Passive Infrared Sensor Housing for Compact Multi-Sensor Integration
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Solution Overview
Problem
Sensor devices with smaller housings often have limited space, restricting the number and size of sensors and user interface elements, which can compromise functionality.
Innovation Solution
A sensor device design that includes a housing with integrated components such as a passive infrared (PIR) sensor, light pipe, metal mask, and airflow gasket, along with a button activation mechanism, tamper switch, and ambient light sensor, all within a compact structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the housing size is reduced, then the device becomes more compact and easier to install, but the number and size of sensors and user interface elements are limited
Solution Approach 1:
The patent implements nesting by placing the PIR sensor, light pipe, and metal mask within the button assembly housing, and by integrating the tamper switch mechanism into the same compact structure. The light pipe is positioned around the PIR sensor, and the metal mask is inserted into the lens assembly, creating a nested arrangement that maximizes component density within the reduced housing volume.
Solution Approach 2:
The button assembly serves multiple functions: it houses the PIR sensor for motion detection, contains the light pipe for optical coupling, includes the metal mask for infrared filtering, and integrates the tamper switch mechanism. This multi-functional design allows a single compact component to perform multiple sensing and actuation roles, maintaining functionality despite the reduced housing size.
2Volume of moving object
If multiple sensors and user interface elements are integrated into a compact housing, then space efficiency is improved, but the complexity of assembling and positioning components increases
Solution Approach 1:
The patent merges the PIR sensor, light pipe, metal mask, and tamper switch into a single integrated button assembly. This consolidation reduces the number of separate components that need to be assembled and positioned individually, thereby simplifying the assembly process despite the compact housing. The merged design allows for pre-assembly of the button unit before installation into the housing.
Solution Approach 2:
The device is segmented into distinct functional modules: the button assembly containing the PIR sensor and light pipe, the tamper switch mechanism, and the housing. This segmentation allows for modular assembly where the button assembly can be prepared separately and then installed into the housing, reducing the complexity of final assembly while maintaining compact integration.
3Measurement precision
If the light pipe is positioned around the PIR sensor and lens, then optical performance is improved, but the available space for other components is reduced
Solution Approach 1:
The light pipe is nested around the PIR sensor in a concentric arrangement, with the metal mask inserted into the lens assembly. This nested configuration allows the light pipe to be positioned optimally for optical coupling with the PIR sensor while minimizing the radial space required. The concentric design maximizes the use of available housing volume around the central sensor axis.
Solution Approach 2:
Instead of expanding the light pipe in a planar direction, the design utilizes the axial dimension by positioning the light pipe around the PIR sensor in a three-dimensional concentric arrangement. This dimensional approach allows the light pipe to be compact while maintaining optimal optical coupling, and the metal mask is positioned in the axial direction within the lens assembly, efficiently using available space in multiple dimensions simultaneously.
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
Enhances the functionality of sensor devices by allowing for a more efficient use of space, integrating multiple sensors and user interface elements while preventing false positives and ensuring secure attachment and operation.
Implementation Method 1
a passive infrared (PIR) sensor underneath the lens and the metal mask
Implementation Method 2
a light pipe around the PIR sensor, the lens, and the metal mask
Data Source
AI summary
Systems and techniques are provided for sensor device. A sensor device may include a housing, a lens inserted into a first opening of the housing, a metal mask covering a portion of the interior of the lens, a passive infrared (PIR) sensor underneath the lens and the metal mask, and a light pipe around the PIR sensor, the lens, and the metal mask. Part of the light pipe may be positioned above an activation mechanism for a button. An airflow gasket may be around the PIR sensor. A filter circuit board may be under the PIR sensor and connected to leads of the PIR sensor. A control circuit board may include the activation mechanism for the button. A backplate may include a slot for attachment to a snap of a magazine in the housing of the sensor device.