Abstract: A sacrificial anode assembly operative to inhibit corrosion in the metal tank portion of a water heater includes a cylindrical metal anode member having an end retained within a tubular, electrically non-conductive plastic insulating sleeve which, in turn, is captives retained within a metal cap portion of the assembly. A resistor is received in an end surface groove of the sleeve and has a lead wire spot-welded or soldered to a core wire portion of the anode member. To prevent contact between the lead wire and the metal cap, and to protect the lead wire against vibration caused breakage at its spot weld or solder area, a U-shaped central portion of the lead wire is received in a through-opening in the resistor-supporting end of the sleeve which is covered by an annular insulating wafer formed from an electrically non-conductive material.

Abstract: Electrical resistance heating elements, hot water heaters containing such elements, and methods of preparing such elements are provided. The electrical resistance heating elements of this invention can be disposed through a wall of a tank for heating fluid, such as water. They include a skeletal support frame having a first supporting surface thereon. They also include a resistance wire wound onto the first supporting surface and preferably connected to at least a pair of terminal end portions. The support frame and resistance wire are then hermetically encapsulated and electrically insulated within a thermally-conductive polymeric coating. The skeletal support frame of this invention improves injection molding operations for encapsulating the resistance wire, and can include heat transfer fins for improving thermal conductivity.

Abstract: Electrical resistance heating elements are provided which are useful in heating fluid mediums, such as air and water. The heating elements include an element body having a supporting surface and a resistance wire wound onto the supporting surface which is connected to a pair of terminal end portions. Disposed over the resistance wire, and over most of the supporting surface, is a thermally-conductive polymeric coating which hermetically encapsulates and electrically insulates the resistance wire from the fluids to be heated. This thermally-conductive polymer coating has a thermal conductivity value of at least about 0.5 W/m .degree.K. Improved properties are preferably provided by ceramic powder, such as Al.sub.2 O.sub.3 and MgO, and glass fiber additives.

Abstract: Electrical resistance heating elements, hot water heaters containing such elements, and methods of preparing such elements are provided. The electrical resistance heating elements of this invention can be disposed through a wall of a tank for heating fluid, such as water. They include a skeletal support frame having a first supporting surface thereon. They also include a resistance wire wound onto the first supporting surface and preferably connected to at least a pair of terminal end portions. The support frame and resistance wire are then hermetically encapsulated and electrically insulated within a thermally-conductive polymeric coating. The skeletal support frame of this invention improves injection molding operations for encapsulating the resistance wire, and can include heat transfer fins for improving thermal conductivity.

Abstract: A water heater includes a metal storage tank for holding a quantity of water to be heated. Extending into the interior of the tank is a sacrificial anode assembly operative to inhibit corrosion of the tank and including a cylindrical metal anode member having an end retained within a cylindrical plastic insulating sleeve which, in turn, is captively retained within a metal cap portion of the assembly. To regulate the amount of electrical current generated by the assembly during use thereof, a barrel-shaped resistor is supported within the assembly and interconnected between its anode and cap portions. The insulating sleeve has a generally U-shaped groove formed in a closed end thereof, with one leg of the groove extending diametrically across a central opening in the sleeve end that receiving a core wire portion of the anode member, and the other groove leg extending generally chordwise relative to the sleeve end.

Abstract: A sacrificial anode assembly is insertable into a metal water storage tank to inhibit corrosion thereof and includes a cylindrical metal anode member having an end retained within a cylindrical plastic insulating sleeve which, in turn, is captively retained within a metal cap portion of the assembly. To regulate the amount of electrical current generated by the assembly during use thereof, a barrel-shaped resistor is supported within the assembly and interconnected between its anode and cap portions. The insulating sleeve has a generally U-shaped groove formed in a closed end thereof, with one leg of the groove extending diametrically across a central opening in the sleeve end that receives a core wire portion of the anode member, and the other groove leg extending generally chordwise relative to the sleeve end.