Heating system
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Solution Overview
Problem
Conventional temperature monitoring and/or control elements in heating systems experience slow response times due to improper fixation methods, such as screw mounting, leading to inefficient heat transfer and delayed safety responses.
Innovation Solution
The temperature monitoring and/or control elements are directly fixed onto the heating unit using laser welding, with a beveled edge of less than 90°, enhancing thermal contact and reducing the need for additional mounting elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If temperature monitoring and/or control elements are fixed using conventional screw mounting to a mounting plate, then the mounting structure is simple to assemble, but the response time of the temperature elements becomes unacceptably slow
Solution Approach 1:
The temperature monitoring and/or control element is merged directly with the heating unit by laser welding, eliminating the separate mounting plate and screw fixation structure. This direct integration creates optimal thermal contact and dramatically reduces response time while simplifying the overall mounting structure.
Solution Approach 2:
The mechanical screw mounting system is replaced with laser welding technology. This substitution eliminates the thermal resistance introduced by mechanical fasteners and mounting plates, providing direct thermal coupling between the temperature element and heating unit for faster response.
2Reliability
If the mounting plate is soldered to the heating unit, then the temperature element can be mounted, but the mounting plate curves and the temperature element is lifted away from the hot location
Solution Approach 1:
The mounting plate is completely removed from the system. The temperature monitoring and/or control element is fixed directly onto the heating unit without any intermediate mounting plate, eliminating the curvature problem and ensuring consistent thermal contact.
Solution Approach 2:
The temperature element and heating unit are merged into a single integrated assembly through direct laser welding, eliminating the mounting plate that caused deformation and lifting issues.
3Temperature
If fixing screws are used to mount the temperature element, then the mounting is secure, but the temperature element remains in the air above the hot location and cannot receive heat directly
Solution Approach 1:
Mechanical screw fixation is replaced with laser welding, enabling direct thermal contact between the temperature element and heating unit. This eliminates the air gap that prevented efficient heat transfer while maintaining secure attachment.
Solution Approach 2:
The laser weld seam acts as an intermediary that provides both mechanical fixation and optimal thermal contact, eliminating the need for separate fixing screws that created air gaps and thermal resistance.
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 method improves the response time of the temperature monitoring and/or control elements by up to four seconds and reduces overshoot by approximately 20°C, providing more robust and efficient temperature regulation.
Implementation Method 1
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
Implementation Method 2
said lower part has a beveled edge... wherein said beveled edge comprises a bevel angle of less than 90°... wherein said welded seam is located essentially along said beveled edge
Data Source
Figure 1~2
Figure 3~4
Figure 5A~5B
AI summary
The present invention relates to a heating system component comprising: 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.