Universal dimmer switch knob with non-cylindrical engagement surface

Abstract

A universal dimmer switch knob is provided having an inner bore to receive an intermediate member. A plurality of intermediate members are provided in a kit, such that a user may select a particular one of the intermediate members to correspond to a particular dimmer switch shaft. The intermediate member preferably has a non-cylindrical outer periphery and the knob has a non-cylindrical inner bore. The intermediate member is generally A-shaped with a central apex lobe and two side lobes. The lobes are received in notches in the knob. When the knob is turned, the lobes and notches resist slippage between the knob and the intermediate member.

1 . A dimmer switch knob comprising: 
 a dimmer switch knob having an inner bore, said inner bore being non-cylindrical;    an intermediate member having an inner bore to receive a shaft from a dimmer switch, said intermediate member having a non-cylindrical outer periphery; and    said non-cylindrical inner bore and said non-cylindrical outer periphery mating to provide a contact surface such that rotation of said dimmer switch knob rotates said intermediate member, said contact surface includes at least three lobes extending from one of said knob and said intermediate member, and at least three notches formed in the other of said knob and said intermediate member.    
   
   
       2 . (canceled)  
   
   
       3 . A knob as set forth in  claim 1 , wherein said intermediate member has said at least three lobes extending from said outer periphery that fit into said at least three notches formed in said bore of said knob.  
   
   
       4 . A knob as set forth in  claim 3 , wherein said intermediate member has only three lobes and is generally A-shaped.  
   
   
       5 . A knob as set forth in  claim 4 , wherein said intermediate member has a central apex lobe, and two side lobes.  
   
   
       6 . A knob as set forth in  claim 5 , wherein said apex lobe being generally stiffer than said side lobes.  
   
   
       7 . A knob as set forth in  claim 5 , wherein said intermediate member has said two side lobes spaced by an angle that is greater than an angle spacing of said corresponding notches in said bore in said knob, and such that there is a spring force tending to separate said side lobes from each other when received in said corresponding notches.  
   
   
       8 . A knob as set forth in  claim 1 , wherein said lobes have split ends circumferentially spaced from each other and separated by a separate channel.  
   
   
       9 . A knob as set forth in  claim 1 , wherein said lobes have a ribbed outer surface, with side ribs extending circumferentially outwardly of a central leg portion, and a forward rib extending forwardly of said central leg.  
   
   
       10 . A universal dimmer switch knob kit comprising: 
 a knob having a particular appearance, and a bore with an inner periphery that is non-cylindrical; and    a plurality of intermediate members, said intermediate members each having a central bore design to receive a particular dimmer switch shaft, said intermediate members having a non-cylindrical outer periphery, said non-cylindrical bore and said non-cylindrical outer periphery mating to provide a contact surface such that rotation of said knob rotates said intermediate member, said contact surface includes a plurality of lobes extending from one of said knob and said intermediate member, and a plurality of notches formed in the other of said knob and said intermediate member.    
   
   
       11 . (canceled)  
   
   
       12 . A kit as set forth in  claim 10 , wherein said intermediate members have a plurality of lobes extending from said outer periphery that fit into notches formed in said bore of said knob.  
   
   
       13 . A kit as set forth in  claim 12 , wherein said intermediate members have three lobes and are generally A-shaped.  
   
   
       14 . A kit as set forth in  claim 13 , wherein said intermediate members have a central apex lobe, and two side lobes.  
   
   
       15 . A kit as set forth in  claim 14 , wherein said apex lobe being generally stiffer than said side lobes.  
   
   
       16 . A kit as set forth in  claim 13 , wherein said intermediate members has its two side lobes spaced by an angle that is greater than an angle spacing of said corresponding notches in said bore in said knob, and such that there is a spring force tending to separate said lobes from each other when received in said corresponding notches.  
   
   
       17 . A kit as set forth in  claim 10 , wherein said intermediate members have split ends spaced circumferentially from each other and separated by a separate channel.  
   
   
       18 . A kit as set forth in  claim 10 , wherein said lobes have a ribbed outer surface, with side ribs extending circumferentially outwardly of a central leg portion, and a forward rib extending forwardly of said central leg.  
   
   
       19 . A method of assembling a particular universal dimmer switch knob to a dimmer switch comprising the steps of: 
 (1) providing a knob having an inner bore with a non-cylindrical shape, and providing a plurality of intermediate members each having an inner bore to correspond to a particular shaft for a dimmer switch, said intermediate members having an outer periphery that is non-cylindrical, and that mates with said non-cylindrical shape of said inner bore;    (2) selecting a particular one of said intermediate members to correspond to a particular shaft on a dimmer switch; and    (3) assembling said intermediate member onto a dimmer switch shaft, and assembling said knob onto said intermediate member.    
   
   
       20 . A method as set forth in  claim 19 , wherein said intermediate member includes a plurality of lobes, and at least two of said lobes being biased away from a relaxed position when received in corresponding notches in said knob.  
   
   
       21 . A dimmer switch knob comprising: 
 a dimmer switch knob having an inner bore, said inner bore being non-cylindrical;    an intermediate member having an inner bore to receive a shaft from a dimmer switch, said intermediate member having a non-cylindrical outer periphery; and    said non-cylindrical inner bore and said non-cylindrical outer periphery mating to provide a contact surface such that rotation of said dimmer switch knob rotates said intermediate member, and said non-cylindrical inner bore and said non-cylindrical outer periphery having differing shapes such that there is clearance between the two.