Abstract:
An apparatus related to a contactless sound device, such as a horn, which may be configured to output different and/or multiple pitches using a replaceable, or interchangeable, electronic integrated circuit (“IC”) module is disclosed. The electronic IC module may include one or more sequencers electrically connected via one or more relays to at least one signal generator which is electrically connected to an output driver. Each signal generator is configured to generate at least one frequency signal, and optionally multiple frequency signals. The electronic IC module may be physically attached to an IC connection interface located on the exterior of the contactless horn body. The IC connection interface electrically connects the electronic IC module to an electro-magnet that drives the diaphragm of the contactless horn to create the selected preconfigured frequency sound.

Description:
BACKGROUND 
       [0001]    Apparatuses consistent with the exemplary embodiments relate to a contactless sound device, such as a horn, that may be configured to output different and/or multiple pitches using a replaceable, or interchangeable, electronic integrated circuit (“IC”) module. In particular, the exemplary embodiments relate to a more energy-efficient and longer-lasting sound device that utilizes a contactless horn or sound device in connection with a replaceable, or interchangeable, electronic IC module to generate sound. 
         [0002]    Apparatuses of the related art include a metal contact, typically but not always made out of tungsten, which is magnetically manipulated by an electromagnet in order to cause the diaphragm of a horn to move, thus generating sound in a single pitch. By varying the distance between the contact and the diaphragm, one may manipulate the horn to output different pitches. However, in order to vary the distance between the contact and the diaphragm, and thus achieve these different pitches, the horn&#39;s physical structure must be changed, which is a time-consuming, labor-intensive, and costly exercise. 
         [0003]    Furthermore, in the related art, the contact used by the sound device requires a relatively large amount of energy to move the diaphragm due to the extra weight of the metal contacts required by the related art horn designs. The use of metal contacts in a horn or sound device may also cause sparking around the contact, which increases the risk of fire when the horn is used in certain environments, thus making these related art apparatuses unsuitable for use in highly flammable environments such as mining operations. The fire risk inherent in related art horn and sound devices also limits the types of materials that can be used in the construction of the horn to materials that are nonflammable, thus precluding the use of some lightweight and/or less expensive alternative materials in the horn design. 
         [0004]    The metal contacts used in related art horn devices also frequently wear out or corrode, thereby forcing the user to replace the contact or, in most cases, the entire horn. 
         [0005]    In certain applications, such as in vehicle horns, there is a need for a horn that can produce multiple pitches. Currently, vehicle manufacturers use multiple horns (typically one low note horn and one high note horn) to overcome this limitation. However, the use of multiple horns increases the weight of the vehicle, which negatively impacts the fuel efficiency of the vehicle and increases the energy usage of the vehicle. Indeed, extant vehicle horns consume a large amount of energy, making them undesirable for use in electric and hybrid vehicles. 
       SUMMARY 
       [0006]    According to an aspect of one or more exemplary embodiments, there is provided a contactless horn and sound device including a replaceable, or interchangeable, electronic IC module, which provides greater energy-efficiency over related art horn and sound devices by eliminating the metal contacts required by prior art designs. 
         [0007]    According to another aspect of one or more exemplary embodiments, there is provided a contactless horn and sound device with a replaceable, or interchangeable, electronic IC module, with a longer expected lifespan than prior art horn and sound devices through the elimination of the metal contacts required by prior art designs. 
         [0008]    According to another aspect of one or more exemplary embodiments, there is provided a replaceable, or interchangeable, IC module that allows a single contactless horn and sound device to generate multiple frequency tones. 
         [0009]    According to another aspect of one or more exemplary embodiments, there is provided a replaceable, or interchangeable, IC module that allows for faster and easier modification of the tones produced by the contactless horn and sound device. 
         [0010]    According to another aspect of one or more exemplary embodiments, there is provided a contactless horn and sound device that may be used in highly flammable environments. 
         [0011]    According to another aspect of one or more exemplary embodiments, there is provided a contactless horn and sound device that may be constructed out of lighter weight materials. 
         [0012]    According to another aspect of one or more exemplary embodiments, there is provided a contactless horn and sound device that may be constructed out of less expensive materials. 
         [0013]    According to another aspect of one or more exemplary embodiments, there is provided a contactless horn and sound device that is more energy efficient and more suitable for use in hybrid and electric vehicles. 
         [0014]    According to an aspect of one or more exemplary embodiments, there is provided a contactless horn that may be configured to output different and/or multiple pitches at different intervals using a replaceable, or interchangeable, electronic IC module. The electronic IC module may include one or more sequencers electrically connected via one or more relays to at least one signal generator which is electrically connected to an output driver. If present, the one or more sequencers may be used to select the at least one signal generator. Each signal generator is configured to generate at least one frequency signal, and optionally multiple frequency signals. The output of the signal generator is electrically connected to an output driver, which amplifies the signal received from the signal generator. The electronic IC module may be physically attached to an IC connection interface located on the exterior of the contactless horn body. The IC connection interface electrically connects the electronic IC module to an electromagnet that drives the diaphragm of the contactless horn to create the selected preconfigured frequency sound(s). 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0015]      FIG. 1  is a circuit diagram illustrating an electronic circuit for a contactless horn and sound device according to an exemplary embodiment. 
           [0016]      FIG. 2  is a diagram illustrating a contactless horn and sound device with attached electronic integrated circuit module according to an exemplary embodiment. 
           [0017]      FIG. 3  is a diagram illustrating the side and bottom view of the diaphragm portion of a contactless horn and sound device according to an exemplary embodiment. 
           [0018]      FIG. 4  is a diagram illustrating a contactless horn and sound device that interacts with a vehicle system according to an exemplary embodiment that generates multiple tones based on input received from the vehicle system. 
           [0019]      FIG. 5  is a diagram illustrating a contactless horn and sound device according to an exemplary embodiment that may communicate with surrounding vehicles. 
           [0020]      FIG. 6  is a circuit diagram illustrating an electronic circuit for a contactless horn and sound device according to an exemplary embodiment. 
       
    
    
     DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS 
       [0021]    Reference will now be made in detail to the following exemplary embodiments, which are illustrated in the accompanying drawings, wherein like reference numerals refer to the like elements throughout. The exemplary embodiments may be embodied in various forms without being limited to the exemplary embodiments set forth herein. Descriptions of well-known parts are omitted for clarity. 
         [0022]      FIG. 1  is a circuit diagram of an electronic circuit for a contactless horn and sound device according to an exemplary embodiment. Referring to  FIG. 1 , a contactless horn and sound device according to an exemplary embodiment may include a sequencer  100 , a relay  180 , a signal generator  200 , an output driver  300 , and a contactless horn and housing  400 . 
         [0023]    The sequencer  100  is responsible for selecting the frequency of the sound to be output by the signal generator  200  through the use of the relay  180 , as well as the interval of the sound signal. The sequencer  100  may include a timer IC chip  110 , such as the LM555 Timer IC chip of Texas Instruments, configured to output a signal waveform that drives a relay between two states. Alternatively, the sequencer can use a transistor or other suitable circuitry or electronics instead of an LM555 Timer IC chip. 
         [0024]    The control voltage pin ( 8 ) and reset pin ( 4 ) of the timer IC chip  110  may be connected to a voltage source that may range from 5V to 15V DC. An adjustable resistor  120  may be wired to the voltage source and to control voltage pin ( 8 ), reset pin ( 4 ), threshold pin ( 6 ), and discharge pin ( 7 ) of the timer IC chip  110 , and may also be wired to electrolytic capacitor  130 . A switch  150  may be connected to the trigger pin ( 2 ) of the timer IC chip  110 . The output pin ( 3 ) of the timer IC chip  110  may be connected to a forward-biased diode  160 . The diode  160  may be connected to a reverse-biased diode  170  and may also be connected to a relay  180 . Electrolytic capacitors  130  and  140 , ground pin ( 1 ) of the timer IC chip  110 , switch  150 , and diode  170  may then be wired to ground. 
         [0025]    The output signal of the timer IC  110  may be used to select the position of the relay  180 , thereby selecting the frequency generated by the signal generator  200 . Signal generator  200  may include two timer IC chips  210  and  220 , each of which may be configured to produce a set frequency signal by adjusting the resistance values of the adjustable resistors  230 ,  240 ,  260 , and  270 , as well as adjusting the capacitance values of electrolytic capacitors  250  and  280 . Some exemplary frequencies that may be produced include 250 Hz, 300 Hz, and 435 Hz, however, the timer IC chips may be configured to produce any frequency that may be desirable in a particular application. Timer IC chips  210  and  220  may be the  555  timer IC chip discussed above or any other suitable timer IC chip. 
         [0026]    The output of the relay  180  may be connected to the control voltage pin ( 8 ) and reset pin ( 4 ) of the timer IC chips  210  and  220 , and also may be connected to the adjustable resistors  230  and  260 , respectively. The adjustable resistors  230  and  260  may be connected to the discharge pin ( 7 ) of the timer IC chips  210  and  220 , respectively, and may also be connected to adjustable resistors  240  and  270 , respectively. Adjustable resistors  240  and  270  may be connected to threshold pin ( 6 ) and trigger pin ( 2 ) of the timer IC chips  210  and  220 , respectively, and may also be connected to electrolytic capacitors  250  and  280  respectively. Ground pin ( 1 ) of the timer IC chips  210  and  220  and electrolytic capacitors  250  and  280  may be wired to ground. Output pin ( 3 ) of the timer IC chips  210  and  220  may be connected to forward-biased diodes  290  and  291 , respectively, and may output a signal of a preconfigured frequency and interval to those diodes. 
         [0027]    The diodes  290  and  291  may be connected to the output driver  300 . The output driver  300  may be used to amplify the signal outputted by the circuitry of signal generator  200 . Output driver  300  may comprise a resistor  310  which may be connected to the base of the NPN transistor  320 . The emitter of the NPN transistor may be connected to ground and the diode  330  may also be connected to ground. The collector of the NPN transistor  320  may be connected to the reverse-biased diode  330  and may also be connected to the contactless horn and housing  400 , or other circuits to provide the desired signal output. 
         [0028]      FIG. 2  is a diagram illustrating a contactless horn and sound device with attached electronic integrated circuit module according to an exemplary embodiment. Referring now to  FIG. 2 , the contactless horn and housing  400  may comprise an electromagnet  410  which may magnetically manipulate (i.e., repel and attract) the metal plate  490  secured to the bottom diaphragm  430  of the contactless horn to create a tone in accordance with the selected frequency generated by the signal generator  200 . The electromagnet  410  may be comprised of a coil, preferably a copper coil that is  20  gauge or higher (i.e., smaller in diameter), wrapped around a metal (e.g., steel, iron, or other magnetizable metal) bolt. However, the gauge of the copper coil may be higher or lower depending on a variety of factors, such as power, weight, etc. The output of the output driver  300  is electrically connected to the electromagnet  410  via the IC connection interface  450 , which is preferably positioned on the exterior of the base  440 . The base  440  may be constructed using a lightweight plastic, a lightweight metal, or another suitable material. Top diaphragm  420  and bottom diaphragm  430  may be secured together using bolt  460  and washers  470  and  480  and the bottom diaphragm  430  may then be secured to the base  440  along the rim of the base  440 , thereby allowing the free movement of the center portion of the diaphragms  420  and  430  so as to produce the preconfigured frequency sound. 
         [0029]    According to an exemplary embodiment, the signal generator  200  may be used to generate multiple pitches, tones or notes simultaneously by modifying the interval at which different frequencies are generated to create different tones. For example, the electromagnet  410  may be switched from operating at 300 Hz to 500 Hz every millisecond, so as to create a low and high tone from a single device. This provides an advantage over related art horns that use two separate horns to create two different tones. 
         [0030]      FIG. 3  is a diagram illustrating the side view and bottom view of the diaphragm portion of a contactless horn and sound device according to an exemplary embodiment. Referring now to  FIG. 3 , there may be a separation between the electromagnet  410  and the metal plate  480 . The separation, or “air gap,” preferably comprises a distance between 0.05 to 0.25 inches, with a tolerance of +/−0.05 inches. However, this separation or “air gap” may be adjusted as needed based on the desired application. 
         [0031]    Furthermore, one skilled in the art will recognize that the contactless horn device may be modified to play additional frequency tones by adding additional signal generators  200  and additional sequencers  100  to the electronic IC module and configuring them according to the present teachings. 
         [0032]      FIG. 4  is a diagram illustrating a contactless horn and sound device that interacts with a vehicle system according to an exemplary embodiment that generates multiple tones based on input received from the vehicle system. Referring to  FIG. 4 , sound device  500  may interface with a vehicle&#39;s motherboard  510  or other similar component that receives data signals from various vehicle triggers, switches, and external sensors  520  indicating the status of the vehicle, such as, without limitation, the Intelligent Power Distribution Module (IPDM) found in Nissan vehicles. Sound device  500  may produce different tones, pitches, frequencies, sounds and/or intervals of sounds based on data received from the vehicle motherboard  510 . For example, one or more of the various sensors  520  may send a signal  515  indicating the speed of the vehicle to the vehicle&#39;s motherboard  510 , which includes one or more vehicle central processing units (CPUs)  511 . The vehicle CPU  511  may send a signal  505  to the sound device  500  that is used to control the output of signal generators  200  to output a particular tone, pitch, frequency, sound, or sound interval, as discussed above. Data signal  505  or  515  may be received by receiver  501  of the sound device  500 , and provided as input to a CPU  502  to control mechanical parts  503  of the sound device  500  to generate a particular sound. Sound device  500  may also include a transmitter  504  that provides feedback to the vehicle CPU  511 or the various sensors  520  indicating the status of the sound device and the pitches, tones, frequencies, or sounds it has produced. 
         [0033]    The contactless horn and sound device of the exemplary embodiment may modify the pitch, frequency, or tone produced based on a variety of inputs provided from the various sensors  520 . For example, the sound device  400  may produce a louder (that is, higher amplitude) sound if the vehicle is moving at a high rate of speed than if the vehicle is moving slowly or stopped. The sound device  500  may also produce different sounds in response to a signal that the vehicle&#39;s anti-theft alarm has been triggered, or to announce that the driver has locked or unlocked the vehicle. The sound device  500  of the exemplary embodiment may also produce multiple alarm sounds depending how the alarm was triggered. For example, if the vehicle is accidentally and innocently bumped while the vehicle is not moving, the sound device  500  may produce a softer tone or more delayed sound interval, as compared to an alarm that is triggered by someone or something smashing the vehicle&#39;s windshield or window. The pitches, frequencies, tones and sounds generated by the sound device  400  may also be tailored to each vehicle manufacturer and/or model. 
         [0034]    Transmitter  504  may also be used to notify the driver of various conditions relating to the vehicle. For example, when the vehicle&#39;s alarm is triggered, in addition to generating a particular sound according to the type of alarm triggered, the sound device  400  may cause transmitter  504  to notify the driver that the alarm has been triggered. For example, transmitter  504  may notify the driver of the alarm via text message, email, or other electronic notification means. 
         [0035]    In addition, many vehicles include proximity sensors that detect when the driver is within a certain distance of the vehicle, for example, to unlock the doors of the vehicle as the driver approaches. Sound device  500  may receive a signal from these proximity sensors to alert the driver that the vehicle doors are unlocked when the driver is a certain distance away from the vehicle. The tone, pitch, frequency, and volume of the sound may be configured depending on the driver&#39;s distance from the vehicle. 
         [0036]    Sound device  500  may generate various sounds depending on various other sensors  520  in accordance with the exemplary embodiment. For example, many vehicles include sensors that detect proximity to other vehicles to alert the driver of a potential impact, (e.g., alerting the driver attempting to change lanes of other vehicles in the driver&#39;s blind spot). According to the exemplary embodiment, such sensors  520  may send signals to sound device  500  indicating the proximity of an object, and the size or type of object, based on which the sound the signal generator  200  will cause the sound device  500  to produce an appropriate sound. For example, the sound device  500  of the vehicle in the blind spot may generate a sound in response to a signal indicating that the vehicle changing lanes approaches within a specified distance of the vehicle. As another example, if a pedestrian is detected, the sound device  500  may generate a softer sound to warn the pedestrian. If a fast-moving vehicle is detected, the sound device  500  may generate a louder sound to warn the driver of the fast moving vehicle. If an animal, such as a deer, is detected, the sound device  500  may generate a sound having a frequency that will deter the animal and potentially avoid an impact. 
         [0037]    According to an exemplary embodiment, the sound device  500  may be connected to the vehicle CPU  511  or the vehicle&#39;s sensors  520  wirelessly. One skilled in the art would understand that many wireless technologies (e.g., Bluetooth) may be used to effect wireless communication between these devices. Using a wireless connection between these devices would eliminate the need for wiring material and switches, reducing cost and weight and simplifying manufacturing. 
         [0038]    According to an exemplary embodiment, the vehicle sensors  520  or transmitter  504  may also send a wireless signal that is received by sound devices of surrounding vehicles within a certain radius. The sound devices in the surrounding vehicles may generate sound having a pitch, frequency, tone, and/or volume that depends on the type of signal received from the vehicle sensors  520 . For example, sound devices of vehicles closer to the vehicle whose sensors  520  transmitted the wireless signal may generate a louder sound than sound devices in vehicles that are further away. In addition, the frequency or tone of the generated sound may depend on the type of vehicle from which the signal originates. For example, vehicle sensors  520  located on a truck may cause a deeper and/or louder sound to be produced in surrounding vehicles, as compared to vehicles sensors  520  located on a smaller car. The sound generated by the sound devices of the surrounding vehicles may be generated within the surrounding vehicle, e.g., through the speaker system of the surrounding vehicle, or external of the surrounding vehicle, e.g., by the horn of the surrounding vehicle. By generating sound in the surrounding vehicles, background interference and noise are less likely to prevent surrounding drivers from being alerted to potential dangers. 
         [0039]      FIG. 5  is a diagram illustrating a contactless horn and sound device according to an exemplary embodiment that may communicate with surrounding vehicles to cause a sound to be generated by a horn or audio system in the surrounding vehicles. Referring to  FIG. 5 , in step  601 , the driver activates the contactless horn trigger of the exemplary embodiment, which may be located on the vehicle steering wheel or other location. In step  602   a , a signal indicating that the horn trigger has been activated may be sent to the vehicle CPU or Controller Area Network (CAN) bus wirelessly or via wired connection. In step  602   b , a signal indicating that the horn trigger has been activated may be sent directly to the contactless horn. In step  603 , the vehicle CPU or CAN bus may send a signal to the contactless horn indicating one or more current operating states of the vehicle. For example, and without limitation, the vehicle CPU or CAN bus may transmit a signal indicating the vehicle speed, time of day, vehicle location, etc. In step  604 , the contactless horn may process the signal received in step  603  to determine the appropriate outcome corresponding to the received signal. In step  605 , the contactless horn may transmit a signal to the vehicle CPU, CAN bus, or vehicle-to-vehicle communication system indicating operational instructions for a horn or audio system in surrounding vehicles. In step  606 , the vehicle-to-vehicle communication system may transmit operational instructions to vehicles located within a specified radius of the vehicle. In step  607 , the CPU, CAN bus, or vehicle-to-vehicle communication system of the surrounding vehicles may transmit the received operational instructions to the respective contactless horns of the surrounding vehicles. In step  608 , the contactless horns of the surrounding vehicles may process the received operational instructions to determine the appropriate output. In step  609 , the contactless horns of the surrounding vehicles may transmit the appropriate operational instructions to their respective CPU or CAN bus. In step  610 , the CPU or CAN bus of the surrounding vehicle may transmit operational signals to an internal sound device or audio system to generate sound according to the operational signal. 
         [0040]      FIG. 6  is a circuit diagram illustrating an electronic circuit for a contactless horn and sound device according to an exemplary embodiment. The exemplary embodiment depicted in  FIG. 6  may include a power input stage  701 , a voltage regulator  702 , a microprocessor  703 , resistors  704  and  705 , transistor  706  and output stage  707 . Referring to  FIG. 7 , power is input to the contactless horn circuit at power input stage  701 . The input power is received as an input at voltage regulator  702 , which modifies the voltage level of the input power to an appropriate voltage for microprocessor  703 . Voltage regulator  702  outputs the modified voltage to an input pin of microprocessor  703 . Also connected to the same input pin of microprocessor  703  is resistor  704 , which is also in parallel with voltage regulator  702 . The frequency of the signal output by the microprocessor  703  is controlled by the resistance value of resistor  704 . Resistor  705  is connected in parallel with resistor  704 , and the resistance value of resistor  705  controls the duty cycle of the signal output by the microprocessor  703 . According to the resistance values of resistors  704  and  705 , microprocessor outputs a signal having a particular frequency and duty cycle. The output signal of microprocessor  703  is received as input to transistor  706 . According to the exemplary embodiment of  FIG. 6 , transistor  706  may be a MOSFET transistor. Transistor  706  controls the signal output from microprocessor  703  and provides the output signal to output stage  706 , which generates a sound through the car horn based on the received output signal. 
         [0041]    Although a few exemplary embodiments of the present general inventive concept have been shown and described, it will be appreciated by those skilled in the art that changes may be made in these embodiments without departing from the principles and spirit of the general inventive concept, the scope of which is defined in the appended claims and their equivalents.