Sealed toggle switch

Claim 1

A sealed switch comprising a hollow base member of insulator material having a peripheral wall, a bottom, and a rim at an upper surface of said peripheral wall with a perimetric groove extending along said upper surface; an O-ring seal disposed in said groove; a metal cover disposed on said base member to define an interior and an exterior of the switch and having a portion mating with said upper surface compressively against said O-ring seal; electrical switching means disposed in said interior and including a rockably mounted conductive blade disposed generally parallel to said bottom; a manual actuator having a metal lever handle extending from said exterior to said interior, with a telescoping non-conductive finger resiliently mounted to slide relative thereto and to contact said blade directly and bias it towards said bottom, said lever handle having a metal ball disposed thereon, the metal being of a type which forms a seal when compressively contacted by an O-ring seal of resilient material, a bushing disposed on said cover, having a socket to mate with said ball to permit at least limited rotary motion in at least the direction along said blade and having upper and lower openings leading to said exterior and said interior, respectively, with a first annular groove in said socket extending around said lower opening; an O-ring seal disposed in said annular groove compressively against said ball; means for holding said ball against said O-ring seal; wherein said electrical switching means includes a plurality of contact rivets extending through the base member; a like plurality of terminals secured by said contact rivets, said contact rivets each having a contact head, a shank passing through a cooperating aperture in said base member, a rivet end passing through an aperture in a respective one of said terminals, and a flattened head formed against the respective terminal securing the latter; and respective flat resilient sealing members compressed between the contact heads of said contact rivets and said bottom, with the portions of said bottom underlying said contact heads being substantially flush with adjacent portions of said bottom, so that said contact heads are held off the bottom by said sealing members, wherein said bottom is provided without recesses around said shanks of said contact rivets so that the sides of said flat sealing members facing said bottom are disposed flush with said bottom.