The disclosure relates generally to water heaters, and more particularly, to a mounting bracket for a water heater for mounting a temperature sensor, a gas valve, a power delivery unit, a controller and/or any other suitable object or device to the water heater.
Water heaters are used in homes, businesses and just about any establishment having the need for heated water. A conventional water heater typically has at least one heating element or “heater,” such as a gas-fired and/or electric burner. Each water heater also typically has at least one thermostat or controller for controlling the heater. The controller typically receives signals related to the temperature of the water within the water heater tank, often from a temperature sensor that is thermally engaged with the water in the water heater tank.
In some instances, a water heater may operate in accordance with a first temperature set point and a second temperature set point. The difference between the first and second temperature set point may be referred to as the temperature differential of the water heater. When temperature signals from the temperature sensor indicate that the water temperature is below the first set point, for example when the water temperature is below about 120° F., the controller may turn on the heater and the water within the water heater tank begins to heat. After some time, the water temperature within the water heater tank will increase to the second set point, which, for example may be about 140° F. At this point, the controller may cause the heater to reduce its heat output or, alternatively, causes the heater to turn off. This heat cycle begins again when the water temperature within the water heater tank cools down below the first set point.
For a gas fired water heater, a temperature sensor, a gas valve and a controller are often mounted relative to the water heater tank. The controller typically receives a temperature signal from the temperature sensor. The temperature sensor often protrudes into and is thermally coupled to the water in the water heater tank. The controller typically is programmed to control the gas valve such that the temperature of the water in the water heater tank remains between the first and second temperature set points, as described above. For an electric water heater, a temperature sensor, a power delivery unit and a controller may be mounted to the water heater tank. In this case, the controller may control the power delivery unit such that the temperature of the water in the water heater tank is kept between the first and second temperature set points.
What would be desirable is an improved mounting bracket for mounting the temperature sensor, the gas valve, the power delivery unit, the controller and/or any other suitable object or device to the water heater tank.
The present disclosure pertains generally to an improved mounting bracket for mounting a temperature sensor, a gas valve, a power delivery unit, a controller and/or any other suitable object or device to a water heater tank. An illustrative but non-limiting example of the disclosure may be found in a mounting bracket that includes a polymeric body that has a sensor portion configured to receive a temperature sensor. The sensor portion may have a distal end that extends into and supports the temperature sensor within the water heater tank. The polymeric body may also includes a threaded portion that is configured to threadably engage a threaded spud in a water heater tank such that the distal end of the sensor portion extends into the water tank of the water heater.
In some cases, the sensor portion may be an elongated stem that has an internal well for receiving the temperature sensor. The threaded portion may extend around the elongated stem. In some instances, the elongated stem may include a thread lead in region between the threaded portion and the distal end of the elongated stem. The thread lead in region may help guide the mounting bracket relative to the water heater while the sensor portion is inserted into the water heater tank but before the threaded portion of the stem threadably engages the threaded spud of the water heater. In some cases, the distal end of the elongated stem may include a blade element that can be used to help pierce a barrier or the like of the water heater when the mounting bracket is installed on the water heater.
In some embodiments, the mounting bracket may include a component retaining region. The component retaining region may be use to retain a gas valve, a power delivery unit, a controller and/or any other suitable object or device relative to the water heater tank. In some cases, the component retaining region may include two or more ribs for providing additional support to the component retaining region. In some instances, the two or more ribs may radiate out from the elongated stem, but this is not required. In some cases, the polymeric body may be molded as a single piece, and may be made from a material that, when sufficiently stressed, suddenly fractures in a clean break, such as Entec Hylon. In some instances, the polymeric body may be configured to suddenly fracture at or near an outside edge of the threaded spud, but this is not required in all embodiments.
The following description should be read with reference to the drawings. The drawings, which are not necessarily to scale, depict selected embodiments and are not intended to limit the scope of the disclosure. The disclosure may be more completely understood in consideration of the following detailed description of various embodiments in connection with the accompanying drawings, in which:
While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular illustrative embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention.
For the following defined terms, these definitions shall be applied, unless a different definition is given in the claims or elsewhere in this specification.
All numeric values are herein assumed to be modified by the term “about”, whether or not explicitly indicated. The term “about” generally refers to a range of numbers that one of skill in the art would consider equivalent to the recited value (i.e., having the same function or result). In many instances, the term “about” may be indicative as including numbers that are rounded to the nearest significant figure.
The recitation of numerical ranges by endpoints includes all numbers within that range (e.g., 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, and 5).
Although some suitable dimensions ranges and/or values pertaining to various components, features and/or specifications are disclosed, one of skill in the art, incited by the present disclosure, would understand desired dimensions, ranges and/or values may deviate from those expressly disclosed.
The following description should be read with reference to the drawings, in which like elements in different drawings are numbered in like fashion. The drawings, which are not necessarily to scale, depict selected embodiments and are not intended to limit the scope of the invention. Although examples of construction, dimensions, and materials are illustrated for the various elements, those skilled in the art will recognize that many of the examples provided have suitable alternatives that may be utilized.
As can be seen, water heater 10 includes a temperature sensor 28. In some cases, temperature sensor 28 may enter water tank 12 at a location laterally offset from gas control unit 18. In some instances, however, temperature sensor 28 may instead be located behind gas control unit 18, and in some cases, may be supported and retained by a common mounting bracket such as that described more fully below. In any event, water tank 12 may include an aperture 30 that is sized and configured to accept temperature sensor 28. This can be seen in
Bracket 32 may be formed of any suitable material. In some cases, bracket 32 may include non-metallic materials such as a polymeric material, glass, ceramic, plastic, and the like. In some cases, bracket 32 may be manufactured as a single piece by injection molding a nylon material such Hylon®, available from Entec Polymers in Manchester, Tenn. The thermal conductivity of such non-metallic materials may be less than those of metallic materials, and as a result, may partially thermally isolate the temperature sensor assembly 49 from the water in the water tank 12, but may be less expensive to produce than a metallic well. It is contemplated that in some cases, bracket 32 may not be formed entirely from the same material, or bracket 32 may not be formed as a single piece. As will be discussed in more detail with respect to
Sensor portion 36 of the bracket 32 may include an elongated stem extending from component retaining region 33. Sensor portion 36 may include an internal well 39 (shown in more detail in
In some instances, distal end region 42 may have a reduced cross-sectional area relative to remaining regions 37, 38 and 40 of sensor portion 36. However, it is contemplated that in some cases, the cross-sectional area of distal end 42 may be the same as, or substantially the same as the remaining regions 37, 38 and 40 of sensor portion 36. In some embodiments, distal end 42 may include a cutting element 54 disposed at or near the tip. In some instances, the cutting element 54 may include a blade-like feature. Cutting element 54 may be capable of puncturing and/or piercing a plastic sheet or barrier commonly wrapped around the water tank 12 of many water heaters during installation of the bracket 32. It is contemplated that in some cases, the cutting element 54 may be omitted from the design.
In some embodiments, bracket 32 may also include two (or more) bosses 44 on a first lateral side, and two (or more) bosses 44 on a second opposing lateral side. While bracket 32 is shown having four bosses 44, it is contemplated that bracket 32 may have any number of bosses 44 as desired, for example, but not limited to, one, two, three, or more. Additionally, it is contemplated that bosses 44 may be disposed on fewer than, or more than, two lateral sides. Bosses 44 may provide, among other things, an area for torque to be applied directly to the bracket 32 during installation. For example, an installation tool may grip and apply torque to bosses 44 to threadably engage threaded region 38 of sensor portion 36 with the threaded water heater spud on a water tank 12. In some instances, bosses 44 may further include a rib 46 disposed between adjacent bosses 44. Rib(s) 46 may provide additional support to the bracket 32, and may also help prevent an installation tool from contacting the component retaining region 33 of bracket 32 during installation.
Turning now to
During assembly, it will be appreciated that heat traps 58 and temperature sensor 56 may be attached to a sensor assembly structure 50. This may be accomplished by snap fits, frictional fits, glue, screws, rivets, or any other suitable attachment mechanism. In some instances, heat traps 58 may be integrally molded or otherwise formed as part of sensor assembly structure 50. In some cases, the heat traps 58 may each include a slot 60 in order to accommodate and/or secure a wiring harness 68 for the temperature sensor 56. Once heat traps 58 and temperature sensor 56 have been secured or otherwise attached to sensor assembly structure 50, sensor assembly structure 50 may be inserted into a void 52 that is molded or otherwise formed within sensor portion 36. It can be seen that sensor assembly structure 50 may include one or more protrusions such as protrusion 62 that may help to locate sensor assembly structure 50 within void 52 and/or limit penetration of sensor assembly structure 50 into void 52 while allowing wiring harness 68 to pass without being pinched. The one or more protrusions 62 may align the sensor assembly structure 50 with inwardly extending ribs 48 disposed on the inner walls of the sensor portion 36 and into the void. One or more protrusions 62 in cooperation with one or more ribs 48 may, in some instances, help properly align and assemble the temperature sensor assembly 49 within the sensor portion 36. One or more protrusions 62 may also ensure that sensor assembly 49 is not installed in the wrong bracket. As can be seen, when temperature sensor assembly 49 is assembled within sensor portion 36, sensor 56 may be disposed within an internal well 39 within the distal tip portion 42 of the sensor portion.
It is contemplated that the ribs 64 may provide additional strength to bracket 32. In some cases, the ribs 64 may be sufficient for the bracket 32 to withstand a 500 pound-force (1 bf) static vertical load (roughly equivalent to a 300 lb person stepping on the installed bracket). When so provided, bracket 32 may resist accidental breakage. In the event bracket 32 breaks or fails, however, bracket 32 may have other safety features to help prevent a user from being exposed to hot water from the water tank 12, as will be discussed in more detail below with respect to
In the event that a torque or a vertical load is applied to the bracket 32 that exceeds the design load limits, or the bracket 32 is otherwise sufficiently stressed, bracket 32 may break in a sudden manner resulting in a brittle fracture. A suitable material for creating such a break is Entec Hylon, however, other materials may be used. The stress from such an event may be concentrated in the last thread 70 that engages the water heater spud. A brittle material may result in a clean break at or near the outside edge of the water heater spud such that the portion of the sensor portion 36 that has been threadably engaged with the water heater spud remain positioned within the water heater spud. For example, if a breakage occurs, the distal portion 42 and part of the threaded region 38 of the sensor portion 36 may remain disposed within the water tank 12 and water heater spud. This may help prevent significant leakage of hot water from the water heater. Once the water is removed, or the water is cooled, the internal ribs 48 (see
Returning briefly to
In some instances, controller 74 may include a microprocessor 78 that may be configured to accept appropriate signals from INPUT/OUTPUT block 76, and to determine appropriate output signals that can be outputted via INPUT/OUTPUT block 76, such as to other components within gas control unit 18 (
The disclosure should not be considered limited to the particular examples described above, but rather should be understood to cover all aspects of the invention as set out in the attached claims. Various modifications, equivalent processes, as well as numerous structures to which the invention can be applicable will be readily apparent to those of skill in the art upon review of the instant specification.
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