U.S. patent application number 11/393462 was filed with the patent office on 2007-10-04 for apparatus and method for introducing and drawing water in a water heater.
This patent application is currently assigned to Bradford White Corporation. Invention is credited to Wade Bernreuter, Michael Gordon, Ryan Ritsema.
Application Number | 20070227468 11/393462 |
Document ID | / |
Family ID | 38261500 |
Filed Date | 2007-10-04 |
United States Patent
Application |
20070227468 |
Kind Code |
A1 |
Gordon; Michael ; et
al. |
October 4, 2007 |
Apparatus and method for introducing and drawing water in a water
heater
Abstract
A water heater having a water storage tank an inlet conduit and
an outlet conduit is provided. The inlet conduit has a top end
portion coupled to an inlet of the water storage tank, a bottom end
portion extending into an interior of the water storage tank, and a
passage for water flow from the top end portion to the bottom end
portion. The top end portion of the inlet conduit defines at least
one outlet opening configured to divert a portion of the water flow
from the passage of the inlet conduit into the water storage tank.
The outlet conduit defines a top end portion coupled to an outlet
of the water storage tank, a bottom end portion extending into an
interior of the water storage tank, and a passage for water flow
from the bottom end portion to the top end portion. The top end
portion of the outlet conduit defines at least one inlet opening
configured to draw water from the water storage tank and into the
passage in the top end portion of the outlet conduit. The bottom
end portion of the outlet conduit defines an inlet opening
configured to draw water from the water storage tank and into the
passage in the bottom end portion of the outlet conduit.
Inventors: |
Gordon; Michael; (East Grand
Rapids, MI) ; Bernreuter; Wade; (Lowell, MI) ;
Ritsema; Ryan; (Middleville, MI) |
Correspondence
Address: |
RATNERPRESTIA
P O BOX 980
VALLEY FORGE
PA
19482-0980
US
|
Assignee: |
Bradford White Corporation
|
Family ID: |
38261500 |
Appl. No.: |
11/393462 |
Filed: |
March 30, 2006 |
Current U.S.
Class: |
122/13.01 |
Current CPC
Class: |
Y02E 60/142 20130101;
F24H 1/18 20130101; F28D 20/0034 20130101; F24H 9/124 20130101;
F24D 19/0092 20130101; Y02E 60/14 20130101 |
Class at
Publication: |
122/013.01 |
International
Class: |
F24H 1/00 20060101
F24H001/00 |
Claims
1. A water heater comprising: a water storage tank; an inlet
conduit having a top end portion coupled to an inlet of said water
storage tank, a bottom end portion extending into an interior of
said water storage tank, and a passage for water flow from said top
end portion to said bottom end portion, said top end portion of
said inlet conduit defining at least one outlet opening configured
to divert a portion of the water flow from said passage of said
inlet conduit into said water storage tank; and an outlet conduit
having a top end portion coupled to an outlet of the water storage
tank, a bottom end portion extending into an interior of the water
storage tank, and a passage for water flow from said bottom end
portion to said top end portion, said top end portion of said
outlet conduit defining at least one inlet opening configured to
draw water from said water storage tank and into said passage in
said top end portion of said outlet conduit, and said bottom end
portion of said outlet conduit defining an inlet opening configured
to draw water from said water storage tank and into said passage in
said bottom end portion of said outlet conduit.
2. The water heater of claim 1 further comprising a plurality of
outlet openings defined in said top end portion of said inlet
conduit.
3. The water heater of claim 2, said outlet openings being arranged
in a common radial plane.
4. The water heater of claim 3 wherein said outlet openings are
arranged in a plurality of common radial planes.
5. The water heater of claim 1, said inlet conduit additionally
defining at least one inlet opening configured to draw water from
said water storage tank into said passage in said top end portion
of said inlet conduit.
6. The water heater of claim 5 further comprising a plurality of
inlet openings defined in said top end portion of said inlet
conduit.
7. The water heater of claim 6 wherein said inlet openings are
arranged in a common radial plane.
8. The water heater of claim 7, said inlet openings being arranged
in a plurality of common radial planes.
9. The water heater of claim 1, wherein said outlet opening is in
the form of a notch formed in said conduit extending into said
passage of said inlet conduit.
10. A method for reducing the stratification of water within a
water heater, said method comprising the steps of: diverting a
portion of inlet water flow from a top end portion of an inlet
conduit and into a top interior segment of the water heater;
delivering water from a bottom end portion of the inlet conduit and
into the water heater; drawing water from the water heater and into
a bottom end portion of an outlet conduit; and drawing water from
the top interior segment of the water heater and into the top end
portion of the outlet conduit.
11. The method of claim 10 further comprising the step of drawing
water from the top interior segment of a water heater and into said
top end portion of said inlet conduit.
12. The method of claim 10 further comprising the step of drawing
water from a bottom interior segment of a water heater and into
said bottom end portion of said inlet conduit.
13. The method of claim 10 further comprising the step of diverting
a portion of the water flow from the passage of the inlet conduit
and into a bottom interior segment of the water heater through an
outlet opening spaced from the bottom end portion of the inlet
conduit.
14. An electric water heater comprising: a water storage tank; at
least two heating elements extending into an interior of said water
storage tank, wherein a top heating element is positioned above a
bottom heating element; and an outlet conduit having a top end
mounted to said water storage tank and a bottom end extending into
said interior of said water storage tank, said bottom end of said
outlet conduit extending to a predetermined elevation with respect
to that of said heating elements.
15. The electric water heater of claim 14, wherein said bottom end
of said outlet conduit extends to an elevation corresponding to a
volume of at least 11 gallons of water above the elevation of said
bottom heating element.
16. The electric water heater of claim 14, said bottom end of said
outlet conduit extending to an elevation below that of said bottom
heating element.
17. The electric water heater of claim 14 wherein said outlet
conduit provides an inlet opening proximal said top end for drawing
water into said outlet conduit from the water storage tank.
18. An outlet configured for use in a water storage tank of a water
heater, said outlet comprising: an outlet conduit having a top end
portion configured to be coupled to an outlet of the water storage
tank, a bottom end portion configured to extend into an interior of
the water storage tank, a passage for water flow from said bottom
end portion to said top end portion, and an inlet opening at a
bottom end of said outlet conduit; and means located at said top
end portion of said outlet conduit for drawing water into said
passage from the water storage tank.
19. The outlet of claim 18, said water drawing means comprising at
least one inlet opening configured to draw water into said passage
in said top end portion of said outlet conduit.
20. A method for withdrawing water from a water heater comprising
the steps of: drawing water into a passage of an outlet conduit
from the water heater through an inlet opening defined in a bottom
end portion of the outlet conduit; drawing water into the passage
of the outlet conduit from the water heater through at least one
inlet opening defined in a top end portion of the outlet conduit;
and withdrawing water from the water heater through the passage of
the outlet conduit.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to a water heater and more
particularly an apparatus and method for introducing and drawing
water in a water heater.
BACKGROUND OF THE INVENTION
[0002] There is a continuing need to further improve the thermal
efficiency of conventional water heaters, as thermal efficiency
improvements facilitate energy conservation and represent cost
savings to the end user. In an effort to improve thermal
efficiency, it is generally beneficial to maintain a substantially
uniform water temperature within the water heater tank. However,
the water temperature tends to be cooler near the bottom of the
water heater tank and rises as the water level approaches the top
of the water heater tank. In other words, as a result of thermal
currents within the water heater, the thermal energy is driven
towards the top of the water heater tank. This phenomena, commonly
known as stacking or thermal stratification, has an adverse impact
on the energy efficiency of a water heater.
[0003] Thermal stratification within a water heater tank decreases
a water heater's First-Hour rating, which is a measure of the
volume of hot water a water heater can supply in a one-hour time
period. The First-Hour rating is an industry-wide indicator used to
establish the thermal efficiency of a water heater. Water Heater
manufacturers continually strive to increase the First-Hour
rating.
[0004] Improvements have been made in this regard. For example,
improved water heater systems are disclosed in U.S. Pat. No.
5,341,770, which illustrates a water heater cold water inlet
deflector means which can create turbulent flow within the inlet
conduit and create turbulent water circulation throughout the water
storage tank so that sediment is disturbed and suspended, stacking
is prevented and efficiency is improved.
[0005] Nevertheless, there continues to be a need to further reduce
thermal stratification within a water heater tank to improve the
thermal efficiency of water heaters and/or to reduce the impact of
any such thermal stratification.
SUMMARY OF THE INVENTION
[0006] In an exemplary embodiment, this invention provides a water
heater having a water storage tank and an inlet conduit having a
top end portion coupled to an inlet of the water storage tank, a
bottom end portion extending into an interior of the water storage
tank, and a passage for water flow from the top end portion to the
bottom end portion. The top end portion of the inlet conduit
defines at least one outlet opening configured to divert a portion
of the water flow from the passage of the inlet conduit into the
water storage tank. The outlet conduit defines a top end portion
coupled to an outlet of the water storage tank, a bottom end
portion extending into an interior of the water storage tank, and a
passage for water flow from the bottom end portion to the top end
portion. The top end portion of the outlet conduit defines at least
one inlet opening configured to draw water from the water storage
tank and into the passage in the top end portion of the outlet
conduit. The bottom end portion of the outlet conduit defines an
inlet opening configured to draw water from the water storage tank
and into the passage in the bottom end portion of the outlet
conduit.
[0007] In another exemplary embodiment, this invention provides a
method for reducing the stratification of water within a water
heater. The method includes the step of diverting a portion of
inlet water flow from a top end portion of an inlet conduit and
into a top interior segment of the water heater. The method further
includes the steps of delivering water from a bottom end portion of
the inlet conduit and into the water heater, drawing water from the
water heater and into a bottom end portion of an outlet conduit and
drawing water from the top interior segment of the water heater and
into the top end portion of the outlet conduit.
[0008] In yet another exemplary embodiment, this invention provides
an outlet configured for use in a water storage tank of a water
heater. The outlet comprises an outlet conduit having a top end
portion configured to be coupled to an outlet of the water storage
tank, a bottom end portion configured to extend into an interior of
the water storage tank, a passage for water flow from the bottom
end portion to the top end portion and an inlet opening at a bottom
end of the outlet conduit. The outlet further comprises means
located at the top end portion of the outlet conduit for drawing
water into the passage from the water storage tank.
[0009] In still another exemplary embodiment, this invention
provides a method for withdrawing water from a water heater. The
method includes the step of drawing water into a passage of an
outlet conduit from the water heater through an inlet opening
defined in a bottom end portion of the outlet conduit. The method
further includes the steps of drawing water into the passage of the
outlet conduit from the water heater through at least one inlet
opening defined in a top end portion of the outlet conduit and
withdrawing water from the water heater through the passage of the
outlet conduit.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a schematic view of an embodiment of a water
heater illustrating exemplary water flow patterns according to
aspects of this invention;
[0011] FIG. 2 is a cross-sectional side view of a gas-fired water
heater in accordance with an exemplary embodiment of the present
invention;
[0012] FIG. 3A is a cross-sectional side view of an electric water
heater in accordance with an exemplary embodiment of the present
invention;
[0013] FIG. 3B is a cross-sectional side view of another exemplary
embodiment of an electric water heater according to aspects of this
invention;
[0014] FIG. 4 is a side view of an embodiment of an inlet conduit
in accordance with aspects of the present invention;
[0015] FIG. 5 is a cross-sectional view of one exemplary embodiment
of an inlet opening shown in FIG. 4 as defined by Section
"5-5";
[0016] FIG. 6 is a cross-sectional view of one exemplary embodiment
of an outlet opening shown in FIG. 4 as defined by Section
"6-6";
[0017] FIG. 7 is a detailed side view of an outlet opening of the
inlet conduit shown in FIG. 6;
[0018] FIG. 8 is a detailed side view of an inlet opening of the
inlet conduit shown in FIG. 5;
[0019] FIG. 9 is a side view of an embodiment of an outlet conduit
in accordance with an aspect of the present invention;
[0020] FIG. 10 is a top end view of an embodiment of an outlet
conduit cap in accordance with an aspect of the present invention;
and
[0021] FIG. 11 is a cross-sectional side view of the outlet conduit
cap shown in FIG. 10 as defined by Section "11-11".
DETAILED DESCRIPTION OF THE INVENTION
[0022] 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 to the illustrated embodiments within the
scope and range of equivalents of the claims and without departing
from the invention. Also, the embodiments selected for illustration
in the figures are not shown to scale and are not limited to the
proportions shown.
[0023] With general reference to the figures, in an exemplary
embodiment this invention provides a water heater 10, 10a, 110, 210
having a water storage tank 11, 111, 211 and an inlet conduit 30,
130, 230 having a top end portion 5a, 105a coupled to an inlet 28,
128 of the water storage tank, a bottom end portion 5b, 105b
extending into an interior of the water storage tank, and a passage
for water flow from the top end portion to the bottom end portion.
The top end portion 5a, 105a of the inlet conduit 30, 130, 230
defines at least one outlet opening 34, 134 configured to divert a
portion of the water flow from the passage of the inlet conduit
into the water storage tank. The outlet conduit 32, 132, 232
defines a top end portion 12a coupled to an outlet 29, 129 of the
water storage tank, a bottom end portion 12b extending into an
interior of the water storage tank, and a passage for water flow
from the bottom end portion to the top end portion. The top end
portion 12a of the outlet conduit 32, 132, 232 defines at least one
inlet opening 63, 163 configured to draw water from the water
storage tank and into the passage in the top end portion of the
outlet conduit. The bottom end portion 12b of the outlet conduit
32, 132, 232 defines an inlet opening 36, 136, 236 configured to
draw water from the water storage tank and into the passage in the
bottom end portion of the outlet conduit.
[0024] In another exemplary embodiment, this invention provides a
method for reducing the stratification of water within a water
heater 10, 10a, 110, 210. The method includes the step of diverting
a portion of inlet water flow from a top end portion 5a, 105a of an
inlet conduit 30, 130, 230 and into a top interior segment 59 of
the water heater 10, 10a, 110, 210. The method further includes the
steps of delivering water from a bottom end portion 5b, 105b of the
inlet conduit 30, 130, 230 and into the water heater 10, 10a, 110,
210, drawing water from the water heater and into a bottom end
portion 12b of an outlet conduit 32, 132, 232 and drawing water
from the top interior segment 59 of the water heater and into the
top end portion 12a of the outlet conduit 32, 132, 232.
[0025] In yet another exemplary embodiment, this invention provides
an outlet configured for use in a water storage tank 11, 111, 211
of a water heater 10, 10a, 110, 210. The outlet comprises an outlet
conduit 32, 132, 232 having a top end portion 12a configured to be
coupled to an outlet 29, 129 of the water storage tank 11, 111,
211, a bottom end portion 12b configured to extend into an interior
of the water storage tank 11, 111, 211, a passage for water flow
from the bottom end portion to the top end portion and an inlet
opening 36, 136 at a bottom end of the outlet conduit. The outlet
further comprises means located at the top end portion 12a of the
outlet conduit 32, 132, 232 for drawing water into the passage from
the water storage tank 11, 111, 211.
[0026] In still another exemplary embodiment, this invention
provides a method for withdrawing water from a water heater 10,
10a, 110, 210. The method includes the step of drawing water into a
passage of an outlet conduit 32, 132, 232 from the water heater
through an inlet opening 36, 136 defined in a bottom end portion
12b of the outlet conduit. The method further includes the steps of
drawing water into the passage of the outlet conduit from the water
heater through at least one inlet opening 63, 163 defined in a top
end portion 12a of the outlet conduit 32, 132, 232 and withdrawing
water from the water heater through the passage of the outlet
conduit.
[0027] In one exemplary embodiment, FIG. 1 illustrates
schematically the flow of water through a water heater designated
generally by the numeral "10". The water heater 10 is provided with
a water tank 11, an inlet conduit 30 and an outlet conduit 32. The
water tank 11, having a top end portion or region 59 and a bottom
end portion or region 60, is configured to store water (or any
other fluid), and is provided with a tank head 17 and tank base 13.
The inlet conduit 30 is connected to the tank head 17 and extends
into the interior of the water tank 11. The outlet conduit 32 is
also connected to the tank head 17 and extends into the interior of
the water tank 11. The inlet conduit 30 has a top end portion 5a
and a bottom end portion 5b. The outlet conduit 32 also has a top
end portion 12a and bottom end portion 12b.
[0028] In use, a supply of unheated or cold water 40 is introduced
into the inlet conduit 30 and directed through the top end portion
5a of the inlet conduit 30. The top end portion 5a of the inlet
conduit 30 is provided with means to divert a portion of the cold
water flow from the inlet conduit 30 into the top end portion 59 of
water tank 11 (the diverted flow is designated schematically by the
numeral 42 in FIG. 1). The cold water flow 42 diverted from the
inlet conduit 30 is mixed with the warmer water residing in the top
end portion 59 of the water tank 11, thereby moderating or
decreasing the temperature of the water in the top end portion 59
of the water tank 11. The means to divert water flow can be
selected from a variety of known structures capable of diverting
fluid flow.
[0029] The top end portion 5a of the inlet conduit 30 is
additionally provided with means to draw a portion of the water
stored within the top end portion 59 of the water tank 11 into the
top end portion 5a of the inlet conduit 30 (the siphoned water flow
schematically designated by the numeral 47). The water drawn from
the top end portion 59 of the water tank 11 is mixed with the
cooler water in the top end portion 5a of the inlet conduit 30,
thereby increasing or tempering the temperature of the water in the
top end portion 5a of the inlet conduit 30 as it flows into the
water tank 11 from the inlet. The means to draw water can be
selected from a variety of known structures capable of drawing
fluid.
[0030] Accordingly, it has been discovered that the means for
diverting and means for drawing water positioned at the top end
portion 5a of the inlet conduit 30 provide several advantages. The
cool water flow 42 diverted into the top end portion 59 of the
water tank 11 combined with the warmer water flow 47 siphoned into
the top end portion 5a of the inlet conduit 30 help to reduce
thermal stratification to provide a more uniform temperature of the
water within the water tank 11. The hottest water in the top end
portion 59 of water tank 11 is tempered with the inclusion of
cooler water diverted from the top end portion 5a of the inlet
conduit 30. Furthermore, the coolest water in the bottom end
portion 60 of water tank 11 is tempered with the inclusion of
warmer water drawn from the top end portion 59 of the water tank 11
through the inlet conduit 30.
[0031] Alternatively, means for diverting and means for drawing
water positioned at the bottom end portion 5b of the inlet conduit
30 provide a different benefit than the means for diverting and
drawing water positioned at the top end portion 5a of the inlet
conduit 30, as described in further detail below.
[0032] In use, the bottom end portion 5b of the inlet conduit 30 is
provided with means to divert a portion of the water flow from the
inlet conduit 30 and into the bottom end portion 60 of water tank
11 (the diverted flow is designated schematically by the numeral
46). The water diverted at 46 from the inlet conduit 30 increases
mixing of the water residing at the bottom end portion 60 of the
water tank 11. Such mixing tends to improve the uniformity of
temperature within the water tank 11.
[0033] Additionally, the water flow 46 diverted from the bottom end
portion 5b of the inlet conduit 30, combined with the water flow 48
siphoned into the bottom end portion 5b of the inlet conduit 30
(described below), induces turbulent conditions within the bottom
end portion 60 of the water tank 11. As described by Lannes in U.S.
Pat. No. 5,341,770, which is herein incorporated by reference in
its entirety, turbulent flow reduces the buildup of sediment on the
inside surfaces of the water tank 11, particularly sediment
accumulated on the tank base 13 of the water tank 11.
[0034] The bottom end portion 5b of the inlet conduit 30 is
additionally provided with means to draw a portion of the water
stored within the bottom end portion 60 of the water tank 11 into
the passage of the inlet conduit 30 (the siphoned water flow
designated schematically by the numeral 48). The water flow drawn
into the bottom end portion 5b of the inlet conduit 30 is mixed
with the water flowing through the bottom end portion 5b of the
inlet conduit 30.
[0035] The remaining flow of water through the inlet conduit 30 is
introduced into the bottom end portion 60 of the water tank 11 (the
flow designated schematically by the numeral 50). In other words,
the sum of flows 40, 47, and 48, minus the flows 42 and 46, exits
the inlet 30 as flow 50. Put differently, the sum of flows 40, 47,
and 48 will equal the sum of flows 42, 46, and 50.
[0036] The outlet conduit 32 permits withdrawal of heated water
from the water tank 11 (e.g., for domestic use or consumption). The
bottom end portion 12b of the outlet conduit 32 is provided with at
least one opening to draw a portion of the water stored within the
water tank 11. By virtue of the elongated outlet conduit 32 of this
embodiment, the opening in the bottom end portion 12b draws water
from a lower elevation of the water tank 11 and can therefore draw
water that may be in a cooler region of the water tank 11. For
example, according to one particular embodiment, the bottom end
portion 12b of the outlet conduit 32 optionally extends into the
bottom end portion 60 of the water tank 11.
[0037] Independent of the length selected for the outlet conduit
32, and independent of whether the outlet conduit 32 extends into
the bottom end portion 60 of the water tank 11, the bottom end
portion 12b of the outlet conduit 32 preferably includes an opening
for water to enter the outlet conduit 32 from the water tank 11
(the siphoned water flow designated schematically by the numeral
52). That water flow forms part of the water flow delivered to the
consumer of the heated water.
[0038] The top end portion 12a of the outlet conduit 32 is also
provided with at least one opening to draw a portion of the water
stored within the top end portion 59 of the water tank 11 (the
siphoned water flow designated schematically by the numeral 54).
The water flow 54 drawn into the top end portion 12a of the outlet
conduit 32 is mixed with the cooler water flow drawn from the
bottom end portion 12b of the outlet conduit 32 from the water tank
11.
[0039] It will be understood, therefore, that the water drawn from
the outlet of the water heater 10 at 56 is a mixture of water drawn
from at least two different elevations within the water tank 11.
The water at these elevations tends to be at different temperatures
as the result of natural thermal principles. Therefore, the
temperature of the water drawn at 56 will be between the
temperatures of the water drawn at 52 and that drawn at 54. Also,
it will be understood that the volumetric flow of water drawn at 56
will be the sum of the water drawn at 52 and 54.
[0040] Referring to FIG. 2, the gas water heater 10a has a water
tank 11 with a tank head 17 and tank base 13. Water heater 10a is
similar to water heater 10 illustrated in FIG. 1 except for the
differences pointed out in the following paragraphs.
[0041] A cold water inlet port 28 and a hot water outlet port 29
are extended from the tank head 17 for the delivery and withdrawal
of water from the water heater 10a. The cold water inlet port 28
may optionally have a heat trap or nipple fitting. An inlet conduit
30 having a top end portion 5a and a bottom end portion 5b is
attached at the cold water inlet port 28. The top end portion 5a of
the inlet conduit includes at least one outlet and at least one
inlet for flow out of and into the inlet conduit, respectively, as
illustrated schematically in FIG. 2 by the arrows. For example, and
according to one non-limiting embodiment of the inlets and outlets,
the embodiment of FIG. 2 illustrates diverting means comprising
plural outlets in the form of smile shaped notches 34 and drawing
means comprising plural inlets in the form of frown shaped notches
44. Other forms of diverting and drawing means are optionally
substituted.
[0042] The smile shaped notches 34 are provided as a means to
divert a portion of the cold water flow from the inlet conduit 30
into the top end portion 59 of water tank 11. While smile shaped
notches 34 provide one means for diverting water flow from the
inlet conduit, other equivalent means are contemplated. For
example, the water diverting means can be one or more aperture,
hole, opening, slot, nozzle, valve, projection, dimple, slit, lip,
channel, fin, groove, surface or other equivalent structure capable
of diverting or otherwise permitting the flow of water from within
a fluid passage to an interior region of a water tank.
[0043] The frown shaped notches 44 are provided as a means to draw
a portion of the water stored within the top end portion 59 of the
water tank 11 into the top end portion 5a of the inlet conduit 30.
While frown shaped notches 44 provide one means for drawing water
into the inlet conduit, other equivalent means are contemplated.
For example, the water drawing means can be one or more aperture,
hole, opening, slot, nozzle, valve, projection, dimple, slit, lip,
channel, fin, groove, surface or other equivalent structure capable
of drawing or otherwise permitting the flow of water from within an
interior region of a water tank to a fluid passage.
[0044] The outlet conduit 32 having a top end portion 12a and
bottom end portion 12b is attached at the hot water outlet port 29.
The outlet conduit 32 is provided with an opening 36 at a bottom
end of the outlet conduit 32 so that water from within the water
tank 11 can be drawn into the outlet conduit 32. In the embodiment
illustrated in FIG. 2, the opening 36 of the outlet conduit 32 is
positioned to draw water from a bottom interior region 60 of the
water tank 11.
[0045] In order to reduce the size of the opening 36 (e.g., to make
opening 36 smaller than the inside cross-sectional area of the
outlet conduit 32), the outlet conduit 32 is provided with a cap
71. Details of an exemplary cap 71 are shown in FIGS. 10 and 11.
Instead of cap 71, however, other means can be used to define the
size of the opening 36. For example, the size of the opening can be
defined by a plug with an aperture, a reducer, a necked-down
portion of the outlet conduit or any equivalent structure capable
of impacting the size of the orifice in the bottom end of the
outlet conduit 32.
[0046] The outlet conduit 32 also provides at least one opening 63
in a top end portion 12a of the outlet conduit 32. The opening 63
allows water to be drawn into the top end portion 12a of the outlet
conduit 32 from the top interior segment 59 of the water tank 11.
The opening 63 is positioned to draw water from a region of the
water tank 11 where the water temperature tends to be higher by
action of thermal effects within the water tank 11.
[0047] Referring to another embodiment of a water heater
illustrated in FIG. 3a, the inlet conduit and outlet conduit are
additionally adapted for operation with an electric water heater.
In this illustrated embodiment, an electric water heater 110 has a
water tank 111 including a tank head 117 and a tank base 113. At
least two heating elements 135 and 135' extend through a wall of
the water tank 111 providing heat to the internal water contained
within the water tank 111. A top heating element 135 is positioned
above a bottom heating element 135'. An inlet conduit 130 is
attached at a cold water inlet port 128 of the water heater 110. An
outlet conduit 132 is attached at a hot water outlet port 129 of
the water heater 110.
[0048] To enhance the first hour rating, the inlet end 136 of the
outlet conduit 132 is configured to extend to an elevation below
that of a lower portion 139' of the bottom heating element 135', as
designated by dimension "B". The dimension "B" optionally
corresponds to a distance greater than or equal to about 1 inch. By
providing the outlet conduit 132 with a length such that the inlet
end 136 is below the heating element 135, the outlet conduit 132
will draw water from the water tank 111 at an elevation below the
bottom heating element 135'. However, the efficiency (according to
a standard use test) of the water heater may be diminished since
the inlet end 136 draws water from the relatively cooler lower
region of tank 111.
[0049] Similar to the water heater embodiment illustrated in FIG.
2, the water heater 110 shown in FIG. 3a includes a water inlet
conduit 130 having water outlets and inlets in the form of notches
134 and 144, respectively, in a top end portion 105a of the inlet
conduit 130. Also, the inlet conduit 130 includes water outlets and
inlets in the form of notches 134 and 144, respectively, in a
bottom end portion 105b of the inlet conduit 130. The purpose and
function of these inlet and outlet openings in the inlet conduit
130 are the same as those described previously with reference to
FIG. 2.
[0050] Referring to FIG. 3b, an alternate embodiment of an electric
water heater, generally designated by the numeral 210, is
illustrated. As in water heater 110, an outlet conduit 232 attached
to the electric water heater 210 is shown. Unlike the water heater
110, the inlet end 236 of the outlet conduit 232 is configured to
extend to an elevation between the heating elements 235 and 235'.
As illustrated in FIG. 3b, the distance separating the inlet end
236 of the outlet conduit 232 and the lower end 239' of the bottom
heating element 235' is designated by dimension "A". The dimension
"A" optionally corresponds to a volume of water, or other fluid, of
at least about 11 gallons in the water heater 210. In other words,
the volume of water contained in the water heater 210 between the
elevation of the lower portion 239' of the heating element 235' and
the end opening 236 of the outlet conduit 232 is at least about 11
gallons, so long as the inlet end 236 of the outlet conduit 232 is
positioned below the top heating element 235. It has been
discovered that both the first hour rating and efficiency
(according to a standard use test) of the water heater are
optimized in this configuration of the electric water heater
210.
[0051] Referring now to FIGS. 4 through 8, details of an exemplary
embodiment of inlet conduit 30 are illustrated. Specifically, FIG.
4 illustrates an inlet conduit 30 comprising a tube 70, a nipple 67
attached to the tube 70, a top end portion 5a and a bottom end
portion 5b. The top end portion 5a of the inlet conduit 30 provides
smile shaped notches 34 and frown shaped notches 44. The smile
shaped notches 34 are provided as a means to divert a portion of
the cold water flow from the inlet conduit 30 into the top end
portion 59 of water tank 11. The frown shaped notches 44 are
provided as a means to draw a portion of the water stored within
the top end portion 59 of the water tank 11 into the top end
portion 5a of the inlet conduit 30. The bottom end 74 of the inlet
conduit 30 is configured to expel the remaining flow of water from
within the inlet conduit 30 into the bottom end portion 60 of the
water tank 11.
[0052] The smile and frown shaped notches positioned at the top end
portion 5a of the inlet conduit 30 reduce thermal stratification to
provide a more uniform water temperature within the water tank 11
and help to compensate for the thermal effects that occur within
the water tank 11. These features are described in further detail
below. The smile and frown shaped notches positioned at the bottom
end portion 5b of the inlet conduit 30, which induce turbulent
water flow within the bottom end portion 60 of the water tank 11,
can adopt structures such as those disclosed in Lannes in U.S. Pat.
No. 5,341,770, which is incorporated herein by reference.
[0053] In the embodiment illustrated in FIGS. 4 through 8, three
smile shaped notches 34 are formed on the top end portion 5a of the
inlet conduit 30. The three smile shaped notches are positioned on
the same radial plane and are separated by a distance "A" from the
frown shaped notches 44. Although a single radial plane of three
smile shape notches 34 is shown, a plurality of radial planes each
comprising an alternative number of smile shape notches 34 is
envisioned. The dimension "A" separating the smile shaped notches
34 from the frown shaped notches 44 may be about 11/2 inches, but
may be any other larger or smaller dimension as long as the smile
shaped notches 34 are positioned along the top end portion 5a of
the inlet conduit. The angle "C" separating the three smile shaped
notches positioned on their respective radial plane may be, for
example, 120 degrees, however the angle may be any other larger or
smaller angle sufficient to draw water from within the water tank
11. The angle "C" is also dependent upon the number of notches in
each plane and other design factors.
[0054] Three frown shaped notches 44 are formed on the top end
portion 5a of the inlet conduit tube 70 proximal to the nipple 67.
The frown shaped notches are positioned on the same radial plane
separated by a distance "B" from smile shaped notches 34 positioned
on the bottom end portion 5b of the inlet conduit 30. Although the
three frown shape notches 44 are positioned on a single radial
plane as illustrated in FIG. 4, a plurality of radial planes each
comprising an alternative number of frown shape notches 44 are
envisioned. The dimension "B" separating the frown shaped notches
44 positioned along the top end portion 5a from the smile shaped
notches 34 positioned along the bottom end portion 5b of the inlet
conduit 30 may be about 8 inches, but may be any other larger or
smaller dimension providing the frown shaped notches 44 are
positioned along the top end portion 5a of the inlet conduit 30.
The angle "C" separating the three frown shaped notches positioned
on the radial plane may be, for example, 120 degrees, however the
angle may be any other larger or smaller dimension sufficient to
divert water (or other fluid) from the inlet conduit 30 and into
the top end portion 59 of the water tank 11. Although the frown
shaped notches 44 and smile shaped notches 34 are shown radially
aligned along longitudinal axis "E", it is envisioned that the
notches may be radially misaligned or staggered to alter the flow
of water through the inlet conduit 30.
[0055] The bottom end portion 5b of the inlet conduit 30
additionally provides smile shaped notches 34 and frown shaped
notches 44. The smile shaped notches 34 are provided as one
exemplary form of a means to divert a portion of the cold water
flow from the inlet conduit 30 and into the bottom end portion 60
of water tank 11. The frown shaped notches 44 are provided as a
means to draw a portion of the water stored within the bottom end
portion 60 of the water tank 11 and into the bottom end portion 5b
of the inlet conduit 30. The smile and frown shaped notches
positioned at the bottom end portion 5b of the inlet conduit 30 are
provided to induce or promote turbulent water flow within the
bottom end portion 60 of the water tank 11.
[0056] A nipple 67 is attached to the top end portion 5a of the
inlet conduit 30. A surface of the nipple 67 is optionally welded
onto the top end portion 5a of the inlet conduit 30 depending upon
the materials selected. However, the nipple 67 may be attached to
the top end portion 5a via fasteners, a press fit, a rolled groove,
high-temperature waterproof adhesive or any other suitable means of
securing the components, as the attachment is not limited to welds.
The nipple 67 may be a separate component from the inlet conduit 30
as shown or, alternatively, the nipple 67 could be integrated with
the inlet conduit 30. The bottom end portion 69 of the nipple 67 is
threaded into the cold water inlet port 28. The top end portion 68
of the nipple 67 is attached to an external pipe or tube, not
shown. The nipple 67 according to one exemplary embodiment is
composed of a metallic material such as zinc plated steel. However,
the nipple 67 may be composed of stainless steel, copper, plastic
or any other suitable material.
[0057] The inner diameter "D" of the inlet conduit tube 70 may be
increased or decreased to tailor the velocity and pressure of the
flow of water through the inlet conduit tube 70. For example, the
inner diameter "D" may be about 0.6 inch, however the inner
diameter "D" may be any other larger or smaller dimension
sufficient to transport water through the inlet conduit tube 70.
The inlet conduit tube 70 is shown in tubular form, however other
embodiments such as a square, rectangular, or any other
cross-sectional shape can be utilized to transport liquid and are
envisioned within the scope of this invention.
[0058] The inlet conduit tube 70 may be composed of polypropylene,
stainless steel, copper, or any other suitable plastic or metallic
material. The inlet conduit tube 70 may be formed using any
suitable manufacturing process such as injection molding, casting,
machining, stamping, or extrusion, or any combination thereof.
[0059] FIG. 5 illustrates a cross-sectional view of a frown shaped
notch 44. The frown shaped notch 44 is optionally a molded feature
integrated with the inlet conduit tube 70. However, other
manufacturing methods to form the frown shaped notches 44 are
envisioned, such as stamping, punching or any other forming method
capable of displacing the inlet conduit tube 70 material.
Alternatively, it is envisioned that the frown shaped notches 44
may be discrete components coupled to the exterior or interior of
the inlet conduit tube 70.
[0060] The gap "A1", deflected height "B1" and the angle "C1" of
the frown shaped notch 44, as illustrated in FIG. 5, may be any
dimension sufficient to draw water (or other fluid) from the water
tank 11 into the inlet conduit 30. For the purposes of illustration
only, the gap "A1" may be about 0.07 inch, deflected height "B1"
may be about 1/8 inch and the angle "C1" may be about 30
degrees.
[0061] FIG. 6 illustrates a cross-sectional view of a smile shaped
notch 34. The smile shaped notch 34 is a molded feature integrated
with the inlet conduit tube 70. However, other manufacturing
methods to form the smile shaped notches 34 are envisioned, such as
stamping, punching or any other forming method capable of
displacing the inlet conduit tube 70 material. Alternatively, it is
envisioned that the smile shaped notches 34 may be discrete
components coupled to the exterior or interior of the inlet conduit
tube 70.
[0062] The gap "A2", deflected height "B2" and the angle "C2" of
the smile shaped notch 34, as illustrated in FIG. 6, may be any
dimension sufficient to divert a portion of the water flow from the
inlet conduit 30 into the top end portion 59 of water tank 11. For
the purposes of illustration only, the gap "A2" may be about 0.07
inch, deflected height "B2" may be about 1/8 inch and the angle
"C2" may be about 30 degrees.
[0063] FIGS. 7 and 8 illustrate a detailed side view of a
smile-shaped notch and a frown-shaped notch, respectively. The
width "A3" and the slot radius "B3" of the smile and frown shaped
notch 34, as illustrated in FIGS. 7 and 8, respectively, may be any
dimension sufficient to divert or draw a portion of the water flow
from the inlet conduit 30 or into the inlet conduit 30. For the
purposes of illustration only, the width "A3" of the smile and
frown shaped notches may be about 3/8 inch and the slot radius "B3"
of the smile and frown shaped notches may be about 0.03 inch.
[0064] FIG. 9 illustrates an exemplary embodiment of an outlet
conduit 32 comprising a tube 72, a nipple 67 attached to the tube
72, a top end portion 12a, a bottom end portion 12b and an inlet
end 36. The top end portion 12a of the outlet conduit 32 provides
an opening 63 configured to draw water stored within the top end
portion 59 of the water tank 11 into the top end portion 12a of the
outlet conduit 32. The inlet end 36 of the outlet conduit 32 is
configured to draw cooler water from the bottom end portion 60 of
water tank 11 through the outlet conduit 32.
[0065] The opening 63 positioned along the outlet conduit 32,
combined with the smile and frown shaped notches positioned along
the inlet conduit 30, further reduces thermal stratification to
promote a uniform water temperature within the water tank 11. The
diameter "B" of the opening 63 may be increased or decreased to
alter the volume, velocity and/or pressure of the water flow
through opening 63. It is additionally envisioned that the opening
63 may be a frown-shaped notch, a rectangular opening or any other
shape or form capable of drawing water into the outlet conduit 32.
The position of the opening 63 along the top end portion 12a of the
outlet tube may be adjusted in order to draw water from alternate
depths of the top end portion 59 of the water tank 11. It is also
envisioned that the outlet conduit 32 may include a plurality of
openings 63 spaced radially and/or longitudinally along the outlet
conduit 32.
[0066] The inner diameter "D" of the outlet conduit tube 72 may be
increased or decreased to tailor the velocity and pressure of the
flow of water through the outlet conduit tube 72. The outlet
conduit tube 72 is shown in tubular form, however other embodiments
such as a square tube, rectangular tube, or any other shape
configured to transport liquid are envisioned.
[0067] The outlet conduit tube 72 may be composed of polypropylene,
stainless steel, copper, or any other suitable plastic or metallic
material. The outlet conduit tube 72 may be formed using any
suitable manufacturing process such as injection molding, casting,
machining, stamping, or extrusion, or any combination thereof.
[0068] An exemplary embodiment of an outlet conduit cap 71 is
illustrated in FIGS. 10 and 11. The cap 71 is optionally applied to
the inlet end 36 of the outlet conduit 32 to restrict the flow of
water from the bottom end portion 60 of the water tank 11 through
the inlet end 36 of the outlet conduit 32. The cap 71 is provided
with an opening 73 of diameter "E". The diameter "E" and position
of the opening 73 may be altered to tailor the flow of water drawn
from the bottom end portion 60 of the water tank 11.
[0069] A surface of the cap 71 is welded to the inlet end 36 of the
outlet conduit 32 according to one embodiment of the invention.
However, the cap 71 may be attached to the inlet end 36 via
fasteners, high-temperature waterproof adhesive or any other
suitable means of securing the components. The cap 71 may be a
separate fitting as shown, or alternatively could be integrated
with the outlet conduit tube 72. The cap 71 can be composed of
either a metallic or plastic material.
[0070] In one exemplary embodiment, water is drawn through both
opening 73 of the cap 71 and opening 63 of the outlet conduit 32.
The size and position of opening 73 relative to the size and
position of opening 63 affects the degree of thermal stratification
within the water tank 11. The relative sizes of opening 73 and
opening 63 may be tailored to influence the volume of water drawn
from the top end portion 59 of the water tank 11 with respect to
the volume of water drawn from the bottom end portion 60 of the
water tank 11. For example, if diameter "E" of opening 73 is
significantly smaller than diameter "B" of opening 63, a greater
volume of water will be drawn from the top end portion 59 of the
water tank 11. Conversely, if the diameter "E" of opening 73 is
significantly larger than the diameter "B" of opening 63, a greater
amount of water will be drawn from the bottom end portion 60 of the
water tank 11.
[0071] Similarly, the length of the outlet conduit (and the
resultant position of openings 63 and 73 with respect to one
another) will affect the impact of the outlet conduit on thermal
stratification within the water heater. For example, by lengthening
the outlet conduit (and thereby increasing the distance between the
openings 63 and 73), the temperature differential between the water
drawn through the respective openings 63 and 73 will tend to
increase. Conversely, by shortening the outlet conduit (and thereby
decreasing the distance between the openings 63 and 73), the
temperature differential between the water drawn through the
respective openings 63 and 73 will tend to decrease.
[0072] While preferred embodiments of the invention have been shown
and described herein, it will be understood that such embodiments
are provided by way of example only. Numerous variations, changes
and substitutions will occur to those skilled in the art without
departing from the spirit of the invention. Accordingly, it is
intended that the appended claims cover all such variations as fall
within the spirit and scope of the invention.
* * * * *