U.S. patent application number 11/904107 was filed with the patent office on 2009-03-26 for water heater having temperature control system with thermostatically controlled mixing device.
This patent application is currently assigned to Bradford White Corporation. Invention is credited to Taylor Alberts, Daniel Beabout, Wade Bernreuter, Michael W. Gordon, Christopher Stafford.
Application Number | 20090078218 11/904107 |
Document ID | / |
Family ID | 40470328 |
Filed Date | 2009-03-26 |
United States Patent
Application |
20090078218 |
Kind Code |
A1 |
Gordon; Michael W. ; et
al. |
March 26, 2009 |
Water heater having temperature control system with
thermostatically controlled mixing device
Abstract
A kit, device and method for improving the hot water supply
performance of a water heater are provided. The device comprises a
fitting, a conduit, and a mixing device. The fitting includes an
inlet port configured for coupling with a cold water supply line,
an outlet port configured for releasably coupling with a cold water
inlet port of the water heater, and a bypass port configured for
diverting a portion of the cold water from the cold water supply
line. The conduit includes an inlet port configured for coupling
with the bypass port of the fitting and an outlet port. The mixing
device includes a mixing port for coupling with the outlet port of
the conduit, an inlet port for releasably coupling with a hot water
outlet port of a water heater, and an outlet port for coupling with
a hot water supply line.
Inventors: |
Gordon; Michael W.; (Grand
Rapids, MI) ; Beabout; Daniel; (Kentwood, MI)
; Alberts; Taylor; (Middleville, MI) ; Stafford;
Christopher; (Hastings, MI) ; Bernreuter; Wade;
(Lowell, MI) |
Correspondence
Address: |
RATNERPRESTIA
P.O. BOX 980
VALLEY FORGE
PA
19482
US
|
Assignee: |
Bradford White Corporation
|
Family ID: |
40470328 |
Appl. No.: |
11/904107 |
Filed: |
September 26, 2007 |
Current U.S.
Class: |
122/13.3 ;
122/511 |
Current CPC
Class: |
Y10T 29/494 20150115;
Y10T 29/49826 20150115; Y10T 137/87571 20150401; F24D 19/1051
20130101; F24H 9/124 20130101 |
Class at
Publication: |
122/13.3 ;
122/511 |
International
Class: |
F24H 9/00 20060101
F24H009/00; F24H 9/12 20060101 F24H009/12; F24H 9/20 20060101
F24H009/20 |
Claims
1. A kit for improving hot water supply performance of a water
heater, said kit being configured to be releasably connected to a
cold water inlet port of the water heater, a hot water outlet port
of the water heater, a hot water supply line, and a cold water
supply line, said kit comprising: a fitting including an inlet port
configured for coupling with the cold water supply line, an outlet
port configured for releasable coupling with the cold water inlet
port of the water heater to deliver cold water into the water
heater, and a bypass port configured for diverting a portion of the
cold water from the cold water supply line; a conduit including an
inlet port configured for coupling with the bypass port of the
fitting, an outlet port, and a fluid flow passageway defined
between the inlet port and the outlet port; and a mixing device
including a mixing port for coupling with the outlet port of the
conduit, an inlet port for releasable coupling with the hot water
outlet port of the water heater, and an outlet port for coupling
with the hot water supply line, wherein the mixing device is
configured to mix the cold water and the hot water together for
delivery of the mixed water into the hot water supply line.
2. The kit of claim 1, wherein the mixing device includes a
thermostatic mixing valve for selectively permitting the flow of
water through the mixing port of the mixing device.
3. The kit of claim 2, further comprising a knob coupled to the
thermostatic mixing valve for biasing the thermostatic mixing
valve.
4. The kit of claim 3, further comprising a locking device coupled
to the mixing device for retaining the knob in a locked
position.
5. The kit of claim 1, wherein the inlet port of the conduit and
the outlet port of the conduit each includes a flared fitting.
6. The kit of claim 5, wherein the bypass port of the fitting and
the mixing port of the mixing device each includes a surface
positioned for mating with one of the flared fittings of the
conduit.
7. The kit of claim 1, wherein at least a portion of the conduit is
flexible for bending.
8. The kit of claim 7, wherein the flexible portion of the conduit
includes corrugations positioned along a length dimension of the
conduit.
9. The kit of claim 1, wherein the mixing port of the mixing device
and the outlet port of the conduit each includes mechanical threads
for releasable threaded coupling.
10. The kit of claim 1, wherein the inlet port of the conduit and
the bypass port of the fitting each includes mechanical threads for
releasable threaded coupling.
11. The kit of claim 1, wherein the inlet port of the fitting
includes mechanical threads for releasable threaded coupling to the
cold water supply line.
12. The kit of claim 11, wherein the mechanical threads of the
inlet port of the fitting are male National Pipe Threads (NPT).
13. The kit of claim 1, wherein the outlet port of the fitting
includes mechanical threads for releasable threaded coupling to the
cold water inlet port of the water heater.
14. The kit of claim 13, wherein the mechanical threads of the
outlet port of the fitting are female National Pipe Threads
(NPT).
15. The kit of claim 1, wherein the outlet port of the mixing
device includes mechanical threads for releasable threaded coupling
to the hot water supply line.
16. The kit of claim 15, wherein the mechanical threads of the
outlet port of the mixing device are male National Pipe Threads
(NPT).
17. The kit of claim 1, wherein the inlet port of the mixing device
includes mechanical threads for releasable threaded coupling to the
hot water outlet port of the water heater.
18. The kit of claim 17, wherein the mechanical threads of the
inlet port of the mixing device are female National Pipe Threads
(NPT).
19. The kit of claim 1, wherein the conduit is formed from
stainless steel.
20. The kit of claim 1 further comprising a package for shipment of
the fitting, the conduit, and the mixing device.
21. The kit of claim 1, wherein the fitting is a "T" shaped conduit
having one inlet end and two outlet ends.
22. A water heater assembly comprising: a water storage tank for
containing water; an inlet port positioned on the water storage
tank for receiving cold water delivered from a cold water supply
line; an outlet port positioned on the water storage tank for
distributing hot water from the water storage tank toward a hot
water supply line; and a water tempering device releasably coupled
to both the inlet port and to the outlet port for diverting a
portion of the cold water from the cold water supply line to the
hot water supply line, wherein the water tempering device is
configured to selectively mix the cold water with the hot water for
delivery of the mixed water into the hot water supply line.
23. The water heater assembly of claim 22, the water tempering
device further comprising a fitting including an inlet port for
coupling with a cold water supply line, an outlet port for
releasably coupling with the inlet port of the water storage tank
to deliver cold water into the water storage tank, and a bypass
port for diverting a portion of the cold water from the cold water
supply line.
24. The water heater assembly of claim 23, the water tempering
device further comprising a conduit including an inlet port for
coupling with the bypass port of the fitting, an outlet port, and a
fluid flow passageway defined between the inlet port and the outlet
port.
25. The water heater assembly of claim 24, the water tempering
device further comprising a mixing device including a mixing port
for coupling with the outlet port of the conduit, an inlet port for
releasably coupling with an outlet port of the water storage tank,
and an outlet port for coupling with a hot water supply line.
26. The water heater assembly of claim 25, wherein the mixing
device includes a thermostatic mixing valve for selectively
permitting the flow of water through the mixing port of the mixing
device.
27. The water heater assembly of claim 22, wherein the water
storage tank inlet and outlet ports are positioned on a top surface
of the water storage tank.
28. A method of improving hot water supply performance of a water
heater having a water storage tank, a cold water inlet port for
receiving cold water from a cold water supply line, and a hot water
outlet port for delivering hot water to a hot water supply line,
said method comprising the steps of: coupling an outlet port of a
water tempering device to the cold water inlet port of the water
heater for delivering cold water from the cold water supply line
into the water storage tank, coupling an inlet port of the water
tempering device to the hot water outlet port of the water heater
for receiving hot water from the water storage tank to the hot
water supply line, positioning a conduit of the water tempering
device between the inlet port and the outlet port of the water
tempering device for diverting a portion of the cold water
delivered from the cold water supply line into the conduit, wherein
the water tempering device is configured to selectively mix the
diverted cold water with the hot water received from the water
storage tank, and deliver the mixed water into the hot water supply
line.
29. The method of claim 28, wherein the step of coupling the outlet
port of the water tempering device further comprises threadedly
coupling the outlet port of the water tempering device of the
fitting to the cold water inlet port of the water heater.
30. The method of claim 28, wherein the step of coupling the inlet
port of the water tempering device further comprises threadedly
coupling the inlet port of the water tempering device to the hot
water outlet port of the water heater.
31. The method of claim 28, wherein the step of coupling an outlet
port to the cold water inlet port of the water heater comprises
coupling to a cold water inlet port extending upwardly from a top
of the water heater.
32. The method of claim 28, wherein the step of coupling an inlet
port to the hot water outlet port of the water heater comprises
coupling to a hot water outlet port extending upwardly from a top
of the water heater.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to a kit for improving the hot
water supply performance of a water heater, a method of installing
the kit, and a water heater having improved hot water supply
performance.
BACKGROUND OF THE INVENTION
[0002] There is a need to improve the thermal performance of
conventional water heaters. Thermal efficiency improvements
facilitate water and energy conservation and represent cost savings
to the end user.
[0003] First-Hour Rating is an industry-wide measure of the
performance of a water heater. It is a measure of the volume of hot
water (at a pre-determined temperature) that a water heater can
supply in a one-hour time period. Water heater manufacturers
continually strive to increase performance, whether quantified in
terms of First-Hour Rating or other measures. Accordingly, there
remains a continuing need to improve the thermal performance of a
water heater.
SUMMARY OF THE INVENTION
[0004] According to one exemplary embodiment of the invention, a
kit for improving the hot water supply performance of a water
heater is provided. The kit is configured to be releasably
connected to a cold water inlet port of the water heater, a hot
water outlet port of the water heater, a hot water supply line, and
a cold water supply line. The kit comprises a fitting including an
inlet port configured for coupling with the cold water supply line,
an outlet port configured for releasable coupling with the cold
water inlet port of the water heater to deliver cold water into the
water heater, and a bypass port configured for diverting a portion
of the cold water from the cold water supply line. The conduit
includes an inlet port configured for coupling with the bypass port
of the fitting, an outlet port, and a fluid flow passageway defined
between the inlet port and the outlet port. The mixing device
includes a mixing port for coupling with the outlet port of the
conduit, an inlet port for releasable coupling with the hot water
outlet port of the water heater, and an outlet port for coupling
with the hot water supply line, wherein the mixing device is
configured to mix the cold water and the hot water together.
[0005] According to another exemplary embodiment of the invention a
water heater assembly is provided. The water heater assembly
comprises a water storage tank for containing water. The water
storage tank includes an inlet port positioned for receiving cold
water delivered from a cold water supply line, and an outlet port
for distributing hot water from the water storage tank to a hot
water supply line. A water tempering device is releasably coupled
to both the inlet port and to the outlet port for diverting a
portion of the cold water from the cold water supply line toward
the hot water supply line, wherein the water tempering device is
configured to selectively mix the cold water with the hot
water.
[0006] According to yet another exemplary embodiment of the
invention a method of improving hot water supply performance of a
water heater is provided. The method comprising the step of
coupling an outlet port of a water tempering device to the cold
water inlet port of a water heater for delivering cold water from
the cold water supply line into the water storage tank. The inlet
port of the water tempering device is coupled to the hot water
outlet port of the water heater for receiving hot water from the
water storage tank to the hot water supply line. A conduit of the
water tempering device is positioned between the inlet port and the
outlet port of the water tempering device for diverting a portion
of the cold water delivered from the cold water supply line into
the conduit. The water tempering device is configured to
selectively mix the diverted cold water with the hot water received
from the water storage tank, and deliver the mixed water into the
hot water supply line.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The invention is best understood from the following detailed
description-when read in connection with the accompanying drawings.
It is emphasized that, according to common practice, the various
features of the drawings are not to scale. On the contrary, the
dimensions of the various features are arbitrarily expanded or
reduced for clarity. Included in the drawings are the following
figures:
[0008] FIG. 1A is a perspective view of an embodiment of a water
heater installation including a water heater and a water tempering
device releasably mounted between the water heater and hot and cold
water supply lines according to aspects of this invention;
[0009] FIG. 1B is a perspective view of the water heater of FIG.
1A;
[0010] FIGS. 2A and 2B depict top plan and front elevation views,
respectively, of an embodiment of a water tempering device
according to aspects of this invention;
[0011] FIGS. 3A and 3B depict front elevation and end views,
respectively, of the flexible conduit assembly of FIGS. 2A and 2B
according to aspects of this invention, wherein the flared fittings
are illustrated in phantom lines;
[0012] FIGS. 4A-4C depict right elevation, rear elevation and top
plan views, respectively, of the fitting of FIGS. 2A and 2B
according to aspects of this invention;
[0013] FIGS. 5A-5C depict front elevation, left elevation and top
plan views, respectively, of the mixing device of FIGS. 2A and 2B
according to aspects of this invention;
[0014] FIG. 5D depicts a partial exploded perspective view of the
mixing device of FIGS. 2A and 2B illustrating the locking ring and
the adjusting knob, according to aspects of this invention;
[0015] FIG. 5E depicts a cross-sectional view of the locking ring
and the adjusting knob taken along the lines 5E-5E of FIG. 5C,
wherein the knob is positioned in a locked configuration according
to aspects of this invention;
[0016] FIG. 5F depicts a detailed view of the locking ring and the
knob illustrated in FIG. 5E;
[0017] FIG. 5G depicts another cross-sectional view of the locking
ring and the adjusting knob taken along the lines 5E-5E of FIG. 5C,
wherein the knob is positioned in an adjustable configuration
according to aspects of this invention;
[0018] FIG. 5H depicts a detailed view of the locking ring and the
knob illustrated in FIG. 5G;
[0019] FIGS. 6A-6C depict front elevation, bottom plan and top plan
views, respectively, of the locking ring of FIG. 5D according to
aspects of this invention; and
[0020] FIG. 7 depicts a top perspective schematic view of a kit
including the water tempering device shown in FIGS. 2A and 2B
positioned within a packaging box according to aspects of this
invention.
DETAILED DESCRIPTION OF THE INVENTION
[0021] 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.
[0022] Referring generally to the figures and according to one
exemplary embodiment of the invention a water tempering device 16
for improving the hot water supply performance of a water heater is
provided. The water tempering device 16 is configured to be
releasably connected to a cold water inlet port 20 of the water
heater 10, a hot water outlet port 22 of the water heater 10, a hot
water supply line 14, and a cold water supply line 12. The water
tempering device 16 comprises a fitting 24 including an inlet port
32 for coupling with the cold water supply line 12, an outlet port
30 for releasably coupling with the cold water inlet port 20 of the
water heater 10 to deliver cold water into the water heater 10, and
a bypass port 56 for diverting a portion of the cold water from the
cold water supply line 12. A conduit assembly 28 includes an inlet
port 34 for coupling with the bypass port 56 of the fitting 24, an
outlet port 36, and a fluid flow passageway 38 defined between the
inlet port 34 and the outlet port 36. A mixing device 26 includes a
mixing port 70 for coupling with the outlet port 36 of the conduit
assembly 28, an inlet port 40 for releasably coupling with the hot
water outlet port 22 of a water heater 10, and an outlet port 42
for coupling with the hot water supply line 14, wherein the mixing
device 26 is configured to mix the cold water and the hot water
together.
[0023] Referring specifically to FIGS. 1A and 1B, a perspective
view of a water heater installation is shown in FIG. 1A and the
water heater 10 is illustrated by itself in FIG. 1B. In the
installation shown in FIG. 1A, a water heater 10 is attached to
cold and hot water supply lines 12 and 14 via a water tempering
device 16. The cold water supply line 12 delivers cold water from a
water source into the water heater 10, and the hot water supply
line 14 delivers hot water from the water heater 10 to one or more
hot water distribution devices (not shown), such as a shower, a
sink, a clothes washer, or a dishwasher.
[0024] The water heater 10 includes a water storage tank 18 for
containing water (or any other fluid or liquid), an inlet port 20
positioned on a top surface of the water storage tank 18 for
receiving cold water from the cold water supply line 12, and an
outlet port 22 that is also positioned on the top surface of the
water storage tank 18 for delivering hot water from the water
storage tank to the hot water supply line 14. Although not shown,
the inlet port 20 and/or the outlet port 22 of the water heater 10
may be connected to a conduit extending into the interior of the
water storage tank 18 for delivering water to/from the water
storage tank 18.
[0025] A water tempering device 16 is releasably coupled to both
the inlet port 20 and to the outlet port 22 of the water heater 10
for diverting a portion of the cold water from the cold water
supply line 12 to the hot water supply line 14. The water tempering
device 16 is configured to selectively mix the cold water with the
hot water.
[0026] The water tempering device 16 is generally configured for
use with any conventional residential or commercial water heater
having a storage tank 18, a cold water inlet port 20 and a hot
water outlet port 22 positioned on the top surface of the water
heater each having standard national pipe threads (NPT) threads
(such as 3/4 inch male NPT), where the ports 20 and 22 are oriented
in parallel and spaced apart a standard distance (such as 8 inches
or 11 inches).
[0027] The water tempering device 16 may be assembled onto a water
heater at the factory or at the water heater installation site.
Moreover, the water tempering device 16 may be provided as a kit
and packaged along with a new water heater. Alternatively, the
device 16 may be provided as a kit and sold and distributed
separately from the water heater. The device 16 may be used for
retrofitting an existing water heater to improve the First-Hour
Rating of the existing water heater. No special tools are required
for installing the water tempering device 16 to a water heater
(either new or pre-existing) and water supply lines.
[0028] FIGS. 2A and 2B depict top plan and front elevation views,
respectively, of an exemplary embodiment of the water tempering
device 16 (referred to hereinafter as device 16) according to
aspects of this invention. The water tempering device 16 generally
includes a fitting 24, a mixing device 26 and a conduit assembly 28
coupled therebetween for delivering fluid from the fitting 24 to
the mixing device 26.
[0029] The device 16 includes a fitting 24 that is threadedly
connectable to the inlet port 20 of the water heater 10, a mixing
device 26 that is threadedly connectable to the outlet port 20 of
the water heater 10, and a flexible conduit assembly 28 releasably
connected between the fitting 24 and the mixing device 26. The
fitting 24 and the mixing device 26 may be releasably connected to
the water heater 10 by couplings or threaded connections using
standard tools, or another releasable connection style that does
not require a welding or sweat soldering operation or pipe
cutting.
[0030] The fitting 24 includes an inlet port 32 for coupling with
the cold water supply line 12, an outlet port 30 for releasably
coupling with the inlet port 20 of the water heater 10 to deliver
cold water into the water storage tank, and a bypass port (not
explicitly depicted in this view) for diverting a portion of the
cold water from the cold water supply line 12 into the conduit
assembly 28.
[0031] The conduit assembly 28 includes an inlet port 34 for
coupling with the bypass port of the fitting 24, an outlet port 36
for coupling with the mixing device 26, and a hollow fluid flow
passageway 38 defined between the inlet port 34 and the outlet port
36 for delivering the diverted cold water to the mixing device 26.
The conduit assembly 28 includes a flexible portion 39 to permit
bending of the conduit assembly 28 without compromising the
structural integrity of the conduit assembly 28.
[0032] The mixing device 26 includes a mixing port (not explicitly
depicted in this view) for coupling with the outlet port 36 of the
conduit assembly 28, an inlet port 40 for releasably coupling with
the outlet port 22 of the water heater 10, and an outlet port 42
for coupling with the hot water supply line 14. The hot water and
cold water are combined and mixed together within the mixing device
26.
[0033] The flow of cold water from the conduit assembly 28 and the
flow of hot water from the outlet port 22 of the water heater 10
into the mixing device 26 forces the hot water and cold water to
mix within the mixing device 26 resulting in water at a lower
temperature. The reduced temperature water is also referred to
herein as tempered water. Combining the hot water with the cold
water conserves the hot water contained within the tank, thereby
increasing the First-Hour Rating of the water heater.
[0034] The temperature of the tempered water delivered into the hot
water supply line 14 is maintained generally at a constant level.
An adjustable knob 44 is provided on the water tempering device 16
for setting the tempered water temperature delivered through the
outlet port 42 of the mixing device 26. The tempered water setting
may be set by the installer of the water heater or the end user, as
discussed in greater detail with reference to FIGS. 5D-5G.
[0035] The amount of cold water flowing into the mixing device 26
is dependent upon the temperature of the hot water delivered
through the outlet port 22 of the water heater 22 and into the
mixing device 26. More specifically, as the hot water temperature
at outlet port 22 drops, the amount of cold water flowing into the
mixing device 26 is reduced to compensate for the drop in
temperature at the outlet port 22. Conversely, as the temperature
of hot water at outlet port 22 rises, the amount of cold water
flowing into the mixing device 26 is increased to compensate for
the rise in temperature at the hot water outlet port 22. Although
not shown, the mixing device 26 includes a thermostatically
controlled valve (not shown) for controlling the volume of cold
water flowing into the mixing device 26. Those skilled in the art
will recognize that the mixing device 26 may include a variety of
devices to control the flow of cold water and/or hot water
therethrough.
[0036] Referring now to the individual components of the water
tempering device 26, FIGS. 3A and 3B depict front elevation and end
views, respectively, of the flexible conduit assembly 28 according
to aspects of this invention. The conduit assembly 28 generally
includes an inlet port 34 for receiving cold water from the bypass
port 56 of the fitting 24 (see FIG. 4A), and an outlet port 36 for
delivering cold water into the mixing port 70 of the mixing device
26 (see FIG. 5A).
[0037] The flexible conduit assembly 28 includes a conduit 43 and
two nuts 45 and 48 that are captively positioned on opposing sides
of the conduit 43. The nuts 45 and 48 are included for captivating
the conduit assembly 28 with the fitting 24 and the mixing device
26, respectively.
[0038] The conduit 43 is a hollow cylindrical tube or pipe defining
a fluid flow passageway 38 therethrough. The fluid flow passageway
38 extends along the entire length "L" of the conduit assembly 28.
Although not shown, the conduit 43 may optionally include a special
coating or liner disposed within the fluid flow passageway 38. In
the interest of reducing the number of components of the
water-tempering device 16, and simplifying the assembly and
installation of the water-tempering device 16, the conduit 43 shown
in the figures does not include a liner positioned within the fluid
flow passageway 38.
[0039] The conduit 43 includes a flexible portion 39 to permit
bending of the conduit 43 without compromising the structural
integrity of the conduit 43. The remaining portion of the conduit
43 is preferably rigid. The installer or end user may leverage the
rigid portion of the conduit 43 to fasten the nuts 45 and 48 onto
the fitting 24 and the mixing device 26, respectively. The conduit
43 is typically bent in the process of installing the conduit
assembly 28 onto the mixing device 26, as described in greater
detail later. The conduit 43 is shown in a bent configuration in
FIGS. 1A, 2A and 2B. The flexible portion 39 may be formed by
corrugating a portion of the length "L" of the conduit 43, as shown
in FIG. 3A. The minimum bend radius of the conduit 43 may be 1.25
inches, for example. Alternatively, although not shown, the entire
length "L" of the conduit 43 may be corrugated for increased
flexibility.
[0040] The conduit 43 includes flare fittings at each end thereof.
Flare fittings are utilized to fluidly connect two metallic tubes
while limiting fluid leakage at the interface between the tubes. It
has been found that flare fittings generally offer a high degree of
long term reliability. Several styles of flare fittings are
commonly used in the industry, including the 45.degree. Society of
Automotive Engineers (SAE) style and the 37.degree. Joint Industry
Conference (JIC) style.
[0041] Each flare fitting comprises a flared portion 46 and 47
(shown in phantom lines) and a nut 45 and 48 floatingly captivated
over the flared portion 46 and 47, respectively. Flared portion 46
corresponds with the inlet port 34 of the conduit assembly 28, and
flared portion 47 corresponds with the outlet port 36 of the
conduit assembly 28. Each flared portion 46 and 47 is sized to mate
with a chamfered surface of the fitting 24 and the mixing device
26. A flare tool (not shown) may be employed to flare the end of
the conduit outward at a predetermined angle (typically 45.degree.
or 37.degree.).
[0042] The nuts 45 and 48 corresponding to the flared portion 46
and 47, respectively, include interior threads 49 for releasably
mating with threaded regions of the fitting 24 and the mixing
device 26. The thread classification of the interior threads 49 may
be 7/8-14 UNF 2B, for example.
[0043] The captivated nuts 45 and 48 are unconstrained and free to
float along a portion of the length "L" of the conduit 43, however,
the corrugations 39 may prohibit the nuts 45 and 48 from floating
along the entire length "L" of the conduit 43. The nuts 45 and 48
float over the conduit 43 so that the nuts 45 and 48 can gradually
compress the flared portion 46 and 47 against the chamfered
surfaces 64 and 84 of the fitting 24 and the mixing device 26, when
the nuts 45 and 48 are threaded onto the fitting 24 and the mixing
device 26, respectively.
[0044] The nuts 45 and 48 and flare fittings 46 are designed to
mate with the fitting 24 and the mixing device 26, as described in
greater detail with reference to FIGS. 4A-5C. Those skilled in the
art will recognize that the conduit assembly 28 may be designed to
mate with the fitting 24 and the mixing device 26 in a variety of
ways, and is not limited to flare fittings.
[0045] By way of non-limiting example, the outer diameter of the
conduit 43 may be about 5/8 inch, and the length "L" of the conduit
assembly 28 may be about 9 inches to about 13 inches to accommodate
water heater ports 20 and 22 (see FIG. 1B) that are separated by an
industry standard 8 inches or 11 inches. The conduit 43 may
optionally be formed from 29 gauge stainless steel type 304 or 306
having a reflective silver appearance. The conduit 43 material may
also be annealed for improved bending characteristics. The nuts 45
and 48 optionally include a hex-shaped exterior for gripping by a
wrench, or other common tool. The nuts 45 and 48 may be formed from
chrome-plated brass, or any other appropriate material. Those
skilled in the art will recognize that the components of the
flexible conduit assembly 28 may be formed from a variety of
different materials, without departing from the scope of the
invention.
[0046] FIGS. 4A-4C depict right elevation, rear elevation and top
plan views, respectively, of the fitting 24 according to aspects of
this invention. The fitting 24 includes an inlet port 32 for
coupling with a cold water supply line 12 (see FIG. 1A), an outlet
port 30 for releasably coupling with the cold water inlet port 20
of the water storage tank 18 to deliver cold water into the water
storage tank 18, and a bypass port 56 for diverting a portion of
the cold water from the cold water supply line 12 into the conduit
assembly 28 (not shown in FIGS. 4A-4C).
[0047] The fitting 24 generally includes a body 50 that is formed
in the shape of the letter "T." The body 50 includes a hollow
interior 51 to permit unrestricted fluid flow between the ports 32,
30 and 56. The body 50 may optionally be formed from die-cast
nickel plated brass, or any other appropriate material known to
those skilled in the art.
[0048] A threaded region 58 extending from the inlet port 32 is
sized for releasable mating with mechanical threads (not shown) of
the cold water supply line 12. The industry standard thread
classification for a water supply line is 3/4 female national pipe
thread (NPT). Accordingly, the classification of the threaded
region 58 may be 3/4 male national pipe thread (NPT) for mating
with the cold water supply line 12.
[0049] A portion of the body 50 is cut-away to illustrate an
interior threaded region 60 extending from the outlet port 30. The
interior threaded region 60 is configured for releasable mating
with mechanical threads of the inlet port 20 of the water heater
10. The industry standard thread classification of the inlet and
outlet ports 20 and 22 of a water heater is 3/4 male national pipe
thread (NPT). Accordingly, the classification of the threaded
region 60 may be 3/4 female national pipe thread (NPT) for mating
with the inlet port 20 of the water heater 10. Although not shown,
the outlet port 30 may include a slidingly captivated female
threaded nut (similar to nut 48), in lieu of threaded region 60,
for releasably coupling with the cold water inlet port 20 of the
water heater 10.
[0050] Another threaded region 62 that is proximal to the bypass
port 56 is sized for releasable mating with the mechanical threads
49 of the nut 45 of the conduit assembly 28. As stated previously,
the thread classification of the interior threads 49 of the nut 45
may be 7/8-14 UNF 2B, for example. Accordingly, the classification
of the threaded region 62 of the fitting 24 may be 7/8-14 UNF, for
example, for threadedly mating with the interior threads 49 of the
nut 45. Those skilled in the art will recognize that the
classification of the aforementioned threaded regions may vary from
that shown and described.
[0051] A chamfered or otherwise configured portion 64 is defined on
the bypass port 56 of the fitting 24. In assembly, the nut 45 is
threaded onto the threaded region 62 of the fitting 24 until the
flared portion 46 of the conduit 43 is positioned in sealing
contact with the chamfered portion 64 of the fitting 24. Sealing
contact between the flared portion 46 and chamfered portion 64
limits leakage of fluid at that interface. The angle of the
chamfered portion 64 corresponds to the angle of the flared portion
46 of the conduit 43 (typically 45.degree. or 37.degree.).
[0052] FIGS. 5A-5C depict front elevation, left elevation and top
plan views, respectively, of the mixing device 26 according to
aspects of this invention. The mixing device 26 generally includes
a mixing port 70 for coupling with the outlet port 36 of the
conduit assembly 28, an inlet port 40 for releasably coupling with
the hot water outlet port 22 of the water heater 10, and an outlet
port 42 for coupling with the hot water supply line 14. The mixing
port 70 receives cold water from the conduit assembly 28, the inlet
port 40 receives hot water from the water storage tank 18 of the
water heater 10, and the outlet port 42 delivers the tempered water
to one or more hot water distribution points (e.g., faucet,
dishwasher, and so forth).
[0053] The mixing device 26 generally includes a body 76 defining a
hollow interior to permit fluid flow between the ports 70, 40 and
42. The body 50 may optionally be formed from die-cast nickel
plated brass, or any other appropriate material known to those
skilled in the art. A thermostatically controlled valve (not shown)
is housed within the hollow interior to control the flow of fluid
between the ports 42 and 70.
[0054] According to one exemplary embodiment, the thermostatically
controlled valve is configured to measure the temperature of the
tempered water delivered through outlet port 42, compare the
tempered water temperature with the setting of the knob 44, and
permit or prohibit the flow of cold water through mixing port 70
based upon the comparison. Alternatively, the thermostatically
controlled valve may be configured to measure the temperature of
the hot water delivered into the inlet port 40, compare the hot
water temperature with the setting of the knob 40, and permit or
prohibit the flow of cold water through mixing port 70. A suitable
thermostatically controlled valve is offered by Cash Acme, a
division of Reliance Worldwide Corporation, of Cullman, Ala.,
USA.
[0055] A portion of the body 76 is cut-away to illustrate an
interior threaded region 78 extending from the inlet port 40. The
threaded region 78 is sized for releasable mating with mechanical
threads of the outlet port 22 of the water heater 10. As noted
previously, the industry standard thread classification of the
inlet and outlet ports 20 and 22 of a water heater is 3/4 male
national pipe thread (NPT). Accordingly, the classification of the
threaded region 78 may be 3/4 female national pipe thread (NPT) for
mating with the outlet port 22 of the water heater 10.
[0056] Although not shown, the inlet port 40 may include a
slidingly captivated female threaded nut (similar to nut 48), in
lieu of threaded region 78, for releasably coupling the inlet port
40 to the hot water outlet port 22 of the water heater 10. Several
benefits are achieved by incorporating slidingly captivated nuts
with the inlet port 40 of the mixing device 26 and the outlet port
30 of the fitting 24. First, the entire water tempering device 16
may be provided as a single pre-assembled unit, as opposed to three
or more separate components that must be assembled together at the
installation site. It follows that the time required to assemble a
pre-assembled water tempering device onto a water heater would be
significantly lower than sequentially assembling separate
components of the water tempering device 16 onto the water heater.
Third, the flexible portion 39 of the conduit may be omitted, which
may represent a cost reduction. Fourth, if the water heater has a
blower unit positioned on the top surface of the water heater, the
blower unit must be removed to accommodate rotation of the long
body 76 of the mixing device 26 onto the hot water outlet port 22
of the water heater 10. By incorporating a slidingly captivated nut
onto the inlet port 40 of the mixing device 26, it is not necessary
to remove the blower unit of the water heater. The female threaded
nut can be rotated onto the hot water outlet port 22 of the water
heater 10 without rotating the body of the mixing device 26
[0057] A threaded region 80 extending from the outlet port 42 of
the mixing device 26 is sized for releasable mating with mechanical
threads (not shown) of the hot water supply line 14. As noted
previously, the industry standard thread classification for a water
supply line is 3/4 female national pipe thread (NPT). Accordingly,
the thread classification of the threaded region 80 may be 3/4 male
national pipe thread (NPT) for mating with the hot water supply
line 14.
[0058] Another threaded region 82 that is proximal to the mixing
port 70 is sized for releasable mating with the mechanical threads
49 of the nut 48 of the conduit assembly 28. As stated previously,
the thread classification of the interior threads 49 of the nut 48
may be 7/8-14 UNF 2B, for example. Accordingly, the classification
of the threaded region 82 of the mixing device 26 may be 7/8-14
UNF, for example, for threadedly mating with the interior threads
49 of the nut 48. Those skilled in the art will recognize that the
classification of the aforementioned threaded regions may vary from
that shown and described.
[0059] A chamfered portion 84 is defined on the mixing port 70 of
the mixing device 26. In assembly, the nut 48 of the conduit
assembly 28 is threaded onto the threaded region 82 of the mixing
device 26 until the flared portion 47 of the conduit 43 is
positioned in sealing contact with the chamfered portion 84 of the
mixing device 26. Sealing contact between the flared portion 47 and
chamfered portion 84 limits leakage of fluid at that interface. The
angle of the chamfered portion 84 corresponds to the angle of the
flared portion 47 of the conduit 43 (typically 45.degree. or
37.degree.).
[0060] A rotatable knob 44 is provided on the water tempering
device 16 for setting the tempered water temperature delivered
through the outlet port 42 of the mixing device 26. The
functionality of the knob 44 is best described with reference to
FIGS. 5D-5H.
[0061] FIG. 5D depicts a partial exploded perspective view of a
portion of the mixing device 26, according to aspects of this
invention. In FIG. 5D, the knob 44 is mounted to a stud 92, such
that rotation of knob 44 induces rotation of stud 92. Specifically,
a fastener 94 is mounted through a hole 95 of the knob 44 and
threadedly engaged with a threaded hole 93 of the stud 92. The
threaded hole 93 and the fastener 94 may optionally include
left-hand threads to limit the fastener 94 from backing out of the
hole 93 upon rotation of knob 44 in a counter-clockwise direction.
The knob 44 optionally includes a gripping surface 96 that is
provided for gripping the knob 44. The gripping surface 96 may be a
knurled surface, scalloped surface, or any other style gripping
surface.
[0062] The knob 44 is rotatable for setting the tempered water
temperature delivered through the outlet port 42 of the mixing
device 26. More specifically, the knob 44 is connected to the stud
92, and the stud 92 is a component of the thermostatic mixing valve
100. The stud 92 is capable of rotation with respect to the
hexagon-shaped body of the thermostatic mixing valve 100
illustrated in FIG. 5E, while the hexagon-shaped body remains fixed
in place. Although not shown, a thermostatic valve is positioned on
the opposing end of the stud 92 for controlling the flow of cold
water through the mixing port 70 (see FIG. 5A). It follows that
rotation of the stud 92 (via knob 44) adjusts the position of the
thermostatic valve (not shown), which controls the volume of cold
water permitted to flow through the mixing port 70. The tempered
water setting may be set by the installer of the water heater or
the end user.
[0063] The mixing device 26 includes a locking ring 90 for either
permitting or prohibiting rotation of the knob 44. In a locked
configuration, as shown in FIGS. SE and 5F, the locking ring 90
prohibits rotation of knob 44, whereas in an adjustable
configuration, as shown in FIGS. 5G and 5H, the knob 44 is free to
rotate with respect to the locking ring 90 in a limited range.
[0064] FIGS. 5E and 5G depicts a cross-sectional view of the
locking ring 90 and the adjusting knob 44 taken along the lines
5E-5E of FIG. 5C. In FIG. 5E the knob 44 is positioned in a locked
configuration, whereas the knob 44 is positioned in an adjustable
configuration in FIG. 5G. FIGS. 5F and 5H depict detailed views of
the locking ring and the adjusting knob illustrated in FIGS. 5E and
5G, respectively.
[0065] The locking ring 90 is provided on the mixing device 26 to
either permit or prohibit rotation of the knob 44. The locking ring
90 includes interior gear teeth 102 for mating with the six edges
104 of the thermostatic mixing device 100 to prevent rotation of
locking ring 90. The locking ring 90 is generally incapable of
rotation once it is mated with the edges 104 of the mixing device
100.
[0066] Two detents 106 are disposed on the interior surface of the
knob 44. The gap "G" disposed between the detents 106 shown in FIG.
5F is sized to accommodate the tab 108 provided on the locking ring
90. In the locked configuration shown in FIGS. 5E and 5F, the knob
44 is positioned over top of the locking ring 90 and the detents
106 are positioned on either side of the tab 108 of the locking
ring 90. The tab 108 prevents rotation of the detents 106 (and knob
44). As discussed in greater detail later, the installer or end
user sets the tempered water temperature to any desired level,
positions the knob 44 to a locked position by positioning the
detents over the tab 108, and engages the fastener 94 with the
threaded hole 93 through the hole 95 of the knob 44. Once the
fastener 94 is secured, the knob 44 is set to the locked
configuration and can not be inadvertently adjusted.
[0067] In the adjustable configuration shown in FIGS. 5G and 5H,
the detents 106 are positioned adjacent to the tab 108 of the
locking ring 90, thereby permitting limited rotation of the detents
106 relative to the tab 108 along a limited range. According to one
aspect of the invention, the knob 44 is capable of 350 degrees of
rotation in a counterclockwise or clockwise direction in the
adjustable configuration. It should be understood that the detents
106 can not rotate past the tab 108 in the adjustable
configuration.
[0068] The end user or installer can change the configuration of
the mixing device 26 from a locked to an adjustable configuration,
and vice versa, by first removing the fastener 94 and the knob 44.
The knob 44 is then repositioned over the locking ring 90 and the
detents 106 of the knob 44 are then repositioned with respect to
the tab 108 of the locking ring 90 to either a locked or an
adjustable configuration.
[0069] FIGS. 6A-6C depict front elevation, bottom plan and top plan
views, respectively, of the locking ring 90. The locking ring 90
includes a hollow cylindrical body defining two axially aligned
cylindrical portions 111 and 113. The diameter of the cylindrical
portion 113 is greater than the diameter of the cylindrical portion
111. The gear teeth 102 are disposed on the interior surface of the
cylindrical portion 111. The tab 108 is disposed on the exterior
surface of the cylindrical portion 111.
[0070] The cylindrical portion 113 includes a base surface 112 for
bearing against the body 76 of the mixing device 26, as shown in
FIG. 5D. An arrow 110 is printed, applied, or formed on the
exterior surface of the cylindrical portion 113, as shown in FIG.
6A. The arrow 110 is radially aligned with the tab 108. The arrow
110 is provided to indicate the position of the tab 108.
[0071] Referring now to FIGS. 1A-5H, the steps for assembling the
water tempering device 16 onto a water heater 10, according to one
exemplary use of the invention, are described hereinafter. It
should be understood that the assembly procedure described
hereinafter are not limited to any particular step, or any
particular order or sequence of steps, and may vary from that shown
and described. In the assembly procedure, it is assumed that the
components of the water tempering device 16 are disassembled and
provided in a kit (see FIG. 7A, for example), according to aspects
of the invention.
[0072] The installer (or end user) first applies pipe thread
sealant to the inlet and outlet ports 20 and 22 of the water heater
10 in an effort to minimize water leakage at the interface between
the ports 20 and 22 and the device 16.
[0073] The fitting 24 is then installed onto the water heater 10 by
fastening the interior threads 60 of the fitting 24 onto the
threaded region of the inlet port 20 of the water heater 10. The
fitting 24 is fastened onto the inlet port 20 until it is
sufficiently seated and the mixing port 70 of the fitting 24 faces
the front end of the water heater 10 (see FIG. 1A).
[0074] The conduit assembly 28 is then installed onto the fitting
24. First, the nut 45 is slid backwards to expose the flared
portion 46 of the conduit 43. The flared portion 46 is then aligned
with the chamfered portion 64 of the fitting 24. The nut 45 is slid
in the forward direction to engage the interior threads 49 of the
nut 45 with the threaded region 62 of the fitting 24. The nut 45 is
gradually tightened, compressing the flared portion 46 of the
tubing 43 against the chamfered portion 64 until the nut 45 is
firmly seated in place. A fluid tight seal is obtained by mating
the two beveled metallic surfaces (i.e., chamfered portion 64 and
flared portion 46). The purpose of the nut 45 is to draw these two
beveled surfaces together into sealing contact.
[0075] The mixing device 26 is then installed onto the water heater
10 by fastening the interior threads 78 of the mixing device 26
onto the threaded region of the outlet port 22 of the water heater
10. The mixing device 26 is fastened onto the outlet port 22 until
it is sufficiently seated and the knob 44 faces the front end of
the water heater 10 (see FIG. 1A).
[0076] The flexible portion 39 of the conduit assembly 28 is then
gently bent to attach the conduit assembly 28 to the mixing device
26. First, the nut 48 is slid backwards to expose the flared
portion 47 of the conduit 43. The flared portion 47 is then aligned
with the chamfered portion 84 of the mixing device 26. The nut 48
is slid in the forward direction to engage the interior threads of
the nut 48 with the threaded region 82 of the mixing device 26. The
interior threads of the nut 48 are rotated onto the threaded region
82 of the mixing device 26 until the nut 48 is firmly seated.
[0077] The female threaded end of the cold water supply line 12 is
threaded onto the threaded portion 58 of the fitting 24. Similarly,
the female threaded end of the hot water supply line 14 is threaded
onto the threaded portion 80 of the mixing device 26.
[0078] Assuming that the locking ring 90 is not pre-assembled to
the mixing device 26, the installer or end user may rotate the knob
44 to set the tempered water temperature. Depending upon the end
user requirements, the installer (or end user) may rotate the knob
44 in a counter-clockwise direction to increase the tempered water
temperature. Conversely, the installer may rotate the knob 44 in a
clockwise direction to decrease the tempered water temperature.
[0079] Once the desired tempered water temperature is reached, the
installer may optionally mount the locking ring 90 to the mixing
device 26, to set the knob 44 to either an adjustable configuration
or a locked configuration.
[0080] More specifically, to set the knob 44 to a locked
configuration, the fastener 94 and the knob 44 are temporarily
removed from the mixing device 26. The locking device 90 is then
installed over the mixing device 100 such that the arrow 110 of the
locking device 90 is oriented as shown in FIG. 5D. The knob 44 is
then repositioned such that the detents 106 of the knob 44 are
positioned on either side of the tab 108 of the locking device 90
(as shown in FIG. 5F). The fastener 94 is then reinserted through
the hole 95 of the knob 44 and threaded into the threaded hole 93
of the stud 92. The tab 108 prohibits rotation of the detents 106,
such that the knob 44 can not be inadvertently rotated. The water
heater 10 and the water tempering device 16 are then ready for
use.
[0081] Alternatively, to set the knob 44 to an adjustable
configuration, the fastener 94 and the knob 44 are temporarily
removed from the mixing device 26. The locking device 90 is then
installed over the mixing device 100 such that the arrow 110 of the
locking device 90 is oriented as shown in FIG. 5D. The knob 44 is
then repositioned such that the detents 106 of the knob 44 are
positioned adjacent the tab 108 of the locking device 90 (as shown
in FIG. 5H). The fastener 94 is then reinserted through the hole 95
of the knob 44 and threaded into the threaded hole 93 of the stud
92. In an adjustable configuration, the knob 44 may be rotated in
either direction until the detents 106 of the knob 44 bear on the
tab 108 of the locking ring 90 indicating that the maximum or
minimum tempered water temperature has been reached. The water
heater 10 and the water tempering device 16 are then ready for
use.
[0082] It should be understood from the foregoing description that
the installation of the water tempering device 16 onto the water
heater 10 does not require any, soldering, welding or pipe cutting
operations. Additionally, no special tools are required for
installing the water tempering device 16 to a water heater (either
new or pre-existing) and water supply lines.
[0083] FIG. 7 depicts a top perspective schematic view of a kit 120
including the disassembled components of the water tempering device
16 (including the fitting 24, conduit assembly 28, locking ring 90
and the mixing device 26) placed within a packaging box 122
according to aspects of this invention. An Allen wrench 124 is
optionally provided with the kit 120 for fastening the fastener 94
of the mixing device 26. An instruction manual 126 may also be
provided with the kit 120. The instruction manual 126 contains
instructions for assembling the water tempering device 16 onto a
water heater. The kit 120 may be provided and packaged along with a
new water heater. Alternatively, the kit 120 may be packaged and
sold separately for retrofitting a water tempering device 16 to an
existing water heater.
[0084] 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.
* * * * *