Patent Application
20070062464
This invention relates generally to water heaters, and specifically to water heaters having increased heating efficiency, provision for producing continuous flow and preventing substantial accumulation of sediment by introducing a self-cleaning mechanism, and to a method of operating the same.
Applicants prior U.S. Pat. No. 6,508,208 issued Jan. 31, 2003, to Frasure, et al. discloses a water heater, for which the present invention provides improvements.
Reames, Jr., U.S. Pat. No. 4,175,518 dated Nov. 27, 1979, discloses a preheating device for hot water heaters, which employs hot gases of combustion from the flue to preheat incoming cold water and to continually preheat water stored in the water tank by natural recirculation. Use of the device provides for increased fuel efficiency because hot combustion gases from the heat source are used for warming of water before venting to the atmosphere, the result being an average increased temperature within the tank so that lesser amounts of fuel are required to reach any desired hot water temperature.
Leiter Klaus and Walder Gerhar, PCT Publication No. WO01 13045 dated Feb. 22, 2001, discloses a sanitation unit having a hot water boiler and a water treatment unit with a functional element, in particular for the prevention of deposits of scale, whereby a circulation pump is provided, through which water taken from the hot water connection of the boiler can be routed through the functional element to the water treatment unit of the cold water connection of the boiler. The circulation pump and the functional element are constructed as one compact structural unit.
Burwell, U.S. Pat. No. 2,549,755 dated Apr. 24, 1951, discloses a burner base for a hot water tank of the type having a side arm heat-transfer coil carried within a chamber disposed adjacent the tank and means defining a flue passage in said base and communicating, respectively with the said open chamber and the chamber in which the heat-transfer coil of the said tank is carried, whereby gaseous products of combustion emanating from said burner may be directed from the bottom of said tank to the heat transfer coil thereof.
All the water heaters utilizing a coil that were found in the prior art relied on natural convection to circulate water through the coil. As a result, the coil can become overheated and get damaged when the burner is operating. None of the aforesaid prior arts teaches for increasing the efficiency by controlling the condensation problem. The condensation problem is solved by keeping the water vapor produced by the flame away from the cooler flue wall and by utilizing the hot air many a times by circulation of the same keeping safety and atomization of the system in mind. Moreover none of the prior arts also teaches a self-cleaning mechanism of tank and the coils used by the system. Hence, the prior art devices do-not appear to substantially use the waste heat energy and prevent the accumulation of the sediments, despite claims to the contrary.
It is an object of the present invention to provide an improved, efficient, tank type, water heater.
A specific object of the present invention is to reduce condensation in the coil and the flue pipe.
Another object is to provide means to prevent overheating of the system.
Another object of one embodiment of the present invention is to provide means for instant and continuous flow of hot water.
Another object of the present invention is to provide means for self cleaning components of the system.
It has been found that improvements can be made to water heaters, such as providing an increase in the efficiency of heating, providing a continuous supply of water, and providing self cleaning of the water heater, and that these improvements can be obtained by using principle of conservation of heat energy by several means, and with the use of attachments.
The present invention provides a water heater comprising a closed tank having a water inlet for connection with a water supply, and a hot water outlet connected to the tank interior; a flue pipe extending vertically through the tank and having an upper portion for connection with a vent pipe; a cylinder having a lower and upper open end disposed within the flue pipe, and spaced from inner walls of the flue pipe, and extending substantially the length of the flue pipe; a burner disposed in a lower region of the cylinder, such that combustion products from the burner rise through the cylinder, and a water conducing coil disposed within the cylinder connected with the interior of the tank.
With reference to
Preferably, the coil 202 has valve means 301 and 304 at its upper end for selectively connecting with the interior of the tank 140 or with the water supply, and valve means 305 and 306, at the lower end, for selectively connecting with the interior the tank or to a drain 307. Control means activate the valve means, such that in one selected activated state heat from the flue pipe is transferred from the coil to the water in the tank, and in another activated state water from the water supply is directed through the coil, immediately after burner shut-off, providing thermal shock to dislodge deposits from the inside walls of the coils for disposing to the drain.
As shown in
In one embodiment of the invention, the water heater system includes a pump, a thermostat, and a flow sensor, wherein the pump is responsive to the thermostat, and the burner is responsive to flow detected by the flow sensor.
The water heater temperature is set by gas control valve 175, a gas burner 302, which is located inside the bottom of the cylinder and adjustable temperature controller 180. The gas burner is placed one inch above from the bottom of the cylinder to preclude any water contact with the flame. For clarity, the drawing does not show heater insulation, which covers all sections of the heater and hot water outlet pipe 185. Penetrating the heater top section 186 are pressure and temperature relief valves 190, cold-water inlet pipe 195, and corrosion reducing anode 200.
The coil 202 is located inside a cylinder 309 and extends substantially the full length of the flue portion 401 that is disposed within the tank 140. The cylinder 309 is sized to leave a space (about ¼ inch) between the cylinder wall and the flue wall. This distance is preferable, but other distances in this range will work. The area between the top of the coil and the flue could be covered with a ¼ inch wide ring/flange.
The burner is placed inside the cylinder approximately one inch from the bottom of the cylinder. This prevents steam or water to flow in the direction of flame or entering the area between the flue and the cylinder. The flow of the steam/hot gases is so directed that no flow is directed towards the bottom of the water tank. This inturn results in the lowering of the temperature of the bottom of the tank and thereby significantly reducing/preventing the ability of the minerals present in the water to adhere to the bottom surfaces of the tank and flue. The bottom of the tank and flue thus becomes free from the hard water sediments which is a solution of a major problem in the water tanks in areas where the water contains many types of minerals. The heat transfer efficiency of the system is improved and the problem of overheating of the bottom of the water tank is thus eliminated and also enhances the life of the tank.
In one embodiment the area between the top of the flue and cylinder is to be sealed and the area between the flue and the cylinder would preferably contain upwardly pointing perforations. This would allow for the heat flow to be controlled. Any condensation, if there is any, being trapped and drained at that point if necessary.
To solve the condensation problem in the flue, the coil is enclosed in a cylinder 309, which runs full length of the flue portion 401 within the tank. This also increases the efficiency. The cylinder would preferably be attached to the top of area of the flue. The flue in the prototype extends approximately one inch above the top surface of the tank. A person skilled in the art can very well evaluate the disadvantages of the condensation of the steam and hot gases in the coil/cylinder.
The temperature at the top of the primary coil is approximately 200 degrees F. To further take advantage of the heat, a second coil 314 is added to further increase the efficiency and also causes the condensation to collect on the coil and exit through the drain 313 below. The second coil is located in the generally horizontal or transverse section 317 of vent pipe 201. This coil is cooler than the heat flow venting up the stack, which causes the water to condense on the coil and drain at 313. The coil also absorbs a significant portion of the remaining heat in the vent pipe at that point, which inturn increases the efficiency. The transverse section 317 is preferably slanted downward, which allows the condensate to collect at the drain 313. The wall of transverse section 317 and area around drain 313 would be coated with a non-corrosive material to prevent deterioration of the vent pipe. The internal wall of the total area of the vent pipe 201 could be coated with a non-corrosive material or the vent pipe 201 could be made of a material such as PVC, CPVC, or stainless steel that would accommodate the necessary temperatures and not deteriorate.
The lower coils of the coil in the present case are larger than the coils in the upper portion of the coil as a result of the coils. This pulls the bulk of the heat out of the air at the bottom verses at the top where condensation could occur as a result of cooler temperatures.
In one embodiment of present invention a third coil may be included and fitted around the outside of the cylinder between the cylinder wall and the flue wall. The coil would tie into the bottom of the primary coil via a tee and at the top of the primary coil via a tee. There would be a 1/16th to a ¼ inch gap between the outside wall of the coil and the flue wall.
A steam trap 430 is preferably located just above the elbow 420. The trap could catch any condensate that may get past second coil 314. The drain 440 of the trap hangs down and drains into drain 313. The trap consists of a funnel with perforations protruding. The steam can pass upward, but it cannot get back through perforations and directed to the drain. The trap can be made of stainless steel or a material that will not deteriorate due to the acidic properties of the condensate such as PVC or CPVC. The steam trap may be located at different places in the coil system. In an economical model of the claimed water tank the steam trap may be located in the vent pipe above the coil 202 and the top of the cylinder for draining out the condensate through the side of the vent pipe via a tube running to the drain.
The gas burner used in the said water heater, as described earlier in the description, can be replaced by some electrical heating equipment as per the need and availability.
Flue pipe 309 penetrates the center of the top section 186 and extends down to the top of inverted cone 150. Handhold cover 205 provides access to the tank interior for manual cleaning and inspection.
A pump 450 is added to circulate the water through the system, which prevents the coil from overheating, significantly increases the efficiency and eliminates stacking.
Heat flow restrictors are strategically placed in the center and around the outside of the coil to force the heat from the burner through the coil. The lower inside restrictor 308 forces the heat flow through from the inside to the outside of the coil, the outer restrictor 310 located higher in the coil forces the heat flow from the outside of the coil to the inside of the coil. The restrictor 308 at the top of the coil forces the heat flow from the inside of the coil to the outside of the coil. This forces the heat through the fins of the coil and allows more of the heat to be transferred to the coil. Additional heat flow restrictors may be added based on the dimensions of the coil.
Line 311 can enter heat exchanger 450; the line then proceeds from heat exchanger 450 to filter 312. A circulation loop circulates through building from heat exchanger 450. The heat exchanger 450 contains a pump for the hydronic circulation. The said attachment can be used separately in other water heaters for obtaining better results.
When the loop option is being utilized a check valve is required to be installed at the hot outlet line 185, preventing the water from being sucked back into the tank.
When the thermostat calls for heat in response to water being removed from the tank through hot water outlet 185, the thermostat turns the pump on. The pump creates water flow pass a flow sensor, the flow sensor then turns the burner on. If there is no water flow, the flame cannot come on. Water is then pumped through check valve 306, through primary coil 202, through leg 316 (316 can be located inside of outside of vent pipe), through secondary coil 314, through return line 315 (315 can be located in or outside of vent pipe, but preferably inside), 316 could also be located in the insulation under the sheet metal skin of the tank. The water continues its path through solenoid 303, into tank opening 301, out of tank into line 311 (311 may be utilized as a loop for hydronic heating) to filter 312 and into pump. All water lines outside the skin of the unit, filter and the water flow area of the pump would be adequately insulated. A manually reset high temperature limit switch is connected in the control circuit.
As a less preferred method, the water could flow in reverse counter flow during the recovery cycle.
The flue pipe 309 is located in the center of tank 140 therefore drain 152 cannot be centrally located. Consequently, drain 152 is located in proximity to exterior wall 145, at the lowest portion 220 of flange 240 that extends from the lowest edge of cone 150 and is bonded, e.g., by seam welding or soldering, to wall 145. Cone 150 forms a vertically and horizontally extending bottom wall portion of tank 140. The bottom edge of cone 150 has a zenith point 222 diametrically opposite from drain 152, which is at the nadir of the cone bottom edge. In each vertical cross section of tank 140, flange 240 extends horizontally between the bottom edge of cone 150 and wall 145. Flange 240 extends continuously and smoothly around the circumference of the bottom edge of cone 150, between zenith point 222 and drain 152 to, in effect, provide a runway for sediment incident on the flange and cone 150. The inclination angle .beta. of the horizontally and vertically extending wall of cone 150 relative to the horizontal plane is such that washed sediment in tank 140 drifts by gravity along the wall of cone 150 to the runway flange 240 forms. Inclination angle .beta. continuously varies from a minimum angle along a straight line of the wall segment between flue 201 and zenith point 222 to a maximum angle along a straight line of the wall segment between flue 201 and nadir 220. The inclination angle of the runway between zenith point 222 and drain 152 is such that the washed sediment incident on the runway also drifts by gravity to the drain. Experiments have shown that the optimum minimum inclination angle .beta. is 42 degrees below a horizontal plane extending through a horizontal intersection of cone 150 and flue 201.
With reference to both
In response to water exiting hot water pipe 185, shown by arrow 230, or opening of drain valve 165, cold water enters cold water pipe 195 as shown at arrow 235, causing water to flow from slits 214 to gently wash sediment in tank 140 to the wall of cone 150, thence to the runway that flange 240 forms and to drain 152.
During the cleaning cycle of coils 202 and 314, solenoid valve 304 opens, solenoid valve 303 closes and solenoid valve 305 opens. The cold water enters solenoid valve 304, proceeds through return line 315, through secondary coil 314, through leg 316, through primary coil, to solenoid 305 and out 307 to drain. The cycle would occur from time to time immediately after burner shuts off. A sensor would determine when burner or pump turns off and would send a signal to a pre-programmed timer which would activate the solenoid valves after a predetermined number of heating cycles. The solenoid valves would be activated for a pre-programmed period of time. The process causes the coils to quickly contract, thus causing the hard water scale to dislodge from the inside wall of the coils. When the timer activates all solenoid valves, cold water from the supply line is introduced into the coil, which causes a thermal shock and flushes the sediment out 307 to drain. There are other patents that pump water from a water heater to a filter and back to a water heater, but they do not disclose the cooler water must enter the coil immediately after the burner turns off in order to cause the unit to contract.
In a preferred arrangement an opening is included at the bottom of dip tube 340. This would allow for water to wash the zenith (top of the runway) and cause it to begin a natural slide toward the drain 152. The design also includes an opening 350 (slit or round opening) in the ends of manifold 212, as shown in
This gas water heater has convex top 186 and vertical sides of about 40 inches. The bottom edge of cone 150 at zenith point 222 is about 8 inches below the bottom of flue 210; at nadir 220, the cone bottom edge is about 12 inches below the bottom of flue 210. A 1.5 inch diameter outlet and a 90 degree elbow 155 are connected adjacent to drain 152, at nadir 220 of cone 150. A bell reducer reduces the piping from 1.5 inch diameter to 1.25 inch diameter. Stainless steel ball valve 160 isolates stainless solenoid valve 165 for maintenance or replacement. Tank 140 is about 2 feet in diameter and has a volume of about 33 gallons. Stainless steel inlet dip tube 195 terminates at the 90 degree T 210 about one inch above the bottom edge of cone 150. Three legs support the tank and can therefore accommodate uneven floors. The preferred tank material is stainless steel surrounded by foam insulation and a thin outer metal shell.
The electrical components include solenoid valve 165 and timer and valve controller 170. Timer and valve controller 170 is adjusted to activate solenoid valve 165 for varying durations and frequencies depending on the hardness of the water and amount of particulate residue in the water.
Although the materials referred to for construction are stainless steel, a less expensive heater could be made from a glass-lined carbon steel body using copper pipe and bronze valves.
In one embodiment of the invention as an option, line 311 can be plumbed to all of the hot water taps in a building as a loop, returning to the entrance of the heat exchanger 450. The water is circulated continuously by pump 300 in order to supply instant hot water to all taps in a building. In this embodiment, the burner would be responsive to the thermostat, but would be prevented from turning on unless the flow sensor detected water flow.
In another embodiment of the invention an adjustable burner, pump and flow control valves can be utilized to increase the volume of hot water during periods when high volumes of hot water are desired. The speed of the pump could be increased and a fan would be incorporated into the stack.
In another embodiment of the present invention electrodes 454 can be inserted into the center of the coil to generate an electric arc at a desired height or a Jacobs ladder. This helps eliminate unburned hydrocarbons, increases the efficiency and lowers the emissions. Screens, protruding objects and various types of mixers can be added to create turbulence and mix the air. A transformer energizes the electrodes. A spark distributor can also be utilized to create multiple arcs.
In another embodiment of the present invention the drain pipe is connected to the water reservoir/source of the water heater. It has been noticed that in large capacity water heaters the cleaning cycle needs a good volume of water in the coils and other parts, which goes to waste. The invention recirculates and/or recycles fluids normally lost down the drain. A drain pipe is fitted with a filter 255 (optional) and recirculating/recycling valve 256, through which the water flows to the reservoir or inlet of the water heater.
In yet another embodiment of the present invention is to introduce automatic controls so as to monitor the overflow, overheating, choke in pipeline/disorders, control for timing the heating and cleaning cycle, pump controls etc. The control device comprises of circuits for determining and displaying the temperatures at different sensitive zones, timer circuits to control the timing different cycles and level detectors showing the water level and flow directions and alarms in case of failure at any level. The control circuit includes a memory section for a recordal of previous entries.
In yet another embodiment of the present invention the coil is installed using a method, which would allow it to be removed and replaced easily. This is done utilizing a flange around the top of the cylinder that rests on the top of the flue or by various other methods such as pins etc. Similarly the filters and valves can be dismantled easily in case of repair.
The thermal shock used to clean the coil of the design also works in other water heaters using a coil for continuous flow type water heater such as the Rinnia and Aqua Star brands.
The lower end of the cylinder 309 has an outwardly and downwardly extending funnel or dome-shaped portion 409 for directing combustion products inwardly and upwardly into cylinder 309 and preventing combustion products from coming in contact with the flue wall 105 or the bottom of the tank 150. As shown, the outwardly and downwardly extending portion/funnel 409 is extended to the outer area of the bottom of the tank and attached in a suitable manner. The distance between the outwardly and downwardly portion/funnel 409 and the bottom surface of tank 150 is in the range of about 0.0625 to 0.25 inches. The exact distance would be determined based on the particular design.
The outwardly and downwardly portion/funnel 409 would be positioned such that combustion products would be prevented from coming in contact with the flue wall 105 or the bottom of the tank 150. This could be accomplished by utilizing a number of methods such as welding a seam between cylinder 309 and the outwardly and downwardly extending portion/funnel 409, extending the outwardly and downwardly portion/funnel 409 a suitable amount above the lower end of cylinder 309, installing a seal between the two members, or any other suitable method.
Cylinder 309 and the outwardly and downwardly extending portion/funnel 409 would be attached by either a continuous weld, a tung and groove design or a number of other economical methods. The lower end of the outwardly and downwardly extending portion/funnel 409 could be attached to the lower portion of tank bottom 150 via a limited number of appropriately sized attachment points. The attachment point would be sized and spaced appropriately in order to prevent condensation from occurring. The attachment points would facilitate heat transfer to the bottom of the tank and assist in preventing the warping of the outwardly and downwardly portion/funnel 409.
In another embodiment, in order to prevent hard water from building up on raceway 240 described in U.S. Pat. No. 6,508,208, the outer edge of the outwardly and downwardly extending portion/funnel 409 would not extend under raceway 240. An insulating material may also be added to the bottom side of the raceway 240.
In another embodiment, heat transfer tabs 510 would be placed in strategic spots on the upper surface of the outwardly and downwardly portion/cylinder 409 and on the flue wall side of cylinder 309 to and make contact with the flue wall 105 and bottom surface of the bottom of the tank 150. The tabs 510 would be sized and spaced appropriately in order to prevent condensation.
In another embodiment, a plurality of clips 508 forming baffles are welded to the interior surface of cylinder 309. The clips 508 are arranged to form a spiral with a desired rifling based up the position, angle and dimension of the clips 508, creating turbulence in the cylinder which increases the amount of hot gases coming in contact with the cylinder wall and increases the amount of heater transfer to the cylinder wall through conduction of heat through the clips 508. The size of the clips 508 will vary depending on the location in the flue, but would typically be 0.25 to 3 inches long depending on the particular water heater design and extend out into the flow of hot gases. The clips 508 in the area around the coil 202 would be appropriately sized and located in optimum areas to enhance the heat transfer capability of the coil 202 while increasing the heat transfer capability of the cylinder. The long dimension of the upper and lower sides of the clips 508 would be slightly angled toward the bottom of the water heater. The narrow dimension of the upper and lower sides of the clips 508 would be angled slightly to allow the hot gases to flow under them and pass to the next clip above without being directed to center of cylinder 309. The clips 508 would be arranged to form a spiral causing the hot gases to flow in a spiral until reaching the area of coil 202 where the flow of the hot gases would be directed to maximize the heat transfer properties of coil 202. The clips 508 would be attached to cylinder 309 by spot welding with a device such as described in U.S. Pat. No. 4,761,532. The heat would have the option of flowing through the weld adjoining the clip 508 to the cylinder wall 309. The number and dimension of the clips 508 would be determined based on the appropriate number necessary to prevent condensation on the clips 508 and coil 202.
The primary purpose of the clips 508 is to reduce the size of coils 202 and 314. In another embodiment, clips 508 would be sized, shaped, positioned and attached as desired in any area within the cylinder based on the design needs of the water heater.
In another embodiment, heat transfer clips, splines or other protruding objects would be attached to the bottom of the outwardly and downwardly extending portion/funnel 409 to increase the heat transfer abilities of the cylinder. They would be positioned in a manner that would not interfere with the flame or the flow of hot gases across the outwardly and downwardly extending portion/funnel 409 to cylinder 309.
The outwardly and downwardly extending portion/funnel 409 is configured to allow use of a variety of different burners; for example, larger than that allowed in the embodiment of
The vent pipe in this area would be made of ABS, PVC CPVC or a suitable material capable of withstanding the heat and acidic condensation at this point. Drain pipe 440 would be connected to the condensate trap 430 and lead to a drain. Various types of condensate traps could be utilized to reduce costs.
In another embodiment, the pump 300 would be located in the upper area of the tank 140 which would allow the hottest water in the tank to enter the coil 202. The pump and piping would be adequately insulated either by being located within the insulation of the tank or by adding additional insulation if it was mounted on the on the skin of the tank.
Water enters the tank 140 through water inlet 235, exits the tank at line 311, proceeds through an optional filter 306, proceeds through pump 300, through condensate trap 430 check valve 50, through coil 202, through condensate trap 430, through optional, vertical coil 314, through flow control valve 320.
If water is exiting the tank through hot water outlet 185, solenoid 340 is closed, solenoid 330 is open and solenoid 187 is open. When in instantaneous mode, the water is exiting through solenoid 340. Solenoid 330 is closed, 340 is open, and solenoid 187 is closed. Flow control valve/temperature control valve 320 controls the water temperature by utilizing a capillary tube probing the heating coil and is always in use when the unit is in instantaneous continuous flow mode. For example, if the water temperature is set at 130 F, and the temperature drops below 130, the valve will restrict the flow until the temperature reaches 130; thus maintaining a constant temperature.
It is understood that the invention is not limited to the particular construction and arrangement of parts herein illustrated and described, but embraces all such modified forms thereof as come within the scope of the claims. For example, the size of the various components of the water heater would be sized to accommodate various sizes of residential and commercial water heaters.
This is a continuation-in-part of patent application Ser. No. 994,627 filed Nov. 22, 2004 (Publication. No. 2005/0109287 A1, published May 26, 2005).
| Number | Date | Country | |
|---|---|---|---|
| Parent | 10994627 | Nov 2004 | US |
| Child | 11515965 | Sep 2006 | US |
