Method and system for securing temperature sensors on the outer surface of a tank of an electric water heater
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Solution Overview
Problem
Existing temperature sensor mounting systems for electric water heaters face challenges in accessing and replacing sensors due to thermal insulation, leading to complications in troubleshooting and repair, and require multiple sensors to accurately monitor water temperature across the tank, increasing costs and complexity.
Innovation Solution
A system using expandable foam to pressure-bias temperature sensors against the tank's outer surface, allowing for precise temperature readings while enabling removable circuit boards and frictional sliding contact for easy maintenance, with sensors positioned vertically from the bottom to the top of the tank to monitor water temperature effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If temperature sensors are mounted on the tank wall and sealed with foam insulation, then temperature monitoring accuracy is improved, but access to sensors for replacement and troubleshooting is lost
Solution Approach 1:
The system divides the sensor assembly into separable components: the temperature sensor mounted on the circuit board can be independently replaced while the circuit board itself remains accessible through the foam insulation. This segmentation allows the sensor to be sealed against the tank wall for accurate measurement while maintaining access to the circuit board for troubleshooting and replacement.
Solution Approach 2:
The foam insulation serves as an intermediary that provides dual functionality: it seals the temperature sensor against the tank wall to ensure accurate temperature monitoring, while simultaneously allowing the circuit board to remain accessible for maintenance. The foam acts as a medium that connects the sealing requirement with the accessibility requirement.
2Loss of information
If multiple temperature sensors are installed to monitor different regions of the tank, then temperature profile monitoring is improved, but device complexity and cost increase
Solution Approach 1:
Multiple temperature sensors are mounted on a single circuit board, merging multiple sensing functions into one integrated assembly. This consolidation reduces wiring complexity and simplifies installation while maintaining the capability to monitor temperature at multiple locations along the tank wall.
Solution Approach 2:
The circuit board serves multiple functions: it provides electrical connections for multiple temperature sensors, acts as a mounting structure for the sensors against the tank wall, and maintains accessibility for troubleshooting. This multi-functionality reduces the need for separate components and simplifies the overall system.
3Loss of energy
If foam insulation is used to seal access to temperature sensors, then thermal insulation performance is improved, but sensor replacement becomes impractical
Solution Approach 1:
The system segments the sealing function from the sensor replacement function. The foam insulation seals the temperature sensor mounting area to maintain thermal insulation performance, while the circuit board remains accessible through the foam for easy replacement of sensors or troubleshooting of wiring issues.
Solution Approach 2:
The foam insulation is applied selectively around the temperature sensor mounting area rather than completely sealing the entire sensor assembly. This localized insulation approach maintains thermal performance where needed while leaving access paths open for maintenance activities.
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 solution provides accurate and reliable temperature monitoring across the tank, preventing bacterial growth and enabling efficient control of heating elements, while simplifying maintenance and reducing costs by using the foam insulation to secure sensors directly against the tank wall.
Implementation Method 1
A system using expandable foam to pressure-bias temperature sensors against the tank's outer surface, allowing for precise temperature readings
Implementation Method 2
Because the water tank is constructed of steel material which is a good thermal conductor, by sensing the temperature of the steel by mounting thermistors there against, the temperature of the water inside the tank can be fairly accurately determined
Implementation Method 3
Thermistors are excellent electrical components for sensing temperature variations as its resistance varies with temperature changes
Data Source
AI summary
A temperature sensor securing system and method is described for securing two or more temperature sensors against an outer surface of a side wall of a tank of an electric water heater. The temperature sensors are secured spaced apart on an elongated support such as a circuit board which is held in position against the tank outer surface by support means. An expandable liquid foam causes the temperature sensors to be biased against the outer surface of the tank side wall to sense the temperature of the side wall at the location of the sensors and to generate actual temperature signals to a controller which is programmed to communicate with a subscriber and/or energy provider to control the water temperature inside the tank.