Abstract: A water heater and method of assembling the water heater are disclosed. The method includes the step of positioning an insulation member around a water tank. An expandable tube is positioned at an elevation between a top surface and a bottom surface of the insulation member. An outer shell is positioned over the water tank, the insulation member, and the expandable tube to at least partially encapsulate the water tank. The expandable tube is expanded to compress at least a portion of the insulation member against the water tank or the outer shell. Foam insulation is delivered into a space defined adjacent the top surface of the insulation member and between the water tank and the outer shell. The foam insulation is substantially limited from traveling past the expandable tube when the expandable tube is maintained in an expanded state.

Abstract: The present invention is directed towards a water heater having a combustion chamber and a water tank positioned adjacent to the combustion chamber. The water tank has a flue tube extending through or surrounded by the water tank and has an upstream end positioned to receive combustion gases from the combustion chamber and a downstream end positioned to exhaust the combustion gases. The flue tube also has a wall that extends between the upstream and downstream ends. The wall of the flue tube has an inner surface defining a combustion gas passage and an outer surface positioned to contact water received in said water tank. The walls have convolutions along at least a portion of their length and are configured to reduce laminar flow of the water adjacent the outer surface of flue tube, thereby providing increased heat transfer between the combustion gases in the flue tube and the water in the water tank.

Abstract: A collector assembly is provided for directing products of combustion between segments of a flue of a water heater. The assembly includes an insulator at least partially defining a chamber configured to direct products of combustion between the flue segments. The assembly also includes a cover configured to at least partially surround the insulator. The cover is also configured to be coupled to a water tank of the water heater. The insulator in an uncompressed state is dimensioned to extend outwardly from the cover when the insulator is positioned in the cover. The insulator in a compressed state is dimensioned to permit coupling of the cover to the water tank.

Abstract: A foam dam is provided for use with a water heater having a tank and a jacket together defining an annular region. The foam dam includes a central region having a surface configured to cover a component coupled to the tank. The foam dam also includes a perimeter region extending from the central region. The perimeter region of the foam dam defines a surface to at least substantially traverse the annular region between the tank and jacket of the water heater. The perimeter region is configured to substantially prevent foam insulation from flowing into an area proximate to the component.

Abstract: A heat pump water heater system including a water storage tank and a heat exchange system. The heat exchange system includes a heat absorber positioned below the water storage tank and a heat rejecter in fluid communication with the heat absorber and positioned within the water storage tank. The heat absorber is configured to transfer heat to fluid in the heat exchange system, and the heat rejecter is configured to transfer heat from fluid in the heat exchange system to the water in the water storage tank.

Abstract: A method of manufacturing a combustion chamber for use in a water heater is provided. A skirt is formed, and an edge portion of a plate is spot welded to the skirt. The edge portion of the plate is circumferentially welded to the skirt, thereby forming a seal between the plate and the skirt.

Abstract: A heat pump water heater system including a water storage tank and a heat exchange system. The heat exchange system includes a heat absorber positioned below the water storage tank and a heat rejecter in fluid communication with the heat absorber and positioned within the water storage tank. The heat absorber is configured to transfer heat to fluid in the heat exchange system, and the heat rejecter is configured to transfer heat from fluid in the heat exchange system to the water in the water storage tank.

Abstract: A heat trap assembly for providing a thermal dam within piping associated with water heaters is disclosed. The heat trap includes an elongated housing, a fin and a flap member. The housing includes first and second ends, and an interior opening extending therethrough to define an internal passage. The fin has a multi-sided body and is fixedly inserted into the housing. The flap member has a flexible disk-shaped body with first and second faces, an outer peripheral edge and an aperture disposed inward of the outer peripheral edge. A portion of the fin is inserted through the aperture. The outer peripheral edge is essentially contiguous with an interior wall surface of the housing in the absence of water flow within the internal passage, and is bendable in a direction of flow when water is flowing toward the first face or the second face.

Abstract: A water heater including a tank having a wall defining an interior for holding water is provided. A heat exchange assembly is positioned at least partially within the interior of the tank. The heat exchange assembly includes a metallic outer tube positioned within the interior of the tank. The outer tube has a wall with an inner surface and end portions positioned within the interior of the tank. The heat exchange assembly further includes a metallic inner tube extending within the outer tube and having end portions extending through the wall of the tank. A portion of the outer surface of the inner tube contacts a portion of the inner surface of the outer tube. An elongated passageway is defined between a portion of the outer surface of the inner tube and a portion of the inner surface of the outer tube to facilitate a flow of fluid.

Abstract: A water heater including a tank having a wall defining an interior for holding water is provided. A heat exchange assembly is positioned at least partially within the interior of the tank. The heat exchange assembly has an outer tube extending within the interior of the tank. The outer tube has a wall with an inner surface. An inner tube extends within the outer tube. The inner tube has a wall with an outer surface. A gap is defined between the outer surface of the inner tube and the inner surface of the outer tube. Heat conducting fluid is contained within the gap. The fluid facilitates the transfer of heat between the inner tube and the outer tube.

Abstract: A heat exchange assembly adapted for use in a water tank is provided. The heat exchange assembly includes a tube having end portions and a coiled portion between the end portions. A fitting is connected to at least one of the end portions of the tube. The fitting has an end configured to extend through an opening in the water tank, and a surface positioned to limit the extension of the end through the opening in the water tank. The fitting also has an opposite end defining a bore configured to receive one of the end portions of the tube and to limit the extension of the end portion of the tube into the opposite end of the fitting. The bore extends axially beyond the surface of the fitting.

Abstract: A cold water inlet for a tank of a water heater is provided. The inlet includes an inlet conduit configured to extend toward a flue extending upwardly through the tank. The inlet conduit includes a proximal, intermediate, and distal conduit portion, the distal portion terminating at a closed end configured to reduce the amount of the water flow directed toward the flue. The cold water inlet further includes flow openings defined in the distal portion to permit the water flow to exit the inlet conduit. Deflectors are positioned along the distal portion proximal respective ones of the flow openings, and are oriented for deflecting the water flow. The closed end and the deflectors of the inlet conduit coact, as the water flows into the tank, to direct the water flow away from the flue and toward the side wall and bottom of the tank, thereby reducing an accumulation of scale.

Abstract: The present invention is directed to a water heater that sustains energy during the standby mode so that it can power energy saving devices while e minimizing energy loss and controlling the stored water temperature. The present invention may include an outer casing, an insulated tank containing flue tubes, a combustion chamber, a burner rack containing a pilot and thermopile assembly, a flue collector, a damper and a draft diverter. These components are preferrably arranged to enable heat from the main burners to be transferred in an efficient manner to the water when needed and heat loss from the water to be minimized when the main burners are not fired. This may be accomplished without the use of external electric power, and the energy producing and heat transferring components of the water heater are optimally balanced, resulting in a sustained energy level that minimizes heat loss, prevents unwanted increases in water temperature, and enables the use of a damper without external electrical power.

Abstract: An apparatus for heating a domestic water supply including a glass-lined storage tank for the domestic water supply and having a domestic water inlet port, a domestic water outlet port, and a heat-exchanging coil mounted therein. A heating tube is connected to the heat-exchanging coil to contain a recirculating fluid supply. The heat-exchanging coil within the glass-lined storage tank has a double-wall construction with a non-metallic outer wall in contact with a metallic inner wall. The double-wall prevents mixing of the domestic water supply with the recirculating fluid supply. The apparatus also includes a recirculating fluid heater positioned externally of the glass-lined storage tank to heat recirculating fluid to a temperature sufficient to heat the domestic water supply by heat transfer from the recirculating fluid in the heat-exchanging coil to the domestic water supply in the glass-lined storage tank.

Abstract: A burner is disclosed, comprising: a burner body and a burner lid coupled to the burner body so as to form a plurality of gas ports in a substantially circular and substantially planar arrangement, said gas ports being interposed between the burner body and the burner lid and adapted to have a corresponding array of flames extending from the gas ports during combustion of a fuel gas.

Abstract: The gas burner of the present invention includes a mated burner body and a burner lid. A plurality of gas ports in a substantially circular and planar arrangement are interposed between the mated body and lid and are directed radially from the body and lid. An air shield member is coformed to and extends radially from the burner body or burner lid. Extending radially from the air shield member in substantial radial alignment with the gas ports is a plurality of flame partitions equal in number to the gas ports. Each flame partition has two attached tabs which are substantially perpendicular to each other when the flame partition is observed in cross-section.

Abstract: An inlet is provided for delivering water into a water heater through a port in its side. The inlet includes a conduit having a distal portion that extends toward a bottom of the water heater. That portion includes means for deflecting the water flow in order to reduce the generation of temperature gradients that otherwise tend to develop within water heater tanks. A water heater assembly including such an inlet is also described.

Abstract: A water heater is capable of being hung from a support, and includes a water tank, a water inlet, a water outlet, and a jacket positioned around the water tank so as to define a space between the water tank and the jacket. Foam insulation is positioned in the space between the water tank and the jacket, and the foamed insulation has increasing density and cell uniformity gradients in a direction running from a first portion to a second portion of the water heater. A curved bracket assembly is positioned on the second portion of the jacket to coincide with the positioning of foam insulation having highest density and best cell uniformity. A bumper is optionally positioned on the outer surface of the jacket and is vertically aligned with the bracket assembly.

Abstract: A method of making a water heater capable of being hung from a support, which includes a water tank, a water inlet, a water outlet, and a jacket positioned around the water tank so as to define a space between the water tank and the jacket. Foamed insulation is positioned in the space between the water tank and the jacket, and the foamed insulation has increasing density and cell uniformity gradients in a direction running from a first portion to a second portion of the jacket. A curved bracket assembly is positioned on the outer surface of the jacket at the second portion of the jacket to coincide with the positioning of foam insulation having highest density and best cell uniformity. A bumper is optionally positioned on the outer surface of the jacket and is vertically aligned with the bracket assembly.

Abstract: An apparatus for heating a domestic water supply including a glass-lined storage tank to contain the domestic water supply. A combustible fuel burner is positioned to heat the domestic water supply within the glass-lined storage tank. A solar heating tube is connected to supply solar heated fluid to a heat transfer coil mounted within the glass-lined storage tank. The heat transfer coil has a double-wall including a non-metallic outer wall in contact with a metallic inner wall, both walls being sealed to prevent mixing of the domestic water supply with the solar heated fluid. A sensor is positioned to sense the temperature of the solar heated fluid as it is delivered to the heat transfer coil.