Abstract: A water heater includes a spud connected to a tank wall and surrounding an opening in the tank wall. A support surface is provided in the spud, preferably by the tank wall, that supports a heat trap within the spud. A pipe is inserted into the spud and a portion of the heat trap is disposed between the end of the pipe and the support surface. The heat trap preferably includes and elongated portion that acts as a dielectric between the tank and the pipes.

Abstract: A self-cleaning water heater element is provided. The water heater element is plated with a layer of gold such that the gold surface has a low surface roughness. The smooth gold surface inhibits scale formation on the water heater element. The gold-plated smooth-surfaced water heater element may be manufactured by coating a standard water heater element with an adhesion layer, electroplating a layer of bright nickel on the adhesion layer, and electroplating a gold layer on top of the bright nickel layer.

Abstract: A water heater including a water tank, a combustion chamber beneath the tank, a gas burner in the combustion chamber, an air plenum upstream of the combustion chamber, a flame arrestor located such that air in the air plenum passes through the flame arrestor to reach the combustion chamber, and a flue extending upwardly from the combustion chamber and through the water tank.

Abstract: A water heater including a water tank, a combustion chamber beneath the tank, a gas burner in the combustion chamber, an air plenum upstream of the combustion chamber, a flame arrestor located such that air in the air plenum passes through the flame arrestor to reach the combustion chamber, and a flue extending upwardly from the combustion chamber and through the water tank.

Abstract: A combined potable water heater and hydronic heating system including: a water tank for holding hydronic heating water; a flue extending through the tank; a burner below the flue so that heat and exhaust gases generated by the burner pass through the flue to heat the water in the tank; and a potable water container mounted in the tank so that the hydronic heating water heats the water in the potable water container and so that the hydronic water is separated from the potable water.

Abstract: An inlet tube or dip tube for use in a water heater includes a cylindrical tube having near its top end a plurality of outwardly-facing upper openings having a combined upper surface area. The tube also has near its bottom end a plurality of outwardly-facing lower openings having a combined lower surface area, and a downwardly-facing bottom opening defining a bottom surface area. The lower surface area is about fourteen times larger than the upper surface area, and about four times larger than the bottom surface area to provide an even distribution of water in the water heater tank.

Abstract: A water heater including a water tank, a combustion chamber beneath the tank, a gas burner in the combustion chamber, an air plenum upstream of the combustion chamber, a flame arrestor located such that air in the air plenum passes through the flame arrestor to reach the combustion chamber, and a flue extending upwardly from the combustion chamber and through the water tank.

Abstract: A combustion burner includes a housing secured to the top of a water heater, a gas tube in fluid communication with a source of gas and depending vertically from the housing and positioned within a heat exchange tube of the water heater. The An ignition assembly depends vertically from the top of the housing through the gas tube and into the heat exchange tube. An angled nozzle, extending from the housing, transports air from an air blower through the housing and into an annulus defined between the exterior of the annular chamber and the interior of the heat exchange tube. A deflector plate having a first and second series of slots and adjacent louvers effects the mixture of the gas and air in the interior of the heat exchange tube and enables the production of a long narrow flame within the heat exchange tube.

Abstract: A gas combustion apparatus including a housing having a top wall and a side wall, the top wall and the side wall defining vertical and horizontal openings, respectively, and the housing defining a combustion chamber having an exhaust opening; a burner mounted in the combustion chamber; and a vent assembly for venting exhaust gases generated by the burner to either the vertical or the horizontal opening, the vent assembly including two substantially identical vent conduits, each of the vent conduits having a central axis, a first end defined by a first continuous edge lying in a plane perpendicular to the central axis, and a second end defined by a second continuous edge lying in a plane at a forty-five degree angle to the central axis, the second ends of the vent conduits being connected together with the central axes of the conduits aligned to conduct exhaust gases between the exhaust opening and one of the vertical opening and the horizontal opening, and the second ends of the conduits being connected toget

Abstract: A water-based inorganic coating formulation that contains no lead, and no organic matters, and provides for better control of the viscosity, the stability, the material separation, the homogeneity, and the re-crystallization properties of the formulation. This improved water-based inorganic coating formulation includes a water-based alkaline metal silicate solution, a pigment, and colloidal alumina dispersed within the coating formulation.

Abstract: Coatings are described to improve the performance of cathodic protection systems used in water heater tanks. Semi-permeable sparingly soluble films of silicates and other organic resins protect critical areas of sacrificial anodes from concentrated usage which could sever their tank connections, yet preserve the total amount of protection available. They reduce usage of these more active anode areas and return them to service after less active ones are used up, and when the corrosion rate of exposed metal in the tank has been reduced by prolonged service, thus further extending anode life. Other coatings reduce usage of the entire anode in high conductivity waters and in electric heaters where such protection is rapidly consumed by secondary chemical reactions or absorbed by electric heating elements. These coatings also prevent complete deactivation of the anode by oxides, and bacterial interactions which generate objectionable odors.

Abstract: A multi-function controller for a water heater is advanced comprising a control panel and a plurality of sensors that monitor a variety of functions that impact the operation of a water heater. A flammable gas sensor, placed in proximity to the air intake, detects the presence of an unsafe concentration of gas and issues a signal to the control panel, which subsequently discontinues the operation of the burners. Detection of a blocked vent pipe is achieved by a carbon monoxide sensor placed near the draft hood. The control panel is equipped with circuitry which monitors usage of the heater for a specified time period to develop a pattern of use. Subsequent to the monitoring period, the controller will activate the burners a predetermined time prior to an anticipated period of high use. During periods of low use, the controller will decrease the temperature to which the water is to be heated, thereby resulting in a more efficient heater.

Abstract: A combination punch and rivet tool, the tool being adapted to be mounted on the end of a robot arm, the tool comprising a C frame having two opposed sides, a punch die mounted on one side of the C frame, an anvil slidably mounted on said one side adjacent the punch die and selectively movable between a first position away from the punch die and a second position over the punch die, and a combination cylinder mounted on the other side of the C frame opposite the punch die, the combination cylinder comprising a coaxial inner punch and an outer rivet forming tool.

Abstract: The present invention is a commercial water heater comprising a tank dimensioned to hold a quantity of water, a blower, a heater, a heat exchanger in the water, and a control system. The heat exchanger includes a central tube running from the top of the tank to the bottom and a coil connected to and encircling the central tube. The heater is mounted inside the central tube, and the blower is mounted to the top of the tank, which together simplify manufacture and servicing. The blower is capable of delivering sufficient air for combustion at a pressure and velocity sufficient to drive the exhaust gases fifty feet beyond the water heater outlet, thus avoiding the need for a chimney. The water heater according to the present invention has an average efficiency of 93% with a 1% standby loss and is considerably cheaper to manufacture than other similarly efficient water heaters.

Abstract: Combustion apparatus comprising a combustion chamber, a forced draft mixer and burner assembly extending into the combustion chamber, the assembly including a mixing tube having an open end, an opposed closed end, and a generally cylindrical, foraminous side wall extending between the ends, and a plurality of generally circular disks supported in the tube in spaced-apart relation over the length of the tube, the diameters of the disks increasing in the direction from the open end to the closed end, a blower for supplying air to the to the open end of the mixing tube, and a heat exchanger located in the combustion chamber adjacent the mixer and burner assembly.

Abstract: A water heater comprising a tank defining a water chamber and having an outer surface, a spud mounted on the outer surface, a jacket surrounding the tank and having an inner surface spaced from the tank outer surface, an opening aligned with the spud, a margin around the opening and converging inwardly toward the tank, insulating material between the tank and the jacket, and a fitting threaded into the spud and having a tapered outer surface which engages the margin to form a seal against the insulating material.

Abstract: A water heater comprising a tank adapted to hold water, a water outlet communicating with the tank, a water inlet communicating with the tank and communicable with the outlet independently of the tank, and a temperature responsive valve in the tank for permitting unrestricted communication of heated water in the tank with the water outlet when the water temperature in the tank is below a predetermined value, and for restricting communication of heated water in the tank with the water outlet when the water temperature in the tank is above the predetermined value.

Abstract: A water heater comprising a tank defining a water chamber, a combustion chamber for heating water in the water chamber, and a combustion air inlet pipe including an outlet end communicating with the combustion chamber. The inlet pipe also includes an inlet end having a longitudinal axis, and a plate in the combustion air inlet pipe adjacent the inlet end, which plate extends outwardly of the inlet end along the longitudinal axis.

Abstract: An electric water heater tank defines a water chamber having an electrical component extending outwardly of the outer surface of the tank. A spaced outer jacket surrounds the tank and has a opening affording access to the component. A protective dam in the opening bridges the gap between the tank and jacket in surrounding relationship to the component and is covered by a cap extending over the component and engaging the dam. Electrical wires connected to the component extend outwardly of the jacket between the cap and dam. A door covers the cap and dam and is secured to the jacket such that the door engages the cap to force the dam into sealing engagement with the jacket and tank. Foam thermal insulation material fills the space between the jacket and the outer surface of the tank.