Stainless Steel Water Heater Tank With Deep-Drawn Welded Halves
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Solution Overview
Problem
Existing pressure tank manufacturing techniques in stainless steel require numerous parts, extensive welding, and significant material usage, limiting tank volume and efficiency, while plastic tanks are unsuitable for high-temperature and pressure applications.
Innovation Solution
A pressure tank design featuring two identical deep-drawn tank halves welded together in a common dividing plane, using encircling flanges as melting material for joining without additional material, reducing the welding path and allowing thinner plate usage, along with a method for internal staining to ensure a strong and seamless weld.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional rolled plate welding method is used, then weld joint strength can be achieved, but welding path length increases and material thickness must be increased to avoid through-burning
Solution Approach 1:
The tank is divided into two identical deep-drawn halves that are joined together. This segmentation allows for a more efficient welding approach where the weld is concentrated at the joining plane rather than distributed along a long rolled seam, reducing the overall welding path length while maintaining joint strength
Solution Approach 2:
The invention transitions from a rolled plate construction (1D seam welding) to a deep-drawn half-tank assembly (2D face welding). By changing the dimensional approach to joining, the weld path is concentrated at the circular joining plane rather than extending along the length of the tank, significantly reducing total weld length
2Strength
If traditional rolled plate welding method is used, then tank structural integrity is maintained, but plate thickness must be increased to ensure safe welding without through-burning
Solution Approach 1:
The invention changes the welding parameters and approach by using deep-drawn halves with integrated flanges that are positioned for optimal welding. This allows the use of thinner plates (reducing weight) while maintaining structural integrity through proper weld design and execution at the joining plane
3Adaptability or versatility
If many parts are used in tank construction, then assembly flexibility is improved, but device complexity and material usage increase
Solution Approach 1:
The invention merges multiple functions into the deep-drawn tank halves: the halves themselves, the joining flanges, and the structural components are integrated into a single forming operation. This reduces the number of separate parts while maintaining assembly flexibility, as the two identical halves can be assembled in different configurations
Solution Approach 2:
The deep-drawn tank halves serve multiple functions: they form the tank structure, provide the joining surfaces via integrated flanges, and define the internal volume. This multi-functionality reduces the need for separate components, simplifying the overall device while maintaining versatility
4Ease of manufacture
If traditional deep drawing limitations are applied, then manufacturing simplicity is maintained, but tank volume is limited to about 100 liters
Solution Approach 1:
By segmenting the tank into two deep-drawn halves that are joined together, the invention overcomes the volume limitation of single-piece deep drawing. Each half can be drawn to optimal dimensions, and when joined, they create a larger total volume while maintaining the simplicity of the deep drawing process for each component
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 results in a lighter, more efficient tank with reduced material usage, simplified assembly, and increased volume flexibility, achieving a safe and strong weld without internal crevices, while minimizing the need for additional material and operations.
Implementation Method 1
the flange in its entirety is melted during the welding and forms a surface which largely is in line with the tank wall
Implementation Method 2
the joining together of the tank parts takes place with the help of a clamp ring and gaskets
Implementation Method 3
it is possible to weld by using a greater strength of current and also to be able to operate at a higher welding speed by using laser welding without additional material
Data Source
AI summary
The present invention relates to a pressure tank in stainless steel to be used as a water heater. The tank is provided by two identical tank halves (12a, 12b; 14a, 14b). The two tank halves are joined about a common dividing plane (7) and have a longitudinal axis (26) that lies in the dividing plane (7) so that an extended tank is provided. The tank halves have welding flanges (22a, 22b) that are placed against each other in the joint dividing plane (7) and are joined together by welding or melting of the flanges (22a,22b) to a watertight tank. The plate thickness is calculated according to the maximum test pressure of the tank and not limited by the welding. An efficient welding of the internal welding seam (24), by placing the tank in a rig and rotating the tank, provides safe protection against corrosion in the weld.