Heating System Temperature Sensor Laser Welding for Fast Response
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Solution Overview
Problem
Conventional heating systems for domestic appliances face slow response times due to inadequate thermal contact between temperature monitoring and control elements and the heating unit, often resulting in delayed temperature regulation and potential overheating.
Innovation Solution
The implementation of a laser-welded seam between the temperature monitoring and control unit and the carrier unit, with a beveled edge to facilitate better thermal contact and reduce the required laser power, enhances the attachment and response time of the temperature monitoring and control elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If temperature monitoring and control elements are fixed with screws to a mounting plate, then the mounting plate can be soldered to the heating unit, but the mounting plate curves and the temperature monitoring element is lifted away from the hot location, resulting in slow response time
Solution Approach 1:
The temperature monitoring and control element is merged directly with the heating unit through welding, eliminating the intermediate mounting plate and fixing screws. This direct integration ensures the temperature element remains in optimal thermal contact with the heat source, improving response time while maintaining reliable temperature monitoring.
Solution Approach 2:
The mounting plate and fixing screws are extracted from the system. By removing these intermediate components that cause thermal contact issues, the temperature monitoring element can be directly welded to the heating unit, eliminating the problem of the element being lifted away from the hot location and significantly reducing response time.
2Loss of time
If a welded seam is used to attach the temperature monitoring unit to the carrier unit, then thermal contact is improved and response time is reduced, but manufacturing complexity increases
Solution Approach 1:
The mechanical fixing system (screws, mounting plate) is replaced with a welding process. This substitution creates a permanent, thermally conductive bond that eliminates response time delays while the welding process itself can be automated, reducing the actual increase in manufacturing complexity.
Solution Approach 2:
The attachment method changes from mechanical (screws) to thermal (welding). This parameter change in the joining process enables direct thermal contact between the temperature monitoring element and the heating unit, dramatically improving response time while allowing for automated manufacturing processes.
3Strength
If laser welding is used to attach the temperature monitoring unit, then attachment strength and thermal contact are improved, but the required laser power increases
Solution Approach 1:
The carrier unit surface is preliminarily prepared with a specific geometry (protrusion or recess) before the welding process. This pre-preparation creates an optimal welding surface that enhances laser absorption and thermal contact, allowing for strong attachments with reduced laser power requirements.
Solution Approach 2:
The welding interface is given local geometric quality through protrusions or recesses. This localized geometric modification concentrates the thermal energy and improves laser coupling at the critical welding zone, achieving strong attachments with lower overall laser power while maintaining excellent thermal contact.
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 configuration significantly improves the response time of temperature monitoring and control elements, reducing overshoot and ensuring faster heat transfer, thus providing reliable and efficient temperature regulation.
Implementation Method 1
attached to each other by means of a welded seam, preferably by means of a laser-welded seam
Implementation Method 2
preferably by means of a laser-welded seam
Implementation Method 3
at least a part of said lower surface of said temperature monitoring and/or control unit is in thermal contact with at least a part of said upper surface of said carrier unit
Data Source
AI summary
The present disclosure relates to a heating system component including a temperature monitoring and/or control unit comprising a lower surface, and a carrier unit comprising an upper surface. At least a part of said lower surface of said temperature monitoring and/or control unit is in thermal contact with at least a part of said upper surface of said carrier unit. Said lower surface of said temperature monitoring and/or control unit and said upper surface of said carrier unit are attached to each other by means of a welded seam, preferably by means of a laser-welded seam.