Acceleration switch

• US 5,828,138 A
• Filed: 12/02/1996
• Issued: 10/27/1998
• Est. Priority Date: 12/02/1996
• Status: Expired due to Fees

• Current Assignee: TRW Limited (Zeppelin - Stiftung der Stadt Friedrichshafen)
• Original Assignee: TRW Limited (Zeppelin - Stiftung der Stadt Friedrichshafen)
• Inventors: Lammert, Michael Dean, McIver, George William
• Primary Examiner(s): Gaffin, Jeffrey A.
• Assistant Examiner(s): Ganjian, Peter
• Application Number:
  US08/756,948
• Time in Patent Office: 694 Days
• Field of Search: 200/61.45 R, 200/61.49 R, 200/61.51, 200/61.45 M, 307/9.1, 307/10.1, 307/116, 307/119, 307/120, 307/121, 307/122, 307/123, 307/124, 180/268, 180/271, 180/281, 180/282, 180/286, 280/735, 280/806, 701/1, 701/29, 701/31, 701/34, 701/36, 701/45, 73/1.37, 73/1.38, 73/1.39, 73/488, 73/514.01, 73/514.36, 73/514.16
• US Class Current: 307/10.1
• CPC Class Codes: G01P 15/135 by making use of contacts which are actuated by a movable inertial mass
• CPC Class Codes: G01P 21/00 Testing or calibrating of apparatus or devices covered by the preceding groups
• CPC Class Codes: H01H 1/0036 Switches making use of microelectromechanical systems [MEMS] for electromagnetic relays H01H50/005; for electrostatic relays H01H59/0009
• CPC Class Codes: H01H 2001/0063 having electrostatic latches, i.e. the activated position is kept by electrostatic forces other than the activation force
• CPC Class Codes: H01H 35/142 Damping means to avoid unwanted response

Abstract

An acceleration sensitive switch (10) equipped with an inertial mass member ("IMM") (12) that is deflectable from a holding position to an actuated position in response to a predetermined acceleration force. A voltage controlled hold plate (18) generates an electrostatic force that opposes the acceleration forces and holds the IMM (12) in a holding position until overcome by the predetermined acceleration force. The predetermined acceleration force necessary to trigger the switch may conveniently be adjusted by adjusting the voltage applied to the hold plate (18). The switch includes a self-test plate (34) that tests proper functioning of the switch. Other features include the interchangeability of the self-test plate and the hold plate. The switch is particularly useful as a safing switch in a system for controlling an air bag or other vehicle occupant restraint system.

Claims

1. A switch adjustably responsive to an acceleration force, said switch comprising:

an inertial mass member ("IMM") relatively movable from a hold position to an actuated position, said member relatively moving when said switch is accelerated and being deflectable out of its hold position in response to said switch acceleration of sufficient magnitude,

electrical contacts, at least one of which is coupled to said IMM, for moving between closed and open positions when said IMM moves between said hold position and said actuated position,

hold means comprising at least one hold electrode to which a hold voltage may be applied for adjustably establishing an electrostatic field creating a restraining force urging the IMM into its hold position, said field and said restraining force having a magnitude functionally related to said hold voltage, and

means for applying a hold voltage to said hold electrode, and

wherein said IMM remains in said hold position when said switch is subjected to acceleration forces that are insufficient to overcome forces tending to restrain said IMM to said hold position, including the restraining force established by said electrostatic field, and deflects to said actuated position when said switch is subjected to acceleration forces that are sufficient to overcome said forces tending to restrain said IMM,

whereby the acceleration required to move relatively said IMM from said hold position to said actuated position may be adjusted by selecting the hold voltage applied to said hold means.

2. A switch as set forth in claim 1 further comprising means for adjusting said restraining force of said hold means by varying said hold voltage.

3. A switch as set forth in claim 1 further comprising a substrate adapted to be mounted on a member whose acceleration is to be sensed, wherein said IMM comprises a deflectable spring-like arm having a predetermined mass, and means for suspending said arm in cantilevered fashion above said substrate such that said arm extends generally parallel to said substrate.

4. A switch as set forth in claim 3 wherein said means for suspending comprises a base mounted on said substrate, said deflectable arm being rigidly joined to said base at the proximal end of said arm such that deflection of said IMM results in bending of said arm.

5. A switch as set forth in claim 3 wherein said means for suspending comprises a base mounted on said substrate, and means for flexibly joining said deflectable arm to said base at the proximal end of said arm such that deflection of said IMM results in flexing of said flexible joining means.

6. A switch as set forth in claim 5 wherein said flexible joining means comprises first and second torsion bars extending from said base at opposite sides thereof and in directions generally transverse to said deflectable arm, and means for joining said deflectable arm to the ends of said torsion bars, whereby deflection of said IMM results in torsional flexing of said torsion bars.

7. A switch as set forth in claim 6, said IMM further comprising an elongated continuation arm and means for joining said continuation arm to said deflectable arm and to said ends of said torsion bars such that said continuation arm extends from said base on the opposite side from said deflectable arm and deflects in unison with said deflectable arms.

8. A switch as set forth in claim 7 wherein said one of said electrical contacts is fixed to said continuation arm.

9. A switch as set forth in claim 3 wherein said hold electrode is disposed on said substrate, and is below said arm.

10. A switch as set forth in claim 9 wherein said arm has disposed thereon a second electrode generally in registration above said hold electrode, whereby said arm electrode and said hold electrode are generally parallel to one another and are closely spaced from one another.

11. A switch as set forth in claim 10 wherein said arm is formed of an electrically conductive material and said arm electrode is an integral part thereof.

12. A switch as set forth in claim 3 wherein said hold electrode is supported by said substrate and is disposed above said IMM.

13. A switch as set forth in claim 3 wherein said electrical contacts are positioned above said IMM relative to said substrate and are adapted to be normally open and to close when said IMM is deflected away from said substrate.

14. A switch as set forth in claim 3 wherein the electrical contacts are positioned below the IMM relative to the substrate and are adapted to be normally open and to close when said IMM is deflected toward said substrate.

15. A switch as set forth in claim 3 wherein said electrical contacts comprise first and second pairs of electrical contacts, with one contact of each said pair being coupled to said IMM for movement therewith and the other contact of said pair being coupled to said substrate.

16. A switch as set forth in claim 15 wherein one of said pairs of electrical contacts is positioned above said IMM relative to said substrate and is adapted to close when said IMM moves away from said substrate, and the other of said pairs of electrical contacts is positioned below said IMM relative to said substrate and is adapted to close when said IMM is moved toward said substrate.

17. A switch as set forth in claim 3 further comprising means for damping relative movement of said IMM.

18. A switch as set forth in claim 3 wherein said IMM moves through a fluid and has openings formed therein for controlling the flow of the fluid past said IMM as said IMM relatively moves in said fluid, whereby said openings control damping of relative movement of said IMM.

19. A switch as set forth in claim 3 wherein said IMM is electrically conductive and has at least one portion depending toward said hold electrode, whereby said electrostatic field interacts with said at least one depending portion of said IMM.

20. A switch as set forth in claim 19 wherein each of said at least one depending portions includes a generally planar surface that is closely adjacent to, and generally parallel to, said hold electrode.

21. A switch as set forth in claim 1 further comprising a substrate adapted to be mounted on a member whose acceleration is to be sensed, and hinge means for pivotally mounting said IMM to said substrate.

22. A switch as set forth in claim 1 wherein said hold electrode and said electrical contacts are disposed on opposite sides of said IMM.

23. A switch as set forth in claim 1 wherein said hold electrode and said the electrical contacts are disposed on the same side of said IMM.

24. A switch as set forth in claim 1 further including self test means for testing the operational integrity of said electrical contacts.

25. A switch as set forth in claim 24 wherein said self test means comprises a test electrode to which a voltage may be applied for urging said IMM towards its actuated position.

26. A switch as set forth in claim 25 wherein said test electrode and said hold electrode are disposed on opposite sides of said IMM.

27. A switch as set forth in claim 1 wherein said hold electrode comprises a generally planar, electrically conductive sheet covered with an electrically insulating layer.

28. A switch as set forth in claim 27 wherein said insulating layer is formed of silicon nitride.

29. A switch as set forth in claim 1 wherein said IMM comprises plated metal.

30. A switch as set forth in claim 29 wherein said plated metal is plated nickel.

31. A switch as set forth in claim 1 wherein said IMM is mounted on a substrate formed of glass or alumina.

32. A switch as set forth in claim 1 wherein said IMM is mounted on a substrate comprised of a semiconductor material.

33. A switch as set forth in claim 32 wherein said semiconductor is silicon or gallium arsenide.

34. A switch as set forth in claim 32 wherein said hold electrode is formed of doped polysilicon.

35. A switch as set forth in claim 34 wherein said hold electrode is formed by p+ diffusion into an n- silicon layer.

36. A switch as set forth in claim 34 wherein said hold electrode is formed by n+ diffusion into a p- silicon layer.

37. A switch as set forth in claim 1 wherein said hold means is disposed closely adjacent said IMM and wherein said switch further includes stop means for limiting the relative movement of said IMM into said hold position so as to thereby prevent said IMM from contacting said hold means.

38. A switch as set forth in claim 1 wherein said at least one hold electrode comprises at least two hold electrodes.

39. A switch as set forth in claim 38 further comprising means for adjusting said restraining force by controlling the application of said hold voltage to selected ones of said at least two hold electrodes.

40. A system for recognizing the onset of a crash of a vehicle and providing a control signal indicative thereof, comprising:

an accelerometer responsive to crash acceleration of said vehicle for providing a crash acceleration signal which varies as a continuous function of said crash acceleration;

microprocessor means responsive to the crash acceleration signal for determining from said signal whether said vehicle is experiencing a crash condition;

a safing switch responsive to crash acceleration of said vehicle, said safing switch comprising

an inertial mass member ("IMM") supported by a tensile force and relatively movable from a hold position to an actuated position in response to acceleration of said vehicle,

electrical contact means associated with said IMM for generating an electrical signal when said IMM is in its actuated position,

hold means responsive to a voltage for applying an electrostatic force to said IMM to bias said IMM into said hold position, and

means for applying a voltage to said hold means to thereby establish the magnitude of the bias on said IMM and thus the predetermined vehicle crash acceleration necessary to force said IMM from its hold position to its actuated position; and

means responsive to said microprocessor means and to said electrical signal provided by said electrical contact means for providing said control signal in accordance therewith.

41. The system as set forth in claim 40 further comprising an occupant restraint device for restraining the movement of a vehicle occupant upon a crash of said vehicle, said occupant restraint device being responsive to said control signal for controlling the operation of said device.

42. The system as set forth in claim 41, wherein occupant restraint device is an air bag.

43. The system as set forth in claim 41 wherein said voltage is selected such that said IMM moves to said actuated position upon said safing switch experiencing acceleration of a magnitude indicating that said vehicle is experiencing a crash.

44. The system as set forth in claim 40 wherein said force applied by said hold means is an electrostatic attractive force having a magnitude functionally related to said applied voltage.

45. The system set forth in claim 40 wherein said safing switch further comprises self test means for determining the operational integrity of said electrical contacts.

46. The system set forth in claim 40 wherein hold means comprises a conductive substrate capable of generating an electrostatic attractive force, and an insulating layer covering and protecting said conductive substrate, said conductive substrate being positioned closely adjacent said IMM such that said electrostatic attractive force affects said IMM.

47. The system as set forth in claim 40 wherein said electrical contact means comprises a pair of electrical contacts, said contacts being "closed" when said IMM is in one of said hold and actuated positions, and "open" when said IMM is in the other of said hold and actuated positions.

48. The system as set forth in claim 40 wherein said IMM is plated metal.

49. The system as set forth in claim 40 wherein said IMM is mounted on a substrate comprised of a semiconductor material.

50. The system as set forth in claim 49 wherein said semiconductor is silicon or gallium arsenide.

51. A method of deploying occupant crash restraint apparatus in a vehicle as a function of the crash acceleration experienced by said vehicle comprising the steps of:

providing a control circuit for assessing changes in the acceleration experienced by said vehicle, said control circuit including a safing switch having an inertial mass member ("IMM") that relatively moves in response to a predetermined crash acceleration level to generate an electrical signal indicating a crash event;

applying an electrostatic force to said IMM to urge said IMM in the direction opposite the direction of acceleration movement of said safing switch, said applied electrostatic force being selected according to the predetermined level of acceleration to which said switch is to be responsive;

generating an electrical signal when said IMM moves in response to acceleration of said switch greater than said predetermined crash acceleration level; and

actuating said occupant crash restraint apparatus when said electrical signal is being generated by said IMM.

52. In a crash detection apparatus capable of deploying an occupant air bag restraint, a safing switch responsive to a predetermined acceleration force and generating an electrical signal when said safing switch is actuated, said safing switch comprising:

an inertial mass member ("IMM") relatively movable from a hold position to an actuated position in response to each acceleration of said switch;

electrical contact means associated with the inertial mass member for generating an electrical signal when said IMM is in its actuated position; and

hold means for generating an electrostatic attractive force urging the IMM into its hold position and restraining the IMM from relatively moving in response to a crash acceleration less than a predetermined crash acceleration value;

whereby said IMM is relatively moved to its actuated position in response to a crash acceleration which overcomes the restraining action of the electrostatic force, and, when said IMM is in its actuated position, the electrical contacts means generates the electrical signal so as to enable the deployment of said air bag.

53. The apparatus set forth in claim 52 further including self test means for testing the electrical continuity of the safing switch.

54. The apparatus as set forth in claim 53 wherein said self-test means and said hold means are interchangeable.

55. The apparatus as set forth in claim 53 wherein each of said self-test means and said hold means is an electrically conductive plate, and wherein said self-test plate and hold plate are disposed on opposite sides of said IMM but are generally equidistant from said IMM.

56. The apparatus as set forth in claim 55 wherein said self-test plate is adapted to latch said electrical contact means once said predetermined acceleration force is sensed thereby preventing interruption of the deployment of said air bag.

57. The apparatus as set forth in claim 52 wherein said hold force applied by said hold means is adjusted by said applied voltage.

58. The apparatus as set forth in claim 52 wherein said electrical contacts comprise dual pairs of aligned electrical contacts, and wherein one pair is disposed on one side of said IMM and the second pair is disposed on the opposite side of said IMM.

59. The apparatus as set forth in claim 58 wherein one of said pairs of electrical contacts confirms that said IMM is in its hold position and the other pair generates said electrical signal when said safing switch senses a predetermined acceleration force.

60. The apparatus as set forth in claim 58 wherein one of the pairs of electrical contacts is normally open.

61. The apparatus as set forth in claim 58 wherein one of the pairs of electrical contacts is normally closed.

62. An acceleration responsive switch comprising:

a base member;

a switch arm;

mounting means for mounting said switch arm to said base member so that acceleration of said base member results in relative movement between said switch arm and said base member;

a pair of electrical contacts, one of said electrical contacts mounted to said switch arm and a second of said electrical contacts mounted to said base member so that said acceleration of said base member changes the switching state of said pair of electrical contacts; and

electrostatic bias means operatively coupled to between said base member and said switch arm for providing a bias force to resists relative movement between said switch arm and said base member.

63. The apparatus of claim 62 wherein said electrostatic bias means prevents said pair of electrical contacts from changing switching state until said base member is subjected to an acceleration greater than a predetermined amount.

64. The apparatus of claim 63 wherein said base member, said switch arm, said mounting means, and said electrostatic bias means are arranged so that said electrical contacts are normally open and said electrical contacts close when said base member is subjected to an acceleration greater than said predetermined amount.

65. A system for recognizing the onset of a crash of a vehicle and providing a control signal indicative thereof, comprising:

an accelerometer responsive to crash acceleration of said vehicle for providing a crash acceleration signal which varies as a continuous function of said crash acceleration;

microprocessor means responsive to the crash acceleration signal for determining from said signal whether said vehicle is experiencing a crash condition;

a safing switch responsive to crash acceleration of said vehicle, said safing switch comprising

a base member;

a switch arm;

mounting means for mounting said switch arm to said base member so that acceleration of said base member results in relative movement between said switch arm and said base member;

a pair of electrical contacts, one of said electrical contacts mounted to said switch arm and a second of said electrical contacts mounted to said base member so that said acceleration of said base member changes the switching state of said pair of electrical contacts; and

electrostatic bias means operatively coupled to between said based member and said switch arm for providing a bias force to resists relative movement between said switch arm and said base member; and

means responsive to said microprocessor means and to said change of the switching state of said pair of electrical contacts for providing said control signal in response thereto.