Wireless Sensor Flex Antenna Magnetic Assembly
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Solution Overview
Problem
Existing sensors integrated with luminaire systems are susceptible to detuning and require mechanical fasteners and secondary assembly processes, which can impact wireless communication performance and increase assembly and disassembly time and cost.
Innovation Solution
A sensor module with a flex antenna supported on a battery enclosure, allowing for tool-free assembly and minimizing metallic interference, combined with a modular design that includes a sensor module, cover, and base, enabling wireless communication and self-contained power without external connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If mechanical fasteners and wired connectors are used to hold components together, then structural strength and electrical connectivity are improved, but assembly time and complexity increase
Solution Approach 1:
The patent replaces mechanical fasteners and wired connectors with magnetic attachment systems. The battery enclosure and sensor module use magnetic forces instead of mechanical fasteners to achieve structural strength, while the battery connector uses magnetic coupling instead of wired connections, eliminating the need for tools and secondary assembly processes.
2Manufacturing precision
If wire antennas are held in place by mechanical features, then antenna positioning is improved, but wireless communication performance deteriorates due to detuning
Solution Approach 1:
The patent replaces mechanical antenna mounting features with magnetic attachment. The wire antenna is held in place by magnetic forces between the battery enclosure and sensor module, eliminating mechanical contact points that cause detuning while maintaining precise antenna positioning through magnetic field control.
3Manufacturing precision
If tools and secondary assembly processes are used, then assembly precision is improved, but manufacturing cost and cycle time increase
Solution Approach 1:
The patent implements self-aligning magnetic attachment systems that automatically position components correctly during assembly. The magnetic forces guide the battery enclosure and sensor module into proper alignment without requiring tools or secondary assembly processes, achieving high precision through self-service mechanisms.
4Reliability
If battery connectors are wired to printed circuit board, then electrical connectivity is improved, but assembly complexity and time increase
Solution Approach 1:
The patent replaces wired battery connectors with magnetic electrical connections. The battery and printed circuit board are electrically connected through magnetic coupling, eliminating wires and soldering operations while maintaining reliable electrical connectivity through direct magnetic contact between conductive surfaces.
Data Source
AI summary
A sensor that that can be, but do not have to be, communicatively coupled with luminaires, includes a sensor module having an electronics board and a battery enclosure. The electronics board includes a sensing component, a controller, and a flex antenna. The battery enclosure is couple with the electronics board and includes a base and a side wall having an outer wall surface. The flex antenna is supported on the outer wall surface such that the flex antenna forms a radially outermost portion of the sensor module, and the flex antenna is conformable to a profile of the outer wall surface. In certain aspects, the sensor module is configured to support a power source on the sensor module. In some cases, the sensor is an indoor sensor.