Heating system component providing a compact temperature sensor design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional heating systems for domestic appliances face challenges in compact design and cost-effectiveness due to the limitations of temperature monitoring and control elements, which are often slow to respond and require expensive thermistors that cannot withstand high temperatures.
Innovation Solution
A heating system component with a carrier unit and a heating unit, where an NTC thermistor is effectively in thermal contact with the carrier unit's dry side, thermally insulated from the heating unit, allowing for compact and cost-effective temperature measurement without exposing the sensor to excessive temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional temperature monitoring elements are fixed with screws to a mounting plate, then the mounting plate can be soldered to the heating unit, but the temperature monitoring element is lifted from the fixing plate and remains in the air above the hot location, resulting in slow response time
Solution Approach 1:
The temperature monitoring element is integrated directly into the carrier unit structure, merging the temperature sensing function with the structural support function. This eliminates the separate mounting plate and screw fixation, allowing the sensor to be in direct thermal contact with the heating unit while maintaining structural integrity.
Solution Approach 2:
The carrier unit acts as an intermediary structure that provides both mechanical support and thermal conduction path. It mediates between the heating unit and the temperature monitoring element, ensuring direct thermal contact while protecting the sensor from excessive temperatures through its material properties and geometric design.
2Ease of manufacture
If inexpensive NTC thermistors are used for temperature sensing, then manufacturing cost is reduced, but they cannot continuously withstand temperatures exceeding 100° C. which are reached by the heating unit
Solution Approach 1:
The carrier unit creates a local thermal environment for the NTC thermistor that is different from the overall heating unit temperature. Through strategic placement and thermal path design, the sensor location maintains temperatures below 100° C. while the heating unit operates at higher temperatures, allowing inexpensive sensors to be used in a high-temperature application.
Solution Approach 2:
The carrier unit serves as a thermal intermediary that decouples the temperature experienced by the sensor from the temperature of the heating unit. It conducts necessary thermal energy for sensing while limiting maximum sensor temperature through its material selection and geometric configuration, protecting inexpensive NTC thermistors from overheating.
3Volume of stationary object
If the heating system component is designed to be compact, then space is reduced, but temperature sensor placement and thermal contact optimization become more difficult
Solution Approach 1:
The temperature sensing function is merged into the carrier unit structure itself, eliminating separate mounting components and reducing overall volume. The carrier unit simultaneously provides structural support, thermal conduction path, and sensor mounting function, achieving compact design without increasing device complexity.
Solution Approach 2:
The carrier unit is designed as a multi-functional component that performs structural support, thermal management, and sensor integration functions simultaneously. This universal design approach reduces the number of separate parts needed for compact configuration while simplifying the overall 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 enables reliable and efficient temperature measurement of the fluid medium while preventing damage and reducing assembly risks, allowing for a compact and cost-efficient heating system component.
Implementation Method 1
The temperature sensor is effectively in thermal contact with at least a part of an upper surface of the dry side of the carrier unit
Implementation Method 2
the part of the upper side of the carrier unit is effectively thermally insulated from the heating unit
Data Source
AI summary
The invention relates to a heating system component for a heating system for heating a fluid medium, with a carrier unit, and a heating unit coupled to said carrier unit, wherein said carrier unit comprises a wet side and a dry side, wherein said wet side corresponds to a surface of said carrier unit configured to be in contact with said fluid medium, wherein said dry side is located on a surface opposite to said wet side; and wherein said heating unit is recessed in a groove provided on said dry side of the carrier unit. A temperature sensor, in particular an NTC thermistor, positioned to measure a temperature of a fluid medium at the wet side of the carrier unit, wherein the temperature sensor is effectively thermally insulated from the heating unit.