Plastic Boiler Heater Mounting Without Metal Flanges
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Solution Overview
Problem
The high manufacturing costs and complexity of metal components in existing plastic boilers for heating flowable media, such as water, due to the need for metal mounting flanges and sealing measures, hinder cost-effective production and assembly.
Innovation Solution
Designing a plastic boiler with an unheated section for the heating device that matches the inner diameter of the installation opening, allowing for direct insertion and sealing without a separate mounting flange, and using a clamping element for secure attachment, which can be deformed to engage with the boiler housing, thereby simplifying assembly and reducing material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metal mounting flange is used to attach the heating device to the boiler housing, then the heating device can be securely fastened, but the manufacturing costs increase due to high material costs and complex sealing measures
Solution Approach 1:
The patent replaces the expensive metal mounting flange with a plastic heating device body that integrates the mounting function. The heating device itself serves as the mounting component, eliminating the need for separate metal flanges and reducing material costs while maintaining secure attachment through the integrated design
Solution Approach 2:
The patent combines the heating device body with the mounting function into a single integrated component. The heating device is designed with an outer diameter that directly corresponds to the installation opening, merging the heating function and mounting function into one element, thereby eliminating separate mounting flanges and complex sealing measures
2Ease of operation
If a large opening is provided in the boiler housing for the mounting flange, then the heating device can be attached, but the sealing complexity and production costs increase
Solution Approach 1:
The patent merges the heating device body with the mounting interface, designing the heating device's outer diameter to match the installation opening. This integration eliminates the need for separate large mounting flanges and reduces sealing complexity to a simple seal between the heating device and boiler housing
Solution Approach 2:
The patent replaces complex metal flange sealing systems with a simpler plastic-based sealing solution. A single seal element is used between the heating device and boiler housing, eliminating the need for complex metal flange sealing measures and reducing production costs
3Strength
If metal components are used in the plastic boiler, then the heating device can be securely mounted, but the manufacturing costs increase
Solution Approach 1:
The patent uses homogeneous plastic material for both the boiler housing and the heating device body. This material uniformity eliminates the need for metal components while maintaining sufficient mounting strength through the integrated plastic design, thereby reducing manufacturing costs and simplifying production
Solution Approach 2:
The patent replaces expensive metal mounting components with a plastic heating device body that provides sufficient mounting strength. The integrated plastic design eliminates the need for metal flanges and fasteners, reducing material costs while maintaining adequate attachment strength for the application
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 approach reduces manufacturing costs and simplifies the assembly process by eliminating the need for metal flanges and complex sealing measures, while ensuring a secure and reliable attachment of the heating device within the plastic boiler housing.
Implementation Method 1
heating device (40) for heating a flowable medium
Implementation Method 2
In order to ensure that the heat generated by the heating device does not damage the walls of the boiler housing made of plastic, it is also provided that the unheated section of the heating device continues on the inside of the boiler housing
Data Source
Figure 1~3
Figure 4~5
Figure 6~7
AI summary
The invention relates to a boiler (10) for heating a flowable medium, in particular for heating water, with a boiler housing (12) made of plastic and with a heating device (40) which can be installed via an assembly opening (46) in the boiler housing (12) in protrudes into the interior of the bollard housing (12) and is fixed in the mounting opening (46) by fastening means (56). It is also provided that the inner diameter of the assembly opening (46) in the boiler housing (12) at least partially corresponds at least approximately to the outer diameter of the heating device (40) and that the heating device has an unheated section (42) in the region of the assembly opening (46).