Thermal Mass Flow Backflow Module for Carbonator Shut-Off Control
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Solution Overview
Problem
Existing backflow preventers in carbonators, such as dual check valves, can fail, allowing carbonated water to flow into the water supply and potentially contaminate it with copper, causing health issues.
Innovation Solution
A backflow preventer module incorporating a thermal mass flow meter and check valves that actively detect and prevent backflow by measuring flow rate, temperature, and bubble presence, using a controller to shut off the system when a backflow condition is detected.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a dual check valve is used for backflow prevention, then backflow protection is provided, but the system can still fail and allow carbonated water to flow into the water supply
Solution Approach 1:
The patent replaces the purely mechanical dual check valve system with an active detection system using a thermal mass flow meter to sense backflow conditions. The thermal mass flow meter electronically detects flow direction and triggers a shut-off valve, substituting mechanical reliance with electronic sensing and control for improved reliability.
Solution Approach 2:
The thermal mass flow meter continuously monitors flow conditions and provides feedback to the control system. When backflow is detected, the system receives real-time information about flow direction and activates the shut-off valve accordingly, creating a closed-loop feedback mechanism that dynamically responds to changing flow conditions.
2Difficulty of detecting and measuring
If a thermal mass flow meter is added to detect backflow conditions, then active monitoring and detection capability is improved, but device complexity increases
Solution Approach 1:
The thermal mass flow meter serves multiple functions: it measures flow rate, detects backflow conditions, and provides data for control decisions. By making this single component multi-functional, the system achieves enhanced detection capability without proportionally increasing complexity, as one device performs several critical tasks.
3Object-affected harmful factors
If the shut-off valve is activated upon backflow detection, then prevention of contamination is improved, but system downtime for maintenance increases
Solution Approach 1:
The system performs preliminary detection of backflow conditions using the thermal mass flow meter before contamination occurs. By detecting abnormal flow patterns early and activating the shut-off valve in advance, the system prevents contamination while allowing for planned maintenance scheduling, reducing unexpected downtime.
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
Effectively prevents backflow by actively monitoring fluid conditions, ensuring the water supply remains safe and preventing contamination, and providing alerts for maintenance when necessary.
Implementation Method 1
a thermal mass flow meter configured to communicate a first signal based on a measured amount of heat transferred from a heater to a temperature sensor by a flow of a fluid through the backflow preventer module
Implementation Method 2
a thermal mass flow meter configured to communicate a second signal based on a measured temperature of the fluid
Data Source
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AI summary
A carbonated water dispenser comprises a carbonator with a water inlet and a carbonated water outlet. A backflow preventer module is fluidically coupled to the water inlet and comprises a check valve and a thermal mass flow meter. The thermal mass flow meter is configured to communicate a first signal based on a measured amount of heat transferred from a heater to a temperature sensor by a flow of a fluid through the backflow preventer module. A shut-off valve is fluidically coupled between the carbonated water outlet and a nozzle. The shut-off valve is configured to allow or prevent fluid flow from the carbonated water outlet to the nozzle base on a control signal. A controller is configured to detect a backflow condition based on the first signal and generate the control signal to configure the shut-off valve to prevent dispensing carbonated water upon detection of the backflow condition.