Polymeric Water Heater Mounting Bracket for Thermal Isolation
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Solution Overview
Problem
Conventional water heaters lack an efficient and reliable mounting system for temperature sensors, gas valves, power delivery units, and controllers, which can lead to suboptimal performance and safety issues due to inadequate thermal isolation and installation challenges.
Innovation Solution
A polymeric mounting bracket with a sensor portion and threaded spud engagement system, featuring a distal end for thermal contact and a component retaining region with ribs for additional support, designed to securely attach these components to the water heater tank while providing thermal isolation and safety features like clean breakage under stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional mounting system is used for temperature sensors and control components, then installation is simpler, but thermal isolation is inadequate and reliability is reduced
Solution Approach 1:
The patent combines multiple mounting functions into a single integrated bracket structure that simultaneously mounts the temperature sensor, gas valve, power delivery unit, and controller. This merging of mounting functions into one component improves reliability by providing a unified securement system while the polymeric material provides thermal isolation, resolving the contradiction between reliability and complexity.
Solution Approach 2:
The mounting bracket is made from a polymeric material that combines mechanical fastening capabilities with thermal isolation properties. This composite material approach allows the single bracket to provide both secure mounting and thermal protection, improving reliability without requiring additional complex components.
2Measurement precision
If the temperature sensor is thermally engaged with the water, then temperature sensing is accurate, but thermal isolation of control components is inadequate
Solution Approach 1:
The mounting bracket segments the thermal environment by providing a thermal interface for the temperature sensor while simultaneously providing thermal isolation for the control components. The polymeric material creates distinct thermal zones: one allowing thermal contact for accurate sensing, and another providing thermal protection for electronics, resolving the contradiction between measurement accuracy and thermal protection.
3Adaptability or versatility
If multiple components are mounted to the water heater tank, then functionality is improved, but installation difficulty increases
Solution Approach 1:
The integrated mounting bracket combines multiple component mounting capabilities into a single installation operation. The bracket is designed with features that simultaneously secure the temperature sensor, gas valve, power delivery unit, and controller, allowing all components to be mounted in one operation rather than separately, thus improving versatility without increasing installation difficulty.
4Object-affected harmful factors
If the mounting bracket is made from a polymeric material, then thermal isolation is improved, but structural strength may be reduced
Solution Approach 1:
The use of polymeric material in the mounting bracket provides inherent thermal isolation properties while maintaining sufficient structural strength through proper material selection and bracket design. The polymeric material acts as both the structural component and the thermal barrier, eliminating the need for separate thermal isolation components and resolving the contradiction between thermal protection and structural 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 solution enhances the securement and thermal isolation of temperature sensors and control components, improving the operational efficiency and safety of water heaters by maintaining temperature set points and preventing accidental exposure to hot water in case of bracket failure.
Implementation Method 1
The polymeric body may also includes a threaded portion that is configured to threadably engage a threaded spud in a water heater tank
Implementation Method 2
The sensor portion may have a distal end that extends into and supports the temperature sensor within the water heater tank
Data Source
AI summary
A mounting bracket for mounting a temperature sensor, a gas valve, a power delivery unit, a controller and/or any other suitable object or device to a water heater tank. An illustrative but non-limiting example may be found in a mounting bracket that includes a polymeric body that has a sensor portion configured to receive a temperature sensor. The sensor portion may have a distal end that extends into and supports the temperature sensor within the water heater tank. The polymeric body may also includes a threaded portion that is configured to threadably engage a threaded spud in a water heater tank such that the distal end of the sensor portion extends into the water tank of the water heater.