Solid Thermal Simulator Device for Accurate Perishable Food Monitoring
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing temperature monitoring devices for perishable elements are inaccurate due to air temperature fluctuations in refrigeration units and lack of in situ calibration capabilities, leading to premature disposal of valuable products and increased costs.
Innovation Solution
A solid thermal simulator device made of a single piece of material with a sensing channel and calibration channel, equipped with a temperature sensor, allowing for accurate thermal characterization and in situ calibration to mimic the thermal mass of perishable elements, facilitating minimal and efficient calibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If air temperature monitoring is used in refrigeration units, then temperature changes can be detected, but the measurements overestimate the thermal exposure of perishable elements leading to inaccurate data
Solution Approach 1:
The patent creates a physical copy of a perishable element using a material with matched thermal properties (specific heat capacity, density, thermal conductivity) to replicate the thermal behavior of the actual product. This thermal twin is placed in the same environment to experience identical thermal conditions, providing accurate thermal history data without measuring the actual perishable element directly.
Solution Approach 2:
The patent introduces a thermal intermediary substance with specific heat capacity and thermal properties that acts as a mediator between the environment and the measurement system. This intermediary absorbs and releases thermal energy in the same manner as the perishable element, allowing indirect but accurate measurement of thermal exposure through a temperature sensor embedded in the intermediary material.
2Reliability
If liquid-filled thermometer bottles are used to simulate perishable elements, then thermal mass can be achieved, but the devices are fragile, require visual reading, and may leak contaminating products
Solution Approach 1:
The patent employs a solid material construct that is inherently leak-proof and durable, eliminating the fragility and contamination risks associated with liquid-filled bottles. The solid material structure cannot leak or break easily, providing a reliable, maintenance-free monitoring device that eliminates harmful contamination factors.
Solution Approach 2:
The patent replaces the liquid-based mechanical thermometer system with a solid material system equipped with an electronic temperature sensor. This substitution eliminates the mechanical fragility of glass bottles and liquid columns, providing a more robust and reliable measurement system that does not risk contamination.
3Measurement precision
If complex porous materials with liquid distribution are used to simulate food, then thermal characteristics can be matched, but fabrication becomes cumbersome and difficult to use
Solution Approach 1:
The patent uses a homogeneous solid material with uniform thermal properties throughout its structure, eliminating the complexity of porous materials and liquid distribution systems. This homogeneous construction simplifies manufacturing while maintaining accurate thermal characteristics through carefully selected material properties and geometric dimensions.
Solution Approach 2:
The patent achieves accurate thermal simulation by adjusting key parameters of the solid material construct, including its dimensions, shape, and material composition, to match the thermal mass and heat transfer characteristics of the actual perishable element. This parameter-based approach simplifies fabrication compared to complex internal structures.
4Measurement precision
If temperature sensors are removed and recalibrated regularly, then measurement accuracy can be maintained, but time and costs increase significantly
Solution Approach 1:
The patent incorporates a built-in reference temperature sensor during the manufacturing of the thermal simulation device itself. This reference sensor is pre-calibrated and embedded within the solid material construct, allowing for in-situ verification and calibration of the measurement sensor without removing the device from service. The preliminary integration of calibration capability eliminates downtime and reduces calibration costs.
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 device provides accurate temperature monitoring and reduces calibration time and costs by allowing in situ calibration, ensuring precise thermal data collection and minimizing the disposal of usable perishable items.
Implementation Method 1
A temperature sensor having a thermal response time is mounted within the sensing channel
Implementation Method 2
The single piece of solid material has a thermal mass substantially equal to that of the perishable element
Data Source
AI summary
A solid thermal simulator sensing device, the device can simulate and sense the thermal characteristics of a perishable element and is easily calibrated to a verifiable standard. The device is fabricated from a single piece of solid material sized to have a thermal mass substantially equal to that of said perishable element. A sensing channel is located within the single piece of solid material. The sensing channel extends from one end towards the center. A temperature sensor is mounted within the sensing channel. The thermal response time of the device is slowed by the single piece of solid material to mimic the thermal properties of the perishable element. A calibration channel is extends from the outer surface of the device to a point adjacent the temperature sensor. A calibration probe may be inserted into the calibration channel to quickly verify the accuracy of the device.