Water Heater Tank Sensors With Foam-Biased Serviceable Mounting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing temperature sensor mounting systems for electric water heaters face challenges in accessing and replacing sensors due to thermal insulation, leading to complications in troubleshooting and repair, and require multiple sensors to accurately monitor water temperature across the tank, increasing costs and complexity.
Innovation Solution
A system utilizing expandable foam to pressure-bias temperature sensors against the tank's outer surface, allowing for precise temperature readings while enabling removable circuit boards and flexible conduit arrangements to facilitate sensor replacement and reduce insulation interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If temperature sensors are mounted on the tank wall and sealed with foam insulation, then temperature monitoring accuracy is improved, but access for replacement and repair becomes difficult
Solution Approach 1:
The system is divided into modular components: the circuit board with mounted sensors is separated from the tank structure, allowing the sensors to remain sealed against the tank wall for accurate measurement while the circuit board can be independently accessed and replaced through the outer casing
Solution Approach 2:
The foam insulation serves as an intermediary that performs dual functions: it seals the temperature sensors against the tank wall to ensure accurate temperature monitoring, while simultaneously being removable or accessible through the outer casing to allow sensor replacement without compromising the seal
2Measurement precision
If multiple temperature sensors are installed to monitor different regions of the tank, then temperature control precision is improved, but device complexity increases
Solution Approach 1:
Multiple temperature sensors are merged onto a single circuit board, which consolidates the wiring and connection infrastructure. This allows precise multi-point temperature monitoring while reducing overall system complexity by centralizing the sensor interface and control connections
3Loss of energy
If foam insulation is used to seal temperature sensors, then thermal insulation performance is improved, but access to sensors for troubleshooting becomes complicated
Solution Approach 1:
The system separates the sealing function (foam insulation against tank wall) from the access function (outer casing with access doors). The foam maintains thermal insulation performance by sealing sensors against the tank, while the modular outer casing allows convenient access for troubleshooting and sensor replacement
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 across the water heater tank, preventing bacterial growth and enabling efficient control of heating elements, while simplifying maintenance and reducing costs by integrating sensors within the existing insulation structure.
Implementation Method 1
A system utilizing expandable foam to pressure-bias temperature sensors against the tank's outer surface
Implementation Method 2
by sensing the temperature of the steel by mounting thermistors there against, the temperature of the water inside the tank can be fairly accurately determined
Data Source
AI summary
A temperature sensor securing system and method is described for securing two or more temperature sensors against an outer surface of a side wall of a tank of an electric water heater. The temperature sensors are secured spaced apart on an elongated support such as a circuit board which is held in position against the tank outer surface by support means. An expandable liquid foam causes the temperature sensors to be biased against the outer surface of the tank side wall to sense the temperature of the side wall at the location of the sensors and to generate actual temperature signals to a controller which is programmed to communicate with a subscriber and/or energy provider to control the water temperature inside the tank.