BOOT FOR PREVENTING WATER INCURSION INTO A WATER HEATER

FIELD OF THE INVENTION

The subject matter of the present disclosure relates generally to water heater appliances.

BACKGROUND OF THE INVENTION

Water heaters provide for the heating and storage of water for various uses. A heat source is provided for raising the temperature of water in a water tank. The heat energy may be supplied e.g., by gas burners, electrically resistant coils, or a heat pump using a refrigerant cycle. Typically, the water tank is surrounded by a casing and is insulated to prevent the water stowed within the water tank from heat loss before use.

Many water heater appliances include various power consuming loads. For instance, some water heaters may include a controller, a display, electric heating sources, and other power consuming loads. To provide electrical power to such power consuming loads, an electrical conduit or power supply line typically is fed to or through an access point of the water heater, such as a junction box. The junction box may provide a means of grounding the incoming wires and for providing a safe environment for making electrical connections. In some instances, water may leak or seep into the junction box. For example, water may drip along the power supply line or a pipe above the water heater may leak water into the junction box. Consequently, the junction box may fill with water, particularly when the junction box is encased or at least partially encased within the insulation disposed between the casing and the water tank. Water within the junction is undesirable. For instance, water may short or damage the electrical components within the junction box and thus an unsafe condition may result.

Accordingly, a water heater appliance that addresses one or more challenges noted above would be useful.

BRIEF DESCRIPTION OF THE INVENTION

Aspects and advantages of the invention will be set forth in part in the following description, or may be apparent from the description, or may be learned through practice of the invention.

In one exemplary embodiment, a water heater appliance is provided. The water heater appliance includes a casing. The water heater appliance also includes a tank positioned within the casing and defining a chamber for heating water. The water heater appliance further includes a heating source in thermal communication with the tank for selectively heating water within the chamber. Moreover, the water heater appliance includes a junction box mounted to the casing. In addition, the water heater appliance includes a conduit extending into the junction box. Further, the water heater appliance includes a boot defining a pass-through opening for receiving the conduit passing therethrough, the boot forming an impermeable seal around the conduit where the conduit passes therethrough and having a canopy extending from the impermeable seal to a canopy edge contacting at least a portion of the casing.

In another exemplary embodiment, a water heater appliance is provided. The water heater appliance includes a casing. The water heater appliance also includes a tank positioned within the casing and defining a chamber for heating water. Further, the water heater appliance includes a heating source in thermal communication with the tank for selectively heating water within the chamber. Moreover, the water heater appliance includes an access point for providing ingress into the casing. In addition, the water heater appliance includes a conduit in communication with the access point. Moreover, the water heater appliance includes a boot defining a pass-through opening for receiving the conduit passing therethrough, the boot forming an impermeable seal around the conduit where the conduit passes therethrough and having a canopy extending from the impermeable seal to a canopy edge contacting at least a portion of the casing.

These and other features, aspects and advantages of the present invention 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 invention and, together with the description, serve to explain the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:

FIG. 1 provides a perspective view of a water heater appliance according to an exemplary embodiment of the present subject matter;

FIG. 2 provides a perspective view of a bottom portion of the exemplary water heater appliance of FIG. 1 with the wrapper of the water heater removed;

FIG. 3 provides a close up view of an exemplary boot for preventing moisture incursion into a junction box of the water heater appliance of FIG. 1;

FIG. 4 provides a close up, side cross sectional view of the water heater appliance of FIG. 1;

FIG. 5 provides a close up, cross-sectional view of one exemplary manner in which a canopy edge of the boot of FIG. 3 may be attached to a casing of the water heater appliance of FIG. 1; and

FIG. 6 provides a close up, cross-sectional view of another exemplary manner in which a canopy edge of the boot of FIG. 3 may be attached to a casing of the water heater appliance of FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. 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 or spirit 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. As used herein, terms of approximation, such as “approximately,” “substantially,” or “about,” refer to being within a ten percent (10%) margin of error.

FIG. 1 provides a perspective view of a water heater appliance 100 according to an exemplary embodiment of the present subject matter. Water heater appliance 100 includes a casing 102 that generally surrounds a tank 120 (FIG. 2) and may be formed from a variety of components. As illustrated, casing 102 may include a wrapper or jacket 130 and one or more covers, such as a top cover 132 and a bottom cover 134. The covers may be coupled to wrapper 130 to form casing 102.

Water heater appliance 100 also includes a cold water conduit 104 and a hot water conduit 106 that are both in fluid communication with a chamber 122 (FIG. 2) defined by tank 120. As an example, cold water from a water source, e.g., a municipal water supply or a well, can enter water heater appliance 100 through cold water conduit 104 (shown schematically with arrow labeled F_cold). Cold water can enter chamber 122 of tank 120 through cold water conduit 104 wherein it is heated by a heating source, e.g., hot refrigerant circulating through coils 118 (FIG. 2). Thus, heating source or coils 118 are in thermal communication with tank 120 for selectively heating water within chamber 122 of tank 120. Such heated water can exit water heater appliance 100 at hot water conduit 106 (shown schematically with arrow labeled F_hot) and, e.g., be supplied to a bath, shower, sink, or any other suitable feature.

Water heater appliance 100 defines a vertical direction V. Water heater appliance 100 extends between a top portion 108 and a bottom portion 110 along the vertical direction V. Thus, water heater appliance 100 is generally vertically oriented. Water heater appliance 100 can be leveled, e.g., such that casing 102 is plumb in the vertical direction V, to facilitate proper operation of water heater appliance 100. A drain pan 112 is positioned at bottom portion 110 of water heater appliance 100 such that water heater appliance 100 sits on drain pan 112. Drain pan 112 sits beneath water heater appliance 100 along the vertical direction V, e.g., to collect water that condenses on an evaporator (not shown) of water heater appliance 100.

FIG. 2 provides a perspective view of bottom portion 110 of water heater appliance 100 with wrapper 130 (FIG. 1) removed. As noted above, tank 120 is configured for storing heated water. As will be understood by those skilled in the art and as used herein, the term “water” includes purified water and solutions or mixtures containing water and, e.g., elements (such as calcium, chlorine, and fluorine), salts, bacteria, nitrates, organics, and other chemical compounds or substances. Tank 120 may have a generally cylindrically-shaped body that extends vertically between a tank bottom and a top (not shown). For this exemplary embodiment, water heater appliance 100 is shown as a refrigerant based heat pump water heater that circulates hot refrigerant through coils 118 to transfer heat to water in tank 120. However, the present subject matter is not limited to heat pump water heaters. As will be understood by one of skill in the art using the teachings disclosed herein, the present subject matter may also be used with, e.g., water heaters that rely upon electric resistance heating elements, gas burners, and/or other heat sources as well. Further, as shown in FIG. 2, water heater appliance 100 includes one or more heating source covers 124 that provide selective access to the heating source or sources (e.g., coils 118) of water heater appliance 100.

Returning to FIG. 1, water heater appliance 100 also includes a user interface panel 140, e.g., mounted to top cover 132 of water heater appliance 100. Although user interface panel 140 is shown mounted to top cover 132 of water heater appliance 100 in FIG. 1, user interface panel 140 may be mounted to casing 102 in other suitable locations in alternative embodiments. User interface panel 140 includes input components or controls 142, such as one or more of a variety of electrical, mechanical, or electro-mechanical input devices. Controls 142 may include, for example, rotary dials, knobs, push buttons, and/or touch pads. A controller 144 is communicatively coupled with user interface panel 140 and controls 142, e.g., by a suitable wired or wireless connection, for controlling water heater appliance 100. Thus, a user may select various operational features and modes via controls 142 and may monitor progress of water heater appliance 100, e.g., via a display 146, such as a digital or analog display communicatively coupled with controller 144. Display 146 is configured to provide operational feedback to a user, among other possible items. In certain embodiments, user interface panel 140 represents a general purpose I/O (“GPIO”) device or functional block.

As noted above, controller 144 is communicatively coupled (i.e., in operative communication) with user interface panel 140, including controls 142 and display 146. Controller 144 may also be communicatively coupled with various operational components of water heater appliance 100 as well, such as heating sources (e.g., coils 118), sensors, etc. Input/output (“I/O”) signals may be routed between controller 144 and the various operational components of water heater appliance 100. Thus, controller 144 can selectively activate and operate these various components. Various components of water heater appliance 100 are communicatively coupled with controller 144 via one or more communication lines such as, for example, conductive signal lines, shared communication busses, or wireless communications bands.

In some embodiments, controller 144 includes one or more memory devices and one or more processors. The processors can be any combination of general or special purpose processors, CPUs, or the like that can execute programming instructions or control code associated with operation of water heater appliance 100. The memory devices (i.e., memory) may represent random access memory such as DRAM or read only memory such as ROM or FLASH. In one embodiment, the processor executes programming instructions stored in memory. The memory may be a separate component from the processor or may be included onboard within the processor. Alternatively, controller 144 may be constructed without using a processor, for example, using a combination of discrete analog or digital logic circuitry (such as switches, amplifiers, integrators, comparators, flip-flops, AND gates, and the like) to perform control functionality instead of relying upon software.

In certain embodiments, controller 144 includes a network interface such that controller 144 can connect to and communicate over one or more networks with one or more network nodes. Controller 144 can also include one or more transmitting, receiving, or transceiving components for transmitting/receiving communications with other devices communicatively coupled with water heater appliance 100. Additionally or alternatively, one or more transmitting, receiving, or transceiving components can be located off board controller 144. Generally, controller 144 can be positioned in any suitable location throughout water heater appliance 100. For example, controller 144 may be located proximate user interface panel 140 as shown in FIG. 1.

As further shown in FIG. 1, a conduit 150 is connected to water heater appliance 100. For this embodiment, conduit 150 is a power supply line for providing electrical power to water heater appliance 100. More particularly, for this embodiment, conduit 150 is a power supply line that facilitates electrical communication between a power source and various features of water heater appliance 100, such as e.g., features of user control panel 140, controller 144, heating sources, etc. Conduit 150 may carry one or more electrical wires or may itself be a wire. Conduit 150 may be flexible or rigid. As depicted in FIG. 1, conduit 150 connects to or enters water heater appliance 100 at an access point of water heater appliance 100. For this embodiment, access point is a junction box 160 mounted to top cover 132 of casing 102. In alternative embodiments, junction box 160 may be mounted to casing 102 in other suitable locations.

In some instances, water may leak from pipes above water heater appliance 100 or condensed moisture may drip along conduit 150 and down into junction box 160. Water filling into junction box 160 is undesirable for safety and operational purposes. For instance, if water fills to a predetermined level within junction box 160, one or more electrical connectors or connections within junction box 160 may short or become damaged by the water. As will be described below, in accordance with exemplary aspects of the present disclosure, water heater appliance 100 includes features for preventing water from leaking or seeping into junction box 160.

FIGS. 3 and 4 provide various views of an exemplary boot 180 for preventing moisture incursion into junction box 160 of water heater appliance 100. In particular, FIG. 3 provides a close up perspective view of boot 180 (shown transparent) and FIG. 4 provides a close up, side cross sectional view of boot 180 preventing water incursion into junction box 160.

As shown in FIGS. 3 and 4, junction box 160 is mounted to casing 102. More particularly, junction box 160 includes a mounting flange 168 that is mounted to top cover 132 via one or more mechanical fasteners 170, e.g., screws. Junction box 160 defines a volume 162 into which conduit 150 extends and passes through as shown best in FIG. 4. Within the volume 162 of junction box 160, the electrical wires within conduit 150 may be grounded, e.g., by an electrical ground. Conduit 150 and/or the wires carried by conduit 150 may exit junction box 160 via an outlet 164 defined by junction box 160. For this embodiment, outlet 164 is defined at a bottom portion of junction box 160; however, outlet 164 may be defined at other suitable locations as well. Conduit 150 and/or the wires carried by conduit 150 may extend to various power consuming loads of water heater appliance 100, such as e.g., features of user interface panel 140 (FIG. 1). Junction box 160 also includes an access door 166 for selectively providing access to volume 162 of junction box 160, e.g., for installation or maintenance purposes. Further, as depicted best in FIG. 4, an insulation material 116 at least partially encases junction box 160. For this embodiment, insulation 116 encases substantially all of junction box 160. Insulation 116, such as an expanding foam insulation, is provided within an interior 114 defined by casing 102 to reduce the amount of heat transfer to the environment. Insulation 116 can be provided as foamed-in insulation but other materials may be used as well.

As further provided in FIGS. 3 and 4, as shown, boot 180 is configured to prevent water from leaking or seeping into junction box 160. For this embodiment, boot 180 is formed of a compliant impermeable material. As one example, the compliant impermeable material may be a rubber material, such as e.g., an ethylene propylene diene monomer (EPDM) rubber material. As another example, the compliant impermeable material may be a polymeric material in some embodiments. In yet other embodiments, boot 180 may be formed of a semi-rigid material or a rigid material, e.g., a plastic material.

Boot 180 defines a pass-through opening 186 for receiving conduit 150 passing therethrough. For this embodiment, the outer diameter of conduit 150 is greater than the diameter of pass-through opening 186. In this way, when conduit 150 is passed through the pass-through opening 186, boot 180 is stretched to accommodate conduit 150 passing therethrough. Accordingly, boot 180 forms an impermeable seal 188 around conduit 150 where conduit 150 passes therethrough. Accordingly, water dripping down or along conduit 150 is prevented continuing toward junction box 160, and as will be described below, is shed onto the surrounding casing 102 of water heater appliance 100. Further, in some embodiments, a clamp or ring clamp (not shown) may be secured around impermeable seal 188 to further secure and connect boot 180 with conduit 150.

Boot 180 has a roof or canopy 182 that extends from impermeable seal 188 to a canopy edge 184 contacting at least a portion of casing 102. As best shown in FIG. 3, for this embodiment, the entirety of canopy edge 184 contacts casing 102 such that canopy 182 drapes entirely over junction box 160. In this way, when water drips down along conduit 150 and is redirected at impermeable seal 188 onto canopy 182, canopy 182 sheds or directs the water onto casing 102 away from junction box 160. As canopy 182 completely surrounds junction box 160, there is no way for water to enter junction box 160. Notably, impermeable seal 188 is formed above where canopy edge 184 is positioned on casing 102 along the vertical direction V. In this way, water is shed off canopy 182 and does not pool thereon. Moreover, canopy 182 is sized such that it has a gradual downward slope from impermeable seal 188 to canopy edge 184.

In some embodiments, as shown best in FIG. 3, boot 180 includes one or more reinforcement poles 190 attached to or integrally formed with canopy 182 for reinforcing canopy 182. For instance, poles 190 may extend substantially between impermeable seal 188 and canopy edge 184. Poles 190 may facilitate the gradual downward slope of canopy 182, may help retain the general shape of canopy 182, and as noted above, may reinforce canopy 182. In some embodiments, the boot 180 need not include reinforcement poles.

For the depicted embodiment of FIGS. 3 and 4, canopy edge 184 is positioned on casing 102 but is not attached to casing 102, or more particularly, canopy edge 184 is positioned on top cover 132 of casing 102 but is not attached thereto. In this way, a user may access junction box 160 by lifting up canopy edge 184 of boot 180. The user may then open access door 166 of junction box 160 to access volume 162 of junction box 160. After accessing junction box 160, a user may shut access door 166 and position canopy edge 184 back onto casing 102.

In some alternative embodiments, canopy edge 184 is positioned on casing 102 and is attached to casing 102. Canopy edge 184 may be attached to casing 102 in a number of suitable ways. As one example, canopy edge 184 is attached to casing 102 via an adhesive, such as e.g., a glue, gum, or paste. In some embodiments, canopy edge 184 is positioned on casing 102 and is removably attached to casing 102. Examples are provided below.

FIG. 5 provides a close up, cross-sectional view of one exemplary manner in which canopy edge 184 of boot 180 may be removably attached to casing 102 of water heater appliance 100. As shown in FIG. 5, canopy 182 defines an attachment opening 192 at or proximate canopy edge 184. Although only one attachment opening 192 is shown in FIG. 5, it will be appreciated that canopy 182 may define a plurality of attachment openings 192 at or proximate canopy edge 184, e.g., spaced around canopy edge 184. Further, for this embodiment, boot 180 includes a grommet 194 at the attachment opening 192. Grommet 194 may reinforce boot 180 at attachment opening 192 and may, for example, prevent boot 180 from tearing at attachment opening 192 during attachment/removal of boot 180 to or from casing 102.

To attach canopy 182 of boot 180 to casing 102, canopy edge 184 is positioned between mounting flange 168 of junction box 160 and casing 102, or more particularly, canopy edge 184 is positioned between mounting flange 168 of junction box 160 and top cover 132 of casing 102. Attachment opening 192 is aligned in communication with an opening defined by mounting flange 168 and an opening defined by casing 102. Mechanical fastener 170 is inserted through mounting flange 168, attachment opening 192, and casing 102 to compress canopy edge 184 between mounting flange 168 and casing 102. One mechanical fastener may be inserted through each attachment opening 192 of boot 180. By compressing canopy edge 184 between mounting flange 168 and casing 102, canopy edge 184 of canopy 182 forms a gasket seal 196 between mounting flange 168 and casing 102. Gasket seal 196 may prevent from water from leaking or seeping into junction box 160 and/or between mounting flange 168 and casing 102. Accordingly, electrical components within junction box 160 and insulation 116 disposed within interior 114 may be protected, among other benefits.

To remove or detach canopy 182 of boot 180 from casing 102, e.g., for access to junction box 160, mechanical fastener 170 is removed. Thus, mounting flange 168 becomes loose and canopy edge 184 may be removed from between mounting flange 168 and casing 102. A user may access junction box 160 by lifting up canopy edge 184 of boot 180. A user may then reattach boot 180 to casing 102 as described above.

FIG. 6 provides a close up, cross-sectional view of another exemplary manner in which canopy edge 184 of boot 180 may be removably attached to casing 102 of water heater appliance 100. For the depicted embodiment of FIG. 6, canopy 182 does not define attachment openings at or proximate canopy edge 184, e.g., as shown in FIG. 5. Rather, for this embodiment, to attach boot 180 to casing 102, canopy edge 184 is inserted between mounting flange 168 of junction box 160 and top cover 132 of casing 102. Canopy edge 184 is then compressed between mounting flange 168 of junction box 160 and casing 102. To compress canopy edge 184 between mounting flange 168 and casing 102, mechanical fastener 170 is inserted through an opening defined by mounting flange 168 and an opening defined by top cover 132 of casing 102. When mechanical fastener 170 is inserted through mounting flange 168 and top cover 132, canopy edge 184 becomes sandwiched between mounting flange 168 and top cover 132 thereby securing canopy edge 184 in place and forming gasket seal 196 between mounting flange 168 and casing 102. As noted above, gasket seal 196 may prevent from water from leaking or seeping into junction box 160 and/or between mounting flange 168 and casing 102. Accordingly, electrical components within junction box 160 and insulation 116 disposed within interior 114 may be protected, among other benefits. To remove or detach canopy 182 of boot 180 from casing 102, e.g., for access to junction box 160, mechanical fastener 170 is removed and canopy edge 184 may be slipped out of or removed from between mounting flange 168 and top cover 132.

Although boot 180 was shown and described herein as attaching to conduit 150 and configured for preventing water incursion into junction box 160, boot 180 may be attached or connected to other conduits for preventing water incursion into other access points of water heater appliance 100. For instance, in some embodiments, the access point is an opening defined in top cover 132 of casing 102 and the conduit is one of cold water conduit 104 (FIG. 1) and hot water conduit 106 (FIG. 1). In some embodiments, a boot may be connected to and form an impermeable seal about both cold water conduit 104 and hot water conduit 106. Thus, water may be prevented from entering between cold and/or hot water conduits 104, 106 and casing 102, and thus, insulation 116 (FIG. 4) may be protected from water damage. Moreover, in some embodiments, the access point or ingress into water heater appliance 100 is removable heat source cover 124 (FIG. 2). In such embodiments, boot 180 may be connected to and form an impermeable seal about a fluid-carrying or current-carrying conduit extending into or through removable heat source cover 124. As noted above, in some embodiments, the access point is junction box 160 and the conduit is conduit 150 configured as a power supply line for providing electrical power to water heater appliance 100.

Boot described herein provides a number of advantages. For instance, water dripping along a conduit entering an access point of water heater appliance is prevented from entering through or into the access point. Particularly, boot may form an impermeable seal around the conduit and may also include a roof or canopy that drapes over the access point. In this way, as water drips along the conduit, the water is directed onto the boot at impermeable seal and is shed away from the access point by the canopy. In some embodiments, the canopy edge of canopy may contact the casing (e.g., as shown in FIG. 3) so that water flows from the impermeable seal along the canopy and onto the surface of the casing. In this way, water is prevented from leaking or seeping into the access point. This may, for example, protect electrical components and the foam insulation between the casing and the tank from being damaged. Further, the boot is configured to provide readily available access to the access point. For instance, the boot may be removable attached to the casing as described herein. In embodiments in which the boot is attached to the casing, the boot may be positioned between a mounting flange of the access point and the casing. The boot may be compressed therebetween to form a gasket seal. In yet other embodiments, the boot may be formed of a rigid or semi-rigid material, e.g., such as plastic, and may be fastened or secured to casing, e.g., by one or more fasteners.

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.

BOOT FOR PREVENTING WATER INCURSION INTO A WATER HEATER

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Date Filed

Date Published

Inventors

CPC

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Abstract

Description

Claims