Overmolded Water Level Probe Assembly for Steam Humidifier Tanks
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current humidification systems face challenges in accurately sensing water levels in steam humidifiers, leading to potential overfilling or under-filling, which can cause failures and safety issues such as mold growth, rust, and water damage, especially in residential applications where pressurized steam is not readily available.
Innovation Solution
A water level sensor system for steam humidifiers featuring a plurality of conductive probes, including a common probe and multiple water level probes, covered by non-conductive overmolding, which provides a sealed and reliable method for detecting water levels within the tank, preventing false readings and ensuring proper humidification control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple conductive probes are used to sense water levels, then measurement precision is improved, but device complexity increases due to multiple separate probes requiring individual sealing and connection
Solution Approach 1:
Multiple separate conductive probes are merged into a single integrated sensor assembly where the probes are positioned within a common non-conductive body. This single assembly seals as one unit against the tank wall and provides multiple water level detection points, reducing the number of separate components while maintaining accurate multi-level measurement capability
2Measurement precision
If conductive probes are exposed to detect water levels, then measurement precision is improved, but reliability decreases due to risk of false readings from condensation or liquid bridges between probes
Solution Approach 1:
A non-conductive body serves as an intermediary structure that holds and positions the conductive probes. This non-conductive material prevents unwanted electrical conduction between probes through condensation or liquid bridges, while still allowing the probes to detect water levels accurately through the tank wall. The non-conductive body acts as an electrical insulator that maintains probe independence
Solution Approach 2:
The non-conductive body provides a protective shell around the conductive probes, isolating them from direct exposure to moisture and condensation that could cause false readings. This shell structure maintains the electrical independence of each probe while allowing them to function together as a multi-level detection system
3Ease of manufacture
If multiple separate probes are used without integrated sealing, then ease of manufacture is improved, but reliability decreases due to potential leakage paths between probes
Solution Approach 1:
Multiple sealing functions are merged into a single integrated sealing structure. The non-conductive body provides a unified seal against the tank wall that encompasses all conductive probes, eliminating the need for separate sealing elements for each probe. This single seal ensures tank integrity while accommodating multiple detection probes
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
The sensor system effectively monitors water levels, preventing overfilling and under-filling, reducing the risk of mold growth, rust, and water damage, while being cost-effective and suitable for residential applications without the need for pressurized steam sources.
Implementation Method 1
The water level sensor includes a plurality of conductive probes, where the plurality of conductive probes includes at least one common probe and a plurality of water level probes
Implementation Method 2
The water level sensor further includes a non-conductive overmolding covering at least a portion of each of the conductive probes
Data Source
AI summary
A water level sensor for a steam humidifier. The water level sensor includes a plurality of conductive probes, where the plurality of conductive probes includes at least one common probe and a plurality of water level probes. Each of the conductive probes are separated from each other conductive probe. The water level sensor further includes a non-conductive overmolding covering at least a portion of each of the conductive probes. The non-conductive overmolding defines a flange configured to seal an opening in a tank of the steam humidifier and an electrical connection point configured to receive an electrical connector for providing electrical connections to each of the conductive probes. A steam humidifier is also disclosed.