Integrated Pressure Switch Mounting System for Furnace Applications
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional pressure switch mounting solutions, such as screws and snap-fit mountings, are costly, prone to loss, and can lead to improper support and failure in sensing vacuum conditions in furnace applications, particularly in gas furnaces where accurate operation is critical.
Innovation Solution
A mounting system that combines mechanical support and integrated pressure communication using a flexible material, such as ethylene propylene diene terpolymer, to securely attach the pressure switch to a mounting body while transmitting pressure signals, eliminating the need for separate screws and hoses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If screws are used for mounting the pressure switch, then the mechanical support is provided, but the mounting cost increases and the complexity of installation increases
Solution Approach 1:
The patent combines the mechanical mounting function and the pressure signal transmission function into a single integrated conduit assembly. The conduit serves dual purposes: providing structural support to hold the pressure switch in place and simultaneously transmitting the pressure signal from the furnace plenum to the pressure switch diaphragm. This eliminates the need for separate mounting screws and separate pressure hoses, directly resolving the technical contradiction by reducing device complexity while maintaining mechanical support strength.
Solution Approach 2:
The conduit is designed as a multi-functional component that performs multiple roles: it acts as a structural mounting element, a pressure signal transmission channel, and a physical connection between the pressure switch and the furnace plenum. This universal design allows a single component to replace what would traditionally require multiple separate parts (mounting screws, brackets, and pressure hoses), thereby reducing installation complexity and cost while maintaining adequate mechanical support.
2Reliability
If separate mounting screws and pressure hoses are used, then the functions are provided, but the number of parts increases and the risk of improper assembly increases
Solution Approach 1:
The patent merges the mounting screw function and the pressure hose function into a single integrated conduit assembly. This eliminates the need for multiple separate parts that would need to be assembled together, reducing the risk of improper assembly. The integrated design ensures that the pressure switch is mechanically secured and pressure signals are transmitted through the same component, eliminating potential assembly errors that could occur when installing separate mounting hardware and pressure hoses independently.
Solution Approach 2:
The pressure switch and conduit are pre-assembled as an integrated unit during manufacturing, with the conduit already positioned and secured to the pressure switch housing. This preliminary assembly ensures proper alignment and connection before installation in the furnace, eliminating the need for field technicians to separately assemble mounting screws and pressure hoses, thereby reducing the risk of improper assembly and ensuring reliable functionality.
3Strength
If the pressure switch is improperly mounted, then the mechanical support is insufficient, but the pressure sensing accuracy deteriorates
Solution Approach 1:
By integrating the mounting support and pressure signal transmission into a single conduit assembly, the patent ensures that the pressure switch is mechanically secured in the correct position while simultaneously establishing a direct pressure signal path from the furnace plenum to the pressure switch diaphragm. This integrated approach eliminates the risk of improper mounting that could occur with separate components, as the conduit's structural design inherently provides both mechanical support and proper pressure communication alignment, thereby maintaining both mechanical strength and measurement precision.
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 robust, cost-effective, and easy-to-install mounting that ensures proper support and orientation of the pressure switch, reduces the risk of mechanical failure, and maintains calibration by damping vibrations and ensuring consistent pressure communication.
Implementation Method 1
damping vibrations and ensuring consistent pressure communication
Implementation Method 2
configured to carry a pressure signal from the mounting body to the pressure switch
Data Source
AI summary
A mounting system for mounting a pressure switch to a mounting body without using screws or brackets. The mounting system includes a support physically supporting the pressure switch on the mounting body, a conduit carrying a pressure signal from the mounting body to the pressure switch, and a connector extending between and connecting the support to the conduit. The support and conduit may have ends constructed of synthetic rubber to frictionally engage support and conduit mounts, and the support and conduit may have approximately the same length and/or the same cross-sectional shape. The mounting body may be a draft inducer, a condensate collector box, or a drain trap in a furnace.