Multi-Function Water Sensor Assembly for Fast Low-Maintenance Sensing
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Solution Overview
Problem
Existing water quality sensors for spas suffer from slow response times, high maintenance requirements, and high costs due to individual packaging and complex installations, particularly affecting temperature, flow, conductivity, ORP, and pH measurements.
Innovation Solution
A multi-functional sensor assembly with a compact, non-conductive substrate featuring conductive traces in three regions, including electrodes for conductivity, ORP, and pH sensing, and circuits for temperature and flow sensing, utilizing heat pulses and dynamic electrode polarization to achieve fast and reliable measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a stainless steel dome is used to protect the temperature sensor, then corrosion resistance is improved, but response time deteriorates due to increased thermal mass
Solution Approach 1:
The patent removes the protective stainless steel dome from the temperature sensor, extracting the harmful thermal mass while maintaining sensor functionality through alternative protective measures
Solution Approach 2:
The sensor assembly integrates multiple sensing functions (temperature, flow, conductivity, ORP, pH) into a single multi-functional device, eliminating the need for separate protected temperature sensors
2Ease of operation
If traditional impeller type flow sensors are used, then flow measurement capability is achieved, but reliability deteriorates due to vulnerability to debris and corrosion
Solution Approach 1:
The patent replaces mechanical impeller-based flow sensing with a thermal-based flow sensor that uses heated elements and temperature differential measurement, eliminating mechanical parts vulnerable to debris and corrosion
Solution Approach 2:
The invention changes the measurement parameter from mechanical rotation to thermal conductivity differential, using resistance changes in heated wires to detect flow rate without mechanical components
3Measurement precision
If equilibrium reference electrodes are used for pH and ORP sensing, then measurement accuracy is improved, but maintenance requirements increase due to membrane clogging and electrolyte mixing
Solution Approach 1:
The patent employs non-equilibrium reference electrodes that can be easily replaced or recalibrated, treating the reference electrode as a consumable component rather than a permanent fixture requiring meticulous maintenance
Solution Approach 2:
The invention changes from equilibrium reference electrodes to non-equilibrium reference electrodes, fundamentally altering the operational mode to eliminate membrane clogging and electrolyte mixing issues
4Reliability
If individual temperature, flow, conductivity, ORP, and pH sensors are packaged separately, then each sensor can be optimized for its specific function, but device complexity and installation cost increase
Solution Approach 1:
The patent combines multiple individual sensors (temperature, flow, conductivity, ORP, pH) into a single integrated sensor assembly, merging their functions while maintaining individual optimization through separate sensing elements
Solution Approach 2:
The invention creates a multi-functional sensor assembly that performs temperature, flow, conductivity, ORP, and pH measurements simultaneously, providing universal water quality monitoring in one device
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 sensor provides fast, low-maintenance, and cost-effective monitoring of temperature, flow, conductivity, ORP, and pH with reduced thermal mass and interference, enabling sub-second response times and minimal calibration needs.
Implementation Method 1
The electrically conductive traces comprise at least electrical circuits to sense temperature and flow of the media and one or more electrodes to sense one or more of conductivity, oxidation reduction potential (ORP), and acidity (pH) of the media
Implementation Method 2
utilizing heat pulses and dynamic electrode polarization to achieve fast and reliable measurements
Implementation Method 3
utilizing heat pulses and dynamic electrode polarization to achieve fast and reliable measurements
Data Source
AI summary
A multi-functional sensor assembly includes an electrically non-conductive substrate defining at least a distal region, intermediary region, and proximal region that are each covered with electrically conductive traces. The proximal region is configured to be exposed to a media to be sensed and the distal and intermediary regions are configured to be protected from the media. The electrically conductive traces comprise at least electrical circuits to sense temperature and flow of the media and one or more electrodes to sense one or more of conductivity, oxidation reduction potential (ORP), and acidity (pH) of the media.