Fluid Warmer Switch Assembly with Embedded Thermocouple
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Solution Overview
Problem
Conventional fluid warmers in hospitals are inefficient in heating fluids to body temperature and lack effective tracking of thermal history, leading to underutilization and energy loss due to excess capacity and potential spoilage.
Innovation Solution
A modular fluid warmer with a support surface, heating element, and integrated switch assembly that includes a thermocouple-embedded movable switch plate for precise temperature measurement and presence detection, allowing for efficient heating and tracking of fluid temperature and time at temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a large capacity oven is used to heat fluid containers, then sufficient capacity is available to satisfy hospital needs in worst case scenarios, but energy is lost when the oven is at less than capacity and heating time increases
Solution Approach 1:
The patent divides the large capacity oven into multiple smaller heating zones or modules. Each zone can be independently controlled and heated only when needed, allowing the system to scale heating capacity according to actual demand rather than always operating at full capacity. This segmentation enables energy-efficient operation by activating only the necessary number of heating zones.
Solution Approach 2:
The patent implements dynamic control of heating capacity based on real-time monitoring of container presence and heating requirements. The system adjusts the number of active heating zones, power levels, and timing automatically, transitioning from static full-capacity operation to dynamic demand-responsive operation, thereby reducing energy waste during partial utilization periods.
2Productivity
If multiple containers are warmed simultaneously in an oven, then throughput is improved, but it becomes difficult to track the thermal history of individual containers
Solution Approach 1:
The patent introduces RFID tags or wireless sensors as intermediary devices attached to each container. These intermediaries communicate container identity and thermal exposure data to a central control system, enabling individual tracking of thermal history even when multiple containers are heated simultaneously. The intermediary acts as a bridge between the bulk heating process and individual container monitoring requirements.
Solution Approach 2:
The patent implements a feedback system where thermal sensors continuously monitor temperature and time parameters for each container, and this data is fed back to the control system. The control system uses this feedback to track cumulative thermal exposure, adjust heating parameters, and ensure each container receives appropriate thermal treatment, maintaining individual container tracking capability during simultaneous heating operations.
3Temperature
If conventional ovens are used to heat fluids, then heating capability is provided, but there is no integrated system to detect presence or monitor temperature of containers
Solution Approach 1:
The patent merges previously separate functions (heating, presence detection, temperature monitoring, and data tracking) into a single integrated fluid warming system. The heating elements, RFID readers, temperature sensors, and control processing are combined into one unified device, eliminating the need for separate ovens, manual tracking systems, and monitoring equipment, thereby reducing overall system complexity despite increased functionality.
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 modular fluid warmer efficiently heats fluids to body temperature while minimizing energy usage and preventing spoilage by only heating occupied containers, providing accurate temperature monitoring and thermal history tracking.
Implementation Method 1
One or more thermocouples are embedded in the movable switch plate below the contact surface. The movable switch plate comprises a material having a thermal conductivity that permits the thermocouple(s) embedded in the switch plate to measure a temperature of an item placed on the support surface within a predetermined period of time.
Implementation Method 2
The switch assembly includes a switch, a movable switch plate, and one or more thermocouples.
Implementation Method 3
a heating element configured to selectively heat the support surface
Data Source
Figure 1
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AI summary
A fluid warmer is disclosed. The fluid warmer includes a support surface, a heating element configured to selectively heat the support surface, and a switch assembly extending through the support surface. The switch assembly includes a switch, a movable switch plate, and a thermocouple. The switch has at least two states, one of which indicates the presence of an item on the support surface. The movable switch plate operably links to the switch to move the switch between the states and further includes a contact surface that contacts an item placed on the support surface. One or more thermocouples are embedded in the movable switch plate below the contact surface. The movable switch plate comprises a material having a thermal conductivity that permits the thermocouple(s) embedded in the switch plate to measure a temperature of an item placed on the support surface within a predetermined period of time.