Steam Generator Intermetallic Bonding and Sensor Integration
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Solution Overview
Problem
Current steam generating apparatuses face challenges in accurately controlling steam pressure due to suboptimal heat transfer and delayed temperature sensing, leading to uneven temperature distribution and potential overshooting or undershooting of steam pressure.
Innovation Solution
A steam generating apparatus with an intermetallic layer connecting the heating device to the body, allowing for improved mechanical and thermal conductivity, and a temperature sensor integrated with the heating device for rapid temperature measurement, enabling precise control of steam pressure through adjustable target water temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the temperature sensor is attached to the side walls of the boiler shell, then the mounting is simplified, but a flat portion is required which complicates the forming of the shell and additional mounting processes are necessary
Solution Approach 1:
The temperature sensor mounting is merged with the heating element assembly. The sensor is integrated into the heating plate structure, combining the heating function and temperature sensing function into a single integrated component, eliminating the need for separate mounting processes and flat portions on the boiler shell.
Solution Approach 2:
The heating plate serves as an intermediary between the heating element and the water, and simultaneously as the mounting base for the temperature sensor. This intermediary structure provides a convenient mounting surface without requiring modifications to the boiler shell.
2Measurement precision
If the temperature sensor is attached to the bottom of the boiler shell with a heating plate, then the sensor is positioned close to the water, but the heat transfer between the boiler shell and heating plate is not optimal causing time delay in temperature sensing
Solution Approach 1:
The temperature sensor is merged with the heating element assembly, positioned in direct thermal contact with the heating plate. This integration ensures the sensor immediately detects temperature changes at the heat source, eliminating the time delay associated with heat transfer through the boiler shell.
Solution Approach 2:
The temperature sensor is positioned at the specific location of the heating plate where the most rapid temperature changes occur. This local positioning optimizes the sensing of temperature variations at the point of heat input, providing the most responsive feedback for pressure control.
3Strength
If the heating plate is mounted by bolts or screws with thermal conducting material, then the assembly is mechanically secure, but the heat transfer is not optimal and temperature distribution is uneven
Solution Approach 1:
The mechanical fastening system (bolts or screws with thermal conducting material) is replaced by a welding process. Welding provides both the mechanical attachment strength and optimal thermal contact, eliminating the thermal resistance introduced by mechanical joints and thermal paste layers.
Solution Approach 2:
The heating plate assembly uses a composite structure where the heating plate is welded to the boiler shell, creating a metallurgical bond that combines the mechanical strength of a permanent joint with the thermal conductivity of direct metal-to-metal contact, superior to mechanical fastening systems.
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 faster and more accurate control of steam pressure, reducing feedback time and ensuring uniform heat transfer, thus improving the efficiency and reliability of steam generation.
Implementation Method 1
a heating device (14) comprising a heating plate (15) connected with the body (12) by forming an intermetallic layer (20) between the first portion (16) and the second portion (15), wherein the intermetallic layer (20) provides both a mechanical and a thermal connection between the first portion (16) and the second portion (15)
Implementation Method 2
a heating device (14) comprising a heating plate (15) and a heating element (22)
Data Source
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AI summary
The present invention relates to a steam generating apparatus (10), comprising a body (12) for receiving water to be heated and comprising a first portion (16) comprising a first metal, and a heating device (14) comprising a second portion (18) comprising a second metal, wherein the heating device (14) comprises a heating plate (15) connected with the body (12) by forming an intermetallic layer (20) between the first portion (16) and the second portion (18), and a temperature sensor (24) for measuring a temperature that is indicative of a pressure inside the body (12) is arranged in thermal contact to the heating device (14) outside the body (12). The present invention further relates to a method of controlling the pressure of steam in a steam generating apparatus comprising a body for receiving water to be heated and comprising a first portion (16) comprising a first metal; a heating device (14) comprising a second portion (18) comprising a second metal, the body being connected with a heating plate (15) of the heating device (14) by forming an intermetallic layer between the first portion (16) and the second portion (18), and a temperature sensor (24) for measuring a temperature that is indicative of a pressure inside the body (12), the temperature sensor (24) being arranged in thermal contact to the heating device (14) outside the body (12), the method comprising the steps of setting the target water temperature for a first time period to a first set temperature; setting the target water temperature for a second time period to a second set temperature higher than the first set temperature; and setting the target water temperature for a third time period to a third set temperature lower than the second set temperature.