Compact Two-Stage Impactor Dust Sensor for Fine Particle Measurement

Resolve Bottlenecks,
Find Innovative Solutions
Generate Solutions

Solution Overview

Problem

Conventional dust sensors with impactors are complex, large, expensive, and difficult to disassemble and clean, making them unsuitable for consumer or vehicle applications, and they struggle to accurately measure fine dust concentrations due to the entry of large particles and external light interference.

Innovation Solution

A compact, two-stage impactor assembly with a disk-shaped design featuring central depressions and protrusions, rubber rings, and a guide portion to filter out large particles and prevent external light entry, allowing only small particles to reach the sensor for precise fine dust measurement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If a conventional impactor is used to filter large particles, then measurement precision of fine dust is improved, but device complexity increases and size becomes large

Engineering Contradiction:
Improvefine dust measurement accuracyVSAvoidimpactor structure complexity
Core Design Contradiction:
Measurement precisionVSDevice complexity

Solution Approach 1:

The impactor is divided into multiple stages (first impactor, second impactor) with each stage having specific slots and protrusions that create separate trapping regions. This segmentation allows different particle sizes to be filtered at different stages, achieving fine dust measurement accuracy while keeping each individual component simple and compact.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The impactor components are designed with nested structures where the first impactor contains trapping regions within its body, and the second impactor similarly contains trapping regions. This nesting approach maximizes filtering functionality within a compact footprint, reducing overall device size while maintaining effective particle separation.

Inventive Principle:
Principle #7Nested doll (Nesting)

2Measurement precision

If a conventional impactor is used to filter large particles, then measurement precision of fine dust is improved, but the impactor size becomes large

Engineering Contradiction:
Improvefine dust measurement accuracyVSAvoidimpactor size
Core Design Contradiction:
Measurement precisionVSVolume of moving object

Solution Approach 1:

The impactor functionality is segmented into two compact units (first and second impactors) that can be arranged in series. Each unit has optimized dimensions with slots and protrusions that create efficient trapping regions, achieving effective particle filtering without requiring a large single-stage impactor structure.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The impactor design utilizes three-dimensional spatial arrangement with protrusions extending in different directions (first protrusion, second protrusion, third protrusion) to create trapping regions. This dimensional approach allows efficient particle filtering within a compact volume by utilizing vertical and radial space effectively.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

3Measurement precision

If an impactor is added to prevent large particle entry, then measurement precision is improved, but ease of manufacture decreases

Engineering Contradiction:
Improvefine dust measurement accuracyVSAvoidimpactor manufacturing simplicity
Core Design Contradiction:
Measurement precisionVSEase of manufacture

Solution Approach 1:

The impactor is designed as separable components (first impactor, second impactor, upper case, lower case) that can be manufactured independently and then assembled. This segmentation allows each component to be produced using standard manufacturing processes without requiring complex integrated tooling, improving ease of manufacture while maintaining measurement precision.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The impactor components are designed with universal features such as standardized slots, protrusions, and sealing surfaces that can be replicated across multiple units. This multi-functionality approach allows the same basic structure to serve both filtering and sealing functions, simplifying the manufacturing process while achieving the required measurement precision.

Inventive Principle:
Principle #6Universality (Multi-functionality)

4Measurement precision

If a conventional impactor is used, then large particles are filtered, but ease of operation for cleaning and maintenance deteriorates

Engineering Contradiction:
Improvefine dust measurement accuracyVSAvoidcleaning and maintenance ease
Core Design Contradiction:
Measurement precisionVSEase of operation

Solution Approach 1:

The impactor is designed as modular components (first impactor, second impactor, upper case, lower case) that can be easily separated from each other. This segmentation allows users to disassemble the impactor into individual pieces for thorough cleaning of trapping regions and slots, significantly improving ease of operation for maintenance while maintaining the filtering precision required for fine dust measurement.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The trapping regions and slots are designed as accessible features that can be easily reached and cleaned. The protrusions and slots are positioned to allow removal of accumulated particles without requiring complex disassembly, enabling simple maintenance operations while preserving the precise particle filtering capability.

Inventive Principle:
Principle #2Taking out (Extraction)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution enables accurate measurement of fine dust concentrations by filtering out large particles and preventing external light interference, extending sensor life and reducing maintenance costs through easy disassembly and cleaning.

Implementation Method 1

a first impactor (43) with which dust particles contained in air passing through an inlet (411) of the upper case (41) collide, a second impactor (45) through which dust particles passing through the first impactor (43) pass

Methodology Applied
Scientific EffectCentrifugal separation: Centrifugal Separation

Implementation Method 2

The dust sensor emits light toward the air passage path via a light emitting unit disposed in the air passage path, collects the light radiated by the light emitting unit and then scattered by dusts included in the air via a light receiving unit disposed in the air passage path

Methodology Applied
Scientific EffectLight scattering: Scattering

Implementation Method 3

measures the concentration of dust contained in the air by using an electric signal of the light receiving unit

Methodology Applied
Scientific EffectPhotoelectric effect: Photoelectric Effect

Data Source

PatentUS10529209B2Dust sensor adopting impactor
Publication Date: 2020.01.07 HITACHI LG DATA STORAGE KOREA INC
  • US10529209B2 patent drawing
  • US10529209B2 patent drawing
  • US10529209B2 patent drawing

AI summary

The present invention provides a dust sensor comprising an impactor assembly for passing only relatively small particles among particles contained in air; a light emitting unit for radiating light in a path through which the air introduced through the impact assembly passes; and a light receiving unit for receiving light scattered from particles included in the air passing through the path. The impact assembly may comprise an upper case, a first impactor, and a second impactor. The upper case may include an inlet and an outer downward protruding portion. The first impactor may include a central downward depression and a plurality of slots. The second impactor may include an outlet, a central upward protruding portion, a double-bent portion, an outer upward protruding portion and a guide portion.