Conduit and junction box assemblies and methods for water heaters
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Solution Overview
Problem
In existing water heaters, the hardened insulating foam between the tank and jacket prevents the replacement of control lines, necessitating external installation, which is costly and aesthetically unpleasing.
Innovation Solution
A system of conduits and junction boxes is used to route wires externally between the control system and electrical devices, with conduits placed between the tank and jacket, allowing for easy replacement of control lines without disrupting the insulating foam.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If control lines are routed through hardened insulating foam between tank and jacket, then insulation performance is improved, but control line replacement becomes impossible
Solution Approach 1:
The space between tank and jacket is segmented into two functional zones: a foam-filled insulation zone and a conduit-based wire management zone. Conduits are installed within the foam layer, creating dedicated pathways that separate the insulation function from the wire routing function, enabling both thermal efficiency and serviceability.
Solution Approach 2:
Conduits act as intermediary structures embedded within the insulating foam. These conduits provide protected pathways for control lines while maintaining the integrity and continuity of the foam insulation layer, allowing wire replacement without compromising thermal performance.
2Ease of repair
If control lines are installed on exterior of jacket, then control line replacement becomes possible, but aesthetics deteriorate and additional protection is needed
Solution Approach 1:
Conduits are nested within the insulating foam layer between the tank and jacket, creating a hidden wire management system. The control lines are routed through these concealed conduits, eliminating the need for external wire routing and maintaining a clean, finished appearance while enabling easy wire replacement.
3Reliability
If wire sheathing is added to protect external control lines, then protection is improved, but cost and complexity increase
Solution Approach 1:
The conduit system merges multiple functions into a single integrated structure: thermal insulation maintenance, mechanical protection of control lines, and facilitated wire replacement. The conduits are embedded within the existing foam insulation, eliminating the need for separate wire sheathing and reducing overall system complexity.
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
Enables straightforward replacement of control lines internally, eliminating the need for external installations, reducing costs and improving aesthetics by maintaining a clean, finished appearance.
Implementation Method 1
The layer of hardened insulating foam 116 insulates the water tank 102 to reduce parasitic heat conduction from the water tank 102 to the air outside of the jacket 104
Data Source
AI summary
A junction box is provided for use with a water heater, a conduit, and a wire, the water heater having a water tank, a jacket separated from and concentrically surrounding the water tank, a coupling on the water tank, an electrical device associated with the coupling, and insulation disposed between the water tank and the jacket, the conduit being configured to be disposed between the water tank and the jacket, the wire being configured to be disposed within the conduit and being configured to be connected to the electrical device, the jacket having a jacket opening at the coupling.