U.S. patent application number 14/081414 was filed with the patent office on 2014-05-29 for water heater valves and controllers and methods of mounting the same.
This patent application is currently assigned to Emerson Electric Co.. The applicant listed for this patent is Emerson Electric Co.. Invention is credited to Donald L. Blessing, Thomas P. Buescher.
Application Number | 20140144395 14/081414 |
Document ID | / |
Family ID | 50772161 |
Filed Date | 2014-05-29 |
United States Patent
Application |
20140144395 |
Kind Code |
A1 |
Blessing; Donald L. ; et
al. |
May 29, 2014 |
Water Heater Valves and Controllers and Methods of Mounting the
Same
Abstract
Exemplary embodiments are disclosed of valves and controllers
for water heaters. Also disclosed are mounting methods for valves
and controllers for water heaters. In an exemplary embodiment, a
gas valve and controller are mounted to and/or located at a burner
door of a water heater.
Inventors: |
Blessing; Donald L.; (St.
Louis, MO) ; Buescher; Thomas P.; (St. Louis,
MO) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Emerson Electric Co. |
St. Louis |
MO |
US |
|
|
Assignee: |
Emerson Electric Co.
St. Louis
MO
|
Family ID: |
50772161 |
Appl. No.: |
14/081414 |
Filed: |
November 15, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61730484 |
Nov 27, 2012 |
|
|
|
Current U.S.
Class: |
122/14.22 ;
122/19.2 |
Current CPC
Class: |
F24H 9/2035 20130101;
F24H 1/186 20130101 |
Class at
Publication: |
122/14.22 ;
122/19.2 |
International
Class: |
F24H 9/20 20060101
F24H009/20 |
Claims
1. A water heater comprising: a storage tank; a combustion chamber
below the storage tank; a burner assembly within the combustion
chamber for heating water in the storage tank; a burner tube for
supplying fuel to the burner assembly; a tank jacket disposed
around the storage tank and including an opening through which the
burner tube passes; and a gas valve and controller located at the
opening of the tank jacket and including a valve outlet coupled to
the burner tube for controlling a supply of fuel to the burner
assembly via the burner tube.
2. The water heater of claim 1, further comprising a housing
coupled to the water heater that houses components of the gas valve
and controller and covers the opening of the tank jacket.
3. The water heater of claim 1, wherein the gas valve and
controller comprises one or more user interface items facing
upward, whereby the one or more user interface items are visible
from above.
4. The water heater of claim 1, wherein the gas valve and
controller comprises one or more user interface items facing
upward, whereby the one or more user interface items are visible
from above by a user in a standing position.
5. The water heater of claim 4, wherein the one or more user
interface items comprise: a switch for selectively changing an
operational setting of the burner assembly between OFF, PILOT, and
ON; a pilot indicator light configured to illuminate when there is
sufficient heat to hold a pilot valve open; and a mirrored surface
configured to allow verification that a pilot light is lit.
6. The water heater of claim 5, further comprising a housing that
houses components of the gas valve and controller and covers the
opening of the tank jacket, wherein the switch, the pilot indicator
light, and the mirrored surface are on an upper surface of the
housing.
7. The water heater of claim 1, further comprising one or more
surface mount temperature sensors coupled to an outer surface of
the storage tank for sensing a temperature of water in the storage
tank without using immersion temperature sensors.
8. The water heater of claim 7, wherein the one or more surface
mount temperature sensors comprise: a first temperature sensor
printed circuit board including a thermistor positioned against the
outer surface of the storage tank adjacent a bottom of the storage
tank; and/or a second temperature sensor printed circuit board
including a thermistor positioned against the outer surface of the
storage tank adjacent a top of the storage tank.
9. The water heater of claim 1, further comprising a temperature
selection control for selectively changing a temperature setpoint
for water in the storage tank, and including one or more surface
mount temperature sensors for sensing a temperature of water in the
storage tank without using immersion temperature sensors, wherein
the temperature selection control is located closer to a top of the
water heater than to a bottom of the water heater, whereby the
temperature selection control is at eye level.
10. A gas valve and controller for controlling a supply of fuel for
a sealed combustion water heater having a burner door, the gas
valve and controller comprising: a valve outlet configured to be
coupled to a burner tube passing through the burner door; a housing
in which components of the gas valve and controller are housed, the
housing configured to be mounted to the water heater and to cover
and seal the burner door; and one or more user interface items
facing upward and visible from above.
11. The gas valve and controller of claim 10, wherein the one or
more user interface items comprise: a switch for selectively
changing an operational setting between OFF, PILOT, and ON; a pilot
indicator light configured to illuminate when there is sufficient
heat to hold a pilot valve open; and a mirrored surface configured
to allow verification that a pilot light is lit.
12. The gas valve and controller of claim 11, wherein the switch,
the pilot indicator light, and the mirrored surface are on an upper
surface of the housing.
13. A water heater comprising the gas valve and controller of claim
10, the water heater further comprising: one or more surface mount
temperature sensors configured to be coupled to an outer surface of
a storage tank of the water heater for sensing a temperature of
water in the storage tank without using immersion temperature
sensors; and a temperature selection control for selectively
changing a temperature setpoint for water in the storage tank, and
including at least one of said one or more surface mount
temperature sensors.
14. The water heater of claim 13, wherein the one or more surface
mount temperature sensors comprise: a first temperature sensor
printed circuit board including a thermistor positionable against
the outer surface of the storage tank adjacent a bottom of the
storage tank; and/or a second temperature sensor printed circuit
board including a thermistor positionable against the outer surface
of the storage tank adjacent a top of the storage tank, the
temperature selection control including the second temperature
sensor printed circuit board.
15. A sealed combustion water heater comprising: a burner door; a
burner tube passing through the burner door; a gas valve and
controller located at the burner door and including a valve outlet
coupled to the burner tube for controlling a supply of fuel to the
burner tube; and a housing in which components of the gas valve and
controller are housed, the housing mounted to the water heater so
as to cover and seal the burner door.
16. The water heater of claim 15, wherein the burner door is an
opening in an outside tank jacket of the water heater.
17. The water heater of claim 15, further comprising one or more
user interface items on an upper surface of the housing and facing
upward, whereby the one or more user interface items are visible
from above.
18. The water heater of claim 17, wherein the one or more user
interface items comprise: a switch for selectively changing an
operational setting between OFF, PILOT, and ON; a pilot indicator
light configured to illuminate when there is sufficient heat to
hold a pilot valve open; and a mirrored surface configured to allow
verification that a pilot light is lit.
19. The water heater of claim 15, further comprising: one or more
surface mount temperature sensors coupled to an outer surface of a
storage tank of the water heater for sensing a temperature of water
in the storage tank without using immersion temperature sensors;
and a temperature selection control for selectively changing a
temperature setpoint for water in the storage tank, and including
at least one of said one or more surface mount temperature
sensors.
20. The water heater of claim 19, wherein: the one or more surface
mount temperature sensors comprise first and second thermistors
positioned against the outer surface of the storage tank adjacent a
respective bottom and top of the storage tank; and/or the
temperature selection control is located closer to a top of the
water heater than to a bottom of the water heater, whereby the
temperature selection control is at eye level.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional
Application No. 61/730,484 filed Nov. 27, 2012. The entire
disclosure of the above application is incorporated herein by
reference.
FIELD
[0002] The present disclosure generally relates to valves and
controllers for water heaters.
BACKGROUND
[0003] This section provides background information related to the
present disclosure which is not necessarily prior art.
[0004] Water heater controllers are currently mounted to an
immersion flange on or at the bottom of the water heater. Recently,
water heaters moved to flammable vapor systems that have a sealed
combustion system to prevent ignition of flammable vapors outside
the water heater. The sealed system uses a burner door, through
which the burner tube passes.
SUMMARY
[0005] This section provides a general summary of the disclosure,
and is not a comprehensive disclosure of its full scope or all of
its features.
[0006] Exemplary embodiments are disclosed of valves and
controllers for water heaters. Also disclosed are mounting methods
for valves and controllers for water heaters. In an exemplary
embodiment, a gas valve and controller of are mounted to and/or
located at a burner door of a water heater.
[0007] Further areas of applicability will become apparent from the
description provided herein. The description and specific examples
in this summary are intended for purposes of illustration only and
are not intended to limit the scope of the present disclosure.
DRAWINGS
[0008] The drawings described herein are for illustrative purposes
only of selected embodiments and not all possible implementations,
and are not intended to limit the scope of the present
disclosure
[0009] FIG. 1 is a perspective view of a water heater having a gas
valve and controller mounted to or fixed to or at the burner door
according to an exemplary embodiment;
[0010] FIG. 2 is an exploded perspective view showing the gas valve
and controller aligned with a burner door of the water heater shown
in FIG. 1 without the cover or housing that houses the controller
and covers the burner door;
[0011] FIG. 3 is an exploded perspective view of the temperature
selection control for adjusting the temperature setting or setpoint
for water in the storage tank, where the knob, dial, and PCB are
aligned with an opening in the storage tank of the water heater
shown in FIG. 1;
[0012] FIG. 4 is an upper perspective view of the gas valve and
controller of the water heater shown in FIG. 1, and also
illustrating how the user interface items are upwardly facing such
that various features and functions (e.g., knob, indicator light,
mirrored surface to verify whether pilot light is lit, etc.) are
visible to a user from above or standing position according to an
exemplary embodiment;
[0013] FIG. 5 is a perspective view of the knob and dial for
adjusting the temperature setting of the water heater shown in FIG.
1, and also illustrating the dial features including a
vacation/warm setting, a very hot setting, and a factory test
setting to allow a system functional test (e.g., at the factory,
etc.) from a lower portion of the tank according to an exemplary
embodiment;
[0014] FIG. 6 is an upper perspective view of a gas valve and
controller having a side entry option for the gas supply according
to an exemplary embodiment;
[0015] FIG. 7 is a perspective view of an exemplary embodiment of a
water heater having a gas valve and controller mounted to or fixed
to the burner door, where the water heater has the side entry
option for the gas supply as shown in FIG. 6, and a knob and dial
located towards a top of the water heater to be at or close to eye
level of the user;
[0016] FIG. 8 is a perspective view of another exemplary embodiment
of a water heater having a gas valve and controller mounted to or
fixed to the burner door, where the water heater has the side entry
option for the gas supply as shown in FIG. 6, and a knob and dial
located towards a bottom of the water heater; and
[0017] FIG. 9 is a perspective view of another exemplary embodiment
of a water heater having a gas valve and controller mounted to or
fixed to the burner door, where the water heater has the side entry
option for the gas supply as shown in FIG. 6 without a knob and
dial dial mounted on the water heater tank jacket.
[0018] Corresponding reference numerals indicate corresponding
parts throughout the several views of the drawings.
DETAILED DESCRIPTION
[0019] Example embodiments will now be described more fully with
reference to the accompanying drawings.
[0020] As mentioned above in the background, water heater
controllers or controls are currently mounted to an immersion
flange on or at the bottom of the water heater. The inventors
hereof have realized that such immersion mounting methods of the
valve and controller require an expensive brass or engineering
polymer to achieve mounting strength (e.g., 300 pounds per square
inch (psi) burst, etc.) and water leakage tightness (e.g., over 15
years, etc.). This is a potential failure point for some systems
and adds costs to the tank to weld the flange mounting spud to the
hole.
[0021] The inventors have also recognized that the user interface
is forward facing (e.g., about 18 inches off the ground, etc.)
which is not user friendly. For example, the user may be unable
view the user interface when standing up and may need to bend down
to view the user interface. This mounting arrangement is due to the
legacy of water heaters being open burner systems.
[0022] After recognizing the above, the inventors developed and
disclose herein exemplary embodiments in which certain components
typically used in a standing storage gas fired water heater (e.g.,
the burner assembly, pilot light assembly, flame sense rod,
ignition device (e.g., spark to pilot light, spark to main burner,
or hot surface igniter, etc.), and the gas valve and controller if
the system is microprocessor controlled, etc.) are mounted to a
burner door or opening of a sealed combustion water heater.
[0023] In exemplary embodiments, the parts that pass through the
sealed door into the combustion chamber are sealed. Exemplary
embodiments may include a sealed door assembly in which a burner
assembly, pilot light assembly, and flame sense rod may be mounted
to the door of a sealed combustion water heater. By way of example,
an exemplary embodiment may include a door assembly similar to that
disclosed in U.S. Patent Application Publication US2010/0101510,
U.S. Patent Application Publication US2010/0154724, U.S. Pat. No.
6,302,062, U.S. Pat. No. 6,439,171, and/or U.S. Pat. No. 6,554,610.
Generally, these patent documents disclose various concepts of
sealing the parts that pass through the sealed door into the
combustion chamber. Significantly, aspects of the present
disclosure may build upon and improve upon these concepts disclosed
by adding a gas valve and controller to the components that may be
typically fixed or mounted to the burner door.
[0024] In exemplary embodiments in which the gas valve and
controller are also mounted or fixed to or at the burner door, this
construction may necessitate the use of one or more surface mount
temperature sensors to replace the immersion temperature sensors
that are typically part of the tank mounted gas valves. In
alternative embodiments, the temperature setting user interface
(e.g., rotary switch, other switch, etc.) is located on the tank
and connected to the surface mount sensor and also the main
controller or control on the door.
[0025] With reference now to the figures, FIGS. 1 and 2 illustrate
an exemplary embodiment of a sealed combustion water heater 100
embodying one or more aspects of the present disclosure. A gas
valve and controller 104 is mounted to or fixed to a door 108 of
the sealed combustion water heater 100. As shown in FIG. 2, the
door 108 is an opening in the outside tank jacket 122 located at,
adjacent, or towards a bottom of the water heater 100.
[0026] As shown in FIG. 1, the water heater 100 includes a gas (or
other fuel) supply line 112. In this example, the gas supply thus
enters the valve from the top. Also in this example, the controller
or control has a built in trap for added protection.
[0027] The water heater 100 also includes a temperature selection
assembly or control comprising a rotatable knob 116 (broadly, a
switch or temperature setting user interface), a dial 120, and
printed circuit board 148. The rotary knob 116 allow a user to
select or adjust the temperature setting or setpoint for the hot
water in the storage tank. By way of example, the temperature
selection control may comprise a potentiometer on a circuit board
and an actuating knob/dial for temperature setting at a sensor
location. The circuit board may be the same circuit board as the
sensor circuit board or a separate circuit board. The knob may be a
cover for a plastic mounting that also is a foam dam.
[0028] In this exemplary embodiment, the knob 116 is located
towards a top of the water heater 100 such that the knob 116 will
be at or close to the eye level of the user (e.g., between about
51/2 feet and 6 feet above floor level, etc.). The knob 116 and
dial 120 are closer to the top than the bottom of the water heater
100. Alternative embodiments may include different means for
adjusting the temperature settings and/or at different locations.
See, for example, FIG. 7 in which the knob 416 and dial 420 are
located towards a bottom of the water heater 400.
[0029] In FIG. 2, the gas valve and controller 104 is shown aligned
with the burner door or opening 108 in the outside tank jacket 122.
The gas valve and controller 104 is shown in FIG. 2 without a cover
or housing 128. FIG. 1 illustrates the cover or housing 128 that
may be used to house components of the gas valve and controller
104. The cover or housing 128 may also be used to cover and seal
the burner door or opening 108 in the outer tank jacket 122. The
housing 128 may comprise a plastic part or other suitable material
that is configured to be snapped into the outside tank jacket 122
or mounted by some other mechanical means to the tank jacket
122.
[0030] The gas valve and controller 104 includes a rotatable knob
132 (broadly, a switch) for selectively changing the operational
status or settings of the water heater between OFF, PILOT, and ON
(FIG. 4). The outlet of the valve may be coupled to the burner tube
140 (e.g., valve outlet threaded onto or over the threaded portion
of the burner tube 140 (FIG. 2), etc.) exiting the burner door 108.
The valve may thus supply gas to the burner assembly within the
combustion chamber via the burner tube 140. The combustion chamber
is located beneath the water storage tank of the water heater
100.
[0031] FIG. 3 shows the temperature adjustment knob 116 and dial
120 aligned with an opening 144 in the outside tank jacket 122.
Also shown in FIG. 3 is a temperature sensor printed circuit board
(PCB) 148. The PCB 148 may include a temperature sensor, e.g., a
thermistor attached to the PCB 148, etc. For example, the
temperature sensor may be a surface mount thermistor for the
purpose of detecting the temperature of the water in the storage
tank. The sensed temperature input from the temperature sensor may
be compared to a potentiometer input from the knob 116. The knob
116 may be used by the user of the water heater to select the
desired temperature of the water being heated. The PCB 148 of FIG.
3 is connected (e.g., via a wired or wireless connection, etc.) to
the PCB 136 of FIG. 2.
[0032] An electrically conductive, electrically insulating barrier
may be applied to the PCB 148 or to a second part installed between
the thermistor and the storage tank wall. The PCB 148 may be
positioned such that the temperature sensor is against the outer
surface of the storage tank wall, to thereby provide surface
temperature sensing.
[0033] FIG. 2 shows a main control board 136 for the gas valve. The
component 136 might also be considered or referred to as the
combustion control. The purpose of this circuit or control 136 is
to receive temperature information from the temperature selection
assembly shown in FIG. 3 and begin a heating cycle of the water
heater 100, if required or appropriate. The temperature information
received from the temperature selection control shown in FIG. 3 may
be in the form of a variable voltage signal or a discreet voltage
level, e.g., depending on whether or not the logic for the
temperature measurement is in the PCB of the main control board 136
(FIG. 2) or the PCB 148 (FIG. 3). In an exemplary embodiment, the
comparison of sensed temperature to the selected setpoint (chosen
by the knob 116 of FIG. 3) occurs in the temperature selection
control of FIG. 3. In an alternative embodiment, the voltage of a
thermistor (e.g., attached to PCB 148 in FIG. 3, etc.) and the
voltage due to the selected setpoint (via knob 116) may be sent to
the PCB of the main control board 136 (FIG. 2) for comparison.
[0034] The PCB 148 and temperature sensor thereof may be located at
or adjacent the top, middle, or bottom of the water heater 100.
Some embodiments include only one temperature sensor, while other
embodiments may include two or more temperature sensors. For
example, the temperature sensor of the PCB 148 and another
temperature sensor may be located at or adjacent the respective top
and bottom of the water heater 100, or vice versa. In which case,
there is a first temperature sensor at or towards the bottom of the
tank and a second temperature sensor at or towards the top of the
tank.
[0035] Advantageously, mounting the gas valve and controller 104 to
the burner door 108 may allow for the elimination of various costs
associated with conventional mounting and immersion sensing. For
example, costs associated with a conventional flange assembly,
burner tube, Noryl plastic, threaded spud, knob/pot, and steel
cover may be eliminated. Costs may be added to achieve surface
sensing and to cover the burner door, such as costs associated with
a harness, temperature sensor (T-sense) printed circuit board (PCB)
and knob, T-sense PCB and cover, valve support bracket, and bottom
cover.
[0036] As shown in FIG. 4, the gas valve and controller 104
includes user interface items that are upwardly facing such that
various features and functions are visible to a user from above or
standing position. For example, the rotatable knob 132, OFF, PILOT,
ON settings, the pilot indicator light 152, and mirrored surface
156 are visible to a user from above, e.g., when standing above the
gas valve and controller 104, etc. The pilot indicator light 152
illuminates to verify when sufficient heat to hold a pilot valve
open has been attained. The mirrored surface 156 allows for easy
verification that the pilot light is lit. The knob 132, the pilot
indicator light 152, and the mirrored surface 156 are disposed
within recessed portions on or along an upper surface of the
housing or cover 128.
[0037] FIG. 5 shows the knob 116 and dial 120 for adjusting the
temperature setting of the water heater 100. As shown, the dial
features include a vacation/warm setting, a very hot setting, and
settings therebetween. This example also includes a factory test
setting 160 to allow a system functional test (e.g., at the
factory, etc.) from a lower portion of the tank according to an
exemplary embodiment. The knob 116 and dial 120 may be relatively
large, easy to read, and located at eye level.
[0038] FIG. 6 shows a gas valve and controller 204 having a side
entry option for the gas supply 212 according to another exemplary
embodiment. Accordingly, the gas supply thus enters the valve from
the side. Also in this exemplary embodiment, the gas valve and
controller 204 also includes a rotatable knob 232 for selectively
changing the settings between OFF, PILOT, and ON. There is also a
pilot indicator light 252 and a mirrored surface 256. The pilot
indicator light 252 illuminates to verify when sufficient heat to
hold a pilot valve open has been attained. The mirrored surface 256
allows for easy verification that the pilot light is lit. A housing
or cover 228 may be used to house components of the gas valve and
controller 204. The cover or housing 228 may also be used to cover
and seal the burner door.
[0039] FIGS. 7 through 9 illustrate exemplary embodiments of
respective water heaters 300, 400, and 500 having a gas valve and
controller 304, 404, 504 mounted to or fixed to the burner door and
also having a side entry option for the gas supply 312, 412, 512 as
shown in FIG. 6. A comparison of FIGS. 7 through 9 generally shows
how aspects of the present disclosure allow for incremental
features. And, surface sensing with dual sensors may also allow for
control optional upgrades in some exemplary embodiments.
[0040] As shown in FIG. 7, the water heater 300 includes a knob 316
and dial 320 located towards a top of the water heater 300. The
knob 316 and dial 320 will thus be at or close to eye level of the
user. By comparison, the water heater 400 shown in FIG. 8 includes
a knob 416 and dial 420 located towards a bottom of the water
heater 400.
[0041] The water heater 500 shown in FIG. 9 does not include a knob
and dial mounted on the water heater tank jacket. In this exemplary
embodiment, a temperature selection control (e.g., knob, dial,
etc.) may be located with the control 502 and mounted on the
combustion door cover. This exemplary embodiment may include at
least one surface mounted temperature sensor mounted on the storage
tank near the cold water inlet at the bottom.
[0042] By way of example, the water heater may include only one
surface mount temperature sensor if the temperature selection
control shown in FIG. 3 is located towards a bottom of the water
heater as shown in FIG. 8. If the temperature selection control
(e.g., knob 116, dial 120, and PCB 148, etc.) is located towards a
top of the water heater 300 as shown in FIG. 7, then there may be
two surface mounted temperature sensors. For example, one sensor
may be located behind the temperature selection control towards a
top of the water heater, and another sensor may be located towards
the bottom of the water heater, e.g., at about the same location
that the temperature setpoint selection device is located in FIG.
8, etc. But the water heater 300 (FIG. 7) may also include only a
single surface mounted temperature sensor. In which case, the
single temperature sensor may be located towards a bottom of the
tank (e.g., at about the same location that the knob 416 is located
in FIG. 8, etc.) with a wired connection running up to the
selection knob 316 as located in FIG. 7. For gas storage water
heaters, there is typically at least one temperature sensor located
near the bottom of the tank to detect the cold water entering the
tank during a draw of hot water from the top of the tank. This
helps ensure the heating process will start soon (e.g., as soon as
possible, etc.) to avoid a shortage of hot water. In some exemplary
embodiments, a second sensor may be added such that there at least
two sensors, where one sensor is at or towards the bottom and
another sensor is at or towards the top to help control or avoid a
condition called "stacking".
[0043] Conventional immersion flange/spud mounting for water heater
controls generally has three functions. First is to structurally
mount the control system, second is to sense water temperature, and
third is provide a water seal for the immersion sensing. These
three functions may be addressed in exemplary embodiments disclosed
herein as follows. The structural mounting of the control system is
moved to the burner door area. The outlet of the valve is mounted
to the pipe or burner tube exiting the burner door. Extra brackets
or features may be used to support the valve when necessary. A
housing or cover (e.g., plastic part, etc.) may be used to cover
the burner door area that also allows integration of the valve
control knobs, LEDs, and other user interface items on the top of
the cover, such that a user is able to see these items from a
standing position. A mirrored surface may be provided to allow a
user to see the pilot light or burner status from a standing
position. The sensing function may be achieved using surface mount
sensors. The sensors may be mechanical, electrical, or a
combination of both. Lastly, the seal function is no longer needed
because the tank no longer needs a hole for immersion sensing when
the sensing is accomplished using surface mount sensors.
[0044] Typically, a surface mount sensor system on a gas water
heater will have two sensors, specifically one sensor at the bottom
of the tank and one sensor at the top. A method of achieving this
temperature sensing that has cost and customer usage benefits may
be provided as follows in exemplary embodiments. An electrically
conductive, electrically insulating barrier could be applied to a
circuit board having an attached thermistor. Or, an electrically
conductive, electrically insulating barrier may be applied to a
second part installed between the thermistor and the tank wall. A
PCB may be positioned such that the PCB temperature sensor (e.g.,
thermistor, etc.) is against an outer surface of the storage tank
wall, to thereby provide surface temperature sensing. A housing
(e.g., plastic, etc.) may cover the area in the outside tank jacket
and spring load the temperature sensor against the tank wall. The
housing (e.g., plastic part, etc.) may be snapped into the outside
tank jacket or mounted by some other mechanical means to the tank
jacket.
[0045] In an alternative embodiment, a first housing (e.g., plastic
housing, etc.) may be used as an insulation foam dam to protect
this area from the insulation process to allow field service. In
this alternative construction, the first housing may not cover the
hole or opening in the tank jacket. Instead, an additional or
second cover may be used to fill the hole or opening in the outside
tank jacket.
[0046] Additionally, a sensor/plastic mounting assembly may also
use a potentiometer on a circuit board and an actuating knob/dial
for temperature setting at a sensor location. An optimal or
preferred location is at the top sensor. The circuit board could be
the same circuit board as the sensor circuit board, or a separate
circuit board. The knob could be a cover for a plastic mounting
that also is a foam dam.
[0047] Exemplary embodiments disclosed herein may provide one or
more (but not necessarily any or all) of the following advantages,
such as differentiation in the market, more feasible methodology to
integrate flammable vapor ignition resistant (FVIR) sensing,
placement of the main user interaction at eye level, and/or hide or
conceal the gas valve and related components from view. Also by way
of example, attaching the valve and control system to the burner
door area reduces costs associated with mounting and sealing the
water heater control to the tank. It also allows for a cover to be
mounted over the control system that would allow user information,
including pilot light status and visuals, to be seen from a
standing position. The thermistor mounting method allows for the
use of a low cost circuit board mounted thermistor, and provides
the means to move the temperature control interface to the top of
the heater, where it is easily accessed and seen. Mounting the
valve and control system to the burner door allows for the
elimination of costs associated with the conventional mounting and
immersion sensing, such as the costs associated with a conventional
flange assembly, burner tube, Noryl plastic, threaded spud,
knob/pot, and steel cover.
[0048] Example embodiments are provided so that this disclosure
will be thorough, and will fully convey the scope to those who are
skilled in the art. Numerous specific details are set forth such as
examples of specific components, devices, and methods, to provide a
thorough understanding of embodiments of the present disclosure. It
will be apparent to those skilled in the art that specific details
need not be employed, that example embodiments may be embodied in
many different forms, and that neither should be construed to limit
the scope of the disclosure. In some example embodiments,
well-known processes, well-known device structures, and well-known
technologies are not described in detail. In addition, advantages
and improvements that may be achieved with one or more exemplary
embodiments of the present disclosure are provided for purpose of
illustration only and do not limit the scope of the present
disclosure, as exemplary embodiments disclosed herein may provide
all or none of the above mentioned advantages and improvements and
still fall within the scope of the present disclosure.
[0049] Specific dimensions, specific materials, and/or specific
shapes disclosed herein are example in nature and do not limit the
scope of the present disclosure. The disclosure herein of
particular values and particular ranges of values for given
parameters are not exclusive of other values and ranges of values
that may be useful in one or more of the examples disclosed herein.
Moreover, it is envisioned that any two particular values for a
specific parameter stated herein may define the endpoints of a
range of values that may be suitable for the given parameter (i.e.,
the disclosure of a first value and a second value for a given
parameter can be interpreted as disclosing that any value between
the first and second values could also be employed for the given
parameter). For example, if Parameter X is exemplified herein to
have value A and also exemplified to have value Z, it is envisioned
that parameter X may have a range of values from about A to about
Z. Similarly, it is envisioned that disclosure of two or more
ranges of values for a parameter (whether such ranges are nested,
overlapping or distinct) subsume all possible combination of ranges
for the value that might be claimed using endpoints of the
disclosed ranges. For example, if parameter X is exemplified herein
to have values in the range of 1-10, or 2-9, or 3-8, it is also
envisioned that Parameter X may have other ranges of values
including 1-9, 1-8, 1-3, 1-2, 2-10, 2-8, 2-3, 3-10, and 3-9.
[0050] The terminology used herein is for the purpose of describing
particular example embodiments only and is not intended to be
limiting. As used herein, the singular forms "a," "an," and "the"
may be intended to include the plural forms as well, unless the
context clearly indicates otherwise. The terms "comprises,"
"comprising," "including," and "having," are inclusive and
therefore specify the presence of stated features, integers, steps,
operations, elements, and/or components, but do not preclude the
presence or addition of one or more other features, integers,
steps, operations, elements, components, and/or groups thereof. The
method steps, processes, and operations described herein are not to
be construed as necessarily requiring their performance in the
particular order discussed or illustrated, unless specifically
identified as an order of performance. It is also to be understood
that additional or alternative steps may be employed.
[0051] When an element or layer is referred to as being "on,"
"engaged to," "connected to," or "coupled to" another element or
layer, it may be directly on, engaged, connected or coupled to the
other element or layer, or intervening elements or layers may be
present. In contrast, when an element is referred to as being
"directly on," "directly engaged to," "directly connected to," or
"directly coupled to" another element or layer, there may be no
intervening elements or layers present. Other words used to
describe the relationship between elements should be interpreted in
a like fashion (e.g., "between" versus "directly between,"
"adjacent" versus "directly adjacent," etc.). As used herein, the
term "and/or" includes any and all combinations of one or more of
the associated listed items.
[0052] The term "about" when applied to values indicates that the
calculation or the measurement allows some slight imprecision in
the value (with some approach to exactness in the value;
approximately or reasonably close to the value; nearly). If, for
some reason, the imprecision provided by "about" is not otherwise
understood in the art with this ordinary meaning, then "about" as
used herein indicates at least variations that may arise from
ordinary methods of measuring or using such parameters. For
example, the terms "generally," "about," and "substantially," may
be used herein to mean within manufacturing tolerances.
[0053] Although the terms first, second, third, etc. may be used
herein to describe various elements, components, regions, layers
and/or sections, these elements, components, regions, layers and/or
sections should not be limited by these terms. These terms may be
only used to distinguish one element, component, region, layer or
section from another region, layer or section. Terms such as
"first," "second," and other numerical terms when used herein do
not imply a sequence or order unless clearly indicated by the
context. Thus, a first element, component, region, layer or section
discussed below could be termed a second element, component,
region, layer or section without departing from the teachings of
the example embodiments.
[0054] Spatially relative terms, such as "inner," "outer,"
"beneath," "below," "lower," "above," "upper" and the like, may be
used herein for ease of description to describe one element or
feature's relationship to another element(s) or feature(s) as
illustrated in the figures. Spatially relative terms may be
intended to encompass different orientations of the device in use
or operation in addition to the orientation depicted in the
figures. For example, if the device in the figures is turned over,
elements described as "below" or "beneath" other elements or
features would then be oriented "above" the other elements or
features. Thus, the example term "below" can encompass both an
orientation of above and below. The device may be otherwise
oriented (rotated 90 degrees or at other orientations) and the
spatially relative descriptors used herein interpreted
accordingly.
[0055] The foregoing description of the embodiments has been
provided for purposes of illustration and description. It is not
intended to be exhaustive or to limit the disclosure. Individual
elements, intended or stated uses, or features of a particular
embodiment are generally not limited to that particular embodiment,
but, where applicable, are interchangeable and can be used in a
selected embodiment, even if not specifically shown or described.
The same may also be varied in many ways. Such variations are not
to be regarded as a departure from the disclosure, and all such
modifications are intended to be included within the scope of the
disclosure.
* * * * *