Vertically Oriented PCB With Projections for Smoke Detector Assembly
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Solution Overview
Problem
The assembly of traditional smoke detectors is labor-intensive and difficult to automate, particularly due to the complex placement of optical and temperature sensors within the detector housing.
Innovation Solution
A vertically oriented printed circuit board (PCB) with a planar shape and protrusions for temperature sensors, allowing for automated mounting of sensors and a compact smoke detection design with integrated light emitters and receivers, enabling efficient manufacturing and reduced manual labor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If traditional sensor placement methods are used, then sensors can be placed in the detector housing, but the assembly process becomes labor-intensive and difficult to automate
Solution Approach 1:
The patent combines multiple sensor mounting functions into a single integrated PCB structure. The PCB includes integrated mounting features for both optical sensors and temperature sensors, eliminating the need for separate mounting operations and enabling automated assembly processes.
Solution Approach 2:
The patent transitions from traditional planar PCB mounting to a three-dimensional structure with vertical projections extending from the PCB surface. This dimensional change allows sensors to be positioned in space while maintaining automated assembly compatibility through standardized mounting features.
2Manufacturing precision
If optical components are placed in a preform-jig for predetermined angles, then accurate optical alignment is achieved, but the assembly process becomes labor-intensive
Solution Approach 1:
The patent incorporates pre-formed mounting features and alignment structures directly into the PCB during manufacturing. Optical components are positioned using these pre-integrated features, eliminating the need for separate preform-jig alignment operations and enabling direct automated assembly.
Solution Approach 2:
The patent replaces the mechanical preform-jig alignment system with integrated PCB mounting structures that provide predetermined angular positioning. This substitution eliminates complex mechanical alignment tools while maintaining precise optical component positioning.
3Adaptability or versatility
If a vertically oriented PCB is used, then automated mounting and compact design are enabled, but the PCB structure becomes more complex
Solution Approach 1:
The patent divides the PCB into functional segments with distinct mounting projections for different sensor types. This segmentation allows each section to be optimized for its specific function while maintaining overall structural integration, making the complexity manageable and modular.
4Reliability
If temperature sensors are mounted on PCB projections, then access for air flow and temperature sensing is improved, but the PCB design becomes more complex
Solution Approach 1:
The patent provides localized three-dimensional projections at specific PCB locations where temperature sensors need enhanced air flow access. These projections are strategically positioned only where needed for sensing accuracy, while the rest of the PCB maintains a simpler structure.
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 enables efficient and automated assembly of smoke detectors with improved access for air flow and temperature sensing, reducing manufacturing complexity and increasing design versatility while maintaining accurate temperature and smoke detection capabilities.
Implementation Method 1
Detecting smoke fires may be performed using a light emitter and a light receiver disposed at an angle relative to each other. The detector may sense light scattered by smoke.
Implementation Method 2
For heat sensing, a leaded thermistor may be soldered to the PCB. The leads may allow a sensing element to be placed in the airstream.
Data Source
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AI summary
Disclosed is a smoke detector comprising: a housing including a base, the base including a planar surface configured for being positioned against and attached to a ceiling, a printed circuit board (PCB) comprising a substantially planar shape with a front surface and an opposing back surface spaced in a thickness direction T, and a plurality of perimeter edges including a bottom edge and an opposing top edge spaced in a height- wise direction H, a first side edge and an opposing second side edge spaced in a transverse direction, wherein the top edge comprises a first projection extending in the height-wise direction away from the top edge, the first projection including a first temperature sensor height- wise spaced from the top edge, and the PCB is mounted to the housing so that the front surface of the PCB is perpendicular to the planar surface of the base.