WATER HEATER INLET FITTING, FLOW SENSOR, SHUT OFF VALVE AND DIFFUSER
An integrated valve and flow sensor for a water heater can have a valve body that includes a valve and a flow sensor for measuring the flow of water through the valve. The integrated valve and flow sensor can be disposed within a fitting that can be attached to a water heater. An actuator for opening and closing the valve can be attached to the fitting. A diffuser can also be attached to the fitting.
The present application is a divisional application of U.S. patent application Ser. No. 16/042,386 filed Jul. 23, 2018, which claims priority to U.S. Provisional Patent Application No. 62/535,592, filed Jul. 21, 2017, the entire contents of which are incorporated herein by reference.
TECHNICAL FIELDThe present disclosure relates generally to water heaters and particularly to water heater inlet fittings.
BACKGROUNDBoilers, water heaters, and other similar devices have various types of water inlet fittings. For example, gas water heaters typically have an inlet with a diffuser that extends into the water heater. The diffuser can be designed and positioned within the water heater to optimize the thermal efficiency of the water heater. The proper orientation and geometry of the diffuser will deliver cold inlet water to the proper location within the water heater allowing mixing and counter-flow and preventing the cold inlet water from being directed at one or more heat exchanger pipes which could cause thermal stress. In one example, the optimum orientation for the diffuser is the 2 o'clock position for the diffuser outlet, assuming the diffuser is positioned extending vertically downward into the cylindrically shaped water heater tank, the diffuser outlet is on a side of the diffuser pointing outward toward a wall of the water heater tank, the 12 o'clock position is pointing inward toward a gas flue running through the central longitudinal axis of the cylindrically shaped water heater tank, and the 6 o'clock position is pointing outward directly towards the closest section of the outer wall of the water heater tank. Because the diffuser is a separate component that must be attached to the gas water heater during installation, there is an increased likelihood the installer may not position the diffuser properly during the installation thereby negatively affecting the thermal efficiency of the water heater. For example, if the diffuser is attached to the water heater and then the separate flow sensor is attached to the diffuser, torque is separately applied to both the diffuser and the flow sensor. When torque is applied to the flow sensor, there is a tendency for the diffuser to shift from the optimal position.
Another drawback in some existing water heaters is the length of the diffuser and the inlet fitting because longer components require more space in which to install the water heater.
Yet another drawback of some existing water heaters is that the inlet fittings lack integrated components for measuring the flow of water through the fitting or shutting off the flow of water through the fitting.
The following disclosure describes example water inlet fittings, flow sensors, shut off valves, and diffusers that can address one or more of the foregoing limitations associated with water heaters and other similar devices.
SUMMARYThe present disclosure is directed to a flow sensor for a water heater. In one embodiment, an integrated flow sensor and diffuser for a water heater include a flow sensor body with a diffuser attachment mechanism and a diffuser with a complementary attachment mechanism. An inlet of the flow sensor body includes an inlet attachment mechanism for attaching the flow sensor body to a water supply pipe. The diffuser attachment mechanism is located on an extended cylindrical flange at an outlet of the flow sensor body. The complementary diffuser attachment mechanism is configured to couple to the diffuser attachment mechanism of the extended cylindrical flange. The flow sensor body includes a cavity for retaining a flow sensor. The integrated flow sensor and diffuser can have a single set of threads on the outer surface of the extended cylindrical flange so that the integrated flow sensor and diffuser can be attached to the water heater as a single assembly.
In another example embodiment, an integrated valve and flow sensor include a valve body, a rotatable ball disposed within the valve body, a flow sensor comprising a Hall effect sensor and a turbine disposed within the rotatable ball, a stem extending from the rotatable ball and comprising a lead from the Hall effect sensor, and an actuator coupled to the stem for controlling the operation of the rotatable ball. The lead from the Hall effect sensor can be coupled to a meter that measures a flow of water through the integrated valve and flow sensor. An outlet of the integrated valve and flow sensor can include an attachment mechanism for mating with a complementary attachment mechanism of a diffuser.
In yet another example, a fitting for a water heater comprises a valve, an actuator coupled to the valve for opening and closing the valve, a flow sensor, and a heat trap. The flow sensor can comprise a turbine and a Hall effect sensor for measuring the flow of water through the fitting. The heat trap can prevent undesirable mixing or loss of heated water. The fitting can be coupled to either an inlet fitting or an outlet fitting on a water heater.
These and other aspects and examples will be described in the following description and the accompanying drawings.
Reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:
The example embodiments discussed herein are directed to systems, apparatuses, and methods for water heaters with optimized inlet structures, diffusers, flow sensors and shut off valves. The following embodiments are non-limiting examples and those working in this field should understand that various modifications can be applied to the examples described herein without departing from the scope of this disclosure.
The components described herein can be made of one or more of a number of suitable materials to allow the component or other associated components to meet certain standards and/or regulations. Examples of such materials can include, but are not limited to, aluminum, stainless steel, copper, fiberglass, plastic, PVC, ceramic, and rubber.
Components described herein can be made from multiple pieces that can be mechanically coupled to each other using one or more of a number of coupling methods, including but not limited to epoxy, welding, soldering, fastening devices, compression fittings, mating threads, and slotted fittings. One or more pieces that are mechanically coupled to each other can be coupled to each other in one or more of a number of ways, including but not limited to fixedly, hingedly, removeably, slidably, and threadably. An attachment or coupling feature can include, but is not limited to, a swage, a snap, a clamp, a portion of a hinge, an aperture, a recessed area, a protrusion, a slot, a spring clip, a tab, a detent, a compression fitting, and mating threads.
Any component described in one or more figures herein can apply to any other figures having the same label. In other words, the description for any component of a figure can be considered substantially the same as the corresponding component described with respect to another figure unless otherwise noted. For any figure shown and described herein, one or more of the components may be omitted, added, repeated, and/or substituted. Accordingly, embodiments shown in a particular figure should not be considered limited to the specific arrangements of components shown in such figure.
Referring to
In contrast,
The combined flow sensor and diffuser assembly 200 can have a single set of threads on the outer surface of the extended cylindrical flange 207 so that the combined flow sensor and diffuser assembly 200 can be attached to the water heater as a single assembly. Because only one tightening procedure is required to attach the single flow sensor and diffuser assembly 200, the installer is better able to ensure that the diffuser 210 is in the correct orientation to optimize the flow of the cold inlet water entering the water heater from the diffuser outlet 212. The combined flow sensor and diffuser assembly 200 also comprises an inlet 202 that is configured to couple to a water supply pipe.
The single flow sensor and diffuser assembly 200 is also an improvement over the prior art components shown in
The example embodiment shown in
In the embodiment shown in
Referring now to
As shown in
While example embodiments of integrated inlet fittings are discussed herein, the principles of the described embodiments can be applied to a variety of types of water heaters. Accordingly, many modifications of the embodiments set forth herein will come to mind to one skilled in the art having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that water inlet structures, flow sensors, shut off valves, and diffusers are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of this application. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.
Claims
1. An inlet fitting for a water heater comprising:
- an inlet configured for fluid coupling to a water supply and comprising threads for threaded attachment to the water supply;
- an outlet configured for fluid coupling to an inlet of a water heater and comprising threads for threaded attachment to the inlet of the water heater;
- a shut-off valve disposed between the inlet and the outlet of the fitting, the shut-off valve comprising a valve body, a valve stem, and a rotatable ball disposed with the valve body; and
- an electronic actuator for opening and closing the shut-off valve via controlling the operation of the rotatable ball, the electronic actuator being coupled to the shut-off valve via the valve stem,
- wherein the inlet fitting is effective to control a flow of water into the water heater and to maintain a vacuum seal within the water heater.
2. The inlet fitting of claim 1, wherein the electronic actuator is controlled by a controller coupled to the electronic actuator via a lead.
3. The inlet fitting of claim 1, wherein the inlet fitting is further configured for selective, operable fluid coupling to an outlet of a water heater.
4. The inlet fitting of claim 1, further comprising a heat trap downstream of the shut-off valve to prevent heated water from the water heater from flowing through the inlet fitting and mixing with cold water from the water supply.
5. A fitting assembly for a water heater, comprising:
- the inlet fitting of claim 1; and
- a dip tube in communication with the inlet fitting.
6. A fitting assembly for a water heater, comprising:
- the inlet fitting of claim 1, wherein the outlet further comprises: an extended cylindrical flange comprising a diffuser attachment mechanism; and a diffuser with a complementary diffuser attachment mechanism, the complementary diffuser attachment mechanism configured to couple to the diffuser attachment mechanism of the extended cylindrical flange, the diffuser being configured to extend into a tank of the water heater.
7. A water heater, comprising:
- a tank comprising an inlet for receiving a flow of water from a water supply and an outlet for releasing heated water from the tank;
- a heating element configured to heat water in the tank;
- an inlet fitting coupled to the inlet of the tank, the inlet fitting comprising: a fitting inlet configured for fluid coupling to a water supply and comprising threads for threaded attachment to the water supply; a fitting outlet configured for fluid coupling to the inlet of the tank and comprising threads for threaded attachment to the inlet of the tank; a shut-off valve disposed between the fitting inlet and the fitting outlet, the shut-off valve comprising a valve body, a valve stem, and a rotatable ball disposed with the valve body; and an electronic actuator for opening and closing the shut-off valve via controlling the operation of the rotatable ball, the electronic actuator being coupled to the shut-off valve via the valve stem, wherein the inlet fitting is effective to control a flow of water into the tank and to maintain a vacuum seal within the tank.
8. The water heater of claim 7, wherein the electronic actuator is controlled by a controller coupled to the electronic actuator via a lead.
9. The water heater of claim 7, wherein the inlet fitting is further configured for selective, operable fluid coupling to an outlet of the water heater.
10. The water heater of claim 7, wherein the inlet fitting further comprises a heat trap downstream of the shut-off valve to prevent heated water from the tank from flowing through the inlet fitting and mixing with cold water from the water supply.
11. The water heater of claim 7, further comprising a dip tube in communication with the inlet fitting.
12. The water heater of claim 7, wherein the fitting outlet further comprises:
- an extended cylindrical flange comprising a diffuser attachment mechanism; and
- a diffuser with a complementary diffuser attachment mechanism, the complementary diffuser attachment mechanism configured to couple to the diffuser attachment mechanism of the extended cylindrical flange.
Type: Application
Filed: Mar 28, 2022
Publication Date: Jul 7, 2022
Inventors: Timothy D. Scott (Tallassee, AL), Michael C. Mitchell (Auburn, AL), Raheel A. Chaudhry (Montgomery, AL), William T. McLemore (Montgomery, AL), Hector J. Donastorg (Auburn, AL)
Application Number: 17/705,502