Flexible Connector Design for Water Heater Spud-to-Pipe Misalignment
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Solution Overview
Problem
The existing tank-type water heaters face installation challenges due to a large gap between the top of the tank and the shroud, which can result in misalignment of pipe nipples, leading to perpendicular offsets that complicate threaded interconnections and may damage threads, especially when manufacturing tolerances cause the spud axis to deviate from the pipe axis.
Innovation Solution
The use of a flexible connector with a non-collinear axis at one end and a collinear axis at the other, combined with a torque carrier to prevent rotation, allows for smooth threading and fluid communication between the tank and pipes, even when the spud axis is not collinear with the pipe axis, and includes rigid connectors and a mixing valve for enhanced functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If long pipe nipples are used to span the component space, then the gap between spuds and pipes can be bridged, but misalignment and perpendicular offsets occur leading to thread damage
Solution Approach 1:
The patent employs a flexible connector instead of a rigid long pipe nipple to bridge the component space. The flexible connector can dynamically adjust to misalignments between the spud axis and pipe axis, accommodating manufacturing tolerances without causing thread damage. This dynamic flexibility resolves the contradiction by allowing the connector to adapt to varying alignment conditions while maintaining secure threaded connections.
Solution Approach 2:
The patent changes the physical state or properties of the connector from rigid to flexible, allowing it to bend and accommodate angular deviations. This parameter change enables the connector to handle misalignments up to certain degrees without transmitting damaging forces to the threads, thus resolving the contradiction between spanning large gaps and maintaining thread alignment precision.
2Manufacturing precision
If the spud axis deviates from the pipe axis due to manufacturing tolerances, then assembly becomes difficult, but using rigid connectors transmits misalignment forces to threads causing damage
Solution Approach 1:
The patent uses a flexible connector with corrugated or bent geometry to accommodate axis deviations between spuds and pipes. This flexible structure absorbs misalignment forces that would otherwise be transmitted to the threaded connections, preventing thread damage while allowing assembly despite manufacturing tolerances. The flexible connector essentially decouples the rigid alignment requirements from the connection points.
Solution Approach 2:
The flexible connector acts as an intermediary element between the spud and the pipe, absorbing and isolating misalignment forces. This intermediary component protects the threaded connections from damaging forces while still enabling fluid communication, thus resolving the contradiction between accommodating axis deviation and preventing thread damage.
3Reliability
If a flexible connector is used to accommodate misalignment, then thread damage is prevented, but the connector may rotate under torque during installation
Solution Approach 1:
The patent segments the connection system into distinct functional zones: rigid connectors for torque transmission and alignment, and flexible connectors for accommodating misalignment. By separating these functions and using rigid connectors at the interface between flexible connectors and pipes/spuds, the system prevents rotation of the flexible connector while maintaining its ability to accommodate misalignment, thus resolving the contradiction between connection integrity and installation control.
Solution Approach 2:
The patent employs preliminary alignment features such as alignment pins or keyed interfaces in the rigid connectors to establish proper orientation before the flexible connector is installed. This preliminary action prevents rotation during installation by pre-establishing the correct angular position, allowing the flexible connector to be properly seated without rotating under torque, thus maintaining both connection integrity and installation control.
Data Source
AI summary
A water heater includes a tank defining an interior space adapted to contain water and a shroud over the water heater and defining a component space inside the shroud. A first pipe nipple is coupled to a spud of the water heater, the first pipe nipple and spud defining a non-collinear axis that is non-collinear with a pipe axis of a pipe to be fluidly connected to the tank. A flexible connector is connected at one end to the first pipe nipple along the non-collinear axis. A second end of the flexible connector is positioned collinear with the pipe axis. A second pipe nipple is coupled at one end to the second end of the flexible connector and coupled at an opposite end with the pipe. Fluid communication is established between the pipe and the interior space of the tank through the pipe nipple and flexible connector.