Underfloor Heater Sensing Region for Accurate Liquid Temperature
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Solution Overview
Problem
Existing underfloor heaters for liquid heating vessels do not provide complete thermal isolation between the thermal sensor and the heating element, as there must always be a connection between the diffuser plate and the heating element, which can affect the accuracy of temperature measurement of the liquid.
Innovation Solution
A separate diffuser portion is used in the sensing region, thermally isolated from the main heat diffuser portion, with locating means such as a continuous wall surrounding the sensing region to securely attach and maintain the diffuser portion during manufacturing and enhance thermal isolation, allowing for better temperature sensing and mechanical filtering of the temperature signal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a continuous diffuser plate is used to conduct heat from the heating element to the thermal sensor, then heat conduction is improved, but thermal isolation between the sensor and heating element deteriorates
Solution Approach 1:
The diffuser plate is divided into two separate portions: a main heat diffuser portion that conducts heat from the heating element, and a sensing region with a second diffuser portion that is thermally isolated from the main portion. This segmentation allows the sensor to measure liquid temperature without direct thermal influence from the heating element, resolving the contradiction between heat conduction and thermal isolation.
Solution Approach 2:
The sensing region is extracted as a separate, thermally isolated component from the main heat diffuser portion. By removing the direct thermal connection between the heating element path and the sensor path, the invention eliminates thermal interference while maintaining the sensor's ability to detect liquid temperature through the base plate.
2Object-affected harmful factors
If a separate diffuser portion is provided in the sensing region, then thermal isolation is improved, but manufacturing complexity increases
Solution Approach 1:
The locating means is integrated directly into the base plate structure, combining the mounting function with the base plate itself. This merging approach reduces the number of separate components and simplifies manufacturing, as the locating features are formed as part of the base plate rather than requiring separate locating elements.
Solution Approach 2:
The base plate serves multiple functions: it provides structural support, contains the locating means for positioning the separate diffuser portion, and acts as part of the thermal management system. This multi-functionality reduces overall device complexity by eliminating the need for separate components for each function.
3Object-affected harmful factors
If the second diffuser portion is not connected to the main diffuser portion, then thermal isolation is improved, but mechanical stability during manufacturing deteriorates
Solution Approach 1:
The locating means acts as an intermediary mechanism that mechanically connects the second diffuser portion to the base plate during manufacturing and assembly, without creating a thermal conduction path. This intermediary structure provides the necessary mechanical stability and positioning while maintaining thermal isolation, as the locating features are designed to minimize thermal contact.
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 allows for accurate temperature measurement of the liquid by minimizing the influence of the heating element on the thermal sensor, improving thermal sensing capabilities and mechanical stability, while simplifying manufacturing by eliminating the need for separate parts during brazing.
Implementation Method 1
a main heat diffuser portion in good thermal contact with the base plate
Implementation Method 2
a heating element in good thermal contact with the main diffuser portion
Implementation Method 3
a sensing region for receiving a thermal sensor
Data Source
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AI summary
An underfloor heater for a liquid heating vessel comprises a base plate (2), a heat diffuser portion (4) in good thermal contact with the base plate (2), a heating element (6) in good thermal contact with the diffuser portion (4) and a sensing region (8) for receiving a thermal sensor. The sensing region (8) is not directly connected to the diffuser portion (4) and is at least partly surrounded by a wall. The sensing region (8) may be provided with a second separate diffuser portion comprising a disc of aluminium brazed to the underside of the base plate (2).