Resistor Anode Assembly With Protected Lead Connections
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Solution Overview
Problem
Existing sacrificial anode assemblies for water heaters are difficult to assemble and prone to damage, leading to accelerated corrosion of the water heater tank due to fragile resistor connections.
Innovation Solution
A sacrificial anode assembly design featuring a sacrificial anode with an insulator, an electric coupler, and a resistor with leads, where the electric coupler extends beyond the anode without a direct connection, and a cap is positioned to have a direct connection to the coupler but not the anode, enhancing manufacturing ease and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If an exposed solder connection is used to connect the resistor lead to the metal cap, then the assembly process is simplified, but the connection becomes susceptible to damage during installation and handling
Solution Approach 1:
The patent applies beforehand cushioning by providing recesses in the metal cap and anode that receive and protect the exposed solder connections. These recesses act as protective structures that cushion and secure the fragile solder joints before damage can occur during installation and handling, thus maintaining both ease of manufacture and connection durability
Solution Approach 2:
The patent uses the metal cap and anode recesses as intermediary protective structures between the fragile solder connection and the external environment. These intermediaries absorb mechanical stresses and protect the solder joint from damage during installation and shipping while allowing the simple exposed solder connection to remain
2Ease of manufacture
If the resistor connection is made fragile to simplify assembly, then manufacturing is easier, but the connection can be broken resulting in accelerated corrosion failure
Solution Approach 1:
The recesses in the metal cap and anode provide beforehand cushioning protection for the fragile resistor connections. By securing the connections in protected positions before installation, the patent prevents connection breakage that would lead to corrosion failure, thus maintaining manufacturing ease while eliminating the harmful corrosion risk
Solution Approach 2:
The patent converts the potential harm of fragile connections into a benefit by using the simplicity of exposed solder connections for easy assembly, then compensating with protective recesses. The fragile connection design becomes acceptable because the recesses ensure its protection, turning what would be a disadvantage into an acceptable trade-off that maintains both ease of manufacture and corrosion protection
3Reliability
If the anode assembly is made more robust to prevent damage, then reliability improves, but manufacturing complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the anode assembly into distinct components: the anode, metal cap, resistor, and insulator material. Each component has a specific function and can be manufactured separately, then assembled together. This segmentation allows for simplified manufacturing of individual parts while achieving overall assembly durability through proper design of each segment
Solution Approach 2:
The patent uses nesting by placing the insulator material inside the metal cap, which in turn fits onto the anode. The resistor is positioned within this nested structure. This nested arrangement protects internal components while maintaining a compact, simple external structure, thus improving reliability without significantly increasing manufacturing 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
The design improves manufacturing ease and reduces susceptibility to damage, thereby extending the anode's lifespan and preventing accelerated corrosion of the water heater tank.
Implementation Method 1
The addition of a resistor in the galvanic circuit can reduce the consumption time of the anode
Implementation Method 2
When water is introduced into the water heater tank, a galvanic circuit is created between the metal tank (and/or connectors) and the anode rod. As a result, electrical current flows from the anode, to the cathode
Implementation Method 3
The insulator is positioned around the anode and the electric coupler is positioned around the insulator
Data Source
AI summary
A sacrificial anode assembly. The sacrificial anode assembly includes a sacrificial anode, an insulator positioned around an end of the anode, an electric coupler positioned around the insulator and extending beyond the end of the anode, the electric coupler electrically isolated from the anode, a resistor having a first lead and a second lead, the first lead electrically connected to the anode and the second lead electrically connected to the electric coupler, and a cap positioned around the electric coupler, the cap electrically connected to the electric coupler and electrically isolated from the anode. The cap complete encapsulates the resistor, the first lead, and the second lead.