Abstract: Water heaters, baffles for water heaters, and methods for manufacturing such baffles are disclosed. One baffle includes a core, an outer wall, and a plurality of fins. The outer wall surrounds the core and defines at least one flow path between the outer wall and the core. The plurality of fins extend from the outer wall toward the core. Each of the plurality of fins has a serpentine shape. One method for manufacturing a baffle includes extruding at least one portion of the baffle in one piece, the at least one portion of the baffle having an at least partially cylindrical outer wall and a plurality of fins extending inward from the outer wall, each of the plurality of fins having a serpentine shape. One water heating system includes a burner, a vent, at least one flue tube, and at least one baffle as described above.

Abstract: A method of heating water in a tankless water heating appliance in conditions of low water flow or no water flow is disclosed. A water supply is introduced into a heat exchanger configured to transfer heat to the water supply from a burner when the water supply is contained in the heat exchanger. A pulse fire duration is determined for the burner and a pre-defined condition of the water supply is sensed. When the pre-defined condition is sensed, the burner is activated to fire for the pulse fire duration, and the burner is deactivated after the pulse fire duration is elapsed. The pre-defined condition of the water supply is monitored, such that when the pre-defined condition is sensed again, the burner is activated to fire for another pulse fire duration, and the burner is deactivated after the another pulse fire duration is elapsed.

Abstract: A heating system for a water heating appliance includes a heater for generating heated process air, a blower for delivering the heated process air through an airflow path, a flue that defines an upstream section of the airflow path, a heat exchange structure disposed downstream of the flue and defining a medial section of the airflow path, and a condensing section that defines a downstream section of the airflow path and is disposed downstream of the heat exchange structure. The heat exchange structure includes a heat exchange portion having airflow obstructions that generate a turbulence and transfer heat from the heated process air to a media surrounding an outer surface of the heat exchange structure. The airflow path within the heat exchange portion extends outward and generally perpendicular to a direction of the airflow path within the flue.

Abstract: According to one aspect of the invention, a water heater is provided comprising an electric heating element circuit; a circuit coupled to the electric heating element circuit and configured to supply current to the electric heating element; a sensor coupled to the circuit and configured to detect a temperature associated with operation of the electric heating element circuit; and a controller coupled to the circuit.

Abstract: A water heater system includes a first water heater including a first controller configured to transmit and receive a token; and a second water heater including a second controller configured to transmit and receive the token. The first water heater is plumbed to the second water heater in a twinned configuration, and the first controller is in communication with the second controller. The first controller is configured to control the first water heater to perform a first heating cycle while in possession of the token, and then transmit the token to the second controller, and the second controller is configured to control the second water heater to perform a second heating cycle while in possession of the token, and then transmit the token to the first controller.

Abstract: A method for manufacturing a one-piece woven (OPW) air bag includes method for manufacturing an OPW airbag. The method includes providing yarns, warping the yarns on at least one beam of a loom, and simultaneously weaving yarns into a fabric air bag structure having two layer portions defining an inflatable volume and single layer portions forming seams delimiting the inflatable volume. A plurality of the yarns overlay one another to form nonwoven alignment elements in at least one of the single layer portions. The air bag structure is cut to define the OPW air bag. The alignment elements are aligned with alignment elements on a panel. The air bag structure is sewn to the panel with the alignment elements aligned with one another.

Abstract: A water heater including a tank having a wall with an external surface and an internal surface defining an interior, and a circuit board mounted to the external surface of the tank. The circuit board including a thermal path for conducting heat through the circuit board, where the thermal path of the circuit board is thermally coupled to the external surface of the tank. An electronic switch is mounted to the circuit board and electronically coupled to a heating element, where the electronic switch is thermally coupled to the thermal path of the circuit board so that heat generated by the electronic switch is transferred along the thermal path. A temperature sensor is thermally coupled to the circuit board to sense a temperature of the thermal path relating to a temperature of the electronic switch and relating to a temperature of water stored in the tank.

Abstract: An airbag and a method for manufacturing the airbag. The airbag is manufactured by weaving yarns to form a one-piece woven (OPW) airbag having inflatable portions and non-inflatable portions. The non-inflatable portions are woven with varying weave patterns so as to form recesses in the surface of the airbag in the form of an indicia.

Abstract: A method for manufacturing a one-piece woven (OPW) air bag includes providing yarns and warping the yarns on at least one beam of a loom. Yarns are simultaneously woven into a fabric air bag structure having two layer portions defining both an inflatable volume and non-inflatable portions and single layer portions forming seams delimiting the inflatable volume. The air bag structure is cut to define the OPW air bag and at least one opening extending through only one layer of the two layer portions.

Abstract: A method for manufacturing a one-piece woven (OPW) air bag includes providing yarns and warping the yarns on at least one beam of a loom. Yarns are simultaneously woven into a fabric air bag structure having two layer portions defining both an inflatable volume and non-inflatable portions and single layer portions forming seams delimiting the inflatable volume. The air bag structure is cut to define the OPW air bag and at least one opening extending through only one layer of the two layer portions.

Abstract: A method for manufacturing a one-piece woven (OPW) air bag includes method for manufacturing an OPW airbag. The method includes providing yarns, warping the yarns on at least one beam of a loom, and simultaneously weaving yarns into a fabric air bag structure having two layer portions defining an inflatable volume and single layer portions forming seams delimiting the inflatable volume. A plurality of the yarns overlay one another to form nonwoven alignment elements in at least one of the single layer portions. The air bag structure is cut to define the OPW air bag. The alignment elements are aligned with alignment elements on a panel. The air bag structure is sewn to the panel with the alignment elements aligned with one another.

Abstract: Water heaters, baffles for water heaters, and methods for manufacturing such baffles are disclosed, One baffle includes a core, an outer wall, and a plurality of fins. The outer wall surrounds the core and defines at least one flow path between the outer wall and the core. The plurality of fins extend from the outer wall toward the core. Each of the plurality of fins has a serpentine shape. One method for manufacturing a baffle includes extruding at least one portion of the baffle in one piece, the at least one portion of the baffle having an at least partially cylindrical outer wall u and a plurality of fins extending inward from the outer wall, each of the plurality of fins having a serpentine shape. One water heating system includes a burner, a vent, at least one flue tube, and at least one baffle as described above.

Abstract: Aspects of the invention relate to water heaters including a water storage tank having a top wall, a bottom wall, and a side wall extending between the top wall and the bottom wall; a combustion chamber extending below the bottom wall of the water storage tank and a heat exchanger configured to receive combustion gases and to transfer heat to water in the water storage tank. The heat exchanger includes a first pass flue extending through the water storage tank and a plurality of second pass flues coupled to receive combustion gases from the first pass flue. The second pass flues extending through the water storage tank and having a straight top portion, a curved bottom portion, and a longitudinal axis residing in a plane. The curved bottom portion of the second pass flues exits the water storage tank through at least one aperture defined in the side wall of the water storage tank.

Abstract: Aspects of the invention relate to water heaters including a water storage tank having a top wall, a bottom wall, and a side wall extending between the top wall and the bottom wall; a combustion chamber extending below the bottom wall of the water storage tank and a heat exchanger configured to receive combustion gases and to transfer heat to water in the water storage tank. The heat exchanger includes a first pass flue extending through the water storage tank and a plurality of second pass flues coupled to receive combustion gases from the first pass flue. The second pass flues extending through the water storage tank and having a straight top portion, a curved bottom portion, and a longitudinal axis residing in a plane. The curved bottom portion of the second pass flues exits the water storage tank through at least one aperture defined in the side wall of the water storage tank.

Abstract: A water heater system, including a water storage tank, an electrical heating element, a power switch, and a controller. The controller is configured to store a number of heating cycles completed to heat water in the tank. When electric power is applied to the water heater system, the controller controls the power switch to turn OFF power to the electrical heating element in response to the number of heating cycles being less than a threshold number of heating cycles, and controls a user output interface to output the indicator indicating that the controller is inhibiting operation of the electrical heating element, and control the power switch to turn ON power to the electrical heating element in response to receiving user input through a user input interface requesting power to be applied to the electrical heating element, and a sensed temperature of the tank being less than a setpoint temperature.

Abstract: Aspects of the invention relate to water heaters including a water storage tank having a top wall, a bottom wall, and a side wall extending between the top wall and the bottom wall; a combustion chamber extending below the bottom wall of the water storage tank and a heat exchanger configured to receive combustion gases and to transfer heat to water in the water storage tank. The heat exchanger includes a first pass flue extending through the water storage tank and a plurality of second pass flues coupled to receive combustion gases from the first pass flue. The second pass flues extending through the water storage tank and having a straight top portion, a curved bottom portion, and a longitudinal axis residing in a plane. The curved bottom portion of the second pass flues exits the water storage tank through at least one aperture defined in the side wall of the water storage tank.

Abstract: A water heater system, including a water storage tank, an electrical heating element, a power switch, and a controller. The controller is configured to store a number of heating cycles completed to heat water in the tank. When electric power is applied to the water heater system, the controller controls the power switch to turn OFF power to the electrical heating element in response to the number of heating cycles being less than a threshold number of heating cycles, and controls a user output interface to output the indicator indicating that the controller is inhibiting operation of the electrical heating element, and control the power switch to turn ON power to the electrical heating element in response to receiving user input through a user input interface requesting power to be applied to the electrical heating element, and a sensed temperature of the tank being less than a setpoint temperature.

Abstract: A thermostat including bi-metal element configured to be activated at a maximum dial setpoint temperature manually set on the thermostat and a switch coupled to the bi-metal element and configured to open upon activation of the bi-metal element. The thermostat also includes a temperature sensor positioned to sense temperature, a thermostat heating element positioned to heat the bi-metal element to the maximum dial setpoint temperature, and a controller coupled to the temperature sensor and the thermostat heating element and storing a desired controller setpoint temperature. In response to determining that the desired controller setpoint temperature is sensed, the controller controls the thermostat heating element to heat the bi-metal element to the maximum dial setpoint temperature, thereby activating the bi-metal element and opening the switch.

Abstract: A computer-readable medium on which are stored computer-executable executable instructions that, when executed in at least one electronic system coupled to a display device and a network, enable the at least one system to perform a method comprising at least the steps of determining the geo-location of the system, determining at least one on-sale retail product associated with the determined geo-location of the system, recording a data set indicating a current price of the determined on-sale retail product, and electronically transferring the data set and an indication of the determined geo-location over the network to a processing device.

Abstract: A system for adjusting a bias voltage of a flame sensing system. The system may use pulse width modulation to adjust the bias voltage. The system may have a flame sensing rod that conveys an electrical equivalent circuit of a flame presence to a detector via low pass filter. An excitation voltage may be conveyed via a DC blocking mechanism to the sensing rod. A pulse width modulation signal may be conveyed via a bias resistor to a node of the low pass filter and the detector. The input of an A/D converter may be that of the detector for flame signals. Also, leakages between the node of the A/D converter connection and the voltage source and/or ground may be detected and compensated. Further, leakage of the DC blocking mechanism may be minimized.