Heating system component providing a compact temperature sensor design
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Solution Overview
Problem
Conventional heating systems face challenges in achieving a compact design with efficient temperature monitoring due to the limitations of inexpensive NTC thermistors, which cannot withstand temperatures above 100°C, and the slow response time caused by indirect heat transfer through mounting screws and plates.
Innovation Solution
A heating system component with a carrier unit and a heating unit recessed in a groove, featuring an NTC thermistor thermally connected to the carrier's dry side, which is thermally insulated from the heating unit, and conductor paths formed on a thin polymer foil for direct temperature measurement, ensuring effective thermal contact and insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If NTC thermistors are directly mounted on the heating unit, then response time is improved, but the sensor cannot withstand temperatures above 100°C
Solution Approach 1:
The system is divided into a wet side (in contact with fluid) and a dry side (heating unit side), with the temperature sensor mounted on the dry side where temperatures are below 100°C, allowing NTC thermistors to function while still providing timely temperature monitoring of the fluid
Solution Approach 2:
The carrier unit acts as an intermediary between the heating unit and the temperature sensor, thermally coupling the sensor to the carrier's wet side so that the sensor indirectly measures fluid temperature without being directly exposed to high temperatures at the heating unit
2Reliability
If temperature sensors are mounted using screws on a mounting plate, then secure fixation is achieved, but heat transfer becomes indirect and response time increases
Solution Approach 1:
The temperature sensor, conductor paths, and connection elements are merged into a single integrated assembly mounted on the carrier unit, eliminating the need for separate mounting plates and screws, thereby achieving both secure fixation and direct thermal contact for fast response
Solution Approach 2:
The mounting plate and fixing screws are extracted from the design, replacing them with a direct mounting approach where the sensor assembly is fixed to the carrier unit itself, simplifying the structure and improving heat transfer efficiency
3Volume of moving object
If the heating unit and temperature sensor are integrated closely, then compact design is achieved, but thermal insulation becomes challenging
Solution Approach 1:
Thermal insulation is applied locally only where needed - between specific regions of the carrier unit and heating unit - rather than throughout the entire assembly, maintaining compactness while providing sufficient thermal management in critical areas
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 allows for reliable, compact, and cost-effective temperature monitoring of fluid media, reducing assembly risks and enhancing response time by directly mounting the temperature sensor at the fluid contact point, while avoiding the limitations of conventional temperature monitoring methods.
Implementation Method 1
NTC thermistors are temperature sensors well known in the art
Implementation Method 2
said temperature sensor is effectively in thermal contact with at least a part of an upper surface of said dry side of the carrier unit
Data Source
Figure 1
Figure 2a~2b
Figure 3a~3b
AI summary
The invention relates to a heating system component (100) for a heating system for heating a fluid medium, with a carrier unit (110), and a heating unit (120) coupled to said carrier unit (110), wherein said carrier unit (110) comprises a wet side and a dry side, wherein said wet side corresponds to a surface of said carrier unit (110) 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 (120) is recessed in a groove (112) provided on said dry side of the carrier unit (110). A temperature sensor (170a), 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 (120).