Patent Application
20250230953
The present subject matter relates generally to consumer appliances, such as to a water heater appliance, and the operation thereof at multiple different voltage levels.
Water heater appliances are often used for storing and supplying hot water to residential and commercial properties. Energy efficiency is a common concern in such appliances, as significant energy may be required to heat or maintain water for immediate use by an owner or user of the appliance. Recently, heat pump water heaters have gaining broader acceptance as a more economic and ecologically-friendly alternative to electric water heaters. Heat pump water heaters include a sealed system for heating water to a set temperature. The sealed system generally includes a condenser configured in a heat exchange relationship with a water storage tank within the water heater appliance and an evaporator. A microcontroller or processor may be provided, such as to control or direct operation of the sealed system—or of the water heater appliance generally.
Traditionally, water heater appliances have been configured at operate at relatively high voltage currents. For instance, in the United States, water heater appliances are connected to 240 Volt (V) power outlets. Most, if not all, of the heat-generating elements of the same are configured to operate on an alternating current.
Recently, interest has grown in operating water heater appliances on relatively low-voltage (e.g., 110 V) currents. For instance, a user may not have a high-voltage power outlet immediately available. The rise in electric vehicles, and the need for home charging systems, has decreased the availability of high-voltage power outlets for many homes and garages. However, water heater appliances configured to operate a relatively high-voltage currents are often unable to operate at low-voltage currents. Even if some operation is possible, performance can be severely limited.
Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.
In one exemplary aspect of the present disclosure, a water heater appliance is provided. The water heater appliance may include a housing, a tank, a refrigeration system, and a controller. The tank may be attached to the housing. The tank may define an interior volume. The refrigeration system may include a sealed refrigerant loop in thermal communication with the tank to heat the interior volume. The controller may be operably coupled to the refrigeration system. The controller may be configured to direct a heater operation. The heater operation may include determining a voltage input for the water heater appliance, selecting, based on the determined voltage input, an operational mode from a plurality of predetermined mode options that include a high-voltage mode and a low-voltage mode, and directing the refrigeration system according to the selected operational mode.
In another exemplary aspect of the present disclosure, a water heater appliance is provided. The water heater appliance may include determining a voltage input for the water heater appliance. The method may further include selecting, based on the determined voltage input, an operational mode from a plurality of predetermined mode options. The plurality of predetermined mode options may include a high-voltage mode and a low-voltage mode. The method may still further include directing a refrigeration system of the water heater appliance according to the selected operational mode.
These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.
A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures.
Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present invention.
Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents. The word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” In addition, references to “an embodiment” or “one embodiment” does not necessarily refer to the same embodiment, although it may. Any implementation described herein as “exemplary” or “an embodiment” is not necessarily to be construed as preferred or advantageous over other implementations.
As used herein, the terms “first,” “second,” and “third” may be used interchangeably to distinguish one component from another and are not intended to signify location or importance of the individual components. The terms “includes” and “including” are intended to be inclusive in a manner similar to the term “comprising.” Similarly, the term “or” is generally intended to be inclusive (i.e., “A or B” is intended to mean “A or B or both”). In addition, here and throughout the specification and claims, range limitations may be combined or interchanged. Such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise. For example, all ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other. The singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise.
Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “generally,” “about,” “approximately,” and “substantially,” are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value, or the precision of the methods or machines for constructing or manufacturing the components or systems. For example, the approximating language may refer to being within a 10 percent margin (i.e., including values within ten percent greater or less than the stated value). In this regard, for example, when used in the context of an angle or direction, such terms include within ten degrees greater or less than the stated angle or direction (e.g., “generally vertical” includes forming an angle of up to ten degrees in any direction, such as, clockwise or counterclockwise, with the vertical direction V).
The terms “coupled,” “fixed,” “attached to,” and the like refer to both direct coupling, fixing, or attaching, as well as indirect coupling, fixing, or attaching through one or more intermediate components or features, unless otherwise specified herein.
Except as explicitly indicated otherwise, recitation of a singular processing element (e.g., “a controller,” “a processor,” “a microprocessor,” etc.) is understood to include more than one processing element. In other words, “a processing element” is generally understood as “one or more processing element.” Furthermore, barring a specific statement to the contrary, any steps or functions recited as being performed by “the processing element” or “said processing element” are generally understood to be capable of being performed by “any one of the one or more processing elements.” Thus, a first step or function performed by “the processing element” may be performed by “any one of the one or more processing elements,” and a second step or function performed by “the processing element” may be performed by “any one of the one or more processing elements and not necessarily by the same one of the one or more processing elements by which the first step or function is performed.” Moreover, it is understood that recitation of “the processing element” or “said processing element” performing a plurality of steps or functions does not require that at least one discrete processing element be capable of performing each one of the plurality of steps or functions.
Notably, water heater appliances in accordance with the present disclosure may be able to effectively operate at various different voltage levels (e.g., providing flexibility to a user after the point of sale). Additionally or alternatively, water heater appliances in accordance with the present disclosure may be able to easily switch or convert between operating at the different voltage levels (e.g., without requiring significant labor, rewiring, or knowledge from the user).
Turning briefly to
Returning generally to
In exemplary embodiments, water heater appliance 100 extends longitudinally between a top portion 108 and a bottom portion 109 along a vertical direction V. Thus, water heater appliance 100 is generally vertically oriented. Water heater appliance 100 can be leveled (e.g., such that casing 102 is plumb in the vertical direction V) in order to facilitate proper operation of water heater appliance 100. A drain pan 110 is positioned at bottom portion 109 of water heater appliance 100 such that water heater appliance 100 sits on drain pan 110. Drain pan 110 sits beneath water heater appliance 100 along the vertical direction V (e.g., to collect water that leaks from water heater appliance 100 or water that condenses on an evaporator 128 of water heater appliance 100). It should be understood that water heater appliance 100 is provided by way of example only and that the present subject matter may be used with any suitable water heater appliance, including for example a heat pump water heater appliance.
As may be seen in
Sealed system 120 may include a compressor 122 (e.g., DC compressor), one or more condensers (e.g., a first condenser 124 and a second condenser 126), and an evaporator 128. Compressor 122 or evaporator 128 of sealed system 120 may be disposed within casing 102 at top portion 108 of water heater appliance 100. As is generally understood, various conduits may be utilized to flow refrigerant between the various components of sealed system 120. Thus, for example, evaporator 128 may be between and in fluid communication with second condenser 126 and compressor 122. During operation of sealed system 120, refrigerant may flow from evaporator 128 through compressor 122. For example, refrigerant may exit evaporator 128 as a fluid in the form of a superheated vapor or high quality vapor mixture. Upon exiting evaporator 128, the refrigerant may enter compressor 122. Compressor 122 may be operable to compress the refrigerant. Accordingly, the pressure and temperature of the refrigerant may be increased in compressor 122 such that the refrigerant becomes a superheated vapor.
Each condenser 124, 126 may be assembled in a heat exchange relationship with tank 112 in order to heat water within interior volume 114 of tank 112 during operation of sealed system 120. First condenser 124 may be positioned downstream of and in fluid communication with compressor 122, and may be operable to heat the water within interior volume 114 using energy from the refrigerant. For example, the superheated vapor from compressor 122 may enter first condenser 124 wherein it transfers energy to the water within tank 112 and condenses into a saturated liquid or liquid vapor mixture. Second condenser 126 may be positioned downstream of and in fluid communication with first condenser 124, and may additionally be operable to heat the water within interior volume 114 using energy from the refrigerant, such as by further condensing the refrigerant.
Sealed system 120 may also include a throttling device 132 between second condenser 126 and evaporator 128. Refrigerant, which may be in the form saturated liquid vapor mixture, may exit first condenser 124 or second condenser 126 and travel through throttling device 132 before flowing through evaporator 128. The throttling device 132 may generally expand the refrigerant, lowering the pressure and temperature thereof. The refrigerant may then be flowed through evaporator 128.
Throttling device 132 may be any suitable component(s) s for generally expanding the refrigerant. For example, in some exemplary embodiments, throttling device 132 may be a Joule-Thomson expansion valve, also known as a “J-T valve.” In other exemplary embodiments, throttling device 132 may be an ejector. In still other exemplary embodiments, a capillary tube, fixed orifice, electronic expansion valve (EEV), or other suitable apparatus may be utilized as throttling device 132.
In optional embodiments, a diverter valve 130 is included with sealed system 120, such as between the first condenser 124 and the second condenser 126. The diverter valve 130 may be configured to control the direction of the refrigerant flow, allowing for the refrigerant to be directed either through both condensers 124, 126, only the first condenser 124, or only the second condenser 126. This may enable precise control over the heat distribution within the appliance 100, which may be beneficial for efficient heating (e.g., akin to existing segmented approaches). The diverter valve 130 may be configured to selectively redirect the flow of the refrigerant without changing its pressure or temperature. In turn, the task of reducing the refrigerant's pressure and temperature may still be handled by the throttling device 132.
A fan or air handler 140 may assist with heat transfer between air about water heater appliance 100 (e.g., within casing 102) and refrigerant within evaporator 128. Air handler 140 may be positioned within casing 102 on or adjacent to evaporator 128. Thus, when activated, air handler 140 may direct a flow of air towards or across evaporator 128, and the flow of air from air handler 140 may assist with heating refrigerant within evaporator 128. Air handler 140 may be any suitable type of air handler, such as an axial or centrifugal fan. Additionally or alternatively, air handler 140 may be provided as a DC fan, and thereby configured to rotate as powered by supplied DC voltage.
Water heater appliance 100 may additionally include a temperature sensor 152. Temperature sensor 152 may be configured for measuring a temperature of water within interior volume 114 of tank 112. Temperature sensor 152 can be positioned at any suitable location within water heater appliance 100. For example, temperature sensor 152 may be positioned within interior volume 114 of tank 112 or may be mounted to tank 112 outside of interior volume 114 of tank 112. Temperature sensor 152 may further be positioned within upper portion 160 or lower portion 162. When mounted to tank 112 outside of interior volume 114 of tank 112, temperature sensor 152 can be configured for indirectly measuring the temperature of water within interior volume 114 of tank 112. For example, temperature sensor 152 can measure the temperature of tank 112 and correlate the temperature of tank 112 to the temperature of water within interior volume 114 of tank 112. Temperature sensor 152 may be any suitable temperature sensor. For example, temperature sensor 152 may be a thermocouple or a thermistor.
In some embodiment, water heater appliance 100 further includes a controller 150 that regulates operation of water heater appliance 100. Controller 150 may be, for example, in operative communication with sealed system 120 (such as compressor 122, or other components thereof), auxiliary heating elements, or temperature sensor 152. Thus, controller 150 can selectively activate system 120 or auxiliary heating elements in order to heat water within interior volume 114 of tank 112.
In certain embodiments, controller 150 includes memory and one or more processing devices such as microprocessors, CPUs or the like, such as general or special purpose microprocessors operable to execute programming instructions or micro-control code associated with operation of water heater appliance 100. The memory can represent random access memory such as DRAM, or read only memory such as ROM or FLASH. During use, the processor executes programming instructions stored in the memory. The memory can be a separate component from the processor or can be included onboard within the processor. Alternatively, controller 150 may be constructed without using a microprocessor (e.g., using a combination of discrete analog or digital logic circuitry; such as switches, amplifiers, integrators, comparators, flip-flops, AND gates, and the like) to perform control functionality instead of relying upon software.
Generally, controller 150 may be mounted at any suitable location on or within housing 101. For instance, at least one electronics board (e.g., such as a control board, circuit, MOSFET, or inverter board of controller 150) may be housed or mounted within top cover 156. When assembled, controller 150 may be selectively connected (e.g., electrically connected) to at least two different power sources (e.g., AC voltage sources). For instance, as will be described in greater detail below, controller 150 may be configured to connect and draw power from a high-voltage (e.g., 240 Volt) power source or a low-voltage (e.g., 120 Volt) power source. Specifically, and depending on the availability or desire to use a corresponding power outlet, water heater appliance 100 (including controller 150) may connect to the high-voltage power source 182 or the low-voltage power source 184. Thus, under certain conditions, water heater appliance 100 may be able to connect (e.g., via a power cable 180) to the high-voltage power source 182, while under other conditions, water heater appliance 100 may be able to connect (e.g., via power cable 180) to the low-voltage power source 184. In optional embodiments, controller 150 is configured to detect the voltage level of a connected power source. For instance, as would be understood, controller 150 may be configured to measure the voltage input at the controller 150 (e.g., the voltage of the current delivered to the controller 150, such as via the power cable 180).
In certain embodiments, water heater appliance 100 includes a control panel 103 having one or more user inputs (e.g., physical button, capacitive touch pad, knobs, sliders, keypads, etc.). As shown, control panel 103 may be attached to casing 102 or top cover 156 or otherwise proximal to top portion 108. Control panel 103 may be in communication with a controller 150, as would be understood. Control panel 103 may thus receive power as directed by controller 150. Additionally or alternatively, a user of water heater appliance 100 may interact with the user inputs of control panel 103 to operate the water heater appliance 100, and user commands may be transmitted between the user inputs and controller 150 to facilitate operation of the water heater appliance 100 based on such user commands. A display may additionally be provided in the control panel 103 in communication with the controller 150. The display may, for example be a touchscreen or other text-readable display screen, or alternatively may simply be a light that can be activated and deactivated as required to provide an indication of, for example, an event or setting for water heater appliance 100.
Drain pan 170 may define a collection volume for receiving and collecting liquid runoff from evaporator 128. The collection volume may be positioned directly below at least a portion of evaporator 128 or above (e.g., directly above) tank 112. Drain pan 170 may include a side wall 174 and a bottom wall 176 that assist with defining collection volume.
In some embodiments, a power inverter 186 is provided in electrical communication with one or more other components. For instance, power inverter 186 may connect to an alternating current (AC) power cable 180 (
Turning now to
In certain embodiments, power cable 180 is provided with a separable connector interface 188 (e.g., at a distal end opposite from a proximal end joined to the water heater appliance 100). The separable interface 188 may be able to selectively mate with an interchangeable (i.e., quick-change) plug 190 or 192. For instance, separable connector interface 188 may include a threaded collar, poka yoke fitting, friction-fit collar, or other suitable separable connector to which the interchangeable plug 190 or 192 may mechanically connect. In addition to the mechanical connection, one or more conductive or electrical connectors may be provided to electrically connect the separable interface 188 to the interchangeable plug 190 or 192. As shown, the interchangeable plug 190 or 192 may include a male-prong set, such as to connect to a standard corresponding (e.g., high-voltage or low-voltage) power outlet. In some embodiments, multiple interchangeable prongs 190, 192 are provided, such that the interchangeable plugs 190, 192 may be swapped or exchanged on power cable 180 (e.g., at the separable interface 188). For instance, a first high-voltage plug 190 configured to connect to a high-voltage (e.g., 240 Volt) power outlet may be selectively exchanged or swapped with a low-voltage plug 192, which is configured to connect to a low-voltage (e.g., 110 Volt) power outlet. In optional embodiments, separable interface 188 comprises a connector switch 194 (e.g., proximity switch, Hall-effect sensor, reed switch, etc.) configured to interface with the first high-voltage plug 190 or the second low-voltage plug 192. The connector switch 194 may be in operable (e.g., electrical or wireless) communication with the controller 150. Thus, connector switch 194 (e.g., with or without the controller 150) may be configured to detect which of the high-voltage plug 190 and the low-voltage plug 192 is connected to the power cable 180 at a given moment (e.g., based on one or more differences in how the corresponding plug interacts with or affects the connector switch 194).
Turning now to
Advantageously, the present methods may provide for effective operation of a water heater appliance at various different voltage levels. Additionally or alternatively, methods in accordance with the present disclosure may facilitate an easy switch or conversion of a water heater appliance between operating at the different voltage levels.
As shown, at 610, the method 600 includes determining a voltage input. Specifically, the voltage being or to be input to the water heater appliance from a power source (e.g., AC voltage supplied through a power outlet) may be determined. As noted above, the water heater appliance may be able to selectively or alternately connect to a high-voltage (e.g., 240 Volt) power source or a low-voltage (e.g., 110 Volt) power source.
The determination may be a direct or indirect (e.g., inferential) determination. As an example, 610 may include measuring the voltage input at the controller. Thus, the controller (or circuitry connected to the same) may detect an electrical current being supplied from the power source (e.g., via the power cable) and generate a measurement value or range corresponding to the voltage of the current (e.g., as would be understood). As an additional or alternative example, 610 may include receiving a selection signal at a user input of the water heater appliance. Such a selection signal may be provided, for instance, at the control panel. Thus, a user may manually specify to the controller what power source or what the voltage is of a connected power source. As another additional or alternative example, 610 may include detecting a predetermined plug type of the quick-change plug. For instance, based on a signal received from a connector switch, the controller may determine if either a high-voltage plug or a low-voltage plug is attached to the power cable (e.g., as described above).
At 620, the method 600 includes selecting an operational mode from a plurality of predetermined mode options. In particular, the predetermined mode options may include a high-voltage mode and a low-voltage mode. Generally, such mode options may include specific instructions, operational variables, or conditions for the water heater appliance. Specifically, each mode option may include different conditions for operating one or more of the electric heating elements or the compressor. Thus, the compressor or one or more of the heating elements may be directed differently in one operational mode than in another.
Optionally, a discrete temperature setpoint for the interior volume may be provided for each of the operational modes. For instance, the high-voltage mode may include a first temperature setpoint while the low-voltage mode includes a second temperature setpoint that is greater than the first temperature setpoint. Additionally or alternatively, a discrete recovery setpoint (e.g., percentage of hot-water depletion to trigger heat generation at the heater or heating elements) for the interior volume may be provided for each of the operational modes. For instance, the high-voltage mode may include a first recovery setpoint (e.g., about 30% hot-water depletion) while the low-voltage mode includes a second recovery setpoint (e.g., about 15% hot-water depletion) that is less than the first recovery setpoint. Further additionally or alternatively, a discrete compressor speed (e.g., rate at which the compressor is rotated or otherwise directs heat to the interior volume) may be provided for each of the operational modes. For instance, the high-voltage mode may include a first compressor speed while the low-voltage mode includes a second compressor speed that is greater than the first compressor speed. Still further additionally or alternatively, the low-voltage mode may include a load-shedding-inhibitor factor in which the controller is configured to disregard one or more shedding requests (e.g., indicating an elevated detected temperature that might otherwise trigger a hot-water shedding event), while the load-shedding inhibitor factor is absent from the high-voltage mode (e.g., such that the controller is configured to initiate a hot-water shedding event based on an elevated detected temperature).
At 630, the method 600 includes directing one or more of the heating elements or the compressor (e.g., according to the selected operational mode).
As an example, the high-voltage mode may permit simultaneous operation of the refrigeration system (e.g., as driven by the compressor or fan) and an electric heating element (e.g., one or both of the upper and lower heating elements). In turn, 630 may include simultaneous operation of the refrigeration system (e.g., at the compressor or fan) and the electric heating element(s), such as to reach or maintain a temperature setpoint in the interior volume (e.g., as is understood). Optionally, the high-voltage mode may include a predetermined first heating rate for one or more of the electric heating elements. Thus, in the high-voltage mode, the electric heating elements may be activated or directed to heat at the predetermined first heating rate (e.g., in order to reach or maintain the temperature setpoint in the interior volume).
As an additional or alternative example, the low-voltage mode may restrict simultaneous operation of the refrigeration system and the electric heating element. In turn, 630 may include restricting or preventing activation one of the refrigeration system (e.g., at the compressor or fan) and one or more of the electric heating elements while activating the other of the refrigeration system and one or more of the electric heating elements (e.g., such that only the refrigeration system or the electric heating element(s) is actively generating heat for the interior volume at a given moment). The refrigeration system and the electric heating element(s) may be alternately activated such as to reach or maintain a temperature setpoint in the interior volume (e.g., as is understood). Optionally, the low-voltage mode may include a predetermined second heating rate for one or more of the electric heating elements. Thus, in the low-voltage mode, the electric heating elements may be activated or directed to heat at the predetermined second heating rate (e.g., in order to reach or maintain the temperature setpoint in the interior volume). The second heating rate may be less than the first heating rate.
It is noted that, as would be understood in light of the present disclosure, the method 600 may include or permit repetition of one or more of the above steps. For instance, following a first instance of 610, 620, and 630 wherein a first voltage input is determined and the selected operational mode is one of the high-voltage mode and the low-voltage mode (i.e., either the high-voltage mode or the low-voltage mode is selected and implemented such that the heating element(s) and the compressor are directed according to either the high-voltage mode or the low-voltage mode), the method 600 may include a second voltage input determining a second voltage input for the water heater appliance. Subsequently, the method 600 may include selecting, based on the determined second voltage input, the other of the high-voltage mode and the low-voltage mode. In other words, if the high-voltage mode was selected and implemented at the first instance of 620 and 630, the low-voltage mode may be selected. Following selection of the other of the high-voltage mode and the low-voltage mode, the method may further include directing the electric heating element and the refrigeration system according to the other of the high-voltage mode and the low-voltage mode.
This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.
