Patent Application
20250224144
Example aspects of the present disclosure relate generally to household appliances, such as water heater appliances.
Household appliances (e.g., a washer and/or dryer, water heater appliances, air conditioner appliances, kitchen appliances, etc.) are utilized for a variety of tasks by a variety of users. One such household appliance is a water heater appliance, which may be used for storing or supplying hot water to residential and commercial properties. Some water heater appliances include a housing, a tank attached to the housing, and a sealed system in thermal communication with the tank to heat the tank.
Residential water heaters hold a volume (e.g., about 2.5 gallons to about 50 gallons or more) of water inside the tank (e.g., a steel reservoir tank). Other residential water heaters are known as “constant flow” water heaters and include a relatively small tank or heat-exchange pipe in which water is heated as it flows through the water heater. Many water heaters permit a consumer to set the thermostat to a temperature between about 90 and about 150 degrees Fahrenheit (F) (about 32 to about 65 degrees Celsius (C)). To prevent scalding and to save energy, consumers may set the thermostat to heat the reservoir water to a temperature up to about 140 degrees F. (about 60 degrees C.), such as about 120 degrees F. (about 49 degrees C.).
Aspects and advantages of embodiments of the present disclosure will be set forth in part in the following description, or can be learned from the description, or can be learned through practice of the embodiments.
One example aspect of the present disclosure is directed to a water heater appliance. The water heater appliance may include a tank. The water heater appliance may further include a gas valve. The water heater appliance may further include a blower. The water heater may further include a power circuit. The power circuit may include a gas valve controller on a gas valve control printed circuit board. The power circuit may further include a first power conductor coupled to a blower motor of the water heater appliance. The power circuit may further include a second power conductor coupled to the blower motor of the water heater appliance through a relay such that the power circuit for the blower motor bypasses the gas valve control printed circuit board.
These and other features, aspects and advantages of various embodiments will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the present disclosure and, together with the description, serve to explain the related principles.
Detailed discussion of embodiments directed to one of ordinary skill in the art are set forth in the specification, which makes reference to the appended figures, in which:
Repeat use of reference characters in the present specification and drawings is intended to represent the same and/or analogous features or elements of the present invention.
Reference now will be made in detail to embodiments, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the embodiments, not limitation of the present disclosure. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made to the embodiments without departing from the scope or spirit of the present disclosure. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that aspects of the present disclosure cover such modifications and variations.
Example aspects of the present disclosure are directed to a gas water heater appliance. Certain gas water heater appliances may include a gas valve controller as well as a blower fan to facilitate ventilation. In some examples, these water heater appliances may include a switch for controlling the blower fan on the gas valve controller printed circuit board. In some instances, an excessive amount of current may flow through the gas valve control printed circuit board, which may create a potential hazard (e.g., arc tracking).
Example aspects of the present disclosure include a relay (e.g., a solid-state relay) as part of the power circuit for a blower fan assembly. The relay allows for blower current to bypass the gas valve controller printed circuit board. This new combination of blower and relay arrangement outside the gas valve control printed circuit board provides an economical solution without impacting the performance of the blower or the water heater. In one example aspect, a power circuit for a water heater appliance including a gas valve controller on a gas valve control printed circuit board includes a first power conductor and a second power conductor. The first power conductor is coupled to a blower of the water heater appliance and the second power conductor is coupled to the blower of the water heater appliance through a relay such that current drawn by the blower bypasses the gas valve control printed circuit board. The gas valve controller can be coupled to the relay through a signal line and can be configured to communicate a control signal for the relay via the signal line. In some examples, the control signal can include an AC control signal having one or more pulses of AC power in a range of about 0V to about 120V. In some examples, the control signal can include one or more DC pulses in a range of about 0.5V to about 50V, such as about 5V to about 30V, such as about 10V to about 20V, such as about 1V to about 5V. The second power conductor can also be coupled to the gas valve control printed circuit board via a fuse. The fuse is configured to protect the gas valve control printed circuit board from high currents. The power circuit can also include a ground conductor coupled to the blower.
In another example aspect, a method of operation for a power circuit of a water heater appliance is disclosed. The method may include providing power to a blower of a water heater appliance via a first power conductor coupled to the blower and a second power conductor coupled to the blower via a relay. The method may include controlling the relay by a controller on a gas valve control printed circuit board. In one example, the current drawn by the blower can bypass the gas valve via the power circuit. In another example, controlling the relay comprises providing one or more AC pulses to the relay, wherein the one or more AC pulses are in a range of about 0V to about 120V. In another example, controlling the relay comprises providing one or more DC pulses to the relay, wherein the one or more DC pulses are in a range of about 0.5V to about 50V, such as about 5V to about 30V, such as about 10V to about 20V, such as about 1V to about 5V.
In another example aspect, a water heater appliance is disclosed, wherein the water heater appliance comprises a tank, a gas valve, a blower, and a power circuit. In one example aspect, a power circuit for the water heater appliance includes a first power conductor and a second power conductor. The first power conductor is coupled to a blower of the water heater appliance and the second power conductor is coupled to the blower of the water heater appliance through a relay such that current drawn by the blower bypasses the gas valve control printed circuit board. The gas valve controller can be coupled to the relay through a signal line and can be configured to communicate a control signal for the relay via the signal line. In some examples, the control signal can include an AC control signal having one or more pulses of AC power in a range of about 0V to about 120V. In some examples, the control signal can include one or more DC pulses in a range of about 0.5V to about 50V, such as about 5V to about 30V, such as about 10V to about 20V, such as about 1V to about 5V. The second power conductor can also be coupled to the gas valve control printed circuit board via a fuse. The fuse is configured to protect the gas valve control printed circuit board from high currents. The power circuit can also include a ground conductor coupled to the blower.
Example aspects of the present disclosure provide technical effects and benefits. For instance, in some examples, the relay is located off the gas valve controller printed circuit board which allows the gas valve controller to control the switch without requiring the current needed for the blower to pass through the gas valve printed circuit board. Since the blower includes a motor that may require a high level of current, this advantage avoids having the high level of current run through the gas valve control printed circuit board which reduces the likelihood of failures (e.g., arc tracking failures). This addition allows the blower to perform at its intended ability, without risking damage to the gas valve control printed circuit board.
As used herein, the terms “first,” “second,” and “third” may be used interchangeably to distinguish one component from another and are not intended to signify location or importance of the individual components. The terms “includes” and “including” are intended to be inclusive in a manner similar to the term “comprising.” Similarly, the term “or” is generally intended to be inclusive (e.g., “A or B” is intended to mean “A or B or both”). The term “at least one of” in the context of, e.g., “at least one of A, B, and C” refers to only A, only B, only C, or any combination of A, B, and C. In addition, here and throughout the specification and claims, range limitations may be combined and/or interchanged. Such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise. For example, all ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other. The singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise.
Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “generally,” “about,” “approximately,” and “substantially,” are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value, or the precision of the methods or machines for constructing or manufacturing the components and/or systems. For example, the approximating language may refer to being within a 10 percent margin, i.e., including values within ten percent greater or less than the stated value. In this regard, for example, when used in the context of an angle or direction, such terms include within ten degrees greater or less than the stated angle or direction, e.g., “generally vertical” includes forming an angle of up to ten degrees in any direction, e.g., clockwise or counterclockwise, with the vertical direction V.
The word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” In addition, references to “an embodiment” or “one embodiment” does not necessarily refer to the same embodiment, although it may. Any implementation described herein as “exemplary” or “an embodiment” is not necessarily to be construed as preferred or advantageous over other implementations. Moreover, each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.
The terms “coupled,” “fixed,” “attached to,” and the like refer to both direct coupling, fixing, or attaching, as well as indirect coupling, fixing, or attaching through one or more intermediate components or features, unless otherwise specified herein.
Except as explicitly indicated otherwise, recitation of a singular processing element (e.g., “a controller,” “a processor,” “a microprocessor,” etc.) is understood to include more than one processing element. In other words, “a processing element” is generally understood as “one or more processing element.” Furthermore, barring a specific statement to the contrary, any steps or functions recited as being performed by “the processing element” or “said processing element” are generally understood to be capable of being performed by “any one of the one or more processing elements.” Thus, a first step or function performed by “the processing element” may be performed by “any one of the one or more processing elements,” and a second step or function performed by “the processing element” may be performed by “any one of the one or more processing elements and not necessarily by the same one of the one or more processing elements by which the first step or function is performed.” Moreover, it is understood that recitation of “the processing element” or “said processing element” performing a plurality of steps or functions does not require that at least one discrete processing element be capable of performing each one of the plurality of steps or functions.
Turning to the figures,
Appliance 100 may also include an inlet conduit and an outlet conduit that are both in fluid communication with tank 104 within casing 102. The inlet conduit may support the flow of a liquid from a source to the tank 104 for heating and the outlet conduit may support the flow of the heated liquid away from the tank 104. As an example, supply water from a water source, such as a municipal water supply or a well, enters appliance 100 through the inlet conduit at an upper portion of tank 104. From the inlet conduit, such supply water enters interior volume 106 of tank 104 wherein the water is heated to generate heated water. Such heated water exits appliance 100 at the outlet conduit through a top portion of tank 104 and, for example, is supplied to fixtures requiring heated water.
From the inlet conduit, supply water may travel into tank 104 through a dip tube 116 that generally extends along a vertical direction V towards the bottom portion 110 of tank 104. The inlet conduit is fluidly coupled with dip tube 116. According to some embodiments, dip tube 116 extends a predetermined distance or length into interior volume 106 of tank 104. For instance, a lower end of dip tube 116 may be located below a midpoint of tank 104 along the vertical direction V. Advantageously, supply water supplied via dip tube 116, which may be relatively colder that the heated water, may be directed to a lower portion of tank 104, thus allowing a high volume of heated water to be maintained at or near the top of tank 104 to be output via the outlet conduit to a network of hot water conduits (not shown).
As illustrated in
Gas control valve 123 may selectively control the flow of gas to the gas burner 122 as determined by controller 133 to allow the gaseous fuel to be burned. Controller 133 may be in communication with temperature sensors, flow sensors, and the like (not shown), and may also control the burner 122 cycling on and off as determined to maintain a preset water temperature, or temperature range, in tank 104.
Referring again to
Appliance 100 may further include or be in operative communication with a processing device or a controller 133 that may be generally configured to facilitate appliance operation. In this regard, control panel 127, user input devices 129, and display 131 may be in communication with controller 133 such that controller 133 may receive control inputs from user input devices 129, may display information using display 131, and may otherwise regulate operation of appliance 100. For example, signals generated by controller 133 may operate appliance 100, including any or all system components, subsystems, or interconnected devices, in response to the position of user input devices 129 and other control commands. Control panel 127 and other components of appliance 100 may be in communication with controller 133 via, for example, one or more signal lines or shared communication busses. In this manner, Input/Output (“I/O”) signals may be routed between controller 133 and various operational components of appliance 100.
As used herein, the terms “processing device,” “computing device,” “controller,” or the like may generally refer to any suitable processing device, such as a general or special purpose microprocessor, a microcontroller, an integrated circuit, an application specific integrated circuit (ASIC), a digital signal processor (DSP), a field-programmable gate array (FPGA), a logic device, one or more central processing units (CPUs), a graphics processing units (GPUs), processing units performing other specialized calculations, semiconductor devices, etc. In addition, these “controllers” are not necessarily restricted to a single element but may include any suitable number, type, and configuration of processing devices integrated in any suitable manner to facilitate appliance operation. Alternatively, controller 133 may be constructed without using a microprocessor, e.g., using a combination of discrete analog and/or digital logic circuitry (such as switches, amplifiers, integrators, comparators, flip-flops, AND/OR gates, and the like) to perform control functionality instead of relying upon software.
Controller 133 may include, or be associated with, one or more memory elements or non-transitory computer-readable storage mediums, such as RAM, ROM, EEPROM, EPROM, flash memory devices, magnetic disks, or other suitable memory devices (including combinations thereof). These memory devices may be a separate component from the processor or may be included onboard within the processor. In addition, these memory devices can store information and/or data accessible by the one or more processors, including instructions that can be executed by the one or more processors. It should be appreciated that the instructions can be software written in any suitable programming language or can be implemented in hardware. Additionally, or alternatively, the instructions can be executed logically and/or virtually using separate threads on one or more processors.
For example, controller 133 may be operable to execute programming instructions or micro-control code associated with an operating cycle of appliance 100. In this regard, the instructions may be software or any set of instructions that when executed by the processing device, cause the processing device to perform operations, such as running one or more software applications, displaying a user interface, receiving user input, processing user input, etc. Moreover, it should be noted that controller 133 as disclosed herein is capable of and may be operable to perform any methods, method steps, or portions of methods as disclosed herein. For example, in some embodiments, methods disclosed herein may be embodied in programming instructions stored in the memory and executed by controller 133.
The memory devices may also store data that can be retrieved, manipulated, created, or stored by the one or more processors or portions of controller 133. The data can include, for instance, data to facilitate performance of methods described herein. The data can be stored locally (e.g., on controller 133) in one or more databases and/or may be split up so that the data is stored in multiple locations. In addition, or alternatively, the one or more database(s) can be connected to controller 133 through any suitable network(s), such as through a high bandwidth local area network (LAN) or wide area network (WAN). In this regard, for example, controller 133 may further include a communication module or interface that may be used to communicate with one or more other component(s) of appliance 100, controller 133, an external appliance controller, or any other suitable device, e.g., via any suitable communication lines or network(s) and using any suitable communication protocol. The communication interface can include any suitable components for interfacing with one or more network(s), including for example, transmitters, receivers, ports, controllers, antennas, or other suitable components.
A power circuit 402 includes a gas valve control printed circuit board 404, power vent blower 406, and a power supply 432 (e.g., 120 V or 240 V main power supply) coupled together via one or more conductors. The power vent blower 406 comprises a blower motor 412 and a relay 414, wherein the relay 414, in some embodiments, is incorporated into the power vent blower 406 or proximate to the power vent blower 406. The relay 414, in some embodiments, is not located on the gas valve control printed circuit board 404.
The blower motor 412 is coupled to the power supply 432 via a first power conductor 408. The blower motor 412 is also coupled to the power supply 432 via a second power conductor 410, wherein the second power conductor 410 is coupled to the blower motor 412 through a relay 414 such that a current drawn by the blower motor 412 bypasses the gas valve control printed circuit board 404. The relay 414 is coupled to the blower motor 412 and the power source supply 432 via the second power conductor 410. The relay 414 is also coupled to the power source supply 432 via the first power conductor 408, and to the gas valve control printed circuit board 404 via a signal line 418. The relay 414 receives a control signal from a gas valve controller 416 on the gas valve control printed circuit board 404. In some examples, the control signal can include an AC control signal having one or more pulses of AC power in a range of about 0V to about 120V. In some examples, the control signal can include one or more DC pulses in a range of about 0.5V to about 50V, such as about 5V to about 30V, such as about 10V to about 20V, such as about 1V to about 5V. Furthermore, the blower motor 412 is also coupled to a ground conductor 422.
The power circuit 402 also includes one or more sensors configured to detect an environmental condition associated with the blower, such as a temperature switch sensor 424 and a vacuum switch sensor 426. In some embodiments, the temperature switch sensor 424 can be a temperature switch that is implemented to monitor the temperature within the power vent blower 406. In some embodiments, the vacuum switch sensor 426 can monitor the pressure within the power vent blower 406. The temperature switch sensor 424 is coupled to the gas valve control printed circuit board 404 via a first sensor conductor 428. The temperature switch sensor 424 is also coupled to the vacuum switch sensor 426 via a second sensor conductor 430, and the vacuum switch sensor 426 is coupled to the gas valve control printed circuit board 404 via the second sensor conductor 430. The gas valve controller 416 may be configured to control the relay 414 based at least in part on one or more signals from the one or more sensors. For instance, the gas valve controller 416 may turn on or turn off the blower (e.g., by controlling the relay 414) based on signals from the temperature switch sensor 424 and/or the vacuum switch sensor 426.
The gas valve control printed circuit board 404 is coupled to the power source supply 432 via the first power conductor 408 and the second power conductor 410. In some examples, second power conductor 410 may include a fuse 420. In one embodiment, the fuse 420 can be an inline fuse incorporated into the second power conductor 410. In another embodiment, the fuse 420 can be an inline fuse incorporated into the gas valve control printed circuit board 404. The gas valve control printed circuit board 404 is also coupled to a vapor sensor 436 via a vapor sensor conductor 438. A second temperature switch sensor 424 may be coupled to the gas valve control printed circuit board 404 and the vapor sensor 436 via the vapor sensor conductor 438. The gas valve controller 416 may be configured to control the relay 414 based at least in part on one or more signals from the vapor sensor 426. For instance, the gas valve controller 416 may turn on or turn off the blower (e.g., by controlling the relay 414) based on signals from the vapor sensor 436.
At 501, the method 500 includes providing power to a blower of a water heater appliance via a first power conductor coupled to the blower and a second power conductor coupled to the blower via a relay. For instance, as shown in
At 502, the method includes controlling the relay 414 from a gas valve controller 416 on a gas valve control printed circuit board 404. For instance, the relay 414 is coupled to the gas valve control printed circuit board 404 via a signal line 418. The relay 414 receives a control signal from a gas valve controller 416 on the gas valve control printed circuit board 404 through the signal line 418. In some examples, the control signal can include an AC control signal having one or more pulses of AC power in a range of about 0V to about 120V. In some examples, the control signal can include one or more DC pulses in a range of about 0.5V to about 50V, such as about 5V to about 30V, such as about 10V to about 20V, such as about 1V to about 5V. The control signal provided to the relay 414 via the signal line 418 can selectively control the relay 414 to turn the blower motor 412 on and to turn the blower motor 412 off. For instance, the gas valve controller 416 can send a first pulse via the signal line 418 to the relay 414 to turn the blower motor 412 on. The gas valve controller 416 can send a second pulse via the signal line 418 to the relay 414 to turn the blower motor 412 off. In this way, the current drawn by the blower motor 412 passes through the relay 414 and bypasses the gas valve control printed circuit board 404.
While the present subject matter has been described in detail with respect to specific example embodiments thereof, it will be appreciated that those skilled in the art, upon attaining an understanding of the foregoing can readily produce alterations to, variations of, and equivalents to such embodiments. Accordingly, the scope of the present disclosure is by way of example rather than by way of limitation, and the subject disclosure does not preclude inclusion of such modifications, variations and/or additions to the present subject matter as would be readily apparent to one of ordinary skill in the art.
