Shroud Structure

FIELD OF THE DISCLOSURE

The disclosed technology relates generally to shroud structures, and more particularly, to shroud structures for a heat pump system, such as a heat pump water heater.

BACKGROUND

Heat pump systems, such as those used for water heating applications, typically include a compressor. The compressor plays an important role in the heat pump system by pressurizing and circulating the refrigerant throughout a refrigerant circuit of the system, which results in heat being transferred from one location to another via the refrigerant. Specifically for water heating applications, heat is transferred to water via the refrigerant. Unfortunately, operation of the compressor typically produces a loud and undesirable sound.

While certain sound dampening products are available, they can fail to satisfactorily dampen the sound produced by the compressor at least partly because they are unable to adequately cover the compressor and other sound-producing objects. In addition, such products are generally after-market products that are difficult and/or time-consuming to install. Typically, such products require an end user to install them, which can be burdensome on the end user. Further, such products are generally manufactured to accommodate a wide range of models of a given component type, which can result in an ill fit of product on the component. For example, existing sound blankets are typically designed to be wrapped around a compressor or other component. However, sound blankets can be unnecessarily large, which can result in gaps or openings among portions of the sound blanket, permitting sound to escape and/or a bundle of excess material once installed. Conversely, sound blankets can be of insufficient size to fully cover a compressor or other component, which can likewise permit sound to escape.

Further, installation of existing sound dampening products can be difficult to install on a mass-scale, such as during manufacturing or assembly of the heat pump system. For example, existing sound dampening products can be difficult and/or time-consuming to install, which can negatively impact the manufacturing efficiency of the heat pump system (e.g., a heat pump water heater). As such, it can be difficult or impractical to achieve economical high-volume manufacturing of such systems with existing sound dampening products. Thus, a solution that enables adequate dampening of sounds from heat pump components while cost effectively may be desirable.

SUMMARY

These and other problems can be addressed by the technologies described herein. Examples of the present disclosure relate generally to shroud structures and systems, and more particularly, to shroud structures for use in a heat pump system, such as a heat pump water heater.

The disclosed technology includes a shroud structure, which can be configured to dampen or absorb sound waves, thereby reducing the sound associated with a corresponding system, such as a heat pump. Alternatively or in addition, the shroud structure can be configured to provide thermal insulation for one or more components of the corresponding system: provide improved air flow through at least a portion of the corresponding system (e.g., across the evaporator coil of a heat pump); and/or be sized and shaped (1) to at least partially receive one or more components of the system via one or more corresponding recesses that are sized and contoured to be a substantial negative of the component(s) and/or (2) such that separate sections of the shroud structure can easily interface with one another, either of which can help facilitate fast and easy assembly of the shroud structure, as described more fully herein. The shroud structure can include various recesses, apertures, and/or cavities such that the shroud structure can easily interface with various components of the heat pump and/or such that air can flow through the shroud structure. The shroud structure can include, or be made entirely from, a sound dampening material, such as a foam (e.g., a plastic foam). The shroud structure can include multiple distinct sections, which can help facilitate fast and easy assembly of the shroud structure.

The disclosed technology also includes a heat pump system including the shroud structure. As a more specific example, the disclosed technology includes a heat pump water heater including the shroud structure.

These and other aspects of the present disclosure are described in the Detailed Description below and the accompanying figures. Other aspects and features of the present disclosure will become apparent to those of ordinary skill in the art upon reviewing the following description of specific examples of the present disclosure in concert with the figures. While features of the present disclosure may be discussed relative to certain examples and figures, all examples of the present disclosure can include one or more of the features discussed herein. Further, while one or more examples may be discussed as having certain advantageous features, one or more of such features may also be used with the various other examples of the disclosure discussed herein. In similar fashion, while examples may be discussed below as devices, systems, or methods, it is to be understood that such examples can be implemented in various devices, systems, and methods of the present disclosure.

BRIEF DESCRIPTION OF THE FIGURES

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate various aspects of the presently disclosed subject matter and serve to explain the principles of the presently disclosed subject matter. The drawings are not intended to limit the scope of the presently disclosed subject matter in any manner.

FIG. 1A illustrates a perspective view of an example shroud structure, in accordance with the disclosed technology.

FIG. 1B illustrates another perspective view of the example shroud structure shown in FIG. 1A, in accordance with the disclosed technology.

FIG. 2A illustrates a perspective view of an example first section of a shroud structure, in accordance with the disclosed technology.

FIG. 2B illustrates a top view of an example first section of a shroud structure, in accordance with the disclosed technology.

FIG. 2C illustrates a bottom view of an example first section of a shroud structure, in accordance with the disclosed technology.

FIG. 2D illustrates a front view of an example first section of a shroud structure, in accordance with the disclosed technology.

FIG. 2E illustrates a rear view of an example first section of a shroud structure, in accordance with the disclosed technology.

FIG. 2F illustrates a left view of an example first section of a shroud structure, in accordance with the disclosed technology.

FIG. 2G illustrates a right view of an example first section of a shroud structure, in accordance with the disclosed technology.

FIG. 3A illustrates a perspective view of an example second section of a shroud structure, in accordance with the disclosed technology.

FIG. 3B illustrates a top view of an example second section of a shroud structure, in accordance with the disclosed technology.

FIG. 3C illustrates a bottom view of an example second section of a shroud structure, in accordance with the disclosed technology.

FIG. 3D illustrates a front view of an example second section of a shroud structure, in accordance with the disclosed technology.

FIG. 3E illustrates a rear view of an example second section of a shroud structure, in accordance with the disclosed technology.

FIG. 3F illustrates a left view of an example second section of a shroud structure, in accordance with the disclosed technology.

FIG. 3G illustrates a right view of an example second section of a shroud structure, in accordance with the disclosed technology.

FIG. 4A illustrates an example first section of a shroud structure atop a top pan of a heat pump water heater, in accordance with the disclosed technology.

FIG. 4B illustrates an example first section of a shroud structure atop a top pan of a heat pump water heater with certain heat pump components installed, in accordance with the disclosed technology.

FIG. 4C illustrates an exploded view of an example shroud structure installed on a heat pump water heater, in accordance with the disclosed technology.

FIG. 5A illustrates a perspective view of an example shroud structure, in accordance with the disclosed technology.

FIG. 5B illustrates another perspective view of the example shroud structure shown in FIG. 5A, in accordance with the disclosed technology.

FIG. 5C illustrates a perspective view of the example shroud structure of FIG. 5A being partially disassembled, in accordance with the disclosed technology.

FIG. 5D illustrates a perspective view of the example shroud structure of FIG. 5A being further disassembled, in accordance with the disclosed technology.

FIG. 6A illustrates a perspective view of an example first section of a shroud structure, in accordance with the disclosed technology.

FIG. 6B illustrates a top view of an example first section of a shroud structure, in accordance with the disclosed technology.

FIG. 6C illustrates a bottom view of an example first section of a shroud structure, in accordance with the disclosed technology.

FIG. 6D illustrates a front view of an example first section of a shroud structure, in accordance with the disclosed technology.

FIG. 6E illustrates a rear view of an example first section of a shroud structure, in accordance with the disclosed technology.

FIG. 6F illustrates a left view of an example first section of a shroud structure, in accordance with the disclosed technology.

FIG. 6G illustrates a right view of an example first section of a shroud structure, in accordance with the disclosed technology.

FIG. 6H illustrates cross-sectional view of an example first section of a shroud structure, in accordance with the disclosed technology.

FIG. 7A illustrates a perspective view of an example third section of a shroud structure, in accordance with the disclosed technology.

FIG. 7B illustrates a top view of an example third section of a shroud structure, in accordance with the disclosed technology.

FIG. 7C illustrates a bottom view of an example third section of a shroud structure, in accordance with the disclosed technology.

FIG. 7D illustrates a front view of an example third section of a shroud structure, in accordance with the disclosed technology.

FIG. 7E illustrates a rear view of an example third section of a shroud structure, in accordance with the disclosed technology.

FIG. 7F illustrates a left view of an example third section of a shroud structure, in accordance with the disclosed technology.

FIG. 7G illustrates a right view of an example third section of a shroud structure, in accordance with the disclosed technology.

FIG. 8A illustrates a perspective view of an example second section of a shroud structure, in accordance with the disclosed technology.

FIG. 8B illustrates a top view of an example second section of a shroud structure, in accordance with the disclosed technology.

FIG. 8C illustrates a bottom view of an example second section of a shroud structure, in accordance with the disclosed technology.

FIG. 8D illustrates a front view of an example second section of a shroud structure, in accordance with the disclosed technology.

FIG. 8E illustrates a rear view of an example second section of a shroud structure, in accordance with the disclosed technology.

FIG. 8F illustrates a left view of an example second section of a shroud structure, in accordance with the disclosed technology.

FIG. 8G illustrates a right view of an example second section of a shroud structure, in accordance with the disclosed technology.

FIG. 9 illustrates an exploded view of an example shroud structure installed on a heat pump water heater, in accordance with the disclosed technology.

FIG. 10A illustrates a perspective view of an example shroud structure, in accordance with the disclosed technology.

FIG. 10B illustrates another perspective view of the example shroud structure shown in FIG. 10A, in accordance with the disclosed technology.

FIG. 10C illustrates a cross-sectional view of the example shroud structure shown in FIG. 10A, in accordance with the disclosed technology.

FIG. 10D illustrates a top view of a first section of the example shroud structure shown in FIG. 10A, in accordance with the disclosed technology.

FIG. 10E illustrates a top view of a third section the example shroud structure shown in FIG. 10A, in accordance with the disclosed technology.

FIG. 10F illustrates a bottom view of a third section the example shroud structure shown in FIG. 10A, in accordance with the disclosed technology.

FIG. 11 illustrates an example shroud structure having a plurality of inlet apertures, in accordance with the disclosed technology.

FIG. 12A illustrates a perspective view of a shroud structure, in accordance with another embodiment of the disclosed technology.

FIG. 12B illustrates another perspective view of the shroud structure shown in FIG. 12A.

FIG. 13A illustrates a perspective view of the first section of the shroud structure shown in FIGS. 12A and 12B.

FIG. 13B illustrates another perspective view of the first section of the shroud structure shown in FIG. 13A.

FIG. 13C illustrates a top view of the first section of the shroud structure shown in FIGS. 13A and 13B.

FIG. 13D illustrates a bottom view of the first section of the shroud structure shown in FIGS. 13A and 13B.

FIG. 13E illustrates a front view of the first section of the shroud structure shown in FIGS. 13A and 13B.

FIG. 13F illustrates a left view of the first section of the shroud structure shown in FIGS. 13A and 13B.

FIG. 13G illustrates a right view of the first section of the shroud structure shown in FIGS. 13A and 13B.

FIG. 14A illustrates a perspective view of the second section of the shroud structure shown in FIGS. 12A and 12B.

FIG. 14B illustrates another perspective view of the second section of the shroud structure shown in FIG. 14A.

FIG. 14C illustrates a top view of the second section of the shroud structure shown in FIGS. 14A and 14B.

FIG. 14D illustrates a bottom view of the second section of the shroud structure shown in FIGS. 14A and 14B.

FIG. 14E illustrates a front view of the second section of the shroud structure shown in FIGS. 14A and 14B.

FIG. 14F illustrates a left view of the second section of the shroud structure shown in FIGS. 14A and 14B.

FIG. 14G illustrates a right view of the second section of the shroud structure shown in FIGS. 14A and 14B.

DETAILED DESCRIPTION

The disclosed technology includes a shroud structure. The shroud structure can be configured to be quickly and easily assembled and/or installed on a heat pump system, such as a heat pump water heater. For example, the shroud structure can include a small number of separate and distinct sections, which can help facilitate quick and easy assembly or installation. Further, the various sections of the shroud structure can be sized and shaped to accommodate or interface with various components of the heat pump system, which can also help facilitate quick and easy assembly or installation. As discussed more fully herein, a given section of the disclosed shroud structure can have one or more recesses or cavities configured to accommodate or interface with one or more components of the heat pump system. As such, the section of the shroud structure can be configured to easily slide or otherwise attach and/or interface with components of the heat pump system.

Although various aspects of the disclosed technology are explained in detail herein, it is to be understood that other aspects of the disclosed technology are contemplated. Accordingly, it is not intended that the disclosed technology is limited in its scope to the details of construction and arrangement of components expressly set forth in the following description or illustrated in the drawings. The disclosed technology can be implemented and practiced or carried out in various ways. In particular, the presently disclosed subject matter is described in the context of being systems and methods for use with a heat pump water heating system. The present disclosure, however, is not so limited, and can be applicable in other contexts. The present disclosure can, for example, include devices and systems for use with air conditioning systems, refrigeration systems, pool water heat systems, and other similar systems. Furthermore, although described in the context of being a water heater, the disclosed technology can be configured to heat fluids other than water. For example, the disclosed technology can be implemented in various commercial and industrial fluid heating systems used to heat fluids other than water. Accordingly, when the present disclosure is described in the context of a heat pump water heater system, it will be understood that other implementations can take the place of those referred to.

It should also be noted that, as used in the specification and the appended claims, the singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise. References to a composition containing “a” constituent is intended to include other constituents in addition to the one named.

Also, in describing the disclosed technology, terminology will be resorted to for the sake of clarity. It is intended that each term contemplates its broadest meaning as understood by those skilled in the art and includes all technical equivalents which operate in a similar manner to accomplish a similar purpose.

Ranges may be expressed herein as from “about” or “approximately” or “substantially” one particular value and/or to “about” or “approximately” or “substantially” another particular value. When such a range is expressed, the disclosed technology can include from the one particular value and/or to the other particular value. Further, ranges described as being between a first value and a second value are inclusive of the first and second values. Likewise, ranges described as being from a first value and to a second value are inclusive of the first and second values.

Herein, the use of terms such as “having,” “has,” “including,” or “includes” are open-ended and are intended to have the same meaning as terms such as “comprising” or “comprises” and not preclude the presence of other structure, material, or acts. Similarly, though the use of terms such as “can” or “may” are intended to be open-ended and to reflect that structure, material, or acts are not necessary, the failure to use such terms is not intended to reflect that structure, material, or acts are essential. To the extent that structure, material, or acts are presently considered to be essential, they are identified as such.

It is also to be understood that the mention of one or more method steps does not preclude the presence of additional method steps or intervening method steps between those steps expressly identified. Moreover, although the term “step” can be used herein to connote different aspects of methods employed, the term should not be interpreted as implying any particular order among or between various steps herein disclosed unless and except when the order of individual steps is explicitly required. Further, the disclosed technology does not necessarily require all steps included in the methods and processes described herein. That is, the disclosed technology includes methods that omit one or more steps expressly discussed with respect to the methods described herein.

The components described hereinafter as making up various elements of the disclosed technology are intended to be illustrative and not restrictive. Many suitable components that would perform the same or similar functions as the components described herein are intended to be embraced within the scope of the disclosed technology. Such other components not described herein can include, but are not limited to, similar components that are developed after development of the presently disclosed subject matter.

Referring now to the drawings, and particularly to FIGS. 1A-4C, a shroud structure 100 can include multiple distinct sections that can abut and/or connect to one another to form the shroud structure. A “shroud” can refer to structure or assembly that can substantially cover and/or substantially envelop at least one component of a system (e.g., a heat pump component) when assembled and/or installed. As described more fully herein, one or more of the sections of the shroud structure 100 can be configured to support and/or suspend a given heat pump component. That is to say, the shroud structure 100 can additionally serve as a structural support in addition to providing sound attenuating or dampening benefits.

When assembled, the shroud structure 100 can have a cross-sectional shape that is approximately circular, ovular, triangular, square, rectangular, or any other polygonal shape. As a non-limiting example, the shroud structure 100 can have a cylindrical shape. The shroud structure 100 can have cross-sectional shape that is substantially the same as the shape of the top pan 10 or another surface configured to support the heat pump component(s). The cross section of the shroud structure 100 can have dimensions (e.g., a diameter) that is substantially equal to the dimensions of the top pan 10 or another surface configured to support the heat pump component(s).

As illustrated, the shroud structure 100 can be installed on a top pan 10 of a water heater. For simplicity of discussion, the shroud structure is described herein in relation to a heat pump water heater (HPWH), but the disclosed technology is not so limited and can be used in other systems, such as other heat pump systems (e.g., air conditioning systems).

The shroud structure 100 can be formed at least partially from a sound dampening material. For example, the shroud structure 100 can comprise a foam, such as a plastic (polymeric) foam. The foam can be a rigid or semi-rigid foam. As non-limiting examples, the shroud structure 100 can comprise polyethylene, polyurethane, or the like, or a combination thereof. The shroud structure 100 can made entirely from the sound dampening material(s).

For ease of installation and/or manufacturing, the shroud structure 100 can include a small number of distinct sections. For example, the shroud structure 100 can include five or fewer distinct sections, four or fewer distinct sections, three or fewer distinct sections, or two or fewer distinct sections.

The shroud structure 100 can include two distinct sections, such as a first section 110 and a second section 140. Upon installation, the first section 110 can serve as the lowermost section, and the second section 140 can serve as the uppermost section. As described more fully herein, the various sections of the shroud structure 100 can combine to at least partially surround or envelop one or more components of the heat pump. Alternatively or in addition, the various sections of the shroud structure 100 can combine to substantially and/or entirely surround or envelop one or more components of the heat pump. For example, the shroud structure 100 can be configured to provide sound dampening material below, above, and on each side of a given heat pump component. Alternatively or in addition, the shroud structure 100 can be configured to provide sound dampening material in close proximity of the heat pump component. Therefore, the shroud structure 100 can provide a more complete sound attenuation or dampening of the heat pump component(s) as compared to existing systems. Further, as described more fully herein, the material of the shroud structure 100 can have thermally insulating benefits, such that the shroud structure 100 can thermally insulate the heat pump component(s).

The first section 110 can include a base portion 112 and a body portion 114. The base portion 112 can be configured to be installed on the top pan 10 before one, some, or all of the components of the heat pump water heater such that the base portion 112 can provide a layer of sound insulation between the top pan 10 and the bottom sides of the corresponding heat pump components. The base portion 112 can have a cross-sectional shape that is substantially the same as the shape of the top pan 10 or another surface configured to support the heat pump component(s). The base portion 112 can have dimensions (e.g., a diameter) that is substantially equal to the dimensions of the top pan 10 or another surface configured to support the heat pump component(s). For example, the base portion 112 can have a generally circular cross-sectional shape and can have a diameter that is approximately equal to the diameter of the top pan.

The shroud structure 100 can be configured to at least partially receive a fan 12 of the heat pump water heater system. For example, one or more sections of the shroud structure 100 can receive and structurally support the fan 12 (which can include a fan assembly including a corresponding motor) such that the load of the fan is transferred to the top pan 10 or bottom pan other underlying surface by way of the shroud structure 100 (e.g., the first section 110). The body portion 114 can include a fan aperture 116 extending therethrough, and the fan aperture can be configured to at least partially receive the fan 12. As illustrated in FIGS. 1A-4C, the fan aperture 116 of the body portion 114 can include all edges of the 20) aperture such that the circumferential edges of the fan are surrounded by the fan aperture 116. That is to say, the fan aperture 116 can have a size and shape that is approximately equal to an outer size and shape of the fan 12. As illustrated, the fan 12 can be configured to discharge air through a side of the shroud structure 100. Thus, the fan aperture 116 can extend in a generally radial direction (e.g., relative the top pan 10), relative the generally cylindrical shape of the shroud structure 100). As such, the lower portion of the fan aperture 116 can support the load of the fan 12.

The body portion 114 of the first section 110 can have an outer surface that is curved (e.g., a portion of a side wall of a cylinder), and the body portion 114 can have one or more inner surfaces 115 configured to abut or contact one or more corresponding inner surfaces of one or more other sections of the shroud structure 100 (e.g., the second section 140), as described more fully herein.

As shown perhaps most clearly in FIGS. 2A-4C, the shroud structure 100 can be include one or more recesses that are each configured to at least partially receive an evaporator 14 of the heat pump system. For example, the body portion 114 of the first section 110 can include one or more evaporator recesses 118 configured to at least partially receive the evaporator 14. Each evaporator recess 118 can have a size and shape that is approximately equal to an outer size and shape of a corresponding portion of the evaporator As illustrated, the body portion 114 can include a lower evaporator recess 118 configured to at least partially receive a lower portion of the evaporator 14 and at least one side evaporator recess 118 configured to at least partially receive a side portion of the evaporator 14. The evaporator recess(es) 118 can be located and spaced apart from the fan aperture 116 such that, when assembled, a void 119 exists between the evaporator 14 and the fan 12.

The first section 110 can include a condensate collector 120. The condensate collector 120 can be configured to be located under the evaporator 14. For example, the condensate collector 120 can be located within the lower evaporator recess 118. The condensate collector 120 can include one or more surfaces that are each sloped toward a condensate outlet 122 extending through a sidewall of the shroud structure 100 (e.g., a sidewall of the body portion 114). Accordingly, condensate dripping from the evaporator 14 can be collected and flowed out of the shroud structure 100.

The base portion 112 can include one or more compressor recesses 124 configured to at least partially receive a compressor 16 of the heat pump system. For example, a compressor recess 124 can be configured to receive a base portion of the compressor 16. The compressor recess 124 can have a size and shape that is approximately equal to an outer size and shape of the compressor 16. The compressor recess(es) 124 can further include one or more compressor anchor apertures 125 extending therethrough, which can be used to bolt or otherwise anchor the compressor 16 to the top pan 10 or another underling surface. The base portion 112 can include one or more refrigerant line apertures 126 extending therethrough and configured to permit a refrigerant line to pass therethrough. Each refrigerant line apertures 126 can have a size and shape that is approximately equal to an outer size and shape of the corresponding refrigerant line.

The shroud structure 100 (e.g., the base portion 112) can include a controller recess or aperture 128 configured to at least partially receive a controller 18 of the heat pump system. As illustrated in FIGS. 2A-2C, an aperture is illustrated. If, however, the shroud structure 100 includes a controller recess 128, the base portion 112 can include one or more apertures configured to permit wiring associated with the controller 18 to pass therethrough.

Referring now to FIGS. 3A-3G in particular, the second section 140 can include a body portion 142 and a top portion 144. The top portion 144 can have a cross-sectional shape that is substantially the same as the shape of the base portion 112 and/or the top pan 10 or another surface underlying the shroud structure 100. The top portion 144 can have dimensions (e.g., a diameter) that is substantially equal to the dimensions of the base portion 112 and/or the top pan 10 or another surface underlying the shroud structure 100. For example, the top portion 144 can have a generally circular cross-sectional shape and can have a diameter that is approximately equal to the diameter of the base portion 112 and/or the top pan 10.

The body portion 142 of the second section 140 can have an outer surface that is curved (e.g., a portion of a side wall of a cylinder), and the body portion 142 can have one or more inner surfaces 145 configured to abut or contact one or more corresponding inner surfaces of one or more other sections of the shroud structure 100 (e.g., the first section 110), as described more fully herein.

The body portion 142 of the second section 140 can include one or more air inlets 146, which can be in direct fluid communication with an internal cavity 148 of the body portion 142. As such, air can be permitted to flow through the shroud structure 100 by flowing through the air inlet 146 and the internal cavity 148, across the evaporator 14, and discharging out of the shroud structure 100 via the fan aperture 116. While illustrated as having a single air inlet 146, the body portion 142 can instead include multiple air inlets 146 that are spaced, sized, and shaped to provide a desired air flow through the cavity (e.g., to efficiently direct airflow toward and/or across the evaporator 14) (see, e.g., FIG. 11). Moreover, the shape and/or contour of the inner wall(s) and/or surface(s) of the body portion 142 of the second section 140 (i.e., the shape and contour of the cavity 148), can be configured to efficiently direct air flow from the air inlet(s) 146 to the evaporator 14 (e.g., to reduce eddies within the cavity 148). For example, the internal geometry of the body portion 142 can form a scoop that graduates in thickness, which can help efficiently change the direction of the air flow from a generally vertical direction (e.g., through the air inlet(s) 146) to a generally horizontal or radial direction (e.g., across the evaporator 14). The particular shape and contour of the cavity 148 can depend at least in part on the size, shape, and/or other characteristics of the evaporator 14.

The shroud structure 100 can be configured to at least partially receive the compressor 16. For example, the body portion 142 can include a compressor recess 150 configured to at least partially receive the compressor 16. The compressor recess 150 can have a size and shape that is approximately equal to an outer size and shape of the compressor 16. The compressor recess 150 can extend in a generally upward direction (i.e., from a bottom surface of the second section 140). The shroud structure 100 can be configured to at least partially receive one or more refrigerant lines (e.g., refrigerant lines extending the compressor 16). For example, the body portion 142 can include one or more refrigerant line recesses 152. The refrigerant line recess(es) can extend in a generally upward direction (i.e., from a bottom surface of the second section 140). The geometry and size of the refrigerant line recesses 152 can be configured to track or mirror the diameter and/or any turns or bends of the refrigerant tubing. As will be appreciated, the upright portion can provide thermal insulation in addition to acoustic insulation. Thus, by situating the refrigerant tubing within the second piece, the refrigerant tubing can be thermally insulated, which can improve the efficiency of the heat pump system and/or obviate the need for alternative insulation to wrapped around or otherwise installed on the refrigerant tubing.

Optionally, the second section 140 can include a protruding portion extending from an internal portion of the body portion 142 into the cavity 148. The protruding portion can envelop and/or surround at least some of the compressor recess 150. As will be appreciated, it may be desirable (e.g., based on air flow dynamics within the cavity 148, to reduce material required by the second section 140) to include the protruding portion 154, rather than body portion 142 including material extending from the top of the compressor recess 150 to the top of the second section 140.

Depending on the size and location of other heat pump components, the second section 140 can include one or more recesses configured to at least partially receive a top portion or other portion of the component. For example, as illustrated, the second section 140 can include a controller recess 128 configured to receive a top portion of a corner of the controller 18. As another example, as illustrated, the second section 140 can include a side evaporator recess 118 configured to at least partially receive a side portion of the evaporator 14 (e.g., the side portion opposite the side portion being at least partially received by the side evaporator recess 118 of the first section 110). As illustrated, the top portion 144 of the second section 140 can abut and/or cover the top portion of the evaporator 14. Alternatively or in addition, the shroud structure 100 (e.g., the second section 140) can include an upper evaporator recess 118 configured to at least partially receive a top portion of the evaporator 14.

The various recesses, channels, and/or corridors of the second section 140 can open to a bottom side of the second section 140. That is to say, the second section 140 can be easily installed by sliding the second section downward atop the compressor 16 and/or other heat pump components, such as the refrigerant tubing or the evaporator 14. Once installed, the bottom surface of the second section's 140 body portion 142 can contact the top surface of another section of the shroud structure 100, such as the top of the first section's 110 base portion 112, and at least some of the inner surface 145 of the second section's 140 body portion 142 can contact at least some of the inner surface 115 of the first section's 110 base portion 112. As such, the shroud structure 100 can be assembled with minimal or no gaps or separation.

While the shroud structure 100 has been primarily described to this point as being a two-piece system, the disclosed technology is not so limited. For example, the shroud structure 100 can include five or fewer distinct sections, four or fewer distinct sections, or three or fewer distinct sections. As a specific example, the shroud structure 100 is illustrated in FIGS. 5A-9 as having three sections.

The shroud structure 100 can include a first section 110, a second section 140, and a third section 160. Upon installation, the first section 110 can serve as the lowermost section, the second section 140 can serve as the uppermost section, and the third section 160 can serve as a middle section.

As described previously, the first section 110 can include the base portion 112 and body portion 114. As before, the base portion 112 can be configured to be located below one or more heat pump components (e.g., between one or more heat pump components and the top pan 10). As illustrated in FIGS. 5A-9, however, the volume of the shroud structure 100 can be divided among the various sections differently as compared to the shroud structure 100 as illustrated in FIGS. 1A-4C. For example, the fan aperture 116 can be defined by two sections, such as the first section 110 and the second section 140. That is to say, the fan aperture 116 of the first section 110 can be a first fan aperture portion that is configured to at least partially receive a first portion (e.g., lower portion) of the fan 12, and a fan aperture 116 of the second section 140 can be a second fan aperture portion that is configured to at least partially receive a second portion (e.g., upper portion) of the fan 12.

The base portion 112 can further include one or more wiring apertures 129 configured to permit wires to pass between the controller and other parts of the heat pumps, such as various sensors. The base portion 112 can include one or more anchor apertures 130 configured to receive one or more bolts, mushroom attachment devices 22, or the like, which can help secure the first section 110 to the top pan 10.

The shroud structure 100 can include attachment structures integrated into the various sections. For example, each section can include one or more protrusions 132 and/or one or more sockets 134. The protrusions 132 can extend from an inner wall or surface of a given section (e.g., an inner surface 115, an inner surface 145) and can have a width that increases as the protrusion 132 extends from the wall or surface. Stated otherwise, the width of the protrusion 132 can be greater at a tip end of the protrusion 132 than at a base end of the protrusion 132. The sockets 134 can each be configured to slideably receive a corresponding protrusion 132 to thereby connect the corresponding sections. The sockets 134 can be vertical recesses or apertures in a given section. The sockets 134 can extend into an inner wall or surface of a given section (e.g., an inner surface 115, an inner surface 145) and can have a width that increases as the depth of the socket 134 increases. Stated otherwise, the width of the socket 134 at a first depth (with respect to the surface from which the socket 134 extends) can be less than a thickness of the socket 134 at a second depth that is greater than the first depth. The cross-sectional shape and dimensions of each socket 134 can substantially equal the cross-sectional shape and dimensions of the corresponding protrusion 132 such that the mating of the protrusion 132 and socket 134 can provide a secure fit, while permitting the protrusion 132 to easily slide into the socket 134. For example, the protrusions 132 and sockets 134 can each have a narrow portion and a bulbous portion, such that the protrusions 132 and sockets 134 resemble jigsaw puzzle pieces.

The third section 160 can include one or more elements or features heretofore discussed with respect to the body portion 142 of the second section 140. That is to say, the various elements and features of the shroud structure 100 can be incorporated into different sections. The precise division of elements and features among the various sections can depend on the arrangement and size of heat pump components, as well as the division of the shroud structure's 100 volume among the various sections. As will be appreciated, increasing the number of sections of the shroud structure 100 can facilitate easier manufacturing and storage for a given section (e.g., by reducing the size of a given section), but reducing the number of sections of the shroud structure 100 can facilitate easier assembly of the shroud structure 100 and therefore easier manufacturing of the associated heat pump. Therefore, the precise number of sections, and how the volume of the shroud structure 100 is divided among the various sections, can depend on several factors, including desired ease and speed of assembly, cost of manufacturing the shroud structure 100, and the like.

As illustrated, the third section 160) can include the controller recess 128 and wiring apertures 129 that are configured to align with the wiring apertures 129 of the first section 110. The third section 160 can include a protrusion 132 configured to slide into a corresponding socket of the first section 110 and/or a socket 134 configured to slideably receive a corresponding protrusion 132 of the first section. The third section 160 can include one or more compressor recesses 124. If, upon assembly, the top of the third section 160 is lower than the top of the compressor 16, the compressor recess(es) 124 can extend entirely through the third section 160 to form one or more generally vertical apertures configured to slideably receive at least a portion of the compressor 16, such as is illustrated in FIGS. 7A-7G, for example. Likewise, the third section 160) can include one or more refrigerant line apertures and/or recesses configured to slideably receive one or more corresponding refrigerant lines (e.g., extending from the compressor 16 or another heat pump part). The shroud structure 100 can include a thermal expansion valve (TXV) recess or aperture 127. The TXV recess or aperture 127 can be configured to at least partially receive a TXV 20. The TXV recess or aperture can have a size and shape that is approximately equal to an outer size and shape of the TXV 20. As illustrated, the third section 160 can include a TXV aperture 127 configured to slideably receive the TXV 20. The third section 160 can have one or more internal surfaces that at least partially define the cavity 148 of the shroud structure 100.

The second section 140 can include a body portion 142 and a top portion 144 as previously described. The second portion 140, as illustrated in FIGS. 5A-9, however, can have a body portion 142 with a smaller volume than the body portion 142 of the second section 140 as illustrated in FIGS. 1A-4C (e.g., due to some of the volume being applied to the third section 160) and/or the second portion 140, as illustrated in FIGS. 5A-9, however, can have a top portion 144 with a larger volume than the top section 144 of the second section 140 as illustrated in FIGS. 1A-4C (e.g., due to some of the volume above the fan aperture 116 being included in the second section 140).

The second section 160 can include one or more protrusions 132 and/or one or more sockets 134. For example, as perhaps shown most clearly in FIGS. 5A-5D, the second section 160 can include a protrusion 132 configured to interface with a corresponding socket 134 of the third section 160, and the second section can include a socket 134 configured to interface with a corresponding protrusion 132 of the third section 160. It should be noted that a given socket 134 can interface with more than one protrusion 132 such that the section including that socket can be connected to more than one other section. For example, as illustrated, the protrusion 132 of the third section 160 is configured to slide into the socket 134 of the first section 110, and the socket 134 of the second section 140 is configured to slide over the protrusion 132 of the third section 160. In this way, the protrusion 132 of the third section 160 is configured to simultaneously engage the sockets 134 of both the first and second sections 110, 140. Similarly, as illustrated, the socket 134 of the third section is configured to slide over the protrusion 132 of the first section 110, and the protrusion 132 of the second section 140 is configured to slide into the socket 134 of the third section 160. As such, the socket 134 of the third section 160 is configured to simultaneously engage the protrusions 132 of both the first and second sections 110, 140. Thus, the three sections 110, 140, 160 are connected to one another, and because the first section 110 can be anchored to the top pan 10, the shroud structure 100 can therefore be secured to the top pan 10.

Other configurations are contemplated. For example, FIGS. 10A-10F illustrate views of an example shroud structure 100 having three sections. As can be seen from the drawings, the shroud structure 100 as illustrated in FIGS. 10A-10F can be substantially similar to the shroud structure 100 as illustrated in FIGS. 5A-9 except that the shroud structure 100 as illustrated in FIGS. 10A-10F can omit the protrusion(s) 132 and socket(s) 134.

As another example, FIG. 11 illustrates an example shroud structure 100 including a plurality of air inlets 146. As illustrated, the air inlets 146 can be located in or on a panel 1100 that can be hingedly attached to an aperture on a top side of the shroud structure 100 (e.g., second section 140). Alternatively, the panel 1100 can be slideably or otherwise removeably attached to the shroud structure 100. Each air inlet 146 can have a sidewall that can oriented to direct air passing therethrough in a specific direction. Stated otherwise, the air inlets 146 can have a louver-like configuration.

Yet another embodiment of a shroud structure 100 is illustrated in FIGS. 12A-14G. Shroud structure 100 has two sections, similar to the shroud structure illustrated in FIGS. 1A-1B. However, the first section 110 does not include a base portion 112 and a body portion 114. As shown in FIGS. 12A-12B, and more clearly in FIGS. 13A-13G, the first section 110 substantially forms the lower half of the shroud structure 100. The first section 110 can have a cross-sectional shape and dimensions that are substantially the same as the shape of the top pan 10 or another surface configured to support the heat pump component(s). The first section 110 can also have a lateral outer surface that is curved, and one or more inner surfaces 115 configured to abut or contact one or more corresponding inner surfaces of one or more other sections of the shroud structure 100.

Similarly, the second section 140 does not include a top portion 144 and a body portion 142. As shown in FIGS. 14A-14G, the second section 140 substantially forms the upper half of the shroud structure 100. The second section 140 can have a cross-sectional shape and dimensions that are substantially the same as the shape of the first section 110 and/or the top pan 10 or another surface underlying the shroud structure 100. The second section 140 can also have a lateral outer surface that is curved (e.g., a portion of a side wall of a cylinder), and one or more inner surfaces 145 configured to abut or contact one or more corresponding inner surfaces of one or more other sections of the shroud structure 100.

When assembled, the shroud structure 100 in this embodiment is configured to at least partially receive a fan 12 of the heat pump water heater system. The first section 110 includes a first fan aperture portion 116a extending therethrough, and the second section 140 include a second fan aperture portion 116b extending therethrough. When the first section 110 and second section 140 are assembled together, the first fan aperture portion 116a and second fan aperture portion 116b combine to define a single fan aperture 116, configured to at least partially receive the fan 12. As illustrated in FIGS. 12A-12B, the fan aperture 116 has a size and shape that is slightly smaller than an outer size and shape of the fan 12. The circumferential edges of the fan may be affixed to the first section 110 and the second section 140 outside of the fan aperture 116 disposed therein, while a majority of the fan 12 is disposed within the fan aperture 116.

The second section 140 includes an air inlet 146, which is fluid communication with an internal cavity 148 of the shroud structure 100. The second section 140 can include one or more air inlets 146, which can be in direct fluid communication with an internal cavity 148 of the body portion 142. As such, air can be permitted to flow through the shroud structure 100 by flowing through the air inlet 146 and the internal cavity 148, across the evaporator 14, and discharging out of the shroud structure 100 via the fan aperture 116. While illustrated as having a single air inlet 146, the second section 140 can instead include multiple air inlets 146 that are spaced, sized, and shaped to provide a desired air flow through the cavity. Moreover, the shape and/or contour of the inner wall(s) and/or surface(s) of the second section 140 can be configured to efficiently direct air flow from the air inlet(s) 146 to the evaporator 14. For example, the internal geometry of the second section 140 can form a scoop that graduates in thickness, which can help efficiently change the direction of the air flow from a generally vertical direction to a generally horizontal or radial. The particular shape and contour of the cavity 148 can depend at least in part on the size, shape, and/or other characteristics of the evaporator 14.

The shroud structure 100 can be configured to at least partially receive the compressor 16. For example, the second section 140 can include a compressor recess 150 configured to at least partially receive the compressor 16. The compressor recess 150 can have a size and shape that is approximately equal to an outer size and shape of the compressor 16. The compressor recess 150 can extend in a generally upward direction. The shroud structure 100 can be configured to at least partially receive one or more refrigerant lines. For example, the second section 140 can include one or more refrigerant line recesses 152. The refrigerant line recess(es) can extend in a generally upward direction. The geometry and size of the refrigerant line recesses 152 can be configured to track or mirror the diameter and/or any turns or bends of the refrigerant tubing. As will be appreciated, the upright portion can provide thermal insulation in addition to acoustic insulation. Thus, by situating the refrigerant tubing within the second piece, the refrigerant tubing can be thermally insulated, which can improve the efficiency of the heat pump system and/or obviate the need for alternative insulation to wrapped around or otherwise installed on the refrigerant tubing.

Optionally, the second section 140 can include a protruding portion extending into the cavity 148. The protruding portion can envelop and/or surround at least some of the compressor recess 150.

Depending on the size and location of other heat pump components, the second section 140 can include one or more recesses configured to at least partially receive a top portion or other portion of the component. For example, the second section 140 can include a controller recess 128 configured to receive a top portion of a corner of the controller 18. As another example, as illustrated, the second section 140 can include a side evaporator recess 118 configured to at least partially receive a side portion of the evaporator 14. As illustrated, the second section 140 can abut and/or cover the top portion of the evaporator 14. Alternatively or in addition, the shroud structure 100 can include an upper evaporator recess 118 configured to at least partially receive a top portion of the evaporator 14.

The various recesses, channels, and/or corridors of the second section 140 can open to a bottom side of the second section 140. That is to say, the second section 140 can be easily installed by sliding the second section downward atop the compressor 16 and/or other heat pump components, such as the refrigerant tubing or the evaporator 14. Once installed, the bottom surface of the second section 140 can contact the top surface of another section of the shroud structure 100, such as the top of the first section's 110 base portion 112, and at least some of the inner surface 145 of the second section 140 can contact at least some of the inner surface 115 of the first section's 110 base portion 112. As such, the shroud structure 100 can be assembled with minimal or no gaps or separation.

The disclosed technology provides several advantages. For example, the disclosed shroud structures can accommodate several heat pump components with only a small number of distinct pieces. In addition, the various pieces of the disclosed shroud structures can be easy to install and/or can improve heat pump component organization (e.g., as compared to previous systems), which can increase manufacturing throughput. Further, the disclosed shroud structures can provide a substantial amount of support and cushioning for the compressor, thereby dampening its vibration, and can reduce the noise emitted by the HPWH during operation.

While the present disclosure has been described in connection with a plurality of exemplary aspects, as illustrated in the various figures and discussed above, it is understood that other similar aspects can be used, or modifications and additions can be made to the described subject matter for performing the same function of the present disclosure without deviating therefrom. In this disclosure, methods and compositions were described according to aspects of the presently disclosed subject matter. But other equivalent methods or compositions to these described aspects are also contemplated by the teachings herein. Therefore, the present disclosure should not be limited to any single aspect, but rather construed in breadth and scope in accordance with the appended claims.

Moreover, the various diagrams and figures presented herein are for illustrative purposes and are not be considered exhaustive. That is, the systems described herein can include one or more additional components, such as various valves, expansions tanks, and the like, as will be appreciated by one having ordinary skill in the art.

Shroud Structure

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