Toaster Sensor Bracket Design for Consistent Food Property Detection
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Solution Overview
Problem
Heatable kitchen devices, such as toasters, experience inconsistent sensing performance due to difficulties in assembling sensor elements, leading to variations in signal quality and performance limitations from insufficient cooling.
Innovation Solution
A heatable kitchen device design featuring a bracket with sloped apertures and a gasket to securely mount a sensor assembly, allowing for improved detection of food properties and enhanced cooling through air volume management, reducing spillage of test signals and increasing manufacturing consistency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the sensor assembly is mounted directly to the inner wall, then the structure is simple, but the sensor seating is inconsistent leading to poor sensing performance
Solution Approach 1:
A bracket is introduced as an intermediary component between the inner wall and the sensor assembly. The bracket includes a seat that receives and secures the sensor assembly, ensuring consistent positioning. The bracket has first and second apertures that allow the sensor to detect food properties through the inner wall, while the spacer creates an air gap for thermal isolation. This intermediary structure resolves the contradiction by providing reliable sensor mounting without requiring direct attachment to the inner wall.
2Temperature
If the sensor assembly is cooled by air flow, then the sensor temperature is controlled, but the air flow may interfere with the test signal detection
Solution Approach 1:
The bracket is segmented to provide separate functions: the first aperture allows the test signal to pass from the emitter to the food, the second aperture allows the reflected signal to reach the receiver, and the spacer creates a third functional zone (air gap) for thermal management. This segmentation isolates the cooling air flow from the optical path, allowing temperature control without interfering with signal detection precision.
3Measurement precision
If the apertures in the bracket have large area, then the sensor can detect food properties effectively, but more test signal spills out reducing detection accuracy
Solution Approach 1:
The apertures in the bracket have asymmetric positioning and sizing relative to the sensor assembly. The first aperture is positioned to optimize emitter signal transmission, while the second aperture is positioned to optimize receiver signal collection. The apertures are sized to provide sufficient detection capability while minimizing spillage, with the spacer thickness carefully controlled to maintain proper optical geometry. This asymmetric design allows each aperture to be optimized for its specific function.
4Temperature
If the spacer creates a large air gap, then thermal isolation of the sensor is improved, but the structural stability decreases
Solution Approach 1:
The spacer thickness is carefully controlled within a specific parameter range to balance thermal isolation and structural stability. The air gap created by the spacer provides sufficient thermal isolation to prevent heat from the inner wall from affecting the sensor assembly, while the bracket material and geometry are designed to maintain structural integrity. The apertures are positioned and sized to optimize both optical performance and mechanical strength.
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 design ensures consistent sensor accuracy across toaster units, reduces cooling requirements for the sensor assembly, and improves signal control and air flow for effective heating and cooling, resulting in enhanced performance and reliability.
Implementation Method 1
the bracket has a channel connecting the lower air volume to the upper air volume, the channel being in thermal communication with the sensor assembly
Implementation Method 2
air from the channel is able to flow into the heating area and the upper air volume, thereby drawing air from the lower air volume into the channel
Implementation Method 3
a heating element located between the heating area and the inner wall
Implementation Method 4
a receiver located adjacent the second aperture so as to receive the test signal when reflected by the foodstuff in the heating area
Data Source
AI summary
A heatable kitchen device such as a toaster has a housing having an outer wall and an inner wall (114), a heating area within the housing for receiving foodstuff to be heated, a heating element located between the heating area and the inner wall (114), a bracket (140) mounted to the inner wall (114) adjacent the heating area. The bracket (140) has a seat (142) located opposite the inner wall (114). The seat receives a sensor assembly (150) and has a first aperture and a second aperture through the bracket (140) to the seat (142). The first aperture has an area and the second aperture has an area, and the inner wall (114) has an opening (148) that is larger than the combined areas of the first and second apertures to allow the sensor assembly (150) to detect a property of the foodstuff.