Heater plate
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Solution Overview
Problem
Existing methods for measuring the temperature of heater plates in humidifiers and medical devices are often inaccurate, leading to variations of up to 10°C, which can result in insufficient or excessive humidity, temperature inconsistencies, and potential bacterial growth or dryness issues.
Innovation Solution
A heater plate design featuring a thermally-conductive plate with a temperature sensor affixed directly to its bottom surface and a ceramic heating element directly affixed to a thermally-conductive layer, allowing for more accurate and direct temperature measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If indirect contact or calculated temperature measurement methods are used for the heater plate, then the device complexity is reduced, but the measurement precision deteriorates with temperature variances of up to 10°C
Solution Approach 1:
The patent introduces a thermally-conductive layer as an intermediary between the heater plate and the temperature sensor. This layer facilitates direct thermal contact, allowing the sensor to accurately measure the heater plate temperature without requiring complex indirect measurement systems or calculations, thereby resolving the contradiction between measurement precision and device complexity
Solution Approach 2:
The patent replaces complex indirect temperature measurement mechanisms (such as thermal imaging or calculation-based methods) with a simple direct-contact temperature sensor system. This substitution achieves high measurement precision through straightforward thermal conduction rather than complex mechanical or computational systems
2Reliability
If accurate temperature measurement is implemented, then the reliability of humidity control improves, but the device complexity increases due to additional sensing components
Solution Approach 1:
The patent combines the temperature sensing function directly into the heater plate structure by integrating the temperature sensor with the thermally-conductive layer. This merging approach improves humidity control reliability through accurate temperature measurement while avoiding the need for separate, complex sensing systems
Solution Approach 2:
The thermally-conductive layer serves multiple functions: it provides thermal conduction for heating, facilitates temperature measurement for the sensor, and potentially acts as a structural support. This multi-functionality improves reliability through accurate sensing while minimizing the addition of separate components that would increase device complexity
3Manufacturing precision
If temperature variance of up to 10°C is tolerated, then the ease of manufacture is improved, but the manufacturing precision of temperature control deteriorates
Solution Approach 1:
The patent incorporates the temperature sensor and thermally-conductive layer into the heater plate assembly during the manufacturing process, rather than adding them as separate post-assembly components. This preliminary integration ensures precise temperature control from the outset while maintaining ease of manufacture through a streamlined assembly process
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
This design provides more accurate and immediate temperature feedback, leading to a more evenly distributed heating profile and improved humidity control, reducing the risk of temperature inconsistencies and bacterial growth.
Implementation Method 1
A ceramic heating element is directly-affixed to the thermally-conductive layer
Implementation Method 2
a thermally-conductive layer is directly-affixed to the bottom surface
Implementation Method 3
A temperature sensor is affixed to the bottom surface
Data Source
AI summary
A heat plate for a humidifier contains a thermally conductive plate having a top surface and a bottom surface opposite the top surface. A temperature sensor is affixed to the bottom surface and a thermally conductive layer is directly-affixed to the bottom surface. A ceramic heating element is directly affixed to the thermally conductive layer. A humidifier and medical device may also contain such a heater plate.