Composite Water Heater Sensor Bracket for Secure Thermal Mounting
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Solution Overview
Problem
Existing mounting solutions for temperature sensors, gas valves, and power delivery units in water heaters lack an efficient and secure method for attachment, leading to potential thermal isolation issues and safety concerns due to the lack of a robust and reliable mounting mechanism.
Innovation Solution
A polymeric mounting bracket with a sensor portion and threaded spud engagement system, featuring a thread lead-in region and distal end with a blade element for piercing barriers, along with a component retaining region with ribs for added support, designed to securely attach temperature sensors, gas valves, and power delivery units to the water heater tank.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional mounting bracket is used to attach temperature sensors and components to the water heater tank, then the components can be mounted, but thermal contact with the water tank is compromised and the mounting is not sufficiently secure
Solution Approach 1:
The mounting bracket utilizes a composite construction combining a polymeric body with a metal reinforcement insert. The polymeric material provides thermal insulation and corrosion resistance, while the metal insert ensures secure mechanical attachment to the water heater tank. This composite structure resolves the contradiction by maintaining structural integrity for secure mounting while managing thermal contact through material selection and design.
Solution Approach 2:
The mounting bracket is divided into distinct functional segments: a polymeric body for thermal management and component mounting, a metal reinforcement insert for secure attachment, and a threaded spud for tank engagement. This segmentation allows each part to optimize its specific function - the metal portion provides secure mechanical fastening while the polymeric portions manage thermal contact and provide mounting surfaces for sensors and components.
2Reliability
If the mounting bracket is designed with a threaded spud for secure engagement, then mounting reliability improves, but the complexity of installation increases due to the need to pierce barriers
Solution Approach 1:
The distal end of the mounting bracket incorporates a pre-formed cutting edge or piercing element that enables the bracket to cut through insulation and barrier materials during installation. This preliminary action feature allows the threaded spud to penetrate the tank wall and surrounding barriers in a single operation, combining the security of threaded engagement with simplified installation that does not require separate piercing steps.
3Measurement precision
If the sensor portion extends into the water tank to maintain thermal contact, then temperature sensing accuracy improves, but the risk of accidental breakage and safety hazards increases
Solution Approach 1:
The mounting bracket serves as an intermediary structure that extends into the water tank to provide thermal contact for the temperature sensor while simultaneously providing mechanical support and protection. The bracket's rigid structure protects the sensor from breakage, and the polymeric material provides thermal management. This intermediary design allows the sensor to maintain accurate thermal contact with the water while being protected from the harsh environment, thus resolving the safety hazard.
4Temperature
If a polymeric body is used for the mounting bracket to provide thermal insulation, then thermal management improves, but the structural strength and load-bearing capacity decrease
Solution Approach 1:
The mounting bracket employs a composite structure where a polymeric body provides thermal insulation and corrosion resistance, while a metal reinforcement insert embedded within the polymeric material provides the necessary structural strength and load-bearing capacity. This composite construction allows the bracket to simultaneously achieve good thermal management properties from the polymeric material and mechanical strength from the metal insert, resolving the contradiction between thermal insulation and structural strength.
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 or other appliance. 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. Various features for increasing the strength and durability of the bracket are also disclosed.