Deicer Temperature Sensor Thermal Isolation

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Solution Overview

Problem

Conventional deicing systems are inefficient and unsafe due to inaccurate temperature sensing, leading to unnecessary energy consumption and potential overheating, as they lack precise control over temperature conditions and are prone to overheating when the heating element is exposed.

Innovation Solution

A deicer system with a main body, a heating element, a thermally isolated temperature sensor, and a control unit that communicates with the heating element to accurately detect water temperature and prevent overheating, using a movable tab to adjust the heat flow path for improved response time and efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If a conventional thermostat is used to control the heating element, then the deicer can maintain basic temperature control, but the temperature sensing is inaccurate leading to unnecessary energy consumption and potential overheating

Engineering Contradiction:

Improvetemperature sensing accuracyVSAvoidenergy consumption

Core Design Contradiction:

Measurement precisionVSLoss of energy

Solution Approach 1:

The patent introduces a thermal isolation barrier (intermediary) between the heating element and the thermostat. This barrier prevents direct thermal contact, allowing the thermostat to sense only the water temperature rather than being influenced by the heating element's temperature. This intermediary enables accurate temperature measurement, which in turn allows for precise control and reduced energy waste from unnecessary heating cycles.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces the conventional mechanical thermostat with an electronic temperature sensor and microprocessor control system. This substitution enables more precise temperature measurement and control, allowing the system to accurately detect water temperature and control the heating element accordingly, thereby reducing energy consumption by avoiding unnecessary heating cycles.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of operation

If the heating element is exposed to air instead of being submerged in water, then installation is easier, but overheating occurs because the heating element cannot dissipate heat efficiently

Engineering Contradiction:

Improveinstallation easeVSAvoidoverheating prevention

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent implements a feedback control system where the temperature sensor continuously monitors the water temperature and sends signals to the microprocessor. The microprocessor adjusts the heating element's operation based on this feedback, turning it on when the water is cold and turning it off when the water reaches the desired temperature. This feedback mechanism prevents overheating while maintaining ease of installation.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The deicer system is designed to automatically control its own operation through the temperature sensor and microprocessor. The system self-regulates the heating element's operation based on real-time temperature conditions, eliminating the need for manual intervention and ensuring reliable overheating prevention while maintaining simple installation.

Inventive Principle:

Principle #25Self-service

3Speed

If the thermostat is placed in direct contact with the heating element, then the response time is faster, but the temperature reading is inaccurate due to thermal influence from the heating element

Engineering Contradiction:

Improveresponse timeVSAvoidtemperature reading accuracy

Core Design Contradiction:

SpeedVSMeasurement precision

Solution Approach 1:

The patent introduces a thermal isolation barrier (intermediary) between the heating element and the thermostat. This barrier prevents direct thermal contact, allowing the thermostat to sense only the water temperature rather than being influenced by the heating element's temperature. This intermediary enables accurate temperature measurement while maintaining acceptable response time through thermal conduction through the barrier material.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Productivity

If the deicer operates at high power (1000-1500 watts) to ensure rapid heating, then the deicing effectiveness is improved, but the energy consumption increases and safety risks increase

Engineering Contradiction:

Improvedeicing effectivenessVSAvoidenergy consumption

Core Design Contradiction:

ProductivityVSUse of energy by stationary object

Solution Approach 1:

The patent implements a feedback control system where the temperature sensor continuously monitors the water temperature and sends signals to the microprocessor. The microprocessor adjusts the heating element's operation based on this feedback, turning it on when the water is cold and turning it off when the water reaches the desired temperature. This feedback mechanism allows the system to operate at high power only when necessary, reducing overall energy consumption while maintaining deicing effectiveness.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent employs periodic cycling of the heating element operation rather than continuous operation. The microprocessor controls the heating element to cycle on and off based on temperature conditions, allowing the system to maintain deicing effectiveness while reducing overall energy consumption through periodic rather than continuous high-power operation.

Inventive Principle:

Principle #19Periodic action

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 system achieves more accurate temperature control, reduces energy consumption by cycling temperatures within narrow ranges, and prevents overheating, ensuring safer operation and efficient deicing.

Implementation Method 1

a temperature sensor adapted to detect a temperature

Methodology Applied

Scientific EffectTemperature sensing:

Implementation Method 2

a heating element adapted to heat the water

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 3

The thermostat is separated from the heater by a thermally isolating material

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 4

The tab is adapted to provide a heat flow path from the heater to the thermostat

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS8478118B2Systems and methods for temperature sensing in a deicer

Publication Date: 2013.07.02 MILLER MFG CO INC

AI summary

Certain embodiments of the present invention provide a deicer system for heating water within a fluid receptacle to prevent ice from forming including a main body configured to be positioned within the fluid receptacle, a heating element adapted to heat the water, a temperature sensor adapted to detect a temperature, and a control unit in communication with the heating element and the temperature sensor. The heating element is supported by the main body. The temperature sensor is thermally connected to the heating element. The control unit is adapted to determine a temperature of the water based at least in part on the temperature detected by the temperature sensor. The control unit is adapted to control the heating element based at least in part on the determined temperature of the water.