System, device and associated methods for temperature and pressure relief in a water heater
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional temperature and pressure relief valves in water heaters are prone to corrosion and calcification, leading to catastrophic failures such as fires and explosions due to the exposure of components to water, which results in structural damage, injuries, and deaths.
Innovation Solution
A temperature and pressure relief valve design that includes a protective chamber for the valve spring and a plunger assembly with protective fluids to prevent corrosion and calcification, ensuring the valve operates effectively during over-temperature and over-pressure events, with an end cap assembly and release mechanism for manual operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the valve components are exposed to water for normal operation and pressure relief, then the valve can perform its pressure relief function, but corrosion and calcification occur rendering the valve inoperative
Solution Approach 1:
The valve is divided into two separate chambers: a first chamber containing the valve spring and valve head, and a second chamber containing the thermal element assembly. This segmentation isolates critical components from water exposure while maintaining pressure relief functionality.
Solution Approach 2:
A piston assembly acts as an intermediary between the water environment and the valve spring/valve head. The piston transmits water pressure to open the valve while preventing direct water contact with the valve spring, thereby eliminating corrosion and calcification risks.
2Reliability
If the thermal element assembly is exposed to water for temperature sensing, then the valve can detect over-temperature conditions, but corrosion and mineral deposits affect the thermal element operation
Solution Approach 1:
The thermal element assembly is isolated in a separate second chamber from the water environment. This segmentation allows the thermal element to sense temperature through the tank wall without direct water contact, preventing corrosion and mineral deposit formation.
Solution Approach 2:
The tank wall and chamber structure serve as intermediaries that transmit thermal energy from the water to the thermal element without allowing direct water contact. This maintains temperature sensing capability while eliminating corrosive exposure.
3Reliability
If a conventional pressure relief valve design is used, then the valve can relieve overpressure, but the valve spring and components are subject to corrosion and calcification requiring regular manual testing and replacement
Solution Approach 1:
The protected valve design eliminates the need for regular manual testing and replacement by preventing corrosion and calcification through its sealed chamber architecture. The valve maintains operational reliability without requiring user intervention for maintenance, making it self-sustaining.
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 solution effectively prevents corrosion and calcification, ensuring the valve functions reliably, reducing the risk of fires and explosions by protecting the valve components from mineral deposits and water exposure.
Implementation Method 1
a protective chamber configured to contain a protective fluid to protect the valve spring from corrosion, calcification and mineral deposits
Implementation Method 2
A thermal element assembly is carried by an internal tongue of the valve casing and includes an elongated plunger body configured to detect an increase in temperature
Implementation Method 3
A valve assembly is carried by the valve casing and includes a moveable valve shaft and associated valve head sealingly biased against the valve seat by a valve spring
Data Source
AI summary
The T&P relief valve includes a valve casing. A valve assembly is carried by the valve casing and includes a moveable valve shaft and associated valve head sealingly biased against a valve seat by a valve spring which is sealed within a protective chamber configured to contain a first protective fluid. The valve spring is protected, by the protective chamber and first protective fluid, from corrosion, calcification and/or mineral deposits which would affect the valve assembly. A thermal element assembly is carried by an internal tongue of the valve casing. A plunger casing, encasing the upper end of the elongated plunger body and sealing around the captive plunger, is configured to contain a second protective fluid to protect the upper end and captive plunger from corrosion, calcification and/or mineral deposits which could affect the thermal element. An end cap assembly includes a casing seal held against the protective chamber by an end cap that is secured to, and closes, the open top of the valve casing.