Composite Sensor Mounting Bracket for Water Heater Tanks
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional water heaters lack an efficient and reliable mounting system for temperature sensors, gas valves, power delivery units, and controllers, which can lead to suboptimal performance and increased risk of water-related degradation.
Innovation Solution
A polymeric mounting bracket with a sensor portion and a shell, where the sensor portion extends into the water tank and is secured to the water heater using a threaded spud, and the shell is made from a different material to protect against water degradation, with optional features like crimping or adhesive attachment for securement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a single-material mounting bracket is used to maintain thermal communication with water, then thermal efficiency is improved, but water-related degradation increases
Solution Approach 1:
The mounting bracket is constructed from multiple materials: a polymeric body (resistant to water degradation) and a metal shell (stainless steel or brass for thermal conductivity). This composite structure allows the bracket to maintain thermal communication with the water through the metal shell while the polymeric body provides resistance to water-related degradation. The metal shell is mechanically deformed (crimped) to engage a mating feature on the sensor portion, securing the assembly.
Solution Approach 2:
Different portions of the mounting bracket have different material properties tailored to their specific functions. The sensor portion extending into the water tank is made of polymeric material for water resistance, while the shell surrounding it is made of metal for thermal conductivity. This local differentiation of material quality allows each part to optimize its performance for its specific role in the assembly.
2Reliability
If a polymeric mounting bracket is used to reduce water degradation, then reliability is improved, but thermal communication efficiency decreases
Solution Approach 1:
The mounting bracket combines polymeric material for the main body with a metal shell for thermal conduction. The polymeric material (e.g., nylon) provides resistance to water degradation and corrosion, while the metal shell (stainless steel or brass) compensates for the lower thermal conductivity of the polymer, ensuring adequate thermal communication between the temperature sensor and the water.
3Adaptability or versatility
If multiple separate components are used for mounting, then adaptability is improved, but device complexity increases
Solution Approach 1:
The mounting bracket integrates multiple functions into a single unified component: the polymeric body houses the temperature sensor, the threaded spud provides secure attachment to the water heater, and the metal shell provides both structural support and thermal conduction. This merging of functions reduces the number of separate parts while maintaining adaptability for mounting temperature sensors, gas valves, power delivery units, and controllers.
Solution Approach 2:
The mounting bracket is designed as a universal component that can accommodate and mount multiple different devices (temperature sensor, gas valve, power delivery unit, controller) through its component retaining region. The standardized threaded spud and sensor portion design allow it to be adapted to various water heater configurations and device types, providing versatility without requiring multiple specialized mounting components.
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 provides a secure, thermally efficient, and cost-effective mounting system that reduces water-related degradation while maintaining thermal communication with the water, ensuring reliable operation of temperature sensors and controllers.
Implementation Method 1
The polymeric body may also include a first threaded portion that is configured to threadably engage a threaded spud of the water heater such that when the threaded portion threadably engages the threaded spud of the water heater, the sensor portion extends into the water tank of the water heater.
Implementation Method 2
the shell may be mechanically deformed (e.g. crimped) to engage a mating feature on the sensor portion to help secure the shell to the sensor portion
Implementation Method 3
The temperature sensor often protrudes into and is thermally coupled to the water in the water heater tank
Data Source
AI summary
A mounting bracket for mounting a temperature sensor, a gas valve, a power delivery unit, a controller and/or any other suitable object or device to a water heater tank. An illustrative but non-limiting example may be found in a mounting bracket that includes a polymeric body that has a sensor portion configured to receive a temperature sensor. The sensor portion may have a distal end that extends into and supports the temperature sensor within the water heater tank, and may include a shell disposed over at least a portion of the sensor portion.