Flat Water Heater with Direct Tank Coupling to Eliminate By-Pass Ducts
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Solution Overview
Problem
Existing flat-type storage water heaters with tanks connected in parallel require additional components and processing due to the need for by-pass ducts, which increases overall dimensions and complicates enamelling, making it difficult to maintain standard dimensions and energy efficiency.
Innovation Solution
The water heater connects tanks in parallel using direct reciprocal coupling means, such as plane bosses with induction brazing, eliminating the need for by-pass ducts and allowing for electrostatic powder enamelling, while maintaining compact dimensions and energy performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If by-pass ducts are used to connect tanks in parallel, then tanks can be connected in parallel for faster hot water availability, but the overall width dimensions increase beyond standard Flat water heater dimensions
Solution Approach 1:
The patent merges the tank connection function directly into the tank walls by integrating coupling means (such as flanges or direct welding surfaces) on the adjacent shells. This eliminates the need for separate by-pass ducts and reduces the width dimension while maintaining parallel connection functionality for fast hot water availability.
Solution Approach 2:
The patent extracts the by-pass duct component from the system and replaces it with direct coupling means integrated into the tank shells. This removal of the intermediate by-pass duct component eliminates the need for additional processing and reduces the overall width dimension while preserving the parallel connection function.
2Reliability
If by-pass ducts with circumferential welding are used, then tanks can be connected in parallel, but electrostatic powder enamelling cannot be uniformly applied to welding zones and duct interiors
Solution Approach 1:
The patent merges the connection function directly into the tank walls, eliminating separate by-pass ducts. This integration ensures that the entire surface including connection zones can be uniformly enamelled using the standard electrostatic powder process, as there are no separate duct interiors or circumferential welding zones that would prevent uniform coating application.
Solution Approach 2:
The patent extracts and eliminates the by-pass duct component that caused the enamelling problem. By removing this intermediate component with its circumferential welding zones and interior surfaces, the patent allows uniform electrostatic powder enamelling application across all tank surfaces without the Faraday cage and back-ionization effects that plagued the previous design.
3Adaptability or versatility
If by-pass ducts are used for parallel connection, then additional components and processing are required, but this increases device complexity and production costs
Solution Approach 1:
The patent merges the parallel connection functionality directly into the tank structure through integrated coupling means on adjacent shells. This eliminates the need for separate by-pass ducts, reducing the number of components and simplifying the device while maintaining the adaptability and versatility of parallel connection capability for fast hot water delivery.
Solution Approach 2:
The patent extracts and removes the by-pass duct component from the system, eliminating the associated complexity of additional components and processing steps. The parallel connection capability is maintained through direct coupling means integrated into the tank shells, reducing device complexity while preserving functionality.
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 reduces the overall width of the water heater, enables retrofitting, and allows for uniform enamelling, maintaining energy efficiency and compact dimensions comparable to those with tanks connected in series, while avoiding the drawbacks of traditional by-pass ducts.
Implementation Method 1
plane bosses with induction brazing
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3A~4
AI summary
The object of the present invention is a Flat water heater (1) having at least two tanks (2.D, 2.S) connected in parallel by direct reciprocal coupling means (6), comprising at least two opposing pairs of plane bosses (6.D, 6.S) having a circular cross-section, made by moulding on the adjacent shells of two contiguous tanks of said at least two tanks (2.D, 2.S). Each of said plane bosses (6.D; 6.S) comprises a circular opening (6.DA; 6.SA), circumscribed by an annular collar (6.DB; 6.SB), slightly projecting from the surface of the shell and jointed thereto by jointing portions (6.DR; 6.SR).