Patent Application
20140144395
The present disclosure generally relates to valves and controllers for water heaters.
This section provides background information related to the present disclosure which is not necessarily prior art.
Water heater controllers are currently mounted to an immersion flange on or at the bottom of the water heater. Recently, water heaters moved to flammable vapor systems that have a sealed combustion system to prevent ignition of flammable vapors outside the water heater. The sealed system uses a burner door, through which the burner tube passes.
This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.
Exemplary embodiments are disclosed of valves and controllers for water heaters. Also disclosed are mounting methods for valves and controllers for water heaters. In an exemplary embodiment, a gas valve and controller of are mounted to and/or located at a burner door of a water heater.
Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure
Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.
Example embodiments will now be described more fully with reference to the accompanying drawings.
As mentioned above in the background, water heater controllers or controls are currently mounted to an immersion flange on or at the bottom of the water heater. The inventors hereof have realized that such immersion mounting methods of the valve and controller require an expensive brass or engineering polymer to achieve mounting strength (e.g., 300 pounds per square inch (psi) burst, etc.) and water leakage tightness (e.g., over 15 years, etc.). This is a potential failure point for some systems and adds costs to the tank to weld the flange mounting spud to the hole.
The inventors have also recognized that the user interface is forward facing (e.g., about 18 inches off the ground, etc.) which is not user friendly. For example, the user may be unable view the user interface when standing up and may need to bend down to view the user interface. This mounting arrangement is due to the legacy of water heaters being open burner systems.
After recognizing the above, the inventors developed and disclose herein exemplary embodiments in which certain components typically used in a standing storage gas fired water heater (e.g., the burner assembly, pilot light assembly, flame sense rod, ignition device (e.g., spark to pilot light, spark to main burner, or hot surface igniter, etc.), and the gas valve and controller if the system is microprocessor controlled, etc.) are mounted to a burner door or opening of a sealed combustion water heater.
In exemplary embodiments, the parts that pass through the sealed door into the combustion chamber are sealed. Exemplary embodiments may include a sealed door assembly in which a burner assembly, pilot light assembly, and flame sense rod may be mounted to the door of a sealed combustion water heater. By way of example, an exemplary embodiment may include a door assembly similar to that disclosed in U.S. Patent Application Publication US2010/0101510, U.S. Patent Application Publication US2010/0154724, U.S. Pat. No. 6,302,062, U.S. Pat. No. 6,439,171, and/or U.S. Pat. No. 6,554,610. Generally, these patent documents disclose various concepts of sealing the parts that pass through the sealed door into the combustion chamber. Significantly, aspects of the present disclosure may build upon and improve upon these concepts disclosed by adding a gas valve and controller to the components that may be typically fixed or mounted to the burner door.
In exemplary embodiments in which the gas valve and controller are also mounted or fixed to or at the burner door, this construction may necessitate the use of one or more surface mount temperature sensors to replace the immersion temperature sensors that are typically part of the tank mounted gas valves. In alternative embodiments, the temperature setting user interface (e.g., rotary switch, other switch, etc.) is located on the tank and connected to the surface mount sensor and also the main controller or control on the door.
With reference now to the figures,
As shown in
The water heater 100 also includes a temperature selection assembly or control comprising a rotatable knob 116 (broadly, a switch or temperature setting user interface), a dial 120, and printed circuit board 148. The rotary knob 116 allow a user to select or adjust the temperature setting or setpoint for the hot water in the storage tank. By way of example, the temperature selection control may comprise a potentiometer on a circuit board and an actuating knob/dial for temperature setting at a sensor location. The circuit board may be the same circuit board as the sensor circuit board or a separate circuit board. The knob may be a cover for a plastic mounting that also is a foam dam.
In this exemplary embodiment, the knob 116 is located towards a top of the water heater 100 such that the knob 116 will be at or close to the eye level of the user (e.g., between about 5½ feet and 6 feet above floor level, etc.). The knob 116 and dial 120 are closer to the top than the bottom of the water heater 100. Alternative embodiments may include different means for adjusting the temperature settings and/or at different locations. See, for example,
In
The gas valve and controller 104 includes a rotatable knob 132 (broadly, a switch) for selectively changing the operational status or settings of the water heater between OFF, PILOT, and ON (
An electrically conductive, electrically insulating barrier may be applied to the PCB 148 or to a second part installed between the thermistor and the storage tank wall. The PCB 148 may be positioned such that the temperature sensor is against the outer surface of the storage tank wall, to thereby provide surface temperature sensing.
The PCB 148 and temperature sensor thereof may be located at or adjacent the top, middle, or bottom of the water heater 100. Some embodiments include only one temperature sensor, while other embodiments may include two or more temperature sensors. For example, the temperature sensor of the PCB 148 and another temperature sensor may be located at or adjacent the respective top and bottom of the water heater 100, or vice versa. In which case, there is a first temperature sensor at or towards the bottom of the tank and a second temperature sensor at or towards the top of the tank.
Advantageously, mounting the gas valve and controller 104 to the burner door 108 may allow for the elimination of various costs associated with conventional mounting and immersion sensing. For example, costs associated with a conventional flange assembly, burner tube, Noryl plastic, threaded spud, knob/pot, and steel cover may be eliminated. Costs may be added to achieve surface sensing and to cover the burner door, such as costs associated with a harness, temperature sensor (T-sense) printed circuit board (PCB) and knob, T-sense PCB and cover, valve support bracket, and bottom cover.
As shown in
As shown in
The water heater 500 shown in
By way of example, the water heater may include only one surface mount temperature sensor if the temperature selection control shown in
Conventional immersion flange/spud mounting for water heater controls generally has three functions. First is to structurally mount the control system, second is to sense water temperature, and third is provide a water seal for the immersion sensing. These three functions may be addressed in exemplary embodiments disclosed herein as follows. The structural mounting of the control system is moved to the burner door area. The outlet of the valve is mounted to the pipe or burner tube exiting the burner door. Extra brackets or features may be used to support the valve when necessary. A housing or cover (e.g., plastic part, etc.) may be used to cover the burner door area that also allows integration of the valve control knobs, LEDs, and other user interface items on the top of the cover, such that a user is able to see these items from a standing position. A mirrored surface may be provided to allow a user to see the pilot light or burner status from a standing position. The sensing function may be achieved using surface mount sensors. The sensors may be mechanical, electrical, or a combination of both. Lastly, the seal function is no longer needed because the tank no longer needs a hole for immersion sensing when the sensing is accomplished using surface mount sensors.
Typically, a surface mount sensor system on a gas water heater will have two sensors, specifically one sensor at the bottom of the tank and one sensor at the top. A method of achieving this temperature sensing that has cost and customer usage benefits may be provided as follows in exemplary embodiments. An electrically conductive, electrically insulating barrier could be applied to a circuit board having an attached thermistor. Or, an electrically conductive, electrically insulating barrier may be applied to a second part installed between the thermistor and the tank wall. A PCB may be positioned such that the PCB temperature sensor (e.g., thermistor, etc.) is against an outer surface of the storage tank wall, to thereby provide surface temperature sensing. A housing (e.g., plastic, etc.) may cover the area in the outside tank jacket and spring load the temperature sensor against the tank wall. The housing (e.g., plastic part, etc.) may be snapped into the outside tank jacket or mounted by some other mechanical means to the tank jacket.
In an alternative embodiment, a first housing (e.g., plastic housing, etc.) may be used as an insulation foam dam to protect this area from the insulation process to allow field service. In this alternative construction, the first housing may not cover the hole or opening in the tank jacket. Instead, an additional or second cover may be used to fill the hole or opening in the outside tank jacket.
Additionally, a sensor/plastic mounting assembly may also use a potentiometer on a circuit board and an actuating knob/dial for temperature setting at a sensor location. An optimal or preferred location is at the top sensor. The circuit board could be the same circuit board as the sensor circuit board, or a separate circuit board. The knob could be a cover for a plastic mounting that also is a foam dam.
Exemplary embodiments disclosed herein may provide one or more (but not necessarily any or all) of the following advantages, such as differentiation in the market, more feasible methodology to integrate flammable vapor ignition resistant (FVIR) sensing, placement of the main user interaction at eye level, and/or hide or conceal the gas valve and related components from view. Also by way of example, attaching the valve and control system to the burner door area reduces costs associated with mounting and sealing the water heater control to the tank. It also allows for a cover to be mounted over the control system that would allow user information, including pilot light status and visuals, to be seen from a standing position. The thermistor mounting method allows for the use of a low cost circuit board mounted thermistor, and provides the means to move the temperature control interface to the top of the heater, where it is easily accessed and seen. Mounting the valve and control system to the burner door allows for the elimination of costs associated with the conventional mounting and immersion sensing, such as the costs associated with a conventional flange assembly, burner tube, Noryl plastic, threaded spud, knob/pot, and steel cover.
Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms, and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail. In addition, advantages and improvements that may be achieved with one or more exemplary embodiments of the present disclosure are provided for purpose of illustration only and do not limit the scope of the present disclosure, as exemplary embodiments disclosed herein may provide all or none of the above mentioned advantages and improvements and still fall within the scope of the present disclosure.
Specific dimensions, specific materials, and/or specific shapes disclosed herein are example in nature and do not limit the scope of the present disclosure. The disclosure herein of particular values and particular ranges of values for given parameters are not exclusive of other values and ranges of values that may be useful in one or more of the examples disclosed herein. Moreover, it is envisioned that any two particular values for a specific parameter stated herein may define the endpoints of a range of values that may be suitable for the given parameter (i.e., the disclosure of a first value and a second value for a given parameter can be interpreted as disclosing that any value between the first and second values could also be employed for the given parameter). For example, if Parameter X is exemplified herein to have value A and also exemplified to have value Z, it is envisioned that parameter X may have a range of values from about A to about Z. Similarly, it is envisioned that disclosure of two or more ranges of values for a parameter (whether such ranges are nested, overlapping or distinct) subsume all possible combination of ranges for the value that might be claimed using endpoints of the disclosed ranges. For example, if parameter X is exemplified herein to have values in the range of 1-10, or 2-9, or 3-8, it is also envisioned that Parameter X may have other ranges of values including 1-9, 1-8, 1-3, 1-2, 2-10, 2-8, 2-3, 3-10, and 3-9.
The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.
When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
The term “about” when applied to values indicates that the calculation or the measurement allows some slight imprecision in the value (with some approach to exactness in the value; approximately or reasonably close to the value; nearly). If, for some reason, the imprecision provided by “about” is not otherwise understood in the art with this ordinary meaning, then “about” as used herein indicates at least variations that may arise from ordinary methods of measuring or using such parameters. For example, the terms “generally,” “about,” and “substantially,” may be used herein to mean within manufacturing tolerances.
Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.
Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.
The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements, intended or stated uses, or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.
This application claims the benefit of U.S. Provisional Application No. 61/730,484 filed Nov. 27, 2012. The entire disclosure of the above application is incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 61730484 | Nov 2012 | US |
