Optical chamber mount for particle detection with integrated reflective surface

Abstract

Described herein are devices, systems, and methods that provide an optical chamber mount for smoke detection with an integrated reflective surface for optical particle detection. A one-piece reflective component insert includes a one-piece reflective component insert body having a non-reflective portion and a reflective portion, and wherein the reflective portion forms two transmitter and receiver mirrors, wherein the emitter mirror is shaped to direct light emitted from an emitter positioned below the emitter mirror toward a scattering region of the optical chamber.

Description

Technical Field

[0001] The present disclosure relates to apparatus, systems, and methods for providing an optical chamber mount for particle detection utilizing an integrated reflective surface. Background Art

[0002] Facilities (e.g., buildings) such as commercial facilities, office buildings, hospitals, etc. may have a fire detection system that can be triggered during an emergency (e.g., a fire) to warn occupants to evacuate. For example, the fire detection system may include a fire alarm control panel within the building and a plurality of smoke detectors located throughout the facility (e.g., on different floors of the facility and / or in different rooms of the facility) that can sense smoke conditions indicative of a fire in the facility and provide notification of the smoke condition to occupants of the facility and / or building monitoring personnel via an alarm or other mechanism.

[0003] Such detectors may use a pre-configured optical block which, in the case of detecting a single forward scattered signal, consists only of:

[0004] Transmitter;

[0005] a receiver; and

[0006] One or more plastic parts used to hold and align optical components.

[0007] Various types of such optical configurations are currently utilized.

[0008] These optical blocks are integrated into a system that also includes a printed circuit board (PCB) for electrical connections of the optical transmitters and receivers and other mechanical parts (e.g., plastic covers) that direct smoke particles toward the detection zone and complete the configuration of the sensing chamber for sensing fire conditions.

[0009] In one previous implementation, the transmitter and receiver are carried by a plastic optical block that provides a fixed orientation and barrier between them. The optical block with the transmitter and receiver and the metal shield constitutes a surface mounted device (SMD) that can be placed on a printed circuit board using an automated assembly process through multiple pick and place areas.

[0010] Optical block SMD configurations have advantages over manually soldered optical transmitters and receivers. However, optical blocks are custom SMD components with low scalability (e.g., it is very difficult to integrate additional detection-based components, such as for backscattering, by adding other SMD components), and their pick-and-place process is complex and prone to rejects.

[0011] In another prior art configuration, two prisms (one for light emission and one for light reception) are usually made of transparent resin material and arranged in the guide hole along the light emission axis direction: the two prisms are adapted to the transmitter and the receiver respectively. The two prisms have a total reflection surface and a lens, so that the light is guided and concentrated to and from the sensing area.

[0012] This previous configuration has the advantage of allowing the use of standard and commercial surface mount device transmitters and receivers mounted on a printed circuit board using standard surface mount technology (SMT); the functions of guiding light to and collecting light from smoke particles are ensured by two prisms with a total reflection surface and a lens. However, this optical system is basically composed of different parts, including two prisms and a box-shaped body with dedicated guide holes covering them. This previous design provides the convenience of using commercial surface mount device transmitters and receivers, but the design has a higher number of components (in addition to the surface mount device transmitter and receiver, there is at least one dedicated body and two prisms), and thus may not be desired.

[0013] Other existing designs use light guides or multiple separate reflective components to guide light to or collect light from SMD or through-hole optical transmitters and receivers (see, for example, EP3584775A1 and WO2020247187A1). Using light guides has the advantage of accurately and efficiently guiding light, but light guide manufacturing may be affected by bubble formation problems during molding. Therefore, accurate quality control is expensive and there is no guarantee that defects will be fully detected.

[0014] The quality of the reflective surfaces can be more easily controlled, so these parts are produced separately. For a typical system with a dual-optic / dual-wavelength optical sensing configuration using SMD parts, three mirrors and only a small portion of the optical chamber must be made reflective, while the rest of the optical chamber must be black and equipped with light traps to reduce unwanted reflections. Therefore, manufacturers usually place different multiple small mirrors in different locations near the optical transmitter and receiver. However, the placement of these mirrors may lead to incorrect alignment, resulting in poor performance. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 is a top view of a chamber base of a smoke detector optical chamber according to one or more embodiments of the present disclosure.

[0016] Figure 2 is an exploded view of components of a smoke detector optical chamber according to one or more embodiments of the present disclosure.

[0017] Figure 3Ais a top view of a reflective component insert of a smoke detector of a fire alarm system according to one or more embodiments of the present disclosure.

[0018] Figure 3B is a top perspective view of a reflective component insert of a smoke detector of a fire alarm system according to one or more embodiments of the present disclosure.

[0019] Figure 4A is an exploded bottom perspective view of a chamber base and a reflective component insert of a smoke detector optical chamber according to one or more embodiments of the present disclosure.

[0020] Figure 4B is a top perspective view of a chamber base and a reflective component insert of a smoke detector optical chamber according to one or more embodiments of the present disclosure.

[0021] Figure 4C is a bottom perspective view of a chamber base and a reflective component insert of a smoke detector optical chamber according to one or more embodiments of the present disclosure.

[0022] Figure 4D is a top perspective view of a chamber base and a reflective component insert of a smoke detector optical chamber according to one or more embodiments of the present disclosure.

[0023] Figure 4E is a bottom perspective view of a chamber base and a reflective component insert of a smoke detector optical chamber according to one or more embodiments of the present disclosure. DETAILED DESCRIPTION

[0024] Devices, systems and methods are described herein to provide an optical chamber mount for smoke detection with an integrated reflective surface for optical particle detection. The present disclosure relates to optical smoke detectors or multi-standard smoke detectors that use an optical system to detect light scattered by particles (smoke particles): these systems typically include a sensing chamber (where the particles enter), an optical transmitter, a receiver, and electronic control circuitry for operating the system.

[0025] Embodiments of the present disclosure are intended to overcome the above-mentioned problems by providing a solution that integrates simplicity of assembly process (e.g., SMT, minimizing the number of mechanical parts), scalability to dual-angle / dual-wavelength (2A / 2W) optical detection, cost-effectiveness while maintaining good optical sensitivity, and / or high immunity to interference sources.

[0026] The chamber base embodiment of the present disclosure is unique in that multiple reflective surfaces (e.g., two reflective surfaces direct light from two forward scattering emitters to the scattering / sensing area and one reflective surface collects light from the sensing area to the receiver) are integrated into one reflective plastic part (an integral reflective component insert) that can be pre-assembled and incorporated into the remainder of a non-reflective (e.g., black) chamber base (the non-reflective part can be a two- or three-material molded part). In this way, the unique part, the chamber base, can arrive at an automated placement location for smoke detector manufacturing and can be precisely aligned (also due to the chamber base's optional three alignment pegs that can fit into three holes in a printed circuit board (PCB), thereby ensuring relatively accurate positioning of the reflective surfaces with respect to the optical emitters and receivers) and mounted on the PCB by a fully automated process.

[0027] In this detailed description, reference is made to the accompanying drawings which form a part hereof. The drawings show, by way of illustration, the manner in which one or more embodiments of the disclosure may be practiced.

[0028] These embodiments are described in sufficient detail to enable one of ordinary skill in the art to practice one or more embodiments of the present disclosure. It is to be understood that other embodiments may be utilized and process, electrical and / or structural changes may be made without departing from the scope of the present disclosure.

[0029] It should be understood that the elements shown in the various embodiments herein may be added, exchanged, combined and / or eliminated to provide multiple additional embodiments of the present disclosure. The proportions and relative sizes of the elements provided in the drawings are intended to illustrate embodiments of the present disclosure and should not be limiting.

[0030] The drawings herein follow the following numbering convention: one or more first digits correspond to the drawing number, and the remaining digits identify the element or component in the drawing. Similar elements or components between different drawings may be identified by using similar numerals. For example, 102 may be in Figure 1 The component is referenced as "02" in the Figure 2 Cited as 202.

[0031] As used herein, "a" or "a number of" things may refer to one or more such things, and "a plurality" of things may refer to more than one such thing. For example, "a number of components" may refer to one or more components, and "a plurality of components" may refer to more than one component.

[0032] Figure 11 is a top view of a chamber base of a smoke detector optical chamber according to one or more embodiments of the present disclosure. Chamber base 100 includes a chamber base body 106 having an integral reflective component insert 102 positioned therein. As shown, at least portions of the side walls and end walls of a recess (typically a rectangular aperture 101) in the chamber base body are designed to closely abut at least portions of the side walls 103 and end walls 105 of the integral reflective component insert 102.

[0033] exist Figure 1 In the example shown, the corners of the integral reflective component insert 102 are rounded, and therefore, not all side wall surfaces and end wall surfaces are in contact with each other. The interaction between the side and end walls of the chamber base aperture 101 and the integral reflective component insert 102 allows for precise alignment between the components on the integral reflective component insert 102 and the chamber base body 106.

[0034] This alignment can cause the components on the circuit board to Figure 2 The receiver 219 and the transmitters 211, 213, 215 and 217) are precisely aligned, such as Figure 2 Although Figure 1 1, the circuit board is not shown, but the receiver 119 and the transmitters 111, 113, 115 and 117 are shown to illustrate the orientation and positioning of these components relative to the chamber base body 106 and the integrated reflective component insert 102. Such precise positioning between these seven components can be easily achieved by the embodiments of the present disclosure.

[0035] Figure 2 is an exploded view of components of a smoke detector optical chamber according to one or more embodiments of the present disclosure. Figure 2 In the illustrated embodiment, the smoke detector optical chamber components include a chamber base body 206 , an integral reflective component insert 202 , and a circuit board 208 with a receiver 219 and transmitters 211 , 213 , 215 , and 217 .

[0036] The assembly process of a smoke detector including an optical chamber with a reflective surface may, for example, include different stages such as: SMT circuit board assembly; placing the circuit board on the detector base; covering the circuit board with a circuit board cover (in this example, the chamber base body 206) having a reflective surface (in this example provided in an integral reflective component insert); placing the chamber cover on the circuit board cover; installing the smoke detector cover; programming, calibrating and pre-package testing the smoke detector microcontroller; and packaging the smoke detector.

[0037] In an embodiment of the present disclosure, the integrated reflective component insert 202 includes a reflective surface that acts as a reflector to direct light from the emitter, as discussed in more detail below. Components on the circuit board that work in conjunction with the reflective surface include a group of forward scatter emitters 211 and 213 (e.g., surface mounted emitters) positioned below the reflective surface emitter reflectors 326 / 328 (of FIG. 3 ), which are part of the integrated reflective component insert 202 / 302. Also included is a group of backscatter emitters 215 and 217 (e.g., surface mounted emitters) positioned within the chamber base body 206 / 406 formed within the chamber base body 206 / 406. Figure 4A 3 ) within the backscatter cavity 442. Additionally, a receiver 219 (eg, a surface mount receiver) is positioned below the reflective surface receiver reflector 324 (of FIG. 3 ) as part of the integral reflective component insert 202 / 302.

[0038] As described herein, the optical chamber base with an integrated reflective component insert embodiment for forming an optical chamber of a smoke detector can be integrated into many current photoelectric-based smoke detector designs. As previously described, the unique optical chamber base with an integrated reflective component insert can be formed of three parts:

[0039] - a circuit board (e.g., circuit board 208) with surface mounted device (SMD) components (e.g., four SMD transmitters (two forward scatter and two backscatter) and one SMD receiver mounted thereon, e.g., using, e.g., standard SMT assembly processes;

[0040] - an integrated reflective component insert 202; and

[0041] - Chamber base body 206.

[0042] Figure 2 A circuit board of a smoke detector of a fire alarm system that can be used with one or more embodiments of the present disclosure is shown. Preferably, the circuit board integrates a transmitter, a receiver, and all the electronic circuits required to drive the transmitter and collect, analyze, and / or transmit information from the receiver to, for example, a control panel of the fire system (located remotely from the detector device).

[0043] To implement a dual angle / dual wavelength configuration, a single receiver and four transmitters (eg, one infrared 411 and one blue 413 transmitter for forward optical scattering, one infrared 417 and one blue 415 transmitter for backward optical scattering) may be utilized. Figure 2Such an embodiment is shown in , where a printed circuit board 208 includes a set of forward scatter transmitters ( 211 and 213 ) and a set of backscatter transmitters ( 215 and 217 ) and a receiver 219 disposed on the printed circuit board.

[0044] The electronic circuit can pulse one emitter at a time, and the radiation scattered by the smoke from the emitter is collected by the receiver to generate a related optical signal. During a cycle (e.g., 4 seconds), all four emitters can be pulsed in sequence (e.g., every second), thereby generating four different optical signals at the receiver (e.g., infrared forward scattering (IR FS), blue forward scattering (blue FS), infrared backscattering (IR BS), and blue backscattering (blue BS)). As used herein, suitable infrared wavelength emitters are in the range between 700nm and 1mm, and suitable blue wavelength emitters are in the range between 400 and 525nm. In some specific implementations, such as in high-sensitivity applications that require more optical power, multiple emitters are pulsed simultaneously (e.g., two backscattering emitters with the same wavelength or two forward scattering emitters with the same wavelength), generating an optical signal with double amplitude at the receiver. In some specific implementations, a red light source can be used instead of an infrared light source, and / or a UV light source can be used instead of a blue light source.

[0045] Smoke detectors are important components in some types of fire detection systems. Also important is a controller that provides detection analysis, alarm functions, and communication functions with other fire system devices. A circuit board 208 designed according to an embodiment of the present disclosure can provide these functions in an integrated circuit board. The signals discussed above from the receiver can be stored in a memory and / or analyzed by a controller on or connected to the printed circuit board to determine, for example, whether a fire condition exists near the detector.

[0046] The type of data obtained by the dedicated software in the firmware in the controller and / or stored in the memory can be a volatile integer data representing the amount of particles detected in the optical chamber of the smoke detector. In addition, this data can be stored in the random access memory (RAM) and used for fire alarm generation, or stored in the non-volatile RAM (NVRAM) at the application level for diagnostic purposes using different types of algorithms (e.g., average, mode, etc.) to evaluate the particle density. This layer can be provided, for example, at the fire system control panel.

[0047] An exemplary embodiment of the present disclosure includes a smoke detector for a fire sensing system, the smoke detector for a fire sensing system including a circuit board body having: a group of forward scattering emission light sources located on one side of an optical chamber; a receiver for forward scattering light beams and backscattering light beams, the forward scattering light beams coming from the forward scattering emission light sources; and a group of backscattering emission light sources located between the group of forward scattering emission light sources and the receiver, the backscattering light beams being emitted from the backscattering emitters. These light beams are directed to the receiver via a reflective surface of an integral reflective component insert. About Figure 3A and Figure 3B The elements and advantages of an integrated reflective component insert are discussed in greater detail.

[0048] Figure 3A is a top view of a reflective component insert of a smoke detector of a fire alarm system according to one or more embodiments of the present disclosure. Figure 3B is a top perspective view of a reflective component insert of a smoke detector of a fire alarm system according to one or more embodiments of the present disclosure.

[0049] At 326 and 328 in FIG. 3 , one can see the reflective surface used with the dual transmitter structures 211 and 213. As shown, the entire surface has two main parts, each of which is designed to interact with a corresponding transmitter (e.g., 211 interacts with 328, and 213 interacts with 326). The integrated reflective component insert 302 also has a reflective surface at 324 for use with the receiver structure 219.

[0050] Figure 3B The illustrated embodiment shows how the insert 302 has a reflective housing forming therein cavities 326 and 328. The emitters 211 and 213 emit light beams into the cavities 326 and 328, respectively, and the inner surface of the housing of the integral reflective component insert 302 directs the light into the optical cavity (central scattering region) of the detector device in a predictable manner.

[0051] From this description, it can be inferred that the shape of the reflective interior surface can be used to change the direction of the emitted light. For example, to integrate two forward scattering emitters (e.g., IR and blue) into a smoke chamber, a dual elliptical reflector can be utilized that directs the light of these two emitters in a central scattering region. For example, each portion of the ellipse can be offset and tilted 5 degrees relative to its optical axis.

[0052] The chamber base body is integrated with unique features that can be used to direct and focus the radiation from the four emitters and scattered by the smoke. These optical features are not prisms or lenses, but the reflective surfaces (324, 326 and 328) of the insert 302 mounted therein are of appropriate shape, size and position to direct the light from the light source as desired.

[0053] The geometry of these reflective surfaces is unique to the embodiments of the present disclosure. The geometry of the emitter reflector structure includes dual tilted elliptical reflectors (emitter reflectors 326 and 328) that reflect light from two adjacent forward scattering emitters (e.g., Figure 2 211, 213) collect the light beam and guide it toward the central area of ​​the smoke chamber.

[0054] Transmitter reflectors 326 and 328 together consist of two elliptical sections, each of which is tilted relative to the optical axis (e.g., ±5 degrees). In addition, elliptical receiver reflector 324 collects radiation scattered by smoke particles and directs it to the device receiver (e.g., Figure 2 219).

[0055] For example, the reflective surface can be made of polycarbonate using a 12-cavity injection mold to allow PVD (physical vapor deposition) of aluminum processing and facilitate placement of the reflectors on the frame, with each shot of 12 reflectors remaining connected by their gates. After processing, the reflectors, still connected by their gates, will be placed on a tray to be selected for placement on a circuit board.

[0056] The chamber base body can be assembled as follows: Acrylonitrile, butadiene, and styrene (ABS) or other suitable materials can be used to form the chamber base body. The body can include some elastomeric parts (seals and / or gaskets). For example, these elastomeric parts can be made of SEBS thermoplastic elastomer (TPE). In some embodiments where a light guide is added, polymethyl methacrylate (PMMA) can also be used. The chamber base body can be molded with, for example, a 4-cavity mold. This process forms the chamber base body 206.

[0057] In a separate process, the polycarbonate reflector part is molded using, for example, a 12-cavity injection mold. For example, the polycarbonate reflector can be metalized using a PVD process in a vacuum chamber to form the one-piece reflective component insert 302. Then, the gate used to form the one-piece reflective component insert 302 is removed, for example, by laser. Then, a pick-and-place process for extracting the ABS / TPE (PMMA) parts and connecting them to the one-piece reflective component insert 302 can be completed.

[0058] The body of the insert 302 may also be constructed of different materials, using a multi-material molding process, to maximize reflectivity only on surfaces that are used to direct light from the emitter to the scattering region and focus light from the scattering region to the receiver. In some implementations, other surfaces that are not required for directing or focusing light may be black or another suitable surface color / texture to absorb light and minimize unwanted reflections.

[0059] Another feature of the integrated reflective component insert 302 is a barrier 320 positioned at the entrance of the receiver cavity 338, which helps to avoid direct illumination from the transmitter to the receiver (the light beam travels directly from the transmitter to the receiver). This can be beneficial, for example, in the event of inaccurate positioning between the circuit board 208 and the chamber base 206.

[0060] In some embodiments, the integral reflective component insert may include a plurality of alignment features. For example, Figure 3A and Figure 3B An integral reflective component insert 302 having a plurality of side walls 318 adjacent to the Figure 4A A corresponding number of side walls 416 within the rectangular cavity 404.

[0061] Additionally or alternatively, the integral reflective component insert 302 may include a plurality of tooth structures 312 that are connected to the Figure 4A The mirrored surfaces can be more accurately aligned with the transmitter and receiver on the circuit board by using one or more of these alignment features.

[0062] An additional mechanism that can be used to ensure proper alignment of the integral reflective component insert 302 is for each end of the insert to have a different exterior shape. For example, one end 330 has an exterior with two arched portions, and the other end 332 has a single arched portion. This feature can be beneficial when arranging the transmitter reflector on the transmitter and the receiver reflector on the receiver.

[0063] Another mechanism that can be used to ensure proper alignment of the integral reflective component insert 302 is the thickness of each end of the insert. Figure 3B As shown, the thickness of the first end 334 is greater than the thickness of the end 336. These thicknesses can be easily identified and used to correctly orient the ends of the insert. In addition, the cavity 404 can be shaped so that the thickness of the insert at each end only fits well in one direction within the cavity 404.

[0064] In this way, an integrated reflective component insert can be produced that can accurately direct light beams from multiple emitting light sources. In addition, the modular design of the integrated reflective component insert can allow precise positioning within the chamber base body, and thereby precisely positioning within the smoke detector, thereby achieving more accurate smoke detection and more reliable fire detection.

[0065] Figure 4A is an exploded bottom perspective view of a chamber base and a reflective component insert of a smoke detector optical chamber according to one or more embodiments of the present disclosure. Figure 4B is a top perspective view of a chamber base and a reflective component insert of a smoke detector optical chamber according to one or more embodiments of the present disclosure.

[0066] Figure 4C is a bottom perspective view of a chamber base and a reflective component insert of a smoke detector optical chamber according to one or more embodiments of the present disclosure. Figure 4D is a top perspective view of a chamber base and a reflective component insert of a smoke detector optical chamber according to one or more embodiments of the present disclosure. Figure 4E is a bottom perspective view of a chamber base and a reflective component insert of a smoke detector optical chamber according to one or more embodiments of the present disclosure.

[0067] exist Figure 4A In the illustration of FIG. 4 , the integrated reflective component insert 402 is positioned in the chamber base body 406. As described above, the integrated reflective component insert 402 can be shaped to fit in a specific position in the chamber base body. For example, in Figure 4A In the illustrated embodiment, the integral reflective component insert 402 has a generally rectangular shape (when viewed from the top). The chamber base body 406 has a correspondingly shaped cavity 404, wherein when the rectangular insert 402 is placed in the cavity, the rectangular insert is precisely positioned in the chamber base body 406 and relative to the transmitter and receiver and their associated mirrored surfaces.

[0068] The shapes of the insert perimeter and the cavity opening do not have to match in all areas, e.g. Figure 4A In some embodiments, only a portion of each of the insert perimeter and the cavity opening has a matching surface that cooperates to help align. In addition, the shape of the insert perimeter and the cavity opening does not need to be rectangular, and can be any suitable shape that can be used to assist alignment.

[0069] Figure 4A The embodiment also shows alignment features, such as teeth 412 on the insert 402 that interact with the grooves 414 , and side walls 418 of the insert 402 that interact with the side walls 416 .

[0070] Another alignment feature for aligning the integrated reflector component insert 402 with the transmitter and receiver located on the circuit board is a plurality of alignment pegs 422 located at the corners of the cavity opening 404. These pegs may mate with corresponding holes precisely located on the surface of the circuit board so that when the pegs are seated in the holes, the insert 402 is precisely aligned with respect to the transmitter and receiver.

[0071] Figure 4A 4, where the inner perimeter shape 410 matches the outer surface shape of the block in which the backscatter cavity 442 is located. The inner perimeter shape 410 may include the shape of the teeth 412, the sidewalls 418, and the surface of the barrier 420. The outer surface perimeter of the block on the chamber space body may include the shape of the grooves 414 and the sidewalls 416. Figure 4A Also shown is a barrier 420 that separates a receiver cavity 438 from a transmitter cavity 440 .

[0072] like Figure 4A As shown, in some embodiments, a backscatter (BS) cavity 442 can be positioned between the transmitters (211 and 213) and the receiver 219 to separate the two forward scatter transmitters and the receiver. The cavity 442 can provide several functions, including: avoiding direct illumination of the receiver and hosting the two backscatter transmitters. For these reasons, the backscatter cavity 442 can have a barrier (e.g., Figure 4B and Figure 4D A barrier 444 is provided in the backscatter cavity to limit the propagation of the light beam generated from the forward scatter transmitter and to limit the field of view of the receiver, and the top of the backscatter cavity has one or two apertures to limit the propagation of the light beams generated by the two backscatter transmitters.

[0073] These backscattering features and the other features mentioned above can be found in FIG. 4B to FIG. 4E 44. Backscattering component 445 may form a cavity 442 therein that houses a backscattering receiver or one or two backscattering emitters. In addition, as described above, the backscattering component may be constructed with a barrier 444 and an elliptical aperture 447 from which infrared and blue backscattered radiation is collected by the backscattering receiver or from which radiation is emitted by one or two backscattering emitters. These features may be used to control the direction from which backscattered radiation is collected, or to limit the propagation of a beam generated by a backscattering emitter.

[0074] In some embodiments, the backscatter cavity may include multiple backscatter emitters (e.g., two backscatter emitters 215, 217), such as Figure 2 However, in low-cost applications, a backscatter transmitter may be used. Additionally, the backscatter cavity may include a backscatter receiver.

[0075] The top of the backscatter cavity 442 can be FIG. 4A to FIG. 4E The top of the backscatter cavity may have multiple apertures (e.g., Figure 4B Orifices 446 and 448 in the Figure 4D and Figure 2 A plurality of apertures 447 are provided in the backscatter cavity 442 to limit the propagation of the light beam generated by the backscatter emitter (or, if a backscatter receiver is disposed in the backscatter cavity, to limit the field of view of the backscatter receiver). In various embodiments, the plurality of apertures may be different sizes, such as 446 and 448, for example, based on the amount of light that needs to be limited. In some embodiments, in high sensing applications where more optical power is required, it may be very useful to use a large aperture 447 in the backscatter cavity 442 rather than multiple smaller apertures.

[0076] The chamber base may also include a "V" shaped barrier 444 which has the function of limiting the propagation of the light beams generated from the forward scattering emitters (211, 213) and limiting the field of view of the receiver 219. For example, in Figure 4B and Figure 4D , the points of the two V 444 intersect at the center of the chamber base 406 (typically at the location of the orifices 446 / 448, 447).

[0077] Since the cavity 442 is an integral part of the integral reflective component insert 402, the accuracy between detector devices can be more accurate than designs that place one or more mirrored surfaces to achieve reflection of the forward scattering or backscattering of the light beam. In addition, if these parts are formed by a molding process, the surfaces between the same parts produced by the molding process can be almost identical, which also increases the predictability of detection.

[0078] As discussed, by using embodiments of the present disclosure, smoke detectors can be more reliable, easier to manufacture, and more cost-effective to produce, have more consistency between produced devices and less opportunity for human error, and can be more accurate in detecting smoke particles in air streams. Such features can be very beneficial in detecting fires early in the event of a fire and alerting emergency personnel and building occupants, among other benefits.

[0079] Although specific implementations have been illustrated and described herein, those of ordinary skill in the art will appreciate that any arrangement calculated to achieve the same technique may be substituted for the specific implementations shown. This disclosure is intended to cover any and all modifications or variations of various implementations of the present disclosure.

[0080] It should be understood that the above description is given in an illustrative rather than limiting manner.By reading the above description, combinations of the above embodiments, as well as other embodiments not specifically described herein, will be apparent to those skilled in the art.

[0081] The scope of the various embodiments of the present disclosure includes any other applications using the above-described structures and methods.The scope of the various embodiments of the present disclosure should therefore be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.

[0082] In the above detailed description, various features are grouped together in the exemplary embodiments shown in the drawings for the purpose of simplifying the disclosure. This method of disclosure should not be interpreted as reflecting an intention that the embodiments of the present disclosure require more features than are expressly recited in each claim.

[0083] Rather, as the following claims reflect, inventive subject matter lies in less than all features of a single disclosed embodiment.Thus the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separate embodiment.

Claims

1. An optical chamber base (206 / 406), the optical chamber base comprising: One-piece reflective component insert (202 / 302 / 402); and A chamber base body having a cavity (404) formed therein, wherein the one-piece reflective component insert (202 / 302 / 402) is positioned in the cavity; and wherein the one-piece reflective component insert (202 / 302 / 402) includes a body having a non-reflective portion and a reflective portion, and wherein the reflective portion forms two transmitter reflectors (326, 328) and a receiver reflector (324).

2. The optical chamber base (206 / 406) of claim 1, wherein the integrated reflective component insert (202 / 302 / 402) includes a plurality of alignment teeth (312 / 412) that mate with a corresponding number of grooves (314 / 414) formed on the chamber base body.

3. The optical chamber base (206 / 406) of claim 1, wherein the integrated reflective component insert (202 / 302 / 402) includes a plurality of alignment side walls (418) that mate with a corresponding number of side walls (416) formed on the chamber base body.

4. The optical chamber mount (206 / 406) of claim 3, wherein the integrated reflective component insert (202 / 302 / 402) includes a plurality of alignment teeth (312 / 412) that mate with a corresponding number of grooves (314 / 414) formed on the chamber mount body.

5. The optical chamber base (206 / 406) of claim 1, wherein the integral reflective component insert (202 / 302 / 402) includes a portion of an inner peripheral surface (410) that mates with a corresponding portion of an outer peripheral surface (412) of a block formed within the cavity of the chamber base body.

6. The optical chamber base (206 / 406) of claim 1, wherein the integrated reflective component insert (202 / 302 / 402) includes a first outer end (334) surface having a shape different from a shape of a second outer end (336) surface.

7. The optical chamber base (206 / 406) of claim 1, wherein the integrated reflective component insert (202 / 302 / 402) includes a first outer end (334) surface having a thickness greater than a thickness of a second outer end (336) surface.

8. The optical chamber base (206 / 406) of claim 1, wherein the integrated reflective component insert (202 / 302 / 402) is made of polycarbonate.

9. The optical chamber base (206 / 406) of claim 1, wherein the chamber base body is made of acrylonitrile, butadiene, and styrene.

10. The optical chamber mount (206 / 406) of claim 1, wherein the chamber mount body includes at least one alignment peg (422) that mates with a hole in a circuit board.

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