Water Heater Temperature Switch With Combustion Chamber Probe
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional temperature monitoring systems for gas fueled water heaters are unreliable and prone to ambient temperature influences, making it difficult to accurately detect unsafe combustion chamber temperatures, which can lead to incomplete combustion or production of unwanted by-products.
Innovation Solution
A gas fueled water heater appliance with a conductive probe extending through the chamber wall from an outer temperature control switch to an inner surface within the combustion chamber, allowing for direct temperature measurement independent of ambient conditions, and a temperature control switch that communicates with the gas valve to shut off fuel flow when unsafe temperatures are reached.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a temperature-dependent switch is placed in direct contact with the outer surface of the combustion chamber wall, then the switch can detect temperature changes, but the measurement is indirect and influenced by ambient temperatures rather than directly measuring combustion chamber temperature
Solution Approach 1:
A thermally conductive probe is introduced as an intermediary element that extends from the temperature-dependent switch into the combustion chamber. The probe conducts heat directly from the combustion chamber environment to the switch, serving as a thermal mediator that isolates the switch from ambient temperature influences while maintaining accurate temperature sensing capability.
Solution Approach 2:
The patent replaces the conventional approach of direct mechanical contact with the chamber wall with a thermal conduction-based system. Instead of relying on ambient heat transfer to the switch housing, the system uses a dedicated thermal conduction path through the probe, substituting indirect thermal fields with a controlled thermal conduction mechanism.
2Measurement precision
If the switch is placed in contact with the combustion chamber wall, then temperature monitoring is enabled, but ambient temperatures can draw heat from the wall and prevent the switch from detecting unsafe temperatures
Solution Approach 1:
The thermally conductive probe acts as a thermal intermediary that preferentially conducts heat from the combustion chamber to the switch, outweighing the parasitic heat draw to the chamber wall. This intermediary path ensures that the switch responds to combustion chamber temperatures rather than being influenced by ambient conditions through the wall.
Solution Approach 2:
The system changes the thermal parameters of the monitoring setup by introducing a high thermal conductivity probe material and optimizing the probe's thermal mass and geometry. This parameter optimization ensures that the thermal conductance through the probe exceeds the thermal conductance through the chamber wall, making the switch insensitive to ambient temperature variations.
3Measurement precision
If a temperature sensor is mounted on or within the combustion chamber with a control board, then direct temperature measurement is achieved, but assembly and installation difficulty increases and the system becomes susceptible to damage at the control board
Solution Approach 1:
The patent combines the temperature-dependent switch and the thermally conductive probe into a single integrated temperature monitoring assembly. This merged design eliminates the need for separate control board electronics within the combustion chamber, simplifying assembly and installation while maintaining direct temperature measurement capability. The entire monitoring function is achieved through the passive thermal conduction mechanism.
Solution Approach 2:
The control electronics (switch) are extracted from the combustion chamber environment and placed outside, connected only through the passive thermal conduction path of the probe. This extraction removes the complex electronic components from the harsh combustion environment, reducing installation complexity and protecting sensitive electronics from damage while preserving temperature sensing functionality.
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 accurate and reliable temperature monitoring, ensuring safe operation by preventing overheating and reducing the risk of incomplete combustion or by-product production, regardless of ambient conditions.
Implementation Method 1
The conductive probe may extend through the chamber wall from a first end positioned on the temperature control switch to a second end positioned within the combustion chamber
Data Source
AI summary
A gas fueled water heater appliance having a temperature control switch is provided herein. The gas fueled water heater appliance may include a tank for storage of water for heating, a chamber wall, a gas burner, a valve, the temperature control switch, and a conductive probe. The chamber wall may define a combustion chamber. The gas burner may be positioned adjacent to the tank and within the combustion chamber to heat the water in the tank. The valve may control a flow of gaseous fuel to the gas burner. The temperature control switch may be in operable communication with the valve. The conductive probe may extend through the chamber wall from a first end positioned on the temperature control switch to a second end positioned within the combustion chamber.