Adaption element for screw-in heaters of a hot water boiler
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing connections between screw-in heaters and hot water storage tanks face issues with electrical separation and hydraulic tightness, leading to potential leaks and corrosion due to manufacturing inaccuracies and temperature fluctuations.
Innovation Solution
A cylindrical adaptation element made of electrically insulating plastic with brass rings provides defined electrical separation and hydraulic tightness, using a threaded connection and O-rings for sealing, and incorporates a high-impedance resistor for current flow management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the heating element protrudes far into the storage tank to ensure adequate heating performance, then the heating efficiency is improved, but the bending moment on the electrically insulating seal increases leading to seal failure
Solution Approach 1:
The patent introduces an adaptation element as an intermediary component between the heating element and the storage tank. This adapter provides electrical insulation and mechanical support, allowing the heating element to be electrically isolated while maintaining structural stability and reducing the bending moment on the seal.
Solution Approach 2:
The connection system is divided into separate functional components: the heating element, the adaptation element (adapter), and the storage tank. This segmentation allows each component to perform its specific function optimally - the adapter handles electrical insulation and mechanical support, while the heating element focuses on thermal performance.
2Manufacturing precision
If manufacturing tolerances are tightened to improve fitting precision between components, then the assembly precision is improved, but the manufacturing cost and complexity increase
Solution Approach 1:
The adaptation element incorporates a defined electrical resistance as a key parameter, which provides both electrical insulation and a controlled current path. This parameter-based approach simplifies the design by using standard resistance values rather than requiring precise dimensional tolerances for electrical isolation.
Solution Approach 2:
The adaptation element serves multiple functions simultaneously: electrical insulation, mechanical support, and defined current path provision. This multi-functionality reduces the need for separate components and simplifies the overall assembly, compensating for standard manufacturing tolerances.
3Reliability
If the seal is made more rigid to improve sealing performance, then the hydraulic tightness is improved, but the seal's resistance to temperature jumps and mechanical stress decreases
Solution Approach 1:
The adaptation element uses composite construction combining electrically insulating material with integrated sealing elements. This composite approach allows the seal to be optimized for both tightness and flexibility, with the insulating material providing structural support while the sealing elements accommodate thermal expansion and contraction.
4Reliability
If the screw-in heater is electrically isolated from the storage tank to prevent anode consumption, then the anode protection efficiency is improved, but the electrical connection complexity increases
Solution Approach 1:
The adaptation element acts as an electrical intermediary, providing insulation between the heating element and storage tank while incorporating a defined resistance for controlled current flow. This single component solution simplifies the electrical connection system compared to using separate insulators and resistors.
Solution Approach 2:
The defined electrical resistance in the adaptation element provides a controlled parameter for current flow, transforming the electrical isolation from a binary state (completely isolated or connected) to a controlled resistance-based connection that protects the anode while allowing minimal current flow.
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
Ensures reliable electrical separation and hydraulic tightness, protecting against corrosion and leaks while allowing for easy assembly and use with conventional connections, enhancing the service life of the seal and the heating system.
Implementation Method 1
the sleeve accommodating the stainless steel screw-in heater has electrical insulation so that there is no current flow from the heating coils of the screw-in heater to the anode
Implementation Method 2
a defined resistance between two contact bodies enables a limited current flow
Implementation Method 3
The adaptation element is sealed by seals, preferably O-rings, to the screw-in heater and the storage sleeve
Implementation Method 4
Sacrificial anodes are used to protect the metal. This is a base metal, such as magnesium, which is electrically connected to the metal to be protected. The base metal then acts as the anode and the metal to be protected as the cathode, with current flowing in the direction of the metal to be protected.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The adaptation element (1) has an electrical conductive contact body (7) i.e. brass ring, in electrical connection with a storage sleeve (6). Another electrical conductive contact body (8) is in electrical connection with a screw-in heating body (2). An electric resistor is arranged between the electrical conductive contact bodies. The adaptation element is made of electrical insulative material i.e. plastic. A cylindrical mold comprises an outer screw thread for connecting with the storage sleeve at an end. An inner screw thread is connected with the screw-in heating body at another end.