Modular Ionizer Enclosure for Circuit Isolation and Custom Assembly

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Solution Overview

Problem

Customized enclosures for air ionizers increase manufacturing costs and time due to the need for specific designs for each location and task.

Innovation Solution

A modular case for air ionizers featuring a top compartment for a low voltage circuit board, a removable compartment with high dielectric material for a high voltage circuit board, and a front compartment for receiving the removable compartment, allowing for customizable configurations without the need for extensive redesign.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If customized enclosures are designed for each specific task and location, then the air ionizer can be optimized for specific applications, but the manufacturing cost and time increase

Engineering Contradiction:

Improvecustomization for specific tasks and locationsVSAvoidmanufacturing cost and time

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The enclosure is divided into multiple standardized modules (top compartment, front compartment, removable compartment) that can be assembled in different configurations. Each module has standardized dimensions and interfaces, allowing customization through combination rather than custom design, thus reducing manufacturing complexity while maintaining adaptability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The modular components are designed with universal interfaces and standardized dimensions that allow the same modules to be used across different air ionizer configurations and applications. This enables a single set of standardized modules to serve multiple purposes and locations, eliminating the need for entirely custom enclosures for each application.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If customized enclosures are designed for each specific task and location, then the air ionizer can be optimized for specific applications, but the manufacturing time increases

Engineering Contradiction:

Improvecustomization for specific tasks and locationsVSAvoidmanufacturing time

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The modular components are pre-designed with standardized interfaces, mounting features, and dimensions. This preliminary standardization allows for quick assembly without requiring custom fabrication for each application, significantly reducing manufacturing time while maintaining the ability to customize configurations.

Inventive Principle:

Principle #10Preliminary action

3Ease of manufacture

If a modular design is used, then manufacturing is simplified and costs are reduced, but the electrical isolation between circuit boards must be ensured

Engineering Contradiction:

Improvemanufacturing simplicity and costVSAvoidelectrical isolation between circuit boards

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

A removable compartment with high dielectric material serves as an intermediary barrier between the first circuit board (in the top compartment) and the second circuit board (in the removable compartment). This intermediate structure provides the necessary electrical isolation while maintaining the modular design benefits of ease of manufacture and assembly.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The high dielectric material is specifically applied in the removable compartment where electrical isolation is needed, rather than throughout the entire enclosure. This localized approach ensures reliable electrical isolation between circuit boards while maintaining manufacturing simplicity and cost-effectiveness for the rest of the structure.

Inventive Principle:

Principle #3Local quality

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 modular design simplifies manufacturing, reduces costs, and allows for easy customization of air ionizers, enabling them to be assembled and deployed with minimal variations.

Implementation Method 1

a removable compartment configured to house the high voltage circuit board, the removable compartment physically and electrically isolating the high voltage circuit board from the low voltage circuit board

Methodology Applied

Scientific EffectDielectric: Dielectric

Data Source

PatentUS20250196162A1Modularized ionizer envelope

Publication Date: 2025.06.19 BE AEROSPACE INC

AI summary

A modular case for an air ionizer is disclosed herein. The modular case includes a top compartment having a first opening, the top compartment configured to house a first circuit board, a removable compartment configured to house a second circuit board, the removable compartment physically and electrically isolating the second circuit board from the first circuit board, a front compartment having a second opening, the front compartment coupled to and disposed below the top compartment, the front compartment configured to receive and house the removable compartment, a top lid configured to cover the first opening, and a front lid configured to cover the second opening.