HK1173570A - Self-powered switch initiation system - Google Patents

Description

Self-powered switch starting system

The divisional application is based on the divisional application of Chinese patent application with the application number of 02815871.7, the application date of 2002, 7 and 3, and the invention name of self-powered switch starting system.

Technical Field

The present invention relates generally to switching devices for energizing lights, appliances and the like. More particularly, the present invention relates to a self-powered switch starter device that generates a start signal for a latching relay. Electrical energy is generated by the piezoelectric element and transmitted through a signal generating circuit that is connected to a transmitter for transmitting RF signals to one or more receivers that can activate the latching relays. The receiver also trains the response to multiple transmitters.

Background

Switches and latching relays for energizing lights, appliances and the like are well known in the art. Typical lamp switches include, for example, single-pole switches and three-way switches. The single-pole switch has two hot wire terminals for incoming wires (power supply) and one outgoing wire to the lamp. A three-way switch can control a lamp from two different positions. Each three-way switch has three terminals: a common terminal and two moving terminals. A typical pair of three-way switches uses two boxes, each box having two cables, a first box having an incoming line from a power source and an outgoing line to a second box, and the second box having an incoming line from the first box and an outgoing line to a light.

In each of these switching schemes, it is often necessary to drill and install switches and junction boxes for the outlets and to run cables. Drilling and installing switches and junction boxes can be difficult and time consuming. Moreover, cabling requires starting at a fixture, pulling the cable through holes in the frame to each fixture in the circuit, and continuing all the way back to the service panel. While theoretically simple, it is difficult and time consuming to install the cable. Cables are often kinked, tangled or twisted when pulled and need to be straightened out in some places when laid.

Remotely actuated switches/relays are also known in the art. Known remote start controllers include desktop controllers, wireless remote controls, timers, motion detectors, voice start controllers, and computers and related software. For example, the remote activation device may include a module that is plugged into a wall outlet and into which the power cord of the device may be plugged. The device can then be switched on and off by a controller. Other remote starting devices include a screw-in light module, wherein the module is screwed into a light socket and then a light bulb is screwed into the module. The lamp can be switched on and off and can be dimmed or brightened by the controller.

An example of a typical remote control for the above-described module is a transceiver of a radio frequency base. With this controller, a base is plugged into the outlet and can control the module set with a hand-held wireless RF remote control. RF repeaters can be used to extend the range of compatible wireless remote controls, switches and security system sensors up to 150 ft. The base is necessary for all wireless RF remote controls and allows control of several lights or appliances. Batteries are also required in handheld wireless remote controls.

Instead of using a hand-held RF remote control, a remote wall switch may be used. These wall switches are 3/4 "thick and are adhesively secured in the desired position. The remote wall switch in combination with the base unit (plugged into a 110V outlet) controls the compatible module or switch (receiver). The wireless switch sends an RF signal to the base unit, which then transmits a signal along the existing 110V wiring in the residence to a compatible switch or module. Each switch can be set with an addressable signal. Wireless switches also require a battery.

These remote controls may also control, for example, audio/video devices such as TVs, VCRs, and stereo systems, as well as lights and other devices using RF to Infrared (IR) bases. The RF remote control is able to control the audio/video device by sending proprietary RF commands to a converter that converts the commands to IR. The IR command is then sent to the audio/video device. The console responds to signals from the infrared remote control and then transmits device commands to a compatible receiver.

One problem with conventional wall switches is that the wiring runs a larger amount of wiring from the switch box to the lamp than from the switch box to the power supply in the service panel.

Another problem with conventional wall switches is that the wiring runs additional wiring to the lamps controlled by more than one switch.

Another problem with conventional wall switches is that the lamp voltage lines appear as input and output to the switch.

Another problem with conventional wall switches is the cost associated with the initial installation of the wires to and from the switch and between them.

Another problem with conventional wall switches is the cost and inconvenience associated with retrofitting, reconfiguring, or rewiring existing switches.

One problem with conventional RF switches is that they require an external power source, such as a high voltage AC power source or a battery.

Another problem with conventional RF switches is the cost and inconvenience associated with battery replacement.

Another problem with conventional RF switches is that they require high voltage power to the modules and base unit.

Another problem with conventional AC-powered RF switches is the difficulty when retrofitting in rewiring or reconfiguring wall switches.

Another problem with conventional RF switches is that a pair comprising a transmitter and a receiver must generally be purchased together.

Another problem with conventional RF switches is that the transmitter may inadvertently activate the wrong receiver.

Another problem with conventional RF switches is that the receiver may only receive an activation signal from one transmitter.

Another problem with conventional RF switches is that the transmitter may only activate one receiver.

It would therefore be desirable to provide a network of switch actuators and/or latching relay devices that overcomes the above-described problems of the prior art.

Disclosure of Invention

The present invention provides a self-powered switch starter or latching relay device using an electro-or electro-magnetic actuator. Piezoelectric elements in an electro-active actuator are capable of deforming with high axial displacement and generate an electric field when deformed by mechanical shock. In an electromagnetic device, relative motion between a magnet and a series of coils generates an electrical signal. The electro-exciter acts as an electromechanical generator for generating a transient signal to activate the latching or relay mechanism. Whereby a latching or relay mechanism turns electrical devices such as lights and appliances on or off, or provides an intermediate or dimming signal.

The mechanical actuating means for the electro-active actuator element applies a suitable mechanical impulse to the electro-active actuator element to generate an electrical signal, such as a pulse or wave, of sufficient magnitude and duration to actuate downstream circuit components. For example, a switch similar to a light switch may apply pressure through a toggle, tapping action, slapping, or striking mechanism. Larger or multiple electro-active actuator elements may also be used to generate the electrical signal. A co-pending application 09/616,978 entitled Self-Powered Switch Device, incorporated herein by reference, discloses a Self-Powered Switch in which an electro-active element generates an electrical pulse. Co-pending provisional application 60/252,228 entitled "Self-Powered trackable Switching Network", incorporated herein by reference, discloses a Network such as the switch disclosed in application 09/616,978, but with the modification that the switch and receiver are capable of receiving a plurality of encoded RF signals. In the present invention, the mechanical actuation of the electro-active element is mechanically modified, resulting in a modification of the type of electrical signal generated by the actuator. A self-powered switch starter is described having an electro-active element and an accompanying circuit designed to operate with an oscillating electrical signal. To utilize the electrical energy generated by the electro-active element, the accompanying RF signal generating circuitry is also modified to make the most efficient use of the electrical signal.

In one embodiment of the invention, the electro-exciter is stressed by a manual or mechanical excitation device, and the oscillating electrical signal generated by the electro-exciter is applied to the relay or switch through a circuit designed to modify the electrical signal. In another embodiment, an electromagnetic or electro-active exciter signal powers an RF transmitter that sends an RF signal to an RF receiver, which then energizes a relay. In another embodiment, an electromagnetic or electro-active exciter signal energizes a transmitter which transmits a pulsed RF signal to an RF receiver, which then energizes a relay. The digitized RF signal may be encoded (e.g., as a garage door opener) and only the relay encoded with the digitized RF signal is energized. The transmitter is capable of forming one or more encoded RF signals and the receiver is similarly capable of receiving one or more encoded RF signals. In addition, a receiver may be "trainable" to receive encoded RF signals from a new or multiple transmitters.

It is therefore a principal object of the present invention to provide a switch or relay device in which an electro-active or piezoelectric element is used to energize the device.

It is another object of the invention to provide a device of the character described in which the switch can be installed without additional wiring.

It is another object of the present invention to provide a device of the character described wherein the switch can be installed without cutting holes into the building structure.

It is another object of the present invention to provide a feature described device wherein the switch does not require an external electrical input, such as 120 or 220VAC or a battery.

It is another object of the present invention to provide a device of the character described incorporating an electrical activation device that generates an electrical signal of sufficient magnitude and duration to energize a latching relay and/or switch initiator.

It is another object of the present invention to provide a device of the character described incorporating an electro-active device that generates an electrical signal of sufficient magnitude and duration to energize a radio frequency transmitter for energizing a latching relay and/or switch initiator.

It is another object of the present invention to provide a device of the character described incorporating an actuator which generates an electrical signal of sufficient magnitude to actuate a radio frequency transmitter which is used to actuate a latching relay and/or switch actuator.

It is another object of the present invention to provide a device of the character described incorporating a transmitter capable of forming at least one encoded RF signal.

It is another object of the present invention to provide a device of the character described incorporating a receiver capable of receiving at least one encoded RF signal from at least one transmitter.

It is another object of the present invention to provide a device of the character described incorporating a receiver capable of "learning" to receive encoded RF signals from one or more transmitters.

It is another object of the present invention to provide a device of the character described for energizing lights, appliances, safety devices and other equipment in a building.

Further objects and advantages of the invention will become apparent upon consideration of the drawings and ensuing description.

Drawings

FIG. 1 is a front view showing details of the construction of a flextensional piezoelectric actuator for use in the present invention;

FIG. 1a is a front view showing a detail of the structure of the flextensional piezoelectric actuator of FIG. 1 with an additional pre-stressed layer;

FIG. 2 is a front view showing details of another multilayer flextensional piezoelectric actuator used in a modification of the present invention;

FIG. 3 is a front view of an embodiment of an apparatus for mechanically applying and removing force to the center of an actuator;

FIG. 4 is a front view of the device of FIG. 3 showing deformation of the actuator when force is applied;

FIG. 5 is a front view of the device of FIG. 3 showing the return of the actuator when the force is removed by the diffusion release trip;

FIG. 6 is a front view of an actuator assembly for generating an electrical signal by deflecting a flextensional piezoelectric actuator in accordance with the present invention;

FIG. 7 is a front view of a preferred activation apparatus of the present invention for generating an electrical signal by deflecting a flextensional piezoelectric actuator;

FIG. 8 is a block diagram representing circuit components using electrical signals generated by the apparatus of FIG. 6 or 7;

FIG. 9 is a detailed circuit diagram of FIG. 8;

10a-c show the electrical signal generated by the exciter, the rectified electrical signal and the conditioned electrical signal, respectively;

FIG. 11 is a plan view of the tuned loop antenna of FIG. 8 showing the crossover at a location that maximizes the cross-section of the inductor;

FIG. 12 is a plan view of the tuned loop antenna of FIG. 8 showing the crossover at a location where the cross-section of the inductor is minimized;

FIG. 13 is a front elevational view of a preferred deflector assembly and housing enclosing the actuator of the present invention;

FIG. 14 is a front view of another embodiment of a deflector assembly using a sliding lever;

15a-c are cross-sectional elevation views taken along line 15-15 of FIG. 13 illustrating a preferred embodiment of a housing and deflector assembly using a diffusion release mechanism; and

fig. 16a-d are cross-sectional elevation views taken along line 16-16 of fig. 14.

Detailed Description

Electro-exciter

Piezoelectric and electrostrictive materials (generally referred to herein as "electro" devices) form electric fields of polarity when placed under pressure or tension. The electric field formed by piezoelectric and electrostrictive materials is a function of the force applied by the induced polar pressure or tension. In contrast, an electroluminescent device undergoes a dimensional change in the applied electric field. The change in the size of the electroluminescent device is a function of the applied electric field. Electroluminescent devices are commonly used as drivers, or "actuators," due to their property of deforming under such electric fields. These electro-active devices or actuators also have various capabilities to generate electric fields in response to deformation caused by applied forces.

The electro-mechanical device comprises direct and indirect mode actuators which typically use changes in material dimensions to effect displacement, but are preferably used as electromechanical generators in the present invention. A direct mode actuator typically comprises a piezoelectric or electrostrictive ceramic plate (or stack of plates) sandwiched between a pair of electrodes formed on a major face thereof. These devices typically have a sufficiently large piezoelectric and/or electrostrictive coefficient to create the desired tension in the ceramic plate. However, a disadvantage of direct mode exciters is that only small displacements (tensions) can be achieved, i.e. in the best case only a few tenths of a percent. Conversely, in order for the piezo to generate a pulsed transient electrical signal of sufficient magnitude to actuate the latching relay, the direct mode generator-actuator needs to apply a high amount of force.

Indirect mode actuators are known, in which the application of tension is achieved by an external structure, exhibiting greater displacements and tensions than can be achieved with direct mode actuators. An example of an indirect mode exciter is a flextensional transducer. The flextensional transducer is a composite structure composed of a piezoelectric ceramic element and a metal shell, a prestressed plastic, a glass fiber, or the like. The actuator motion of a conventional flextensional device typically occurs as an expansion of a piezoelectric material that is mechanically linked to an enlarged contraction of the device in the transverse direction. In operation, they can exhibit orders of magnitude greater tension and displacement than can be exhibited by direct mode actuators.

By constructing them as "unimorph" or "bimorph" flextensional actuators, the amount of achievable strain in an indirect mode actuator can be increased. A typical unimorph is a concave structure consisting of individual piezoelectric elements externally bonded to a flexible metal foil, with the result that axial bending or deflection occurs when power is applied. A common unimorph can exhibit up to 10% strain. A conventional bimorph device includes an intermediate flexible metal foil sandwiched between two piezoelectric elements. Electrodes are welded to each major face of the ceramic element and metal foils are welded to the inner two electrodes. Bimorphs exhibit greater displacement than comparable unimorphs because under an applied voltage one ceramic element will contract while the other will expand. Bimorphs can exhibit tensions as high as 20%.

For certain applications of electro-actuators, electro-devices biased with asymmetric stress have been proposed in order to increase the axial deformation of the electro-material and thereby increase the achievable strain of the electro-material. In such devices (including, for example, "rainbow" actuators (as disclosed in U.S. patent 5,471,721), and other flextensional actuators), asymmetric stress biasing produces a curved structure, typically having two major faces, one concave and the other convex.

Referring to fig. 1: a unimorph actuator known as "THUDER" has been recently developed and is disclosed in U.S. patent 5,632,841, with improved displacement, tension and load capacity. THUNDER (which is an acronym for thin layer composite unimorph ferroelectric driver and sensor) is a unimorph actuator in which a pre-stressed layer is bonded to a thin piezoelectric ceramic wafer at high temperature and an asymmetric stress bias is imparted to the ceramic wafer during cooling of the composite structure due to the difference in thermal shrinkage of the pre-stressed layer and the ferromagnetic layer.

The THUNDER exciter 12 is a composite structure, the construction of which is shown in fig. 1. Each of the THUNDER actuators 12 is formed as an electro-active component which preferably includes a piezoceramic layer 67 of PZT, namely plating 65 and 65a on opposite sides thereof. A pre-stressed layer 64, preferably a spring steel, stainless steel, beryllium alloy or other metal substrate, is bonded to the surface of the electroplated layer 65 on the side of the ceramic layer 67 by a first adhesive layer 66. In the simplest embodiment, the adhesive layer 66 functions as a pre-stressed layer. The first adhesive layer 66 is preferably a LaRCTM-SI material such as that available from NASA-Langley Research Center and disclosed in U.S. Pat. No.5,639,850. A second adhesive layer 66a, also preferably comprising LaRCTM-SI material, is adhered to the opposite side of the ceramic layer 67. During the manufacture of the THUNDER actuator 12, the ceramic layer 6, the adhesive layers 66 and 66a and the pre-stressed layer 64 are simultaneously heated to a temperature above the melting point of the adhesive material. In practice, the layers that make up the THUNDER actuator (i.e., the ceramic layer 67, the adhesive layers 66 and 66a, and the pre-stress layer 64) are typically placed as a composite structure in an autoclave or convection oven and heated slowly by convection until all layers of the structure reach a temperature above the melting point of the adhesive material 66 and below the curie point of the ceramic layer 67. It is desirable to keep the temperature of the ceramic layer 67 below the curie temperature of the ceramic layer to avoid destroying the piezoelectric properties of the ceramic layer 67. Because the multilayer structure is typically heated by convection at a low rate, all layers tend to be at about the same temperature. In any event, because the adhesive layer 66 is generally located between two other layers (i.e., between the ceramic layer 67 and the pre-stressed layer 64), the ceramic layer 67 and the pre-stressed layer 64 are generally very close to this same temperature and are at least as hot as the adhesive layers 66 and 66a during the heating step of the process. Then the THUNDER exciter 12 is cooled.

During cooling of the process (i.e., after the adhesive layers 66 and 66a have re-solidified), the ceramic layer 67 becomes compressively stressed by the adhesive layers 66 and 66a and the pre-stressed layer 64 due to the higher coefficient of thermal contraction of the materials of the adhesive layers 66 and 66a and the pre-stressed layer 64 than the ceramic layer 67. Moreover, due to the greater thermal shrinkage of the laminate (e.g., the first pre-stress layer 64 and the first adhesive layer 66) on one side of the ceramic layer 67 relative to the thermal shrinkage of the laminate (e.g., the second adhesive layer 66a) on the other side of the ceramic layer 67, the ceramic layer deforms in an arc shape, typically having a convex surface 12a and a concave surface 12c as shown in fig. 1 and 2.

See fig. 1 a: one or more additional pre-stressed layers may similarly be affixed to one or both sides of the ceramic layer 67, for example, to increase the pressure in the ceramic layer 67 or to strengthen the actuator 12B. In a preferred embodiment of the present invention, a second pre-stressed layer is placed on the concave surface 12a of the actuator 12B with the second adhesive layer 66a, and similarly heated and cooled. The second pre-stressed layer 68 preferably comprises a layer of conductive material. Preferably, the second pre-stress layer 68 comprises a thin foil (thinner than the first pre-stress layer 64) comprising aluminum or other conductive metal. During the cooling step of the process (i.e., after the adhesive layers 66 and 66a have re-solidified), the ceramic layer 67 is similarly made to be compressively pressurized by the adhesive layers 66 and 66a and the pre-stressed layers 64 and 68 due to the higher coefficient of thermal shrinkage of the adhesive layers 66 and 66a and the pre-stressed layers 64 and 68 material than the ceramic layer 67. Moreover, due to the greater thermal shrinkage of the laminate (e.g., the first pre-stress layer 64 and the first adhesive layer 66) on one side of the ceramic layer 67 relative to the thermal shrinkage of the laminate (e.g., the second adhesive layer 66 and the second pre-stress layer 68) on the other side of the ceramic layer 67, the ceramic layer 67 deforms into an arc shape having a generally concave surface 12a and a generally concave surface 12c as shown in fig. 1 a.

In addition, substrates comprising a separate pre-stress layer 64 may be excluded and the adhesive layers 66 and 66a may pre-stress the ceramic layer 67, either alone or in combination. In addition, only the pre-stress layers 64 and 68 and the adhesive layers 66 and 66a may be heated and bonded to the ceramic layer 67 while the ceramic sub-layer 7 is at a lower temperature so as to induce a greater compressive stress to the ceramic layer 67 when the actuator 12 is cooled.

Referring now to fig. 2: another alternative actuator 12D includes a composite piezoceramic layer 69 comprising a plurality of thin layers 69a and 69b of PZT bonded to one another. Each layer 69a and 69b comprises a thin layer of piezoelectric material, preferably on the order of about 1 mil thick. Each of the thin layers 69a and 69b is a plating layer 65 and 65a and 65b and 65c, respectively, on the main surface. The layers 69a and 69b are then adhered to each other with the adhesive layer 66b shown in an adhesive such as LaRC-SI. In addition, the thin layers 69a and 69b are preferably bonded to each other by co-firing sheets of piezoelectric material together. Here as few as two layers 69a and 69b, but preferably at least four sheets of piezoelectric material are bonded/co-fired together. The composite piezoceramic layer 69 may then be bonded to the pre-stress layer 64 using the adhesive layers 66 and 66a and heated and cooled as described above to produce the improved THUNDER actuator 12D. By making the piezoelectric material multiple thinner layers 69a and 69b in the improved actuator 12D, the composite ceramic layer produces a lower voltage and higher current than the high voltage and low current produced by a THUNDER actuator 12 having a single thicker ceramic layer 67.

A flexible insulator may be used to coat the convex face 12a of the actuator 12. This insulating coating helps prevent unintended discharge of the piezoelectric element through inadvertent contact with other conductors, liquids, or people. The coating also makes the coated element more durable against chipping or damage from impact. Since LaRC-SI is a dielectric, the adhesive layer 67a on the convex surface 12a of the actuator 12 can function as an insulating layer. Additionally, the insulating layer may comprise plastic, TEFLON or other durable coating.

Electrical energy may be recovered from or introduced to the actuator element 12 by a pair of electrical wires 14. Each wire 14 is attached to an end of the actuator element 12 on the opposite side. The leads 14 may be connected (e.g., by glue or solder 20) to the plated layers 65 and 65a face directly connected to the ceramic layer 67, or they may be additionally connected to the pre-stressed layer 64. The pre-stressed layer 64 is preferably bonded to the ceramic layer 67 by a LaSC-SI material as a dielectric, as discussed above. When the wire 14 is connected to the pre-stressed layer 64, it is desirable to roughen the surface of the pre-stressed layer 64 so that the pre-stressed layer 64 interstitially penetrates the respective paste layers 66 and 66a and forms electrical contacts with the respective plating surfaces 65 and 65a of the ceramic layer 67. In addition, the Larc-SI paste layer 66 may have a conductive material, such as nickel or aluminum particles, that act as a filler for the paste and maintain electrical contact between the pre-stress layer and the ceramic plating surface. The opposite end of each wire 14 is preferably connected to an electrical pulse modification circuit.

Pre-stressed flextensional transducers 12 are desirable because of their durability and their relatively large displacement, coupled with the relatively high voltages such transducers are capable of developing. The invention may be practiced with any electro-active element having the properties and characteristics described herein, i.e., capable of generating a voltage in response to such deformation. For example, the invention may be implemented using a magnetostrictive or ferroelectric device. The transducer also typically need not be curved, but may also comprise a generally flat transducer, and may in turn comprise stacked piezoelectric elements.

In operation as in fig. 4, when a force indicated by arrow 16 is applied to the convex face 12a of the actuator 12, the force deforms the piezoelectric element 12. Such force may be applied to the piezoelectric actuator 12 by any suitable method, such as applying manual pressure directly to the piezoelectric actuator, or by other mechanical means. Such force is preferably applied through a mechanical switch (e.g., plunger, toggle, roller switch) capable of creating a mechanical impact to be applied and removed from actuator 12. The mechanical shock (or its removal) is a sufficient force to cause the actuator 12 to rapidly deform and accelerate a distance (approximately 10mm) to generate an electrical signal of sufficient magnitude to actuate the electromechanical latching relay.

See fig. 3, 4 and 5: the illustration of the prior art device for generating an electrical pulse by applying a mechanical force includes a switch plate 18 and a plunger assembly 13. The two ends of the piezoelectric actuator are each pivotally supported at a position within the recess 44 of the switch plate 18. The switch plate 18 is of the same shape as the exciter 12 contained therein, preferably rectangular. In addition, a circular actuator is mounted in a circular recess of a circular switch plate. A notch 44 in the switch plate 18 holds the actuator 12 in its relaxed, i.e., undeformed, state position. The recess 44 is also deep enough to adequately receive the edge termination of the actuator 12 in its fully deformed, i.e., flattened, state. The plunger assembly includes a button 22 pivotally connected to a quick release mechanism of the hinge. The opposite end of the quick release mechanism 24 contacts a shaft 26 that is connected to a pair of plates 27 and 28 that are clamped on either side of the actuator 12. The release gear 25 is located along the path of the quick release mechanism 24.

In operation, when button 22 is depressed in the direction of arrow 16, quick release mechanism 24 pushes down on shaft 26 and plates 27 and 28 and deforms actuator 12. When the quick release mechanism 24 reaches the release gear 25, the quick release mechanism 24 rotates on its hinge and releases downward pressure from the shaft 26, plates 27 and 28, and actuator 12, rapidly returning to its undeformed state as shown by arrow 30 in FIG. 5 due to the restoring force of the pre-stressed layer 64.

As previously described, the applied force causes the piezoelectric actuator 12 to deform. Due to the piezoelectric response, the deformation of the piezoelectric element 67 generates a transient voltage between the faces 12a and 12c of the actuator 12, which generates a pulse of electrical energy. Further, when the force is removed from the piezoelectric actuator 12, the actuator 12 returns to its original curved shape. This is because the ceramic 67 bonded substrate or pre-stressed layers 64 and 68 exert a compressive force on the ceramic 67 such that the modulus of elasticity of the actuator 12 causes the actuator 12 to return to its undeformed state. On the return stroke of the actuator 12, the ceramic 67 returns to its undeformed state and thus generates another electrical pulse of opposite polarity. The downward (applied) or upward (restored) stroke should induce a force over a distance of sufficient magnitude to generate the required electrical pulse. The duration of the return stroke, and thus the duration of the pulse generated, is preferably in the range of 50-100 milliseconds, which is related to the force applied to the actuator 12.

Referring to fig. 6: in a preferred embodiment of the invention, the actuator 12 is clamped at one end 121 and the mechanical pulse is applied to the edge of the free end 122, i.e. at the end opposite the clamped end 121 of the actuator 12. By applying force to the edge on the free end 122 of the actuator 12 and releasing it, the electrical pulse generated when the force is removed is a vibration wave rather than a signal pulse as in the prior actuating devices disclosed above.

See also fig. 6: fig. 6 shows an embodiment of a device for generating an electrical pulse by applying a mechanical force to one end of the excitation 12. This device includes an actuator 12 and a deflector 72 mounted between a substrate 70 and a clamping member 75. The substrate 70 is preferably substantially the same shape (in plan view) as the exciter 12 attached thereto, and is preferably rectangular. One end 121 of the piezoelectric actuator 12 is held in position between the holding member 75 and the upper surface 70a of the substrate 70, preferably at one end thereof. The clamping member 75 comprises a plate or block having a lower surface 75a designed to mate with the upper surface 70a of the base plate 70 with the actuator 12 therebetween. The apparatus also has means for forcing the clamp block mating surface 75a against the upper surface 70a of the substrate 70. This allows the lower surface 75a of the clamping plate 75 to be substantially rigidly bonded to the upper surface 70a of the base plate 70, preferably towards one side of the switch plate 70. The means for urging 76 the mating surfaces 70a and 75a of the base plate 70 together may comprise bolts, clamping jaws or springs, or the like. The compression device 76 preferably includes at least one bolt 76 that passes through the clamping member 75 and into a threaded hole 77 in the upper surface 70a of the base plate 70.

One end 121 of the actuator 12 is interposed between the mating surfaces 70a and 75a of the base plate 70 and the chucking plate 75. The mating surfaces 70a and 75a are then pressed against each other with the bolts 76 and the opposite end 122 of the actuator 12 is free to move by manual or preferably mechanical impulses applied by the deflector assembly 72 towards the position where the rigid holding end 121 of the actuator 12 is between the base plate 70 and the clamping plate 75.

Referring now to fig. 7: in the preferred embodiment of the present invention, the surfaces 70a and 75a of the base plate 70 and clamping plate 75 are designed to preferably evenly distribute pressure along the actuator tip 121 therebetween. To this end, the upper surface 70a of the substrate 70 contacting the actuator tip 121 is preferably substantially flat, and the lower surface 75a of the clamping member 75 preferably has a recess 74 therein adapted for insertion of the actuator tip 121 therein. The depth of the recess 74 is preferably equal to half the thickness of the actuator substrate 64, but may be the same as the substrate thickness. Thus, the tip 121 of the exciter 12 can be placed between the recess 74 and the upper surface 70a of the base plate 70 and held therebetween by the bolts 76. In addition, the mating surfaces 70a and 75a of the base plate 70 and the clamping plate 75 may have notches therein to accommodate insertion and retention of the tips 121 of the actuators 12 therebetween. The bottom surface 75a of the holding member 75 is not in contact with the exciter 12 above the recess 74, and is a portion through which the bolt 76 passes. This portion of the bottom surface 75a may contact the upper surface 70a of the base plate 70, but preferably there is a small gap (equal to the difference between the substrate thickness and the recess depth) between the lower surface 75a of the clamping member 75 and the top surface 70a of the base plate 70 when the actuator 12 is inserted between grinds. In another embodiment of the present invention, the mating surfaces 70a and 75a of the base plate 70 and clamping plate 75 may be adhesively bonded (rather than bolted) to the end 121 of the actuator 12 clamped therebetween. In another embodiment of the invention, the clamping member 75 and the base plate 70 may comprise a single molded structure having a central socket into which the end 121 of the exciter 12 may be inserted.

The clamping assembly 75 holds the actuator 12 in its relaxed, i.e., undeformed state on the substrate 70 with the free end 122 of the actuator 12 proximate the deflector 72 assembly. More specifically, the actuator 12 is preferably clamped between the mating surfaces 70a and 75a of the substrate and clamping plates 70 and 75 with the convex surface 12a of the actuator 12 facing the substrate 70. Since the actuator 12 in its relaxed state is curved, the convex surface 12a of the actuator 12 curves away from the upper surface of the substrate 70 while approaching the free end 122 of the actuator 12. A mechanical force may then be applied to the free end 122 of the actuator 12 to deform the electro-element 67 to generate an electrical signal.

Because of the composite, multi-layer construction of the exciter 12, it is important to ensure that the clamping member 75 not only holds the exciter 12 rigidly in place, but also that the exciter 12 is not damaged by the clamping member 75. In other words, the ceramic layer 67 should not be damaged by the clamping action of the clamping member 67 by the actuator 12, more specifically in a static mode but in particular in a dynamic state when a mechanical pulse is applied to the actuator 12 with the plunger 72. For example, referring to fig. 8, when a mechanical pulse is applied to actuator 12 in the direction of the arrow, the ceramic base corners (at point C) contact substrate 70 and are pushed further toward the substrate, which may crack or damage ceramic layer 67.

See also fig. 7: it has been found that the tolerances between the contact and mating surfaces 75a and 70a of the substrates 75 and 70 are very narrow. It has also been found that the application of a downward force (as indicated by arrow 181) to the free end 122 of the actuator 12 will cause the ceramic 67 of the actuator 12 to have contacted the upper surface 70a of the substrate 70, thereby making it more likely that the ceramic 67 will be damaged. Thus, in a preferred embodiment of the invention, the switch plate 70 has a recess 80 in its upper surface 70a which not only provides protection for the electro-active element 67 from damage, but also provides electrical contact with the raised face 12a of the actuator 12 so that the electrical signal formed by the actuator 12 can be applied to downstream circuit elements.

As can be seen in fig. 7, one end 121 of the actuator is positioned between the surfaces 75a and 70a of the contact and substrate plates 75 and 70 such that only surface 64 contacts both surfaces 75a and 70 a. The clamping plate 75 preferably contacts the recessed surface 12a of the actuator 12 along the surface 64 until near the edge of the ceramic layer 67 on the opposite side 12a of the actuator 12. However, the clamping member may extend further along the raised face 12c than the edge of the ceramic layer 67 to apply greater or more uniform pressure to the actuator surfaces 12a and 12c between the clamping member 75 and the substrate 70. The ceramic layer 67 on the convex surface 12a extending above the surface of the substrate 64 extends to the recess 80 of the switch plate 70. This prevents the ceramic layer 67 from contacting the upper surface 70a of the substrate 70, thereby reducing potential damage to the ceramic layer 67.

The recess 80 is designed not only to prevent damage to the ceramic layer 67, but also to provide a surface along which electrical contact can be maintained with the electrode 68 on the convex face of the actuator 12. The recess 80 extends into the substrate 70 and has a variable depth, preferably at an angle to accommodate the angle at which the convex face 12a of the actuator 12 rises from the recess 80 and above the top face 70a of the substrate 70. More specifically, recess 80 preferably has a deep end 81 and a shallow end 82, the greatest depth of which is below the point where deep end 81 clamps component 75 and substrate 12, just before ceramic layer 67 is deep into recess 80 at point C. The recess 80 then becomes shallower proximate the free end 122 of the actuator 12 to a minimum depth at its shallow end 82.

Recess 80 preferably includes a layer of rubber 85 along its lower surface which helps prevent ceramic 67 from being damaged when actuator 12 is deformed and lower edge C of ceramic layer 67 is pushed into recess 80. The rubber layer 85 preferably has a generally uniform thickness along its length, the thickness of the rubber layer 85 being substantially equal to the depth of the recess 80 at the shallow end 82. The length of the rubber layer 85 is preferably slightly shorter than the length of the recess 80 to accommodate deformation of the rubber layer 85 when the actuator 12 is pushed into the recess and the rubber layer 85.

The rubber layer 85 preferably has a flexible electrode layer 90 overlying it to facilitate electrical contact with the aluminum layer 68 on the ceramic layer 67 on the convex side 12a of the actuator 12. More preferably, the electrode layer 90 comprises a copper-clad KAPTON film layer, such as manufactured by e.i. du Pont de Nemours and company, bonded to the rubber layer 85 with an adhesive, preferably a CIBA adhesive. The electrode layer 90 preferably extends over the entire rubber layer 85 from the deep end 81 to the shallow end 82 of the recess 80 and continues a short distance above the recess 80 on the top surface 70a of the substrate 70.

In the preferred embodiment of the present invention, the tip 121 of the actuator 12 is not only fixed between the clamping plate 75 and the substrate 70, but also the aluminum electrode layer 68 covering the ceramic layer 67 of the actuator 12 is always in fixed contact with the electrode layer 990 regardless of the position of the actuator 12 throughout its range of motion. To this end, the depth of recess 80 (from top surface 70a to electrode 90) is at least equal to, and preferably slightly less than, the laminated layer thicknesses (paste layer 66, ceramic layer 67 and pre-stress layer 68) extending into recess 80.

An assembly having the dimensions shown below was constructed. The actuator comprised a 1.59 by 1.79 inch spring steel substrate, 8 mils thick. A 1-1.5 mil thick layer of adhesive with 1.51 square inches of nickel dust filler was placed on one end of the substrate 0.02 inches from three sides of the substrate (leaving a 0.25 inch stub at one end 121 of the actuator 12). In the center of the adhesive layer was a 1.5 square inch 8-mil thick layer of PZT-5A. A 1-mil thick layer of adhesive (without metal filler) was placed 1.47 square inches centered on the PZT layer. Finally, a 1-mil thick aluminum layer of 1.46 square inches was centered over the adhesive layer. The tip 121 of the actuator is placed in a gripper block 76 having a length of 0.375 inch and a depth of 4 mils. The base plate 70 has a notch 80 of length 0.26 wherein the depth of the deep end 81 of the notch is 20 mils and tapers uniformly to a depth 15 mils at the shallow end 82 of the notch 80. A rubber layer 85 having a depth of 15 mils and a length of 0.24 inches is disposed in the recess 80. A 1 mil layer of copper foil electrode covering the 1 mil KAPTON tape was bonded to the rubber and extended 1.115 inches above the notch. Clamping member 75 is secured to substrate 70 with bolts 76 and the second pre-stressed layer of aluminum of actuator 12 contacts electrode 90 in recess 80, substantially tangentially (near parallel) to angle actuator 12, thereby maximizing the electrical contact surface area between the two.

In another embodiment of the invention, as shown in fig. 7, a counterweight 95 is attached to the free end of the exciter 12. Adding mass 95 to the free end 122 of the actuator 12 reduces the amount of damping of the vibration and thus increases the duration of vibration of the actuator 12 when it is deflected and released. Due to the longer duration and higher total amplitude of vibration, the exciter 12 is able to develop more electrical energy from its vibration than an exciter 12 without additional mass at its free end 122.

See fig. 6 and 7: as described above, it is desirable to generate an electrical signal by deforming the actuator 12. The deformation of the actuator 12 may be achieved by any suitable means, such as manually, or by mechanical deflection means such as a plunger, lever, or the like. In fig. 6 and 7a simple deflector 72 is mounted to the base plate 70 proximate the free end 122 of the actuator 12. This deflector assembly 72 includes a lever 86 having first and second ends 87 and 88. The lever is pivotally mounted to a pivot point 89 between ends 87 and 88. By applying a force in the direction of arrow 91 at the first end 87 of the lever 86, the lever pivots about the pivot point 89 and applies a mechanical impulse in the direction of arrow 81 to the free end 122 of the actuator 12. Additionally, the sum or 86 may be moved in the direction opposite arrow 91, and thus the actuator 12 may be deflected in the direction opposite arrow 181.

Referring now to fig. 13 and 15 a-c: fig. 13 and 15a-c show a preferred embodiment of the housing with deflector 72 and including actuator 12. The substrate 70 forms the base of a housing 200 that encloses the exciter 12. On each side of the housing 200 are walls 201, 202, 203 and 204 extending perpendicularly from the top surface 70a of the substrate 70. A deflector assembly 72 is mounted at one end of the housing 200. The plunger has an inner surface 172b and an outer surface 172a, and free end 173 and mounting end 174. More specifically, the plunger 172 is pivotally mounted at one end to the wall 201 of the housing 200. The free end 173 of the plunger 172 has a ridge 173a thereon that engages a ledge on the opposite wall 202 of the housing. The free end 173 of the plunger 172 is preferably spring loaded so that the ridge 173a is held pressed against the flange 202 a. To this end, a spring 150 is preferably held in compression between the top surface 70a of the base plate 70 and the inner surface of the ridge 173a or plunger 172 b. This provides a device in which the actuator 12 mounted on the spine 70 is contained within a housing 200 formed by the spine 70 and four walls 201, 202, 203 and 204 and a plunger 172 pivotally mounted on the wall 201 of the housing 200 opposite the base 70. Because the plunger is pivotally mounted, pressure is applied to the outer surface 172a of the plunger 172 (in the direction of arrow 190) to pivot it about the hinge 175 toward the top surface of the base plate 70. Because the plunger is pivotally mounted and spring loaded, releasing pressure from the outer surface 172a of the plunger 172 causes it to pivot about the hinge 175 away from the top surface of the base plate 70 until the ridge 173a catches on the flange 202 a.

Within the housing 200 is a quick release mechanism 180 mounted, including a spring loaded rocker 185 on the inner surface 172b of the plunger 172 that cooperates with a release needle 186 mounted on the top surface 70 of the spine 70. The quick release mechanism 180 is designed to deflect and then quickly release the free end 122 of the actuator 12 to allow it to vibrate between positions 291 and 292. The quick release mechanism 180 is also designed not to interfere with the vibration of the actuator 12 and to return to a neutral position for the next deflection of the actuator 12.

See FIGS. 14 a-c: the rocker arm 185 is pivotally attached to the inner surface 172b of the plunger 172 above the free end 122 of the actuator 12. More specifically, the rocker arm 185 is pivoted such that it has a neutral position from which it can pivot away from the exciter clamped end 121, but does not pivot from the neutral position toward the clamped end of the exciter 12. In other words, the rotation stop 183 forms part of the quick release mechanism 180 and is positioned to prevent the rocker arm from pivoting beyond this neutral position at the stop 183. The rocker arm 185 is preferably spring loaded to maintain the rocker arm 185 in its neutral position when not being deflected. For this purpose, the spring 187 is compressed between the rocker arm 185 and the spring stop 188 on the side of the rocker arm 185 opposite the stop 183.

Also inside the housing 200 is a release pin 186 located on the top surface 70a of the spine 70. The release pin 186 is located at a position that is preferably above the free end 122 of the actuator 12 in its deflected position. In other words, when the plunger 172 is depressed toward the release pin 186, which presses the actuator 12 from position 291 toward position 292, the release pin 186 will be in contact with the rocker arm 185, but not the actuator 12. As the rocker arm 185 (and actuator 12) enters pressurized, the release pin 186 pushes the rocker arm 185 open, pivoting the rocker arm 185 away from the contact end 121 of the actuator 12. The rocker arm 185 pivots until the edge 122 of the actuator 12 is no longer held in position 292 by the rocker arm 185, at which point the edge 122 of the actuator 12 is released and springs back to its undeformed state, oscillating between positions 291 and 292.

When the pressure from the plunger 172 is released, the plunger 172 returns to its undeflected position (with the ridge 173a facing the flange 202a) by the restoring force of the spring 150. Also when the pressure from the plunger 172 is released and the plunger 172 returns to its undeflected position, the rocker arm 185 also returns to its undeflected position (up the actuator 12 against the stop 183) by the restoring force of the spring 187. Finally, actuator 12 also returns to undeflected position 291 after vibration between its positions 292 and 292 ceases.

Referring now to FIGS. 14 and 16 a-d: fig. 14 and 16a-d illustrate another embodiment of the deflector assembly 72 mounted to a housing 200 containing the exciter 12. The substrate 70 forms the base of the housing 200 enclosing the exciter 12. On each side of the housing 200 are walls 201, 202, 203 and 204 extending perpendicularly from the top surface 70a of the substrate 70. Attached to the top of the wall of the housing 200 (opposite the base plate 70) is a slide mechanism 230 on which the deflector assembly 72 is mounted. The face plate 220 has an inner surface 220a and an outer surface 220b and a channel 240 extending substantially through the center of the face plate 220. The channel 240 has a first end 241 and a second end 242 and extends substantially linearly along an axis perpendicular to the walls 201 and 202 of the housing 200. In other words, the channel 240 is proximate the first wall 201 of the housing 200 through the first end 241 of the faceplate 220, and the channel 240 is proximate the second wall 202 of the housing 200 through the second end 242 of the faceplate 220. The second end of the channel 240 preferably extends further toward the housing second wall 202 than the free end 122 of the actuator 12.

Channel 240 is adapted to slidably retain a spring-loaded lever 250. The lever preferably has first and second ends 251 and 252, respectively, and a central needle 255. A channel in the face plate 220 allows the joystick to extend through the face plate 220 while also slidably retaining the center pin 255 in the channel 240. More specifically, the lever 250 extends through the panel 220 by means of a channel 240 along which it is slidable in a direction parallel to the channel axis L, i.e. from the clamping end 121 towards the free end 122 of the actuator 12 and back. The first end 251 of the lever 250 is located on the outer surface 220b of the faceplate 220 and the second end 252 of the lever 250 is located within the housing 200 above the actuator 12. The lever 250 is held in the position described by means of a needle 255 held in the channel 240. Thus, the channel 240 has a width at the outer surface 220b sufficient to allow passage of the lever upper portion 251, while the channel 240 has a width at the outer inner surface 220a sufficient to allow passage of the lever lower portion 252. The width and height within the panel 220 of the channel 240 (between the inner and outer surfaces 220a and 220 b) is sufficient to accommodate the width and height of the center pin 255, which is wider than the width of the joystick upper and lower portions 251 and 252.

The first end 251 of the lever 250 preferably extends above the outer surface 220b of the faceplate 220a distance sufficient for manual grasping. The second end 252 of the lever 250 extends into the housing 200 a distance above the actuator 12 such that the lever 250 does not contact the clamping member 75 and/or the clamped end 121 of the actuator 12, but is far enough so that it can contact and deflect the free end 122 of the actuator 12. The lever 250 is also preferably hinged at the second end 252 (within the housing 200 or channel 240, at or near the center pin 255) such that it allows the second end 252 to pivot about the hinge or center pin 255 when traveling in one direction but not the other. The second end 252 of the lever 250 is preferably hinged such that the lever 250 is pivotable when traveling toward the first wall 201 of the housing 200, but is not pivotable when traveling toward the second wall 202 of the housing 200.

The lever 250 is preferably spring loaded so that the lever is always pressed along the channel 240 towards the first wall 201 of the housing 200. To this end, a spring 260 is held between the lever and the first 201 or second wall 202 of the housing 200, or the spring 260 is preferably held between the lever 250 and the first or second end 241 or 242 of the channel 240. The latter is spring 260 held in tension between the lever 250 and the first end 241 of the channel 240 in order to press the lever against the first wall 201, or preferably the spring 260 is held in compression between the lever 250 and the second end 242 of the channel 240.

This provides an arrangement in which the exciter 12 mounted on the substrate 70 is contained within a housing 200 formed by the substrate 70, the four walls 201, 202, 203 and 204 and the panel opposite the substrate 70. Because the lever 250 is slidably mounted, pressure placed on the lever first end 251 (in the direction of arrow 381) causes it to slide along the channel 240 toward the second wall 202 of the housing 200. Because the lever 250 is slidably mounted and spring loaded, releasing pressure from the lever 250 causes it to rotate back along the channel 240 toward the first wall 201 of the housing 200 to rest against the first end 241 of the channel 240.

See FIGS. 16 a-d: the lever portion 251 is pivotally attached to the lever lower portion 252 below the inner surface 220a of the faceplate 220 (within the housing 200) above the actuator 12. More specifically, lower lever portion 252 is pivotally attached such that it has a neutral position from which it is pivoted away from clamp end 121 of actuator 12, but is not pivoted from the neutral position toward clamp end 121 of actuator 12. In other words, the shape of the lever 250 prevents the lower portion 252 from pivoting beyond the neutral position.

In operation, as the lever 250 moves toward the second end 242 of the channel 240, the lever lower portion 252 contacts the concave surface 12 of the actuator 12 and begins to deflect the free end 122 of the actuator 12 (away from position 291). As the lever 250 continues to move in the direction of arrow 281, the lever lower portion 252 forces the free end 122 of the actuator 12 toward its maximum deflection at position 292 when the free end 122 is directly below the lever lower portion 252. As the joystick continues to move from this point in the direction of arrow 281, the free end 122 of actuator 12 is suddenly released from the deflection applied by lower joystick portion 252. Upon release, edge 122 of actuator 12 springs back to its undeformed state at location 291, thereby vibrating between locations 291 and 292. When the pressure (in the direction of arrow 281) is released from the lever 250, the lever now travels in the direction of arrow 282 by virtue of the restoring force of the spring 260. As the lever 250 returns toward its undeflected position (toward the first end 241 of the channel 240), the free end 122 of the actuator 12 applies pressure to the lower portion 252 of the lever 250 at position 291. In response to pressure applied to the lower portion of the joystick opposite the direction of travel of the upper portion 251, the lower portion 252 pivots about the hinged center pin 255 of the joystick. After the joystick lower portion 252 has passed beyond the free end 122 of the actuator 12 in the direction of travel of arrow 282, the lower portion 252 returns to an undeflected (unbent) state. The pivoting of the lever lower portion 252 allows the lever 250 to return to its neutral undeflected position at the first end 241 of the channel 240.

When the tip 122 of the actuator 12 is deflected and then released (either manually or using the deflector assembly 72, as shown in fig. 6-7 or 13-16), the tip 122 of the actuator 12, much like a diving board, oscillates back and forth between positions 291 and 292. This is because the substrate and pre-stressed layers 64 and 68, to which the ceramic 67 is affixed, exert a compressive force on the ceramic 67, thereby providing a restoring force. Thus, the actuator 12 has a spring constant or spring constant that causes the actuator 12 to return to its undeformed neutral condition at position 291. As shown in fig. 10a, the vibration of the exciter 12 has a damped resonant vibration waveform. In other words, the amplitude of the vibration of the free end 122 of the actuator 12 is at its maximum immediately after (several vibrations after) the mechanical pulse is released from the free end 122 of the actuator 12. As the actuator 12 continues to vibrate, the amplitude gradually decreases (nearly exponentially) over time until the actuator 12 comes to rest in its neutral position.

The force exerted by the deflection device 72, whether manual or otherwise, causes the piezoelectric actuator 12 to deform, and by virtue of the piezoelectric effect, the deformation of the piezoelectric element 67 generates a transient voltage between the faces 12a and 12c of the actuator 12 that generates an electrical signal. Further, when the force is removed from the piezoelectric actuator 12, the actuator vibrates between positions 291 and 292 until it gradually returns to 1 original shape. As the exciter 12 vibrates, the ceramic layer 67 strains and otherwise becomes more and less compressed. The polarity of the voltage generated by the ceramic layer 67 depends on the direction of the tension, and thus the polarity of the voltage generated in compression is opposite to the polarity of the voltage generated in tension. Thus, when the actuator 12 vibrates, the voltage generated by the ceramic element 67 vibrates between positive and negative voltages for a duration of time. The duration of the vibration, and thus the duration of the generated vibrating electrical signal, is preferably in the range of 100 and 250 milliseconds, which is related to the shape, mounting and amount of force applied to the actuator 12.

The electrical signal generated by the actuator 12 is applied to downstream circuit elements through a lead 14 connected to the actuator 12. More specifically, the first wire 14 is connected to an electrode 90, which extends to the recess 80 and contacts the electrode on the convex face 12a of the actuator 12. The lead 14 is preferably connected to the electrode 90 outside the recess, near the end of the substrate 70 opposite the end having the clamping member 75. The second wire 14 is directly connected to the first pre-stressed layer 64, i.e. the substrate 64 acting as an electrode on the concave face 12c of the actuator 12.

Referring to fig. 8, an exciter 12 is connected to downstream circuit components to generate an RF signal for energizing the switch starter. These circuit components include rectifier 31, voltage regulator U2, encoder 40 (preferably comprising a Peripheral Interface Controller (PIC) chip), as well as RF generator 50 and antenna 60. Fig. 10b shows the waveform of the electrical signal of fig. 10a after it has been rectified. Fig. 10c shows the waveform of the rectified electrical signal of fig. 10b as it is conditioned to a substantially uniform voltage, preferably 3.3 VDC.

Referring now to fig. 9: the exciter 12 is first connected to the exciter 31. The exciter 31 preferably comprises four diodes D1, D2, D3 and D4 arranged to allow only forward voltage to pass. The first two diodes D1 and D2 are connected in series, i.e. the anode of D1 is connected to the cathode of D2. The last two diodes D3 and D4 are connected in series, i.e. the anode of D3 is connected to the cathode of D4. The anodes of diodes D2 and D4 are connected and the cathodes of diodes D1 and D3 are connected, forming a bridge rectifier. The rectifier is positively biased to the junction D2-D4 and negatively biased to the junction D1-D3. One of the conductors 14 of the actuator 12 is electrically connected between the diode D1 and the D3 junction, while the other conductor 14 (connected to the opposite side of the actuator 12) is connected to the diode D3 and D4 junction. The junction of diodes D1 and D3 is grounded. The capacitor C11 is preferably connected to the D2-D4 junction on one side and to the D1-D3 junction on the other side of the capacitor C11 to isolate the voltages on each side of the rectifier from each other. Thus, a negative voltage applied to the D1-D2 junction or the D3-D4 junction will be grounded through diode D1 or D3, respectively. A positive voltage applied to the D1-D2 junction or the D3-D4 junction will connect to the D2-D4 junction through diode D2 or D4, respectively. The rectified waveform is shown in fig. 10 b.

The circuit also includes a voltage regulator U2 that controls the magnitude of the electrical signal deep downstream of the rectifier 31. The rectifier 31 is electrically connected to the voltage regulator U2, the D2-D4 junction is connected to the Vin pin of the voltage regulator U2, and the D1-D3 junction is connected to the ground and ground pin of the voltage regulator U2. The voltage regulator U2 includes, for example, an LT1121 chip voltage regulator U2, outputting at 3.3 volts DC. The output voltage waveform is shown in fig. 10c and comprises a substantially uniform 3.3 volt voltage signal having a duration of approximately 100-. The adjusted waveform is shown in fig. 10 b. The voltage signal output from the voltage regulator (at the Vout pin) may then be communicated to the relay switch 290 via another conductor to change the position of the relay switch 290 from one position to another. The output voltage is preferably connected to the RF generation portion 50 of the circuit through an encoder 40.

See also fig. 8 and 9: the output of voltage regulator U2 is preferably used to power encoder 40 or a tone generator, which includes a Peripheral Interface Controller (PIC) microcontroller that generates pulsed tones. This pulse tone modulation uses an RF generator portion 50 that tunes a loop antenna 60 to radiate an RF signal. The signal radiated by the loop antenna is intercepted by the RF receiver 270 and the decoder 280, which generates a relay pulse to energize the relay 290.

The output of voltage regulator U2 is connected to a PIC microcontroller that functions as encoder 40 for the electrical output signal of regulator U2. More specifically, an output conductor (nominally 3.3 volts) that outputs a voltage signal is connected to an input pin of programmable encoder 40. Types of register-based PIC microcontrollers include eight-pin PIC12C5XX and PIC12C67x, baseline PIC16C5X, mid-band PIC16CXX and high-end PIC17CXX/PIC18 CXX. These controllers employ a modified Harvard, RISC architecture that supports instruction words of various widths. The data lanes are 8 bits wide, 12 bits wide for the PIC16C5X/PIC12C5XX instruction lanes, 14 bits wide for the PIC12C67X/PIC16CXX, and 16 bits wide for the PIC17CXX/PIC18 CXX. PICMICROROS is available using one-time programmable EPROM, flash and mask ROM. PIC17CXX/PIC18CXX supports external memory. The encoder 40 includes, for example, a PIC module 12C 671. The PIC12C6XX product features a 14-bit instruction set, small package footprint, low operating voltage of 2.5 volts, interrupt handling, internal oscillator, on-board EEPROM data storage, and a deeper stack. The PIC12C671 is a CMOS microcontroller programmable using 35 signal words and contains 1024x14 words of program memory, and 128 bytes of user RAM, with a maximum speed of 10 MHz. The PIC12C671 features an 8-stage deep hardware stack, 2 digital timers (8-bit TMRO and watchdog timer), and a four-channel, 8-bit a/D converter.

The output of the PIC may comprise a square wave, a sine wave or a sawtooth wave, or any of a variety of other programmable waveforms. In general, the output of the encoder 40 is a series of binary square waveforms (pulses) that oscillate between 0 and a positive voltage, preferably +3.3 VDC. The duration (pulse width) of each pulse is determined by the programming of the encoder 40, and the duration of the completed waveform is determined by the duration of the output voltage pulse of the voltage regulator U2. Capacitor C5 is preferably connected to the output of voltage regulator U2 at one end and to ground at the other end, and functions as a filter between voltage regulator U2 and encoder 40.

Thus, the use of the IC as a tone generator or encoder 40 allows the encoder 40 to be programmed with various values. The encoder 40 can generate one of many unique encoded signals by simply changing the programming of the encoder 40 output. More specifically, encoder 40 is capable of generating one of one billion or more possible codes. It is also possible or desirable to have more than one encoder 40 included in the circuit to generate more than one code from one exciter or transmitter. In addition, any combination of multiple actuators and multiple pulse modification subcircuits may be used together to generate each unique encoded signal. In addition, the encoder 40 may include one or more inverters formed in a series circuit of a resistor and a capacitor, the output of which is a square wave whose frequency is determined by the RC constant of the encoder 40.

The DC output of voltage regulator U2 and the encoded output of encoder 40 are connected to RF generator 50. Capacitor C6 may preferably be connected at one end to the output of encoder 40 and at the other end to ground, which functions as a filter between encoder 40 and RF generator 50. The RF generator 50 includes a tank circuit connected to the encoder 40 and the voltage regulator U2 through a Bipolar Junction Transistor (BJT) Q1 and an RF choke. More specifically, the tank circuit consists of a resonant circuit including an inductor L2 and a capacitor C8 (in parallel) connected to each other at their respective ends. Either capacitor C8 or inductor L2 and both may be adjustable to adjust the frequency of the tank circuit. Inductor L1 functions as an RF choke, with one end of inductor L1 connected to the output of voltage regulator U2 and the opposite end of inductor L1 connected to the first junction of the L2-C8 tank. The RF choke inductor L1 is preferably an inductor having a diameter of approximately 0.125 inches and on the order of thirty turns and is connected in the loop of the tank inductor L2. The second and reverse junctions of the L2-C8 tank circuit are connected to the collector of the BJT Q1. The base of BJT Q1 is also connected to the output side of encoder 40 through resistor R2. Capacitor C7 is connected to the base of BJT Q1 and the first junction of the tank circuit. Another capacitor C9 is connected in parallel with the collector and emitter of BJT Q1. This capacitor C9 improves the feedback flexibility of the tank circuit. The emitter of BJT Q1 is connected to ground through resistor R3. The emitter of BJT Q1 is also connected to ground through capacitor C10 in parallel with resistor R3. Capacitor C10 in parallel with resistor R4 provides a more stable conduction path from the emitter at high frequencies.

Referring now to fig. 11 and 12: the RF generator 50 operates in conjunction with a tuned loop antenna 60. In the preferred embodiment, inductor L2 of the tank circuit is used as the loop antenna 60. Preferably, the inductor/loop antenna L2 comprises a single rectangular copper wire loop with an additional smaller loop or jumper 61 connected to the rectangular loop L2. Adjustment of the shape and angle of the smaller loop 61 relative to the smaller loop L2 serves to increase or decrease the outer diameter of inductor L2 and thus tune the RF transmission frequency of RF generator 50. In another embodiment, a separate tuned antenna may be connected to the second junction of the tank circuit.

In operation: the positive voltage output from the first regulator U2 is connected to the encoder 40 and the RF choke inductor L1. The voltage driven encoder 40 produces an encoded square wave output that is connected through resistor R2 to the base of BJT Q1. When the encoded square wave voltage is zero, the base of BJT Q1 remains unpowered and current does not flow through inductor L1. When the encoded square wave voltage is positive, the base of BJT Q1 is powered through resistor R2. Since the base of BJT Q1 is powered, current is allowed to flow from collector to emitter through the base, and current is also allowed to flow through inductor L1. When the square wave returns to zero volts, the base of BJT Q1 is again unpowered.

When current flows through the choke inductor L1, the tank circuit capacitor C8 charges. Once the tank capacitor C8 is charged, the tank circuit begins to resonate at a frequency determined by the circuit LC constant. For example, with a 7 picofarad capacitor and a single tank circuit with a rectangular ring size of 0.7 inches by 0.3 inches, the tank circuit has a resonant frequency of 310 MHz. Choke inductor L1 prevents RF leakage to upstream components of the circuit (PIC) because changing the magnetic field of choke inductor L1 creates an electric field that opposes the flow of upstream current from the tank circuit. In order to generate an RF signal, the charge must vibrate at a frequency in the RF range. Thus, the vibration of the charge in the tank circuit inductor/tuned loop antenna L2 produces an RF signal of preferably 310 MHz. The signal generated from the loop antenna 60 comprises a pulsed RF signal having a duration of 100 and 250 milliseconds and a pulse width determined by the encoder 40 (typically on the order of 0.1 to 0.5 milliseconds) when the inverter square wave output turns bjt 1 on and off, thus generating 20 to 2500 pulses at an RF frequency of about 310 MHz. The RF generator section 50 is tunable to a plurality of frequencies. Thus, the transmitter is not only capable of having a large number of unique codes, but also of generating each of these codes at different frequencies, which greatly increases the number of possible combinations of unique frequency code signals.

The RF generator 50 and antenna 60 work in conjunction with the RF receiver 270. More specifically, an RF receiver 270 near (within 300 feet) the RF transmitter 60 is capable of receiving the pulsed RF signal transmitted by the RF generator 50. The RF receiver 270 includes a receiving antenna 270 for intercepting the pulsed RF signal (tone). The tone produces a pulsed electrical signal in the receiving antenna 270 which is input to a microprocessor chip which acts as a decoder 280. Decoder 280 filters out all signals except for RF signals programmed to be received, such as those generated by RF generator 50. An external power supply is also connected to the microprocessor chip/decoder 280. In response to the tones intercepted from the RF generator 50, the decoder chip generates a pulsed electrical signal. An external power supply connected to the decoder 280 increases the pulse output signal formed by the chip. This increased (e.g., 120VAC) voltage pulse is then applied to a conventional relay 290 for changing the position of the switches within the relay. Changing the position of the relay switch is then used to switch on or off the electrical device having the double pole switch, or to switch between several positions of the multi-position switch. A zero volt switching element may be added to ensure that the relay 290 is only activated once for each push and recovery cycle of the flextensional transducer element 12.

Switch actuator system with trainable receiver

Several different RF transmitters may be used, generating different tones for controlling the relay tuned to receive the tone. In another embodiment, the digitized RF signal may be encoded and programmable (e.g., using a garage opener) so that only the relay encoded with the digitized RF signal is energized. In other words, the RF transmitter is capable of at least one tone, but preferably is capable of producing multiple tones. Each transmitter is preferably programmed with one or more unique coded signals. This is easy to do because the programmable IC used to generate the tones may have a unique signal code that is more than 230 possible, which equates to more than a billion codes. The present invention preferably includes a multiple transmitter system and one or more receivers for energizing building lights, appliances, security systems, and the like. In such a system for remotely controlling such devices, a very large number of codes are available to the transmitters for operating the lights, appliances and/or systems, and each transmitter has at least one unique, permanent and non-user changeable code. The receiver and controller module at the light, fixture and/or system can store and memorize several different codes corresponding to different transmitters so that the controller can be programmed to be energized by more than one transmitted code, which allows two or more transmitters to energize the same light, fixture and/or system.

The remote control system includes a receiver/controller for learning a code unique to the remote control transmitter to cause performance of a function associated with the system, light or fixture with which the receiver/controller module is associated. The remote control system is advantageously used in one embodiment for internal, external lights, household appliances and security systems. Preferably, a plurality of transmitters are provided, wherein each transmitter has at least one unique permanent non-user changeable code, and wherein the receiver is capable of being placed in a program mode in which two or more codes corresponding to two or more different transmitters are received and stored.

The number of codes that can be stored in the transmitter can be very high, e.g. more than one billion codes. The receiver has a decoder module therein that is capable of learning a number of different transmitted codes, which eliminates a code switch in the receiver and also provides multiple transmitters for energizing lights or appliances. In this way, the present invention enables the elimination of the need for a code selection switch in the transmitter and receiver.

Referring to fig. 8: receiver module 101 includes an adapted antenna 270 for receiving radio frequency transmissions from one or more of transmitters 126 and 128 and providing an input to a decoder 280, which provides an output to microprocessor unit 244. The microprocessor unit 244 is connected to a relay device 290 or controller that switches the light or fixture between two or more modes of operation, i.e., on, off, dimmed or some other mode of operation. The switch 222 is mounted on a switch unit 219 connected to the receiver and also to the microprocessor 244. Switch 222 is a two-position switch that can be moved between "operating" and "programming" positions to establish operating and programming modes.

In the present invention, each transmitter, such as transmitters 126 and 128, has at least one unique code determined by the tone generator/encoder 40 contained in the transmitter. The receiver unit 101 is able to memorize and store several different transmitter codes, which eliminates the need for a coded switch in the transmitter or receiver used in the prior art. This also eliminates the need for the user to match the transmitter and receiver code switches. The receiver 101 is preferably capable of receiving a number of transmitted codes up to the amount of memory cells available in the microprocessor 144, e.g., one hundred or more codes.

When the controller 290 for the reach or appliance is initially installed, the switch 222 is moved to the program mode and the first transmitter 126 is powered up so that a code unique to the transmitter 126 is transmitted. This is received by receiver module 101 having antenna 270 and decoded by decoder 280 and provided to microprocessor unit 244. The code of the transmitter 126 is then supplied to the memory address memory 247 and stored there. Then if the switch 222 is moved to the operational mode and the transmitter 126 is powered up, the receiver 270, decoder 280 and microprocessor 244 will compare the received code with the code of the transmitter 126 stored in the first memory location in the memory address memory 247 and since the memory address stored for the transmitter 126 is consistent with the code transmitted by the transmitter 126, the microprocessor 244 will power up the controller mechanism 290 of the light or appliance to power up, power down or otherwise operate the device.

To store the code of the second transmitter 128, the switch 222 is moved to the program mode and the transmitter 128 is powered up. This causes the receiver 270 and decoder 280 to decode the transmitted signal and provide it to the microprocessor 244, which then provides the encoded signal of the transmitter 128 to the memory address memory 247, where it is stored in the second address storage location. The switch is then moved to the operating position and when either of the transmitters 126 and 128 is powered up, the receiver 270 decoder 280 and microprocessor 244 will cause the controller mechanism 290 due to the light or fixture to be powered up to cause the device to power up, power down or otherwise operate. Additionally, signals from the unit transmitter 126 and the second transmitter 128 may cause separate and distinct actions to be performed by the controller mechanism 290.

Thus, during program mode, the code of the transmitters 126 and 128 is transmitted and stored in the memory address memory 247, after which the system, lamp or period controller 290 will respond to either or both of the transmitters 126 and 128. Any desired number of transmitters may be programmed to operate the system, lights or duration up to the available memory cells in the memory address memory 247.

The present invention eliminates the need for a binary switch in the transmitter or receiver as was done in prior art systems. The present invention also allows the controller to respond to several different transmissions because several transmitter specific codes are stored and maintained in the memory address memory 247 of the receiver module 101.

In another more particular embodiment of the invention, each transmitter 126 and 128 contains two or more unique codes for the control system, light or fixture. One code corresponds to the "on" position of the controller 290 in the microprocessor and the other code corresponds to the "off" position of the controller 290 in the microprocessor 244. In addition, the code may correspond to "more" or "less", respectively, in order to raise or lower the volume of the sound device, or for example to dim or highlight an electric lamp. Finally, the unique code in the transmitter 126 or 128 may include four codes that the microprocessor interprets as "on", "off", "more" and "less" by the controller 290, depending on the desired switch setting. Alternatively, transmitters 126 and 128 may have only two codes, but microprocessor 244 interprets repeated pressing of the "on" or "off signals as brightening and dimming, respectively.

In another embodiment of the invention, the receiver 101 may be trained to receive the transmitter code in one step. The memory 247 in the microprocessor 244 of the receiver module 101 will essentially have "slots" where code can be stored. For example one slot may be available for the memory 247 to receive in order to be switched on all codes, another slot for all off codes, all other 30% are dimming codes, etc.

Each transmitter 126 has a certain set of codes. For example, a transmitter may have only one code, a "trigger" code, where the receiver module 101 only knows to reverse its current state, turn off if it is on, and turn on if it is off. In addition, the transmitter 126 may have many codes for complex control of the appliance. Each of these codes is "unique". The sender 126 sends out its set of codes so that the receiver 101 knows among other things to place each code in its slot. Moreover, using an incremental or longer electrical signal that can be generated in the transmitter 126, signaling of the code set can be accomplished even using mechanically generated voltages. As a backup, if this is not true, and if the wireless transmission uses more power than we can obtain, some sort of temporary wire connection between each transmitter and receiver target may be used (jumpers not shown). While the disclosed embodiments show manual or mechanical interaction with the transmitter and receiver to train the receiver, it is also desirable to place the receiver in a wireless transmission programming retuning mode, such as a "training" code.

In another embodiment of the present invention, the transmitter 126 may have multiple unique codes, and the transmitter randomly selects one of many possible codes, all of which are programmed into the memory allocation space 247 of the microprocessor 244.

In another embodiment of the invention, the transmitter 126 signal need not be manually operated or triggered, but can be easily operated by any means of mechanical force, i.e., window movement, doors, security, foot sensors, etc., and the burglar alarm sensor can send a signal to both the security system and the lights of the intruded room. Similarly, the transmitter 126 may be integrated with other devices. For example, the transmitter 126 may be located in a garage door opener that also turns on one or more lights in a house when the garage door is open.

Further, the transmitter may communicate with a central system or repeater that forwards signals to the light or fixture through a wire or wireless device. Thus, there can be one set of transmitters/receivers, or many transmitters interacting with many different receivers, some of which are in communication with one or more receivers and some of which are controlled by one or more transmitters, thus providing a wide range of systems of interactive systems and wireless transmitters. Also, the transmitter and receiver may have the ability to interact with wired communications such as smart home or BLUETOOTH.

Although in the preferred embodiment of the invention the excitation means has been described as mechanical to electrical, it is within the scope of the invention to include a battery in the transmitter to supply power or to compensate for the power of the transmitter. For example, a rechargeable battery may be included in the transmitter circuit and may be recharged by the electromechanical actuator. The rechargeable battery can thus provide a backup power source for the transmitter.

It can be seen that the present invention allows a receiving system to respond to one of a plurality of transmitters having different unique codes that may be stored at the receiver during a programming mode. Each time the "program mode switch" 222 is moved to the program position, a different memory may be connected so that a new transmitter code will be stored at that address. After all address storage capacity has been used, the additional code before storing the new code will delete all old code in the storage address memory.

The invention is safe in that it eliminates each switch that requires 120VAC (220 VAC in europe) wiring to run to the room. Rather, the higher voltage above the AC line is applied only to the fixture or lamp and they are energized through the self-powered switching device and relay switch. The present invention also saves the initial and retrofit construction costs associated with cutting holes and wiring to and from each switch and within the wall. The invention is particularly useful in protected historical structures, such as structures where walls should not be damaged and then rebuilt. The invention is also useful in concrete structures, such as structures constructed using concrete slabs and/or plaster, and eliminates the need to run wiring on the wall and ceiling surfaces of these structures.

While the above description contains many specifics, these should not be construed as limitations of the invention, but merely as exemplifications of one preferred embodiment thereof. Many other variations are possible, for example:

in addition to piezoelectric devices, the electro-active elements may include magnetostrictive or ferroelectric devices;

the actuator shape is not arcuate but may be generally flat and still be deformable;

a plurality of highly deformable piezoelectric actuators may be placed, stacked and/or affixed on top of each other;

a plurality of piezoelectric actuators may be placed adjacent to each other to form an array;

larger or differently shaped THUNDER elements may also be used to generate higher pulses;

the piezoelectric element may be a flextensional actuator or a direct mode piezoelectric actuator.

A bearing material may be disposed between the actuator and the recess to reduce friction and wear of one element against the next element or against the switchboard frame member.

Other means of applying pressure to the actuator may be used, including simple manual pressure application, rollers, pressure plates, toggle switches, hinges, knobs, sliders, twist and twist mechanisms, release latches, spring loaded devices, foot pedals, game consoles, flow activation and seat activation devices.

Claims (10)

1. An self-powered switching system comprising:

the bending and stretching transducer is arranged on the upper surface of the shell,

the flextensional transducer comprises: a first electro-component having opposing first and second electrode major faces;

the first electrode major face is substantially a convex face and the second electrode major face is substantially a concave face;

the flextensional transducer further comprises a pre-stressed layer bonded to the second electrode major face of the first electro component;

the pre-stress layer applies a compressive force to the electro-component;

the pre-stressed layer has first and second ends adjacent the recessed face of the first electro-active component;

wherein the flextensional transducer is adapted to deform from a first position to a second position when a force is applied to the flextensional transducer;

and wherein the flextensional transducer is adapted to generate a first voltage potential between the first electrode major face and the second electrode major face upon the deformation to the second position;

a mounting member for retaining said first end of said pre-stressed layer;

the mounting member comprises a plate adjacent to the first end of the pre-stress layer and the convex face of the flextensional transducer;

the mounting member comprises a clamping device adjacent to the first end of the pre-stressed layer and the recessed surface of the flextensional transducer;

a pressure applying means for applying a force to the second end of the pre-stressed layer, the pressure applying means adapted to apply a force sufficient to deform the flextensional transducer from the first position to the second position, thereby generating the first voltage potential;

a first conductor electrically connected to the first electrode main surface of the first electrical component;

a second conductor electrically connected to the second electrode main surface of the first electrical component;

a first signal transmitting device electrically connected to the first and second conductors;

the first signal transmitting means comprises a first radio frequency generator sub-circuit connected to an antenna;

said first signal transmitting means further comprising a programmable encoder for generating a unique code transmitted by said first signal transmitting means;

signal receiving means for receiving the first encoded signal transmitted by the first signal transmitting means;

the signal receiving means is adapted to generate a switching signal in response to the first coded signal transmitted by the first signal transmitting means; and

a switch having a first switch position and a second switch position;

the switch is in communication with the signal receiving device;

the switch is adapted to change between the first switch position and the second switch position in response to the switch signal.

2. The switching system according to claim 1, wherein,

wherein the mounting component further comprises a recess in the plate defining a depressed face that coincides with at least a portion of the raised face of the electro component adjacent to the first end of the pre-stressed layer and the first electrode major face of the electro component; and

a conductive tab within the recess in electrical contact with the first electrode major face of the electro-component and the first conductor.

3. The switching system according to claim 2, wherein,

wherein the mounting member further comprises a flexible material in the recess in the plate, the flexible material being located between the press face and the conductive tab.

4. The switching system of claim 3, further comprising:

a voltage regulator having an input side and an output side;

the input side of the voltage regulator is electrically connected to the first and second conductors;

the output side of the voltage regulator is electrically connected to the first signal transmitting device.

5. The switching system of claim 4, further comprising:

a rectifier having an input side and an output side;

the input side of the rectifier is electrically connected to the first and second conductors;

the output side of the rectifier is electrically connected with the voltage regulator.

6. The switching system of claim 5 wherein the encoder comprises:

an oscillator array having an input side and an output side;

the input side of the oscillator array is connected with the output side of the voltage regulator,

the oscillator array comprises at least one inverter forming a series circuit with a resistor and a capacitor, the output of which is a square wave having a frequency determined by the RC constant of the series circuit;

and wherein the first radio frequency generator sub-circuit comprises a transistor having an emitter connected to ground and a base connected to the output side of the oscillator array;

and wherein the first radio frequency generator sub-circuit further comprises a resonator sub-circuit having first and second junctions;

the first junction of the harmonic oscillator circuit is connected to the voltage regulator;

the second junction of the harmonic oscillator circuit is connected to a collector of the transistor.

7. The switching system of claim 6 wherein the first radio frequency generator sub-circuit further comprises:

a radio frequency choke connected in series between the output side of the voltage regulator and the first junction of the resonating subcircuit.

8. The switching system of claim 7, wherein the harmonic oscillator circuit comprises:

a first capacitor having first and second plates; and

an inductive loop of a third conductor having first and second ends;

the first plate of the first capacitor is connected to the first end of the third conductor, thereby forming the first junction of the resonator sub-circuit;

the second plate of the first capacitor is connected to the second end of the third conductor, thereby forming the second junction of the resonator sub-circuit.

9. The switching system of claim 8 wherein the oscillator array further comprises an inverter array connected between the output side of the voltage regulator and the base of the transistor.

10. The switching system of claim 9, wherein the radio frequency choke comprises an inductor.