The present disclosure relates to heat pump water heaters and more specifically to sound baffle devices for heat pump water heaters that are configured to minimize sound transmission from compressor units of the heat pump water heaters.
Water heaters are generally used to provide a supply of heated water in a variety of applications, including residential, commercial, and industrial applications. Conventional water heaters use gas burners, electrical heating elements, and/or solar panels to heat water. Some modern water heaters also use heat pumps that heat water by extracting heat from ambient air by using a refrigerant.
A conventional heat pump water heater may include an air inlet that intakes the ambient air and an air outlet that exhausts cool and dehumidified air. The heat pump water heater may include an evaporator that extracts heat from the ambient air by using the refrigerant. The heat pump water heater also may include a compressor that may receive and compress the refrigerant. The compressed refrigerant may be used to heat water in a water storage tank.
In the conventional heat pump water heater, the compressor may generate mechanical noise or sound during operation. The sound waves may flow out of the heat pump water heater from the air inlet and/or the air outlet, which may not be desirable.
The detailed description is set forth with reference to the accompanying drawings. The use of the same reference numerals may indicate similar or identical items. Various embodiments may utilize elements and/or components other than those illustrated in the drawings, and some elements and/or components may not be present in various embodiments. Elements and/or components in the figures are not necessarily drawn to scale. Throughout this disclosure, depending on the context, singular and plural terminology may be used interchangeably.
The present disclosure is directed towards a heat pump water heater that minimizes sound transmission from a compressor unit. In some instances, the compressor unit may include a compressor and an accumulator installed in the heat pump water heater. In certain embodiments, the heat pump water heater may include a sound baffle device that may partially enclose the compressor and the accumulator. The sound baffle device may have one or more baffle side plates and a baffle top plate that may reflect sound waves generated by the compressor unit back towards the compressor unit. For example, the baffle side plates may be configured to surround a portion of the compressor and the accumulator, and the remaining portion of the compressor and the accumulator may be surrounded by a side wall of the water heater housing. The baffle top plate may be configured to cover the top portion of the compressor and the accumulator. In some aspects, the baffle top plate may be disposed above the top portion may of the compressor and the accumulator (in the interior portion of the housing) to cover the top portion of the compressor and the accumulator.
In some aspects, the sound baffle device may include a first piece and a second piece that may be interlocked with each other when the first piece and the second piece are positioned around the compressor unit. In some instances, the size, shape, and configuration of the first piece may be different from the size, shape, and configuration of the second piece. The sound baffle device structure, including the first piece and the second piece, may provide for an easy assembly and disassembly of the sound baffle device around the compressor unit. For example, the sound baffle device structure, including the first piece and the second piece may enable the installation of the sound baffle device without interfering with any other heat pump water heater component (e.g., valves, pipes, heat exchangers, etc.).
In some aspects, the first piece may include a first baffle side plate and a first baffle top plate. Similarly, the second piece may include a second baffle side plate and a second baffle top plate. In some instances, the first baffle side plate may be configured to mate with the second baffle side plate, and the first baffle top plate may be configured to mate with the second baffle top plate to form the sound baffle device. In further aspects, the first baffle top plate and the second baffle top plate may include one or more cut-outs to receive therethrough one or more pipes or other components, such as compressor piping and accumulator piping. The first piece and the second piece may be attached to a base plate disposed in a housing interior portion by using one or more fasteners (e.g., bolts or screws) and/or an adhesive so that the sound baffle device may be stably secured inside the heat pump water heater.
Although certain examples of the disclosed technology are explained in detail herein, it is to be understood that other examples, embodiments, and implementations of the disclosed technology are contemplated. Accordingly, it is not intended that the disclosed technology is limited in its scope to the details of construction and arrangement of components expressly set forth in the following description or illustrated in the drawings. The disclosed technology can be implemented in a variety of examples and can be practiced or carried out in various ways. In particular, the presently disclosed subject matter is described in the context of being a system and method for heating water with a heat pump water heater. The present disclosure, however, is not so limited, and can be applicable in other contexts. The present disclosure, for example and not limitation, can include other water heater systems, such as boilers, pool heaters, industrial water heaters, and other water heater systems configured to heat water or any combination thereof. Furthermore, the present disclosure can include other fluid heating systems configured to heat a fluid other than water such as process fluid heaters used in industrial applications. Such implementations and applications are contemplated within the scope of the present disclosure. Accordingly, when the present disclosure is described in the context of being a system and method for heating water with the heat pump water heater, it will be understood that other implementations can take the place of those referred to.
Although the term “water” is used throughout this specification, it is to be understood that other fluids may take the place of the term “water” as used herein. Therefore, although described as a water heater system, it is to be understood that the system and methods described herein can apply to fluids other than water. Further, it is also to be understood that the term “water” can replace the term “fluid” as used herein unless the context clearly dictates otherwise.
Turning now to the drawings,
The water storage tank 104 (and/or the housing 102) may be any suitable size, shape, or configuration based on the water heating device application. For example, the water storage tank 104 may be sized for common residential use or for commercial or industrial use that may require greater amounts of heated water. Furthermore, the water storage tank 104 may be made of any suitable material for storing and heating water, including copper, carbon steel, stainless steel, ceramics, polymers, composites, or any other suitable material. The water storage tank 104 may also be treated or lined with a coating to prevent corrosion and leakage. The water storage tank 104 may be treated or coated with any suitable coating that may be capable of withstanding temperature and pressure of the water heating device 100 and may include, as non-limiting examples, glass enameling, galvanizing, thermosetting resin-bonded lining materials, thermoplastic coating materials, cement coating, or any other suitable treating or coating for the application. Optionally, the water storage tank 104 may be insulated to retain heat. For example, the water storage tank 104 may be insulated using foam, fiberglass, aluminum foil, organic material, or any other suitable insulation material.
The housing 102 may further include an air inlet 106 and an air outlet 108. In some instances, the air inlet 106 and the air outlet 108 may be disposed in an upper portion of the housing 102 that is disposed above the water storage tank 104. As discussed herein, the upper portion of the housing 102 may be configured to house at least a portion of a heat pump system that forms a vapor compression cycle system. In some aspects, the upper portion of the housing 102 may be integral to or removably attached with the housing 102. The air inlet 106 may be configured to receive ambient air from outside of the housing 102 and pass the air to the housing interior portion, and the air outlet 108 may be configured to output the air from the housing interior portion to outside of the housing 102. In some instances, the air inlet 106 may be disposed through a housing top wall, and the air outlet 108 may be disposed through a housing side wall, or vice versa. In other aspects, the air inlet 106 may be disposed through the housing side wall opposite to the air outlet 108. The air inlet 106 and the air outlet 108 may be disposed at any suitable location about the housing 102. In some aspects, the air inlet 106 and/or the air outlet 108 may include a single opening. In further aspects, the air inlet 106 and/or the air outlet 108 may include a plurality of openings/apertures/vents that collectively form the respective air inlet 106 and air outlet 108. In further aspect, the air inlet 106 and/or the air outlet 108 may be an opening with a grate or mesh type structure covering the opening. The air inlet 106 and/or the air outlet 108 may be of any shape, for example, the air inlet 106 and/or the air outlet 108 may be circular in shape.
The water heating device 100 may further include a heating source. In some aspects, the heating source may be a heat pump assembly. Stated another way, the water heating device 100 may be a heat pump water heater. The heat pump assembly (or heat pump) may include, among other things, a fan, an evaporator, a compressor 112, a heat exchanger/condenser coils, and a refrigerant conduit that distributes a refrigerant to different heat pump assembly components. The heat pump assembly may collectively form a vapor compression cycle system. The various heat pump assembly components may be sized, shaped, and located as would be suitable for the particular application. As will be appreciated, the various heat pump assembly components may be sized for residential, commercial, or industrial applications and for heating water within various temperature ranges and within various time ranges. In some aspects, the heat pump assembly may be at least partially located inside the housing 102.
The fan may draw ambient air from outside of the housing and may pass the air (via the air inlet 106) to the evaporator that may absorb heat from the ambient air. The evaporator may include a plurality of coils that contain the refrigerant. The refrigerant may absorb heat from the ambient air and may evaporate. In some aspects, the refrigerant may be in liquid form and may change state from liquid to vapor when the refrigerant absorbs heat from the ambient air. The vaporized refrigerant may move to the accumulator 110. The accumulator 110 may transfer the refrigerant to the compressor 112 at a preset optimum rate, thereby transferring a mainly vaporized form of refrigerant to the compressor 112. The compressor 112 may be configured to receive the refrigerant from the accumulator 110 and raise the pressure and temperature of the refrigerant. In some aspects, the compressor 112 may be a pump that provides additional pressure to the refrigerant to enable the refrigerant to flow through the refrigerant conduit (in a defined path).
The compressor 112 may be of any suitable type. For example, the compressor 112 may be a positive displacement compressor, a reciprocating compressor, a rotary screw compressor, a rotary vane compressor, a rolling piston compressor, a scroll compressor, an inverter compressor, a diaphragm compressor, a dynamic compressor, an axial compressor, or any other form of compressor that can be integrated into the heat pump assembly for the particular application.
The compressed refrigerant from the compressor 112 may move to the heat exchanger/condenser coils that may enable transfer of energy/heat to the water in the water storage tank 104, thus heating the water. In some aspects, the heat exchanger/condenser coils may be wrapped around water storage tank exterior surface or submerged in the tank. Responsive to the water being heated, cool and dehumidified air may move out of the housing 102 via the air outlet 108.
In certain embodiments, the water heating device 100 may include a sound baffle device 114 that may be configured to at least partially enclose/surround the compressor unit (e.g., the compressor 112 and the accumulator 110). The sound baffle device 114 may surround the compressor unit such that the sound baffle device 114 may be disposed at a predefined distance from the surfaces of the compressor 112 and the accumulator 110 (e.g., in a housing interior portion). Surrounding the compressor unit with the sound baffle device 114 may minimize sound transmission from the compressor unit to outside of the housing 102. The sound baffle device 114 may include one or more baffle side plates (shown as baffle side plates 208, 212 in
Further, the walls of the housing may prevent (or limit) sound transmission from a compressor unit second side portion (e.g., the remaining side portion) and reflect the sound generated by the compressor unit back towards the housing interior portion. In some aspects, the wall of the housing 102 and the sound baffle device 114 may completely enclose the compressor unit. Thus, the sound waves generated by the compressor unit may be prevented from escaping the housing 102 by using the sound baffle device 114 and at least a portion of the housing walls to substantially enclose the sound baffle device 114 within the housing 102. In this manner, the sound generated by the compressor unit may be at least partially maintained within the housing 102 and prevented from escaping out of the air inlet 106 and/or the air outlet 108. In some aspects, the sound baffle device 114 may be a rigid structure. The sound baffle device 114 may be made of any material including, but not limited to, aluminum, steel, fiberglass, plastic, ceramics, composites, or combinations thereof. In some aspects, the sound baffle device 114 may be coated with any material including, but not limited to, foam, vinyl, mass loaded vinyl, etc. or combinations thereof. The details of the sound baffle device 114 may be understood in conjunction with
In certain embodiments, the sound baffle device 200 may include a first piece 202 and a second piece 204 that may be attached (e.g., interlock) with each other and surround the compressor 112 and/or the accumulator 110. Specifically, the first piece 202 may be configured to partially enclose/surround the compressor 112, and the second piece 204 may be configured to partially enclose/surround the accumulator 110 (as shown in
In some aspects, the first piece 202 may have a first integrated connector 206a, and the second piece 204 may have a second integrated connector 206b. The first integrated connector 206a and the second integrated connector 206b may be attached to each other using one or more fasteners and/or adhesives and may connect the first piece 202 and the second piece 204, as shown in
In some aspects, the first piece 202 and the second piece 204 may be removably attached to a base plate 302 via a fastener 304 that may include screws, bolts, adhesives, and/or the like (as shown in
In certain embodiments, the first piece 202 may include the first baffle side plate 208 and the first baffle top plate 210. The first baffle side plate 208 may include a plurality of faces (e.g., three faces as shown in
Similarly, the second piece 204 may include the second baffle side plate 212 and the second baffle top plate 214. The second baffle side plate 212 too may include a plurality of faces (e.g., two faces as shown in
The first baffle side plate 208 may be removably attached to the second baffle side plate 212, and the first baffle top plate 210 may be removably attached to the second baffle top plate 214 to partially enclose the compressor unit. Specifically, the first piece 202 and the second piece 204 may partially enclose the side and top portions of the compressor unit such that the sound baffle device 200 may reflect the sound waves from the side and top portions back towards the compressor unit (e.g., towards the housing interior portion). In this manner, the sound baffle device 200 may prevent (or limit) sound waves from traveling from the compressor unit to outside the sound baffle device 200.
In some aspects, the compressor size may be greater than the accumulator size, and thus a first piece size may be greater than a second piece size. Specifically, the size, shape, and/or configuration of the first piece 202 may be different from the size, shape, and/or configuration of the second piece 204. For example, a first piece width may be greater than a second piece width. For example, the first piece width may be 8 to 24 inches, while the second piece width may be 4 to 20 inches. Any suitable width for either piece may be used herein. In further aspects, a first piece height may be the same as a second piece height. For example, the first piece height may be 8 to 30 inches, while the second piece height may be the same or larger or shorter. In this manner, the width of each sound baffle device side/face may be different or the same depending on the configuration of the compressor unit.
The present disclosure is not limited to the sound baffle device structure described above. For example, in some aspects, the sound baffle device 200 may be of any other shape including, e.g., a semi-circular shape. That is, the first piece may include a single side having a curved surface, and the second piece may include a single side having a similar curved surface. In other instances, the sound baffle device 200 may include a single unitary structure having a curved side wall, which is enclosed by a top wall. The side wall and/or top wall may include one or more apertures for tubing or piping.
As shown in
As described above, the first baffle top plate 210 and the second baffle top plate 214 may be configured to cover the compressor unit top portion. In this manner, the first baffle top plate 210 and the second baffle top plate 214 may be configured to reflect back sound waves from the top portion back towards the compressor unit and into the sound baffle device 200. The first baffle top plate 210 may be configured to at least partially (and in some embodiments completely) cover the compressor top portion, and the second baffle top plate 210 may configured to at least partially (and in some embodiments completely) cover the accumulator top portion. In some aspects, the first baffle top plate 210 may partially cover the accumulator top portion.
In certain embodiments, the first baffle top plate 210 and the second baffle top plate 214 may include one or more cut-outs 216a and 216b (e.g., “U-shaped” cut outs or the like) that may form apertures that are configured to at least partially surround the inlet and/or outlet pipes of the compressor unit (shown as compressor piping 306 and accumulator piping 308 in
In some aspects, the cut-out 216a may be formed in the first baffle top plate 210, and the cut-out 216b may be formed in the second baffle top plate 214. In other aspects (as shown in
In the above disclosure, reference has been made to the accompanying drawings, which form a part hereof, which illustrate specific implementations in which the present disclosure may be practiced. It is understood that other implementations may be utilized, and structural changes may be made without departing from the scope of the present disclosure. References in the specification to “one embodiment,” “an embodiment,” “an example embodiment,” etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a feature, structure, or characteristic is described in connection with an embodiment, one skilled in the art will recognize such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described.
It should also be understood that the word “example” as used herein is intended to be non-exclusionary and non-limiting in nature. More particularly, the word “example” as used herein indicates one among several examples, and it should be understood that no undue emphasis or preference is being directed to the particular example being described.
With regard to the processes, systems, methods, heuristics, etc. described herein, it should be understood that, although the steps of such processes, etc. have been described as occurring according to a certain ordered sequence, such processes could be practiced with the described steps performed in an order other than the order described herein. It further should be understood that certain steps could be performed simultaneously, that other steps could be added, or that certain steps described herein could be omitted. In other words, the descriptions of processes herein are provided for the purpose of illustrating various embodiments and should in no way be construed so as to limit the claims.
Accordingly, it is to be understood that the above description is intended to be illustrative and not restrictive. Many embodiments and applications other than the examples provided would be apparent upon reading the above description. The scope should be determined, not with reference to the above description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. It is anticipated and intended that future developments will occur in the technologies discussed herein, and that the disclosed systems and methods will be incorporated into such future embodiments. In sum, it should be understood that the application is capable of modification and variation.
All terms used in the claims are intended to be given their ordinary meanings as understood by those knowledgeable in the technologies described herein unless an explicit indication to the contrary is made herein. In particular, use of the singular articles such as “a,” “the,” “said,” etc., should be read to recite one or more of the indicated elements unless a claim recites an explicit limitation to the contrary. Conditional language, such as, among others, “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments could include, while other embodiments may not include, certain features, elements, and/or steps. Thus, such conditional language is not generally intended to imply that features, elements, and/or steps are in any way required for one or more embodiments.
This application claims priority to and the benefit of U.S. provisional application No. 63/596,467, filed Nov. 6, 2023, which is hereby incorporated by reference herein in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63596467 | Nov 2023 | US |