Field of invention

The present invention relates to handle bar switch module for two wheelers / three wheelers / all terrain vehicles, particularly, the present invention relates to an illuminated switch module, more particularly, the present invention relates to an illumination sub- assembly for illuminated handle bar switch module with symbols.

Background of the invention Two wheeled or three wheeled vehicles include various electrical/electronic components that perform a variety of functions for smooth operation, safe driving and for providing indication to other riders while driving. Some of these functions include, Head lamp ON- OFF-Parking ON, Engine start, Engine kill, Dipper or High-Low, Turn Indicator with push cancel, Horn, Pass etc.

These functions are achieved by implementing control buttons mounted over control switches via battery in series. Conventionally, a module housing at least one control switch is mounted on a handle bar of the two wheeled or three wheeled vehicle. More particularly, the control switches for frequently used functions such as horn, dipper, blinker, turn indicator, etc are grouped together in the form of a first switching module (or alternatively referred to as left hand side switching module), which is mounted over left hand side of the handle bar. Similarly, control switches for less frequently used functions such as engine kill, engine start, head lamp ON-OFF, etc. are grouped together in the form of a second switching module (or alternatively referred to as right hand side switching module) mounted over right hand side of the handle bar.

Each of the switch modules can accommodate one or more control switches. The control switches can be contacting type switches or contact-less type switches. In other words, the control switches can be electrical or electronic switches.

Since, a switching module accommodate plurality of switches, each of which provides a different functionality, in order to enable the user of a vehicle to easily identify the functionality of a particular control switch, each control switch carries a unique symbol

(also known as homologation symbols) indicating the function which will be performed by the activation of said switch. These symbols have now become standard symbols which are recognized throughout the automotive industry. Figure l(a) represents a conventional left hand side switching module and figure l(b) represents a conventional right hand side switching module. As can be observed from figures l (a) and l(b), the symbol is disposed either adjacent to or over the respective control switch.

Conventionally, most of the symbols are either printed or pasted or paint filled or embossed over a surface of console or a control button of the control switch. However, the symbols present over the control switches are not visible to the rider while driving under insufficient illumination levels (such as during night time). Also, the aforesaid symbols become dull or eroded over a period of time due to cumulative effect of UV light, rain water, salt content in rain water, grease, oil, dust, other contamination, etc.

In few conventional two-wheeled vehicles, the symbols are printed over a plastic sheet that is pasted or glued over top surface of switch console. The sheet gets damaged and peeled off during extensive exterior use of product due to individual or combined effect of environment such as water, UV rays, dust etc.

Recent technical advancements have led to development of illuminated control switches by placing an illumination source below the symbol inside the handle bar switch module of two wheeled vehicles. In the conventional illuminated switches the illumination source does not provide uniform illumination. Also, the illumination source in the conventional switches is not protected against the vibrations, water, dust and other contamination resulting into small life of the illuminated switches and higher maintenance cost.

Further, the sets of illuminating source within control switches are controlled by the main control unit of the conventional two wheeler vehicle. Main control unit is generally placed below head lamp or below seat area of a two wheeler. This increases cost of wiring harness. This also increases the cost of illumination due to more wiring harness length, complex and bulky electronic control units with more number of parts, high cost of protection against water and dust to electronic control unit, ceases the scope for customization. As the number of parts is more, the chances for failure are also more.

Therefore, there exists a need to develop an illuminated switch module which overcomes the afore-mentioned problems of conventional switches. Objects of the present invention:

The main object of the present invention is to provide an illuminated handle bar switch module for two wheeler vehicle or motorcycle.

Another object of the present invention is to provide an illumination sub-assembly for an 5 illuminated handle bar switch module which provides uniform illumination of the symbol. Still another object of the present invention is to provide an illumination sub-assembly for an illuminated handle bar switch module which protects the illumination source from dust, water or other contamination and also withstand to the vibrations and protect electrical connections of illumination source.

10 Yet another objective of the present invention is to provide an illuminated handle bar switch module which accommodates electronic control unit in the switch module itself that simplifies wire routing, reducing the length of wiring harness, comparatively less voltage drop, reducing number of water tight connectors between control unit and illumination source output.

15. One more object of the present invention is to provide a function symbol insert which us insert moulded in the switch module itself and where symbols are screen printed from inner side of the insert for enhancing the life of symbol from severe use of product in exterior environmental condition. 0 Summary of invention:

The present invention provides an illuminated handle bar switch module with an illumination sub-assembly. The illumination sub assembly comprises reflector, an illumination source, a rubber grommet and an illumination source cap. In an embodiment of the present invention the illumination source is a light emitting diode (LED). The LED 5 is placed over the rubber grommet that acts as a pad and protects the LED from vibration deriving out of vehicle engine. The rubber grommet also acts as an insulator that prevents heat transfer from LED soldering joints during soldering to LED. The said LED along with grommet is placed over LED cap. Both the legs of LED are passed through holes provided over LED cap (plastic cap). The purpose of LED cap is to hold the LED and 0 grommet at right location and snap fit the same with reflector. Connecting wires from electronic control unit (ECU) that is part of handle bar switch itself is soldered to the two ends of LED legs emerging out of the LED cap. The legs are cut to suitable length after soldering. The soldered ends are further potted with conformal coating that prevents LED failure due to water, dust, grease, oil or other contamination at soldering points. The conformal coating also acts as a vibration dampener that prevents soldering joints from dc- soldering. The aforesaid description is of one illumination sub-assembly comprising of only four parts including reflector, LED, grommet, and LED cap. One illumination sub- assembly is responsible for illuminating one or more symbols of one function symbol insert in the said switch module. The number of illumination sub-assemblies can be more than one in a switch module for each function symbol inserts. The said illumination sub- assemblies is fastened right below respective function symbol inserts and provide uniform illumination with the help of reflector over entire symbols of the function symbol inserts during night time.

The shape and size of each illumination sub-assembly may differ from other illumination sub-assembly because size and shape of the function symbol insert varies which vary the size and shape of the reflector placed below respective function symbol insert. The size and shape of the illumination sub-assembly depend upon the shape and size of function symbol insert, packaging space available for illumination sub-assembly inside the respective switch and shape of left hand side switch module and right hand side switch module.

In an embodiment of the present invention, the illuminated handle bar switch module comprises one or more function symbol insert. In the function symbol insert, the symbols are screen printed from the bottom side over transparent plastic sheet in black ink (first screen) followed by white ink (second screen) in first stage. Thereafter, these printed symbols over sheet are cut to the desired layout and size followed by forming (operation) of each cut sheet as per the shape required in the first stage. These formed symbols over sheet are injection moulded to form function symbol insert in second stage. The said function symbol insert is further insert molded with switch module in third stage. The function symbol inserts are placed ^" at desired location in the mould. These symbols do not erode and comparatively less faded during their extensive exterior use, as these symbols are printed from rear side of the sheet. Also, these symbols have got high life against severe environmental effect and do not get peeled of unlike conventional sticker printed homologation symbols or pad printed/paint filled/ embossed homologation symbols over switch module. In an embodiment of the present invention, an electronic control unit (ECU) is accommodated inside the switch module. The ECU is configured to control the power supply to the illumination source. The electronic control unit is dedicated to control the illumination features of the illuminated switch module.

The illuminated handle bar switch module of the present invention has enhanced life against water, dust and other contamination over soldering joints and also enhances life against vibration deriving out of vehicle engine. Further, the present invention facilitates increased life span of symbols from the effects of UV rays, salt water, dust, sand and other contamination.

Brief description of drawings

Figures 1 (a) and l(b) conventional handle bar switch modules with symbols.

Figures 2(a) and 2(b) illustrates an exemplary view of illuminated handle bar switch module according to an embodiment of the present invention.

Figures 3(a) and 3(b) illustrate function symbol insert for the illuminated handle bar switch module according to an embodiment of the present invention.

Figure 4 shows placement of the function symbol Insert inside the switch module according to an embodiment of the present invention. Figure 5 illustrates an exploded view an illumination sub-assembly according to an embodiment of the present invention.

Figure 6 shows a reflector used for uniform light distribution over the entire function symbol insert according to an embodiment of the present invention.

Figure 7 illustrates light ray travel within the reflector according to an embodiment of the present invention.

Figure 8 shows the assembled view of illumination sub-assembly according to an embodiment of the present invention.

Figures 9(a) and 9(b) illustrate mounting of the illumination sub-assembly with respect to function symbol insert inside the switch module. Figures 10(a) and 10(b) illustrate horn illumination sub-assembly and ignition start illumination sub-assembly mounted respectively inside left hand side and right hand side illuminated handle bar switch modules according to an embodiment of the present invention. Figure 1 1 illustrate two illumination sub-assemblies with respect to respective function symbol inserts inside switch module according to an embodiment of the present invention. Figure 12 shows the receptacle accommodating ECU according to an embodiment of the present invention. Figure 13 illustrates an illuminated handle bar switch accommodating with an electronic control unit dedicated to illumination according to an embodiment of the present invention.

Figure 14 illustrates mounting of both left hand side and right hand side control switch over handle bar and their connection according to an embodiment of the present invention.

Detailed description of the present invention

Accordingly, the present invention provides an illuminated handle bar switch module for motorcycle, said switch module 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 comprising at least one symbol indicative of the function performed by the said control switch; at least one illumination sub-assembly comprises: a reflector comprising a top surface, a bottom surface located opposite to the and side surfaces located adjacent to the said at least one light transmitting surface and/or the bottom surface; said top surface comprises at least one light transmitting portion; a bore extending partially from the bottom surface so as to define an open end on the bottom surface of the reflector and a closed end inside the reflector; an illumination source is being received in the bore for providing illumination; a cap for covering the said open end of the bore; the cap comprises a means for projecting connectors for making electrical connections of the said illumination source; a rubber grommet received in the bore and disposed between the illumination source and the illumination source cap; said at least one illumination sub-assembly located so that the top surface of the reflector is placed directly below the function symbol insert so that the said at least one light transmitting surface receives light from the illumination source thereby illuminating the symbol disposed on the insert.

In an embodiment of the present invention the said function symbol insert is mounted in the switch module by means selected from pasting, hot sealing, fastening and ultrasonic welding.

In another embodiment of the present invention, the said at least one function symbol insert is mounted in the switch module by means of insert moulding.

In still another embodiment of the present invention, the function symbol insert comprises a cavity so as to receive the top surface of the reflector.

In yet another embodiment of the present invention the said at least one function symbol insert comprises a sheet on which the symbol is screen printed.

In a further embodiment of the present invention, the said at least one symbol is disposed on a surface of the said sheet of the function symbol insert which remains inside the switch module.

In a further more embodiment ot the present invention, the said bore is constructed so as to define a predetermined clearance between the reflector and the said illumination source, when the illumination source being received in the bore.

In another embodiment of the present invention, the reflector is made of a transparent material provided with coating on the side and bottom surfaces.

In still another embodiment of the present invention, the reflector comprises plurality of light reflecting surfaces which are located in the reflector so as to reflect and guide the light beam to the said at least one light transmitting portion of the top surface of the reflector.

In yet another embodiment of the present invention, the top surface of the reflector comprises two light transmitting portions for illuminating two symbols disposed on the function symbol insert. In a further embodiment of the present invention, the said illumination source is a light emitting diode (LED).

In further more embodiment of the present invention, the means for projecting connectors are apertures provided in the cap for making the electrical connections of the LED.

In another embodiment of the present invention, the rubber grommet comprises apertures and the rubber grommet is located so that apertures of the rubber grommet are in alignment with the apertures of the cap for projecting the connectors therethrough for making the electrical connections of the LED.

In still another embodiment of the present invention, the bore comprises reduced diameter sections so as to define annular seats for the LED and rubber grommet.

In yet another embodiment of the present invention, the cap is connected with the reflector by snap fit.

In a further embodiment of the present invention, the reflector has one or more projection locatable with one or more recesses provided in the function symbol insert.

In a further more embodiment of the present invention, the reflector comprises at least one projection provided with a connecting arm having a hole for inserting a fastener and interior of the switch module is provided with threaded plug for cooperating with the fastener thereby connecting the illumination sub-assembly with the interior of the switch module.

In another embodiment of the present invention, the illumination source is coupled with an electronic control unit (ECU) accommodated inside the switch module for connecting the illumination source with the power source.

In still another embodiment of the present invention, the said ECU comprises a printed circuit board mounted with plurality of resistors, one or more capacitor and an integrated circuit for providing the voltage drop and current conditioning. In yet another embodiment of the present invention, the ECU is housed in a receptacle inside the switch module.

An embodiment of the present invention provides an illumination sub-assembly for an illuminated switch module, said illumination sub-assembly comprising: a reflector comprising a top surface, a bottom surface located opposite to the and side surfaces located adjacent to the said top surface and/or the bottom surface; said top surface comprises at least one light transmitting portion; a bore extending partially from the bottom surface so as to define an open end on the bottom surface of the reflector and a closed end inside the reflector; an illumination source is being received in the bore for providing illumination; a cap for covering the said open end of the bore; the cap comprises a means for projecting connectors for making electrical connections of the said illumination source; a rubber grommet received in the bore and disposed between the illumination source and the illumination source cap.

The present invention also provides a handle bar with an illuminated left hand side switch module and an illuminated right hand side module; each of the said left hand side switch module and the right hand side module 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 comprising symbol indicative of the function performed by the said control switch; at least one illumination sub-assembly comprises: a reflector comprising a top surface, a bottom surface located opposite to the and side surfaces located adjacent to the said at least one light transmitting surface and/or the bottom surface; said top surface comprises at least one light transmitting portion; a bore extending partially from the bottom surface so as to define an open end on the bottom surface of the reflector and a closed end inside the reflector; an illumination source is being received in the bore for providing illumination; a cap for covering the said open end of the bore; the cap comprises a means for projecting connectors for making electrical connections of the said illumination source; a rubber grommet received in the bore and disposed between the illumination source and the illumination source cap; said at least one illumination sub-assembly located so that the top surface of the reflector is placed directly below the function symbol insert so that the said at least one light transmitting surface receives light from the illumination source thereby illuminating the symbol disposed on the insert an electronic control unit (ECU) received in a receptacle which is disposed in the said left hand side switch module or in the right hand side module; said ECU is configured to connect a power supply to the illumination source; said electronic control unit of one switch module is coupled with the illumination source of the other side of the switch module by one or more water tight connector.

The present invention is described with reference to the figures and specific embodiments; this description is not meant to be construed in a limiting sense. Various alternate embodiments of the invention will become apparent to persons skilled in the art upon reference to the description of the invention. It is therefore contemplated that such alternative embodiments form part of the present invention.

Figures 2(a) and 2(b) illustrates an exemplary view of the illuminated handle bar switch module according to an embodiment of the present invention. The switch module shown in figure 2(a) is left hand side switch module of the motorcycle. The switch module shown in figure 2(b) is right hand side switch module of the motor cycle.

The illuminated handle bar switch • module has at least one function symbol insert comprising at least one symbol which is indicative of the functions performed by the control switch. As shown in figures 2(a) and 2(b) the illuminated handle bar switch module (1) has function symbol inserts (2) comprising illuminated symbols (3) such as dipper, blinker, horn in left hand side switch module and engine kill, main, start in right hand side switch module. As shown in figures 2(a) and 2(b), the function symbol inserts (2) are disposed adjacent to the respective control switches (4). As can be clearly understood, the switch module can be provided with one or more control switches (4). Similarly, the number of function symbol inserts (2) can be one or more. As can be observed from figures 2(a) and 2(b), for each control switch (4) a separate function symbol insert (2) can be provided which is located adjacent to the control switch (4). The number of symbols (3) on the function symbol insert (2) can be one or more than one and the number of symbols can be determined according to the requirement. For example, the function symbol insert respective of the blinker comprises two symbols, the function symbol insert respective of horn comprises one symbol and the function symbol insert respective of the headlight comprises three symbols.

The function symbol insert can be a sheet which has one or more symbols printed or embossed over the said sheet. The said insert can be mounted on the switch module by pasting, hot sealing, fastening or ultrasonic welding or by any other suitable method.

In an embodiment of the present invention the function symbol insert comprises a sheet on which the symbol is screen printed. The said function symbol insert is mounted on the switch module by insert molding such that the surface of the sheet on which the symbol is screen printed remains inside the switch module. It can be clearly understood that such function symbol insert can be prepared by taking a transparent sheet on which the symbol is screen printed and then coating the said sheet with black paint while masking the portion of the sheet on which symbol is printed. Therefore, the light impinges on such function symbol insert, it is transmitted only through the portion on which the symbol is screen printed.

Figures 3(a) and 3(b) illustrate function symbol insert (2) for the illuminated handle bar switch module (1) according to an embodiment of the present invention.

As shown in figures 3(a) and 3(b), the symbols (3) are screen printed over transparent plastic sheet from the rear side with black ink printing followed by white ink printing.

Portions comprising symbol or set of symbols are cut from the said sheet to desired shape and size followed by a forming operation. The said formed symbol over sheet is moulded to form function symbol Insert (2). As can be clearly understood, different function symbol inserts have different shapes and sizes such as symbol insert for blinker, dipper. horn, main or light, engine kill, and ignition start, etc.

Figure 4 shows, the function symbol Insert (2) is placed inside the injection mould at desired location during injection moulding process so as to form a switch module (1). As can be clearly understood, the symbols do not get affected by the environmental factors such as water, dust, shower, salt or UV radiations as symbols are screen printed on a surface the function symbol inserts which remains inside the switch module rather than top surface of the function symbol insert.

In an embodiment of the present invention, the illuminated handle bar switch module comprises one or more illumination sub-assembly. The illumination sub-assembly of the present invention comprises a reflector and an illumination source. The illumination source can be a bulb or a light emitting diode. The illumination sub-assembly can be placed directly below the respective function symbol insert for providing illumination.

Figure 5 illustrates an exploded view of the illumination sub-assembly (5) according to an embodiment of the present invention. As shown in figure 5, the illumination sub-assembly (5) comprises a reflector (6), a light emitting diode (LED) (7), a cap (8) and a rubber grommet (9).

Figure 6 illustrates a reflector (6) of the illumination sub-assembly (5) according to an embodiment of the present invention. Referring to figures 5 and 6, the reflector (6) comprises a top surface (10), a bottom surface (1 1) and side surfaces (12) located adjacent to the top surface (10) and/or bottom surface (1 1). The top surface (10) of the reflector (6) is provided with at least one light transmitting portion. According to an embodiment of the present invention, the top surface (10) of the reflector (6) has two light transmitting portions as shown in figures, 5 and 6. The reflector (6) has a bore (13) on the bottom surface (1 1) which is partially extending from the bottom surface (1 1) i.e. the bore (13) has an open end (14) on the bottom surface (1 1) and a closed end (not shown in figures) inside the reflector (6). The light emitting diode (7) can be received in the bore (13) of the reflector (6) for providing illumination to the function symbol insert (2). The open end (14) of the bore (13) is closed by the cap (8). As shown in figure 5, the cap (8) can be a LED cap which comprises apertures for projecting leg type connectors or wires (15) of the LED (7) for electrically connecting the LED (7) with electronic control unit or power supply. If a bulb is used as illumination source, the cap (8) can be provided with a bulb holder for making electrical connection of the bulb with electronic control unit or power supply. It can be observed from figure 5 that the rubber grommet (9) is disposed between the LED (7) and the LED cap (8). The bore (13) is constructed so as to receive the rubber grommet (9). The rubber grommet (9) prevents the entry of water inside the reflector (6) assembly and also acts as a vibration dampener. The rubber grommet (9) is also provided with apertures for projecting leg type connectors or wires of LED (15). As can be noticed from figure 5, that the apertures of rubber grommet (9) and the apertures of LED cover arc in alignment with each other. For assembling, the connectors of the LED (7) is received through the apertures of rubber grommet (9) and then through the apertures of the LED cap (8). Thereafter, soldering of the LED connectors is done so that the rubber grommet (9) is sandwiched between the LED (7) and the LED cap (8). The LED (7) is then placed inside the bore.

The cap (8) can be connected with the reflector (6) by any suitable method. Referring to figures 5 and 6, the LED cap (8) is connected with the reflector (6) by snap fit. The LED cap (8) is provided with two flanged portions with slots and the reflector (6) is provided with two projections so as to engage with the slots of the flanged portions thereby effecting the snap fit.

Figure 7 shows a reflector (6) with LED (7) according to an embodiment of the present invention. As shown in figure 7, the bore (13) is constructed so as to define a clearance

(16) between the LED (7) and the reflector (6) when the LED (7) is placed inside the bore.

Referring to figure 6, the bore (13) has a first reduced diameter section so as to form a first annular seat (17) for providing a support to a collar potion of the LED (7). The bore (13) can be provided with a second reduced diameter section so as to form a second annular seat (18) for supporting the rubber grommet (9) disposed between the LED (7) and the

LED cap (8). The annular seats act as a stop for the LED (7) thereby introduces a clearance (16) between the reflector (6) and the LED (7). According to an embodiment of the present invention, the clearance (16) between the reflector (6) and the LED (7) is

0.1mm only. Such small gap/clearance (16) between reflector (6) and LED (7) prevents entry of water inside reflector (6) due to surface tension.

Reflector (6) is made of a transparent material with coatings of opaque material on surfaces while masking desired portions of the top surface (10) so as to form one or more light transmitting portions. The said portions can be coated with desired color. Since, the reflector is made of transparent material the light emitted from the LED, which is placed in a bore (13) provided on the bottom surface, travels towards the one or more light transmitting portion which is disposed on the top surface. As can be clearly understood, in the reflector of the present invention, medium of light travel is the reflector material. Figure 7 also illustrate travel of light ray from LED (7) to the desired surface within reflector. As shown in figure 7, the reflector has plurality of light reflecting surfaces which are located so as to reflect and guide the light beam towards the light transmitting portions of the reflector. The side and the bottom surface (1 1) may be provided with reflecting coating so as to make reflecting surfaces. The travel of light is based on principle of optics that is angle of Incidence is equal to the angle of reflection.

Figure 8 shows an assembled illumination sub-assembly (5) according to an embodiment of the present invention. As shown in figure 8, the connecting wires (15) or supply wires are soldered to LED (7). Proper sealant is used at soldering points that act as a vibration dampener and prevents de-soldering at the soldered point. The connecting wires (15) of the LED (7) are coupled with the power supply for supplying power to the LED for illuminating the same.

As shown in figures 9 (a) and 9(b), the illumination sub-assembly (5) is placed over respective function symbol insert inside the switch module. Referring to figures 4 to 9, the function symbol insert is provided with a cavity for receiving the top surface (10) of the reflector. The reflector (6) is provided with a connecting arm (19) which is attached to body of the reflector (6). The connecting arm (19) has a hole (20) for inserting a fastener and a threaded plug (21) can be provided inside the switch module for threadedly receiving the said fattener. As shown figure 8 and 9(b), the reflector (6) has a projection (22) which can be located inside a corresponding recess provided with the function symbol insert. The light transmitted through the one or more transmitting portion of the LED is received by the function symbol insert thereby produces illumination of one more symbol of the function insert.

The shape and size of the reflector depends upon surface area of function symbol insert below which the illumination sub-assembly (5) is to be located, packaging space available for illumination sub-assembly, distance between light source and surface to be illuminated. Therefore the shape and size of reflector for dipper, blinker, horn, start, main or light, ignition start, engine kill, etc may vary from one another.

Figures 10(a) and 10(b) illustrate horn illumination sub-assembly (23) and ignition start illumination sub-assembly (24) mounted respectively inside left hand side and right hand side illuminated handle bar switch modules. As shown in figures 10(a) and 10(b), the reflector has a substantially flat top surface (10) and the LED is located in the bore

(13)which directly opposite to the top surface. The complete top surface (10) can be used for transmitting light. As can observed from figures 10(a) and 10(b), the reflectors may not require any light reflecting surface as the light emitted from the LED can be directly received onto the top surface.

According to an embodiment of the present invention, the illuminated handle bar switch module comprising plurality of illumination sub assemblies for illumination plurality of function symbol insert located adjacent to the plurality of control switches.

Figure 1 1 illustrates two different illumination sub-assembly mounted inside a switch module. Both the illumination sub-assemblies are of different shape, size and placed at respective location over function symbol insert. A separate illumination sub-assembly and a separate function symbol insert can be provided for each of the control switch. As can be clearly observed from figure 1 1 , a single illumination sub-assembly can illuminate all the symbols disposed on the function symbol insert.

According to an embodiment of the present invention, an electronic control unit (ECU) (25) is accommodated in the switch module. The ECU is disposed in the path of current flow from the power supply to the LED. In an embodiment of the present invention the current flows from the power supply to the LED via ECU (25) when the head lamp is switched on. However, a separate switch can be provided for switching on the power supply to the LED. The electronic control unit provides various protections to the LED against surge currents and transient voltage, reverse polarity and battery drainage.

Figure 12 shows an illuminated handle bar switch module accommodating an electronic control unit according to an embodiment of the present invention. The placement of the electronic control unit inside the switch module saves the length of wiring harness and also reduces the number of water tight connectors. The placement of the electronic control unit (ECU) (25) within the switch console simplifies wire routing and also reduces it length thereby saving the overall cost of the system.

In an embodiment of the present invention the electronic control unit (ECU) (25) comprises a printed circuit board (PCB) mounted with plurality of resistors, one or more capacitor and an integrated circuit for providing the voltage drop and current conditioning. The ECU (25) has a PCB including placement of electrical and/or electronic components over both sides of PCB. These components include but not limited to one integrated circuit for dropping the input voltage from 12 volts to 3 volts or as desired by the LED. One or more capacitor is mounted over PCB at input end . as well as output end for filtering the spikes generated while running the vehicle. This protects the circuit from surge current and transient voltage current. On other side of PCB, one or more resistors are placed in series (one for each LED) for stepping down the current i.e. from amperes to milli- amperes. At least one pad has been defined over PCB as an output to the LED. The number of pads can be increased or decreased depending upon the numbers of LED. The output wires to the LED can be directly soldered to these pads.

In an embodiment of the present invention, the present invention, the electronic control unit is a dedicated electronic control unit which controls the illumination feature only. The electronic control unit is smaller in size and accommodated inside the switch module. Figure 12 illustrates an exemplary view of packaging of the electronic control unit in the switch module according to an embodiment of the present invention. As shown in figure 5, the switch module comprises a receptacle (26) for receiving the electronic control unit. As shown in figure 5, the receptacle has an open end (27) and a closed end (28). The ECU (25) is received from the open end of the receptacle. As can be noticed from figure 12, the receptacle is a box type structure with rectangular side walls. Two raceways (29) arc provided on two opposing side walls so that the ECU (25) is received in the receptacle slidably. The raceways (29) extend from the open end to the closed end. The open end of the receptacle is used for routing the wires making electrical connections of the ECU (25) with LED and power supply. As can be observed from figure 13, wiring harness making electrical connections is extending through the open end of the receptacle. The open end of the receptacle (26) can be closed by potting of epoxy resins and/ or sealants. The open end (27) of the receptacle (26) can also be closed by a cover and rubber grommet (9) which is disposed between the cover and the open end. The cover and the open end can be provided with apertures for extending wiring harness.

In an embodiment of the present invention, the said ECU (25) is slided inside the receptacle (26) and wires are routed outside from the open end of the receptacle. This is followed by potting with epoxy or sealant over ECU (25) inside the receptacle. Potting prevents the entry of water, dust, UV radiations or other contamination inside ECU. Potting also protects the said ECU (25) from the effect of vibrations derived out of engine vehicle.

Figure 13 illustrates assembly of the electronic control unit with receptacle (26) inside the switch module according to an embodiment of the present invention. As shown in figures 12 and 13, interior of the switch module is constructed so as to accommodate the receptacle. The receptacle (26) and the interior of the switch module can be provided with means for connecting the receptacle (26) with the interior of the switch module.

As shown in figure 13, wires emerging out of electronic control unit are routed to the respective LED. Both the left hand side switch module and the right hand side switch module is provided with separate electronic control units which are mounted inside the respective switch modules. However, a single ECU can be used for controlling the illumination of both left hand side and the right hand side switch module. Said ECU can be mounted either in the right hand side switch module or in the left hand side switch module. The LEDs on the other side of control switch receives input current from the same ECU via water tight connector. This saves the length of the wiring harness and number of water tight connectors between both switches.

Figure 14 illustrates a handle bar of a motorcycle with illuminated handle bar switch module according to an embodiment of the present invention. As shown in figure 14, the left hand side (30) switch module has function symbol inserts for dipper, blinker, horn and the right hand side (31) switch module has function symbol inserts Engine kill, Main, start. An ECU is provided on right hand side switch module (31). A female water tight connector (32) which is connecting with a male water tight connector (33) of left hand side control switch provides connections of LEDs of the left hand side switch module. Some of the advantages of the present invention are as follows: a) The present invention provides contact-less illumination switch which meets the performance expectations of the end user and is economical to the manufacturer. b) Less number of parts is used in illumination sub-assembly. The illumination sub-assembly comprises of only four parts including reflector, LED or other illuminating device, grommet, and LED cap. Therefore, the said sub-assembly is cost effective. c) Uniform distribution of light over symbol due to reflector. d) Enhanced life of illumination against vibration, water, dust, and other contamination due to use of rubber grommet, sealant at soldering points and due to a small gap between LED and reflector. e) LED has smaller illumination cone angle so with the help of reflector the overall area of illumination is increased with least reflector thickness. f) Reflector assembly also help in protecting light leakage from the sides of switch & g) LED or any other illuminating device can be used for illuminating symbols. h) Insert moulded symbols do not get eroded or faded easily. i) Enhanced life of homologation symbols in present invention over conventional homologation symbols from severe environmental effect of water, dust, UV, salt, sand, as well as from grease, oil, and other contamination.