Modular Manifold Assembly for Scalable Tankless Water Heaters
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Solution Overview
Problem
Existing tankless water heaters require multiple manifolds of fixed sizes, leading to increased manufacturing and inventory costs due to the need for various configurations, as a single, unitary manifold is not adaptable to different applications.
Innovation Solution
A modular manifold design that allows for the coupling of varying numbers of fluid flow conduits, enabling the construction of tankless water heaters of different sizes and configurations, reducing manufacturing and inventory costs by enabling the use of interchangeable components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a one-piece manifold is used for tankless water heaters, then the structural integrity and simplicity of the component is maintained, but the adaptability to different heating capacities and configurations is reduced
Solution Approach 1:
The manifold is divided into multiple separate cavity members (first cavity member, second cavity member, etc.) that can be coupled together in series. Each cavity member can accommodate a specific number of conduits and heating elements, and multiple cavity members are assembled together to achieve the desired total capacity. This segmentation allows the same basic component design to be used across different heating capacities by simply varying the number of cavity members assembled.
Solution Approach 2:
The cavity members are designed with universal coupling features (such as coupling members with complementary receiving features) that allow the same component design to serve multiple functions across different applications. The same first cavity member design can be used in 2-conduit, 4-conduit, 6-conduit, or higher capacity configurations by assembling different numbers of these universal components together.
2Adaptability or versatility
If multiple fixed-size manifolds are manufactured to accommodate different heating capacities, then the specific performance requirements for various applications are met, but the manufacturing and inventory costs increase
Solution Approach 1:
By segmenting the manifold into standardized cavity members, the manufacturer produces a limited set of modular components rather than multiple complete manifold designs. This reduces tooling requirements, simplifies production processes, and decreases inventory complexity while still allowing customization of final product capacity through assembly of different numbers of the same modular units.
Solution Approach 2:
The system allows the capacity parameter of the water heater to be changed by varying the number of cavity members assembled together, rather than manufacturing completely different manifold designs for each capacity level. This parameter change approach maintains manufacturing efficiency while providing product variety.
3Power
If the number of conduits and heating elements is increased to meet higher heating capacity requirements, then the heating performance is improved, but the number of different manifold designs required increases
Solution Approach 1:
The manifold system is segmented into cavity members that can be assembled in series to accommodate increasing numbers of conduits and heating elements. Each cavity member has standardized openings and coupling features that allow scalable assembly, so heating capacity can be increased by simply adding more cavity members rather than redesigning the entire manifold.
Solution Approach 2:
Multiple cavity members are nested or coupled together in a hierarchical arrangement where each cavity member contains a subset of the total conduits and heating elements. The coupling members allow these nested units to be assembled into a complete manifold system that achieves the desired total capacity while maintaining structural coherence.
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 modular manifold allows for the creation of tankless water heaters of various sizes and configurations, decreasing manufacturing and inventory costs while accommodating diverse applications, enhancing flexibility and efficiency.
Implementation Method 1
a heating element inserted in at least one of the plurality of fluid flow conduits and configured to transfer heat to the fluid
Data Source
AI summary
A modular manifold for a tankless water heater includes a first cavity member and a second cavity member. The first cavity member includes a first opening, a second opening, and a first base wall. The second cavity member is coupled to the first cavity member and includes a first opening, a second opening, and a second base wall. Two of the openings are configured to receive a first conduit and a second conduit. The first and second base walls and the two openings that receive the first and second conduits define a fluid flow path through the modular manifold.