Shared Thermostat Layout for Multi-Element Water Heaters
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Solution Overview
Problem
Dual element electrical heating devices require separate thermostats for each heating element, increasing cost and complexity due to the need for multiple overheat prevention mechanisms.
Innovation Solution
A single thermostat is used in thermal contact with multiple heating elements mounted on a common support plate, eliminating the need for separate thermostats by ensuring all elements are in thermal contact with the thermostat, which is positioned adjacent to the common support plate location.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate thermostat is provided for each heating element, then overheat prevention reliability is improved, but device complexity and cost increase
Solution Approach 1:
Multiple separate thermostats are merged into a single shared thermostat that serves all heating elements. The thermostat is positioned to be in thermal contact with multiple heating elements simultaneously, allowing one thermostat to monitor and control the temperature of multiple elements, thereby reducing component quantity while maintaining safety functionality.
Solution Approach 2:
The single thermostat is designed to perform multiple functions by being in thermal contact with multiple heating elements. It universally monitors temperature across all heating elements and can cut off power to any or all elements when overheating is detected, making one component serve the role of multiple separate thermostats.
2Reliability
If multiple separate thermostats are used, then overheat detection accuracy is improved, but manufacturing cost increases
Solution Approach 1:
The patent combines multiple thermostat functions into a single physical component. By positioning the thermostat to contact multiple heating elements, it achieves comprehensive overheat detection without requiring multiple separate thermostat units, thereby reducing part count, assembly complexity, and overall manufacturing cost while maintaining detection capability.
3Device complexity
If heating elements are arranged to contact a common thermostat, then device complexity is reduced, but thermal contact reliability must be maintained
Solution Approach 1:
The support plate serves as an intermediary thermal conductor between the heating elements and the thermostat. The heating elements are mounted on the support plate, and the thermostat contacts the support plate at a location where it can thermally sense the combined heat from multiple heating elements. This intermediary structure ensures reliable thermal contact while simplifying the overall arrangement.
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 configuration reduces the cost and complexity of the heating device while effectively preventing overheating of the heating elements, ensuring safe operation by cutting off power when the temperature exceeds safe levels.
Implementation Method 1
Electrical resistance heating elements are commonly used to heat water
Implementation Method 2
a single thermostat adapted to cut of the supply of electrical power to said plurality of heating elements when the temperature of the thermostat exceeds a predetermined maximum temperature
Data Source
Figure 1~3
AI summary
An electrical heating device for heating water, said heating device comprising a plurality of heating elements operable to heat water stored within a vessel, wherein said plurality of heating elements are all arranged to be in thermal contact with a single thermostat adapted to cut of the supply of electrical power to said plurality of heating elements when the temperature of the thermostat exceeds a predetermined maximum temperature, indicating overheating of at least one of said heating elements.