Long range magnetic proximity sensor

• US 10,564,004 B2
• Filed: 09/26/2016
• Issued: 02/18/2020
• Est. Priority Date: 12/10/2015
• Status: Active Grant

• Current Assignee: Bourns Incorporated
• Original Assignee: Bourns Incorporated
• Inventors: Turner, Kenneth R.
• Primary Examiner(s): Rios Russo, Raul J
• Application Number:
  US15/778,099
• Publication Number:
  US 20180335317A1
• Time in Patent Office: 1,240 Days
• Field of Search: 324 51, 324 55, 324178, 324200, 32420711, 32420713, 3242072, 324251, 324341
• CPC Class Codes: G01D 11/245 Housings for sensors
• CPC Class Codes: G01D 5/12 using electric or magnetic means G01D5/06 takes precedence
• CPC Class Codes: G01D 5/142 using Hall-effect devices measuring magnetic variables using Hall-effect or other galvanomagnetic devices G01R33/06
• CPC Class Codes: G01D 5/145 influenced by the relative movement between the Hall device and magnetic fields see G01R33/06
• CPC Class Codes: G01R 33/0011 comprising means, e.g. flux concentrators, flux guides, for guiding or concentrating the magnetic flux, e.g. to the magnetic sensor
• CPC Class Codes: G01R 33/07 Hall effect devices
• CPC Class Codes: G01R 33/072 Constructional adaptation of the sensor to specific applications
• CPC Class Codes: G01R 33/077 Vertical Hall-effect devices
• CPC Class Codes: G01R 33/09 Magnetoresistive devices

Abstract

A magnetic proximity sensor includes first and second spaced wings. Each wing has a protrusion extending outwardly from an edge near or at a corner thereof. The protrusions face each other to provide a narrow gap area. A magnetic assembly secured to each of the wings extends across the gap and is spaced from the protrusions. A magnetic sensor element is disposed at the narrow gap area. The magnetic assembly projects magnetic flux toward the first wing. Magnetic flux passes via the first wing and the protrusion thereof and crosses the narrow gap area to the protrusion of the second wing. The second wing provides a return path for magnetic flux to the magnetic assembly. The magnetic proximity sensor senses decreased magnetic flux when a target approaches.

Claims

1. A magnetic proximity sensor comprising:

a first wing including a protrusion protruding outwardly from an edge thereof;

a second wing including a protrusion protruding outwardly from an edge thereof, the edge of the second wing being spaced from and facing the edge of the first wing to form a gap therebetween, and the protrusions facing each other to provide a gap area between the protrusions, and the first wing and the second wing are aligned in a common plane and the second wing is a mirror image of the first wing;

a magnetic assembly secured to the first wing adjacent the edge of the first wing and secured to the second wing adjacent the edge of the second wing, and spaced from the gap area, wherein the magnetic assembly extends across the gap and is aligned to project magnetic flux toward the first wing; and

a magnetic sensor element disposed at the gap area between the first wing and the second wing,

wherein the magnetic assembly projects the magnetic flux toward the first wing, and the magnetic flux passes via the first wing and the protrusion of the first wing across the gap area that includes the magnetic sensor element to the protrusion of the second wing and via the second wing to return to the magnetic assembly.

2. The magnetic proximity sensor according to claim 1, wherein the magnetic assembly includes a permanent magnet having a first end adjacent the first wing that projects the magnetic flux and a second end adjacent the second wing that receives the magnetic flux.

3. The magnetic proximity sensor according to claim 1, wherein the magnetic assembly includes a magnetic flux generator.

4. The magnetic proximity sensor according to claim 1, wherein the magnetic sensor element includes a Hall effect sensor.

5. The magnetic proximity sensor according to claim 1, wherein the first wing and the second wing are disposed essentially within a same plane and the first wing and the second wing each comprise a high permeability material.

6. A system including an approaching target and the magnetic proximity sensor according to claim 5, wherein the approaching target provides an alternative path for at least a portion of the magnetic flux sensed by the magnetic sensor element, and wherein reduced magnetic flux sensed by the magnetic sensor element indicates closeness of the approaching target.

7. The system according to claim 6, wherein the approaching target has a substantially rectangular flat sheet of a high permeability material that faces a planar face of the first wing and a planar face of the second wing of the magnetic proximity sensor, wherein a high permeability material attracts magnetic flux.

8. The magnetic proximity sensor according to claim 1, wherein the edge of the first wing is substantially parallel to the edge of the second wing except for the protrusions that face each other.

9. The magnetic proximity sensor according to claim 1, wherein each of the first wing and the second wing have a substantially rectangular shape and the protrusions oriented outwardly each include an outwardly oriented substantially linear edge portion, wherein each of the wings and the respective protrusions are substantially planar on opposing faces thereof.

10. The magnetic proximity sensor according to claim 9, wherein the magnetic proximity sensor has a height that is between about 25% and about 50% of the length of the magnetic proximity sensor.

11. The magnetic proximity sensor according to claim 9, wherein the protrusions of each of the wings are generally triangular shaped protrusions and are planar.

12. The magnetic proximity sensor according to claim 11, wherein the wings each include a thin high permeability metal sheet and the protrusion that is monolithic therewith.

13. The magnetic proximity sensor according to claim 1, wherein the gap area between the protrusions is disposed by a corner of the first wing and disposed by a corner of the second wing.

14. A magnetic proximity sensor comprising:

a first wing having a substantially planar face and a protrusion protruding from an edge;

a second wing having a substantially planar face and a protrusion protruding from an edge thereof, the edge of the second wing being spaced from and facing the edge of the first wing to form a gap therebetween, and the protrusions facing each other to provide a gap area between the first wing and the second wing, and the first wing and the second wing are aligned in a common plane and the second wing is a mirror image of the first wing;

a magnetic assembly secured to the first wing at the edge of the first wing and secured to the second wing at the edge of the second wing, and the magnetic assembly being spaced from the gap area, wherein the magnetic assembly extends substantially across the gap and is aligned to project magnetic flux toward the first wing; and

a magnetic sensor element disposed in the gap area between the first wing and the second wing,

wherein the magnetic assembly projects the magnetic flux toward the first wing, and at least a portion of the magnetic flux passes via the first wing and the protrusion of the first wing across the gap area to the protrusion of the second wing and via the second wing to the magnetic assembly, and

wherein the magnetic sensor element senses the magnetic flux to determine when an approaching target approaches the magnetic proximity sensor.

15. A vehicle seat control system including the magnetic proximity sensor according to claim 14, wherein the magnetic proximity sensor provides a signal to a seat controller.

16. The magnetic proximity sensor according to claim 14, wherein each of the first wing and the second wing have a substantially rectangular shape and the protrusions oriented outwardly each include an outwardly oriented substantially linear edge portion, wherein each of the wings and the respective protrusions are substantially planar on opposing faces thereof, wherein the magnetic proximity sensor has a height that is between about 25% and about 50% of the length of the magnetic proximity sensor.

17. The magnetic proximity sensor according to claim 16, wherein the protrusions of each of the wings are generally triangular shaped protrusions and are planar, wherein the wings each include a thin high permeability metal sheet and the protrusion that is monolithic therewith.

18. The magnetic proximity sensor according to claim 16, wherein the gap area between the protrusions is disposed by a corner of the first wing and disposed by a corner of the second wing.

19. The magnetic proximity sensor according to claim 14, wherein the edge of the first wing is substantially parallel to the edge of the second wing except for the protrusions that face each other.

20. The magnetic proximity sensor according to claim 19, wherein each of the first wing and the second wing have a substantially rectangular shape and the protrusions oriented outwardly each include an outwardly oriented substantially linear edge portion.