Water Heater Shank Mount Assembly for Torque-Stable Calibration

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Solution Overview

Problem

Current water heating systems using machined brass shank mounts face issues with calibration shifts due to excessive torque during alignment, high material costs, and delayed calibration processes, as well as susceptibility to corrosion and temperature changes.

Innovation Solution

An annular shank mount assembly with a removable nipple and shank mount, made from less expensive materials like aluminum or steel, which provides a standard size for calibration and reduces torque transfer to the temperature probe, using a mechanical locking feature and O-rings for a water-tight seal.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a machined brass shank mount is used to provide a rigid mounting means and water-tight seal, then reliability and sealing are improved, but manufacturing cost increases and calibration shifts occur due to excessive torque

Engineering Contradiction:

Improvewater-tight seal and corrosion resistanceVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The shank mount assembly is divided into separate components: a nipple that provides the water-tight seal and a shank mount that provides structural support. This segmentation allows each component to be optimized for its specific function, reducing the need for expensive brass while maintaining reliability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent replaces expensive brass material with cheaper alternative materials such as aluminum or plastic for the shank mount body, while maintaining the essential sealing function through the nipple component. This substitution reduces manufacturing cost while preserving the water-tight seal requirement.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Manufacturing precision

If excessive torque is applied to align the gas valve assembly vertically, then alignment precision is improved, but the position of the invar rod shifts causing calibration errors

Engineering Contradiction:

Improvevertical alignmentVSAvoidtemperature calibration

Core Design Contradiction:

Manufacturing precisionVSMeasurement precision

Solution Approach 1:

The patent incorporates a torque distribution mechanism that cushions against excessive torque application during alignment. The design includes features that allow the assembly to accommodate torque variations without transmitting harmful forces to the temperature probe, thereby preventing calibration shifts while maintaining alignment precision.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The shank mount assembly acts as an intermediary between the mounting structure and the temperature probe, absorbing and distributing torque loads. This intermediary function protects the temperature probe from excessive torque that would otherwise cause calibration errors, while still enabling precise vertical alignment.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If brass material is used for the shank mount, then corrosion resistance is improved, but material cost increases

Engineering Contradiction:

Improvecorrosion resistanceVSAvoidmaterial cost

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The assembly uses composite construction combining different materials: the nipple provides sealing (can be brass or equivalent), while the shank mount body uses cost-effective materials like aluminum or plastic. This composite approach achieves corrosion resistance where needed without unnecessarily using expensive materials throughout the entire assembly.

Inventive Principle:

Principle #40Composite materials

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

Enables immediate calibration of temperature probes after production, reduces production costs, and minimizes calibration shifts by distributing torque loads effectively, while maintaining a water-tight seal and durability under high temperatures and pressures.

Implementation Method 1

The copper tube 126, having a high thermal coefficient of expansion, expands and contracts as the water temperature in the tank increases and decreases, respectively.

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS8776733B2Valve shank mount assembly for a water heater

Publication Date: 2014.07.15 ROBERTSHAW CONTROLS CO

AI summary

A shank mount assembly for a water heater that includes an annular nipple having an opening, the nipple configured to removably attach to an opening in a water heater tank. The shank mount assembly further includes an annular shank mount having an opening, the shank mount configured to removably attach to the nipple, wherein the shank mount is further configured to attach to a gas valve assembly.