Level/position sensor and related electronic circuitry for interactive toy

A sensor for use in an interactive electronic device. The sensor comprises a housing having a side wall defining an inner surface, a top plate attached to the side wall and defining an inner surface, and a bottom plate attached to the side wall and also defining an inner surface. The inner surfaces of the side wall and the top and bottom plates collectively define an interior chamber. Disposed on the inner surface of the top plate is at least one top conductive pad, while disposed on the inner surface of the bottom plate is at least one bottom conductor pad. At least one switch partially extends into the interior chamber of the housing. Disposed within the interior chamber and rotatably connected to the housing is a trigger mechanism. The sensor is operative to generate a plurality of different conditions or states corresponding to respective positions of the housing relative to a reference plane. The conditions are generated by the movement of the housing relative to the reference plane, and the resultant contact between the trigger mechanism and at least one of the top conductive pad, the bottom conductive pad, and the switch.

BACKGROUND OF THE INVENTION

The present application relates generally to interactive electronic toys, and more particularly to a uniquely configured sensor and associated electronic circuitry which may be incorporated into interactive electronic toys and games (including dolls and remote controllers such as joysticks) and is operative to produce various visual and/or audible outputs or signal transmissions corresponding to the level/position of the toy relative to a prescribed plane.

There is currently known in the prior art a multitude of interactive electronic toys which are capable of producing a wide variety of visual and/or audible outputs. In the prior art toys, these outputs are typically triggered as a result of the user (e.g., a child) actuating one or more switches of the toy. The switch(es) of the prior art toys are most typically actuated by pressing one or more buttons on the toy, opening and/or closing a door or a hatch, turning a knob or handle, inserting an object into a complementary receptacle, etc. In certain prior art interactive electronic toys, the actuation of the switch is facilitated by a specific type of movement of the toy. However, in those prior art electronic toys including a motion actuated switch, such switch is typically capable of generating only a single output signal as a result of the movement of the toy.

The present invention provides a uniquely configured sensor and associated electronic circuitry which is particularly suited for use in interactive electronic toys and games, including dolls and remote controllers such as joysticks. The present sensor is specifically configured to generate a multiplicity of different output signals which are a function of (i.e., correspond to) the level/position of the toy relative to a prescribed plane. Thus, interactive electronic toys and games incorporating the sensor and associated electronic circuitry of the present invention are far superior to those known in the prior art since a wide variety of differing visual and/or audible outputs and/or various signal transmissions may be produced simply by varying or altering the level/position of the toy relative to a prescribed plane. For example, the incorporation of the sensor and electronic circuitry of the present invention into an interactive electronic toy such as a spaceship allows for the production of differing visual and/or audible outputs as a result of the spaceship being tilted in a nose-up direction, tilted in a nose-down direction, banked to the left, banked to the right, and turned upside down. As indicated above, the output signals generated by the sensor differ according to the level/position of the sensor relative to a prescribed plane, with the associated electronic circuitry of the present invention being operative to facilitate the production of various visual and/or audible outputs corresponding to the particular output signals generated by the sensor.

If incorporated into a joystick or other remote controller, the present sensor and associated electronic circuitry may be configured to facilitate the production of the aforementioned visual and/or audible outputs, and/or generate electrical/electronic signals, radio signals, infrared signals, microwave signals, or combinations thereof which may be transmitted to another device to facilitate the control and operation thereof in a desired manner. The frequency and/or coding of the radio, microwave, or electrical/electronic signals and the coding of the infrared signals transmitted from the joystick or other remote controller would be variable depending upon the level or position of the same relative to a prescribed plane. Moreover, the present electronic circuitry may be specifically programmed to memorize or recognize a prescribed sequence of movements of the sensor relative to a prescribed plane. More particularly, a prescribed sequence of states or output signals generated by the sensor corresponding to a prescribed sequence of movements thereof, when transmitted to the electronic circuitry, may be used to access a memory location in the electronic circuitry in a manner triggering or implementing one or more pre-programmed visual and/or audible functions or effects and/or the transmission of various electrical (hard wired), infrared, radio, or microwave signals to another device for communication and/or activation of various functions thereof. These, and other unique attributes of the present invention, will be discussed in more detail below.

BRIEF SUMMARY OF THE INVENTION

In accordance with the present invention, there is provided a uniquely configured sensor which is operative to generate or produce a multiplicity of different states or conditions corresponding to respective positions of the sensor relative to a reference plane. The movement of the sensor relative to the reference plane facilitates the rotation of a trigger mechanism of the sensor which in turn results in the generation of the differing conditions corresponding to the particular nature of the electrical contact between the trigger mechanism and various switches and conductive pads of the sensor.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the drawings wherein the showings are for purposes of illustrating preferred embodiments of the present invention only, and not for purposes of limiting the same,FIGS. 1–3illustrate sensor10constructed in accordance with a first embodiment of the present invention. The sensor10comprises a housing12. The housing12itself comprises an octagonally shaped side wall14which defines top and bottom peripheral rims, and includes four cylindrically configured post portions16integrally connected to respective ones of four side wall segments thereof. The post portions16are sized relative to the remainder of the side wall14so as to protrude beyond the top and bottom peripheral rims thereof.

In addition to the side wall14, the housing12comprises an octagonally shaped top plate18which is attached to the side wall14in a manner wherein a peripheral portion of the inner surface of the top plate18abuts the top peripheral rim of the side wall14. To maintain a proper registry between the side wall14and the top plate18, disposed within the top plate18are four apertures20which are sized and configured to receive respective ones of the post portions16of the side wall14. When the top plate18is properly secured to the side wall14, the peripheral edge of the top plate18is substantially flush with the outer surface of the side wall14. Disposed in the approximate center of the top plate18is an aperture22. Additionally, disposed in the approximate center of the inner surface of the top plate18is a circularly configured conductive pad24. The aperture22is concentrically positioned within the conductive pad24. The aperture22is sized and configured to receive a top pin26of the sensor10. As seen inFIG. 2, the top pin26includes a radially extending flange portion which is abutted against the conductive pad24when the top pin26is fully inserted in to the aperture22. The top pin26further defines a pointed inner end, and is preferably fabricated from a conductive metal material.

In addition to the pad24, also disposed on the inner surface of the top plate18are four generally square conductive top inner pads28which are separated from each other at intervals of approximately ninety degrees. Also disposed on the inner surface of the top plate18are four circularly configured conductive top outer pads30. Each of the top inner pads28is electrically connected to a respective one of the top outer pads30via a conductive trace32which extends therebetween. The pads24,28,30and traces32are preferably formed of very thin copper via conventional etching techniques. As such, the top plate18is preferably fabricated from a conventional printed circuit board (PCB) material.

The housing12of the sensor10further comprises an octagonally shaped bottom plate34which is attached to the side wall14such that a peripheral portion of the inner surface of the bottom plate34abuts the bottom peripheral rim of the side wall14. To maintain proper registry between the side wall14and bottom plate34, disposed within the bottom plate34are four apertures36which are adapted to receive respective ones of the post portions16of the side wall14, and in particular those portions of the post portions16which protrude beyond the bottom peripheral rim of the side wall14. Extending perpendicularly from the inner surface of the bottom plate34are four cylindrically configured bosses38, the use of which will be discussed in more detail below.

Disposed within the approximate center of the bottom plate34is an aperture40. Similar to the top plate18, disposed in the approximate center of the inner surface of the bottom plate34is a circularly configured conductive pad42. The aperture40is concentrically positioned within the conductive pad42, and is sized and configured to receive a bottom pin44which is identically configured to the top pin26. In this respect, the bottom pin44is preferably fabricated from a conductive metal material, and includes a radially extending flange portion which is abutted against the pad42when the bottom pin44is fully inserted into the aperture40. Additionally, like the top pin26, the bottom pin44defines a pointed inner end.

In addition to the pad42, disposed on the inner surface of the bottom plate34are four generally square conductive bottom inner pads46which are equidistantly spaced from each other at intervals of approximately ninety degrees. Also disposed on the inner surface of the bottom plate34are four rectangularly configured bottom outer pads48. Each of the bottom inner pads46is electrically connected to a respective one of the bottom outer pads48via a conductive trace50. The bottom outer pads48are disposed adjacent to and extend along respective ones of four elongate slots52disposed within the bottom plate34. The pads42,46,48are themselves preferably formed from very thin copper via conventional etching techniques. Additionally, like the top plate18, the bottom plate34is preferably fabricated from a conventional printed circuit board material.

The sensor10of the first embodiment further comprises four identically configured switches54which are each preferably fabricated from a conductive metal material. Each of the switches54preferably comprises a resilient, flexible lead portion56. In addition to the lead portion45, each of the switches54includes a mount portion58which is integrally connected to one end of the lead portion56. The mount portions58are sized and configured to be insertable into respective ones of the slots52within the bottom plate34so as to protrude from the outer surface thereof in the manner shown inFIGS. 1 and 2. The lead portions56are configured such that when the mount portions58are inserted into the bottom plate34, the distal ends of the lead portions56will be separated from each other by intervals of approximately ninety degrees, as best seen inFIGS. 4A,4B, and4C. When the mount portions58of the switches54are advanced into respective ones of the slots52, portions of the switches54abut and are thus in conductive contact with respective ones of the bottom outer pads48of the bottom plate34. This conductive contact results in the lead portions56of the switches54being electrically connected to respective ones of the bottom inner pads46via respective ones of the bottom outer pads48and traces50.

The housing12of the sensor10is assembled by attaching the top and bottom plates18,34to the side wall14in the above-described manner. Upon such assembly, the inner surfaces of the top and bottom plates18,34and inner surface of the side wall14collectively define an interior cavity or chamber of the housing12. The lead portions56of the switches54are disposed within such interior chamber. The bosses38of the bottom plate34are adapted to act against respective ones of the lead portions56in a manner maintaining the same at prescribed orientations within the interior chamber of the housing12. The distal end of each lead portion56is preferably configured to protrude radially inwardly within the interior chamber beyond the corresponding boss38. As seen inFIGS. 4A,4B, an4C, each of the bottom inner pads46and top inner pads28is disposed between the coaxially aligned axes of the top and bottom pins26,44and a respective one of the distal ends of the lead portions56of the switches54.

The sensor10of the first embodiment further comprises a trigger plate60which is rotatably connected to the housing12and is disposed within the interior chamber defined thereby. The trigger plate60has a generally semi-circular shape, and is preferably fabricated from a conductive metal material. Disposed within the opposed top and bottom surfaces of the trigger plate60is a coaxially aligned pair of recesses62which are used to facilitate the rotatable connection of the trigger plate60to the housing12. More particularly, as seen inFIG. 2, the pointed inner ends of the top and bottom pins26,44are advanced into respective ones of the recesses62and engaged to the trigger plate60. When the housing12is assembled in the above-described manner, the apertures22,40within the top and bottom plates18,34are coaxially aligned with each other, thus resulting in the inner ends of the top and bottom pins26,44being coaxially aligned as well. The engagement of the inner ends of the top and bottom pins26,44to the trigger plate60allows the trigger plate60to be freely rotatable within the interior chamber of the housing12, yet prevented from upward or downward or side-to-side movement therewithin.

Though not shown, it will be recognized that the rotatable connection of the trigger plate60to the housing12may be facilitated by providing the trigger plate60with a pair of posts which protrude axially from the opposed top and bottom surfaces thereof at the same locations as the recesses62. The top and bottom pins26,44could alternatively be provided with recesses in place of the pointed inner ends, with the posts of the trigger plate60being received into respective ones of the recesses of the top and bottom pins26,44.

As seen inFIG. 2, portions of the top and bottom pins26,44protrude from respective ones of the top and bottom plates18,34. Additionally, the pointed inner ends of the top and bottom pins26,44loosely engage the trigger plate60. Importantly, the preferred fabrication of the trigger plate60and top and bottom pins26,44from a conductive metal material and the abutment (i.e., conductive contact) between the flange portions of the top and bottom pins26,44and respective ones of the pads24,42facilitates the placement of the trigger plate60into electrical communication with the pads24,42via the top and bottom pins26,44.

The trigger plate60of the sensor10defines an arcuate outer surface portion which, due to the shape of the trigger plate60, extends about one hundred eighty degrees. Formed on and extending radially outward from the outer surface portion are three identically sized and configured protuberances64which are spaced from each other and the opposed ends of the outer surface portion at intervals of approximately forty-five degrees. Additionally, disposed within the trigger plate60are three identically sized apertures66which are disposed adjacent respective ones of the protuberances64, and are spaced from each other at intervals of approximately forty-five degrees. Disposed within each of the apertures66is a spherically shaped trigger ball68. As best seen inFIG. 2, the diameter of each trigger ball68is less than the diameter of each aperture60, thus allowing each trigger ball68to be freely movable and rotatable within its corresponding aperture66. Each of the trigger balls68is also preferably fabricated from a conductive metal material. The trigger plate60and trigger balls68collectively define a trigger mechanism of the sensor10.

As best seen inFIG. 2, when the trigger mechanism (i.e., the trigger plate60and trigger balls68) of the sensor10is rotatably mounted within the interior chamber of the housing12in the above-described manner, the orientation of the apertures66and hence the trigger balls68within the trigger plate60allows each of the trigger balls68to be passable over or positionable upon any one of the bottom inner pads46of the bottom plate34or top inner pads28of the top plate18. More particularly, when the sensor10is oriented relative to a generally horizontal reference plane such that the bottom plate34is disposed closer to the reference plane than the top plate18, the trigger balls68will move or shift within the apertures66such that portions thereof will protrude from the bottom surface of the trigger plate60and directly contact the inner surface of the bottom plate34. Conversely, if the sensor10is flipped over such that the top plate18is disposed closer to the reference plane than the bottom plate34, the trigger balls68will move or shift within the apertures66such that portions thereof protrude from the top surface of the trigger plate60and directly contact the inner surface of the top plate18. As indicated above, due to the orientations of the apertures66and the top and bottom inner pads28,46relative to each other, each trigger ball68may be passed over or rested upon any one of the top and bottom inner pads28,46relative to each other, each trigger ball68may be passed over or rested upon any one of the top and bottom inner pads28,46depending on the orientation of the sensor10relative to the reference plane and resultant rotation of the trigger mechanism within the interior chamber of the housing12.

Referring now toFIGS. 4A,4B and4C, the sensor10of the first embodiment has the capability of generating or producing a multiplicity of different states corresponding to respective positions of the sensor10relative to the reference plane. The movement of the sensor10relative to the reference plane facilitates the rotation of the trigger mechanism within the interior chamber of the housing12. The sensor10is operative to generate a low state when the protuberances64of the trigger plate60are not in contact with any of the switches54(i.e., the distal ends of the lead portions56) and the trigger balls68are not in contact with any of the bottom inner pads46or top inner pads28. Though not shown, it will be appreciated fromFIGS. 4A,4B and4C that when the protuberances64are not in contact with any of the switches54, the distal end of one of the lead portions56will extend between an adjacent pair of protuberances64, but will not be in contact with the outer surface portion of the trigger plate60. The sensor10is further operative to generate four different high states corresponding to contact between the center protuberance64and respective ones of the switches54(examples of which are shown inFIGS. 4A and 4C), and four additional high states corresponding to the outer pair of protuberances64being in simultaneous contact with any pair of the distal ends of the lead portions56of the switches54separated by a ninety degree interval (an example of which is shown inFIG. 4B).

When any protuberances64of the trigger plate60moves into contact with the distal end of the lead portion56of a switch54, the protuberance64acts against such lead portion56in a manner facilitating a slight amount of flexion thereof, which establishes firm contact between such lead portion56and the corresponding protuberance64. Upon such contact, a closed circuit condition is created since there is a complete conductive path comprising one or both of the top and bottom pins26,44, the trigger plate60(including the protuberances64), and one or two of the switches54(including the lead and mount portions56,58). The particular high state generated by the sensor10is dependent upon the switch54with which electrical contact is established by the center protuberance64, i.e., each switch54produces a different high state when contacted by the center protuberance64. When the trigger plate60is positioned within the interior chamber of the housing12such that the outer pair of protuberances64simultaneously contact a corresponding pair of switches54, the particular high state generated by this sensor10is dependent upon the combination of switches54with which electrical contact is established, i.e., a different high state is produced when any adjacent pair of switches54are simultaneously contacted by the outer pair of protuberances64.

As indicated above, in the sensor10, each of the switches54is in conductive contact with a respective one of the bottom outer pads48due to the advancement of the mount portions58of the switches54into respective ones of the slots52. Since each of the bottom inner pads46is electrically connected to a respective bottom outer pad48via a corresponding trace50, each bottom inner pad46is thus electrically connected to a respective switch54, and more particularly the mount portion58thereof. As such, the bottom inner pads46of the bottom plate34provide failsafe redundancy to the switches54. In this respect, in the event any lead portion56bends or warps such that conductive contact is not achieved between the same and the protuberances64upon the rotation of the trigger plate60, a closed circuit condition is still created since there is a complete conductive path comprising one or both of the top and bottom pins26,44, the trigger plate60, one or two of the trigger balls68, one or two of the bottom inner pads46, one or two of the conductive traces50, one or two of the bottom outer pads48, and one or two of the switches54. Thus, each bottom inner pad46, when contacted by the center trigger ball68, produces the same high state as the adjacent switch54when contacted by the center protuberance64. Similarly, the high state generated by the sensor10when any adjacent pair of the bottom inner pads46are simultaneously contacted by respective ones of the outer pair of trigger balls68is identical to the high state generated when the corresponding switches54are simultaneously contacted by the outer pair of protuberances64.

As indicted above, if the sensor10is oriented such that the top plate18is disposed closer to the reference plane than the bottom plate34, the trigger balls68will move or shift within the apertures66such that portions thereof protrude from the top surface of the trigger plate60and directly contact the inner surface of the top plate18. The sensor10is further operative to generate four different high states (differing from the high states discussed above) corresponding to contact between the center trigger ball68and respective ones of the top inner pads28, and four additional high states corresponding to the outer pair of trigger balls68being in simultaneous contact with any adjacent pair of the top inner pads28separated by a ninety degree interval. A closed circuit condition is created by the complete conductive path comprising one or both of the top and bottom pins26,44, the trigger plate60, one or two of the conductive traces32, and one or two of the top outer pads30. Thus, the sensor10has the capability of generating the low state and a totality of sixteen different high states. As will be discussed in more detail below, the high states generated as a result of one or more of the trigger balls68being in contact with one or more of the top inner pads28are indicative of the sensor10being generally upside down, i.e., the top plate18being disposed closer to the reference plane than the bottom plate34.

The sensor10of the first embodiment is preferably used in combination with programmable electronic circuitry70which is shown schematically inFIG. 26. The programmable electronic circuitry70used in conjunction with the sensor10is in electrical communication therewith, and may be operative to compare at least two successive states generated by the sensor10to each other. The electronic circuitry70may be programmed to translate at least some of the states generated by the sensor10into respective effects, and may be further programmed to produce a selective effect upon successive states of a prescribed sequence being transmitted thereto from the sensor10. The effects may comprise visual outputs, audible outputs, or combinations thereof. The effects may also comprise electrical signals of differing frequencies and/or codings, infrared signals of differing codings, radio signals of differing frequencies and/or codings, microwave signals of differing frequencies and/or codings, or combinations thereof. The successive states generated by the sensor10which may be compared by the electronic circuitry70correspond to the movement of the trigger mechanism (i.e., trigger plate60and trigger balls68) within the interior chamber of the housing12.

Like the electronic circuitry used in conjunction with the sensor601as described in the parent application, the electronic circuitry70further includes the capability to discern a multiplicity of different conditions of the sensor10, and to compare successive conditions to each other to determine the path of movement (i.e., clockwise, counter-clockwise) of the trigger mechanism within the interior chamber of the housing12. As indicated above, sixteen different high states may be generated by the sensor10depending upon the particular combination of switches54and bottom or top inner pads46,28being actuated by the protuberance(s)64and trigger ball(s)68. As the trigger mechanism rotates within the interior chamber of the housing12, a low state is generated between any successive pair of high states. Thus, during a complete clockwise or counter-clockwise rotation of the trigger mechanism within the interior chamber, at least sixteen conditions are achieved comprising the sum of at least eight different high states and the eight intervening low states. As indicated above, the electronic circuitry70used in conjunction with the sensor10is able to discern these different conditions, and to compare any three of these conditions to each other for purposes of monitoring the location or direction of rotation of the trigger mechanism within the interior chamber of the housing12. The electronic circuitry70may be programmed to produce a certain effect or combination of effects in response to any three successive conditions transmitted from the sensor10.

As further seen inFIG. 26, the electronic circuitry70includes an MPU72. The MPU72includes a total of eight input/output ports or i/o's which are labeled as P10–P13and P20–P23. The switches54and hence the bottom inner pads46are electrically connected to respective ones of the i/o's of the MPU72. The MPU72is operative to determine which of the top and bottom plates18,34is disposed closer to the reference plane (i.e., whether the sensor10is upside down) based on the high state(s) being generated by the sensor10, and more particularly the i/o(s) to which current is transmitted. Similarly, the top inner pads28are electrically connected to respective ones of the i/o's of the MPU72. To facilitate the creation of the required conductive path through the sensor10, it is contemplated that one of the top and bottom pins26,44will be in electrical communication with the electronic circuitry70in a manner permitting an electrical signal to be transmitted therefrom and to the switch(es)54and bottom or top inner pad(s)46,28via the protuberance(s)64of the trigger plate60and trigger ball(s)68. That one of the top and bottom pins26,44not used to facilitate the transmission of an electrical signal to the trigger mechanism is preferably used to establish a common ground to the electronic circuitry70.

Referring now toFIG. 5, there is depicted a sensor10awhich is a three-axis version of the sensor10. In the sensor10a, the housings12of three identically configured sensors10are attached to each other or to a common mount such that each corresponding pair of top and bottom pins26,44is coaxially aligned with a respective one of the different axes which extend in generally perpendicular relation to each other. Each of the sensors10of the sensor10afunctions in the above-described manner. The sensor10awould be operative to generate the low state when the protuberances64of the trigger plates60and trigger balls68are not in contact with any of the switches54and bottom or top inner pads46,28, and at least four thousand and ninety six different high states (sixteen to the third power based on three axes) corresponding to the contact between the protuberances64and at least one of the switches54, and between the trigger balls68and at least one of the bottom or top inner pads46,28. The electronic circuitry used in conjunction with the sensor10awould provide the same functionality as the electronic circuitry70, i.e., differentiating and/or comparing states and/or conditions, and generating resultant effects.

Referring now toFIGS. 6–9, there is depicted a sensor100constructed in accordance with the second embodiment of the present invention. The sensor100is substantially similar in structure and function to the sensor10of the first embodiment as described above. The sensor100comprises a housing112, which itself comprises an octagonally shaped side wall114. The side wall114defines top and bottom peripheral rims, and includes four cylindrically configured post portions116integrally connected to respective ones of four side wall segments thereof. The post portions116are sized relative to the remainder of the side wall114so as to protrude beyond the top and bottom peripheral rims thereof.

In addition to the side wall114, the housing112comprises an octagonally shaped top plate118which is attached to the side wall114in a manner wherein a peripheral portion of the inner surface of the top plate118abuts the top peripheral rim of the side wall114. To maintain a proper registry between the side wall114and the top plate118, disposed within the top plate118are four apertures120which are sized and configured to receive respective ones of the post portions116of the side wall114. When the top plate118is properly secured to the side wall114, the peripheral edge of the top plate118is substantially flush with the outer surface of the side wall114. Disposed in the approximate center of the top plate118is an aperture122. Additionally, disposed in the approximate center of the inner surface of the top plate118is a circularly configured conductive pad124. The aperture122is concentrically positioned within the conductive pad124. The aperture122is sized and configured to receive a top pin126of the sensor100. As seen inFIG. 7, the top pin126includes a radially extending flange portion which is abutted against the conductive pad124when the top pin126is fully inserted into the aperture122. The top pin126further defines a pointed inner end, and is preferably fabricated from a conductive metal material.

In addition to the pad124, also disposed on the inner surface of the top plate118are four generally U-shaped first top inner pads128which are each electrically connected to the pad124and are disposed thereabout (i.e., are separated from each other) at equidistant intervals of approximately ninety degrees. Also disposed on the inner surface of the top plate118are four generally E-shaped second top inner pads129which are also separated from each other at intervals of approximately ninety degrees, and are intermeshed with respective ones of the first top inner pads128. However, as seen inFIGS. 6 and 8, the second top inner pads129are not in direct electrical communication with the corresponding first top inner pads128. In addition to the pads124,128,129, disposed on the inner surface of the top plate118are four circularly configured conductive top outer pads130. Each of the second top inner pads129is electrically connected to a respective one of the top outer pads130via a conductive trace132which extends therebetween. The pads124,128,129,130and traces132are preferably formed of very thin copper via conventional etching techniques. As such, like the top plate18, the top plate118is preferably fabricated from a conventional printed circuit board (PCB) material.

The housing112of the sensor100further comprises an octagonally shaped bottom plate134which is attached to the side wall114such that a peripheral portion of the inner surface of the bottom plate134abuts the bottom peripheral rim of the side wall114. To maintain proper registry between the side wall114and the bottom plate134, disposed within the bottom plate134are four apertures136which are adapted to receive respective ones of the post portions116of the side wall114, and in particular those portions of the post portions116which protrude beyond the bottom peripheral rim of the side wall114. Extending perpendicularly from the inner surface of the bottom plate134are four cylindrically configured bosses138.

Disposed within the approximate center of the bottom plate134is an aperture140. Similar to the top plate118, disposed in the approximate center of the inner surface of the bottom plate134is a circularly configured conductive pad142. The aperture140is concentrically positioned within the conductive pad142, and is sized and configured to receive a bottom pin144which is identically configured to the top pin126. The bottom pin144is preferably fabricated from a conductive metal material, and includes a radially extending flange portion which is abutted against the pad142when the bottom pin144is fully inserted into the aperture140. Additionally, like the top pin126, the bottom pin144defines a pointed inner end.

In addition to the pad142, disposed on the inner surface of the bottom plate134are four generally U-shaped conductive first bottom inner pads146which are identically configured to the first top inner pads128and are disposed about the periphery of the pad142in equidistantly spaced intervals of approximately ninety degrees. Each of the first bottom inner pads146is electrically connected to the pad142. Also disposed on the inner surface of the bottom plate134are four generally E-shaped second bottom inner pads147which are identically configured to the second top inner pads129. In this respect, the first bottom inner pads146are intermeshed with respective ones of the second bottom inner pads147in the same manner described above with respect to the intermesh of the first top inner pads128to respective ones of the second top inner pads129.

In addition to the pads142,146,147, disposed on the inner surface of the bottom plate134are four rectangularly configured bottom outer pads148. Each of the second bottom inner pads147is electrically connected to a respective one of the bottom outer pads148via a conductive trace150. The bottom outer pads148are disposed adjacent to and extend along respective ones of four elongate slots152disposed within the bottom plate134. The pads142,146,147,148are themselves preferably formed from very thin copper via conventional etching techniques. Additionally, like the top plate118, the bottom plate134is preferably fabricated from a conventional printed circuit board material.

The sensor100of the second embodiment further comprises four identically configured switches154which are identically configured to the above-described switches54, and are each preferably fabricated from a conductive metal material. Each of the switches154preferably comprises a resilient, flexible lead portion156. In addition to the lead portion156, each of the switches154includes a mount portion158which is integrally connected to one end of the lead portion156. The mount portions158are sized and configured to be insertable into respective ones of the slots152within the bottom plate134so as to protrude from the outer surface thereof in the manner shown inFIGS. 6 and 7. The lead portions156are configured such that when the mount portions158are inserted into the bottom plate134, the distal ends of the lead portions156will be separated from each other by intervals of approximately ninety degrees, as best seen inFIGS. 9A,9B, and9C. When the mount portions158of the switches154are advanced into respective ones of the slots152, portions of the switches154abut and are thus in conductive contact with respective ones of the bottom outer pads148of the bottom plate134. This conductive contact results in the lead portions156of the switches154being electrically connected to respective ones of the second inner pads147via respective ones of the bottom outer pads148and traces150.

The housing112of the sensor100is assembled by attaching the top and bottom plates118,134to the side wall114in the above-described manner. Upon such assembly, the inner surfaces of the top and bottom plates118,134and inner surface of the side wall114collectively define an interior cavity or chamber of the housing112. The lead portions156of the switches154are disposed within such interior chamber. The bosses138of the bottom plate134are adapted to act against respective ones of the lead portions156in a manner maintaining the same at prescribed orientations within the interior chamber of the housing112. The distal end of each lead portion156is preferably configured to protrude radially inwardly within the interior chamber beyond the corresponding boss138. Each corresponding, intermeshed pair of the first and second top inner pads128,129and the first and second bottom inner pads146,147is disposed between the coaxially aligned axes of the top and bottom pins26,44and a respective one of the distal ends of the lead portions156of the switches154.

The sensor100of the second embodiment further comprises a trigger plate160which is rotatably connected to the housing112and is disposed within the interior chamber defined thereby. The trigger plate160has a generally semi-circular shape, and is preferably fabricated from a conductive metal material. Disposed within the opposed top and bottom surfaces of the trigger plate160is a coaxially aligned pair of recesses162which are used to facilitate the rotatable connection of the trigger plate160to the housing112. More particularly, as seen inFIG. 7, the pointed inner ends of the top and bottom pins126,144are advanced into respective ones of the recesses162and engaged to the trigger plate160. When the housing112is assembled in the above-described manner, the apertures122,140within the top and bottom plates118,134are coaxially aligned with each other, thus resulting in the inner ends of the top and bottom pins126,144being coaxially aligned as well. The engagement of the inner ends of the top and bottom pins126,144to the trigger plate160allows the trigger plate160to be freely rotatable within the interior chamber of the housing112, yet prevented from upward or downward or side-to-side movement therewithin.

Though not shown, it will be recognized that the rotatable connection of the trigger plate160to the housing112may be facilitated by providing the trigger plate160and top and bottom pins126,144with the alternative configurations discussed above in relation to the sensor10of the first embodiment. The pointed inner ends of the top and bottom pins126,144loosely engage the trigger plate160. Additionally, the preferred fabrication of the trigger plate160and the top and bottom pins126,144from a conductive metal material and the conductive contact between the flange portions of the top and bottom pins126,144and respective ones of the pads124,142facilitates the placement of the trigger plate160into electrical communication with the pads124,142via the top and bottom pins126,144.

The trigger plate160of the sensor100defines an arcuate outer surface portion which extends about one hundred eighty degrees. Formed on and extending radially outward from the outer surface portion is a protuberance164which extends about ninety degrees, and is preferably spaced from the opposed ends of the outer surface portion at equal intervals of approximately forty-five degrees. Additionally, disposed within the trigger plate160are three identically sized apertures166, the outer pair of which are disposed adjacent respective ones of the opposed ends of the protuberance164. The apertures166are spaced from each other at intervals of approximately forty-five degrees as well. Disposed within each of the apertures166is a spherically shaped trigger ball168. As seen inFIG. 7, the diameter of each trigger ball168is less than the diameter of each aperture160, thus allowing each trigger ball168to be freely movable and rotatable within its corresponding aperture166. Each of the trigger balls168is also preferably fabricated from a conductive metal material. The trigger plate160and trigger balls168collectively define a trigger mechanism of the sensor100.

When the trigger mechanism (i.e., the trigger plate160and trigger balls168) of the sensor100is rotatably mounted within the interior chamber of the housing112, the orientation of the apertures166and hence the trigger balls168within the trigger plate160allows each of the trigger balls168to be passable over or positionable upon any one of the corresponding pairs of the first and second bottom inner pads146,147or the first and second top inner pads128.129. More particularly, when the sensor100is oriented relative to a generally horizontal reference plane such that the bottom plate134is disposed closer to the reference plane than the top plate118, the trigger balls168will move or shift within the apertures166such that portions thereof will protrude from the bottom surface of the trigger plate160and directly contact the inner surface of the bottom plate134. Conversely, if the sensor100is flipped over such that the top plate118is disposed closer to the reference plane than the bottom plate134, the trigger balls168will move or shift within the apertures166such that portions thereof protrude from the top surface of the trigger plate160and directly contact the inner surface of the top plate118.

Referring now toFIGS. 9A,9B, and9C, the sensor100of the second embodiment, like the sensor10of the first embodiment, has the capability of generating or producing a multiplicity of different states corresponding to respective positions of the sensor100relative to the reference plane. The movement of the sensor100relative to the reference plane facilitates the rotation of the trigger mechanism within the interior chamber of the housing112. The sensor100is operative to generate a low state when the protuberance164of the trigger plate160is not in contact with any of the switches154and the trigger balls168are not in contact with any of the corresponding pairs of first and second bottom inner pads146,147or first and second top inner pads128,129. The sensor100is further operative to generate four different high states corresponding to contact between the protuberances164and respective ones of the switches154(examples of which are shown inFIGS. 9A and 9C), and four additional high states corresponding to the protuberance164being in simultaneous contact with any pair of the distal ends of the lead portions156of the switches154separated by a ninety degree interval (an example of which is shown inFIG. 9B).

When the protuberances164of the trigger plate160moves into contact with the distal end of the lead portion156of a switch154, a closed circuit condition is created since there is a complete conductive path comprising one or both of the top and bottom pins126,144, the trigger plate160(including the protuberance164), and one or two of the switches154(including the lead and mount portions156,158). The particular high state generated by the sensor100is dependent upon the switch155with which electrical contact is established by the protuberance164, i.e., each switch154produces a different high state when contacted by the protuberance164. When the trigger plate160is positioned within the interior chamber of the housing112such that the protuberance164simultaneously contacts a pair of switches154, the particular high state generated by the sensor100is dependent upon the combination of switches154with which electrical contact is established, i.e., a different high state is produced when any adjacent pair of switches154are simultaneously contacted by the protuberance164.

As indicated above, each of the switches154is in conductive contact with a respective one of the bottom outer pads148due to the advancement of the mount portions158of the switches154into respective ones of the slots152. Since each of the second bottom inner pads147is electrically connected to a respective bottom outer pad148via a corresponding trace150, each second bottom inner pad147is thus electrically connected to a respective switch154. Like the bottom inner pads46of the sensor10of the first embodiment, each corresponding pair of first and second bottom inner pads146,147provides failsafe redundancy to a respective one of the switches154. In this respect, in the event any lead portion156bends or warps such that conductive contact is not achieved between the same and the protuberance164during the rotation of the trigger plate160, a closed circuit condition is still created since there is a complete conductive path comprising one or both of the top and bottom pins126,144, the trigger plate160(if current is introduced into the sensor100via the top pin126), the pad142, one or two of the first inner bottom pads146, one or two of the trigger balls168, one or two of the second bottom inner pads147, one or two of the conductive traces150, one or two of the bottom outer pads148, and one or two of the switches154. In this respect, electrical communication between the first and second bottom inner pads146,147of any corresponding pair may be facilitated by one of the conductive trigger balls368being in simultaneous contact therewith.

The ability of any one of the trigger balls68to be brought into conductive contact with the first and second bottom inner pads146,147of any corresponding pair at the same time is attributable to the intermeshed arrangement between each such corresponding pair. Each intermeshed pair of first and second bottom inner pads146,147, when contacted by the center trigger ball168facilitates the production of the same high state as the adjacent switch154when contacted by the protuberance164. Similarly, the high state generated by the sensor100when any adjacent pair of the intermeshed first and second bottom inner pads146,147are simultaneously contacted by respective ones of the outer pair of trigger balls168is identical to the high state generated when the corresponding switches154are simultaneously contacted by the protuberance164.

As indicated above, if the sensor100is oriented such that the top plate118is disposed closer to the reference plane than the bottom plate134, the trigger balls168will move or shift within the apertures166such that portions thereof protrude from the top surface of the trigger plate160and directly contact the inner surface of the top plate118. The sensor100is further operative to generate four different high states (different from the high sates discussed above) corresponding to contact between the center trigger ball168and respective ones of the intermeshed pairs of the first and second top inner pads128,129, and four additional high states corresponding to the outer pair of trigger balls168being in simultaneous contact with any adjacent pair of the intermeshed first and second top inner pads128,129separated by a ninety degree interval. A closed circuit condition is created by the complete conductive path comprising one or both of the top and bottom pins126,144, the trigger plate160(if current is introduced into the sensor100via the bottom pin144), the pad124, one or two of the first inner top pads128, one or two of the trigger balls168, one or two of the second inner top pads129, one or two of the conductive traces132, and one or two of the top outer pads130. Thus, the sensor100has the capability of generating the low state and a totality of sixteen different high states. As in the sensor10, the high states generated as a result of one of more of the trigger balls168being in contact with one or more of the intermeshed pairs of first and second top inner pads128,129are indicative of the sensor100being generally upside down, i.e., the top plate118being disposed closer to the reference plane than the bottom plate134.

The sensor100of the second embodiment is preferably used in combination with the above-described programmable electronic circuitry70. The functionality imparted by the electronic circuitry70when used in conjunction with the sensor100is the same as that previously described in relation to the sensor10of the first embodiment. The switches154are electrically connected to respective ones of the i/o's of the MPU72, as are the top inner pads130.

Referring now toFIG. 10, there is depicted a sensor100awhich is a three-axis version of the sensor100. In the sensor100a, the housings112of three identically configured sensors100are attached to each other or to a common mount such that each corresponding pair of top and bottom pins126,144is coaxially aligned with a respective one of three different axes which extend in generally perpendicular relation to each other. Each of the sensors100of the sensor100afunctions in the above-described manner. The sensor100awould be operative to generate the low state when the protuberances164of the trigger plates160and trigger balls168are not in contact with any of the switches154and intermeshed pairs of first and second bottom inner pads146,147or top inner pads128,129. The sensor100awould further be operative to generate at least four thousand ninety six different high states (sixteen to the third power based on three axes) corresponding to the contact between the protuberances164and at least one of the switches154, and between the trigger balls168and at least one of the intermeshed pairs of first and second bottom inner pads146,147or top inner pads128,129. Electronic circuitry used in conjunction with the sensor100awould provide the same functionality as the electronic circuitry70, i.e., differentiating and/or comparing states and/or conditions, and generating resultant effects.

Referring now toFIGS. 11–13, there is depicted a sensor200constructed in accordance with a third embodiment of the present invention. The sensor200comprises a housing212. The housing212itself comprises an octagonally shaped side wall214which defines top and bottom peripheral rims. Extending upwardly from each of the top and bottom peripheral rims is an opposed pair of generally cylindrical bosses215. Additionally, disposed within each of the top and bottom peripheral rims are four apertures216. As best seen inFIGS. 12 and 13, attached to the side wall214are four identically configured contact plates217. Each of the contact plates217is preferably fabricated from a conductive metal material. Additionally, the contact plates217are attached to the side wall214so as to be equidistantly spaced from each other at intervals of approximately ninety degrees. As best seen inFIG. 13, the side wall214defines four equally sized arcuate inner surface sections. These inner surface sections and portions of the contact plates217collectively define a generally circular inner surface of the housing212. Additionally, the contact plates217are sized relative to the side wall214such that portions of each of the contact plates217are substantially flush with each of the top and bottom peripheral rims of the side wall214.

Referring now toFIGS. 11,13, and14A, in addition to the side wall214, the housing212comprises an octagonally shaped top plate218which is attached to the side wall214in a manner wherein a peripheral portion of the inner surface of the top plate218abuts the top peripheral rim of the side wall214. To maintain a proper registry between the side wall214and the top plate218, disposed within the top plate218is an opposed pair of apertures220which are sized and configured to receive respective ones of the bosses215. When the top plate218is properly secured to the side wall214, the peripheral edge of the top plate218is substantially flush with the outer surface of the side wall214. Disposed within the approximate center of the top plate218is an aperture222. Additionally, disposed in the approximate center of the inner surface of the top plate218is a circularly configured conductive pad224. The aperture222is concentrically positioned within the conductive pad224. The aperture222is sized and configured to receive a top pin226of the sensor200. As seen inFIG. 12, the top pin226includes a radially extending flange portion which is abutted against the conductive pad224when the top pin226is fully inserted into the aperture222. The top pin226further defines a pointed inner end, and is preferably fabricated from a conductive metal material.

In addition to the pad224, disposed on the inner surface of the top plate218are four generally U-shaped top inner pads228which are separated or spaced from each other at equidistant intervals of approximately ninety degrees. Also disposed on the inner surface of the top plate218are four generally E-shaped top outer pads229which are also separated from each other at equal intervals of approximately ninety degrees, and are intermeshed with respective ones of the top inner pads228. Each of the top outer pads229extends along the inner surface of the top plate218to the peripheral edge thereof. The top inner pads228are not in direct electrical communication with the corresponding top outer pads229. Further disposed on the inner surface of the top plate218are six top peripheral pads230. The top peripheral pads230are segregated into two sets of three which are disposed in opposed relation to each other along respective peripheral edge segments of the top plate218.

In the top plate218, the top inner pads228are electrically connected to each other and to the center top peripheral pad230of one set thereof via a conductive trace231which includes an arcuate portion interconnecting the top inner pads228and a straight portion extending from the arcuate portion to the center top peripheral pad230of the corresponding set. Similarly, a generally straight conductive trace232is used to electrically connect the pad224to the center top peripheral pad230of the opposed, remaining set thereof. Further, conductive traces233are used to electrically connect the top outer pads229to respective ones of the remaining four outer top peripheral pads230of each of the two sets thereof.

The pads224,228,229,230and traces231,232,233are each preferably formed of very thin copper via conventional etching techniques. As such, the top plate218is preferably fabricated from a conventional printed circuit board material. As best seen inFIG. 14A, it is contemplated that during the fabrication of the top plate218, each of the conductive traces231,232,233will be covered or masked with a layer of insulating ink or other type of insulating material so as not to be exposed upon the inner surface of the top plate218. As further seen inFIG. 14A, portions of each of the top outer pads229between the prongs thereof and the peripheral edge of the top plate218are also preferably covered or masked with a strip of the insulating ink.

Referring now toFIGS. 13 and 14B, the housing212of the sensor200further comprises an octagonally shaped bottom plate234which is attached to the side wall214such that peripheral portion of the inner surface of the bottom plate234abuts the bottom peripheral rim of the side wall214. To maintain proper registry between the side wall214and the bottom plate234, disposed within the bottom plate234is an opposed pair of apertures236which are adapted to receive respective ones of the bosses215of the side wall214, and in particular those bosses215which protrude from the bottom peripheral rim of the side wall214. When the bottom plate234is properly secured to the side wall214, the peripheral edge of the bottom plate234is substantially flush with the outer surface of the side wall214.

Disposed within the approximate center of the bottom plate234is an aperture240. Additionally, disposed in the approximate center of the inner surface of the bottom plate234is a circularly configured conductive pad242. The aperture240is concentrically positioned within the conductive pad242, and is sized and configured to receive a bottom pin244which is identically configured to the top pin226. The bottom pin244is also preferably fabricated from a conductive metal material, and includes a radially extending flange portion which is abutted against the pad242when the bottom pin244is fully inserted into the aperture240. The bottom pin244, like the top pin226, defines a pointed inner end.

In addition to the pad242, disposed on the inner surface of the bottom plate234are four generally U-shaped conductive bottom inner pads246which are identically configured to the top inner pads228and are disposed about the periphery of the pad242in equidistantly spaced intervals of approximately ninety degrees. Each of the bottom inner pads246is electrically connected to the pad242via a generally straight conductive trace247. Also disposed on the inner surface of the bottom plate234are four generally E-shaped bottom outer pads248which are identically configured to the top outer pads229. Each of the bottom outer pads248extends along the inner surface of the bottom plate234to the peripheral edge thereof. Additionally, the bottom outer pads248are separated from each other at equal intervals of approximately ninety degrees, and are intermeshed with respective ones of the bottom inner pads246. However, the bottom inner pads246are not in direct electrical communication with the corresponding bottom outer pads248.

The pads242,246,248and traces247are each preferably formed of very thin copper via conventional etching techniques. As such, the bottom plate234, like the top plate218, is preferably fabricated from a conventional printed circuit board material. As best seen inFIG. 14B, it is contemplated that during the fabrication of the bottom plate234, each of the conductive traces247will be covered or masked with a layer of insulating ink or other type of insulating material so as not to be exposed upon the inner surface of the bottom plate234. As further seen inFIG. 14B, portions of each of the bottom outer pads248between the prongs thereof and the peripheral edge of the top plate234are also preferably covered or masked with a strip of the insulating ink.

The housing212of the sensor200is assembled by attaching the top and bottom plates218,234to the side wall214in the above-described manner. Upon such assembly, the inner surfaces of the top and bottom plates218,234and circular inner surface defined by the inner surface sections of the side wall214and portions of the contact plate217collectively define an interior cavity or chamber of the housing212. Importantly, the side wall214and top and bottom plates218,234are sized and configured relative to each other such that when the top and bottom plates218,234are attached to the side wall214, those portions of the contact plates217flush with the top peripheral rim of the side wall214are in abutting, electrical contact with respective ones of the top outer pads229, and in particular those portions of the top outer pads229extending along the peripheral edge of the top plate218. Similarly, those portions of the contact plates217substantially flush with the bottom peripheral rim of the side wall214are in abutting, electrical contact with respective ones of the bottom outer pads248of the bottom plate234, and in particular those portions of the bottom outer pads248extending along the peripheral edge of the bottom plate234. Thus, the top outer pads229are placed into electrical communication with respective ones of the intervening contact plates217. Additionally, each corresponding, intermeshed pair of the top inner and outer pads228,229and bottom inner and outer pads246,248is disposed between the coaxially aligned axes of the top and bottom pins226,244and a respective one of the contact plates217.

The sensor200of the third embodiment further comprises a trigger plate260which is rotatably connected to the housing212and is disposed within the interior chamber defined thereby. The trigger plate260has a generally semi-circular shape, and is preferably fabricated from a conductive metal material. Disposed within the opposed top and bottom surfaces of the trigger plate260is a coaxially aligned pair of openings262which are used to facilitate the rotatable connection of the trigger plate260to the housing212. As seen inFIG. 12, the pointed inner ends of the top and bottom pins226,244are advanced into respective ones of the openings262and engaged to the trigger plate260. When the housing212is assembled in the above-described manner, the apertures222,240within the top and bottom plates218,234are coaxially aligned with each other, thus resulting in the inner ends of the top and bottom pins226,244being coaxially aligned as well. The engagement of the inner ends of the top and bottom pins226,244to the trigger plate260allows the trigger plate260to be freely rotatable within the interior chamber of the housing212, yet prevented from upward or downward or side-to-side movement therewithin. The pointed inner ends of the top and bottom pins226,244loosely engage the trigger plate260. Additionally, the preferred fabrication of the trigger plate260and the top and bottom pins226,244from a conductive metal material and the conductive contact between the flange portions of the top and bottom pins226,244and respective ones of the pads224,242facilitates the placement of the trigger plate260into electrical communication with the pads224,242via the top and bottom pins226,244.

The trigger plate260defines an arcuate outer surface portion which extends about one hundred eighty degrees. Formed within the outer surface portion are three cavities264which are preferably spaced from each other at equal intervals of approximately forty-five degrees, with the outer pair of cavities264being equally spaced from respective ones of the opposed ends of the outer surface portion. Disposed within each of the cavities264is a spherically shaped trigger ball268. The diameter of each trigger ball268is less than the width of each cavity264, thus allowing each trigger ball268to be freely movable and rotatable within its corresponding cavity264. Each of the trigger balls268is also preferably fabricated from a conductive metal material. The trigger plate260and trigger balls268collectively define a trigger mechanism of the sensor200.

As best seen inFIGS. 13,15A,15B, and15C, the trigger plate260defines a pair of partition walls266which segregate or separate the center cavity264from the outer pair of cavities264. One of these partition walls266is formed to include an enlarged distal end267which partially encloses the center cavity264. This enlarged distal end267is operative to maintain the center trigger ball268disposed within the center cavity264in conductive contact with the trigger plate260, as will be discussed in more detail below.

When the trigger mechanism (i.e., the trigger plate260and trigger balls268) of the sensor200is rotatably mounted within the interior chamber of the housing212, the orientation of the cavities264and hence the trigger balls268within the trigger plate260allows each of the trigger balls268to be passable over or positionable upon any one of the corresponding pairs of bottom inner and outer pads246,247or top inner and outer pads228,229. More particularly, when the sensor200is oriented relative to a generally horizontal reference plane such that the bottom plate234is disposed closer to the reference plane than the top plate218, the trigger balls268will move or shift within the cavities264such that portions thereof will protrude from the bottom surface of the trigger plate260and directly contact the inner surface of the bottom plate234. Conversely, if the sensor200is flipped over such that the top plate218is disposed closer to the reference plane than the bottom plate234, the trigger balls268will move or shift within the cavities264such that portions thereof protrude from the top surface of the trigger plate260and directly contact the inner surface of the top plate218.

Referring now toFIGS. 15A,15B, and15C, the sensor200of the third embodiment itself has the capability of generating or producing a multiplicity of different states corresponding to respective positions of the sensor200relative to the reference plane. The movement of the sensor200relative to the reference plane facilitates the rotation of the trigger mechanism within the interior chamber of the housing212. The sensor200is operative to generate a low state when the trigger balls268of the trigger mechanism are not in contact with any of the contact plates217, and thus any of the corresponding pairs of bottom inner and outer pads246,248or top inner and outer pads228,229. The sensor200is further operative to generate four different high states corresponding to contact between the center trigger ball268and respective ones of the contact plates217(examples of which are shown inFIGS. 15A and 15C), and four additional different high states corresponding to the outer pair of trigger balls268being in simultaneous contact with any pair of the contact plates217separated by a ninety degree interval (an example of which is shown inFIG. 15B). Another different high state is generated when any one of the trigger balls268is in contact with any corresponding pair of the bottom inner and outer pads246,247, with yet another different high state being generated when any one of the trigger balls268is in contact with any corresponding pair of the top inner and outer pads228,229.

When any trigger ball268moves into contact with a contact plate217, a closed circuit condition is created since there is a complete conductive path comprising one or both of the top and bottom pins226,244, the trigger plate260, one or two of the trigger balls268, one or two of the contact plates217, one or two of the top outer pads229(due to the conductive contact between the top outer pads229and respective ones of the contact plates217), one or two of the conductive traces233, and one or two of the outer top peripheral pads230. The particular high state generated by the sensor200is dependent upon the contact plate217with which electrical contact is established by the center trigger ball268, i.e., each contact plate217produces a different high state when contacted by the center trigger ball268. When the trigger plate260is positioned within the interior chamber of the housing212such that the outer pair of trigger balls268simultaneously contact a corresponding pair of contact plates217, the particular high state generated by the sensor200is dependent upon the combination of contact plates217with which electrical contact is established, i.e., a different high state is produced when any adjacent pair of contact plates217are simultaneously contacted by the outer pair of trigger balls268.

As will be recognized, when the sensor200is disposed vertically relative to the reference plane (i.e., the top and bottom plates218,234extend generally perpendicularly relative to the reference plane), the trigger balls268of the trigger mechanism may not be in contact with any of the intermeshed pairs of top inner and outer pads228,229or bottom inner and outer pads246,248. Even in the absence of such contact, a particular high state may still be produced due to the conductive contact between the contact plates217and respective ones of the top outer pads229, which are themselves electrically connected to respective ones of the top peripheral pads230via respective ones of the traces233. As also indicated above, in addition to being in conductive contact with respective ones of the top outer pads229, the contact plates217are further in conductive contact with respective ones of the bottom outer pads248.

As also explained above, when the sensor200is oriented such that the bottom plate234is disposed closer to the reference plane than the top plate218, the trigger balls268will be shifted within the cavities264so as to directly contact the inner surface of the bottom plate234. In this instance, when any one of the trigger balls268is rotated into contact with any one of the contact plates217, such trigger ball268will be in simultaneous conductive contact with the bottom inner and outer pads246,248of the corresponding intermeshed pair. Thus, the bottom outer pads248provide redundancy to the contact plates217since, even if the trigger ball(s)268do not achieve proper conductive contact with the contact plate(s)217, a closed circuit condition is still created by the complete conductive path comprising one or both of the top and bottom pins226,244, the trigger plate260, one or two of the trigger balls268, one or two of the conductive traces233, and one or two of the top peripheral pads230.

When any trigger ball268is in contact with any intermeshed pair of the bottom inner and outer pads246,248, a particular high state is generated by the sensor200which is indicative of the bottom plate234being disposed closer to the reference plane than the top plate218(i.e., the sensor200being disposed in a generally non-inverted orientation). This particular high state is generated as a result of the trigger ball(s)268being in conductive contact with the bottom inner pad(s)246and the resultant closed circuit condition created by the complete conductive path comprising the top and bottom pins226,244, the trigger plate260, one or two of the trigger balls268, one or two of the bottom inner pads246, one or two of the conductive traces247, the conductive pads242,224, the conductive trace232, and the center top peripheral pad230of one set thereof.

Conversely, when the sensor200is flipped over (i.e., turned upside-down) such that the top plate218is disposed closer to the reference plane than the bottom plate234, the trigger balls268will be shifted within the cavities264so as to be brought into direct contact with the inner surface of the top plate218. In this instance, the top outer pads229provide redundancy to the contact between the trigger ball(s)268and the contact plate(s)217in a similar manner to that described above since, even in the absence of conductive contact between the trigger ball(s)268and the contact plate(s)217, a closed circuit condition is still created by the complete conductive path comprising one or both of the top and bottom pins226,244, the trigger plate260, one or two of the trigger balls268, one or two of the top outer pads229, one or two of the conductive traces233, and one or two of the outer top peripheral pads230.

The particular high state generated by the sensor200when any one of the trigger balls268is placed into conductive contact with any intermeshed pair of the top inner and outer pads228,229is indicative of the sensor200being upside-down, i.e., the top plate218being disposed closer to the reference plane than the bottom plate234. This particular high state is generated as a result of the closed circuit condition created by the complete conductive path comprising one or both of the top and bottom pins226,244, the trigger plate260, one or two of the trigger balls268, one or two of the top inner pads228, the conductive trace231, and the center top peripheral pad230of one set thereof. Thus, not only does the sensor200generate different high states depending upon whether the contact plates217are individually or simultaneously contacted by the trigger balls268, the sensor200further generates additional high states depending on whether or not it is upside-down relative to the reference plane. The absence of any high states being generated which are indicative of either of the top or bottom plates218,234being disposed closer to the reference plane is itself indicative of the sensor200being disposed in a generally vertical orientation relative thereto, i.e., the top and bottom plates218,234extending generally perpendicularly relative to the reference plane, as could result in the trigger balls268not being in conductive contact with any intermeshed pair of the top inner and outer pads228,229or bottom inner and outer pads246,248.

As the trigger mechanism comprising the trigger plate260and trigger balls268rotates within the interior chamber of the housing212, the absence of the enlarged distal end267on one of the partition walls266could result in a situation where the center trigger ball268is removed from conductive contact with the trigger plate260. In view of the configuration of the trigger plate260, the outer pair of trigger balls268will, at the very least, always be in contact with at least the partition walls266. If the sensor200was moved into an orientation relative to the reference plane wherein the center trigger ball268would be caused to move out of contact with both of the partition walls266at the same time, conductive contact is still maintained between the center trigger ball268and the trigger plate260due to the contact between the distal end267and the center trigger ball268.

The sensor200of the third embodiment is preferably used in combination with the above-described programable electronic circuitry70. The functionality imparted by the electronic circuitry70when used in conjunction with the sensor200is the same as that described above. However, rather than requiring all eight of the i/o's of the MPU72, the sensor200requires only six i/o's. In this respect, the outer top peripheral pads230(a total of four) are electronically connected to respective ones of the i/o's of the MPU72. Thus, while providing the same functional capability as the above-described sensors10,100of the first and second embodiments, the sensor200of the third embodiment does so through the use of less i/o's of the MPU72(i.e., six i/o's as opposed to eight i/o's).

Referring now toFIG. 28, it is contemplated that as an alternative to the separate metallic contact plates217being attached to the side wall214at ninety degree intervals, a conductive coating may be applied to the side wall214in four (4) sections270which each mimic the configuration of the contact plates217. In this respect, a portion of each section270is disposed on the inner surface of the side wall14, with other portions of each section270being disposed upon each of the top and bottom peripheral rims of the side wall214.

Referring now toFIG. 29, there is depicted a sensor200awhich is a three-axis version of the sensor200. In the sensor200a, the housings212of three identically configured sensors200are attached to each other or to a common mount such that each corresponding pair of top and bottom pins226,244is coaxially aligned with a respective one of three different axes which extend in generally perpendicular relation to each other. Each sensor200of the sensor200afunctions in the above-described manner.

Since each sensor200is operative to generate a low state and ten different high states as described above, the sensor200awould itself be operative to generate the low state and at least one thousand different high states (ten to the third power based on three axes) depending on the orientation thereof relative to the reference plane. The electronic circuitry used in conjunction with the sensor200awould provide the same functionality as the electronic circuitry70, i.e., differentiating and/or comparing states and/or conditions, and generating resultant effects.

Referring now toFIG. 16, there is depicted an exploded view of a sensor300constructed in accordance with a fourth embodiment of the present invention. The sensor300of the fourth embodiment essentially comprises a meld of the sensor100of the second embodiment and the sensor200of the third embodiment. The sensor300comprises an octagonally shaped side wall314which defines top and bottom peripheral rims, and includes four cylindrically configured post portions316. The post portions316are sized relative to the remainder of the side wall314so as to protrude beyond the top and bottom peripheral rims thereof.

The sensor300further comprises an octagonally shaped top plate318which is attached to the side wall314in a manner wherein a peripheral portion of the inner surface of the top plate318abuts the top peripheral rim of the side wall314. To maintain a proper registry between the side wall314and the top plate318, disposed within the top plate318are four apertures320which are sized and configured to receive respective ones of the post portions316. When the top plate318is properly secured to the side wall314, the peripheral edge of the top plate318is substantially flush with the outer surface of the side wall314. Disposed in the approximate center of the top plate318is an aperture322. Additionally, disposed in the approximate center of the inner surface of the top plate318is a circularly configured conductive pad324. The aperture322is concentrically positioned within the conductive pad324. The aperture322is sized and configured to receive a top pin326of the sensor300. The top pin326includes a radially extending flange portion which is abutted against the conductive pad324when the top pin326is fully inserted into the aperture322. The top pin326further defines a pointed inner end, and is preferably fabricated from a conductive metal material.

In addition to the pad324, also disposed on the inner surface of the top plate318are four generally U-shaped top inner pads328which are each electrically connected to the pad324via a conductive trace and are disposed thereabout (i.e., are separated from each other) at equidistant intervals of approximately ninety degrees. Also disposed on the inner surface of the top plate318are four generally E-shaped top outer pads329which are also separated from each other at intervals of approximately ninety degrees, and are intermeshed with respective ones of the top inner pads328. The top outer pads329are not in direct electrical communication with the corresponding top inner pads328. In addition to the pads324,328,329, disposed on the inner surface of the top plate318are four circularly configured conductive top peripheral pads330. Each of the top outer pads329is electrically connected to a respective one of the top peripheral pads330via a conductive trace which extends therebetween. The pads324,328,329,330and traces are preferably formed of very thin copper via conventional etching techniques. Thus, the top plate318is preferably fabricated from a conventional printed circuit board (PCB) material.

The sensor300of the fourth embodiment further comprise an octangonally shaped bottom plate334which is attached to side wall314such that a peripheral portion of the inner surface of the bottom plate334abuts the bottom peripheral rim of the side wall314. To maintain proper registry between the side wall314and the bottom plate334, disposed within the bottom plate334are four apertures336which are adapted to receive respective ones of the post portions316of the side wall314, and in particular those portions of the post portions316which protrude beyond the bottom peripheral rim of the side wall314.

Disposed within the approximate center of the bottom plate334is an aperture340. Additionally, disposed in the approximate center of the inner surface of the bottom plate334is a circularly configured conductive pad342. The aperture340is concentrically positioned within the conducive pad342, and is sized and configured to receive a bottom pin344which is identically configured to the top pin326. The bottom pin344is also fabricated from a conductive metal material, and includes a radially extending flange portion which is abutted against the pad342when the bottom pin344is fully inserted into the aperture340. The bottom pin344also defines a pointed inner end.

Also disposed on the inner surface of the bottom plate334are four generally U-shaped conductive bottom inner pads346which are identically configured to the top inner pads328and are disposed about the periphery of the pad342in equidistantly spaced intervals of approximately ninety degrees. Each of the bottom inner pads346is electrically connected to the pad342via a conductive trace. Also disposed on the inner surface of the bottom plate344are four generally E-shaped bottom outer pads347which are identically configured to the top outer pads329. The bottom inner pads346are intermeshed with respective ones of the bottom outer pads347in the same manner described above with respect to the intermesh of the top inner pads328to respective ones of the top outer pads329. Disposed within each of the bottom outer pads347is a slot352, the use of which will be discussed in more detail below.

The sensor300of the fourth embodiment further comprises four identically configured contact plates354. Each of the contact plates354comprises a main body portion, and a narrow stem portion which extends from one edge of the main body portion. The main body portions of the contact plates354are received into respective ones of four complementary notches formed within the inner surface of the side wall314at equidistant intervals of approximately ninety degrees. Upon the receipt of the main body portions of the contact plates354into the notches, the top edges of the main body portions are substantially flush with the top peripheral rim of the side wall314, with the stem portions protruding downwardly from the bottom peripheral rim of the side wall314. Upon the attachment of the top plate318to the side wall314, the top outer pads329are brought into direct, conductive contact with respective ones of the contact plates354, and in particular the top edges of the main body portions thereof. Additionally, upon the attachment of the bottom plate334to the side wall314, the stem portions of the contact plates354are advanced into respective ones of the bottom outer pads347. Thus, upon the assembly of the housing of the sensor300, the contact plates354are electrically connected to both the top and bottom outer pads329,347, and hence to respective ones of the top peripheral pads330.

The sensor300of the fourth embodiment further comprises a trigger plate360which is identically configured to the above-described trigger plate260, and is rotatably connected to the housing defined by the attachment of the top and bottom plates318,334to the side wall314. More particularly, the trigger plate360is disposed within the interior chamber defined by such housing. The trigger plate360has a generally semi-circular shape, and is fabricated from a conductive metal material. Disposed within the opposed top and bottom surfaces of the trigger plate360is a coaxially aligned pair of openings362which are used to facilitate the rotatable connection of the trigger plate360to the housing. The pointed inner ends of the top and bottom pins326,344are advanced into respective ones of the openings362and engaged to the trigger plate360. When the housing of the sensor300is completely assembled, the apertures322,344are advanced into respective ones of the openings362and engaged to the trigger plate360. When the housing of the sensor300is completely assembled, the apertures322,340within the top and bottom plates318,334are coaxially aligned with each other, thus resulting in the inner ends of the top and bottom pins326,344being coaxially aligned as well. The engagement of the inner ends of the top and bottom pins326,344to the trigger plate360allows the trigger plate360to be freely rotatable within the interior chamber of the housing of the sensor300. Additionally, the preferred fabrication of the trigger plate360and the top and bottom pins326,344from a conductive metal material and the conductive contact of the flange portions of the top and bottom pins326,344and respective ones of the pads324,342facilitates the placement of the trigger plate360into electrical communication with the pads324,342via the top and bottom pins326,344.

The trigger plate360defines an arcuate outer surface portion which extends about one hundred eighty degrees. Formed within the outer surface portion are three cavities364which are preferably spaced from each other at equal intervals of approximately forty-five degrees, with the outer pair of cavities364being equally spaced from respective ones of the opposed ends of the outer surface portion. Disposed within each of the cavities364is a spherically shaped trigger ball368. The diameter of each trigger ball368is less than the width of each cavity364, thus allowing each trigger ball368to be freely movable and rotatable within its corresponding cavity364. Each of the trigger balls368is also fabricated from a conductive metal material. The trigger plate360and trigger balls368collectively define a trigger mechanism of the sensor300.

The trigger plate360defines a pair of partition walls366which segregate or separate the center cavity364from the outer pair of cavities364. One of these partition walls366is formed to include an enlarged distal end367which partially enclosed the center cavity364and is operative to maintain the center trigger ball368disposed within the center cavity364in conductive contact with the trigger plate360as discussed above in relation to the trigger plate260. When the trigger mechanism (i.e., the trigger plate360and trigger balls368) of the sensor300is rotatably mounted with the interior chamber of the housing thereof, the orientation of the cavities364and hence the trigger balls368within the trigger plate360allows each of the trigger balls368to be passable over or positionable upon any one of the intermeshed pairs of bottom inner and outer pads346,347or top inner and outer pads328,329. When the sensor300is oriented relative to a generally horizontal reference plane such that the bottom plate334is disposed closer to the reference plane than the top plate318, the trigger balls366will move or shift within the cavities364such that portions thereof will protrude from the bottom surface of the trigger plate360and directly contact the inner surface of the bottom plate334. Conversely, if the sensor300is flipped over such that the top plate318is disposed closer to the reference plane than the bottom plate334, the trigger balls366will move or shift within the cavities364such that portions thereof will protrude from the top surface of the trigger plate360and directly contact the inner surface of the top plate318.

The sensor300of the fourth embodiment has the capability of generating or producing a multiplicity of different states corresponding to respective positions of the sensor300relative to the reference plane. The sensor300is operative to generate a low state when the trigger balls368of the trigger mechanism are not in contact with any of the contact plates354, and any of the intermeshed pairs of bottom inner and outer pads346,347or top inner and outer pads228,229. The sensor300is further operative to generate four different high states corresponding to contact between the center trigger ball368and respective ones of the contact plates354, and four additional different high states corresponding to the outer pair of trigger balls368being in simultaneous contact with any pair of the contact plates354separated by a ninety degree interval.

When any trigger ball368moves into contact with a contact plate354, a closed circuit condition is created since there is a complete conductive path comprising one or both of the top and bottom pins326,344, the trigger plate360, one or two of the trigger balls368, one or two of the contact plates354, one or two of the top outer pads329(due to the conductive contact between the top outer pads329and respective ones of the contact plates354), and one or two of the top peripheral pads330. The particular high state generated by the sensor300is dependent upon the contact plate354with which electrical contact is established by the center trigger ball368, i.e., each contact plate354produces a different high state when contacted by the center trigger ball368. When the trigger plate360is positioned within the interior chamber of the housing of the sensor300such that the outer pair of trigger balls368simultaneously contact a corresponding pair of contact plates354, the particular high state generated by the sensor300is dependent upon the combination of contact plates354with which electrical contact is established, i.e., a different high state is produced when any pair of adjacent contact plates354are simultaneously contacted by the outer pair of trigger balls368.

In the sensor300, each intermeshed pair of bottom inner and outer pads346,347provides redundancy to a respective one of the contact plates354. In this respect, in the event conductive contact is not achieved between a trigger ball368and a particular contact plate354, a closed circuit condition is still created since there is a complete conductive path comprising one or both of the top and bottom pins326,344, the trigger plate360(if current is introduced into the sensor300via the top pin326), the pad342, one or two of the bottom inner pads346, one or two of the trigger balls368, one or two of the bottom outer pads347, and one or two of the contact plates354. In this respect, electrical communication between the bottom inner and outer pads346,347of any corresponding pair may be facilitated by one of the conductive trigger balls368being in simultaneous contact therewith.

Each intermeshed pair of bottom inner and outer pads346,347, when contacted by the center trigger ball368, facilitates the production of the same high state as the adjacent contact plate354when contacted by the center trigger ball368. Similarly, the high state generated by the sensor300when any adjacent pair of the intermeshed bottom inner and outer pads346,347are simultaneously contacted by respective ones of the outer pair of trigger balls368is identical to the high state generated when the corresponding contact plates354are simultaneously contacted by the outer pair of trigger balls368.

If the sensor300is oriented such that the top plate318is disposed closer to the reference plane than the bottom plate334, the sensor300is operative to generate four different high states (different from the high states discussed above) corresponding to contact between the center trigger ball368and respective ones of the intermeshed pairs of the top inner and outer pads328,329, and four additional different high states corresponding to the outer pair of trigger balls368being in simultaneous contact with any adjacent pair of the intermeshed top inner and outer pads328,329separated by a ninety degree interval. A closed circuit condition is created by the complete conductive path comprising one or both of the top and bottom pins326,344, the trigger plate360(if current is introduced into the sensor300via the bottom pin344), the pad324, one or two of the top outer pads329, and one or two of the top peripheral pads330. Thus, the sensor300has the capability of generating the low state and a totality of sixteen different high states. The high states generated as a result of one or more of the trigger balls368being in contact with one or more of the intermeshed pairs of top inner and outer pads328,329are indicative of the sensor300being generally upside-down, i.e., the top plate318being disposed closer to the reference plane than the bottom plate334.

The sensor300of the fourth embodiment is preferably used in combination with the above-described programable electronic circuitry70. The functionality imparted by the electronic circuitry70when used in conjunction with the sensor300is the same as that previously described in relation to the sensor100of the second embodiment. The contact plates354are electrically connected to respective ones of the i/o's of the MPU72, as are the top peripheral pads330. As a result, eight i/o's of the MPU72are utilized by the sensor300in the same manner eight i/o's of the MPU72are used by the sensor100of the second embodiment. Though not shown, those of ordinary skill in the art will recognize that the sensor300of the fourth embodiment may be provided in a three-axis version, with the states and conditions generated by such three-axis version being the same as previously described in relation to the sensor100a(i.e., the three-axis version of the sensor100).

Referring now toFIGS. 17–19, there is depicted a sensor500constructed in accordance with a fifth embodiment of the present invention. The sensor500comprises a housing512. The housing512itself comprises a circularly shaped side wall514which defines top and bottom peripheral rims. Extending upwardly from each of the top and bottom peripheral rims are generally cylindrical bosses515. Additionally, disposed within each of the top and bottom peripheral rims are apertures516. Attached to the side wall514are nine identically configured contact plates517. Each of the contact plates517is preferably fabricated from a conductive metal material. The contact plates517are attached to the side wall514so as to be equidistantly spaced from each other at intervals of approximately forty degrees. The side wall514defines nine equally sized, arcuate inner surface sections. These inner surface sections and portions of the contact plates517collectively define a generally circular inner surface of the housing512. Additionally, the contact plates517are sized relative to the side wall514such that portions of each of the contact plates517are substantially flush with each of the top and bottom peripheral rims of the side wall514.

Referring now toFIGS. 17,19, and20A, in addition to the side wall514, the housing512comprises an octagonally shaped top plate518which is attached to the side wall514in a manner wherein a peripheral portion of the inner surface of the top plate518abuts the top peripheral rim of the side wall514. To maintain proper registry between the side wall514and the top plate518, disposed within the top plate518are apertures520which are sized and configured to receive respective ones of the bosses515. Disposed within the approximate center of the top plate518is an aperture522. Additionally, disposed in the approximate center of the inner surface of the top plate518is a circularly configured conductive pad524. The aperture522is concentrically positioned within the conductive pad524. The aperture522is sized and configured to receive a top pin526of the sensor500. As seen inFIG. 18, the top pin526includes a radially extending flange portion which is abutted against the conductive pad524when the top pin526is fully inserted into the aperture522. The top pin526further defines a pointed inner end, and is preferably fabricated from a conductive metal material.

In addition to the pad524, disposed on the inner surface of the top plate518are nine generally E-shaped top inner pads528which are separated or spaced from each other at equidistant intervals of approximately forty degrees. Also disposed on the inner surface of the top plate518are nine generally U-shaped top outer pads529which are also separated from each other at equal intervals of approximately forty degrees, and are intermeshed with respective ones of the top inner pads528. Further disposed on the inner surface of the top plate518are nine rectangularly shaped top peripheral pads530which are also separated from each other at equal intervals of approximately forty degrees, and are disposed adjacent respective ones of the top outer pads529. A circularly configured top output pad531, which is best seen inFIG. 20A, is also disposed on the inner surface of the top plate518. In the top plate518, the top inner pads528are electrically connected to each other and to the top output pad531via a conductive trace532. Additionally, conductive traces533are used to electrically connect the top outer pads529to respective ones of the top peripheral pads530.

The pads528,529,530,531and conductive traces532,533are each preferably formed of very thin copper via conventional etching techniques. As such, the top plate518is preferably fabricated from a conventional printed circuit board material. As best seen inFIG. 20A, it is contemplated that during the fabrication of the top plate518, each of the conductive traces532,533will be covered or masked with a layer of insulating ink or other insulating material so as not to be exposed upon the inner surface of the top plate518. As further seen inFIG. 20A, portions of each of the top peripheral pads530are also preferably covered or masked with a strip of the insulating ink.

The sensor500of the fifth embodiment further comprises a generally octagonal bottom plate534which is attached to the side wall514such that a peripheral portion of the bottom plate534abuts the bottom peripheral rim of the side wall514. To maintain proper registry between the side wall514and the bottom plate534, disposed within the bottom plate534are apertures536which are adapted to receive respective ones of the bosses515. Disposed within the approximate center of the inner surface of the bottom plate534is a circularly configured conductive pad542. The aperture540is concentrically positioned within the conductive pad542, and is sized and configured to receive a bottom pin544which is identically configured to the top pin526. The bottom pin544is also fabricated from a conductive metal material, and includes a radially extending flange portion which is abutted against the pad542when the bottom pin544is fully inserted into the aperture540. The bottom pin544also defines a pointed inner end.

Also disposed on the inner surface of the bottom plate534are nine generally E-shaped conductive bottom inner pads546which are identically configured to the top inner pads528and are disposed about the periphery of the pad542in equidistantly spaced intervals of approximately forty degrees. Each of the bottom inner pads546is electrically connected to the pad542via a generally straight conductive trace547. Further disposed on the inner surface of the bottom plate544are nine generally U-shaped bottom outer pads548which are identically configured to the top outer pads529. The bottom inner pads546are intermeshed with respective ones of the bottom outer pads548in the same manner described above with respect to the intermesh of the top inner pads528to respective ones of the top outer pads529.

In addition to the above-described pads542,546,548, disposed on the inner surface of the bottom plate534are nine rectangularly shaped top peripheral pads550which are identically configured to the top peripheral pads530and are disposed adjacent to respective ones of the top outer pads548. Also disposed on the top inner surface of the bottom plate534are ten bottom output pads552which extend in linear, spaced relation to each other along a common edge of the bottom plate534. In the bottom plate534, conductive traces554are used to electrically connect the bottom outer pads548to respective ones of the bottom peripheral pads550. Additionally, conductive traces556are used to electrically connect the bottom peripheral pads550to respective ones of the bottom output pads552. As best seen inFIGS. 19 and 20A, a conductive trace558electrically connects one of the bottom inner pads546directly to one of the bottom output pads552. As such, all of the bottom inner pads546are electrically connected to one, common bottom output pad552by virtue of the electrical interconnection of the bottom inner pads546resulting from the conductive traces547and conductive pad542.

The pads542,546,548,550,552and traces547,554,556,558are each preferably formed of very thin copper via conventional etching techniques. As such, the bottom plate534, like the top plate518, is preferably fabricated from a conventional printed circuit board material. As best seen inFIG. 20B, it is contemplated that during the fabrication of the bottom plate534, each of the conductive traces547,554,556,558will be covered or masked with a layer of insulating ink or other type of insulating material so as not to be exposed upon the inner surface of the bottom plate534. As further seen inFIG. 20B, portions of each of the bottom peripheral pads550are also preferably covered or masked with a strip of the insulating ink.

The housing512of the sensor500is assembled by attaching the top and bottom plates518,534to the side wall514in the above-described manner. Upon such assembly, the inner surfaces of the top and bottom plates518,534and circular inner surfaces defined by the inner surface sections of the side wall514and portions of the contact plates517collectively define an interior cavity or chamber of the housing512. The side wall514and top and bottom plates518,534are sized and configured relative to each other such that when the top and bottom plates518,534are attached to the side wall514, those portions of the contact plates517flush with the top peripheral rim of the side wall514are in abutting, electrical contact with respective ones of the top peripheral pads530. Similarly, those portions of the contact plates517substantially flush with the bottom peripheral rim of the side wall514are in abutting, electrical contact with respective ones of the bottom peripheral pads550. Thus, the top peripheral pads530are placed into electrical communication with respective ones of the bottom peripheral pads550by respective ones of the intervening contact plates517. Additionally, each corresponding, intermeshed pair of the top inner and outer pads528,529and bottom inner and outer pads546,548is disposed between the coaxially aligned axes of the top and bottom pins526,544and a respective one of the contact plates517.

The sensor500of the fifth embodiment further comprises a trigger plate560which is rotatably connected to the housing512and is disposed within the interior chamber defined thereby. The trigger plate560has a generally semi-circular shape, and is preferably fabricated from a conductive metal material. Disposed within the opposed top and bottom surfaces of the trigger plate560is a coaxially aligned pair of openings562which are used to facilitate the rotatable connection of the trigger plate560to the housing512. As seen inFIG. 18, the pointed inner ends of the top and bottom pins526,544are advanced into respective ones of the openings562and engaged to the trigger plate560. When the housing512is assembled in the above-described manner, the apertures522,540within the top and bottom plates518,534are coaxially aligned as well. The engagement of the inner ends of the top and bottom pins526,544to the trigger plate560allows the trigger plate560to be freely rotatable within the interior chamber of the housing512, yet prevented from upward or downward or side-to-side movement therewithin. The pointed inner ends of the top and bottom pins526,544loosely engage the trigger plate560. Additionally, the preferred fabrication of the trigger plate560and the top and bottom pins526,544from a conductive metal material and the conductive contact between the flange portions of the top and bottom pins526,544and respective ones of the pads524,542facilitates the placement of the trigger plate560into electrical communication with the pads524,542via the top and bottom pins526,544.

The trigger plate560defines an arcuate outer surface portion which extends about one hundred eighty degrees. Formed within the approximate center of the outer surface portion is a cavity564. Disposed within the cavity564is a spherically shaped trigger ball568. The diameter of the trigger ball568is less than the width of the cavity564, thus allowing the trigger ball568to be freely movable and rotatable within the cavity564. The trigger ball568is also fabricated from a conductive metal material. The cavity564is specifically configured to maintain the trigger ball568in conductive contact with the trigger plate560. The trigger plate560and trigger ball568collectively define a trigger mechanism of the sensor500.

When the trigger mechanism (i.e., the trigger plate560and trigger ball568) of the sensor500is rotatably mounted within the interior chamber of the housing512, the orientation of the cavity564and hence the trigger ball568within the trigger plate560allows the trigger ball568to be passable over or positionable upon any one of the intermeshed pairs of bottom inner and outer pads546,548or top inner and outer pads528,529. More particularly, when the sensor500is oriented relative to a generally horizontal reference plane such that the bottom plate534is disposed closer to the reference plane such that the bottom plate534is disposed closer to the reference plane than the top plate518, the trigger ball568will more or shift within the cavity564such that a portion thereof will protrude from the bottom surface of the trigger plate560and directly contact the inner surface of the bottom plate534in the manner shown inFIG. 18. Conversely, if the sensor500is flipped over such that the top plate518is disposed closer to the reference plane than the bottom plate534, the trigger ball568will move or shift within the cavity564such that a portion thereof will protrude from the top surface of the trigger plate560and directly contact the inner surface of the top plate518.

Referring now toFIGS. 21A,21B, and21C, the sensor500of the fifth embodiment itself has the capability of generating or producing a multiplicity of different states corresponding to respective positions of the sensor500relative to the reference plane. The movement of the sensor500relative to the reference plane facilitates the rotation of the trigger mechanism within the interior chamber of the housing512. The sensor500is operative to generate a low state when the trigger ball568of the trigger mechanism is not in contact with any of the contact plates517, and thus is not in contact with any of the intermeshed pairs of bottom inner and outer pads546,548or top inner and outer pads528,529. The sensor500is further operative to generate nine different high states corresponding to contact between the trigger ball568and respective ones of the contact plates517, examples of which are shown inFIGS. 21A,21B, and21C.

When the trigger ball268moves into contact with a contact plate517, a closed circuit condition is created since there is a complete conductive path comprising one or both of the top and bottom pins526,544, the trigger plate560, the trigger ball568, the contact plate517, one of the bottom peripheral pads550(due to the conductive contact between the bottom peripheral pads550and respective ones of the contact plates517), one of the conductive traces556, and one of the bottom output pads552. The particular high state generated by the sensor500is dependent upon the contact plate517with which electrical contact is established by the trigger ball568, i.e., each contact plate517produces a different high state when contacted by the trigger ball568due to each contact plate517being electrically connected to a respective, different bottom output pad552by a respective conductive trace556.

As will be recognized, when the sensor500is disposed vertically relative to the reference plane (i.e., the top and bottom plates518,534extend generally perpendicularly relative to the reference plane), the trigger ball568of the trigger mechanism may not be in contact with any of the intermeshed pairs of top inner and outer pads528,529or bottom inner and outer pads546,548. Even in the absence of such contact, a particular high state may still be produced due to the conductive contact between the contact plates517and respective ones of the bottom peripheral pads550which are themselves electrically connected to respective ones of the bottom output pads52via respective ones of the traces556.

When the sensor500is oriented such that the bottom plate534is disposed closer to the reference plane than the top plate518, the trigger ball568will be shifted within the cavity564so as to directly contact the inner surface of the bottom plate534. In this instance, when the trigger ball568is rotated into contact with any one of the contact plates517, the trigger ball568will be in simultaneous conductive contact with the bottom inner and outer pads546,548of the corresponding intermeshed pair. Thus, the bottom outer pads548provide redundancy to the contact plates517since, even if the trigger ball568does not achieve proper conductive contact with the contact plate517, a closed circuit condition is still created by the complete conductive path comprising one or both of the top and bottom pins526,544, the trigger plate560, the trigger ball568, one of the bottom outer pads548, one of the conductive traces554, one of the bottom peripheral pads550, one of the conductive traces556, and one of the bottom output pads552.

When the trigger ball568is in contact with any intermeshed pair of the bottom inner and outer pads546,548, a particular high state is generated by the sensor500which is indicative of the bottom plate534being disposed closer to the reference plane than the top plate518(i.e., the sensor500being disposed in a generally non-inverted orientation). This particular high state is generated as a result of the trigger ball568being in conductive contact with the bottom inner pad546and the resultant closed circuit condition created by the complete conductive path comprising one or both of the top and bottom pins526,544, the trigger plate560, the trigger ball568, two of the bottom inner pads546, two of the conductive traces547, the pad542, the conductive trace558, and one of the bottom output pads552. However, if the trigger ball568rests upon the particular bottom inner pad546electrically connected to the bottom contact pad via the conductive trace558, the conductive path does not include a second bottom inner pad546or a second conductive trace547.

Conversely, when the sensor500is flipped over (i.e., turned upside-down) such that the top plate518is disposed closer to the reference plane than the bottom plate534, the trigger ball568will be shifted within the cavity564so as to be brought into contact with the inner surface of the top plate518. In this instance, the top outer pads529provide redundancy to the contact between the trigger ball568and the contact plates517in a similar manner to that described above since, even in the absence of conductive contact between the trigger ball568and a particular contact plate517, a closed circuit condition is still created by the complete conductive path comprising one or both of the top and bottom pins526,544, the trigger plate560, the trigger ball568, one of the top outer pads529, one of the conductive traces533, one of the top peripheral pads530, one of the contact plates517, one of the bottom peripheral pads550, one of the conductive traces556, and one of the bottom output pads552.

The particular high state generated by the sensor500when the trigger ball568is placed into conductive contact with any intermeshed pair of the top inner and outer pads528,529is indicative of the sensor500being upside-down, i.e., the top plate518being disposed closer to the reference plane than the bottom plate534. This particular high state is generated as a result of the closed circuit condition created by the complete conductive path comprising one or both of the top and bottom pins526,544, the trigger plate560, the trigger ball458, two of the top inner pads528, the conductive trace532and the top output pad531. The conductive path includes only one top inner pad528if the trigger ball568rests upon that top inner pad528in direct contact with that portion of the conductive trace532extending to the top output pad531. The absence of any high states being generated which are indicative of either of the top or bottom plates518,534being disposed closer to the reference plane is itself indicative of the sensor500being disposed in a general vertical orientation relative thereto, i.e., the top and bottom plates518,534extending generally perpendicularly relative to the reference plane, as could result in the trigger ball568not being in conductive contact with any intermeshed pair of the top inner and outer pads528,529or bottom inner and outer pads546,548.

Referring now toFIG. 30, it is contemplated that as an alternative to the separate metallic contact plates517being attached to the side wall514at ninety degree intervals, a conductive coating may be applied to the side wall514in four sections571which each mimic the configuration of the contact plates517. In this respect, a portion of each section571is disposed on the inner surface of the side wall514, with other portions of each section571being disposed upon each of the top and bottom peripheral rims of the side wall514.

The sensor500of the fifth embodiment is preferably used in combination with programmable electronic circuitry570which is shown schematically inFIG. 27. The programmable electronic circuitry570used in conjunction with the sensor500is in electrical communication therewith, and has the same operative capabilities as the electronic circuitry70described above. The electronic circuitry570includes an MPU572. The MPU572includes a total of fifteen input/output ports or i/o's which are labeled as P10–P13, P30–P33, and P40–P42. The bottom output pads552are electrically connected to respective ones of the i/o's of the MPU572. Similarly, the top output pad531is electrically connected to a respective one of the i/o's. Thus, a total of eleven i/o's are used by the sensor500. To facilitate the creation of the required conductive paths through the sensor500, it is contemplated that one of the top and bottom pins526,544will be in electrical communication with the electronic circuitry570is a manner permitting electrical current to be transmitted therefrom into the trigger mechanism. That one of the top and bottom pins526,544not used to facilitate the transmission of current to the trigger mechanism is preferably used to establish a common ground to the electronic circuitry570.

Referring now toFIG. 22, there is depicted a sensor500awhich is a three-axis version of the sensor500. In the sensor500a, the housings512of three identically configured sensors500are attached to each other or to a common mount such that each corresponding pair of top and bottom pins526,544is coaxially aligned with a respective one of three different axes which extend in generally perpendicular relation to each other. Each sensor500of the sensor500afunctions in the above-described manner. Since each sensor500is operative to generate a low state and ten different high states as described above, the sensor500awould itself be operative to generate the low state and at least one thousand different high states (ten to the third power based on three axes) depending on the orientation thereof relative to the reference plane. The electronic circuitry used in conjunction with the sensor500awould provide the same functionality as the electronic circuitry570, i.e., differentiating and/or comparing states and/or conditions, and generating resultant effects.

Referring now toFIG. 23, there is depicted an exploded view of a sensor600constructed in accordance with a sixth embodiment of the present invention. The sensor600is identical both structurally and functionally to the sensor500, with the sole exception lying in the structural attributes of the trigger plate660. More particularly, the trigger plate660of the sensor600is identical to the trigger plate560, except that the trigger plate660further includes a spaced pair of arcuately shaped slots661within the center section thereof. Disposed within each slot661is a spherically shaped slide ball663. The slide balls663assist the rotation of the trigger plate660upon the movement of the sensor600relative to the reference plane.

Referring now toFIGS. 24 and 25, it is contemplated that the sensors of any embodiment of the present invention may be disposed in a stacked configuration and angularly offset relative to each other. For example, inFIG. 24, three of the sensors100of the second embodiment are shown as being stacked upon each other, with each sensor100being angularly offset relative to the sensor100immediately therebelow by a prescribed angle A. As a further example, inFIG. 25, four sensors600of the sixth embodiment are shown as being stacked upon each other, with each sensor600being angularly offset relative to the sensor600immediately therebelow by a prescribed angle A. As will be recognized, such angular offsetting allows for a dramatic increase in the number of states and hence the number of conditions which may be generated by the entirety of the stacked configuration. The electronic circuitry used in conjunction with such stacked sensors would have the capability of comparing/differentiating such states and conditions, and generating resultant effects.

It is contemplated that a sensor possessing the structural and functional attributes described above in relation to the various embodiments of the present invention may be used in conjunction with the infrared communication technology described in Applicant's U.S. Pat. No. 6,309,775 entitled INTERACTIVE TALKING DOLLS issued Oct. 30, 2001, the disclosure of which is expressly incorporated herein by reference. In this regard, interactive electronic toys, games or other devices into which the sensor of any embodiment of the present invention is incorporated may further be outfitted to include the communication system embodied in U.S. Pat. No. 6,309,275 to impart an even higher level of functionality thereto. More particularly, any embodiment of the sensor described above may be placed into electrical communication with such communication system to facilitate the transmission of signals between the toys or other interactive devices through the use of such communication system, the signals generated by the communication system potentially being correlated to those signals generated by the movement or actuation of the sensor.

Additional modifications and improvements of the present invention may also be apparent to those of ordinary skill in the art. Thus, the particular combination of parts described and illustrated herein is intended to represent only certain embodiments of the present invention, and is not intended to serve as limitations of alternative devices within the spirit and scope of the invention.