Aspirating Smoke Detector Tool-less Assembly via Ultrasonic Welding

Solution Overview

Problem

Aspirating smoke detector devices are difficult to assemble and install due to the need for tool-based assembly with fasteners, leading to increased assembly time and cost.

Innovation Solution

A compact and modular design that allows for tool-less assembly without fasteners, featuring a manifold with flow channels, a blower housing, and sensor head housings that are securely connected using gaskets and snap clips, enabling easy alignment and sealing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional tool-based assembly with fasteners is used, then connection strength and reliability are improved, but assembly time and manufacturing cost increase

Engineering Contradiction:

Improveconnection strengthVSAvoidassembly time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent replaces traditional mechanical fastening systems (screws, bolts, clips) with an ultrasonic welding system that uses high-frequency vibration to fuse plastic components directly. This substitution eliminates the need for separate fasteners and mechanical assembly steps, achieving both strong connections and rapid assembly.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The ultrasonic welding process enables the components to join themselves through localized melting and bonding at the contact surfaces. The energy is applied directly to the joint area, causing the materials to fuse without requiring external fasteners or complex mechanical joining mechanisms.

Inventive Principle:

Principle #25Self-service

2Reliability

If traditional tool-based assembly with fasteners is used, then connection strength and reliability are improved, but manufacturing cost increases

Engineering Contradiction:

Improveconnection strengthVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces traditional mechanical fastening systems (screws, bolts, clips) with an ultrasonic welding system that uses high-frequency vibration to fuse plastic components directly. This substitution eliminates the need for separate fasteners and mechanical assembly steps, achieving both strong connections and rapid assembly.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent integrates the manifold, blower housing, and sensor head housings into a single molded assembly where components are ultrasonically welded together. This merging eliminates the need for separate fasteners, gaskets, and multiple assembly steps, reducing both part count and manufacturing complexity.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of manufacture

If modular design with multiple components is used, then ease of assembly and manufacturing are improved, but connection reliability and sealing performance worsen

Engineering Contradiction:

Improvemodular assemblyVSAvoidsealing performance

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent replaces traditional mechanical fastening systems (screws, bolts, clips) with an ultrasonic welding system that uses high-frequency vibration to fuse plastic components directly. This substitution eliminates the need for separate fasteners and mechanical assembly steps, achieving both strong connections and rapid assembly.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent uses compatible thermoplastic materials for all housing components that can be ultrasonically welded together, creating a unified structure with consistent sealing properties. The material selection ensures proper bonding and sealing at all joint interfaces without requiring additional gaskets or sealants.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS12165484B2Aspirating smoke detector device

Publication Date: 2024.12.10 HONEYWELL INTERNATIONAL INC

AI summary

Devices, systems, and methods for an aspirating smoke detector device are described herein. In some examples, one or more embodiments include an aspirating smoke detector device comprising a printed circuit board (PCB), a manifold including a first flow channel and a second flow channel, a blower housing configured to receive a blower, a first sensor head housing connected to the blower housing via the first flow channel, wherein the first sensor head housing is configured to receive a first sensor head, and a second sensor head housing connected to the blower housing via the second flow channel, wherein the second sensor head housing is configured to receive a second sensor head, and a gasket configured to fluidically seal the manifold to the PCB.