Patent Application
20250035340
The present disclosure is generally in the field of water heaters. For example, systems and methods are provided herein for water heaters with water tanks including rotatable electric heating assemblies.
Water heating systems such as water heaters may heat large volumes of water, retained in water tanks, for use in residential and/or commercial settings. For example, a water heating system may include an electric heating assembly designed to heat a volume of water held in a water tank by transferring electric resistance-generated heat from the electric heating assembly extending into the water tank holding the volume of water. The water may be circulated throughout the residential or commercial structure, which may include multiple faucets and/or outlets that demand hot water simultaneously. More efficient water heating may be better suited to satisfy high demand for hot water.
The United States Department of Energy has promulgated a metric known as the Uniform Energy Factor (UEF) to define the energy efficiency of water heating systems. The UEF of a water heating system is based, in part, on a first hour rating (FHR) of the water heating system. The FHR, in turn, defines the quantity (e.g., number of gallons) of hot water generated by the water heating system in the first hour of operation, based, in part, on a maximum capacity of the water tank and a recovery rate of the water heating system (e.g., a rate at which the water heating system may replenish the water tank's supply of hot water once existing hot water in the water tank is distributed via an outlet).
Existing water heating systems often include electric heating assemblies designed such that the electric heater is installed or positioned in a fixed horizontal position oriented in a plane perpendicular to a primary axis of the water heater, as shown in
Accordingly, there is a need for improved systems and methods for water heaters and electric heating assemblies for heating water retained in a water tank of such water heaters.
Water heating systems have been developed that are capable of dispersing heat more efficiently to a volume of water in a water tank of a water heater, which may be distributed, via one or more outlets, to external appliances, faucets, or other devices designed to circulate or use hot water. A water heating system may be a tank-style water heater, which may include a water tank and one or more heating systems and/or assemblies designed to heat a volume of water held in the water tank. For example, the water heating system may be an electric water heater, which may include electric heating assemblies designed to heat volumes of water held in water tanks. Other water heating systems may be hybrid water heaters, which may include gas heating systems, heat pump systems, and/or other heating systems in addition to electric heating assemblies. The water heating system may offer improved heating efficiency over existing water heating systems based, at least in part, on an orientation or position of the electric heating assembly or at least the electric heater therein with respect to the water tank in which at least a portion of the electric heating assembly may be installed.
For example, the water heating system may include the water tank and the electric heating assembly. The water tank may be designed to retain a volume of water and have a tank body including at least one receiving portion defining a through hole and having a threaded engagement. The electric heating assembly may include a base, a rotator, an electric heater, a sealing ring, and/or a guide (e.g., guide portion). The base may include a threaded engagement defining a channel and designed to engage (e.g., via threading) with the threaded engagement of the tank body. The rotator may include a spherical shape and/or at least one through hole, have a diameter larger than an interior diameter of the channel of the base, and may be positionable, at least partially, within the channel.
The electric heater may be designed to extend through the at least one through hole of the rotator such that a proximal end and a distal end of the electric heater may extend beyond the rotator. The electric heater may extend into the water tank to heat at least a portion of the volume of water in the water tank. The sealing ring may be installed within the base such that a fluid-tight seal may be created between the base and the rotator. The guide may include at least one guide channel designed to receive at least a portion of the proximal end of the electric heater or another component of the electric heating assembly. Each guide channel may be a linear channel (a channel that is straight without curvature) or may have any other design to be able to receive one or more components of the electric heating assembly. The rotator may facilitate movement of the electric heater within the base. The guide may be designed to guide the electric heater between a horizontal position and an angled position.
Referring now to
Rotator 204 may have a spherical shape and/or at least one through channel 216 for receiving electric heater 206. Electric heater 206 may be an electric resistive heater and may have proximal end 218 and distal end 220. In one example, electric heater 206 may include a tube or other elongated structure with resistive circuits therein, designed for thermal heater transfer. The tube may be bent such that the proximal end of electric heater 206 includes two ends of the tube and the distal end includes the bent middle portion. Guide 208 may include at least one guide channel and/or chamber 224, which may be a component of guide 208 or may be distinct from guide 208. The guide channel(s) of guide 208 may or may not be linear in design. Chamber 224 may similarly include one or more channels for receiving electric heater 206.
As shown in
Electric heating assembly 200 may be designed for use with a tank-style water heater, such as an electric water heater or a hybrid water heater with a water tank; however, it should be understood that the electric heating assemblies described herein also could be used with tankless or other water heating system types. Such water tanks may be designed for receiving and mating with the fixed electric heating assembly illustrated in
Unlike, for example, electric heating assembly 100 of
In some embodiments, rotator 204 may have a diameter larger than an interior diameter of base 202 and/or may be positionable, partially, within the interior diameter of base 202. Electric heater 206 may be designed to extend through at least one through hole 216 of rotator 204 such that proximal end 218 and/or distal end 220 of electric heater 206 may extend beyond rotator 204. Electric heater 206 (e.g., distal end 220) may be designed to extend into the water tank to heat at least a portion of the volume of water held in the water tank. Guide channel(s) of guide 208 may be designed to receive one or more components of electric heating assembly 200. For example, the guide channel(s) may be designed to receive at least a portion of proximal end 218 of electric heater 206 when proximal end 218 extends beyond rotator 204. Alternatively, or in addition, the guide channel(s) may be designed to receive an extension of rotator 204 and/or another component (e.g., a cap, an adapter, or an extension piece) attached to rotator 204 and/or proximal end 218 of electric heater 206 (e.g., by threaded connection, adhesive, or any other means of attachment), In one example, proximal end 218 is fixed within and/or does not extend beyond rotator 204 in the proximal direction.
In certain embodiments (further described below), the guide channel(s) may be further designed to mechanically guide at least the portion of proximal end 218 (or another component of electric heating assembly 200, as described above) such that movement of electric heater 206 may be restricted to an angle of travel between horizontal position 226 and angled position 228. In embodiments wherein guide 208 includes chamber 224, electric heater 206 may include one or more hardware components (not shown) such as one or more circuits, which may be housed in chamber 224.
Chamber 224 may similarly include channel guides and thus facilitate movement of electric heater 206 within guide 208. For example, the one or more hardware components may include one or more wire leads connected to one or more terminals of electric heater 206 by one or more fasteners, some or all of which may be housed in chamber 224 such that electric heater 206 may move between the horizontal position and the angled position without restriction.
Referring now to
Water heating system 300 may include tank body 306, controller 301 and/or at least one heating assembly (such as electric heating assembly 304) designed to heat water in the water tank. Controller 301 may include any suitable processor and may be in electrical communication with electric heating assembly 304. Tank body 306 may include at least one receiving portion 308, which may define through hole 310 and/or have a threaded engagement. Water tank 302 may be designed to retain volume of water 324, for example, within tank body 306. Water tank 302 may be formed from any material, including but not limited to one or more of metal (e.g., copper, stainless steel, or mild steel), thermoplastic polymer, glass-lined material, porcelain-lined material, enamel-lined material, or any other suitable material. Water tank 302 may be of any size suitable for use in a water heating system, such as any industry-standard water tank size (e.g., 40-gallon or 50-gallon or any other tank size).
Electric heating assembly 304 may include base 314, rotator 316, and/or electric heater 318. Base 314 may be designed to engage (e.g., via threading) with threaded engagement 312 of tank body 306. Rotator 316 may be positioned, partially, within base 314. Electric heater 318 may have proximal end 320 and distal end 322. Proximal end 320 of electric heater 318 may extend beyond rotator 316 such that proximal end 320 does not extend into water tank 302 when electric heating assembly 304 is installed on or within water tank 302. Distal end 322 of electric heater 318 may extend beyond rotator 316 in an opposite direction from proximal end 320 such that distal end 322 may extend into water tank 302.
Rotator 316 may be designed to facilitate movement of electric heater 318 within base 314. For example, rotator 316 may facilitate movement of electric heater 318 between horizontal position 326 and angled position 328, which may be positioned at a set angle from horizontal position 326 (e.g., 30 degrees, 45 degrees, etc.). In this manner, electric heater 318 may be positioned to heat at least a portion of volume of water 325, which may be a greater volume of water which electric heating assembly 304 could heat in the same period of time.
To install electric heating assembly 304, a fixed heater assembly (e.g., the fixed heater assembly of
Installation and/or use of electric heating assembly 304 within water heating system 300 may be positionally dependent. For example, base 314 of electric heating assembly 304 may only be installed when electric heater 318 is oriented in horizontal position 326. It is understood that electric heating assembly may optionally only heat volume of water 324 when electric heater 318 is oriented in the angled position.
When installed, electric heating assembly 304 may provide for one or more fluid-tight seals about receiving portion 308 of water tank 302. For example, base 314 and rotator 316 may meet about a sealing ring (e.g., an O-ring or gasket) installed within base 314, which may create a fluid-tight seal where volume of water 324 might otherwise escape from water tank 302. Moreover, electric heating assembly 304 may include one or more hardware components (not shown), such as wire leads, terminals, and/or fasteners. The one or more hardware components may be housed, for example, in one or more fluid-tight chambers of electric heating assembly 304, thereby preventing potentially damaging contact between live electrical components and water 324. As such, water 324 may be prevented from exiting water tank 302 except via one or more intended outlets.
Electric heater 318 may be designed to distribute heat to a greater portion of volume of water 324 more efficiently in the angled position than in the horizontal position. For example, distribution of heat to the greater portion of volume of water 324 more efficiently may be defined by a first hour rating (FHR). The FHR may be defined as a number of gallons of water supplied at a predefined temperature by water heating system 300 per hour from a starting time at which volume of water 324 retained in water tank 302 may be at or above the predefined temperature. Supplying the number of gallons of water may include replacing volume of water 324 retained in water tank 302 with a replacement volume of water at a replacement temperature below the predefined temperature.
In one example, the number of gallons of water supplied at the predetermined temperature by water heating system 300 per hour may be determined by aggregating one or more measurements at one or more draw times, separated by a recovery time of water heating system 300, during which the replacement volume of water may be heated by electric heater 318 from the replacement temperature to the predefined temperature. The recovery time may be lower when electric heater 318 is oriented in angled position 322 than it is when electric heater 318 is oriented in the horizontal position.
Although
As shown in
Water heating system 350 may be designed to generate hot water via transfer of heat from electric heating assembly 304 and/or heat pump system 330, either alternatively or in combination. Heat pump system 330 may be located within water tank 302 such that condenser coil 340 transfers heat directly to volume of water 324. Electric heating assembly 304 may be installed on or within water tank 352 in an offset manner or otherwise (e.g., around heat pump system 330) with respect to heat pump system 330, such that the two do not physically contact or otherwise disrupt operation of one another.
Whether water heating system 350 may be an electric or hybrid tank-style water heater, or some other type of water heater, cold water inlet 336 and/or hot water outlet 338 may be installed on water tank 352 so as to facilitate ingress and egress of water at various temperatures. For example, cold water inlet 336 may be designed to receive cold water from an external source (e.g., a water hookup port located in a home or business). Hot water outlet 338 may be designed to distribute hot water generated by water heating system 300 for external use. In some embodiments, cold water inlet 336 may be located at a lower height than hot water outlet 338.
In various embodiments, first temperature sensor 332 and/or second temperature sensor 334 may be used to determine one or more temperature readings of at least a portion of volume of water 324 held in water tank 302. For example, first temperature sensor 332 may determine a first temperature reading corresponding to a first portion of volume of water 324 that may have recently entered into water tank 302 via cold water inlet 336.
The first portion of volume of water 324 may flow past electric heating assembly 304 and/or along condenser coil 340 of heat pump system 330, either or both of which may transfer heat to volume of water 324 as it flows by. As such, a second portion of volume of water 324 (e.g., a portion closest to hot water outlet 338) may have a higher temperature than the first portion. Second temperature sensor 334 may determine a second temperature reading corresponding to the second portion of volume of water 324, which may reflect the higher temperature. Accordingly, water heating system 350 may be able to determine whether the first portion, the second portion, and/or an entirety of volume of water 324 may be at or above the predefined temperature associated with the FHR (further described above with respect to
Referring now to
As shown in
Threaded engagement 404 of base 402 may facilitate connection to a corresponding threaded engagement located about a receiving portion of a different component (e.g., a tank body of a water heating system). Rotator 410 may be sized and designed to be positioned, at least partially, within channel 406 of base 402. For example, diameter 416 of rotator 410 may be larger than interior diameter 408 of channel 406 such that rotator 410 may only be partially inserted within channel 406. Electric heater 418 may be sized and designed such that proximal end 420 may be inserted through at least one through hole 414 of rotator 410 and beyond rotator 410. Scaling ring 422 may be circumferentially located around a portion of rotator 410 such that sealing ring 422 may fit within base 402 should rotator 410 be positioned within channel 406 of base 402. In this manner, sealing ring 422 may create a fluid-tight seal together with base 402 and rotator 410.
Referring now to
Base 502 may be connected or attached to guide 508 by any means of connection or attachment (e.g., gluing, fastening, welding forming, slotting, or any other suitable means). Rotator 504 may be inserted, partially, from an opposite face of base 502 than shown in
Rotator 504 may be designed to facilitate movement of electric heater 506 within base 502. Guide 508 may include two guide channels 512, as shown in
In yet another example, the channel guides may be rotated between 1 and 90 degrees in either direction from the orientation illustrated in
Referring now to
Base 602 may separate rotator 604 and guide 610. For example, base 602 may be attached, at one end, to guide 610 about chamber 612. At an opposing end, rotator 604 may be partially positioned within base 602 (e.g., within a recessed portion or channel). Electric heater 606 may extend through rotator 604, base 602, and at least a portion of guide 610 and/or chamber 612.
As assembled, electric heating assembly 600 may be oriented such that a longitudinal axis of electric heater 606 may be at least substantially parallel and/or angled with respect to a horizontal plane. For example, rotator 604 may be able to move electric heater 606 within base 602 (e.g., by rotating electric heater 606) between a horizontal position and an angled position. Guide 610 may guide electric heater 606 between the horizontal position and the angled position.
In embodiments where guide 610 may include chamber 612, chamber 612 may house one or more hardware components (e.g., circuitry or one or more circuits) of electric heater 606 without restricting any movement of electric heater 606 between the horizontal position and the angled position. In various embodiments, the one or more hardware components may include, for example, one or more wire leads connected to one or more terminals of electric heater 606 by one or more fasteners. Chamber 612 may be fluid-tight. Accordingly, chamber 612 may offer a dry and secure housing that may provide a necessary range of motion for the one or more hardware components of electric heater 606.
Sealing ring 608 may prevent, for example, an escape of fluid between rotator 604 and base 602. Sealing ring 608 may be placed around rotator 604 prior to positioning of rotator 604 within at least part of base 602. Base 602 may include a recessed portion for receiving and securing sealing ring. It is understood that more than one sealing ring may be used. Such a fluid-tight seal may remain intact regardless of the relative position of electric heater 606 and/or rotator 604. For example, sealing ring 608 may maintain a fluid-tight seal when electric heater 606 moves to or from any position between the horizontal position and the angled position.
Although specific embodiments of the disclosure have been described, one of ordinary skill in the art will recognize that numerous other modifications and alternative embodiments are within the scope of the disclosure. For example, any of the functionality and/or processing capabilities described with respect to a particular device or component may be performed by any other device or component. Further, while various illustrative implementations and architectures have been described in accordance with embodiments of the disclosure, one of ordinary skill in the art will appreciate that numerous other modifications to the illustrative implementations and architectures described herein are also within the scope of this disclosure.
Although embodiments have been described in language specific to structural features and/or methodological acts, it is to be understood that the disclosure is not necessarily limited to the specific features or acts described. Rather, the specific features and acts are disclosed as illustrative forms of implementing the embodiments. Conditional language, such as, among others, “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments could include, while other embodiments do not include, certain features, elements, and/or steps. Thus, such conditional language is not generally intended to imply that features, elements, and/or steps are in any way required for one or more embodiments or that one or more embodiments necessarily include logic for deciding, with or without user input or prompting. whether these features. elements, and/or steps are included or are to be performed in any particular embodiment.
This application claims priority to and benefit of U.S. provisional patent application No. 63/516,391 filed Jul. 28, 2023, which is herein incorporated by reference.
| Number | Date | Country | |
|---|---|---|---|
| 63516391 | Jul 2023 | US |
