Patent Application
20230099397
The present disclosure relates, in general, to a water heater and, more specifically relates, to a heat trap apparatus for the water heater.
Water heaters are used to heat and store a quantity of water in a tank thereof for subsequent, on-demand delivery of hot water for residential and commercial use. When the water heater is not in an operating mode, it is desirable to reduce or avoid heat loss from the stored hot water to cooler areas. To avoid or minimize such heat loss, the tank of the water heater is insulated. Thermal efficiency is also vital to the operation of the water heater to make the water heater more energy efficient. An effective insulating material is generally used in the body of the water heater. This insulating material traps heat inside the water heater to enhance the thermal efficiency and thereby to improve energy efficiency of the water heater.
However, the heat from the stored hot water may also be lost by the thermal convection flow of the hot water from the tank through the cold-water inlet conduit and hot water outlet conduit. To minimize convective heat loss, various convective heat trap apparatuses have been developed to connect the cold-water inlet conduit and the hot water outlet conduit to the tank. However, the known heat trap apparatuses lack appropriate seal in the water flow path thereof and lack flexibility in the assembly. Thus, there is a need to develop a heat trap apparatus that is flexible in assembly and mitigate shortcomings of the existing heat trap apparatuses.
According to one aspect of the present disclosure, a heat trap apparatus for a water heater is disclosed. The heat trap apparatus includes a tubular body having a length defined between a first end and a second end. In an embodiment, each of the first end and the second end of the tubular body includes threads configured to fluid tightly engage with one or more conduits. In an embodiment, the tubular body is made of a metallic material. The heat trap apparatus further includes a liner disposed within the tubular body, and a length of the liner is greater than the length of the tubular body. An outer surface of the liner is configured to engage with an inner surface of the tubular body using an interference fit. In an embodiment, a difference value between an outer diameter of the liner and an inner diameter of the tubular body is about 0.015 to 0.025 inches. In an embodiment, the liner is made of a plastic material. The liner includes a first end configured to engage with a peripheral edge of the first end of the tubular body. In an embodiment, the first end of the liner includes a flange configured to engage with the peripheral edge of the first end of the tubular body. The liner further includes a second end extending beyond a peripheral edge of the second end of the tubular body for a desired length and configured to connect with a conduit. In an embodiment, the second end of the liner includes one or more radial protrusions defined at the outer surface thereof and is configured to engage with one or more slots defined in the conduit.
The heat trap apparatus further includes a heat trap baffle assembly having a tubular housing coaxially disposed within the liner and configured to inhibit convective fluid flow therethrough. The tubular housing of the heat trap baffle assembly is configured to movably support one or more heat trap inserts to inhibit the convective fluid flow therethrough. In an embodiment, the tubular housing is made of a plastic material. In one embodiment, the heat trap baffle assembly is disposed proximate the first end of the liner. In another embodiment, the heat trap baffle assembly is disposed proximate the second end of the liner. In some embodiments, the tubular housing of the heat trap baffle assembly is configured to removably engage with an inner surface of the liner via an interference fit, one or more fasteners, or a combination thereof.
According to another aspect of the present disclosure, a water heater is disclosed. The water heater includes a tank, and a first heat trap apparatus and a second heat trap apparatus mounted on the tank. The first heat trap apparatus is coupled with a cold-water inlet pipe and a dip tube, and the second heat trap apparatus is coupled with a hot-water outlet pipe and a conduit. The first heat trap apparatus includes a tubular body having a length defined between a first end and a second end. The first end is configured to fluid tightly engage with the cold-water inlet pipe. The heat trap apparatus further includes a liner disposed within the tubular body, and a length of the liner is greater than the length of the tubular body. An outer surface of the liner is configured to engage with an inner surface of the tubular body using an interference fit. The liner includes a first end configured to engage with a peripheral edge of the first end of the tubular body, and a second end extending beyond a peripheral edge of the second end of the tubular body for a desired length, and configured to connect with the dip tube. The heat trap apparatus further includes a heat trap baffle assembly having a tubular housing coaxially disposed within the liner proximate the second end thereof and configured to inhibit convective fluid flow therethrough.
The second heat trap apparatus includes a tubular body having a length defined between a first end and a second end. The first end is configured to fluid tightly engage with the hot-water outlet pipe. The heat trap apparatus further includes a liner disposed within the tubular body, and a length of the liner is greater than the length of the tubular body. An outer surface of the liner is configured to engage with an inner surface of the tubular body using an interference fit. The liner includes a first end configured to engage with a peripheral edge of the first end of the tubular body, and a second end extending beyond a peripheral edge of the second end of the tubular body for a desired length, and configured to connect with the conduit. The heat trap apparatus further includes a heat trap baffle assembly having a tubular housing coaxially disposed within the liner proximate the first end thereof and configured to inhibit convective fluid flow therethrough. In an embodiment, the first end of the tubular body of the first heat trap apparatus and the first end of the tubular body of the second heat trap apparatus comprise threads configured to fluid tightly engage with the cold-water inlet pipe and the hot-water outlet pipe, respectively.
In one embodiment, the tubular housing of the heat trap baffle assembly of each of the first heat trap apparatus and the second heat trap apparatus is configured to removably engage with an inner surface of the liner via an interference fit, one or more fasteners, or a combination thereof. In another embodiment, the tubular housing of the heat trap baffle assembly of each of the first heat trap apparatus and the second heat trap apparatus is configured to movably support one or more heat trap inserts to inhibit the convective fluid flow therethrough.
These and other aspects and feature of non-limiting embodiments of the present disclosure will become apparent to those skilled in the art upon review of the following description of specific non-limiting embodiments of the disclosure in conjunction with the accompanying drawings.
A better understanding of embodiments of the present disclosure (including alternatives and/or variations thereof) may be obtained with reference to the detailed description of the embodiments along with the following drawings, in which:
Reference will now be made in detail to specific embodiments or features, examples of which are illustrated in the accompanying drawings. Wherever possible, corresponding or similar reference numbers will be used throughout the drawings to refer to the same or corresponding parts. Moreover, references to various elements described herein, are made collectively or individually when there may be more than one element of the same type. However, such references are merely exemplary in nature. It may be noted that any reference to elements in the singular may also be construed to relate to the plural and vice-versa without limiting the scope of the disclosure to the exact number or type of such elements unless set forth explicitly in the appended claims.
Referring to
The water heater 100 further includes one or more heat trap apparatuses 122 mounted on the wall 104 at the top end 108 of the tank 102. Particularly, the one or more heat trap apparatuses 122 are coupled through the wall 104 and configured to allow flow of water therethrough while preventing convective fluid flow therethrough. In an embodiment, the water heater 100 includes a first heat trap apparatus 122A associated with a cold-water supply line and a second heat trap apparatus 122B associated with a hot-water discharge line. The first heat trap apparatus 122A and the second heat trap apparatus 122B are hereinafter collectively referred to as ‘the heat trap apparatuses 122’ or individually referred to as ‘the heat trap apparatus 122’ unless otherwise specifically mentioned. The water heater 100 further includes one or more conduits 124 fluidly coupled to the heat trap apparatuses 122. In an embodiment, a cold-water inlet pipe 124A is coupled to the first heat trap apparatus 122A and configured to allow ingress of water into the tank 102 through the first heat trap apparatus 122A. A hot-water outlet pipe 124B is coupled to the second heat trap apparatus 122B and configured to allow egress of water from the tank 102 through the second heat trap apparatus 122B. The cold-water inlet pipe 124A and the hot-water outlet pipe 124B are hereinafter collectively referred to as ‘the conduits 124’ or individually referred to as ‘the conduit 124’ unless otherwise specifically mentioned. When the water heater 100 is not in operating mode, the heat trap apparatuses 122 prevent convective fluid flow therethrough, hence the temperature of the hot water inside the tank 102 is maintained for longer period and thereby the water heater 100 becomes more energy efficient.
In an embodiment, the heat trap apparatus 122 may be a cylindrical body having a length greater than a thickness of the wall 104 of the tank 102. In an assembled condition of the heat trap apparatus 122 with the tank 102, the heat trap apparatus 122 may be inserted through a hole (not shown) provided in the wall 104 of the tank 102 and both ends of the cylindrical body are projected beyond the thickness of the wall 104. As such, top end of the first heat trap apparatus 122A is coupled to the cold-water inlet pipe 124A and bottom end is coupled to a dip tube 126 to discharge colder water towards the base 112 of the tank 102. Similarly, top end of the second heat trap apparatus 122B is coupled to the hot-water outlet pipe 124B and bottom end is coupled to a conduit 128. Heated water is drawn from the tank 102 through the conduit 128 and the hot-water outlet pipe 124B with aid of, for example, a pump, and may be delivered to one or more end devices, such as laundry washer, dishwasher, faucets, and shower heads. In an embodiment, the wall 104 of the tank 102 may be insulated to retain temperature of the water for longer duration.
Referring to
The first heat trap apparatus 122A further includes a liner 222 disposed within the tubular body 202. The liner 222 includes a first end 224 and a second end 226, and has a length ‘L2’ defined between the first end 224 and the second end 226. The length ‘L2’ of the liner 222 is greater than the length ‘L1’ of the tubular body 202. The liner 222 further includes a flange 228 at the first end 224 and configured to engage with a peripheral edge 230 at the first end 204 of the tubular body 202. The flange 228 may further act as a seal between the tubular body 202 and the liner 222 to prevent flow of water. During assembly of the first heat trap apparatus 122A, the second end 226 of the liner 222 is inserted from the first end 204 of the tubular body 202 and the liner 222 is pushed inside the tubular body 202 until the flange 228 contacts with the peripheral edge 230 at the first end 204 of the tubular body 202.
The first heat trap apparatus 122A further includes a heat trap baffle assembly 240 having a tubular housing 242 coaxially disposed within the liner 222. The tubular housing 242 has a first end 244 and a second end 246. The tubular housing 242 is configured to movably support one or more heat trap inserts 248 to inhibit convective fluid flow therethrough. The one or more heat trap inserts 248 are configured to allow flow of water therethrough while preventing convective fluid flow therethrough, thereby maintain temperature of the water within the tank 102 for a longer period when the water heater 100 is not in operating mode.
Referring to
The liner 222 includes a wall 312 defining an inner surface 314 and an outer surface 316. The inner surface 314 of the liner 222 defines an inner diameter ‘D2’ consistent throughout the length ‘L2’ thereof. The outer surface 316 of the liner 222 is configured to engage with the inner surface 304 of the tubular body 202 using an interference fit ‘I1’. The interference fit ‘I1’ is otherwise known as ‘friction fit’ or ‘press fit’. During assembly of the first heat trap apparatus 122A, the liner 222 may be pressed into the tubular body 202 and due to a difference between external dimension of the liner 222 and internal dimension of the tubular body 202, a friction may be created between the outer surface 316 of the liner 222 and the inner surface 304 of the tubular body 202 which in turn causes the interference fit ‘I1’ between the liner 222 and the tubular body 202. Particularly, the outer surface 316 of the liner 222 has an outer diameter ‘D3’ greater than the inner diameter ‘D1’ of the tubular body 202, such a difference value between the outer diameter ‘D3’ of the liner 222 and the inner diameter ‘D1’ of the tubular body 202 causes the interference fit ‘I1’ therebetween. In an embodiment, the difference value between the outer diameter ‘D3’ of the liner 222 and the inner diameter ‘D1’ of the tubular body 202 is about 0.015 to 0.025 inches, to achieve the interference fit ‘I1’ therebetween. In one embodiment, the liner 222 is made of a plastic material. In some embodiments, the liner 222 may be made of any nonflexible plastic material known to a person of ordinary skill in the art to prevent transfer of heat. In some embodiments, the liner 222 may be molded as a single piece using the plastic material. As such, the liner 222 may act as an insulator to prevent transfer of heat from hot water to the tubular body 202. Moreover, the liner 222 may act as a seal along the water flow path of the heat trap apparatus 122 to prevent heat transfer from the hot water to the tubular body 202. As the length ‘L2’ of the liner 222 is greater than the length ‘L1’ of the tubular body 202, the tubular body 202 is completely isolated from the water flow path of the heat trap apparatus 122. As such, the sealing characteristics of the heat trap apparatus 122 is significantly improved over the known heat trap apparatus.
During the assembly of the first heat trap apparatus 122A, the liner 222 may be pushed from the first end 204 of the tubular body 202 with additional force to achieve the interference fit ‘I1’ therebetween. The interference fit ‘I1’ may be defined based on various factors including, but not limited to, material of the liner 222, material of the tubular body 202 and capacity of the water heater 100.
The liner 222 includes the second end 226 that extends beyond a peripheral edge 318 of the second end 206 of the tubular body 202 for a desired length ‘L3’. The desired length ‘L3’ may be defined as a length by which the length ‘L2’ of the liner 222 is greater than the length ‘L1’ of the tubular body 202. Such extended length of the liner 222 allows the heat trap baffle assembly 240 to be placed within the liner 222 but outside the tubular body 202. Further, the desired length ‘L3’ of the liner 222 may be defined based on the water boundary or water level of the tank 102. As such, the portion of the liner 222 defined by the desired length ‘L3’ may be extended beyond the water boundary or water level and thereby the heat trap baffle assembly 240 may be placed below the water boundary to minimize potential heat loss.
The second end 226 of the of the liner 222 is configured to engage with the dip tube 126. In one embodiment, the second end 226 of the liner 222 includes one or more radial protrusions 320 defined on the outer surface 316 thereof. The one or more radial protrusions 320 is configured to engage with one or more slots 322 defined in the dip tube 126. In an example, four circular protrusions 320 may be defined on the outer surface 316 at the second end 226 of the liner 222 along two rows. In some embodiments, more than four protrusions 320 may be provided in one or more rows. In one example, the protrusions 320 may be circular in shape. In some examples, the protrusions 320 may be oval, or any other known polygon shape. One end of the dip tube 126 may be provided with corresponding number of the slots 322 and corresponding shape of the slots 322 to engage with the protrusions 320 of the liner 222. As the dip tube 126 is made of hard materials such as metals, the slots 322 of the dip tube 126 may be easily engaged with the protrusions 320 made of the plastic material of the liner 222. In some embodiments, the protrusions 320 may be in the form an annular ring and configured to engage with a corresponding groove provided in the dip tube 126.
Referring to
In an alternate embodiment, the tubular housing 242 may be removably engaged with the inner surface 314 of the liner 222 using one or more fasteners. In an example, the fasteners may be screws, nut and bolts, rivet pins, or any other known fasteners. In some embodiments, the tubular housing 242 may be removably engaged with the inner surface 314 of the liner 222 using a combination of the one or more fasteners and the interference fit ‘I2’.
The wall 332 of the tubular housing 242 is configured to movably support the one or more heat trap inserts 248 to inhibit convective fluid flow therethrough. In an embodiment, the wall 332 of the tubular housing 242 may include one or more slots 340 to movably support the one or more heat trap inserts 248. In one embodiment, the one or more heat trap inserts 248 may be flapper structures. The flapper structures may be movably received in the slots 340 and configured to rotate or deflect to allow flow of water while preventing convective fluid flow therethrough. In an alternate embodiment, the one or more heat trap inserts 248 may include ball type valve arrangement. In some embodiments, the inner surface 314 of the liner 222 may be defined to accommodate any heat trap baffle assembly known to a person of ordinary skill in the art. In one embodiment, the tubular housing 242 is made of a plastic material. In various embodiments, the tubular housing 242 may be made of any nonflexible plastic material known to a person of ordinary skill in the art.
Referring to
The second heat trap apparatus 122B further includes a liner 422 having inner surface 414 and an outer surface 416 disposed within the tubular body 402. The liner 422 includes a first end 424 and a second end 426, and has a length ‘L5’ defined between the first end 424 and the second end 426. The length ‘L5’ of the liner 422 is greater than the length ‘L4’ of the tubular body 402. The outer surface 416 of the liner 422 is configured to engage with an inner surface 418 of the tubular body 402 using an interference fit ‘I3’. Due to a difference between external dimension of the liner 422 and internal dimension of the tubular body 402, a friction may be created between the outer surface 416 of the liner 422 and the inner surface 418 of the tubular body 402 which in turn causes the interference fit ‘I3’ between the liner 422 and the tubular body 402. The liner 422 further includes a flange 428 at the first end 424 and configured to engage with a peripheral edge 430 at the first end 404 of the tubular body 402. The liner 422 further includes the second end 426 that extends beyond a peripheral edge 432 of the second end 406 of the tubular body 402 for a desired length ‘L6’.
The second heat trap apparatus 122B further includes a heat trap baffle assembly 440 having a tubular housing 442 coaxially disposed within the liner 422. The tubular housing 442 is configured to movably support one or more heat trap inserts 448 to inhibit convective fluid flow therethrough. The one or more heat trap inserts 448 are configured to allow flow of water therethrough while preventing convective fluid flow therethrough, thereby maintain temperature of the water within the tank 102 for a longer period when the water heater 100 is not in operating mode. The heat trap baffle assembly 440 is disposed at a location that is proximate the second thread 410 of the tubular body 402 and coincide with coupling of the tubular body 402 with top head of the tank 102, thereby prevents siphon. In an embodiment, due to difference between external dimension of the tubular housing 442 and the internal dimension of the liner 422, the heat trap baffle assembly 440 is disposed within the liner 422 using an interference fit. In an alternate embodiment, the tubular housing 442 may be removably engaged with the inner surface 414 of the liner 422 using one or more fasteners. In some embodiments, the tubular housing 442 may be removably engaged with the inner surface 414 of the liner 422 using a combination of the one or more fasteners and the interference fit.
The present disclosure relates to the heat trap apparatus 122 having the tubular body 202, the liner 222 disposed within the tubular body 202, and the heat trap baffle assembly 240 having the tubular housing 242 coaxially disposed within the liner 222. The tubular body 202 is made of metal and includes the first thread 208 to couple with the conduit 124. The liner 222 is a single molded piece made of plastic and fitted with the tubular body 202 using the interference fit ‘I1’. The flange 228 of the liner 222 may further seal connection between the tubular body 202 and the liner 222.
In some embodiments, ends of the single piece molded liner creates interference with the tubular body 202 to seal uncoated portion of the tubular body 202. Further, the single piece molded design feature of the liner 222 allows relocation of the heat trap baffle assembly 240 anywhere between the first end 224 and the second end 226 thereof. Also, the single piece liner allows a modular design of the heat trap apparatus 122 to simplify the assembly over the known heat trap apparatuses. Further, the single piece liner allows more controlled placement of the heat trap baffle assembly 240 inside the tank 102 to aid in reduction of heat loss. As shown in
According to the present disclosure, the liner 222 may act as a seal along the water flow path of the heat trap apparatus 122 to prevent heat transfer from the hot water to the tubular body 202. Due to such sealed water flow path through the tubular body 202, the current flow from the galvanic circuit can be reduced to improve or extend functional life of the components of the water heater 100. As the length ‘L2’ of the liner 222 is greater than the length ‘L1’ of the tubular body 202, the tubular body 202 is completely isolated from the water flow path of the heat trap apparatus 122. As such, the sealing characteristics of the heat trap apparatus 122 is significantly improved over the known heat trap apparatus.
While aspects of the present disclosure have been particularly shown and described with reference to the embodiments above, it will be understood by those skilled in the art that various additional embodiments may be contemplated by the modification of the disclosed methods without departing from the spirit and scope of what is disclosed. Such embodiments should be understood to fall within the scope of the present disclosure as determined based upon the claims and any equivalents thereof.
