Dual-Wire Cooktop Sensor Assembly With Pressure-Equalizing Fluid Path
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Solution Overview
Problem
Cooktop appliances face issues with temperature sensor assemblies that are vulnerable to fluid leaks due to gaps or inconsistencies in adhesive sealants, leading to sensor failure and inaccurate temperature feedback.
Innovation Solution
A temperature sensor assembly design featuring a body with plenum, wire paths, and a sensor cavity, where the sensor is positioned within a sealed cavity and connected by wires through separate paths, with a fluid path allowing air exchange to prevent fluid ingress, reducing the need for precise adhesive sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If adhesive sealant is used to join components and seal gaps in temperature sensor assembly, then components are joined and gaps are sealed, but gaps or inconsistencies in the adhesive may allow fluid leakage into the sensor
Solution Approach 1:
The patent introduces a fluid path as an intermediary element that provides a controlled channel for air to enter the sensor assembly. This mediator allows the interior to remain at atmospheric pressure, preventing fluid ingress through the adhesive sealant while maintaining manufacturing simplicity. The fluid path acts as a pressure equalization channel that protects the sensor without requiring perfect sealing.
Solution Approach 2:
The patent extracts the sealing function from the adhesive sealant by introducing a dedicated fluid path structure. Instead of relying solely on the adhesive to prevent fluid ingress, the design separates the sealing role from the adhesive and assigns it to the fluid path geometry, allowing the adhesive to focus on joining components while the fluid path handles pressure equalization.
2Manufacturing precision
If adhesive sealant is used to seal gaps between components, then gaps are sealed, but manufacturing errors and inconsistencies in adhesive application require time-consuming inspection of every sensor
Solution Approach 1:
The fluid path serves as a mediator that compensates for manufacturing imprecision in adhesive application. By providing a controlled air entry channel, it ensures that even if the adhesive seal has gaps or inconsistencies, fluids cannot ingress into the sensor. This eliminates the need for exhaustive inspection while maintaining sensor reliability.
Solution Approach 2:
The design incorporates a preventive measure by including the fluid path that equalizes pressure before fluid ingress can occur. This beforehand cushioning approach ensures that even with manufacturing variations, the sensor is protected from fluid damage without requiring post-manufacturing inspection or rework.
3Reliability
If traditional sealed temperature sensor assembly is used, then sensor is protected from fluids, but any fluid ingress causes sensor failure and incorrect temperature feedback
Solution Approach 1:
The fluid path acts as an intermediary that allows controlled air exchange while preventing harmful fluid ingress. It mediates between the external environment and the sensor interior, permitting pressure equalization through air while blocking liquid entry through surface tension and the controlled geometry of the fluid path opening.
Solution Approach 2:
The design employs a flexible sealing approach where the adhesive sealant creates a barrier that, combined with the fluid path geometry, prevents fluid ingress while allowing pressure equalization. The combination of adhesive seal and fluid path creates a flexible sealing system that accommodates thermal expansion and manufacturing tolerances.
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 design enhances sensor reliability by preventing fluid ingress, reducing manufacturing inspection, and improving accuracy and longevity, while allowing for more tolerant manufacturing processes.
Implementation Method 1
the sensor assembly is configured to allow for air to enter the sensor assembly to prevent fluid ingress into the sensor assembly
Data Source
AI summary
A cooktop appliance including a sensor assembly including a body, a centerbody, a sensor, a first wire, and a second wire is provided. The body forms a plenum, a first wire path, a second wire path, and a sensor cavity. The body forms the first wire path and the second wire path each extending from the plenum from a first end to the sensor cavity at a second end distal to the first end. The centerbody forms a fluid path extending in fluid communication from the plenum to each of the first wire path and the second wire path. The body forms a top wall separating the sensor cavity from the fluid path. The sensor is positioned at the sensor cavity. The first wire extends through the first wire path and the second wire extends through the second wire path. The first and second wires operably couple to the sensor.