Multi-layer PCB Air Quality Sensor for Compact Design
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Solution Overview
Problem
Existing air-quality detection apparatuses are not portable and lack a compact design, which hinders their ability to accurately detect indoor and outdoor air quality due to the inefficient arrangement of sensors, affecting detection accuracy and volume minimization.
Innovation Solution
The air-quality detection apparatus features a multi-layered structure with PCBs accommodating various sensors, including a CO2 sensor, VOC sensor, and dust sensor, optimized for compactness and arranged to minimize light interference between optical sensors, with a wireless communication interface for network transmission, allowing for convenient assembly and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If various types of sensors are mounted on a substrate in a conventional air-quality detection apparatus, then the apparatus can detect overall air quality, but the volume of the apparatus increases and portability is reduced
Solution Approach 1:
The patent implements a multi-layered PCB structure where sensor modules are stacked vertically on different layers of the same substrate. The CO2 sensor, VOC sensor, and dust sensor are arranged on separate layers, with each layer nested above the previous one. This vertical nesting approach consolidates multiple sensor functions into a compact three-dimensional arrangement, significantly reducing the horizontal footprint and overall volume of the apparatus while maintaining all detection capabilities.
Solution Approach 2:
The patent transitions from a conventional two-dimensional planar arrangement of sensors on a single substrate layer to a three-dimensional multi-layered configuration. By utilizing the vertical dimension (Z-axis) through multiple PCB layers, the design accommodates various sensor types without increasing the apparatus's horizontal footprint. This dimensional transition enables compact integration of CO2, VOC, and dust sensors while preserving their individual detection functions.
2Volume of moving object
If sensors are arranged compactly to minimize apparatus volume, then portability is improved, but light interference between optical sensors increases affecting detection accuracy
Solution Approach 1:
The patent segments the optical sensor arrangement by placing the CO2 sensor and dust sensor on different PCB layers with their light paths spatially separated. The CO2 sensor's optical path is confined to its specific layer region, while the dust sensor's optical path is routed through different spatial zones on another layer. This segmentation of optical paths prevents cross-interference between the two optical sensors despite their compact vertical arrangement, maintaining detection accuracy while achieving miniaturization.
Solution Approach 2:
The patent applies local quality optimization by designing layer-specific light shielding structures and optical path configurations tailored to each sensor's requirements. The PCB layers incorporate localized light-blocking features positioned precisely where needed to prevent stray light from reaching adjacent sensors. This localized approach to light management ensures that each optical sensor operates with high accuracy despite the compact multi-layered integration.
3Ease of manufacture
If a multi-layered structure with multiple PCBs is used to accommodate sensors, then assembly convenience is improved, but device complexity increases
Solution Approach 1:
The patent merges multiple sensor modules onto a unified multi-layered PCB architecture, where the CO2 sensor, VOC sensor, and dust sensor are integrated across different layers of the same substrate structure. This consolidation approach allows all sensor components to be assembled and connected simultaneously during a single manufacturing process, rather than requiring separate assembly steps for each sensor module. The unified structure simplifies production while maintaining the benefits of layered arrangement for light interference prevention.
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
This configuration results in a compact, portable, and accurate air-quality detection device that minimizes light interference between sensors, enhances assembly convenience, and enables real-time air quality monitoring via a communication network.
Implementation Method 1
a CO2 sensor, a VOC sensor, and a dust sensor, which are accommodated in a casing body (10)
Implementation Method 2
arranged to minimize light interference between optical sensors
Data Source
AI summary
Disclosed is an air-quality detection apparatus including a casing body including a bottom and a side wall, a first printed circuit board (PCB) disposed horizontally above the bottom, a second PCB disposed horizontally in a first region above the first PCB, a CO2 sensor mounted on the second PCB, a volatile organic compound (VOC) sensor mounted in a second region on the first PCB that is closer to the side wall than the first region, a third PCB, which is disposed horizontally at a position spaced further upwards apart from the bottom than the first PCB and at least a portion of which is disposed in a third region that does not overlap the first PCB when the bottom is viewed from above, a fourth PCB disposed horizontally above the second PCB and the third PCB, and a dust sensor mounted on the fourth PCB.