Abstract:
A modular, cleanable, tactile switch mechanism is developed for use in an electronic pipe style personal vaporizer. The mechanism includes magnets and a pivoting arm of magnetically active material along with a customizable base that supports and guides these interacting parts. In the electronic pipe implementation of this mechanism, guiding niches of the base are integrated with a larger core support structure, demonstrating its versatility and ability to reduce overall enclosure footprint under some circumstances. Additionally, the pipe system features a locking mechanism which allows easy disassembly and repair of hand carved or otherwise fragile devices without risk of damage. 
     The present invention relates primarily to the field of magnetic or mechanical switches, particularly those capable of providing tactile feedback in a compact, durable configuration. Additionally, the invention relates to miscellaneous spring devices as well as tobacco substitute products and components thereof.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    As personal vaporizers, otherwise known as simulated smoking devices or electronic cigarettes, have increased in popularity over recent years, various problems have been identified and addressed. One key issue has been particularly prominent in this evolution. Batteries of an approximately cigarette size are generally too weak and must be recharged too often to provide a satisfactory user experience. This has led to the development of larger, cigar style and pipe style, devices. More advanced or high-end units are hand-carved from exotic woods and designed to accept user-replaceable cells. This unique integration of fine art and consumer electronics has created demand for a switch which generally meets the requirements of being compact and durable with strong tactile feedback. However, due to the carved, wooden, nature of these devices common tactile switches present some unique problems with installation. Because the pushbutton must extend through a wooden body, it must be larger than normal, and in some cases too large for normal installation. 
         [0002]    The demand for durability in this market often manifests as a desire for user maintainable devices. Demand for stronger than average tactile response is part of a broader trend toward preserving qualities of traditional ‘tobacciana.’ However, the constraints on size are perhaps most restrictive. Within the field of simulated smoking devices it is preferred that overall device size remain within dimensions roughly equivalent to traditional tobacco pipes or cigars. This constraint along with the limited energy density of available batteries leaves minimal room for a switch and required circuitry. 
         [0003]    Where a strong tactile response is required, switch manufacturers have traditionally relied upon a flexing metal dome. This type of switch however, does not exhibit the type of long term durability that is desired for this application. As the metal dome repeatedly flexes it becomes worn and eventually fails. There are alternative designs known in the art which instead employ magnetic attraction to create the desired tactile sensations. However, these also fall short of the ideal in some areas of concern to our particular objective. 
         [0004]    U.S. Pat. No. 5,990,772 describes a pushbutton switch with a magnetically coupled armature, however the design disclosed is specialized for membrane type switches and requires some specialized parts which increase manufacturing costs. U.S. Pat. No. 6,556,112 describes a method for making a discrete magnetically coupled pushbutton switch. It is essentially an adaptation of the same magnetically coupled armature for those applications where a dome style tact switch would traditionally be used. This latter design has a smaller surface area and includes solder tabs for mounting on a printed circuit board, however it also requires many specialized parts and is not ideal for use in very small spaces. Neither these designs nor the traditional dome tact switch meets all of our requirements for the present application. 
       BRIEF SUMMARY OF THE INVENTION 
       [0005]    The present invention is a modular, tactile, mechanism comprising: an armature of magnetically active material; a supporting magnet which also acts as a fulcrum for the armature; a customizable supporting structure with guiding niches for the interacting parts; along with a modular, customizable point of user activation to ease manual pivoting of the armature for tactile effect while accomplishing some simple mechanical task, such as closing a circuit. Such a mechanism is ideal for use by hobbyists and craftsmen who require durability and versatility along with a quality tactile response to compliment their hand crafted, heirloom style products. 
         [0006]    A primary object of the invention is a modular, cleanable tactile switch mechanism, further comprising two or more electrical contacts with the tactile mechanism being used to alter continuity between them. This type of switch can be manufactured inexpensively and adapted easily to suit a variety of applications where strong tactile feedback and long term durability are required. A further object is an electromechanical platform for development of electronic pipes or conversion of traditional pipes for use with personal vaporizers, comprising: a supporting core with locking cap; a modular, cleanable tactile switch positioned on the side of that core; a locking mechanism which secures the core within the pipe cavity, easing disassembly and maintenance; along with the requisite electronics to power a device of the user&#39;s choosing. In many respects a pipe style device is better suited to the unique demands of personal vaporizers. Even with a large battery housed in the chamber of an electronic pipe, the device sits comfortably in hand, lending a more natural and traditional feel to the experience. 
         [0007]    The pushbutton or point of user activation in any case must be long enough to extend through device walls, which may often be substantial for structural or purely decorative reasons. This can pose significant installation problems, particularly for those switches most commonly available. It is preferable therefore that the pushbutton be detachable from the rest of the switch mechanism. This added modularity will make it possible to install the switch and other components in confined spaces while still allowing for sufficiently robust enclosure walls. As an added benefit, this means that the point of activation can also be customized and even matched to a particular wood. 
         [0008]    The principal mechanism of the present invention, includes an armature which sits partially on a magnet or magnets while also overhanging substantially in the opposite direction. The armature is formed of a conductive and magnetically active material. It is retained in the described position by its attraction to the magnet(s). Additionally, the magnets are supported and the armature is partially enclosed by a molded base which may also include niches for electrical contacts to be attached under the magnets and under the opposite end of the armature. The centrally located magnet acts both as retainer and fulcrum for the armature which may pivot about its point of contact with that magnet. This pivoting can be used to open or close electrical circuits or for other purely mechanical tasks such as releasing a latch. 
         [0009]    Due to its simplicity, the apparatus described can be inexpensively produced, even in small quantities when necessary. The armature can be formed into a shape appropriate for its task and the base can be produced as a discrete module or integrated structurally with other components of a particular implementation. This apparatus can then be installed in an enclosure where it should align with an opening adjacent to the magnets and slightly off center of the armature lengthwise. Through this opening, a suitable pushbutton can be attached magnetically to the armature to allow activation. It is this simplicity and modularity which significantly distinguish the present invention from what is known in the art. 
         [0010]    When implemented as a switch, the present design has the added advantage of being easily cleanable. Hence it may be expected to endure a long life of heavy use with little degradation. Furthermore, the electromechanical pipe system developed here will provide traditional pipe makers an easy means of entering the personal vaporizer market with quality mechanisms to compliment their craftsmanship. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         [0011]      FIG. 1  is an exploded perspective view of a tactile mechanism according to the present invention. 
           [0012]      FIG. 2  is an assembled perspective view of the mechanism of  FIG. 1 . 
           [0013]      FIG. 3  is an assembled cross section of the mechanism of  FIG. 1 . 
           [0014]      FIG. 4  is an assembled cross section of the mechanism of  FIG. 1  in its actuated state. 
           [0015]      FIG. 5  is an exploded perspective view of a tactile switch based on the mechanism of  FIG. 1 . 
           [0016]      FIG. 6  is an assembled perspective view of the switch of  FIG. 5 . 
           [0017]      FIG. 7  is an exploded perspective view of an electronic pipe according to the present invention. 
           [0018]      FIG. 8  is an assembled perspective view of an electronic pipe according to the present invention. 
           [0019]      FIG. 9  is a perspective view of core support  42   
           [0020]      FIG. 10  is an assembled perspective view of core support  42   
           [0021]      FIG. 11  is a bottom perspective view of core support  42   
           [0022]      FIG. 12  is an assembled bottom perspective view of core support  42   
           [0023]      FIG. 13  is an assembled perspective view of the interior of core support  42  with spring bracket  56 . 
           [0024]      FIG. 14 . is a perspective view of the switch mechanism niches integrated within core support  42 . 
           [0025]      FIG. 15  is an assembled perspective view of the switch implementation within core support  42 . 
           [0026]      FIG. 16  is a perspective view of lock cylinder  66  and connector  70 . 
           [0027]      FIG. 17  is a perspective view of the pipe system components partially assembled, without pipe body  40 . 
           [0028]      FIG. 18  is a perspective view of the system components assembled without pipe body  40 . 
           [0029]      FIG. 19  is an overhead perspective view of the core interior. 
           [0030]      FIG. 20  is an assembled perspective view of the core cap. 
           [0031]      FIG. 21  is an overhead perspective view of the cap. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0032]    As seen in  FIGS. 1 and 2 , the tactile mechanism of the present invention shown generally at  2 , requires a button  4  and attaching magnet  6 , an armature of magnetically active material  8 , a fulcrum magnet  10 , and a molded base  12  which supports and guides the foregoing parts.  FIGS. 1 through 5  show how the tactile mechanism of the present invention might appear in one of its simplest embodiments. 
         [0033]    Pushbutton  4  should include a recess on bottom into which attaching magnet  6  can be pressed and fastened. In a preferred embodiment pushbutton  4  is cut from wood. It could also be rubber, plastic or any similar material. Fulcrum magnet  10 , is pressed and fastened into niche  16  of molded support base  12 . In a preferred embodiment, molded support base  12  is additively manufactured from plastic. It could be made from wood, ceramic, glass, or other non-conductive material. Armature  8 , made of a magnetically active material, is then positioned on top of fulcrum magnet  10  where it is retained magnetically within niche  18 . Pushbutton  4 , along with magnet  6 , is then inserted into guide niche  14  where it attaches to armature  8  magnetically. 
         [0034]    When downward actuating force  20  is applied by the user to pushbutton  4 , as seen in  FIG. 4 , the pushbutton travels along with magnet  6 , within guide niche  14  of molded base  12 , transmitting the downward force to armature  8 . This creates torque about the edge of fulcrum magnet  10  which, when sufficient, will cause the tail of armature  8  to overcome the magnetic attraction which holds it in its non-actuated position. When it does, the armature will quickly pivot until its front end strikes molded base  12  providing both tactile and auditory feedback and distributing the downward force between support base  12  and fulcrum magnet  10 . This transmission of force to support base  12  could potentially be used for a number of purely mechanical purposes. In a preferred embodiment of the present invention it is used to open or close electrical circuits. 
         [0035]    As seen in  FIGS. 5 and 6  this preferred embodiment, shown generally at  6  is similar in construction to  FIG. 2  though it includes several additional elements. Chiefly, the fulcrum magnet  10  has been replaced by two smaller magnets, fulcrum magnet  22  and retainer magnet  24 . These are identical to attaching magnet  6 . Under these magnets are fastened corresponding electrical contacts; fulcrum common contact  30  and normally closed contact  28  within niches  26  . Similarly, a normally open contact plate  32  is added to the point of contact between armature  8  and support base  12 . These three contacts should be pressed or cut from a conductive, magnetically active material. Additionally, molded support base  12  should be of an insulating material and include the requisite niches to accommodate and/or guide each of the foregoing components. 
         [0036]    Fulcrum magnet  22  and retainer magnet  24  must remain electrically isolated but also each be electrically connected and mechanically fastened to the tops of fulcrum common contact plate  30  and normally closed contact plate  28  respectively. This can be accomplished magnetically, though the electrical connection could potentially benefit from a conductive epoxy. Normally open contact plate  32  must be fastened within niche  34  in such a way that it will remain stationary during actuation. 
         [0037]    This arrangement of contacts and magnets allows for two distinct actions with regard to electrical continuity. Upon actuation, the circuit between common contact  30  and normally closed contact  28  shifts from a closed to an open state. Whereas the circuit between common contact  30  and normally open contact  32  shifts from an open state to a closed one. 
         [0038]    When downward actuating force  20  is applied by the user to pushbutton  4  the pushbutton will travel along with magnet  6  within guide niche  14  of molded support base  12 , transmitting downward force to armature  8 . This creates torque about the edge of fulcrum magnet  22  and when sufficient will cause the tail of armature  8  to overcome the magnetic attraction which holds it to retainer magnet  24  opening the circuit between contacts  30  and  28 . When this occurs, armature  8  will quickly pivot until its tip strikes normally open contact plate  32  completing the circuit with common contact  30 . As in the case of the mechanism of  FIG. 2 , this striking will also serve to provide tactile and auditory feedback of the actuation. 
         [0039]    Either of the embodiments described thus far can be integrated structurally with a variety of applications allowing for implementation under very tight spatial constraints. It is only necessary to include the niches and guides of molded support base  12  in the structural design of an application and later add the remaining components in order to arrive at this fully integrated and extremely compact implementation. 
         [0040]    Our primary application of interest, the one which elicited the present invention, is a personal vaporizer device, specifically an electronic pipe like the one seen in  FIG. 8 . The stem portion of this ‘pipe’ would be made up of an electronic atomizer and a mouthpiece, while the pipe assembly described here is merely a source of power for that atomizer and a platform for further development, alternative circuit designs and additional features such as adjustable wattage, LEDs or other indicators. As seen in  FIG. 7 , this application requires: a pipe body  40  with openings for the chamber, shank, and pushbutton; a molded core support  42  which can maintain all parts in their appropriate relationships; a locking cap  44 ; a conductive disc  46 ; a battery  48 ; a fuse  50 ; switch magnets  52 ; switch arm  54 ; a switch to battery bracket  56  with spring; an attaching magnet  58 ; a pushbutton  60  with recess for magnet; a fuse spring  62  with lead; a switch contact plate  64  with lead; a shank to core lock cylinder  66 ; a fastening screw  68  for cylinder  66 ; a press fit atomizer connector  70  with integrated connections for two leads.  FIGS. 9 through 21  illustrate this electronic pipe implementation in more detail. 
         [0041]    The pipe body can be manufactured in much the same manner of traditional smoking pipes. In a preferred embodiment it is carved from wood, however it could also be stone, glass, polymer, etc. It should however meet certain specifications in order to accommodate the remaining parts which form the electronic pipe system. Core support  42  should include guides and niches for all remaining parts to interact. Cap  44  should include locks to mate with support  42  as well as a niche for conductive disc  46 . In one embodiment, core  42  and cap  44  are additively manufactured of plastic. In other embodiments they may be ceramic, glass or any similar non-conductive material. In one embodiment, battery  48  is a rechargeable lithium ion cell. It could conceivably be any source of electricity which can fit within the core. In a preferred embodiment, fuse  50  is a low voltage automotive type. However, it could be any suitable fuse that can be accommodated by the core and enclosure. Magnets  52  and armature  54  are identical to those of previously described mechanisms. Battery spring bracket  56  is fashioned of conductive and magnetically active material with a spring attached to one end. It is designed to sit under magnets  52  and connect them electrically to the spring which will sit under battery  48  (we only need a normally open contact for this application.) Magnet  58  is identical to those previously described. In a preferred embodiment, pushbutton  60  is cut from wood, but it could be made of any similarly durable material. 
         [0042]    Magnet  58  and pushbutton  60  are pressed and secured together as in previous embodiments and will form the point of user activation, protruding from the side of pipe body  40 . Their modularity allows for easier assembly because pushbutton  60  can be attached after core support  42  is fitted, along with other components inside pipe body  40 . Fuse spring with lead  62  is made of conductive material and will serve ultimately to connect fuse  50  to atomizer connector  70  while also forcing the top of fuse  50  into contact with disc  46 . Switch contact plate  64  with lead is also made from conductive material and will serve to connect the switch mechanism to connector  70 . Locking screw  68  will be used to secure locking sleeve  66  to core  42  through the shank of pipe body  40  before attaching modular pushbutton  60 . Connector  70  is a standard atomizer connection for electronic cigarettes. It is modified only by the addition of two mating connectors for the leads, allowing for easier disassembly. 
         [0043]    Assembly of the device requires first that all permanent electronic components are fitted and secured in the niches of core support  42 . Fuse spring with lead  62  is secured within fuse chamber  74  and lead  82  extends through opening  72 . Next switch contact plate with lead  64  is fastened into niche  76 . Battery spring bracket  56  should then be inserted into niche  84  so that the spring is in the battery chamber. Switch magnets  52  can then be fixed within niche  92  and electrically connected to bracket  56  (we only need the normally open circuit for this application.) Finally switch arm  54  is fitted into niche  88  and atop magnets  52  completing the tactile switch apparatus and the core assembly. Next this is combined with the remaining components inside pipe body  40 . 
         [0044]    Begin by feeding leads  80  and  82  through the pipe chamber and pipe shank as core support  42  is inserted into pipe body  40 . Leads  80  and  82  are then threaded through holes  98  and  100  in lock cylinder  66  as it is inserted into the pipe shank. With leads now held out of the way, screw  68  can be fastened through hole  102  of cylinder  66  and into securing point  78  of core support  42 . This will pull the two sides together inside pipe body  40  and serve to stabilize the entire assembly. After this, leads  80  and  82  can be attached to atomizer connector  70  at  94  and  96 . Then the connector is press fit into locking cylinder  66  completing the primary assembly. It should fit in such a way that it is not able to spin over time. Lastly conductive disc  46  is fastened into the bottom of cap  44  and external pushbutton  60  along with attaching magnet  58  is attached through the side of pipe body  40 . 
         [0045]    With these steps completed the device is now in a user ready state and battery  48  along with fuse  50  can be placed in their respective niches within the pipe core. Next, taking advantage of texture  106  on top of cap  44 , the cap assembly is locked into place by pressing down and twisting locks  104  under teeth  86 . This holds disc  46  firmly against the top of battery  48  as well as fuse  50 , allowing positive current to flow first through disc  46  and fuse  50 , then spring  62  and lead  82  into connector  70  where it will power the atomizer. This arrangement is preferred because in an over current situation the fuse would fail before anything else. On the return side of the connector, current will flow through lead  80  to plate  64  where it can be switched by the mechanism previously described. As user supplied pressure forces pushbutton  60  through pipe body  40  and into niche  90  it causes armature  54  to pivot on magnets  52  and strike switch plate  64  allowing current to flow through armature  54 , magnets  52 , and spring bracket  56  back to battery  48 . This completes the circuit and when pressure is released, armature  54  will snap back into position on top of magnets  52 , breaking the circuit. 
         [0046]    The electronic pipe described holds several other key benefits over currently available models. Chief among these is its ease of use and maintenance. Battery  48  can be readily accessed by simply pressing and turning cap  44 , releasing locks  104  from teeth  86 . Fuse  50  can be accessed through the same opening and is intended to be a common automotive fuse, found at many service stations. The shank locking design of this pipe assembly means that interior components, while stabilized, remain fully accessible for cleaning or even complete replacement if necessary without the risk of damaging a highly valued or one of a kind pipe body. 
         [0047]    Perhaps most importantly, the point of user activation is comfortably positioned on the side of pipe body  40  rather than on top of the chamber as with most current designs. This placement allows for more natural handling of the device and an experience more in keeping with traditional pipe smoking Additionally it leaves the cap free to be a primarily decorative component and a point of customization. The modular nature of the switch means that pushbutton  60  can simply be removed if one wishes to disable the device temporarily. This arrangement of components and these benefits are made possible largely by the modular tactile mechanism of the present invention. 
         [0048]    While a very specific implementation has been described here, it is easy to imagine numerous and varied scenarios in which the present invention might be of considerable utility. A number of additional features such as voltage or wattage adjustments, led indicators etc. might be added to this basic pipe platform according to specific preferences. Further, modification of core  42  and cap  44  could easily adapt the pipe design into a cigar or cigarette style vaporizer, a pen light, or a number of other consumer electronics devices. Furthermore, the switch specifically and the tactile mechanism more generally could be employed in countless custom applications, particularly those of hobbyists and craftsmen who may be interested in durability and ease of maintenance. It should be understood that the specific examples given here are in no way meant to limit the following claims.