Dual-channel air quality sensor

Abstract

The utility model discloses a dual-channel air quality sensor, comprising an upper cover, a lower cover, a middle cover and a PCBA board, the middle cover and the PCBA board are arranged between the upper cover and the lower cover, the middle cover is provided with an in-vehicle air channel and an out-vehicle air channel, two wind wheels are integrated on the PCBA board, the two wind wheels are respectively arranged in the in-vehicle air channel and the out-vehicle air channel, and the two wind wheels are connected with the PCBA board. A plurality of sensors are arranged in the in-vehicle air duct and the out-vehicle air duct, and all the sensors are integrated on a PCBA board. The wind wheel is integrated on the PCBA, the wind wheel comprises the stator, the fan blades, the bearing and auxiliary accessories of the bearing, compared with a traditional fan scheme, a PCB, a chip, a wire harness and other parts are omitted, the fan and all the sensors are integrated on one PCBA, and the fan has the advantages of being high in integration level, small in size, few in part and low in cost.

Description

Technical Field

[0001] The utility model relates to the field of gas detection sensors, in particular to a dual-channel air quality sensor. Background Art

[0002] As people's demands for a better quality of life rise, many cars are equipped with dual-channel PM2.5 sensors to measure PM2.5 concentrations inside and outside the vehicle. These sensors, through the air conditioning system, filter the air or switch between internal and external circulation modes, preventing air pollution inside the vehicle and ensuring a fresh driving environment. However, current dual-channel sensors use two independent fans, each containing blades, a stator, a printed circuit board (PCB), a chip, a volute, and other components. These fans are assembled beneath the air duct, resulting in complex structures, complex processes, large size, and high costs. Furthermore, most PM2.5 sensors on the market are single-function sensors with limited functionality and low integration. Utility Model Content

[0003] In response to the shortcomings of the existing technology, the present invention provides a dual-channel air quality sensor that simplifies the installation of the fan, has a compact structure, and has fewer parts. To achieve the above objectives, the present invention is implemented through the following technical solutions:

[0004] A dual-channel air quality sensor includes an upper cover, a lower cover, a middle cover and a PCBA board. The middle cover and the PCBA board are located between the upper cover and the lower cover. The middle cover is provided with an in-vehicle air duct and an out-vehicle air duct. Two wind wheels are integrated on the PCBA board, and the two wind wheels are located in the in-vehicle air duct and the out-vehicle air duct respectively. Several sensors are provided in each of the in-vehicle air duct and the out-vehicle air duct, and all sensors are integrated on the PCBA board.

[0005] Furthermore, a copper middle tube mounting hole and two coil pin mounting holes are provided at the position corresponding to each wind wheel on the PCBA board. The copper middle tube of each wind wheel is inserted into the corresponding copper middle tube mounting hole on the PCBA board and fixedly connected to the PCBA board. Two coil pins connecting the coil are provided on the coil frame of each wind wheel. Each coil pin is inserted into the corresponding coil pin mounting hole on the PCBA board and welded to the PCBA board. The PCBA board controls the opening of the two wind wheels.

[0006] Furthermore, a concave-convex structure is provided on the surface of the copper middle tube to increase the surface roughness of the copper middle tube, and the copper middle tube and the PCBA board are bonded by glue.

[0007] Furthermore, the side of the middle cover is provided with an indoor air inlet, an indoor air outlet, an outdoor air inlet and an outdoor air outlet; the interior of the lower cover is provided with a first sealing rib and a second sealing rib, the first sealing rib and the second sealing rib respectively enclose a first closed area and a second closed area, and the first sealing rib and the second sealing rib are tightly fitted with the bottom surface of the middle cover; the indoor air duct includes a first wind wheel cavity and a first air duct isolated from each other, the first air duct is connected to the outdoor air inlet, the first wind wheel cavity is connected to the outdoor air outlet, a first air inlet is provided at the bottom of the first wind wheel cavity, a first air outlet is provided at the bottom of the first air duct, the first air outlet and the first air inlet are connected to the first closed area in the lower cover; the outdoor air duct includes a second wind wheel cavity and a second air duct isolated from each other, the second air duct is connected to the outdoor air inlet, the second wind wheel cavity is connected to the outdoor air outlet, a second air inlet is provided at the bottom of the second wind wheel cavity, a second air outlet is provided at the bottom of the second air duct, the second air outlet and the second inlet are connected to the second closed area in the lower cover; the two wind wheels are respectively placed in the first wind wheel cavity and the second wind wheel cavity.

[0008] Furthermore, two positioning blocks of different sizes are provided on the coil frame of each wind wheel, and two wind wheel positioning holes of different sizes are provided on the PCBA board. The two wind wheel positioning holes correspond one-to-one to the two positioning blocks. The positioning blocks are inserted into the corresponding wind wheel positioning holes to position the wind wheel stator and prevent them from being misaligned. The positioning blocks are stepped, and the PCBA board is placed on the stepped surface of the positioning blocks to ensure that there is a certain gap between the upper surface of the wind wheel and the PCBA board to prevent collision.

[0009] Furthermore, the bottom surface of the middle cover is covered with rubber at positions corresponding to the first sealing rib and the second sealing rib, and the covered rubber portion is in close contact with the first sealing rib and the second sealing rib.

[0010] Furthermore, the side of the middle cover close to the PCBA board is covered with glue, the air duct outside the vehicle is located in the glue-covered area, and the PCBA board presses the glue-covered area on the middle cover.

[0011] Furthermore, the PCBA board is provided with two different types of connectors, and either connector can connect electricity and transmit signals to the PCBA board.

[0012] Furthermore, several screw mounting posts are provided inside the lower cover, and through holes are provided on the middle cover and PCBA board at positions corresponding to the screw mounting posts. The screws pass through the through holes on the middle cover and PCBA board and are locked on the corresponding threaded hole posts on the lower cover. The middle cover, lower cover and PCBA board are connected by screws.

[0013] Furthermore, the PCBA board is provided with a plurality of PCBA positioning holes, and the middle cover is provided with a plurality of PCBA positioning posts. The PCBA positioning posts are inserted into the corresponding PCBA positioning holes to determine the relative position of the PCBA board and the middle cover, and ensure the accurate position of the wind wheel at the middle cover volute, so as to have a higher suction force.

[0014] The vehicle-mounted dual-channel air quality sensor of the utility model has the following beneficial effects:

[0015] 1. The wind wheel is integrated on the PCBA. The wind wheel contains the stator, fan blades, bearings and their accessories. Compared with the traditional wind turbine solution, it omits the PCB, chip, wiring harness and other parts.

[0016] 2. The volute is integrated into the middle cover, which can save the thickness of the fan;

[0017] 3. The middle shell adopts rubber encapsulation design, which can completely seal the vehicle's external passage after assembly to prevent gas leakage between the inside and outside of the vehicle and affect the measurement accuracy;

[0018] 4. By sealing the lower cover and the middle cover, the air duct design is optimized to create a negative pressure area under the centrifugal impeller, promoting better air suction effect;

[0019] 5. Through the screws through the middle cover and PCBA lock to the lower cover, fewer parts, making assembly easier and the process simpler;

[0020] 6. In addition to the PM2.5 function, the air duct inside the car can also be equipped with carbon dioxide, temperature and humidity, TVOC, etc., and the air duct outside the car can be equipped with an AQS sensor function.

[0021] 7. The fan and sensors are integrated on a PCBA, which has the characteristics of high integration, small size, few parts and low cost. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 This is an exploded view of a dual-channel air quality sensor according to an embodiment of the present invention;

[0023] Figure 2 This is a view of the fan, sensors and connectors installed on the PCBA board. Figure 2 yes Figure 1 A bottom-up view;

[0024] Figure 3 yes Figure 2 Exploded view of each component;

[0025] Figure 4 This is a schematic diagram of the fan, sensor and connector in the middle cover;

[0026] Figure 5 This is a bottom view of the middle cover with the fan installed;

[0027] Figure 6 This is an exploded view of the fan;

[0028] Figure 7 This is another exploded view of the fan. DETAILED DESCRIPTION

[0029] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0030] In the description of the present invention, it should be understood that the terms "upper", "lower", "front", "back", "left", "right", "top", "bottom", "inside", "outside", etc., indicating directions or positional relationships, are based on the directions or positional relationships shown in the accompanying drawings. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific direction, be constructed and operated in a specific direction. Therefore, they cannot be understood as limitations on the present invention.

[0031] like Figures 1 to 7 As shown, a dual-channel air quality sensor includes an upper cover 1, a lower cover 4, a middle cover 3 and a PCBA board 2, wherein the middle cover 3 and the PCBA board 2 are installed between the upper cover 1 and the lower cover 4.

[0032] The upper cover 1 and lower cover 4 are connected by a snap-fit mechanism. Specifically, the upper cover 1 is provided with slots around its perimeter, while the lower cover 4 is provided with snap-fit blocks around its perimeter. The upper cover 1 is removably connected to the lower cover 4 via the matching snap-fit blocks and slots. Alternatively, the slots can be provided on the lower cover 4, and the snap-fit blocks on the upper cover 1. The upper and lower covers 1 and 4 can also be connected using screws, welding, or gluing.

[0033] A first sealing rib 41 and a second sealing rib 42 are protruded from one side of the lower cover 4 close to the middle cover 3 . The first sealing rib 41 and the second sealing rib 42 are both closed in shape, and respectively enclose a first closed area 43 and a second closed area 44 .

[0034] The middle cover 3 is provided with an interior air inlet 31, an interior air outlet 32, an exterior air inlet 33, and an exterior air outlet 34. It is also provided with a first wind wheel cavity 35, a first air duct 36, a second wind wheel cavity 39, and a second air duct 310. A first air inlet 37 and a first air outlet 38 are provided on the middle cover 3 at locations corresponding to the first closed area 43 of the lower cover 4. A second air inlet 311 and a second air outlet 312 are provided on the middle cover 3 at locations corresponding to the second closed area 44 of the lower cover 4. Both the first wind wheel cavity 35 and the second wind wheel cavity 39 are volute structures.

[0035] The first rotor cavity 35 is connected to the external air outlet 34. The first air inlet 37 is located at the bottom of the first rotor cavity 35. The first rotor cavity 35 is connected to the first closed area 43 through the first air inlet 37. The first air duct 36 is connected to the external air inlet 33. The first air outlet 38 is located at the bottom of the first duct 36. The first air duct 36 is connected to the first closed area 43 through the first air outlet 38. The first air duct 36 and the first rotor cavity 35 are connected to form the external air duct. To ensure the sealing of the external air duct and the accuracy of the test, the junction between the external air duct and the PCBA board is sealed with a rubber coating 5. Similarly, the second wind wheel cavity 39 is connected to the vehicle interior air outlet 32, and the second air inlet 311 is located at the bottom of the second wind wheel cavity 39. The second wind wheel cavity 39 is connected to the second closed area 44 through the second air inlet 311. The second air duct 310 is connected to the vehicle exterior air inlet 33, and the second air outlet 312 is located at the bottom of the second wind duct 310. The second air duct 310 is connected to the second closed area 44 through the second air outlet 312. The second air duct 310 and the second wind wheel cavity 39 are connected to form an interior air duct.

[0036] The PCBA board 2 is equipped with mounting locations for a carbon dioxide gas, a laser module, a shielding cover, and two wind wheel mounting locations. Each wind wheel mounting location houses a wind wheel 6, which is positioned within the first wind wheel cavity 35 and the second wind wheel cavity 39, respectively. A first closed area 43 and a second closed area 44 form negative pressure zones below the two wind wheels 6.

[0037] like Figure 3 and Figure 4 , the carbon dioxide mounting point is glued and fixed with an air cavity shell 24, and the electronic devices such as the lamp stack inside the air cavity shell 24 form a carbon dioxide sensor. The PM2.5 dust sensor mounting position is assembled with a laser module 27 and a shielding cover. The wind wheel 6, carbon dioxide sensor, laser module, and shielding cover are all located on the side of the PCBA board 2 facing the middle cover 3. The positions of the middle cover 3 corresponding to the wind wheel 6, carbon dioxide sensor, laser module 27, and shielding cover are all provided with grooves or cavities. Multiple sensors are installed on the PCBA board 2 as needed. For example, a carbon dioxide sensor, a temperature and humidity sensor 28, an AQS sensor 26, etc. are installed on the PCBA board 2. In addition to the PM2.5 detection function, the air duct inside the vehicle can also add the detection of carbon dioxide, temperature and humidity, TVOC, etc., and an AQS sensor 26 can be set in the air duct outside the vehicle. All sensors and the wind wheel 6 are integrated on the PCBA board 2, which has the advantages of high integration, small size, and few parts.

[0038] In this embodiment, an AQS sensor 26, a laser module 27, and a shielding cover are provided in the first air duct 36. The side of the middle cover 3 close to the PCBA board 2 is covered with glue 5. The AQS sensor 26, the laser module 27, the shielding cover, the first air duct 36, and the first wind wheel cavity 35 are all located in the rubber-coated area 5 (that is, the air duct outside the vehicle is located in the rubber-coated area 5). The first sealing ribs 41 and the second sealing ribs 42 of the lower cover 4 are tightly fitted with the bottom surface of the middle cover 3. The PCBA board 2 presses the rubber-coated area 5 on the middle cover 3 to ensure that the air duct outside the vehicle forms a closed air duct to prevent the gas inside and outside the vehicle from mutual leakage and affecting the detection accuracy.

[0039] In this embodiment, the second air duct 310 is equipped with a carbon dioxide sensor, a laser module 27, a shielding cover, and a temperature and humidity sensor. These sensors are configured as needed and integrated onto the PCBA 2. Other types of sensors can also be added. The PCBA 2 also has two different types of connectors 23. Either connector 23 can be used to connect power to the PCBA 2 and transmit signals.

[0040] The PCBA board 2 is provided with a plurality of middle cover positioning holes 25, and the middle cover 3 is provided with a plurality of middle cover positioning posts 313. The middle cover positioning posts 313 are inserted into the corresponding middle cover positioning holes 25 to determine the relative position of the PCBA board 2 and the middle cover 3.

[0041] Several screw mounting posts 45 are provided inside the lower cover 4. Through holes are provided on the middle cover 3 and the PCBA board 2 at positions corresponding to the screw mounting posts 45. Screws are passed through the through holes on the middle cover 3 and the PCBA board 2 and then locked onto the corresponding threaded hole posts on the lower cover 4, thereby realizing the assembly of the middle cover 3, the PCBA board 2, and the lower cover 4.

[0042] like Figure 6 and Figure 7The wind wheel 6 includes a stator and a rotor. The stator is tightly fitted with a copper middle tube assembly 64 and a coil stator assembly 65. The rotor is a fan rotor assembly 66. The copper middle tube assembly 64 includes a copper middle tube 641 and a bearing 642 installed inside the copper middle tube 641. The coil stator assembly 65 includes a coil frame 63, a coil, a silicon steel sheet, and a coil pin 61. The coil pin 61 is connected to the enameled wire. The fan rotor assembly 66 includes a fan blade 661, a soft magnetic ring 662, a magnetic frame, and a central axis 663. The central axis 663 of the fan rotor assembly 66 is fixed to the bearing 642 of the copper middle tube assembly 64. The coil pin 61 is welded to the PCBA board 2, and the copper middle tube 641 is fixed to the PCBA board 2. When the PCBA board 2 is powered on, it controls the start-up of the wind wheel 6. The stator drives the soft magnetic ring 662 to rotate, thereby driving the fan blade 661 to rotate. The rotor 6 is a commonly used component in this field. Unlike conventional designs, the rotor 6 of this embodiment lacks a PCB or chip. Instead, the rotor 6 is activated by the PCBA board 2 on the middle cover 3, and no wiring harness is required for power. Integrating the rotor 6 onto the PCBA board 2 simplifies the connection between the rotor 6 and the PCBA board 2 compared to conventional rotor 6 installation solutions, eliminating the need for the PCB, chip, and wiring harness that typically come with the rotor 6.

[0043] In this embodiment, the wind rotor 6 is equipped with two coil pins 61 and several positioning blocks 62 on the coil frame 63. The two coil pins 61 are connected to the two ends of the coil, respectively. The two coil pins 61 are inserted into corresponding pin mounting holes on the PCBA board 2 and soldered to the PCBA board 2. The PCBA board 2 is equipped with a Hall effect sensor chip for controlling the wind rotor 6.

[0044] The coil frame 63 of the wind wheel 6 is provided with a plurality of positioning blocks 62, and the PCBA board 2 is provided with a plurality of wind wheel positioning holes 21. The positioning blocks 62 are inserted into the wind wheel positioning holes 21 in a one-to-one correspondence to position the wind wheel 6. Preferably, in this embodiment, there are two positioning blocks 62, one on each side of the copper middle tube 641 of the wind wheel 6, and the number of wind wheel positioning holes 21 is also set to two. The two positioning blocks 62 are of different sizes, and each positioning block 62 is inserted into the corresponding wind wheel positioning hole 21 on the PCBA board 2 to prevent misalignment and avoid abnormalities such as fan reversal. The positioning blocks 62 are stepped, and the PCBA board 2 is placed on the stepped surface of the positioning blocks 62 to ensure that there is a certain gap between the upper surface of the fan rotor assembly 66 and the PCBA board 2 to prevent collision.

[0045] like Figure 3The PCBA board is provided with a copper middle tube mounting hole 22 at the position of the copper middle tube 641 of each wind wheel 6. The copper middle tube 641 is inserted into the copper middle tube mounting hole 22 on the PCBA board 2 and fixed and sealed with glue. The surface of the copper middle tube 641 is provided with a concave-convex structure such as knurling or grooves to increase the surface roughness of the copper middle tube 641, thereby increasing the contact area between the copper middle tube 641 and the glue. After the glue is cured, the connection between the copper middle tube 641 and the PCBA board 2 is more secure and is not easily detached even when subjected to vibration.

[0046] Since the middle cover 3 is provided with an air duct and has a certain thickness, all sensors and the wind wheel 6 are integrated on the side of the PCBA board 2 facing the middle cover 3. These components are all accommodated in the middle cover 3, thereby ensuring that the side of the PCBA board 2 facing the upper cover 1 is relatively flat. After the PCBA board 2 is installed in the middle cover 3, the top surface of the PCBA board 2 is not higher than the top surface of the middle cover 3 or only protrudes slightly from the top surface of the middle cover 3.

[0047] The middle cover 3 is installed in the cavity of the lower cover 4. The bottom surface of the middle cover 3 is covered with rubber 5 corresponding to the first sealing ribs 41 and the second sealing ribs 42. The rubber-covered part 5 is tightly attached to the first sealing ribs 41 and the second sealing ribs 42. When the fan is started, the first closed area 43 and the second closed area 44 form a sealed negative pressure area.

[0048] The side of the middle cover 3 facing the PCBA board 2 is covered with glue 5, and the bottom of the middle cover 3 is covered with glue 5. By covering the middle cover 3 with glue 5, there is no need to set sealing gaskets on the upper and lower sides of the middle cover 3, which reduces the number of accessories and assembly steps, and is more conducive to automated assembly.

[0049] The first sealing ribs 41 and the second sealing ribs 42 in the middle cover 3 and the lower cover 4 are tightly attached. The PCBA board 2 integrating various sensors and the wind wheel 6 is installed in the middle cover 3. After the upper cover 1 and the lower cover 4 are assembled, the thickness of the entire product is only slightly thicker than that of the wind wheel 6. It is thin, small in size, and compact in structure.

[0050] The wind wheel 6 and each sensor are integrated on the PCBA board 2. Therefore, there are only four parts during assembly: the upper cover 1, the middle cover 3, the lower cover 4 and the PCBA board 2. The middle cover 3, the lower cover 4 and the PCBA board 2 are assembled together by screwing them together, and then the upper cover 1 and the lower cover 4 are buckled together to simplify the assembly steps.

[0051] The above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit them. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein. These modifications or replacements do not deviate from the spirit and scope of the technical solutions of the embodiments of the present invention. Therefore, all other embodiments obtained by those skilled in the art without creative work fall within the scope of protection of the present invention.

Claims

1. A dual-channel air quality sensor, characterized in that: It includes an upper cover, a lower cover, a middle cover and a PCBA board. The middle cover and the PCBA board are located between the upper cover and the lower cover. The middle cover is provided with an indoor air duct and an outdoor air duct. Two wind wheels are integrated on the PCBA board. The two wind wheels are respectively located in the indoor air duct and the outdoor air duct. Several sensors are provided in the indoor air duct and the outdoor air duct. All sensors are integrated on the PCBA board.

2. The dual-channel air quality sensor according to claim 1, characterized in that: A copper middle tube mounting hole and two coil pin mounting holes are provided at the position corresponding to each wind wheel on the PCBA board. The copper middle tube of each wind wheel is inserted into the corresponding copper middle tube mounting hole on the PCBA board and fixedly connected to the PCBA board. Two coil pins connecting the coil are provided on the coil frame of each wind wheel. Each coil pin is inserted into the corresponding coil pin mounting hole on the PCBA board and welded to the PCBA board. The PCBA board controls the opening of the two wind wheels.

3. The dual-channel air quality sensor according to claim 2, characterized in that: The surface of the copper middle tube is provided with a concave-convex structure to increase the surface roughness of the copper middle tube, and the copper middle tube and the PCBA board are glued together.

4. The dual-channel air quality sensor according to claim 2, characterized in that: Two positioning blocks of different sizes are provided on the coil frame of each wind wheel, and two wind wheel positioning holes of different sizes are provided on the PCBA board. The two wind wheel positioning holes correspond one-to-one with the two positioning blocks. The positioning blocks are inserted into the corresponding wind wheel positioning holes to position the wind wheel stator and prevent misalignment. The positioning blocks are stepped, and the PCBA board is placed on the stepped surface of the positioning blocks to ensure that there is a certain gap between the upper surface of the wind wheel and the PCBA board to prevent collision.

5. The dual-channel air quality sensor according to claim 1, characterized in that: The side of the middle cover is provided with an interior air inlet, an interior air outlet, an exterior air inlet and an exterior air outlet; A first sealing rib and a second sealing rib are provided inside the lower cover, the first sealing rib and the second sealing rib respectively enclose a first closed area and a second closed area, and the first sealing rib and the second sealing rib are tightly fitted with the bottom surface of the middle cover; The in-vehicle air duct includes a first wind wheel cavity and a first air duct isolated from each other, the first air duct is connected to the external air inlet of the vehicle, the first wind wheel cavity is connected to the external air outlet of the vehicle, a first air inlet is provided at the bottom of the first wind wheel cavity, a first air outlet is provided at the bottom of the first air duct, and the first air outlet and the first air inlet are connected to the first closed area in the lower cover; The vehicle exterior air duct comprises a second wind wheel cavity and a second air duct isolated from each other, the second air duct is connected to the vehicle exterior air inlet, the second wind wheel cavity is connected to the vehicle exterior air outlet, a second air inlet is provided at the bottom of the second wind wheel cavity, a second air outlet is provided at the bottom of the second air duct, and the second air outlet and the second air inlet are connected to the second closed area in the lower cover; The two wind wheels are respectively placed in the first wind wheel cavity and the second wind wheel cavity.

6. The dual-channel air quality sensor according to claim 5, characterized in that: The bottom surface of the middle cover is covered with rubber at positions corresponding to the first sealing rib and the second sealing rib, and the covered rubber portion is in close contact with the first sealing rib and the second sealing rib.

7. The dual-channel air quality sensor according to claim 1 or 6, characterized in that: The side of the middle cover close to the PCBA board is covered with glue, the air duct outside the vehicle is located in the rubber-covered area, and the PCBA board presses the rubber-covered area on the middle cover.

8. The dual-channel air quality sensor according to claim 1, characterized in that: There are two different types of connectors on the PCBA board, and either connector can connect power and transmit signals to the PCBA board.

9. The dual-channel air quality sensor according to claim 1, characterized in that: There are several screw mounting posts inside the lower cover, and through holes are provided on the middle cover and PCBA board at the corresponding screw mounting posts. The screws pass through the through holes on the middle cover and PCBA board and are locked on the corresponding threaded hole posts on the lower cover. The middle cover, lower cover and PCBA board are connected by screws.

10. The dual-channel air quality sensor according to claim 1, characterized in that: There are several PCBA positioning holes on the PCBA board, and several PCBA positioning posts are provided inside the middle cover. The PCBA positioning posts are inserted into the corresponding PCBA positioning holes.

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