Mounting adaptor for mounting a sensor assembly to a water heater tank
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Solution Overview
Problem
Existing water heater systems require draining to replace immersion-type temperature sensors, and there is a need for a method to mount non-immersion type sensors on tanks designed for immersion type sensors without through-holes, allowing for easier servicing and standardization across different types of water heaters.
Innovation Solution
A mounting adaptor is used to secure a non-immersion type temperature sensor assembly to a water heater tank, featuring a proximal and distal cavity with a thermally conductive wall to isolate them, allowing for accurate temperature measurement without immersion, and can be retrofitted to immersion type tanks for standardization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If an immersion-type temperature sensor is used to maximize heat transfer accuracy, then temperature measurement precision is improved, but the system requires draining water to replace the sensor and needs a through-hole in the tank wall
Solution Approach 1:
The patent introduces a mounting adaptor as an intermediary device that couples the non-immersion temperature sensor to the tank exterior while maintaining accurate temperature measurement. The adaptor includes a thermally conductive barrier wall that thermally couples the sensor to the tank wall, enabling the sensor to measure water temperature through conduction without direct water contact, thus resolving the contradiction between measurement precision and ease of repair
Solution Approach 2:
The patent replaces the mechanical immersion system (sensor directly in water) with a thermal conduction system (sensor coupled to tank wall via thermally conductive barrier). This substitution allows the sensor to remain outside the water while still achieving accurate temperature measurement through thermal conduction, eliminating the need for draining water during sensor replacement
2Measurement precision
If an immersion-type temperature sensor is installed through a through-hole in the tank wall, then accurate temperature measurement is achieved, but the tank structure complexity increases and waterproof sealing is required
Solution Approach 1:
The mounting adaptor serves as an intermediary that eliminates the need for a through-hole in the tank wall. It couples the sensor assembly to the exterior of the tank while the thermally conductive barrier wall provides the thermal pathway, thereby simplifying the tank structure and eliminating waterproof sealing requirements while maintaining measurement precision
Solution Approach 2:
The patent segments the temperature sensing function from the water containment function. The mounting adaptor handles the thermal coupling and sensor mounting, while the tank wall maintains its simple sealed structure. This segmentation allows the tank to remain structurally simple without through-holes while still enabling accurate temperature measurement
3Measurement precision
If different mounting methods are used for immersion and non-immersion sensors, then each sensor type can be optimized for its function, but standardization across water heater designs is lost
Solution Approach 1:
The mounting adaptor is designed as a universal interface that can accommodate both immersion and non-immersion temperature sensor assemblies. By providing a standardized mounting mechanism with a thermally conductive barrier wall, the same adaptor design can be used across different water heater models and sensor types, achieving standardization while maintaining the functional optimizations of each sensor type
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
Enables accurate temperature measurement and easy replacement of sensors without draining the water heater, facilitating standardization and simplifying maintenance across different water heater designs.
Implementation Method 1
A wall may fluidly isolate the proximal cavity from the distal cavity. The proximal cavity may be configured to receive at least part of the non-immersion sensor assembly
Data Source
AI summary
Apparatus and method for mounting a non-immersion type temperature sensor to a tank, such as a water heater tank, that is designed for an immersion-type temperature sensor. In one example, a mounting adaptor may include a proximal cavity extending from a proximal end toward a distal end and a distal cavity extending from the distal end toward the proximal end. A wall fluidly isolates the proximal cavity from the distal cavity. The mounting adaptor is mounting to the mounting spud of an immersion type water heater tank, such that the distal cavity of the mounting adaptor is filled with water from the water heater tank. A non-immersion type temperature sensor is positioned adjacent to or in the proximal cavity and in thermal communication with the water in the distal cavity.