the light guide branching out and each branch reaching up to one or more homologation symbol/s. The illumination housing (27) is located away from the homologation symbols. In the present illustration, the same is located laterally away from the homologation symbols.

In one of the embodiments of this invention, source of illumination is a Light Emitting Diode (LED) (33), In a further embodiment of this invention, the LED (33) is located inside the Illumination Housing (38).

The homologation symbols are individually located peripherally around on the surface of the switch module. In one embodiment of this invention, the Illumination Housing comprises a PCB (32), LED (33), a lens insert molded with Illumination Cover (36), resisters (34) and sealant (31).

The handlebar switch module of this invention is provided with a Regulator PCB assembly (37) is provided in the switch.

The automotive comprising the handlebar switch module of this invention may be a two-wheeler or a three-wheeler. DETAILED DESCRIPTION OF THE INVENTION

In one aspect this invention comprises a 2-wheelerhandlebar switch wherein source of illumination for all its homologation symbols located on various locations on the round surface of handlebar switch module is a single LED (Light Emitting Diode) per handlebar switch. In a further embodiment, this LED is located away from the homologation symbols and light from the single LED source is conveyed to the homologation symbols via a light guide.

In another aspect the present invention comprises a sub-assembly of Illumination module which is accommodated inside the switch. The sub-assembly consist of a single light source and a light guide. In further aspect of this invention, reduction of the number of LEDs to just one leads to reduction in wiring harness also. This makes the design of the handlebar as well as manufacturing of the same more efficient.

In a still further aspect of this invention, the illumination source is protected against dust, water and vibrations and the electrical connectivity remains shielded and intact.

BRIEF DESCRIPTION OF FIGURES AND LEGENDS

Legends and their description:

“LH” stands for Left Hand Side;“RH” stands for Right Hand Side.

1 -Case upper LH; 2 -Case lower LH; 3-Case upper RH; 4-Case lower RH; 5- Insert dipper; 6-Insert blinker; 7-Insert horn; 8-Insert engine kill; 9-Insert start; 10-Insert head lamp; l l-Knob pass; 12-Knob dipper; 13 - Knob blinker; 14- Knob horn; 15 -Knob engine kill; 16-Knob start; 17- Knob head lamp; l8-Light guide pipe upper LH; 19-Light guide pipe lower LH; 20-Light guide pipe upper RH; 21 -Light guide pipe lower RH; 22-Light guide cover upper - 1 LH; 23Light guide cover lower LH; 24Light guide cover upper -2 LH; 25 - Light guide cover upper RH; 26-Light guide cover lower RH27-Illumination box/housing LH; 28 - Illumination housing cover LH;; 29 - Lens;30-Illumination PCB sub-assembly; 31 - Sealant filled in the cavity; 32 - PCB; 33 - LED; 34 - Resistors; 35-Locating pin; 36 - Lens insert molded with Illumination cover; 37 - Regulator PCB assembly; 38- Illumination Box/Housing Assembly; 39 - Screw mounting features;40 - Holes for insertion of Electrical Wires; 41 - Walls for Regulator PCB Assembly protection; 42a - Engine Kill Serrations/teeth features; 42b - Head Lamp Serrations/ teeth features; 42c - Start Serrations/teeth features; 43a - Dipper Serrations/teeth features; 43b - Blinker Serrations/teeth features; 43c - Horn Serrations/teeth features; 44 - Light Guide Cover mounting feature protrusions for light guide cover lower RH no. 26; 45 - Light Guide Cover Screwing feature for light guide cover lower RH no. 26; 46 - PCB wiring connections; 47 - Branch of light guide pipe upper (18) for dimmer; 48 - Branch of light guide pipe upper (18) for Blinker; 49 - Branch of light guide pipe upper RH (20) for Engine Kill; 50 - Branch of light guide pipe upper RH (20) for Headlamp.

Figure 1(1) shows handlebar switch with homologation symbols, Control Switch RH on right hand side. Figure 1(2) Control Switch LH on left hand side. Figure 2 illustrates exploded view of the illumination module LH on left hand side. A similar illumination module is used on right hand side (RH) which is mirror image of illumination module LH and is not shown in drawings.

Figure 3(1) Light guide pipe upper RH (20) and Light guide pipe lower RH (21) Serrations/ teeth features.

Figure 3(2) Light guide pipe upper LH (18) and Light guide pipe lower LH (19) Serrations/ teeth features.

Figure 4 shows sectional view of Illumination Housing Assembly (38)

Figure 5(1) Control Switch RH with light guide (20) and (21) and covers (25) and (26) inside the switch casings.

Figure 5(2) depicts exploded view of the illumination module shown in fig. 5(1). Figure 6(1) Control Switch LH with light guide (18) and (19) and covers (22, 23 and 24) inside the switch casings.

Figure 6(2) depict exploded view of the illumination module along with light guide and covers inside the switch casings.

Figure 7 portrays all the illumination inserts present in the Control Switch LH and RH switch.

Figure 8 (1) shows walls for Regulator PCB assembly protection (41), Light Guide Cover mounting feature protrusions (44), and 8(2) show Regulator PCB assembly (37) with Case lower RH(4).

The illumination module consists of following major parts: light guide (upper part 18 and lower part 19) with pipes extending towards and conveying light to the locations of homologation symbol inserts that are located on various locations on the surface of the handlebar switch, illumination housing (27), Illumination PCB sub-assembly (30) with LED, wire soldered on it and two resistors, lens (29) and illumination box cover (28) as shown in figure 2.

It is an aspect of this invention that the illumination source for each entire switch module is a single LED. In another aspect of this invention, the Light from the illumination source, the LED, is guided to the homologation symbols via the pipes of the light guide which branch out from the main pipe in the direction of homologation symbols to which the light is to be provided, as shown in figure 5(1) and 6(1). The, source of illumination for the light guide is a single LED. This illumination source, LED, is enclosed within an illumination housing (27) which is closed from all sides and is provided with an illumination housing cover having a hole/opening in it. The illumination housing is located away from the homologation symbols. In the instant illustration of this invention, the illumination housing is located laterally away from the homologation symbols. The light from LED passes through a lens as a beam and then through the hole/opening provided in the illumination housing cover into a main pipe of light guide connected to the hole/opening of the illumination housing cover and gets distributed to the various homologation symbol inserts through branches of pipes connected to the main pipe. Each branch of light guide runs to one or more homologation symbol/s on the handlebar switch, thereby providing uniform illumination at all illumination symbols. In one embodiment, the light guide can be divided into 2 or more parts for manufacturing feasibility and ease of assembly. In the present illustration it is divided into 2 parts; one assembles with case upper and the other assembles with case lower, refer fig 5(1) and fig 6(1). Both are optically connected at the junction so that there is minimal light loss when light traverses from one pipe to another. Case upper light guide illuminates 4 sets of symbols, one by branch no. 47 which illuminates 2 Dimmer Signals (5) and branch no 48 illuminates 2 Blinker signals (6) of the upper part (18), while the case lower part of light guide (19) illuminates only a single symbol - horn (7) Corresponding branches on right side illuminate engine kill and head lamp in one group and Start in another. To achieve homogeneous light output from homologation symbols, serrations/teeth are provided on it to control light path and intensity. This is an optional feature. Some parts of the light guide are etched at the end of the process to get desired light intensity output outside the casing.

In another aspect of invention the light guide is enclosed in covers designed to confine the light inside the light guide and prevent escape of the light from the light guide to outside of the switch from unwanted openings [see fig 4(1) and 4(2)]. The cover is designed in 2 parts, l ^st for light guide portion located in case upper and 2 ^nd for light guide portion located in case lower. Both are assembled with their respective cases via fasteners. Protrusions from the cases are provided which guide the cover for ease of assembly as well as to help seal the light inside the cover.

The light inserts in the present invention are of Polycarbonate (PC) material. However, they can be made of any other material, including glass, that has capability to bear the mark of homologation symbol and also to illuminate it by light passing through it.

To safeguard the LED from excess voltage and current, a voltage regulator is housed inside the switch Single regulator is used for both the LH and RH switches. Walls have been erected so as to receive the regulator PCB (evident in fig 8(1)) and sealed with the sealant for protection from dust, water and vibration.