NZ714978A - Wireless gauge apparatus and manufacturing method thereof - Google Patents
Wireless gauge apparatus and manufacturing method thereofInfo
- Publication number
- NZ714978A NZ714978A NZ714978A NZ71497815A NZ714978A NZ 714978 A NZ714978 A NZ 714978A NZ 714978 A NZ714978 A NZ 714978A NZ 71497815 A NZ71497815 A NZ 71497815A NZ 714978 A NZ714978 A NZ 714978A
- Authority
- NZ
- New Zealand
- Prior art keywords
- antenna
- circuit board
- printed circuit
- protective layer
- gauge apparatus
- Prior art date
Links
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Abstract
The present invention relates to wireless gauge apparatus and manufacturing method thereof, and in particular the problem associated with wireless gauges that are located in harsh environments where they are subjected to shock, moisture, gasses and chemicals The wireless gauge apparatus of the present invention includes a casing is made of polyurethane having a density of 0.8-1.2 g/cm3 and an antenna that is surrounded by a protective layer disposed within the casing that is molded around and encases the antenna, the protective layer extends only around the antenna on the first side of the printed circuit board and on a corresponding portion of the second side of the second surface of the printed circuit board, the protective layer conforming to a shape of the antenna on the first side of the printed circuit board, the protective layer having a thickness of 4-8 mm, a density of at most 50 kg/m3 and a dielectric constant of 1-2.7. This lower density fill around the antenna considerably improves the performance of the antenna and thus improves the performance of the wireless gauge. nt invention includes a casing is made of polyurethane having a density of 0.8-1.2 g/cm3 and an antenna that is surrounded by a protective layer disposed within the casing that is molded around and encases the antenna, the protective layer extends only around the antenna on the first side of the printed circuit board and on a corresponding portion of the second side of the second surface of the printed circuit board, the protective layer conforming to a shape of the antenna on the first side of the printed circuit board, the protective layer having a thickness of 4-8 mm, a density of at most 50 kg/m3 and a dielectric constant of 1-2.7. This lower density fill around the antenna considerably improves the performance of the antenna and thus improves the performance of the wireless gauge.
Description
WIRELESS GAUGE APPARATUS AND MANUFACTURING METHOD THEREOF
TECHNICAL FIELD
The present disclosure relates generally to a wireless gauge apparatus and manufacturing
method thereof; and more specifically, to a wireless gauge apparatus having a robust
construction and improved wireless communication as well as a manufacturing method
thereof.
BACKGROUND
A wireless network consisting of spatially distributed wireless gauge apparatuses to monitor
and determine physical or environmental conditions around the wireless gauge apparatuses is
well known in the art. One such example includes use of a wireless gauge apparatus in
conjunction with a garbage container for determining a fill level or a fill rate of the waste
container. Generally, such gauges are subjected to harsh environment, for example,
temperature changes, physical shocks, moisture, gases and chemicals. For example, an
ambient temperature of a garbage container in areas like middle-east can vary from close to
100 C in daytime to 0 C during night. Further, waste or trash collected in such garbage
container can be organic material, which decomposes and produces gases, such as methane
and carbon dioxide. Also, waste can contain solvents, such as paint and other materials,
which can evaporate and cause corrosion. Moreover, a garbage container may be subjected to
a physical stress in terms of acceleration/shocks up to tens of G. Additionally, in some
instances the gauge may be subjected to fire emergency and in such instances it would be
desirable that the gauge should work for at least few minutes when exposed to direct fire or
should work for about half an hour when exposed to heat, about 50 C, being thus capable of
triggering an alarm and also fulfilling specific regulations.
In order to address the above issues, a gauge typically includes a plastic housing enclosing the
electronic elements thereof. For example, the gauge may be casted with a suitable plastic
material to substantially enclose the electronic elements and for shielding the gauge from
above mentioned harsh environment. Primarily, such gauges are required to operate
wirelessly and thus need to have a well-functioning radio unit, which generally operates on
cellular network standards. In such instance, an antenna of such gauge needs to work
effectively since the gauge is a battery powered device and is expected to have a long battery
powered life. However, the robustness requirement (i.e. the plastic housing) for such gauges
prevent utilization of an external antenna construction, i.e. the antenna is required to be
arranged inside the housing. The plastic housing enclosing the antenna dramatically
decreases effectiveness of the antenna. For example, such an antenna leads to increased
power need or consumption for a transmitter of the gauge while sending signals. Also, such
an antenna reduces sensitivity for a receiver of the gauge while receiving the signals and
consequently reduced operation time.
Therefore, in light of the foregoing discussion, there exists a need to overcome the
aforementioned drawbacks of a wireless gauge apparatus of having a robust construction and
improved wireless communication.
SUMMARY
The present disclosure seeks to provide a wireless gauge apparatus that at least partially
solves the above-mentioned problems.
The present disclosure also seeks to provide a method of manufacturing a wireless gauge
apparatus.
In one aspect, an embodiment of the present disclosure provides a wireless gauge apparatus
comprising:
- a printed circuit board comprising a wireless transceiver and at least one sensor, the printed
circuit board having a first side and a second side;
- a power source electrically coupled with the printed circuit board;
- an antenna electrically coupled with the wireless transceiver and mounted on the first side of
the printed circuit board; and
- a casing encasing the printed circuit board, the power source and the antenna, which casing
is made of polyurethane having a density of 0.8-1.2 g/cm ,
a protective layer disposed within the casing that is molded around and encases the antenna,
the protective layer extending only around the antenna on the first side of the printed circuit
board and on a corresponding portion of the second side of the second surface of the printed
circuit board, the protective layer conforming to a shape of the antenna on the first side of the
printed circuit board, the protective layer having a thickness of 4-8 mm, a density of at most
50 kg/m and a dielectric constant of 1-2.7.
In another aspect, an embodiment of the present disclosure provides a method of
manufacturing a wireless gauge apparatus. The method comprises steps of:
- arranging the protective layer around the antenna;
- arranging the printed circuit board, the power source and the antenna on a support structure
in a mould;
- filling the mould with polyurethane resin;
- allowing the polyurethane resin to harden;
- removing the mould;
- removing the support structure; and
- filling a space left by the support structure with polyurethane resin.
Embodiments of the present disclosure substantially eliminate or at least partially address the
aforementioned problems in the prior art, and provides a wireless gauge apparatus having a
robust construction and improved wireless communication.
Additional aspects, advantages, features and objects of the present disclosure would be made
apparent from the drawings and the detailed description of the illustrative embodiments
construed in conjunction with the appended claims that follow.
It will be appreciated that features of the present disclosure are susceptible to being combined
in various combinations without departing from the scope of the present disclosure as defined
by the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The summary above, as well as the following detailed description of illustrative embodiments,
is better understood when read in conjunction with the appended drawings. For the purpose
of illustrating the present disclosure, exemplary constructions of the disclosure are shown in
the drawings. However, the present disclosure is not limited to specific methods and
instrumentalities disclosed herein. Moreover, those in the art will understand that the
drawings are not to scale. Wherever possible, like elements have been indicated by identical
numbers.
Embodiments of the present disclosure will now be described, by way of example only, with
reference to the following diagrams wherein:
is a perspective view of a wireless gauge apparatus, in accordance with an embodiment
of the present disclosure;
is a sectional view of the wireless gauge apparatus of along a sectional line A-
is a top view of the wireless gauge apparatus of
FIGS. 4A and 4B are top and side views, respectively, of a protective layer adapted to
surround an antenna of the wireless gauge apparatus of
is an illustration of steps of a method for manufacturing a wireless gauge apparatus, in
accordance with an embodiment of the present disclosure; and
is a perspective view of a wireless gauge apparatus, in accordance with another
embodiment of the present disclosure.
In the accompanying drawings, an underlined number is employed to represent an item over
which the underlined number is positioned or an item to which the underlined number is
adjacent. A non-underlined number relates to an item identified by a line linking the non-
underlined number to the item. When a number is non-underlined and accompanied by an
associated arrow, the non-underlined number is used to identify a general item at which the
arrow is pointing.
DETAILED DESCRIPTION OF EMBODIMENTS
The following detailed description illustrates embodiments of the present disclosure and ways
in which they can be implemented. Although some modes of carrying out the present
disclosure have been disclosed, those skilled in the art would recognize that other
embodiments for carrying out or practicing the present disclosure are also possible.
In one aspect, an embodiment of the present disclosure provides a wireless gauge apparatus
comprising:
- a printed circuit board comprising a wireless transceiver and at least one sensor, the printed
circuit board having a first side and a second side;
- a power source electrically coupled with the printed circuit board;
- an antenna electrically coupled with the wireless transceiver and mounted on the first side of
the printed circuit board; and
- a casing encasing the printed circuit board, the power source and the antenna, which casing
is made of polyurethane having a density of 0.8-1.2 g/cm ,
a protective layer disposed within the casing that is molded around and encases the antenna,
the protective layer extending only around the antenna on the first side of the printed circuit
board and on a corresponding portion of the second side of the second surface of the printed
circuit board, the protective layer conforming to a shape of the antenna on the first side of the
printed circuit board, the protective layer having a thickness of 4-8 mm, a density of at most
50 kg/m and a dielectric constant of 1-2.7
In an embodiment, the printed circuit board (PCB) is made of standard FR4 material. "FR"
stands for “flame retardant”, and denotes that safety of flammability of FR4 is in compliance
with the flammability standard. The FR4 material is created from the constituent materials
(epoxy resin, woven glass fabric reinforcement, brominated flame retardant, etc).
Alternatively, the PCB may be made of other suitable material such as ceramic-filled
hydrocarbon with woven glass, and the like. The PCB is further configured have any suitable
shape such as a rectangular, a circular or a polygonal shape.
The PCB is electrically (operatively) mounted or connected with various electronic
components and the power source. According to an embodiment, the various electronic
components comprises the at least one sensors, the wireless transceiver, a microcontroller,
memory and like. It is to be understood that the various electronic components primarily
encompass all electronic components that are required for an operation of a wireless gauge,
such as the wireless gauge apparatus of the present disclosure.
According to an embodiment, the various electronic components (the at least one sensors, the
wireless transceiver, the microcontroller and the like) are electrically mounted or connected to
the PCB, for example, with the help of reflow soldering technique.
According to an embodiment, the at least one sensor is a fill level sensor or a fill rate sensor
operable to determine a fill level or a fill rate of the garbage container. For example, the
sensor can be selected from the group consisting of an ultrasonic sensor, an infrared sensor, a
pressure sensor, a weight sensor, an ultra wideband radar sensor, a CCD camera sensor and a
laser sensor. According to another embodiment, the wireless gauge apparatus of the present
disclosure also comprises other sensors selected from the group consisting of an
accelerometer, a humidity sensor, a gas sensor, an ambient light sensor, a temperature sensor
and the like.
The wireless transceiver of the present disclosure includes a transmitter and a receiver to send
and receive wireless signals. In an embodiment the wireless transceiver includes a cellular
transceiver operable on cellular standards. Also, the wireless transceiver can include a
modem to receive and transmit the wireless signals.
According to an embodiment, the microcontroller of the present disclosure is embedded with
memory for a program data and data storage. The program data includes instructions defining
a pattern of working of the wireless gauge apparatus. For example, the program data includes
instructions for defining a pattern for sensors functioning, such as monitoring a fill level or
fill rate of a garbage container, and transmitting the sensed data based on some predefined
criteria.
According to an embodiment, the power source is an industrial grade Li-Ion battery. The
power source may naturally be any other kind of suitable power source, such as Lithium-
thionyl-chloride battery. The power source provides required electrical power to the various
electronic components and to the antenna for operation of the wireless gauge apparatus.
The antenna of the present disclosure is electrically coupled to the wireless transceiver.
According to an embodiment, the antenna of the present disclosure is a trace antenna. The
trace antenna may be disposed on the surface of the printed circuit board and the protective
layer extends only over the first surface of the printed circuit board corresponding to an area
on which the trace antenna is disposed on the printed circuit board. According to an
embodiment, the antenna (be it a trace antenna or another type of antenna) is mounted flush
with the first side of the printed circuit board. Specifically, the antenna is defined on a portion
of the PCB. For example, the antenna includes the portion of the PCB as a substrate on which
a metallic trace is printed (defining an antenna topology). Alternatively, the antenna can be a
separate PCB (for example made of FR-4 material) and operatively and structurally coupled
to the main PCB of the wireless gauge apparatus. Further, the antenna is configured to be
operable on standard cellular networks, such as Global System for Mobile communication
(GSM), Code Division Multiple Access (CDMA), General packet radio service (GPRS), local
area wireless networks (WiFi, WLAN etc.), Bluetooth or similar.
According to an embodiment, the antenna may be configured to have a shape of substantially
flat dome structure. In an example, the antenna may be configured to have the following
dimensions, i.e. a length of about 65 mm, a height of about 28 mm and a thickness of about 1
mm to 1.6 mm.
As mentioned above, the antenna of the present disclosure is surrounded with the protective
layer having the thickness of about 4-8 mm. The thickness can for example be of about 5-7
mm or about 4-6 mm or about 6-8 mm. Further, it is to be understood that the protective layer
should be configured to have a shape that conforms to the shape of the antenna. For example,
the protective layer is also configured to have the shape of substantially flat structure, with the
following dimensions, i.e. a length of about 65 mm, a height of about 28 mm and a thickness
of about 6 mm (shown in -4B). The protective layer can be a single layer
surrounding the entire antenna or can be a pair of protective layers coupled to both sides of
the antenna. Moreover, the protective layer may be attached to each side of the PCB using a
suitable adhesive or glue. According to an embodiment, the antenna is thus a trace antenna
arranged on the printed circuit board and the protective layer is arranged on both sides of the
printed circuit board.
According to an embodiment, the protective layer is made of a closed cell plastic material.
The closed cell plastic material is preferably a lightweight rigid plastic material which is
immune to rain and sunlight. In an example, the closed cell plastic material is selected from
the group consisting of polyethylene, polypropylene, polyurethane and polystyrene.
The protective layer, as mentioned above, has a density of at most 50 kg/m . Specifically, the
protective layer has a density, i.e. ratio of mass to volume of the closed cell plastic material,
of at most 50 kg/m . The value 50 kg/m indicates that a cube made of the closed cell plastic
material has a volume of 1 m and at most a mass of 50 kg. Therefore, the protective layer
(having dimensions such as the length of about 65 mm, the height of about 28 mm and the
thickness of about 4-8 mm) can be a portion or cutout from such cube (made of closed cell
plastic material and having 1 m volume and at most mass of 50 kg). The density of the
protective layer is preferably at least 10 kg/m .
Further, as mentioned above, the protective layer has a dielectric constant of 1-2.7. The
dielectric constant, also called relative permittivity is the ratio of the permittivity of a
substance to the permittivity of free space. It is an expression of the extent to which a
material concentrates electric flux, and is the electrical equivalent of relative magnetic
permeability. In an example, the dielectric constant of the protective layer is between 1 and
2.4. In another example, the dielectric constant of the casing is 4-7.
According to an embodiment, the protective layer of the present disclosure may be
constructed in a different manner while having the properties disclosed above. In an example,
the protective layer is made of a plastic material consisting of two sheets with gas entrapped
in between the sheets. Alternatively, the protective layer is constructed to be a rigid
protective casing filled with gas.
According to an embodiment of the present disclosure, the casing is configured to have
substantially hemispherical frustum shape (best shown in FIGS. 1-2). In an example, the
casing can be a solid casing which provides robustness to the wireless gauge apparatus. For
example, a size of the casing is such that a distance from the printed circuit board, the power
source and the antenna to an outer surface of the casing is at least 10 mm. When an ultrasound
proximity sensor (also called ultrasound sensor in this description) is used, the sensor is
uncovered by the casing.
Thus, according to an embodiment, the at least one sensor is uncovered by the casing.
Specifically, the casing includes an opening extending along a height (i.e. from a top portion
towards a bottom portion thereof) and the opening end at the at least once sensor, such that
the at least one sensor is visible and accessible through the opening.
As mentioned above, the casing of the present disclosure is made of polyurethane having a
density of 0.8-1.2 g/cm (i.e. 800-1200 kg/m ).
In another aspect, an embodiment of the present disclosure provides a method for
manufacturing the wireless gauge apparatus. The method comprises steps of:
- arranging the protective layer around the antenna;
- arranging the printed circuit board, the power source and the antenna on a support structure
in a mould;
- filling the mould with polyurethane;
- allowing the polyurethane resin to harden;
- removing the mould;
- removing the support structure; and
- filling a space left by the support structure with polyurethane resin.
In an example, the protective layer is glued around the antenna, i.e. the protective layer is
glued on the each (top or bottom) side of the antenna’s PCB portion.
According to an embodiment, the support structure can be inserts used for holding the PCB
along with the power source and the antenna within the mould. As mentioned above, the
casing can be configured to have substantially hemispherical frustum shape; therefore the
mould can be also configured to have a hemispherical frustum shape. In this case, the mould
would include a hemispherical frustum shape cavity along with a hollow structure (provided
to uncover the at least one sensor when this is required).
According to an embodiment, where an ultrasound sensor is used, when the PCB, the power
source and the antenna are arranged on the support structure, the at least one sensor present on
the PCB is positioned next to the hollow structure (having frustoconical shape) of the mould.
Specifically, the mould includes the hollow structure adapted to be placed next to the least
one sensor such that the opening can be formed on top of the least one sensor present, when
the casing is formed by filling the mould with the polyurethane resin.
According to an embodiment, the polyurethane resin is traditionally and most commonly
formed by reacting a diisocyanate or a polyisocyanate with a polyol. Both the isocyanates
and polyols used to make the polyurethane contain on average two or more functional groups
per molecule. Typically, manufacturing principle includes providing the liquid isocyanate
and resin blend at a specified stoichiometric ratio and mixing them together until a
homogeneous blend (polyurethane resin) is obtained.
In an example, the polyurethane resin is poured into the mould in a bottom-up manner with
the mould in an oblique position. Further, prior to pouring the polyurethane resin into the
mould certain measures are taken, such as, the hollow structure of the mould is arranged next
to the at least one sensor.
Thereafter, the polyurethane resin is allowed to harden in the mould for a certain time period
for forming a consistent and a robust casing around the PCB, the power source and the
antenna. Further, the mould is removed, i.e. the casing encasing the PCB, the power source
and the antenna is taken out of the mould. Moreover, the support structure is removed and a
space left by the support structure is again filled with the polyurethane resin. This results in a
solid robust casing around the PCB, the power source and the antenna, which is permanent in
nature and cannot be opened. This precludes tampering the wireless gauge apparatus of the
present disclosure.
The wireless gauge apparatus of the present disclosure also provides improved wireless
communication along with the robust construction thereof. For example, the antenna’s
construction and various properties (such as density and dielectric constant) of the materials
used in the manufacturing of the wireless gauge apparatus provides improved wireless
communication.
According to an embodiment, an improved wireless communication for the wireless gauge
apparatus is determined with respect to an efficiency of the antenna for performing wireless
communication.
Referring now to below Table 1, an efficiency of the antenna (having the protective layer) of
the wireless gauge apparatus of the present disclosure is shown to be compared with an
efficiency of a conventional antenna (without such protective layer). Further, as shown in
Table 1, the efficiency of the antenna is calculated when the antenna is operated on a standard
cellular network, such as GPRS850 MHz (frequency band), ch192. The Table 1 also shows
various other aspects of the antenna taken into consideration while calculating the efficiency
thereof. For example, Table 1 includes EUT ID, i.e. equipment under test ID (which can be
an ID of an antenna or an ID of wireless gauge apparatus having an antenna) and MAX level
(dBm) i.e. maximum power ratio referenced to one milliwatt. The Table1 also includes others
aspects such as, Turntable aspect of the antenna (such as Angle and Tilt) and Antenna
polarisation.
GPRS850, ch192 Turntable Antenna
EUT MAX level (dBm) Angle Tilt polarisation
924 16.17 138 0 HOR Conventional antenna without ETA-
foam
1203 18.30 140 0 HOR Conventional antenna without ETA-
foam
2361 24.06 129 90 VER Antenna with ETA-foam
2362 23.30 129 90 VER Antenna with ETA-foam
1694 20.42 166 0 HOR Conventional antenna with ETA-
foam
Table 1
As shown, an EUT 924 (a conventional antenna without the protective layer), in GPRS850
MHz frequency band, which is polarized horizontally and having a turntable angle 138 and a
tilt 0 is operable (send or receive wireless signals) to have a maximum power ratio of about
16.17 dBm. Similarly, an EUT 1203 (a conventional antenna without the protective layer), in
GPRS850 MHz frequency band, which is polarized horizontally and having a turntable angle
140 and a tilt 0 is operable to have a maximum power ratio of about 18.30 dBm. However,
an EUT 2361 (an antenna having the protective layer based on the present disclosure), in
GPRS850 MHz frequency band, which is polarized vertically and having a turntable angle
129 and a tilt 90 is operable to have a maximum power ratio of about 24.06 dBm. Similarly,
an EUT 2362 (an antenna having the protective layer), in GPRS850 MHz frequency band,
which is polarized vertically and having a turntable angle 129 and tilt 90 is operable to have
a maximum power ratio of about 23.30 dBm. The comparison of the maximum power ratios
of the EUTs 924 and 1203 with respect to the EUTs 2361 and 2362 clearly depicts the EUTs
2361 and 2362 have improved antenna efficiencies. For example, the maximum power ratios
are show to increase in a range of 5 to 8 dBm. Additionally, when an EUT 1694 (a
conventional antenna having the protective layer), in GPRS850 MHz frequency band, which
is polarized horizontally and having a turntable angle 166 and a tilt 0 is operable to have a
maximum power ratio of about 20.42 dBm, which is also better than the maximum power
ratio of the EUTs 924 and 1203 (conventional antennas).
Referring now to below Table 2, the efficiency of the antenna is calculated when the antenna
is operated on another standard cellular network, such as GSM 1900 MHz, ch663.
GSM1900, ch663 Turntable Antenna
EUT MAX level Angle Tilt polarisation
ID (dBm)
924 20.49 158 0 HOR Conventional antenna without
ETA-foam
1203 19.62 159 0 HOR Conventional antenna without
ETA-foam
2361 25.43 199 90 VER Antenna with ETA-foam
2362 24.97 258 90 VER Antenna with ETA-foam
1694 25.28 174 0 HOR Conventional antenna with ETA-
foam
Table 2
As shown, an EUT 924 (a conventional antenna without the protective layer), in GSM1900
MHz frequency band, which is polarized horizontally and having a turntable angle 158 and a
tilt 0 is operable to have a maximum power ratio of about 20.49 dBm. Similarly, an EUT
1203 (a conventional antenna without the protective layer), in GSM1900 MHz frequency
band, which is polarized horizontally and having a turntable angle 159 and a tilt 0 is
operable to have a maximum power ratio of about 19.62 dBm. However, an EUT 2361 (an
antenna having the protective layer based on present disclosure), in GSM1900 MHz
frequency band, which is polarized vertically and having a turntable angle 199 and a tilt 90
is operable to have a maximum power ratio of about 25.43 dBm. Similarly, an EUT 2362 (an
antenna having the protective layer), in GSM1900 frequency band, which is polarized
vertically and having a turntable angle 258 and a tilt 45 is operable to have a maximum
power ratio of about 24.97 dBm. The comparison of the maximum power ratios of the EUTs
924 and 1203 with respect to the EUTs 2361 and 2362 clearly depicts the EUTs 2361 and
2362 have improved antenna efficiencies. For example, the maximum power ratios are show
to increase in a range of 4 to 6 dBm. Additionally, an EUT 1694 (a conventional antenna
having the protective layer), in GSM1900 frequency band, which is polarized horizontally and
having a turntable angle 174 and a tilt 0 is operable to have a maximum power ratio of about
.28 dBm, which is also better than maximum power ratio of the EUTs 924 and 1203
(conventional antennas).
Based on above examples the efficiency of an antenna with protective layer improves with an
average value of about 3 dBm in 900 MHz frequency band and 6 dBm in 1900 MHz
frequency band. Therefore, such improvements, for example, the improvement of 3 dB
results in 50 % reduction in power requirement for transmitting signals, and 100 %
improvement in reception sensitivity for the wireless transceiver (electrically coupled to the
antenna).
The present disclosure provides a wireless gauge apparatus having a robust construction and
improved wireless communication. The wireless gauge apparatus can be suitably used in
harsh environment, such as temperature changes, physical shocks, moisture, gases and
chemicals. Further, the wireless gauge apparatus, particularly, the antenna’s construction and
various properties of material used in the manufacturing of the wireless gauge apparatus
provide improved wireless communication. Moreover, the wireless gauge apparatus of the
present disclosure can have increase battery powered life due to such improved wireless
communication. The application of such wireless gauge apparatus can be found in various
fields (apart from the garbage containers), such as to remotely monitor and determine physical
or environmental conditions (such as acceleration, humidity, gas, light, temperature and the
like).
DETAILED DESCRIPTION OF THE DRAWINGS
Referring to illustrated is a perspective view of a wireless gauge apparatus 100, in
accordance with an embodiment of the present disclosure. The wireless gauge apparatus 100
includes a casing 102 having a substantially hemispherical frustum shape. In this
embodiment, the casing 102 includes an opening 104 extending along a height (i.e. from a top
portion towards a bottom portion thereof), best shown in The casing 102 also
includes an outer surface 106.
Referring now to illustrated is a sectional view of the wireless gauge apparatus 100 of
along a sectional line A-A’. As shown, the casing 102 encases a printed circuit board
(PCB) 200, a power source 202 and an antenna 204. The PCB 200 is electrically
(operatively) mounted or connected with various electronic components, which include but
are not limited to at least one sensor 210 (primarily a fill rate sensor such as an ultrasonic
sensor), a microcontroller 212 and a wireless transceiver 214. The PCB 200 is also
operatively connected to the power source 200 and the antenna 204. The antenna 204 is
electrically coupled with the wireless transceiver 214. The antenna 204 is surrounded by a
protective layer 220.
The PCB 200, the power source 202 and the antenna 204 are supported by a support structure,
such as support struts 230, within the casing 102. Specifically, the support struts 230 are used
to support the PCB 200, the power source 202 and the antenna 204 within a mould during a
manufacturing (casting) of the casing 102, and once the casing 102 is prepared (casted) the
space left by the support struts 230 is filled with polyurethane resin for closing the space. The
casing 102 also includes attachment points 232, such as nut inserts, to provide simple
attachment into target structure.
Referring now to illustrated is a top view of the wireless gauge apparatus 100 of As shown, the at least one sensor 210 is uncovered by the casing 102, i.e. the at least one
sensor 210 is visible or accessible through the opening 104. also illustrates respective
components of the wireless gauge apparatus 100 as shown in the
Referring now to FIGS. 4A and 4B, illustrated are top and side views of the protective layer
220, respectively. As shown, the protective layer 220 is configured to have a shape of
substantially flat dome structure. Specifically, the protective layer 220 is configured to have a
shape such that the protective layer 220 appropriately conforms to or surrounds the antenna
204 (or antenna topology).
Referring now to illustrated are steps of a method 500 for manufacturing a wireless
gauge apparatus, in accordance with an embodiment of the present disclosure. Specifically,
the method 500 illustrates the steps of manufacturing the wireless gauge apparatus 100,
explained in conjunction with the FIGS. 1-3.
At step 502, the protective layer is arranged around the antenna.
At step 504, the printed circuit board, the power source and the antenna are arranged on a
support structure in a mould.
At step 506, the mould is filled with polyurethane resin.
At step 508, the polyurethane resin inside the mould is allowed to harden.
At step 510, the mould is removed. The removal of the mould forms a casing (hardened
polyurethane) encasing the printed circuit board, the power source and the antenna therein.
At step 512, the support structure is removed.
At step 514, a space left by the support structure is filled with polyurethane resin.
The steps 502 to 514 are only illustrative and other alternatives can also be provided where
one or more steps are added, one or more steps are removed, or one or more steps are
provided in a different sequence without departing from the scope of the claims herein. For
example, the method 500 may include gluing the protective layer around the antenna.
is a perspective view of a wireless gauge apparatus 600, in accordance with another
embodiment of the present disclosure. In this embodiment, the at least one sensor is selected
to be such that no opening of the casing is required, i.e. for example an ultra wideband radar
sensor is used.
Modifications to embodiments of the present disclosure described in the foregoing are
possible without departing from the scope of the present disclosure as defined by the
accompanying claims. Expressions such as “including”, “comprising”, “incorporating”,
“have”, “is” used to describe and claim the present disclosure are intended to be construed in
a non-exclusive manner, namely allowing for items, components or elements not explicitly
described also to be present. Reference to the singular is also to be construed to relate to the
plural.
Claims (13)
1. A wireless gauge apparatus comprising: - a printed circuit board comprising a wireless transceiver and at least one sensor, the printed circuit board having a first side and a second side; - a power source electrically coupled with the printed circuit board; - an antenna electrically coupled with the wireless transceiver and mounted on the first side of the printed circuit board; and - a casing encasing the printed circuit board, the power source and the antenna, which casing is made of polyurethane having a density of 0.8-1.2 g/cm , a protective layer disposed within the casing that is molded around and encases the antenna, the protective layer extending only around the antenna on the first side of the printed circuit board and on a corresponding portion of the second side of the second surface of the printed circuit board, the protective layer conforming to a shape of the antenna on the first side of the printed circuit board, the protective layer having a thickness of 4-8 mm, a density of at most 50 kg/m and a dielectric constant of 1-2.7.
2. A wireless gauge apparatus according to claim 1, wherein the protective layer is made of a closed cell plastic material.
3. A wireless gauge apparatus according to claim 2, wherein the closed cell plastic material is selected from the group consisting of polyethylene, polypropylene, polyurethane and polystyrene.
4. A wireless gauge apparatus according to claim 1, wherein the protective layer is made of a plastic material consisting of two sheets with gas entrapped in between the sheets.
5. A wireless gauge apparatus according to claim 1, wherein the protective layer is a rigid protective casing filled with gas.
6. A wireless gauge apparatus according to any of the preceding claims, wherein the density of the protective layer is 10-50 kg/m .
7. A wireless gauge apparatus according to any of the preceding claims, wherein the dielectric constant of the protective layer is between 1 and 2.4.
8. A wireless gauge apparatus according to any of the preceding claims, wherein the antenna is a trace antenna, the trace antenna being disposed on the surface of printed circuit board and wherein the protective layer extends only over the first surface of the printed circuit board corresponding to an area on which the trace antenna is disposed on the printed circuit board.
9. A wireless gauge apparatus according to any of the preceding claims, wherein the antenna is mounted flush with the first side of the printed circuit board.
10. A wireless gauge apparatus according to any of the preceding claims, wherein the casing comprises colour pigments.
11. A wireless gauge apparatus according to any of the preceding claims, wherein a size of the casing is such that the distance from the printed circuit board, the power source and the antenna to an outer surface of the casing is at least 10 mm.
12. A wireless gauge apparatus according to claim 11, wherein the at least one sensor is uncovered by the casing.
13. The wireless gauge apparatus of any one of claims 8-12, wherein the trace antenna is mounted flush on the first side of the printed circuit board. 230 232 ARRANGE PROTECTIVE LAYER AROUND ANTENNA ARRANGE PRINTED CIRCUIT BOARD, POWER SOURCE AND ANTENNA ON SUPPORT STRUCTURE IN MOULD FILL MOULD WITH POLYURETHANE ALLOW POLYURETHANE RESIN TO HARDEN REMOVE MOULD REMOVE SUPPORT STRUCTURE FILL SPACE LEFT BY SUPPORT STRUCTURE WITH POLYURETHANE FIG. 6
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US14567514 | 2014-12-11 |
Publications (1)
Publication Number | Publication Date |
---|---|
NZ714978A true NZ714978A (en) |
Family
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