Plastic Lens Housing Solar Sensor
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Solution Overview
Problem
Existing solar sensors for detecting the direction and intensity of solar radiation are complex and costly due to the use of multiple inclined photo diodes, light guides, diffuser elements, and Lexan caps, requiring adjustments and calibrations.
Innovation Solution
A solar sensor with a plastic housing acting as a lens, embedding photosensors in a common plane outside the focal plane, allowing determination of solar radiation direction and intensity without additional components, and eliminating the need for calibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple individual photo diodes are inclined to detect solar radiation direction and intensity, then the detection capability is improved, but the manufacturing complexity and assembly difficulty increase
Solution Approach 1:
The patent combines multiple individual photo diodes into a single integrated photosensor array, where multiple sensor elements are embedded within one housing. This merging approach maintains the directional detection capability while significantly simplifying manufacturing and assembly, as the entire photosensor array is produced as a single component rather than assembling multiple separate inclined photo diodes.
Solution Approach 2:
The housing structure serves multiple functions simultaneously: it provides mechanical protection, acts as a mounting structure for the photosensors, and defines the optical geometry for directional detection. This multi-functionality reduces the need for separate components and simplifies the overall device structure.
2Measurement precision
If additional components such as light guides, diffuser elements and Lexan caps are used, then the detection accuracy is improved, but the manufacturing cost increases
Solution Approach 1:
The patent integrates the housing and photosensor mounting structure into a single component, eliminating the need for separate light guides, diffuser elements, and protective caps. This consolidation maintains detection accuracy through the embedded photosensor array geometry while significantly reducing the number of parts and assembly steps, thereby lowering manufacturing costs.
3Measurement precision
If photo diodes are inclined for directional detection, then the direction of incidence detection is improved, but the adjustment and calibration requirements increase
Solution Approach 1:
The photosensor array is pre-configured during manufacturing with precise spatial arrangement and embedding depth that automatically establishes the correct detection geometry. This preliminary configuration eliminates the need for field adjustment and calibration, as the directional detection capability is built into the structure itself rather than requiring post-assembly tuning.
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 solution simplifies manufacturing and assembly, reduces costs, and provides accurate detection of solar radiation direction and intensity without additional components, enhancing the efficiency and reliability of the solar sensor.
Implementation Method 1
the housing having a curved side facing the incident solar radiation and the housing optically acting as a lens
Implementation Method 2
at least two photosensors that are embedded in the plastic material of the housing, each photosensor having a sensor area sensitive to at least the part of the radiation
Data Source
AI summary
A solar sensor for the detection of the direction of incidence and the intensity of solar radiation comprises a housing (12) made of a plastic material that is permeable to at least some of the solar radiation, the housing (12) having a curved side (14) facing the incident solar radiation and the housing (12) optically acting as a lens and having an internal focal plane (26) defined by the lens characteristics thereof. At least two photosensors (16) are embedded in the plastic material of the housing (12), each photosensor (16) having a sensor area (18) sensitive to at least the part of the radiation to which the plastic material is permeable, and the sensor areas (18) of the photosensors (16) being arranged in a substantially common plane (19) located in front of or behind the focal plane (26), seen from side (14) facing the incident solar radiation. The direction of incidence of the solar radiation is determinable based on the intensities of the solar radiation received by the sensor areas (18) of the photosensors (16).