Modular HVAC Sensor Housing for Multi-Configuration Adaptability
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Solution Overview
Problem
The existing HVAC device housings are inefficient as they require disparate designs for various component configurations and ornamental appearances, leading to wastefulness in time and materials, and there is a need for a modular housing that can adapt to different form factors and appearances while reducing the risk of damage from collisions.
Innovation Solution
A modular housing system for HVAC devices that includes a back plate with a mounting surface and a protrusion, allowing the housing to fit within a standard electrical junction box, with a front portion that can accommodate multiple sensors such as temperature, occupancy, and carbon dioxide sensors, and allows for customization through interchangeable bezels and face plates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a housing is designed to accommodate multiple sensor components and electronic components, then the device functionality is improved, but the housing volume and complexity increase
Solution Approach 1:
The patent implements nesting by placing the circuit board within a circuit board recess of the housing, and positioning sensors within sensor recesses. The electronic components are nested within the housing structure rather than adding external volume, allowing multiple components to coexist in a compact arrangement.
Solution Approach 2:
The patent utilizes three-dimensional space efficiently by creating recesses at different depths and positions within the housing. Sensors are positioned in recesses that extend from different faces of the housing, and the circuit board is placed in a recess that optimizes vertical space utilization, transforming a two-dimensional layout problem into a three-dimensional space optimization solution.
2Adaptability or versatility
If different configurations and appearances are designed with disparate housings, then customization is achieved, but manufacturing efficiency and material utilization deteriorate
Solution Approach 1:
The housing is segmented into modular components including a front portion, back plate, and interchangeable face plates. Each face plate can be independently manufactured and attached to the base housing structure, allowing different appearances to be produced by simply swapping face plates rather than manufacturing entirely different housings for each configuration.
Solution Approach 2:
The base housing structure serves multiple functions: it provides mechanical support, houses electronic components, and accommodates various sensor configurations. By making the housing structure universal and interchangeable with different face plates, a single base design supports multiple device configurations and appearances, eliminating the need for disparate housings.
3Volume of moving object
If sensors are positioned within the housing, then the device profile is reduced, but sensor accessibility and detection accuracy may worsen
Solution Approach 1:
The housing provides different local qualities through its various recesses: some recesses are open to allow sensor exposure to the environment for accurate detection, while other recesses provide protected mounting spaces for electronic components. The face plates themselves are designed with local transparency or opening characteristics that allow specific sensors to detect environmental conditions while maintaining an overall compact profile.
Data Source
AI summary
A sensor device including a housing and a number of sensors. The housing includes a back plate including a mounting surface, a middle plate attached to the back plate, and a face plate attached to the middle plate, wherein the face plate is formed from a clear material and has a back surface and a front surface with the back surface positioned toward the middle plate and wherein a design is applied to the back surface of the face plate and is visible through the front surface of the face plate. The housing defines an interior housing volume and the number of sensors is positioned within the interior housing volume.