Bathing Unit Heater Flow Detection Using Thermal Conduction
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Solution Overview
Problem
Existing bathing unit control systems fail to effectively detect sufficient water flow through the heating module, leading to potential overheating and damage, particularly in systems with plastic components that have inferior thermal properties, and existing solutions require multiple components or have limited lifespan.
Innovation Solution
A control system that includes a heating module with a thermal element and a controller that derives temperature information from a thermally conductive portion to detect the sufficiency of water flow, using a thermal element in thermally conductive communication with the water, and a method to activate the heating device for a predetermined period to assess temperature changes and determine flow sufficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pressure switches are used to detect water presence, then water level detection is achieved, but the system cannot detect water flow sufficiency and has limited lifespan due to moving parts
Solution Approach 1:
The patent replaces mechanical pressure switches with a thermal-based detection system using temperature sensors and heating elements. This substitution eliminates moving parts while enabling flow sufficiency detection through thermal conductivity measurements, resolving both the lifespan limitation and detection capability issues.
Solution Approach 2:
The system changes the detection parameter from mechanical pressure to thermal conductivity. By measuring temperature changes in response to controlled heating, the system can determine water flow sufficiency without the limitations of pressure switches, improving both reliability and detection capability.
2Difficulty of detecting and measuring
If multiple temperature sensors are used to detect water flow, then flow detection capability is achieved, but device complexity increases
Solution Approach 1:
The heating element serves dual functions: it acts as both the heat source for water heating and the thermal stimulus for flow detection. The temperature sensors serve multiple purposes by monitoring both water temperature for heating control and thermal conductivity for flow detection. This multi-functionality reduces component count while maintaining detection capability.
Solution Approach 2:
The patent combines the heating function and detection function into a single integrated system. The heating element and temperature sensors work together for both water temperature control and flow sufficiency detection, eliminating the need for separate detection components and reducing overall system complexity.
3Ease of manufacture
If plastic components are used in heating modules, then manufacturing cost and corrosion resistance are improved, but thermal properties deteriorate increasing overheating risk
Solution Approach 1:
The system performs preliminary flow sufficiency detection before activating the heating element. By checking thermal conductivity conditions in advance, the system ensures adequate water flow is present to safely conduct heat away from the heating element, preventing overheating despite the use of plastic components with inferior thermal properties.
Solution Approach 2:
The system continuously monitors temperature and thermal conductivity conditions, providing feedback to control heating activation. This feedback mechanism compensates for the inferior thermal properties of plastic components by ensuring heating only occurs when sufficient water flow is detected to safely remove heat.
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
Prevents overheating by accurately detecting insufficient water flow, reducing the risk of damage to heating elements and components, and does so without the need for multiple components or frequent calibration, offering a reliable and long-lasting solution.
Implementation Method 1
a thermal element in thermally conductive communication with water flowing through the passage
Implementation Method 2
a heating device that is operative for heating the water that flows through the body
Data Source
AI summary
The present invention provides a control system for a bathing unit that comprises a heating module, a thermal element and a heating module controller. The heating module includes a body that defines a passage through which water can flow, that has an inner surface and an outer surface. The heating module further includes a heating device that is operative for heating the water that flows through the body. The thermal element is mounted to the outer surface of the body such that the thermal element is in thermally conductive communication with water flowing through the body. The heating module controller is operative for obtaining temperature information associated with the thermal element for detecting at least in part on the basis of the temperature information the sufficiency of water flow through the body.