Sensor switch

Abstract

An inductive switch includes a ceramic body formed by stacking and sintering a plurality of ceramic green bodies, a first conductive unit and a second conductive unit formed by metal materials disposed on corresponding ceramic green bodies, and a conductive member. The ceramic body includes a middle layer portion, a lower layer portion, and an upper layer portion defining a cavity, the middle layer portion having an inner surface, and the lower layer portion having a top surface adjacent to the cavity. The first conductive unit includes a first conductive layer covering the inner surface of the middle layer portion. The second conductive unit includes a second conductive layer protruding from the top surface of the lower layer portion. The conductive member is conductive and can be rolled in the cavity, and is used to form a current path with the first conductive layer and the second conductive layer, and the conductive member is restricted by the second conductive layer to form a current path with the first conductive layer and the second conductive layer under normal conditions. The inductive switch can break through existing limitations and make the overall volume smaller.

Description

Technical Field

[0001] The invention relates to a switch, in particular to an inductive switch. Background Art

[0002] The existing ball-type induction switch is used to be set on a circuit board, and uses the internal ball to sense the vibration of the switch and transmit the sensing result to the circuit board, so it can be used for security alarm devices, anti-theft devices, toys that can sense motion, etc. However, the existing ball-type induction switch has many parts and its size is limited and difficult to reduce. Summary of the invention

[0003] The object of the present invention is to provide an induction switch which can reduce parts and size.

[0004] The inductive switch of the present invention comprises a ceramic body, a first conductive unit, a second conductive unit, and a conductive member.

[0005] The ceramic body is made by stacking and sintering multiple ceramic green bodies, and includes a middle layer portion defining a cavity, a lower layer portion disposed at the bottom of the middle layer portion and closing the bottom end of the cavity, and an upper layer portion disposed at the top of the middle layer portion and closing the top end of the cavity, the middle layer portion having an inner surface adjacent to the cavity, and the lower layer portion having a top surface adjacent to the cavity.

[0006] The first conductive unit is made of a metal material arranged on a corresponding ceramic green body, and includes a first conductive layer covering the inner surface of the middle layer, and at least one first internal circuit connected to the first conductive layer and extending to the outside of the ceramic body.

[0007] The second conductive unit is made of a metal material arranged on a corresponding ceramic green body, and the second conductive unit includes a second conductive layer arranged on the lower portion, and at least one second internal circuit connected to the second conductive layer and extending outward to the outside of the ceramic body, and the second conductive layer has a protruding portion protruding from the top surface of the lower portion, and the protruding portion is spaced apart from the first conductive layer.

[0008] The conductive member is located in the chamber, and can move between a first path position and an open circuit position. When the conductive member is in the first path position, the first conductive layer, the conductive member, and the second conductive layer form a current path. When the conductive member is in the open circuit position, the first conductive layer, the conductive member, and the second conductive layer do not form a current path. When the ceramic body is placed horizontally, the conductive member is restricted by the protrusion of the second conductive layer and is positioned at the first path position.

[0009] In the inductive switch of the present invention, the protruding portion of the second conductive unit is cylindrical.

[0010] In the inductive switch of the present invention, the protruding portion of the second conductive unit is in a cone shape.

[0011] In the inductive switch of the present invention, the protruding portion of the second conductive unit is arc-shaped and arches in a direction away from the lower layer portion.

[0012] In the inductive switch of the present invention, the lower layer of the ceramic body has a blind hole formed on the top surface, the second conductive layer is arranged in the blind hole, the blind hole has an open end and a closed end, the second conductive layer of the second conductive unit extends to the closed end of the blind hole, and the second internal circuit is connected to the second conductive layer at the closed end and extends outward.

[0013] In the inductive switch of the present invention, the first internal circuit of the first conductive unit extends between the middle layer portion and the lower layer portion of the ceramic body or between the middle layer portion and the upper layer portion.

[0014] In the inductive switch of the present invention, the conductive member is spherical or cylindrical, and has a radius of r. The lower layer, middle layer and upper layer of the ceramic body are stacked along an axis. The maximum rolling distance of the conductive member in the chamber perpendicular to the axis is d, and 3r <d<4r。

[0015] The inductive switch of the present invention comprises an upper portion of the ceramic body having a bottom surface, and further comprising a third conductive unit, wherein the third conductive unit is made of a metal material and is disposed on a corresponding ceramic green body, and comprises a third conductive layer disposed on the upper portion, and at least one third internal circuit connected to the third conductive layer and extending outward to the outside of the ceramic body, wherein the third conductive layer has a protruding portion protruding from the bottom surface of the upper portion, wherein the protruding portion is spaced from the first conductive layer, and the distance from the protruding portion of the second conductive layer is greater than the diameter of the conductive member, wherein the conductive member can move between a second passage position, the first passage position and the disconnection position, wherein when the conductive member is in the second passage position, the first conductive layer, the conductive member and the third conductive layer form a current passage, and when the conductive member is in the disconnection position, the first conductive layer, the conductive member, the second conductive layer and the third conductive layer do not form a current passage, and when the ceramic body is inverted and placed horizontally, the conductive member is restricted by the protruding portion of the third conductive layer and is positioned at the second passage position.

[0016] In the inductive switch of the present invention, the first conductive unit and the second conductive unit are made of metal material by applying conductive glue to a screen, a steel plate or inkjet, or by alternately using electroplating, chemical plating, sputtering, etc., and then are stacked and sintered together.

[0017] The beneficial effects of the present invention are as follows: by utilizing the ceramic body that is made by stacking and sintering the ceramic green sheets, and by utilizing the first conductive unit and the second conductive unit that are made by being provided with a metal material on the ceramic green sheets, the inductive switch can be integrated to effectively reduce the number of parts, and the overall volume can break through the minimum volume limit of existing switches made of plastic, thereby obtaining a more streamlined structure and a smaller volume, and at the same time, better sealing can be obtained, so that the first conductive unit and the second conductive unit are not easily damaged by moisture. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Other features and effects of the present invention will be clearly presented in the embodiments with reference to the accompanying drawings, in which:

[0019] Figure 1 is a three-dimensional diagram of a first embodiment of the induction switch of the present invention;

[0020] Figure 2 is a top view of the first embodiment;

[0021] Figure 3 is along Figure 2 A schematic cross-sectional view taken along line III-III in FIG. 1 illustrates a state of a conductive member in an open circuit position and a first path position;

[0022] Figure 4 is along Figure 2 A schematic cross-sectional view taken along line IV-IV in FIG.

[0023] Figure 5 is a perspective exploded schematic diagram of the first embodiment, illustrating that the first embodiment is made of a plurality of ceramic green bodies stacked;

[0024] Figure 6 is a second embodiment of the inductive switch of the present invention similar to Figure 4 A cross-sectional schematic diagram illustrating a state of a conductive member in an open circuit position and a first path position; and

[0025] Figure 7 is a third embodiment of the inductive switch of the present invention similar to Figure 4 Schematic cross-sectional view of . DETAILED DESCRIPTION

[0026] Before the present invention is described in detail, it should be noted that similar components are denoted by the same reference numerals in the following description.

[0027] In addition, in the description of the present invention, the terms “upper”, “lower”, “top” and “bottom” are used only to conveniently indicate the relative positions of components, and do not limit the directions in which each component is actually manufactured or used.

[0028] See also Figure 1 , Figure 2 and Figure 3 A first embodiment of the inductive switch of the present invention comprises a ceramic body 1, a first conductive unit 2, a second conductive unit 3, a third conductive unit 4, an external electrode unit 5, and a conductive member 6.

[0029] The ceramic body 1 is made by stacking and sintering multiple ceramic green bodies 100. The ceramic body 1 is in the shape of a rectangular parallelepiped and includes a middle layer 11 that defines a chamber 10, a lower layer 12 that is arranged at the bottom of the middle layer 11 along an axis L and closes the bottom end of the chamber 10, and an upper layer 13 that is arranged at the top of the middle layer 11 along an axis L and closes the top end of the chamber 10.

[0030] The middle layer 11 has an inner surface 111 adjacent to the chamber 10, and the lower layer 12 has a top surface 121 adjacent to the chamber 10, and a blind hole 122 formed on the top surface 121 and open to the chamber 10. The blind hole 122 has an open end 122a and a closed end 122b. The upper layer 13 has a bottom surface 131, and a blind hole 132 formed on the bottom surface 131 and open to the chamber 10. The blind hole 132 has an open end 132a and a closed end 132b. In this embodiment, the structures of the upper layer 13 and the lower layer 12 are symmetrical to each other.

[0031] See also Figure 3 , Figure 4 and Figure 5 , the first conductive unit 2 is made of a metal material and is disposed on the corresponding ceramic green body 100. The first conductive unit 2 includes a first conductive layer 21 covering the inner surface 111 of the middle layer 11, and at least one first internal circuit 22 connected to the first conductive layer 21 and extending to the outside of the ceramic body 1. In this embodiment, the first conductive unit 2 includes four first internal circuits 22, and two of the first internal circuits 22 extend between the middle layer 11 and the lower layer 12 of the ceramic body 1, and the other two extend between the middle layer 11 and the upper layer 13, and the first internal circuits 22 extend outward along the corresponding ceramic green body 100 to two opposite sides of the ceramic body 1.

[0032] The second conductive unit 3 is made of a metal material and is disposed on the corresponding ceramic green body 100. The second conductive unit 3 includes a second conductive layer 31 disposed in the blind hole 122 of the lower layer 12, and at least one second internal circuit 32 connected to the second conductive layer 31 and extending outward to the outside of the ceramic body. The second conductive layer 31 has a protruding portion 311 protruding from the top surface 121 of the lower layer 12, and an extending portion 312 extending to the closed end 122b of the blind hole 122. The protruding portion 311 is cylindrical and spaced apart from the first conductive layer 21. In this embodiment, the second conductive unit 3 includes two second internal circuits 32, which are connected to the second conductive layer 31 at the closed end 122b and extend outward along the corresponding ceramic green body 100 to the other two opposite sides of the ceramic body 1.

[0033] The third conductive unit 4 is made of a metal material and is disposed on the corresponding ceramic green body 100, and includes a third conductive layer 41 disposed on the upper portion 13, and at least one third internal circuit 42 connected to the third conductive layer 41 and extending outward to the outside of the ceramic body. The third conductive layer 41 has a protruding portion 411 protruding from the bottom surface 131 of the upper portion 13, and an extending portion 412 extending to the closed end 132b of the blind hole 132, the protruding portion 411 is spaced from the first conductive layer 21, and the distance from the protruding portion 311 of the second conductive layer 31 is greater than the diameter of the conductive member 6. In this embodiment, the structure of the third conductive unit 4 is symmetrical to that of the second conductive unit 3, and the third conductive unit 4 includes two third internal circuits 42, the third internal circuits 42 are connected to the third conductive layer 41 at the closed end 132b, and extend outward along the corresponding ceramic green body 100 to two opposite sides of the ceramic body 1, and the extension direction is the same as that of the second internal circuit 32.

[0034] The external electrode unit 5 is disposed on the outer surface of the ceramic body 1. The external electrode unit 5 includes four first external electrodes 51 respectively connected to the first internal circuit 22, and four second external electrodes 52 respectively connected to the second internal circuit 32 and the third internal circuit 42. The first external electrodes 51 and the second external electrodes 52 are respectively disposed at the corners of the ceramic body 1 and cover three adjacent planes of the ceramic body 1. In addition, two of the second external electrodes 52 are connected to form a whole along one side of the ceramic body 1 to facilitate the determination of the direction of the induction switch from the outside and to connect the first conductive unit 2 and the second conductive unit 3 in series.

[0035] The conductive member 6 has conductivity and is located in the chamber 10 in a rollable manner. The conductive member 6 can be in a first passage position (see Figure 3 the position of the solid line in), a second passage position (not shown in the figure, symmetrical to the first passage position), and an open circuit position (see Figure 3 the position of the dash-dot line in) and move therebetween. When the conductive member 6 is in the first passage position, the first conductive layer 21, the conductive member 6, and the second conductive layer 31 form a current path. When the conductive member 6 is in the second passage position, the first conductive layer 21, the conductive member 6, and the third conductive layer 41 form a current path. When the conductive member 6 is in the open circuit position, the first conductive layer 21, the second conductive layer 31, the third conductive layer 41, and the conductive member 6 do not form a current path. In addition, when the ceramic body 1 is placed horizontally, the conductive member 6 is positioned at the first passage position due to the limitation of the protruding portion 311 of the second conductive layer 31. When the ceramic body 1 is inverted and placed horizontally, the conductive member 6 is positioned at the second passage position due to the limitation of the protruding portion 411 of the third conductive layer 41.

[0036] In this embodiment, the conductive member 6 is spherical with a radius of r, and the chamber 10 is cylindrical around the axis L. The maximum rolling distance of the conductive member 6 perpendicular to the axis L in the chamber 10 is d, and 3r < d < 4r. In other embodiments, the conductive member 6 can also be cylindrical, and the chamber 10 can be rectangular to match, but it is not limited thereto.

[0037] Refer to Figure 1 and Figure 3 , when in use, the inductive switch is used by welding the first external electrode 51 and the second external electrode 52 of the external electrode unit 5 to a circuit board (not shown). Wherein, by the setting positions of the first external electrode 51 and the second external electrode 52, the inductive switch can be welded to the circuit board in different directions according to the needs of users or manufacturers.

[0038] During the use process, when the ceramic body 1 is placed horizontally, the conductive member 6 is restricted by the protruding portion 311 of the second conductive layer 31 and simultaneously contacts the first conductive layer 21 and the second conductive layer 31. At this time, the conductive member 6 is in the first passage position (see Figure 3 the position of the solid line in), and a current path is formed; when the ceramic body 1 is tilted or vibrated, and the conductive member 6 is disengaged from the limit of the second conductive layer 31 and does not contact at least two of the first conductive layer 21, the second conductive layer 31, and the third conductive layer 41 (see Figure 3The position of the dotted line at a point in the figure), there is no current path formed between the first conductive layer 21, the second conductive layer 31, the third conductive layer 41 and the conductive member 6, thereby achieving an induction effect. And in this embodiment, due to the upper and lower symmetry of the structure, the same induction effect can also be achieved when the ceramic body 1 is used upside down.

[0039] Refer to Figure 3 , Figure 4 and 5 , it is further explained that in this embodiment, the relationship between the radius r of the conductive member 6 and the maximum rolling distance d perpendicular to the axis L is 3r < d < 4r, which can effectively reduce the overall volume and maintain moderate induction sensitivity at the same time.

[0040] In addition, in other embodiments, the induction switch may also include more than two conductive members 6. For example, two conductive members 6 are jointly accommodated in the chamber 10, and when the ceramic body 1 is placed horizontally, the conductive members 6 are simultaneously positioned by the shape of the second conductive layer 31 and located at the first passage position.

[0041] It should be noted that this embodiment is made by the multi-layer ceramics (MLC) technology, and the manufacturing process is described as follows:

[0042] Step 1: Prepare a plurality of ceramic green bodies 100 made of inorganic ceramic materials, and form holes in the ceramic green bodies 100 by mechanical processing.

[0043] Step 2: Process a metal material, such as silver, gold, palladium, copper, nickel, etc. or their alloys, by means of screen printing, steel plate printing or inkjet printing with conductive glue, or alternately use electroplating, electroless plating, sputtering, etc. to be disposed on the surface of the corresponding ceramic green body 100 to form the first conductive unit 2, the second conductive unit 3 and the third conductive unit 4.

[0044] Step 3: The punched and circuit-set ceramic green bodies 100 are stacked and aligned along the axis L, and then the stacked ceramic green bodies 100 are compacted by hot water equalization to form the lower layer 12, the middle layer 11, and the upper layer 13, wherein the ceramic green bodies 100 constitute the lower layer 12, the middle layer 11, and the upper layer 13, and the metal material disposed on the ceramic green bodies 100 constitutes the first conductive unit 2, the second conductive unit 3, and the third conductive unit 4. In this embodiment, the lower layer 12 is formed by stacking two layers of ceramic green bodies 100, the middle layer 11 is formed by stacking eight layers of ceramic green bodies 100, and the upper layer 13 is formed by stacking two layers of ceramic green bodies 100, but the present invention is not limited thereto. In addition, in this embodiment, the lower layer 12 and the middle layer 11 are stacked and hot-pressed together, while the upper layer 13 is stacked and hot-pressed separately.

[0045] Step 4: stacking a metal layer on the top surface 121 of the lower portion 12 to make the second conductive layer 31 protrude from the top surface 121 of the lower portion 12 , and stacking a metal layer on the bottom surface 131 of the upper portion 13 to make the third conductive layer 41 protrude from the bottom surface 131 of the upper portion 13 .

[0046] Step 5: Cutting the tightly compacted ceramic green body 100 into predetermined sizes.

[0047] Step 6: slowly raise the ambient temperature to between 400 and 600 degrees Celsius, heat the cut ceramic green body 100, burn and crack the polymer additives added during the slurrying of the ceramic green body 100, and then raise the ambient temperature to between 800 and 900 degrees Celsius to densify the ceramic green body 100 and remove the pores. It should be noted that the ceramic green bodies 100 will be sintered into one after heating. Figure 3 and Figure 4 The layered state shown in the figure is only used to illustrate that the ceramic body 1 is composed of multiple layers of ceramic green bodies 100, and is not the actual structural state after sintering.

[0048] Step seven: Process the second conductive layer 31 and the third conductive layer 41 to form the shapes of the protrusions 311 and 411 .

[0049] Step eight: Plate, spray or apply protective metal, such as gold, alloy, etc., on the surfaces of the first conductive unit 2 , the second conductive unit 3 and the third conductive unit 4 as required.

[0050] Step 9: Place the conductive member 6 into the chamber 10 of the middle layer portion 11. Then, apply an adhesive material such as resin or glass to the corresponding portions of the upper layer portion 13 and the middle layer portion 11. Next, heat the ambient temperature to between 300°C and 500°C by means of UV light irradiation or baking to heat the adhesive material, and press and bond the upper layer portion 13 and the middle layer portion 11 together to form the complete ceramic body 1.

[0051] Step 10: Coat, spray, or apply metal, such as silver, gold, palladium, copper, or nickel, or their alloys, onto the outer surface of the bonded ceramic body 1 to form the first external electrode 51 and the second external electrode 52 of the aforementioned external electrode unit 5.

[0052] It should be further noted that after Step 2, the ceramic green body 100 provided with metal can also be first bonded to form one or more blocks, and then sintered into one or more ceramic blocks in the subsequent steps, and then the above ceramic blocks are bonded with glass, metal, or resin and heat-treated to form the integrated ceramic body 1, not limited to the method of the aforementioned steps.

[0053] In addition, the manufacturing process of the induction switch of the present invention can be adjusted by those with ordinary knowledge in the art according to requirements in the order of some of the steps, or some manufacturing methods can be replaced in other ways, not limited to the description in this specification.

[0054] The advantages of this embodiment are summarized as follows through the above description:

[0055] 1. Since the ceramic body 1 is made by stacking and sintering the ceramic green body 100, and the first conductive unit 2, the second conductive unit 3, and the third conductive unit 4 are made of metal materials provided on the ceramic green body 100, the overall volume of the induction switch can break through the minimum volume limit of the existing switches made of plastic, obtaining a more streamlined structure and a smaller volume. In addition, better sealing performance can also be obtained, and the first conductive unit 2, the second conductive unit 3, and the third conductive unit 4 are not easily damaged by moisture.

[0056] 2. By using the relationship between the radius r of the conductive member 6 and the maximum rolling distance d perpendicular to the axis L as 3r < d < 4r, the overall volume can be effectively reduced while maintaining appropriate induction sensitivity.

[0057] Refer to Figure 6 A second embodiment of the induction switch of the present invention is similar to the first embodiment, and the difference lies in:

[0058] The protruding portion 311 of the second conductive unit 3 is arc-shaped and arches in a direction away from the lower layer portion 12 . The protruding portion 411 of the third conductive unit 4 is arc-shaped and arches in a direction away from the upper layer portion 13 .

[0059] See also Figure 7 A third embodiment of the inductive switch of the present invention is similar to the first embodiment, except that:

[0060] The protrusions 311 and 411 of the second conductive unit 3 and the third conductive unit 4 are conical.

[0061] In summary, the inductive switch of the present invention utilizes the ceramic body 1 that is made by stacking and sintering the ceramic green sheets 100, and the first conductive unit 2, the second conductive unit 3 and the third conductive unit 4 that are made by being arranged on the ceramic green sheets 100 using metal materials, so that the inductive switch can be integrated and parts can be effectively reduced, and the overall volume can break through the minimum volume limit of the existing switch made of plastic, thereby obtaining a more streamlined structure and a smaller volume, and at the same time, better sealing can be obtained, so that the first conductive unit 2, the second conductive unit 3 and the third conductive unit 4 are not easily damaged by moisture, so the purpose of the present invention can be achieved.

[0062] The above are merely embodiments of the present invention and should not be used to limit the scope of the present invention. That is, any simple equivalent changes and modifications made according to the claims and description of the present invention still fall within the scope of the present invention.

Claims

1. An induction switch, Features: Include: A ceramic body, which is made by stacking and sintering a plurality of ceramic green bodies, the ceramic body comprising a middle layer portion defining a cavity, a lower layer portion disposed at the bottom of the middle layer portion and closing the bottom end of the cavity, and an upper layer portion disposed at the top of the middle layer portion and closing the top end of the cavity, the middle layer portion having an inner surface adjacent to the cavity, and the lower layer portion having a top surface adjacent to the cavity; A first conductive unit is made of a metal material disposed on a corresponding ceramic green body, wherein the first conductive unit includes a first conductive layer covering an inner surface of the middle layer, and at least one first internal circuit connected to the first conductive layer and extending to the outside of the ceramic body; A second conductive unit is made of a metal material disposed on a corresponding ceramic green body, the second conductive unit includes a second conductive layer disposed on the lower layer, and at least one second internal circuit connected to the second conductive layer and extending outward to the outside of the ceramic body, the second conductive layer has a protruding portion protruding from the top surface of the lower layer, and the protruding portion is spaced apart from the first conductive layer; and a conductive member, located in the chamber, the conductive member being movable between a first passage position and a disconnection position, wherein when the conductive member is in the first passage position, the first conductive layer, the conductive member and the second conductive layer form a current passage, and when the conductive member is in the disconnection position, the first conductive layer, the conductive member and the second conductive layer do not form a current passage, and when the ceramic body is placed horizontally, the conductive member is restricted by the protrusion of the second conductive layer and is positioned at the first passage position; The lower layer of the ceramic body has a blind hole formed on the top surface, the second conductive layer is disposed in the blind hole, the blind hole has an open end and a closed end, the second conductive layer of the second conductive unit extends to the closed end of the blind hole, and the second internal circuit is connected to the second conductive layer at the closed end and extends outward. The upper portion of the ceramic body has a bottom surface. The inductive switch further includes a third conductive unit. The third conductive unit is made of a metal material and is arranged on a corresponding ceramic green body. The third conductive unit includes a third conductive layer arranged on the upper portion, and at least one third internal circuit connected to the third conductive layer and extending outward to the outside of the ceramic body. The third conductive layer has a protruding portion protruding from the bottom surface of the upper portion. The protruding portion is spaced from the first conductive layer, and the distance from the protruding portion of the second conductive layer is greater than the diameter of the conductive member. The conductive member can move between a second passage position, the first passage position and the disconnection position. When the conductive member is in the second passage position, the first conductive layer, the conductive member and the third conductive layer form a current passage. When the conductive member is in the disconnection position, the first conductive layer, the conductive member, the second conductive layer and the third conductive layer do not form a current passage. When the ceramic body is inverted and placed horizontally, the conductive member is restricted by the protruding portion of the third conductive layer and is positioned at the second passage position.

2. The induction switch according to claim 1, Features: The protruding portion of the second conductive unit is cylindrical.

3. The induction switch according to claim 1, Features: The protruding portion of the second conductive unit is in a cone shape.

4. The induction switch according to claim 1, Features: The protruding portion of the second conductive unit is arc-shaped and arches in a direction away from the lower layer portion.

5. The induction switch according to claim 1, Features: The first internal circuit of the first conductive unit extends between the middle layer portion and the lower layer portion of the ceramic body or between the middle layer portion and the upper layer portion.

6. The induction switch according to claim 1, Features: The conductive member is spherical or cylindrical, and has a radius of r. The lower layer, middle layer and upper layer of the ceramic body are stacked along an axis. The maximum rolling distance of the conductive member in the chamber perpendicular to the axis is d, and 3r <d<4r。 7. The induction switch according to claim 1, Features: The first conductive unit and the second conductive unit are made of metal material by applying conductive glue to a screen, a steel plate or inkjet processing, or by alternately using electroplating, chemical plating, and sputtering to set on corresponding ceramic green bodies, and then stacked and sintered together.

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