Temperature control device mounted to a sealed electrical wall box
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Solution Overview
Problem
Temperature control devices, such as thermostats, face inaccuracies in temperature measurement due to heat generated by their display screens and varying environmental conditions, leading to inefficient temperature control in home automation systems.
Innovation Solution
A temperature control system comprising a sealed electrical wall box and glands to prevent air from the wall cavity from entering, ensuring an airtight seal and minimizing the impact of air flow on temperature sensor readings, while accommodating cables and wires of varying thicknesses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the temperature control device is mounted in a standard electrical wall box, then it is easy to install and access cables, but air flow from the wall cavity enters the box and causes inaccurate temperature measurements
Solution Approach 1:
The wall box is segmented into two functional zones: a sealed measurement chamber for the temperature sensor and electronics, and an open cable access region. The sealed chamber isolates the temperature-sensitive components from wall cavity air flow, while the cable access region allows straightforward wire installation through the back plate openings.
Solution Approach 2:
A back plate with sealed openings acts as an intermediary barrier between the wall cavity and the temperature measurement chamber. The back plate allows cable passage while maintaining the seal, preventing direct air flow into the measurement chamber while still enabling electrical connections.
2Illumination intensity
If the display screen operates at high intensity, then it provides good visibility, but it generates heat that interferes with temperature sensor readings
Solution Approach 1:
The display screen and temperature sensor are spatially separated within the device housing. The display is positioned away from the temperature sensor and oriented to dissipate heat away from the sensing element, extracting the heat generation problem from the temperature measurement zone.
Solution Approach 2:
The display screen operates in periodic cycles of high and low intensity rather than continuously at maximum brightness. This reduces the average heat generation while maintaining adequate visibility during active use, allowing the temperature sensor to operate in a more stable thermal environment.
3Measurement precision
If the wall box is completely sealed, then temperature measurements are accurate, but cables cannot be accessed and connected
Solution Approach 1:
The back plate has localized sealed openings at specific positions for cable access, while the rest of the wall box remains completely sealed. This provides targeted access points where connection is needed while maintaining the airtight seal in all other areas to protect temperature measurement accuracy.
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 solution provides accurate temperature measurements by isolating the temperature sensor from air flow, enhancing the reliability and efficiency of temperature control in home automation systems.
Implementation Method 1
The sealed electrical wall box may be configured to prevent air within a wall cavity of the wall from entering the sealed electrical wall box. For example, the sealed electrical wall box may be configured to provide a substantially airtight seal between the wall cavity and the sealed electrical wall box.
Implementation Method 2
The temperature control device may include a temperature sensor. The temperature control device may be configured to be mounted to the sealed electrical wall box such that the temperature sensor is located within the sealed electrical wall box.
Implementation Method 3
The glands may be configured to receive electrical cables and/or electrical wires of various thicknesses. The second surface may be initially sealed and may be punctured by the electrical cable and/or electrical wire to form an aperture. When the second surface is punctured, the aperture may be configured to form a substantially airtight seal around the electrical cable and/or electrical wire.
Data Source
AI summary
A control system may include a control device, an electrical wall box having a hole for passing a wire or cable into the wall box, and a gland configured to be inserted into the hole of the wall box. The control device may include a temperature sensor. The wall box may be configured to be mounted to a wall. The control device may be configured to be mounted to the wall box such that the temperature sensor is located within the wall box. A wire or cable may be passed from a wall cavity of the wall, through the gland, into an interior of the wall box, and attached to the temperature control device. The gland and the wall box may be configured to prevent air within the wall cavity from entering the wall box when the wire or cable is passed into the wall box.