AEROSOL SENSOR COMPONENT

An integrated optical component coupled to a circuit board of an aerosol sensor is provided. The integrated optical component comprising a medium including a first, second plane, third plane, wherein the first plane is adjacent to a detection area, the second plane is positioned about a photosensor, and the third plane is opposite an angle formed by an intersection of the first and second plane. The integrated optical component further comprising a first lens configured on the first sidewall, the first lens configured to receive incident light from the detection area and focus the incident light onto a reflector through the medium, the reflector configured on the third sidewall, the reflector configured to reflect the incident light towards a second lens, and the second lens configured on the second sidewall, the second lens configured to receive the incident light from the reflector and focus the incident light to the photosensor.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority pursuant to 35 U.S.C. 119(a) to Chinese Application No. 202211052596.0, filed Aug. 30, 2022, which application is incorporated herein by reference in its entirety.

FIELD OF THE INVENTION

Example embodiments of the present disclosure relate generally to aerosol sensors, and in particular, an integrated optical component comprising a reflector and lens housing.

BACKGROUND

Thermal runaway is one of the primary risks related to using batteries in electrical vehicles. Thermal runaway may occur when an internal short circuit is created in a battery that is caused by physical damage, overheating, overcharging, or poor maintenance. The short circuit may cause a chain reaction within one or more cells in the battery which causes excessive heat and release of toxic gases. An aerosol sensor may be used to detect potential thermal runaway by detecting aerosols (e.g., smoke, liquid droplets) generated from a battery. However, Applicant has identified technical challenges and difficulties with traditional aerosol sensors, making them unsuitable for vehicle batteries.

BRIEF SUMMARY

Various embodiments described herein relate to components, apparatuses, and systems for detecting aerosols.

In accordance with various embodiments of the present disclosure, an integrated optical component coupled to a circuit board of an aerosol sensor is provided. In some embodiments, the integrated optical component comprises a medium including a first plane, a second plane, and a third plane, wherein the first plane is adjacent to a detection area, the second plane is positioned about a photosensor, and the third plane is opposite an angle formed by an intersection of the first plane and the second plane. The integrated optical component may further comprise a first lens configured on the first plane, the first lens configured to receive incident light from the detection area and focus the incident light onto a reflector through the medium, the reflector configured on the third plane, the reflector configured to reflect the incident light towards a second lens, and the second lens configured on the second plane, the second lens configured to receive the incident light from the reflector and focus the incident light to the photosensor.

In some embodiments, the first lens and the second lens may each comprise light transmissive material including two opposing curved surfaces. In some embodiments, the reflector may comprise a mirror or reflective surface. In some embodiments, the angle may be greater than 90° and up to 135°. In some embodiments, the angle may be 90°. In some embodiments, the angle may be less than 90°.

According to another embodiment, an aerosol sensing system is provided. In some embodiments, the aerosol sensing system comprises a detection area comprising a sampling space, a light source configured to project light to the detection area, an integrated optical component configured to receive incident light from the detection area based at least in part on the light projected by the light source, and direct the incident light to a photosensor, the photosensor configured to receive the incident light from the integrated optical component, and convert the received incident light into an electric signal.

In some embodiments, the electric signal may be representative of characteristics of the incident light. In some embodiments, the electric signal may be usable by a processor of a computing device or a circuit to detect aerosols in the detection area based at least in part on the incident light. In some embodiments, the light source may comprise a semiconductor light emitter. In some embodiments, the semiconductor light emitter may comprise at least one of: a light emitting diode, or a semiconductor laser diode. In some embodiments, the photosensor may comprise an optical sensitive device. In some embodiments, the optical sensitive device may comprise at least one of: a photodiode, a photo integrated circuit diode, a photo transistor, a photomultiplier tube, or a phototriode. In some embodiments, the photosensor may be further configured to generate electric signals associated with a number of particles, particle size, and particle concentration. In some embodiments, the integrated optical component may comprise a reflector and at least a pair of lenses. In some embodiments, the integrated optical component may comprise a first lens facing the detection area, the first lens configured to receive the incident light from the detection area, and focus the incident light onto a reflector. In some embodiments, the integrated optical component may comprise a reflector, the reflector configured to reflect the focused incident light to a second lens. In some embodiments, the integrated optical component may comprise the second lens positioned about the photosensor, the second lens configured to receive the incident light from the reflector, and focus the incident light to the photosensor. In some embodiments, the integrated optical component may comprise a housing, and a plurality of apertures on given sidewalls of the housing.

According to another embodiment, an aerosol sensor is provided. In some embodiments, the aerosol sensor comprises a circuit board configured to generate aerosol detection signals based at least in part on electric signals generated a photosensor, an integrated optical component coupled to the circuit board via a holder, the integrated optical component comprising an input sidewall and an output sidewall, the holder comprising a fixture positioning the integrated optical component in a stationary position relative to a light source and a photosensor, the light source coupled to the circuit board and interfacing with the input sidewall of the integrated optical component, the light source configured to project light to at least a portion of the holder and cause incident light associated with the projected light to be received into the integrated optical component at the input sidewall, the photosensor coupled to the circuit board and interfacing with the output sidewall of the integrated optical component, the photosensor configured to receive the incident light from the integrated optical component via the output sidewall and convert the incident light into the electric signals.

The foregoing illustrative summary, as well as other exemplary objectives and/or advantages of the disclosure, and the manner in which the same are accomplished, are further explained in the following detailed description and its accompanying drawings.

DETAILED DESCRIPTION OF THE INVENTION

As used herein, terms such as “front,” “rear,” “top,” etc. are used for explanatory purposes in the examples provided below to describe the relative position of certain components or portions of components. Furthermore, as would be evident to one of ordinary skill in the art in light of the present disclosure, the terms “substantially” and “approximately” indicate that the referenced element or associated description is accurate to within applicable engineering tolerances.

An aerosol sensor may be useful in applications where detecting aerosols is desired. Such an application may be in a battery package of an electric vehicle where the presence of aerosols, such as smoke, liquid droplets, and other particles may indicate thermal runaway.

As described above, there are many technical challenges and difficulties associated with current aerosol sensors. Conventional aerosol sensors are not designed to withstand shock or vibrations and temperature variations that may be associated with moving vehicle applications. That is, convention aerosol sensors are prone to component misalignment or even damage in the presence of such stresses, which may affect and hinder detection accuracy. There is thus a need to overcome such challenges and difficulties in designing aerosol sensors and components that can be used for electric vehicle batteries.

Aerosol sensors may comprise devices including a light source and a photosensor. The light source may emit light into a detection area where light scattering in the presence of aerosols may be detected using the photosensor.

Referring now toFIG.1, an exemplary aerosol sensing system according to one embodiment is depicted. Aerosol sensing system100comprises light source102, integrated optical component104, and photosensor106. As depicted, light source102is operable to project light to a detection area118. Light source102may comprise a semiconductor light emitter such as a light emitting diode (LED), or a semiconductor laser diode. The light source102may be configured to emit light of a predetermined wavelength, including infrared, red, green, blue, and ultraviolet light.

Detection area118may comprise an aperture, channel, or opening for sampling air from a surrounding environment. The presence of aerosol particles in detection area118may scatter or deflect light projected by light source102. As such, the scattered light may indicate the presence of aerosols. Incident light110from detection area118may be received into a medium of integrated optical component104and directed to photosensor106. The medium may comprise a light transmissive material, such as glass, or plastic (e.g., PMMA, or polycarbonate). In some embodiments, the medium may comprise an air cavity. The incident light110may comprise at least a portion of light projected by light source102into detection area118including any scattering of light upon presence of aerosol particles108, and thus capturing aerosol presence.

A photosensor, as described herewith, may comprise an optical sensitive device, such as a photodiode, a photo integrated circuit diode, a phototransistor, a photomultiplier tube, or a phototriode. Photosensor106may be configured to receive incident light110from the integrated optical component104and convert the received incident light110into an electric signal. As such, the electric signal may be representative of characteristics of the incident light110. According to various embodiments of the present disclosure, the photosensor106may generate electric signals that can be used (e.g., by a processor of a computing device or a circuit) to detect aerosols in the detection area118based at least in part on scattering of incident light110. Particularly, electric signals from photosensor106may be used to detect the presence or absence of aerosols in an environment indicative of an abnormal condition (e.g., thermal runaway). Photosensor106may further generate electric signals associated with the number of particles, particle size, and particle concentration.

The integrated optical component104may be used to sample the incident light110from the detection area118and focus the sampled incident light110to the photosensor106. Integrated optical component104comprises lens112, lens114, a reflector116. A lens, as described herewith, may comprise a light transmissive material such as glass, or plastic (e.g., PMMA, or polycarbonate) including two opposing curved surfaces for concentrating or dispersing light rays. A lens may include a round or oval shape. Lens112is disposed on a plane of integrated optical component104facing the detection area118to receive the incident light110. Incident light110may be focused into the medium of integrated optical component104and onto reflector116via lens112.

A reflector, as described herewith, may comprise a mirror or reflective surface such that light incident on the reflector can be guided towards a given target, e.g., a photosensor106. Reflectors may include, for example, metal, or reflective film formed on a surface (e.g., plastic or glass). Examples of metals or reflective film include, aluminum, gold, silver, copper, specular film, or a dielectric multilayer film. Reflector116may comprise a mirror or reflective surface capable of reflecting, guiding, or redirecting incident light110focused by lens112towards lens114. Lens114is disposed on a plane of integrated optical component104facing photosensor106. Lens114may focus the incident light110reflected from reflector116towards photosensor106. As such, photosensor106can sample the incident light110from the detection area118for analysis.

FIG.2Apresents exemplary elements of an integrated optical component in accordance with some embodiments of the present disclosure. Integrated optical component104A comprises lens112A, lens114A, reflector116A, and medium202A. In some embodiments, medium202A may comprise a solid core of light transmissive material. Each of lens112A, lens114A, and reflector116A are configured on planes of medium202A. The planes may comprise a setting that configures lens112A, lens114A, and reflector116A into a triangular formation. Lens112A may comprise a lens that is configured on a plane that faces detection area118. Reflector116A is configured on a plane opposing angle α formed at an intersection of the planes of lens112A and lens114A.

An angle α between respective planes of lens112A and lens114A may be any suitable angle such that lens112A is capable of receiving incident light110from detection area118and focusing the incident light110through medium202A and onto reflector116A such that the incident light110may be received by lens114A. As depicted inFIG.2A, an angle α between lens112A and lens114A is obtuse (e.g., greater than 90°, up to 135°). However, according to other embodiments of the present disclosure, angle α may be a right angle (i.e., 90°), as illustrated inFIG.2B, or an acute angle (i.e., less than 90°). The positioning of reflector116A and lens114A along their respective planes may vary depending on angle α. That is, angle α may affect a direction of incident light110focused by lens112A such that reflector116A and lens114A may need to be positioned accordingly to align with focusing of the incident light110by lens112A.

FIG.2Bpresents exemplary elements of an integrated optical component in accordance with some embodiments of the present disclosure. Integrated optical component104B comprises lens112B, lens114AB, reflector116B, and medium202B. In some embodiments, medium202B may comprise a solid core of light transmissive material. Each of lens112B, lens114B, and reflector116B are configured on planes of the medium202B. The planes may comprise a setting that configures lens112B, lens114B, and reflector116B into a triangular formation. Lens112B may comprise a lens that is configured on a plane that faces detection area118. Reflector116B is configured on a plane opposing angle α formed at an intersection of the planes of lens112B and114B.

An angle α between respective planes of lens112B and lens114B is 90°. Lens112B is capable of receiving incident light110from detection area118and focusing the incident light110through medium202B and onto reflector116B such that the incident light110may be received by lens114B. It is noted that the positioning of reflector116B in integrated optical component104B may differ from the positioning of reflector116A in integrated optical component104A relative to the lenses. That is, angle α may affect a direction of incident light110focused by lens112A and112B. Similarly, the positioning of lens114B may differ from the positioning of lens114A due to a difference in angle α between integrated optical component104B and integrated optical component104A.

FIG.3andFIG.4present views of an exemplary integrated optical component in accordance with various embodiments of the present disclosure. The integrated optical component300comprises a housing302that may be constructed from, for example, glass, plastics, resins, or other synthetic polymers, such as acrylic or polymethyl methacrylate (PMMA). The integrated optical component300further comprises lens304, lens306, and reflector308, each configured on a given sidewall of the housing302such that the planes of lens304, lens306, and reflector308form a triangular shape. Lens304and lens306may be affixed within an aperture or opening on their respective sidewalls of housing302. Reflector308may be configured within an aperture or opening on the sidewall opposed to an angle formed at an intersection of a sidewall configured with lens304and a sidewall configured with lens306. According to various embodiments of the present disclosure, the housing302may comprise a solid body of light transmissive material such that light may be transmitted between lens304, lens306, and reflector308through housing302.

In some embodiments, an integrated optical component may comprise a plurality of apertures on given sidewalls of the integrated optical component's housing. As depicted inFIG.5, an integrated optical component500comprises a housing502. Housing502includes apertures504on sidewall508and apertures506on sidewall510. The planes of sidewall508and sidewall510may form an angle opposed to reflector sidewall512. Reflector sidewall512may comprise a sideway including a reflector for reflecting incident light, e.g., from apertures504to apertures506. In some embodiments, one or more of apertures504and one or more of apertures506may be configured with a lens. Lenses may be placed in any one of or in a specific one of apertures504and apertures506. For example, apertures504and apertures506may be used to provide specific lens configurations to achieve given incident light input and output properties with respect to the integrated optical component500. That is, lenses, as used with integrated optical component500, may control light refraction or diffraction in concert with a reflector. In certain embodiments, integrated optical component500may be used without any lens placed in one or more, or any of apertures504and apertures506. As such, lenses may be added or removed from apertures504and apertures506due to different applications.

FIG.6presents an exploded view of an exemplary aerosol sensor according to one embodiment of the present disclosure. Aerosol sensor600comprises housing602A, housing602B, integrated optical component604, holder606A, holder606B, circuit board608, light source610, photosensor612, and shield614. Housing602A and housing602B may comprise two halves of a clam-shell structure that encapsulates and is capable of serving as a protective cover of integrated optical component604, holder606A, holder606B, circuit board608, light source610, photosensor612, and shield614. Light source610and photosensor612are configured on circuit board608. Shield614may provide a protective covering to prevent damage to light source610, photosensor612, and at least a portion of circuit board608.

Circuit board608may control operation and functionality of light source610and photosensor612to provide aerosol detection. Integrated optical component604is coupled to circuit board608via holder606A and606B. In particular, integrated optical component604is held between holder606A and606B in a position suitable for receiving incident light from light source610and transmitting the incident light to photosensor612. In some embodiments, holder606A and holder606B may comprise a fixture for firmly positioning integrated optical component604in a stationary position relative to light source610and photosensor612.

Light source610is operable to project light to at least a portion of holder606(comprised of holder606A and holder606B) serving as a detection area. The light source610may comprise a semiconductor light emitter such as a light emitting diode (LED), or a semiconductor laser diode configured to emit light of a predetermined wavelength, including infrared, red, green, blue, and ultraviolet light.

FIG.7presents a cross-sectional view of a portion of an exemplary aerosol sensor according to one embodiment of the present disclosure. Integrated optical component604comprises a lens702at an input sidewall, an internal reflector704, and a lens706at an output sidewall. The input sidewall of the integrated optical component604may interface with the detection area to receive light. The lens702at the input sidewall may be capable of focusing at least a portion of the light in the detection area into a medium of the integrated optical component604. In particular, the lens702may focus light from the detection area onto the internal reflector704. The internal reflector704may direct the focused light from the lens702to lens706at the output sidewall of integrated optical component604. As described above, the medium may comprise light transmissive material, such as glass, or plastic (e.g., PMMA, or polycarbonate), or alternatively, in some embodiments, an air cavity.

The output sidewall may comprise a sidewall of the integrated optical component604configured to allow light to pass out of the integrated optical component604. The photosensor612may be aligned with an output sidewall of the integrated optical component604. Photosensor612may comprise an optical sensitive device configured to receive light from the integrated optical component604. Light received from the integrated optical component604may be converted by the photosensor612into an electric signal. For example, the photosensor612may generate electric signals that can be transmitted to a processor on circuit board608to detect aerosols in the detection area. Particularly, electric signals from photosensor612may correspond to the presence (or absence) of light scattering which is indicative of aerosols in an environment. Photosensor612may further generate electric signals associated with the number of particles, particle size, and particle concentration.

Device connector616may comprise a connection interface configured to transfer data or signals from circuit board608to a computer or processing device. For example, the device connector616may be used to establish a signal connection with circuit board608to communicate aerosol detection signals to, for example, a system controller or system management device. The aerosol detection signals may be based at least in part on electric signals generated by photosensor612. In some embodiments, the system controller or system management device may comprise a battery management system. As an example, the battery management system may be configured to monitor a battery, provide protection to the battery, optimize performance of the battery, and report operational status of the battery to external devices based at least in part on aerosol detection signals from the circuit board608.