The invention is best understood from the following detailed description when read in connection with the accompanying drawings. Included in the drawings are the following figures:
Although the invention is illustrated and described herein with reference to specific embodiments, the invention is not intended to be limited to the details shown. Rather, various modifications may be made in the details within the scope and range of equivalents of the claims and without departing from the invention.
The invention is best understood from the following detailed description when read in connection with the accompanying drawing figures, which shows exemplary embodiments of the invention selected for illustrative purposes. The invention will be illustrated with reference to the figures. Such figures are intended to be illustrative rather than limiting and are included herewith to facilitate the explanation of the present invention.
The benefits associated with the bracket of the present invention, which will be described in detail, include a substantial decrease in the risk of damage to the igniter bracket during its lifetime.
Generally, and according to one embodiment of the invention, an igniter bracket is provided for use with a water heater to mount an igniter to the water heater. The igniter bracket includes a base portion occupying a base plane and at least one mounting portion extending from the base portion, wherein an edge of the at least one mounting portion occupies an edge plane that is not perpendicular to the base plane.
The base portion optionally has a base surface occupying a first plane, and the at least one mounting portion optionally has a mounting surface extending from the base surface, wherein a vertical plane along an edge of the at least one mounting surface is angled less than ninety degrees from the first plane. The at least one mounting portion optionally includes a first mounting portion and at least a second mounting portion spaced from the first mounting portion.
The at least one mounting portion defines an opening configured for receiving the igniter. A center of the opening is spaced in a range of from about ¼ inch to about 1¼ inch from a surface of the base portion. The center of the opening is also spaced in a range of from about ¾ inch to about 1⅜ inch from an end of the surface of the base portion. The opening includes a wall portion extending from an edge of the opening. The opening also includes at least one groove extending from an edge of the opening and configured for receiving a mating portion disposed on the igniter.
The igniter bracket further includes at least one attachment portion extending from the base portion. The base portion of the igniter bracket includes an opening proximal to an edge of the base portion. The igniter bracket also includes at least one attachment hook extending from an edge of the base portion.
According to another embodiment of the invention, an igniter, igniter bracket and gas valve assembly is provided for use with a water heater. According to yet another embodiment of the invention, a water heater is provided.
Referring generally to the figures, one embodiment of this invention provides an igniter bracket 108, 200, 300, 410 for use with a water heater 400. The igniter bracket 108, 200, 300, 410 includes a base surface 128, 206, 306 occupying a first plane. The igniter bracket 108, 200, 300, 410 further includes at least one mounting surface 102, 107, 202, 204, 302, 304 extending from the base surface 128, 206, 306. A vertical plane, along an edge 208, 210, 308, 310 of the at least one mounting surface 102, 107, 202, 204, 302, 304, is angled less than ninety degrees from the base surface 128, 206, 306.
The at least one mounting surface 102, 107, 202, 204, 302, 304 has a base edge 212, 214, 312 and a facing edge 208, 210, 308, 310 extending from the base edge 212, 214, 312. The base edge 212, 214, 312 and the facing edge 208, 210, 308, 310 together define an angle θ less than ninety degrees.
According to another embodiment, the present invention further provides an igniter, igniter bracket and gas valve assembly 101, 404 for use with a water heater 400. The assembly 101, 404 includes a gas valve 112, which, in turn includes a side surface 110. The assembly 101, 404 also includes an igniter bracket 108, 200, 300, 410 coupled to the gas valve 112. The igniter bracket 108, 200, 300, 410 includes a base surface 128, 206, 306 occupying a first plane, wherein the base surface 128, 206, 306 is adjoining and substantially parallel with the side surface 110 of the gas valve 112. The igniter bracket 108, 200, 300, 410 also includes at least one mounting surface 102, 107, 202, 204, 302, 304 extending from the base surface 128, 206, 306. A vertical plane, along an edge 208, 210, 308, 310 of the at least one mounting surface 102, 107, 202, 204, 302, 304, is angled less than ninety degrees from the first plane. The assembly 101, 404 further includes an igniter 100 mounted to the at least one mounting surface 102, 107, 202, 204, 302, 304.
According to yet another embodiment, the present invention further provides a water heater 400. The water heater 400 includes a tank 402 and an igniter, igniter bracket 108, 200, 300, 410 and gas valve assembly. The assembly 101, 404 includes a gas valve 112 coupled to the tank 402. The gas valve 112 includes a rear surface 407 opposing the tank 402 and a side surface 110 substantially perpendicular to the rear surface 407 and extending from the rear surface 407. The assembly 101, 404 also includes an igniter bracket 108, 200, 300, 410 coupled to the gas valve 112. The igniter bracket 108, 200, 300, 410 includes a base surface 128, 206, 306 occupying a first plane. The base surface 128, 206, 306 is adjoining and substantially parallel with the side surface 110 of the gas valve 112. The igniter bracket 108, 200, 300, 410 also includes at least one mounting surface 102, 107, 202, 204, 302, 304 extending from the base surface 128, 206, 306. A vertical plane, along an edge 208, 210, 308, 310 of the at least one mounting surface 102, 107, 202, 204, 302, 304, is angled less than ninety degrees from the first plane. The assembly 101, 404 further includes an igniter 100 mounted to the at least one mounting surface 102, 107, 202, 204, 302, 304 of the igniter bracket 108, 200, 300, 410.
The exemplary gas valve 112 may also include a front surface 114 and a top surface 116. The front surface 114 may include an exemplary temperature setting dial 118 for setting the temperature of the water in a water heater tank (not shown). The top surface 116 may include a pilot ignition gas release button 120 which may release a flow of gas into the water heater when the user pushes the gas release button 120. When the user pushes the igniter button 122, a spark may be created inside the tank in the area where the gas is released into the tank released. This process may be used to light the pilot (not shown) in the water heater tank.
The gas valve 112 may also include an operations dial 124. The operations dial 124 may include settings which allow a user to operate in pilot-setting mode, main mode or off mode. In the pilot setting mode, the user may light the pilot for example, according to the process described above. After the pilot is standing, the user may switch the operation setting to main mode. The gas valve 112 may further include a temperature probe 126 for setting the temperature of the water in the tank responsive to the selected temperature of the temperature setting dial 118. According to another exemplary embodiment of the invention, a coupling element (not shown) may extend from a rear surface (not shown) of the gas valve 112 to the water heater tank (not shown) for coupling the gas valve 112 to the water heater tank. It is contemplated that the coupling element may surround or partially surround the temperature probe 126.
It is contemplated that exemplary gas valves may include other components for assisting with the operation of a water heater. It is also contemplated that exemplary igniter brackets may include only one mounting surface or more than the two mounting surfaces shown in
According to one exemplary embodiment of the invention, the igniter bracket 200 may be configured so that the vertical plane along a facing edge 208 of the first mounting surface 202 is angled less than ninety degrees from the first plane, occupied by the base surface 206. In turn, the igniter bracket 200 may be configured so that the vertical plane along a facing edge 210 of the second mounting surface 204 is angled less than ninety degrees from the first plane, occupied by the base surface 206. It is contemplated that the igniter bracket 200 may be configured so that the angles described above with respect to the first mounting surface 202 and the second mounting surface 204 are equal to each other. It is also contemplated that the igniter bracket 200 may be configured so that the angles described above with respect to the first mounting surface 202 and the second mounting surface 204 are not equal to each other. This configuration will be described in greater detail below with respect to
According to another exemplary embodiment of the invention, the first mounting surface 202 of the igniter bracket 200 may include a base edge 212. The facing edge 208 may extend from the base edge 212. The igniter bracket 200 may be configured so that the base edge 212 and the facing edge 208 together define an angle less than ninety degrees. In turn, the second mounting surface 204 of the igniter bracket 200 may include a base edge 214. The facing edge 210 may extend from the base edge 214. The igniter bracket 200 may be configured so that the base edge 214 and the facing edge 210 together define an angle less than ninety degrees. It is contemplated that the igniter bracket 200 may be configured so that the angles described above with respect to the first mounting surface 202 and the second mounting surface 204 are equal to each other. It is also contemplated that the igniter bracket 200 may be configured so that the angles described above with respect to the first mounting surface 202 and the second mounting surface 204 are not equal to each other. This configuration will be described in greater detail below with respect to
As shown in
According to one exemplary embodiment of the invention, an attachment surface may include a circular opening 222 configured to receive and secure an exemplary igniter (not shown) to be mounted to igniter bracket 200. According to another exemplary embodiment of the invention, an attachment surface may include a square opening 224 configured to receive and secure an exemplary igniter (not shown) to be mounted to igniter bracket 200. It is contemplated that an exemplary attachment surface may include an opening of any shape or size to receive and secure an exemplary igniter to be mounted to an exemplary igniter bracket. The configuration of openings will be described in greater below with respect to
According to another exemplary embodiment of the invention, the opening 222, which may be configured for receiving an exemplary igniter (not shown), may include a wall 226 extending from an edge of the opening 222. The exemplary wall 226 may be configured for securing the igniter when the igniter is mounted to igniter bracket 200. The exemplary wall 226 is also shown in
According to one exemplary embodiment of the invention, mounting surface 302 may include a circular opening 322 configured to receive and secure an exemplary igniter (not shown) to be mounted to igniter bracket 300. As shown in
According to another exemplary embodiment of the invention, mounting surface 302 may include a square opening 324 configured to receive and secure an exemplary igniter (not shown) to be mounted to igniter bracket 300. As described above, it is contemplated that an exemplary attachment surface may include an opening of any shape or size to receive and secure an exemplary igniter to be mounted to an exemplary igniter bracket.
As shown in
Truck clamps 414 or other lift or engagement mechanisms may be used for securing the water heater 400 so that the water heater 400 may be moved to a desired location. It is also contemplated that other means may be used for securing an exemplary water heater. The truck clamps 414 may move toward the packaging 412 and may exert a force onto the packaging 412 to the extent that the packaging 412 gives way. As a result, the clamps 414 may move to an area in the vicinity of the water heater 400, which may cause damage to components coupled to the water heater tank 402, including the igniter bracket 410. Potential damage to the igniter bracket may be decreased by angling the igniter bracket toward the water heater tank 402, as shown in
By configuring the igniter bracket so that the mounting axis of the igniter is moved away from the outermost surface of the gas valve (and toward the center of the water heater), the igniter and the bracket mounting portions are moved to a position of reduced incidence of damage. This orientation reduces the risk of damage to the water heater during shipment, storage, packaging, assembly, installation and use.
Although the invention is illustrated and described herein with reference to specific embodiments, the invention is not intended to be limited to the details shown. Rather, various modifications may be made in the details within the scope and range of equivalents of the claims and without departing from the invention.