Abstract:
A multi-output switch includes a dipole magnet configured to move from a central position to either a first position or a second position and a Hall Effect sensor having a first sensitive area with a first output and a second sensitive area with a second output, wherein the sensor is relatively positioned such that when the magnet is in the central position, the first output and second output read off, when the magnet is in the first position the first sensitive area is activated and the first output reads on, and when the magnet is in the second position the second sensitive area is activated and the second output reads on. The switch may further include a magnet holder configured to house the magnet and define a pathway of movement for the magnet.

Description:
BACKGROUND 
     This document relates to a switch having a Hall Effect device, and more particularly to a multi-position switch having a single Hall Effect device with dual digital outputs. 
     Switches designed to be used in harsh environments are becoming smaller while reliability requirements are simultaneously increasing. For example, switches used in automotive applications, such as gear shifts, would ideally be designed to fit into an isolated area while still maintaining a high reliability as replacing the switch may require significant effort and resources. If the gear shift switch is located in the steering console of an automobile, the entire steering column may need to be removed or replaced to repair the defective switch. Therefore, it is desirable to manufacture reliable compact switches for certain applications. 
     One possible solution is to manufacture a mechanical switch having various moving parts used to switch between various states. A mechanical switch has several drawbacks. One major drawback is the limited life cycle of the moving parts. Another drawback is that mechanical switches are not as robust against extreme environmental conditions. Mechanical switches require a sealed casing to protect against environmental conditions such as dirt and precipitation. Similarly, the moving pieces may be constructed of various metals (e.g., aluminum, steel) that may react differently in different temperatures. This may result in reduced reliability of the switch as in various temperatures due to changes in materials (e.g., shrinkage or expansion) that may cause reduced contact force in the switch. As discussed above, replacing some switches is tedious and time-consuming, making mechanical switches, with the various drawbacks discussed herein, a less than ideal solution. 
     Another solution for increasing reliability in switches is using a solid state compact switch utilizing few, if any, moving parts. One example of a solid state switch is a switch utilizing Hall Effect sensors. Hall Effect sensors are specialized integrated circuits which respond to the presence of a magnetic field. By including Hall Effect sensors along with a magnet positioned to move along the Hall Effect sensors, a switch may be constructed that includes a single moving part. 
     An example of a switch using a Hall Effect sensor is shown in  FIG. 1 . Specifically,  FIG. 1  illustrates switch  100 . Switch  100  uses a side approach for the magnet orientation and movement. Switch  100  includes two Hall Effect sensors  102   a  and  102   b . Each Hall Effect sensor includes plates  104   a  and  104   b  that are sensitive to a certain magnetic pole. In this example, both sensitive plate  104   a  of sensor  102   a  and sensitive plate  104   b  are sensitive to the south pole of magnet  106 . Magnet  106  is configured to move in the direct of the arrow next to sensors  102   a  and  102   b . As the magnet moves toward sensor  102   a , plate  104   a  detects the south pole of magnet  106  and sensor  102   a  turns on. Similarly, as magnet  106  moves toward sensor  102   b , plate  104   b  detects the south pole of magnet  106  and sensor  102   b  turns on. The components of switch  100  are configured and arranged such that there are three possible scenarios: (1) when magnet  106  is moved toward sensor  102   a , only sensor  102   a  turns on, (2) when magnet  106  is moved toward sensor  102   b , only sensor  102   b  turns on, and (3) when magnet  106  is in the central or neutral position, both sensors  102   a  and  102   b  are off. 
     Switches using solid state devices like Hall Effect sensors are more reliable than mechanical solutions as the number of moving parts is greatly reduced. Switches using these typical arrangements of Hall Effect sensors, however, still have several drawbacks. One major drawback is that only a single output is available per Hall Effect sensor requiring two Hall Effect sensors be used. Another drawback of these typical arrangements using Hall Effect sensors is switch point tolerance. The switch point tolerance is influenced by a number of factors, including temperature, positional tolerance of the magnet with respect to the Hall Effect sensor in the direction of travel of the magnet, manufacturing variations in the magnet and variation in the Hall Effect sensor operate/release threshold. The strength of the magnet must be carefully matched with the sensitivity of the Hall Effect sensor. If the sensitivity of the Hall Effect sensor is too high with respect to the magnet strength, then positional tolerances may be poor. A higher sensitivity Hall Effect sensor also raises the risk of interference from outside magnetic fields. Conversely, if the sensitivity of the Hall Effect sensor is too low with respect to the magnet strength, the positional tolerance is improved but there is a higher risk that the magnet will not trigger the Hall Effect device. 
     Due to potentially large positional tolerances, the size of the movements of the magnet from one position to another must be big enough to ensure that there is no overlap in magnetic field detection at the Hall Effect sensor between positions. This large neutral distance between positions is not always desired due to size constraints in certain applications. 
     Another drawback is the size required to house multiple Hall Effect sensors along with the magnet as well as the addition of another component and the increased likelihood that the component may fail. 
     Several attempts have been made to overcome the drawbacks of switches using multiple Hall Effect sensors. One example is to use a multi-pole magnet to improve positional tolerance. In the example of switch  100  of  FIG. 1 , magnet  106  would be replaced with a multi-pole magnet having a north-south-north pole configuration. The multi-pole magnet would create a sharper change in the magnetic field around the switching positions of the magnet&#39;s movement, improving the positional tolerance. However, the multi-pole magnet would need to be larger than the standard dipole magnet, making the switch more difficult to package. Also, the multi-pole magnet is more difficult to manufacture than a dipole magnet, resulting in a cost increase. 
     Another example of a switch providing multiple outputs with a single Hall Effect sensor and magnet utilizes a programmable linear Hall Effect sensor. A programmable linear sensor can be programmed to produce different outputs based on the detected strength of a magnetic field, i.e., as the magnet gets closer, the field increases and changes the output of the sensor. This approach introduces a new set of drawbacks, primarily the need to program the sensors, comparator circuits must be used to interpret the output of the sensor and determine the position of the magnet, and the programmable sensors are significantly more expensive than standard Hall Effect sensors. 
     SUMMARY 
     Before the present methods are described, it is to be understood that this invention is not limited to the particular systems, methodologies or protocols described, as these may vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to limit the scope of the present disclosure which will be limited only by the appended claims. 
     It must be noted that as used herein and in the appended claims, the singular forms “a,” “an,” and “the” include plural reference unless the context clearly dictates otherwise. Thus, for example, reference to a “sensor” is a reference to one or more sensors and equivalents thereof known to those skilled in the art, and so forth. Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art. As used herein, the term “comprising” means “including, but not limited to.” 
     In one general respect, the embodiments disclose a switch. The switch includes a dipole magnet configured to move from a central position to either a first position or a second position and a Hall Effect sensor having a first sensitive area with a first output and a second sensitive area with a second output, wherein the sensor is relatively positioned such that when the magnet is in the central position, the first output and second output read off, when the magnet is in the first position the first sensitive area is activated and the first output reads on, and when the magnet is in the second position the second sensitive area is activated and the second output reads on. 
     In another general respect, the embodiments disclose a second switch. The second switch includes a magnet having a north pole and a south pole and a dual output Hall Effect sensor having a north pole magnetic field sensitive area with a first output and a south pole magnetic field sensitive area with a second output, wherein the sensor is relatively positioned such that when the magnet is in the central position, the first output and the second output both read off, when the magnet is in the first position the north pole magnetic field sensitive area is activated and the first output reads on, and when the magnet is in the second position the south pole magnetic field sensitive area is activated and the second output reads on. 
     In another general respect, the embodiments disclose a third switch. The third switch includes a magnet having a north pole and a south pole and producing a magnetic field and a dual output Hall Effect sensor having a north pole magnetic field sensitive area with a first digital output and a south pole magnetic field sensitive area with a second digital output, wherein the sensor is relatively positioned such that when the magnet is in the central position, both the north pole magnetic field sensitive area and the south pole magnetic field sensitive area measure zero net magnetic field and both the first digital output and the second digital output read off, when the magnet is in the first position the north pole magnetic field sensitive area measures a net magnetic field and is activated resulting in the first digital output reading on, and when the magnet is in the second position the south pole magnetic field sensitive area measures a net magnetic field and is activated resulting in the second digital output reading on. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Aspects, features, benefits and advantages of the present invention will be apparent with regard to the following description and accompanying drawings, of which: 
         FIG. 1  illustrates various prior art embodiments of switches using Hall Effect sensors; 
         FIG. 2  illustrates various embodiments of a switch using a dual output Hall Effect sensor; 
         FIG. 3  illustrates various embodiments of a switch using a dual Output Hall Effect sensor including a magnetic field diagram; 
         FIGS. 4   a - c  illustrate various embodiments of a switch using a dual output Hall Effect sensor in various positions; 
         FIG. 5   a - b  illustrate exemplary circuits including a dual output Hall Effect sensor; 
         FIG. 6  illustrates an exemplary enclosure for housing a switch having a dual output Hall Effect sensor; and 
         FIG. 7  illustrates an exemplary rocker switch assembly. 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 2  illustrates a compact switch  200  using a Hall Effect sensor and having multiple possible outputs. In this example, switch  200  may be configured to produce 3 outputs: (1) Off, (2) On 1  and (3) On 2 . These outputs will be explained in greater detail in the discussion of  FIGS. 4   a - c  below. 
     Unlike switch  100  as discussed above, switch  200  may have a dual output Hall Effect sensor  202 . Dual output Hall Effect sensor  202  may be a Hall Effect sensor having two areas or plates that are sensitive to opposite magnetic poles. Hall Effect sensor  202  may produce two corresponding digital outputs, the previously mentioned On 1  and On 2  depending on which of the sensitive areas detects a change in magnetic field. In switch  200 , sensor  202  may have two sensitive areas or plates  204   a  and  204   b  that are sensitive to opposite magnetic poles. As configured, plate  204   a  may be sensitive to a magnetic south pole and plate  204   b  may be sensitive to a magnetic north pole. Arrows A and B represent the direction of sensitivity to a magnetic field for each of plates  204   a  and  204   b  respectively. 
     Unlike the position of magnet  106  of switch  100 , magnet  206  may be oriented parallel to a longitudinal axis  210  of sensor  202 . More specifically, the north-south pole orientation of magnet  206  may be normal or perpendicular to the sensitivity directions of plates  204   a  and  204   b . At the center plane  207  of the magnet  206 , the normal magnetic field produced by the magnet&#39;s north and south poles is zero. The field increases with distance from the center plane  207  toward one of the poles of the magnet  206 . The normal magnetic field of magnet  206  increases in polarity corresponding with the magnet pole being approached (i.e., north or south). One advantage of this approach is that a reversal point of the magnetic field may be based solely on magnet geometry and is not impacted by variations in magnet strength. Until the center plane  207  of the magnet  206  passes over plates  204   a  and  204   b , there is no risk of accidental actuation as the field normal to the sensor is in the opposite polarity, thereby turning the sensor  202  off. 
     The magnet  206  may be manufactured from various magnetic materials. One possible material may be Neodymium Iron Boron (NeFeB). NeFeB magnets are inexpensive to produce and even small NeFeB magnets may generate a strong magnetic field. One advantage of using a high magnetic energy material such as NeFeB is that a relatively short, powerful magnet may be created. The shorter and more powerful the magnet, the more rapidly the field normal to the sensor changes from the center plane of the magnet, e.g., center plane  207 . This rapid change in field strength may result in superior positional tolerances. As discussed above with respect to typical Hall Effect sensor switches, positional tolerances with respect to the sensors and magnets are an important consideration in switch design. 
     It should be noted that  FIG. 2  shows both a linear path of movement as well as a rotational path of movement for magnet  206 . Depending on the application, a slide switch layout may be used which would result in the magnet  206  moving in the linear path. Alternatively, a rocker or toggle switch layout may be used, resulting in the magnet  206  moving in the rotational path. An exemplary embodiment illustrating a rocker switch layout is addressed below in the discussion of  FIG. 7 . 
       FIG. 3  illustrates switch  200  with an exemplary magnetic field produced by magnet  206 . The magnetic field is represented by the various arrows surrounding sensor  202  and magnet  206 . Here, magnet  206  may be at a central or neutral position such that the net magnetic field detected at plate  204   a  may be identical to the net magnetic field detected at plate  204   b . At this position, no net magnetic field may be detected at either plate, and the output of sensor  202  may be neutral and switch  200  may output off. As magnet  206  moves, the net magnetic field at the plates may change, thereby changing the output of sensor  202  and switch  200  itself.  FIGS. 4   a - c  illustrate various embodiments of switch  200  with magnet  206  in various positions. 
       FIGS. 4   a - c  illustrate switch  200  with magnet  206  in various positions. To move magnet  206 , magnet holder  208  may be used. Holder  208  may be configured to move magnet  206  from the central to either a first or second position. Holder  208  may be further configured to move magnet  206  parallel to sensor  202  while ensuring magnet  206  and sensor  202  do not make contact. 
       FIG. 4   a  shows magnet  206  in the central position. When in the central position, the north pole of magnet  206  is closest to the south sensitive area  204   a  of sensor  202 , the south pole of the magnet is closest to the north sensitive area  204   b  of the sensor, and the center of the magnet is substantially positioned at the center of the space between the two sensitive areas. Thus, the net magnetic field at plates  204   a  and  204   b  is oriented opposite to the sensitivity of the plates, driving the output of sensor  202  to zero and turning (or maintaining) switch  200  off.  FIG. 4   b  shows magnet  206  moved to a first position. The first position may be a position where the center plane  207  of magnet  206  is sufficiently past plate  204   b , thereby moving the north pole of the magnet closer to the north sensitive area or plate  204   b , and producing a normal magnetic field in a proper sensitivity direction at plate  204   b . This normal magnetic field may activate plate  204   b , turning on digital output  1  of sensor  202  and changing the state of switch  200  to On 1 .  FIG. 4   c  shows magnet  206  moved to a second position. The second position may be a position where the center plane  207  of magnet  206  is sufficiently past plate  204   a , thereby moving the south pole of the magnet closer to the south sensitive area or plate  204   a , and producing a normal magnetic field in a proper sensitivity direction at plate  204   a . This normal magnetic field may activate plate  204   a , turning on digital output  2  of sensor  202  and changing the state of switch  200  to On 2 . It should be noted that the output of switch  200  may be reversed and On 1  may occur when magnet  206  is in the second position and On 2  may occur when magnet  206  is in the first position. Similarly, On 1  and On 2  are merely used by way of example and the outputs of switch  200  may be labeled accordingly depending on the application. 
     It should be noted that the linear movement of magnet  206  in  FIGS. 4   a - c  is shown by way of example only. As discussed above, magnet  206  may move in a rotational direction provided the range of rotational movement results in center line  207  of the magnet crosses from between plates  204   a  and  204   b  to a position past one of the plates, thereby activating sensor  202 . 
       FIG. 5   a  shows an exemplary circuit  500  including a dual output Hall Effect sensor  502 . Sensor  502  may be mounted on printed circuit board (PCB)  504 . It should be noted that circuit  500  is shown by way of example only, and a dual output Hall Effect sensor may be integrated into various devices and/or circuits depending on the application. 
     A supply voltage may be provided to sensor  502  via a connection to PCB  504 . Similarly, the two outputs of sensor  502  (e.g., the digital outputs from the two magnetically sensitive plates discussed above) may be obtained by another device (not shown) by connecting to leads coming off PCB  504 . A first output  506   a  of the sensor  502  may deliver a signal (e.g., On 1 ) when one of the sensitive areas (e.g., the north sensitive area) of the sensor returns a voltage triggered by its detection of a magnetic field. A second output  506   b  of the sensor  502  may deliver a signal (e.g., On 2 ) when the other sensitive area (e.g., the south sensitive area) of the sensor returns a voltage triggered by its detection of a magnetic field. When neither output  506   a  or  506   b  delivers a signal, the switch may be in the Off position. The device can monitor the outputs of the leads, and any changes in signals on the leads may indicate the overall output of the switch, i.e., Off, On 1  or On 2 . 
     Depending on the application of PCB  504  and the resulting available supply voltage and current, additional components may be included in circuit  500 . For example, as shown in  FIG. 5   b , in circuit  510  a dual output Hall Effect sensor  512  may be mounted on a PCB  514 . A resistor network, e.g., resistors R 1 , R 2  and R 3 , may be included on PCB  514  or at another location in circuit  500  so that a first sensor output  516   a  leads to R 1  and a second sensor output  516   b  leads to R 2 . The resulting outputs of sensor  512  may thus reduce the number of electrical connections between PCB  514  and another device. Similarly, a capacitor C 1  may be included in parallel with sensor  512  to suppress any noise on the input voltage line. It should be noted that circuit  510  is shown by way of example only, and additional configurations of components may be used depending on the application of the circuit. 
       FIG. 6  shows an exemplary enclosure  600  that may house a switch using a dual output Hall Effect sensor such as the switches described above in  FIGS. 2 ,  3  and  4   a - c . Enclosure  600  may enclose a dual output Hall Effect sensor. A magnet  602  may be directly or indirectly mounted to the enclosure  600 . Similarly, magnet  602  may be configured to be mounted in a magnet holder. Magnet  602  may be configured to either slide or rotate. For example, magnet  602  may be configured to toggle left and right about a central pivot point, resulting in a rotation of the magnet. Conversely, magnet  602  may be configured to slide a short distance left of center and right of center, resulting in a sliding movement of the magnet. Enclosure  600  may also include various tabs  604   a  and  604   b , as well as various notches or indentations  606 . Depending on the application and positioning of enclosure  600 , these tabs and notches may be used to anchor the enclosure firmly to another component. 
     Enclosure  600  may be designed such that various components of the switch, such as the sensor and PCB described in the discussion of  FIGS. 5   a - b  above, fit securely inside the enclosure. 
       FIG. 7  shows an exemplary rocker, or toggle, switch assembly  700 . Switch assembly  700  may include a magnet holder  702 , shown in this example in a center position. Magnet holder  702  may be configured to rotate about rotational point  704  as indicated by arrow R. Movement of magnet holder  702  about rotational point  704  may cause the displacement of magnet  706 , causing one of the sensitive plates of dual output Hall Effect sensor  708  to detect a magnetic field. Sensor  708  may be mounted on PCB  710 , and the outputs of sensor  708  (e.g., Off, On 1  and On 2 ) may be electrically connected to another device by wires  712 . Any movement of magnet holder  702 , e.g., from the center position to a first or second position, may be limited or regulated by a damping device or a device configured to limit the movement of the magnet holder. For example, magnet holder  702  may include detent ball  714 . As magnet holder  702  rotates, detent ball  714  may enter detent  716 , resulting in magnet holder  702  being unable to rotate any further in that particular direction. Additional damping devices such as various springs may be used to limit the movement of magnet holder  702 . 
     It should be noted that the above-disclosed switch and enclosures may be incorporated into various embodiments. For example, the magnet may be mounted to an actuator that is used to move the magnet between the various positions. A connection between the actuator and the body or enclosure of the switch may be, for example, sliding or rotating to make a slide or toggle/rocker switch. The switches disclosed herein may be integrated into automotive controls (e.g., upshift/downshift switch), off-road vehicle controls or industrial machinery controls. 
     It will be appreciated that various of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Also that various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.