Metering Valve System for a Water Heater

Abstract

A metering valve for a water heater system is provided. The metering valve is configured to selectively control the amount of water flowing into the water tank and/or cold-water bypass shunt through rotation of a rotor. The rotor is attached to the motor such that when the motor is driven, the rotor is rotated in either the clockwise or counterclockwise direction. The rotor is shaped such that, depending on the degree of rotation of the rotor, the size of the openings at the cold water inlet and the cold water bypass shunt (as well as the water inlet into the metering valve) are adjusted. That is, the ratio of water entering the tank and/or passing to the cold bypass shunt may be adjusted based on the degree of rotation of the rotor, which in turn controls the temperature of the water exiting the metering valve system at the outlet of the water tank

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 63/746,033, filed Jan. 16, 2025, the entirety of which is hereby incorporated by reference.

FIELD

This application relates generally to water heaters, and more particularly to metering valve systems for water heaters.

BACKGROUND

Hot water systems used in residential, commercial, and/or industrial applications commonly include hot water tanks. In some instances, heated water (e.g., from the hot water tanks) may be combined with cooler water in order to increase the volume of hot water to be delivered (e.g., from the hot water tanks). That is, the water within the hot water tanks may be heated to a temperature greater than a desired end use temperature. The hot water from the hot water tanks may then be mixed with cooler water at an outlet of the hot water tanks in order to lower the temperature of the hot water to the desired end use temperature.

BRIEF DESCRIPTION OF THE DRAWINGS

The detailed description is set forth with reference to the accompanying drawings. In some instances, the use of the same reference numerals may indicate similar or identical items. Various embodiments may utilize elements and/or components other than those illustrated in the drawings, and some elements and/or components may not be present in various embodiments. Throughout this disclosure, depending on the context, singular and plural terminology may be used interchangeably.

FIG. 1 illustrates a water heater, in accordance with one or more embodiments of the disclosure.

FIG. 2 illustrates another water heater including a metering valve, in accordance with one or more embodiments of the disclosure.

FIG. 3 illustrates an exemplary metering valve, in accordance with one or more embodiments of the disclosure.

FIGS. 4A-4D illustrate the operation of the metering valve of FIG. 3, in accordance with one or more embodiments of the disclosure.

FIG. 5 illustrates another exemplary metering valve, in accordance with one or more embodiments of the disclosure.

FIGS. 6A-6C illustrate the operation of the metering valve of FIG. 5, in accordance with one or more embodiments of the disclosure.

FIG. 7 illustrates another exemplary metering valve, in accordance with one or more embodiments of the disclosure.

FIG. 8 illustrates another exemplary metering valve, in accordance with one or more embodiments of the disclosure.

FIG. 9 illustrates another exemplary metering valve, in accordance with one or more embodiments of the disclosure.

FIGS. 10A-10F illustrate another exemplary metering valve, in accordance with one or more embodiments of the disclosure.

FIG. 11 illustrates an example flow diagram for control of a metering valve system of a water heater, in accordance with one or more embodiments of the disclosure.

DETAILED DESCRIPTION

A metering valve system for a water heater is described herein. Particularly, the metering valve system may include a metering valve including a motor, a cold bypass shunt, and a mixing tee. The metering valve system is provided on the water heater and functions by selectively adjusting the supply water into the tank and/or through the cold-water bypass shunt. The tank outlet and cold bypass shunt reconnect at the mixing tee prior to the outlet of the water heater to mix water exiting the water heater to a desired temperature.

To allow for the selective control of water through the tank and/or cold-water bypass, a rotor is provided in the metering valve. The rotor is attached to the motor such that when the motor is driven, the rotor is rotated in either the clockwise or counterclockwise direction. The rotor is shaped such that, depending on the degree of rotation of the rotor, the size of the openings at the cold water inlet and the cold water bypass shunt (as well as the water inlet into the metering valve) are adjusted. That is, the ratio of water entering the tank and/or passing to the cold bypass shunt may be adjusted based on the degree of rotation of the rotor, which in turn controls the temperature of the water exiting the metering valve system at the outlet of the water tank (this metering valve system is generally illustrated in FIG. 2).

The metering valve system may also include a control mechanism to actuate the metering valve based on the temperature of the outgoing water at the outlet of the water tank. This allows for the water heater to ensure that the outgoing water is at the desired setpoint temperature (for example, a temperature set by a user). The metering valve system also provides leak protection, while being provided in a compact form factor including minimal leak points in the structure. The valve also may close off all incoming water supplied to the system if a leak in the system is detected. Finally, the valve is designed in such a way that it fits under the top pan of the current electric storage tank design, so therefore it does not increase space requirements of typical electric water heater.

Turning to the figures, FIG. 1 is a schematic view of a water heater 100 in accordance with one or more embodiments of the present disclosure. The water heater 100 may include a hot water tank 102 having a cold water inlet 105 and a hot water outlet 111. In some instances, the cold water inlet 105 may be a conduit and/or a plurality of conduits for directing cold water from a water source 112 (that serves as the supply of water for the water heater 100) into the hot water tank 101. The hot water outlet 111 may be a conduit for directing hot water that exits the hot water tank 101 to be delivered to various loads 114 throughout a residential, commercial, and/or industrial environment. For example, the hot water may be delivered to a shower, a sink, etc.

The water heater also includes a metering valve system 102 including a metering valve 104 in fluid communication with a cold water bypass shunt 108. The cold water bypass shunt 108 is in communication with a mixing tee 110. The metering valve 104 controls the flow of cold water from the water source 112 into the hot water tank 101 via the cold water inlet 105 and/or through the cold water bypass shunt 108 to the mixing tee 110 to mix with hot water being received from the hot water tank 101 via the hot water outlet 111. Further details about the structure and operation of the metering valve 104 are provided below with respect to at least FIG. 2.

Still referring to FIG. 1, in some embodiments, the metering valve 104 may be selectively controlled using one or more sensors 120, a controller 118 (which may include a processor or the like), and memory 116. However, the operation of the metering valve system 102 may not necessarily require the one or more sensors 120, the controller 118, and the memory 116. The controller 118 may be a commercially available general-purpose controller, such as a controller from the Intel® or ARM® architecture families (as non-limiting examples). Any suitable controller or similar computing device and processors may be used herein. The controller 118 may be in electrical communication (e.g., wired or wirelessly) with the various components of the water heater 100. For example, the controller 118 may be in communication with the one or more sensors 120 and any components of the metering valve 104, among other components.

The memory 116 may be a non-transitory computer-readable memory storing program code and can include any one or a combination of volatile memory elements (e.g., dynamic random access memory (DRAM), synchronous dynamic random access memory (SDRAM), etc.) and can include any one or more nonvolatile memory elements (e.g., erasable programmable read-only memory (EPROM), flash memory, electronically erasable programmable read-only memory (EEPROM), programmable read-only memory (PROM), etc. Any suitable memory may be used herein.

In certain embodiments, the one or more sensors 120, the controller 118, the memory 116, and the metering valve 104 may be configured to control the temperature of water within and/or exiting the water heater 100. For example, a first sensor of the one or more sensors 120 may be coupled to and configured to measure the temperature of water in the water tank 101. A second sensor of the one or more sensors 120 may be coupled to the mixing tee 110 (or at any other location between the water tank 101 and the load 114). In this manner, the second sensor may be configured to measure the temperature of the combined water exiting the mixing tee 110. Additionally, the controller 118 may be electrically connected to the one or more sensors 120 and be configured to receive real-time temperature data from any of the one or more sensors. Based on data from the one or more sensors 120, the controller 118 may be configured to adjust the temperature of the combined water via movement of a rotor within the metering valve 104 (not shown in FIG. 1), as will be more apparent below in the description of FIG. 2. While reference is made to two specific sensors provided at specific locations, this is merely one example configuration and any other number of sensors may also be provided at any other combination of locations as well (or a single sensor may be used). Further, while the one or more sensors 120 are described as being temperature sensors, any other types of sensors may also be used (for example, water flow sensors, etc.).

FIG. 2 illustrates a close-up view of a top portion of a water heater 200 (which may be the same as, or similar to, water heater 100 of FIG. 1) including a metering valve system 202 (which may be the same as, or similar to, metering valve system 102 of FIG. 1). The metering valve system 202 may include the metering valve 204 (which may be the same as, or similar to, metering valve 104), as well as the cold water bypass shunt 220 (which may be the same as, or similar to, cold water bypass shunt 108) and the mixing tee 230 which may be the same as, or similar to, mixing tee 110).

In embodiments, the metering valve 204 includes a motor 206 that is connected to a rotor (not shown in FIG. 2 but shown in FIG. 3). The metering valve 204 also includes a water inlet 208 that receives cold water from a water supply and two outlets. A first outlet 210 of the metering valve 204 is connected to the water tank 201 of the water heater 200 (and thus serves as the water inlet to the water tank 201). A second outlet 212 of the metering valve 204 is connected to the cold water bypass shunt 220 (and thus serves as the inlet to the cold water shunt 220). The cold water bypass shunt 220 directs water from the second outlet 212 of the metering valve 204 to the mixing tee 230. The mixing tee 230 also includes a tank outlet 232 that receives hot water from the water tank 201 to be provided to a load for usage (for example, if the water heater 200 is provided in a residential home, the load may be a shower, a sink, etc.).

Although a portion of the metering valve 204 is shown as extruding from the top pan 260 of the water heater 200, in embodiments, all of the metering valve 204 and the metering valve system 202 as a whole may be provided completely underneath the top pan 260. In some instances, components of the metering valve system 202 may be re-positioned such that they fit beneath the top pan 260 (for example, the metering valve 204 may be rotated). In one or more embodiments, the top pan 260 may be located on top of the water tank 201. A jacket (not shown in the figure) may also be positioned around the water tank 201 and may partially or fully encompass the sidewalls of the water tank 201 (e.g., the circumference of the water tank 201) or any other portion of the water tank 201. The jacket may be made from any suitable material, such as a plastic, metal, etc. The jacket may serve to provide thermal and noise insulation for the water tank 201, for example. Accordingly, an insulating material may also be provided between the water tank 201 and the jacket. For example, an injected foam insulation may be provided between the tank 201 and the jacket, however, any other type of insulating material may also be used.

In operation, the motor 206 is driven to rotate the rotor to an angle that allows cold water received at the water inlet 208 (which may be connected to a water source, such as water source 112 shown in FIG. 1) to flow into the water tank 201 via the first outlet 210 (which may be the same as, or similar to, the cold water inlet 105 shown in FIG. 1) and/or into the cold water bypass shunt 220 via the second outlet 212. The water that is split between the first outlet 210 and the second outlet 212 may converge back at the mixing tee 230. Accordingly, the same volume of water flow may exit the water heater 200 via the mixing tee 230 as is received via the water inlet 208. In some instances, the rotor of the metering valve 204 may be rotated such that the cold water being received by the water inlet 208 is only being supplied through the second outlet 212 to the cold water bypass shunt 220 (and no water is being provided into the water tank 201).

As an example use case, a user may establish a desired temperature setpoint for the water exiting the water heater 200 to 120 degrees Fahrenheit. The temperature setpoint may also be established in any other manner. If the current temperature of the water in the water tank 201 is 120 degrees (which may be determined using a temperature sensor provided in the water tank 201, as a non-limiting example), then the motor 206 is driven to rotate the rotor such that the rotor obstructs the second outlet 212 to prevent water from flowing into the cold water bypass shunt 220, but leaves the first outlet 210 open such that all of the cold water is directed into the water tank 201. In this use case, there is no mixing of cold water from the cold water bypass shunt 220 and hot water from the water tank 201 at the mixing tee 230. Instead, only hot water from the water tank 201 is provided through the mixing tee 230 and directed outside of the water heater 200 to the load requiring the hot water to maintain the current temperature at the temperature setpoint.

However, if the current temperature of the water in the water tank 201 is above the desired temperature setpoint (for example, the water in the water tank 201 is at 150 degrees Fahrenheit), then the motor 206 is driven to rotate the rotor to at least partially open the second outlet 212 of the metering valve 204 to allow at least some of the cold water from the water inlet 208 to flow into the cold water bypass shunt 220. Thus, a fraction of the cold water from the water inlet 208 flows into the water tank 201 and a fraction of the water flows into the cold water bypass shunt 220. The rotor is adjusted such that the ratio of cold water flowing through the cold water bypass shunt 220 and the water flowing from the water tank 201 results in a water mixture in the mixing tee 230 that is at the desired temperature setpoint (for example, 120 degrees Fahrenheit in this example).

The metering valve 204 may also include a shutoff mode to mitigate the impact of any fault detected in the water heater (for example, a leak or any other type of fault). One non-limiting example of a fault is a leak either from the water heater itself, or possibly a leak from the plumbing or pipes adjacent to the water heater. Such a fault may be detected, for example, using any suitable type of sensor.

When a fault is detected, the motor 206 may be driven to rotate the rotor such that the water inlet 208 is fully obstructed and water is prevented from entering the water heater 200. When the fault is determined to no longer exist, the motor 206 may again be driven to rotate the rotor to an angle in which the water inlet 208 is either only partially obstructed or is not obstructed at all by the rotor to allow water to again flow into the water heater 100.

Additionally, a feedback mechanism may exist in the metering valve system 200 that allows for the motor 206 to be controlled to dynamically adjust the amount of water flowing into the first outlet 210 and/or the second outlet 212 of the metering valve 204, depending on the current temperature of the water in the water tank 201 and the desired temperature setpoint.

In embodiments, the feedback mechanism may include a controller 240 and one or more sensors (which may be the same as, or similar to, the controller 118 and the one or more sensor(s) 120). The one or more sensors may include temperature sensors that are used to capture temperature data for water at different locations within the metering valve system 202 and the water tank 201. Any other types of sensors may also be provided, however, such as sensors used to measure the rate of flow of water through various portions of the metering valve system 202, as well as any other types of sensors. In the example configuration shown in FIG. 2, the one or more sensors may include a single temperature sensor 242 provided at the mixing tee 230. Using the temperature data captured by the temperature sensor 242, the controller 240 may provide control signals to the motor 206 to rotate the rotor to adjust the amount of cold water from the water inlet 208 that is provided to the cold water bypass shunt 220.

Continuing the aforementioned example, if the temperature sensor 242 indicates that the temperature of the water in the mixing tee 230 is 150 degrees Fahrenheit and the desired temperature setpoint is 120 degrees, then the controller 240 may sent a signal to the motor 206 to rotate the rotor to allow for some or more cold water from the water inlet 208 to enter the cold water bypass shunt 220. Likewise, if the temperature sensor 242 indicates that the temperature of the water in the mixing tee 230 is 120 degrees Fahrenheit and the desired temperature setpoint is 120 degrees, then the controller 240 may send a signal to the motor 206 to rotate the rotor to prevent cold water from the water inlet 208 from entering the cold water bypass shunt 220. This is merely one example configuration of the feedback mechanism and any other number of sensors may also be provided and the sensors may be provided at any other locations as well. As another non-limiting example, a second temperature sensor may also be provided at the water inlet 208.

In embodiments, the motor 206 may be powered by an external power source, such as an electrical power grid, a renewable energy source (e.g., solar panel), and/or any other type of power source. The motor 206 may also be powered using a battery. In some instances, the motor 206 may be primarily powered by the external power source and the battery may be used as a backup power source if the external power source is temporarily unavailable. For example, the back-up battery power source may be used to drive the motor to rotate the rotor to a closed position to prevent cold water from passing through the water inlet 208. In some implementations, the motor 206 or the rotor may include a spring biased to rotate the rotor to the closed position in the event of a power failure or other error in the system. FIG. 3 illustrates a close-up view of a metering valve 300. The metering valve 300 may be the same as, or similar to, the metering valve 204 shown in FIG. 2 or any other metering valve described herein. Similar to the metering valve 204, the metering valve 300 includes a motor 306 that is connected to a rotor 350 such that a rotation of the motor 306 causes a corresponding rotation of the rotor 350. The metering valve 300 also includes the water inlet 308 (similar to water inlet 208), the first outlet 310 (similar to first outlet 210), and the second outlet 312 (similar to second outlet 212). The metering valve 300 may also include any other components described with respect to FIG. 2, such as the backup battery, spring, etc.

In embodiments, the rotor 350 is shaped and sized such that, depending on the angle of the rotor 350, the rotor 350 prevents, partially allows, or fully allows water flow through any of the water inlet 308, the first outlet 310, and/or the second outlet 312. That is, depending on the angle of the rotor 350, different portions of the rotor 350 may block some or all of the openings on the water inlet 308, the first outlet 310, and/or the second outlet 312. Although not shown in the figure, “O-rings” (or other types of sealing elements) may also be provided at any of the water inlet 308, first outlet 310 and/or second outlet 312 to provide additional sealing between the rotor 350 and the openings of the water inlet 308, first outlet 310 and/or second outlet 312.

In the example configuration shown in FIG. 3, the rotor 350 includes a first portion 352 and a second portion 354. The first portion 352 and the second portion 354 each include a rounded surface and a flat surface. The rounded and flat surfaces form the exterior surfaces of the first portion 352 and the second portion 354. When the rotor 350 is provided in the metering valve 300, the rounded surfaces of the first portion 352 and second portion 354 are flush against the interior surface of the metering valve 300. Accordingly, when a rounded surface of the first portion 352 or the second portion 354 is aligned with an opening of the water inlet 308, the first outlet 310, and/or the second outlet 312, water may be prevented from flowing into and/or out of the water inlet 308, the first outlet 310, and/or the second outlet 312. As aforementioned, the seal formed between a rounded surface and the water inlet 308, the first outlet 310, and/or the second outlet 312 may be supplemented with another sealing element, such as an “O-ring”. Likewise, when a flat surface of the first portion 352 or the second portion 354 is aligned with an opening of the water inlet 308, the first outlet 310, and/or the second outlet 312, water may be able to flow into and/or out of the water inlet 308, the first outlet 310, and/or the second outlet 312. The rotor 350 may also be rotated such that any of the openings of the water inlet 308, the first outlet 310, and/or the second outlet are only partially obstructed.

When the rotor 350 is rotated such that the rounded surface of the first portion 352 is fully aligned with the first outlet 310, water is prevented from flowing through the metering valve 300 and into the first outlet 310. The rotor 350 may be rotated further such that the rounded portion is only partially aligned or is not aligned with the first outlet 310 to selectively control the amount of water that flows through the first outlet 310.

Likewise, the rounded portion of the second portion 354 may be sized such that it is possible for the rounded portion of the second portion 354 to align with and completely obstruct the openings of both the water inlet 308 and the second outlet 312 in one angle. When the rotor 350 is rotated to other angles by the motor 306, the rounded portion of the second portion 354 may not align, partially align, or fully align with the water inlet 308 and/or the second outlet 312 such that the amount of water entering the metering valve 300 through the water inlet 308 and the amount of water entering the cold water bypass shunt (not shown in the figure) may be selectively controlled.

In the specific example shown in FIG. 3, the rotor 350 is rotated such that the rounded portion of the first portion 352 is aligned with the first outlet 310, thereby preventing water from flowing out of the first outlet 310 and into the tank of the water heater (not shown in the figure). Simultaneously, the flat surface of the second portion 354 is aligned with the water inlet 308 and the second outlet 312, thereby allowing water to flow from a water source into the metering valve 300 via the water inlet 308 and out of the second outlet 312 into the cold water bypass shunt.

It should be noted that the specific configuration (size, shape, etc.) of the rotor 350 is merely exemplary and other sizes and/or shapes may also be used to selectively control the water flow through the water inlet 308, the first outlet 310, and/or the second outlet 312.

FIGS. 4A-4D illustrate the operation of the metering valve 300 of FIG. 3. Beginning with FIGS. 4A-4B, the rotor 350 is shown in a first position that allows for a greater amount of water flow into the cold water bypass shunt via the second outlet 312 than the water tank via the first outlet 310. FIG. 4A shows a first angle of the metering valve 300 facing the second outlet 312 to the cold water bypass shunt and FIG. 4B shows a second angle of the metering valve 300 facing the first outlet 310 to the water tank. As shown in FIGS. 4A-4B, the position of the rotor 350 is such that a larger amount of the second outlet 312 is unobstructed than the first outlet 310. That is, the shaded regions shown in FIGS. 4A-4B illustrate the portions of the first outlet 310 and second outlet 312 that are not obstructed by the rotor 350.

Turning to FIGS. 4C-4D, the rotor 350 is shown in a second position that allows for a greater amount of water flow into the water tank via the first outlet 310 than the cold water bypass shunt via the second outlet 312. FIG. 4C shows a first angle of the metering valve 300 facing the second outlet 312 to the cold water bypass shunt and FIG. 4D shows a second angle of the metering valve 300 facing the first outlet 310 to the water tank. As shown in FIGS. 4C-4D, the position of the rotor 350 is such that a larger amount of the first outlet 310 is open than the second outlet 312. Similar to FIGS. 4A-4B, the shaded regions shown in FIGS. 4C-4D illustrate the portions of the first outlet 310 and second outlet 312 that are not obstructed by the rotor 350.

FIGS. 4C-4D illustrate the rotor being rotated to a second position that allows for a greater amount of water flow into the water tank than the cold water bypass shunt.

FIG. 5 illustrates another exemplary metering valve 500. Similar to the metering valves 104, 204, and 300 of FIGS. 1-3, the metering valve 500 includes a water inlet 502, a first outlet 504, and a second outlet 506. The metering valve 500 also includes a rotor 508 that is connected to a motor (not shown in the figure, but may be the same as, or similar to, the motors 206, 306, etc.) that is driven to rotate the rotor 508 to selectively control the amount of water flowing through the water inlet 502, first outlet 504, and/or the second outlet 506.

While the metering valves 204 and 300 of FIGS. 2-3 provide at least one of the various inlets and outlets in a different plane (using the metering valve 300 as an example, the water inlet 308 and the first outlet 310 are provided in one plane and the second outlet 312 is provided in another plane), all of the water inlet 502, first outlet 504, and the second outlet 506 of the metering valve 500 are provided within the same plane. Additionally, the rotor 508 is provided in a different configuration than the rotor 350. That is, the rotor 508 includes round surfaces that are flush with the interior surface of the metering valve 500 (similar to the rotor 350), however, rather than including flat surfaces, the rotor 508 includes concave cutouts that may align with the openings of the water inlet 502, first outlet 504, and the second outlet 506 depending on the angle of the rotor 508. The rotor 350 shown in FIG. 3 (or any other rotor) may also include such concave cutouts, in one or more embodiments.

FIGS. 6A-6C illustrate the operation of the metering valve 500 of FIG. 5. FIGS. 6A-6B show an orientation facing the first outlet 504 and the second outlet 506 (the water inlet 502 is not shown). Beginning with FIG. 6A, the rotor 508 is shown as being rotated to an angle in which both the first outlet 504 and the second outlet 506 are only partially obstructed such that water from the water inlet 502 may flow through both the first outlet 504 to the tank and the second outlet 506 to the cold water bypass shunt. FIG. 6B shows the rotor 508 rotated into a second angle in which both the first outlet 504 and the second outlet 506 are still only partially obstructed, but the first outlet 504 is more obstructed than the second outlet 506. In this example, more of the water from the water inlet 502 flows into the cold water bypass shunt via the second outlet 506 and less of the water flows into the tank via the first outlet 504. Finally, FIG. 6C shows an orientation facing the water inlet 502. Particularly, the rotor 508 is rotated to an angle in which the water inlet 502 is completely blocked by the rotor 508. Accordingly, water is prevented from flowing into the metering valve 500 via the water inlet 502 (thus, the metering valve 500 is in a “shutoff” mode).

FIGS. 7-8 illustrate even further exemplary configurations for a metering valve. For example, FIG. 7 shows a metering valve 700 in a “hexavalve” configuration. FIG. 9 illustrates a metering valve 800 in a ball valve configuration. FIG. 9 illustrates a metering valve 900 in a camshaft valve configuration.

FIGS. 10A-10F illustrate a metering valve 1000 in a shuttle valve configuration. The shuttle valve configuration includes a shuttle 1002 that is actuated laterally by any suitable mechanism, such as a pneumatic cylinder (as one non-limiting example). The shuttle 1002 includes a first portion 1004 and a second portion 1006. The shuttle functions 1002 similarly to the rotors 350, 508, etc. That is, the shuttle 1002 may be actuated laterally by a particular amount to fully obstruct, partially obstruct, or not obstruct a first inlet 1008 (via which hot water is received) and/or a second inlet 1010 (via which cold water is received). The temperature of the water that is output through the outlet 1012 is based on the degree to which the first inlet 1008 and the second inlet 1010 are obstructed by the shuttle 1002. Accordingly, the temperature of the water that is output may be selectively controlled by actuating the shuttle 1002 to control the ratio of hot water from the first inlet 1008 and cold water from the second inlet 1010 that is mixed.

FIGS. 10A-10D illustrate the actuation of the shuttle 1002 to different angles and the resulting temperature of the water that is output. Beginning with FIG. 10A, the shuttle 1002 is actuated such that the second portion 1006 partially obstructs the first inlet 1008 and the second inlet 1010. In this angle, some of the hot water from the first inlet 1010 and some of the water from the second inlet 1010 pass through the metering valve 1000 and mix to form a mixture of warm and cold water.

FIG. 10B shows the shuttle 1002 actuated such that the first portion 1004 fully obstructs the first inlet 1008 and the second portion 1006 fully obstructs the second inlet 1010. Accordingly, no water flows from the first inlet 1008 and the second inlet 1010 and the metering valve 1000 is in a shutoff mode.

FIG. 10C shows the shuttle 1002 actuated such that the second portion 1006 fully obstructs the first inlet 1008 but does not obstruct the second inlet 1010. Accordingly, only cold water flows from the second inlet 1010 (and no hot water flows from the first inlet 1008).

FIG. 10D the shuttle 1002 actuated such that the second portion 1006 fully obstructs the second inlet 1010 but does not obstruct the first inlet 1008. Accordingly, only hot water flows from the first inlet 1008 (and no cold water flows from the second inlet 1010).

FIGS. 10E-10F illustrate simulations of water flow through different shuttle valve configurations. FIG. 10E shows a simulation of water flow through a first shuttle valve configuration and FIG. 10F shows a simulation of water flow through a second shuttle valve configuration (a “Y-shaped” configuration). As shown in the simulations, the second configuration may have a lower maximum flow velocity, but a higher average velocity.

FIG. 11 illustrates an example flow diagram 1100 for control of a metering valve (for example, metering valve 204 or any other metering valve) of a water heater (for example, water heater 200 or any other water heater. The flow diagram 1100 illustrates some of the example operations that may be performed by a controller (for example, controller 118, controller 240 or any other controller) used to control the operation of any metering valve described herein. Some or all of the operations and/or conditions of the flow diagram 1100 may be performed in a distributed manner across any number of devices or systems. The operations of the flow diagram 1100 may be optional and may be performed in any other order as well.

Operation 1102 involves receiving data from one or more sensors. As indicated with respect to FIG. 2, the one or more sensors may include temperature sensors that are used to capture temperature data for water at different locations within a metering valve system. Any other types of sensors may also be provided, however, such as sensors used to measure the rate of flow of water through various portions of the metering valve system, as well as any other types of sensors. In this flow diagram 1100, the temperature data may be data received from a temperature sensor at the outlet of the water heater (for example, temperature sensor 242 at the mixing tee 230, as shown in FIG. 2). This data may be used to determine the output temperature of the water heater in order to determine if the temperature needs to be adjusted in accordance with an established temperature setpoint for the water heater.

Although reference is made to temperature data from a single temperature sensor, this is merely exemplary and any other temperature data may be captured from any other combination of sensors provided at any location in the metering valve system, the water heater tank, etc. Additionally, the controller may also, in some instances, consider other types of data as well, such as water flow rate data or any other type of data.

Based on the data received from the one or more sensors, condition 1104 involves determining if the measured temperature is equal to the temperature setpoint established for the water heater. For example, the temperature setpoint may be manually established by a user or may be automatically established by the water heater or another system or device. If condition 1104 is satisfied (the temperature from the temperature sensor equals the temperature setpoint), then the flow diagram 1100 proceeds to condition 1106. If condition 1104 is not satisfied (the temperature from the temperature sensor does not equal the temperature setpoint), then the flow diagram 1100 proceeds to condition 1110.

Condition 1106 involves determining if the rotor is currently rotated to an angle to obstruct the outlet of the metering valve that connects the metering valve to the cold water bypass shunt. If condition 1106 is satisfied (the rotor is determined to be currently angled to obstruct the outlet to the cold water bypass shunt), then the flow diagram 1100 returns to operation 1102 and the loop repeats.

The angle of the rotor may be tracked using any suitable mechanism. As one example, position sensors may be provided at fixed locations on the rotor to track the rotation of the rotor. As another example, an optical sensor may be provided and images and/or video of the angle of the rotor may be obtained. As yet another example, the angle of the rotor may be tracked by tracking the rotation of the motor. These are merely a few non-limiting examples of ways by which the angle of the rotor may be tracked and other suitable mechanisms may also be used.

If condition 1106 is not satisfied (the rotor is determined to not be currently angled to obstruct the outlet to the cold water bypass shunt), then, at operation 1112, the controller sends a signal to the motor to rotate the rotor such that the openings for the outlet (for example, first outlet 210, first outlet 310, etc.) to the tank (for example, water tank 201 or any other tank) and the outlet (for example, second outlet 212, second outlet 312, etc.) to the cold water bypass shunt (for example, cold water bypass shunt 220 or any other cold water bypass shunt) are at least partially open. In this manner, cold water from the water source may flow through the cold water bypass shunt and ultimately mix with the hot water from the tank at the mixing tee (for example, mixing tee 230 or any other mixing tee) to reduce the temperature of the water being output by the water heater.

While the flow diagram 1106 is only shown as performing a single check at condition 1106 to determine the current angle of the rotor, this check may also be performed any time the rotor is to be rotated to a certain angle. For example, a similar check may be made before operation 1112, etc. In some instances, the check may not be made and the controller may send the signal to the motor regardless of the current angle of the rotor. If the current angle of the rotor is the desired angle of the rotor, then the motor may not perform any rotation of the rotor.

At any point, the controller may determine whether a fault (such as a leak or any other type of fault condition) has been detected (as shown in condition 1114) in the metering valve, the metering valve system, and/or the water heater as a whole that necessitates a shutoff mode (for example, the rotor is rotated to obstruct the water inlet to prevent water from entering the water heater). If the fault is detected in condition 1114, then the controller sends a control signal to the motor to rotate the rotor to obstruct the water inlet (for example, water inlet 208, water inlet 308, or any other water inlet) to the metering valve (at operation 1116). The flow diagram 1100 then returns back to operation 1102 and the loop repeats. The condition 1114 is shown in the figure as occurring after operation 1108 or operation 1112, however, this is merely exemplary and not intended to be limiting.

It should be apparent that the foregoing relates only to certain embodiments of the present application and that numerous changes and modifications may be made herein by one of ordinary skill in the art without departing from the general spirit and scope of the disclosure.

Although specific embodiments of the disclosure have been described, numerous other modifications and alternative embodiments are within the scope of the disclosure. For example, any of the functionality described with respect to a particular device or component may be performed by another device or component. Further, while specific device characteristics have been described, embodiments of the disclosure may relate to numerous other device characteristics. Further, although embodiments have been described in language specific to structural features and/or methodological acts, it is to be understood that the disclosure is not necessarily limited to the specific features or acts described. Rather, the specific features and acts are disclosed as illustrative forms of implementing the embodiments. Conditional language, such as, among others, “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments could include, while other embodiments may not include, certain features, elements, and/or steps. Thus, such conditional language is not generally intended to imply that features, elements, and/or steps are in any way required for one or more embodiments.

Claims

1. A water heater comprising:

a water tank;

a metering valve comprising: a rotor; a motor connected to the rotor and configured to cause a rotation of the rotor; a water inlet in fluid communication with a water source; a first outlet in fluid communication with the water tank; and a second outlet in fluid communication with a bypass shunt; and

a mixing tee in fluid communication with an outlet of the water tank and the bypass shunt, wherein at least one of the water inlet, the first outlet, or the second outlet is partially or fully obstructed by the rotor based on an angle of the rotor.

2. The water heater of claim 1, wherein the rotor further comprises:

a first portion including a first rounded surface and a first flat surface; and

a second portion including a second rounded surface and a second flat surface.

3. The water heater of claim 2, wherein the first flat surface and the second flat surface are non-parallel.

4. The water heater of claim 1, further comprising:

one or more sensors; and

a controller configured to provide a signal to the motor to rotate the rotor based on data received from the one or more sensors.

5. The water heater of claim 4, wherein the one or more sensors include a first temperature sensor provided at the mixing tee.

6. The water heater of claim 5, wherein the one or more sensors further include a second temperature sensor provided at the water inlet of the metering valve.

7. The water heater of claim 4, wherein the controller is further configured to:

determine, based on temperature data from the one or more sensors, that a temperature of water in the mixing tee is greater than a temperature setpoint; and

send, based on determining that the temperature is greater than the temperature setpoint, a signal to the motor to rotate the rotor to partially open the second outlet.

8. The water heater of claim 4, wherein the controller is further configured to:

determine, based on temperature data from the one or more sensors, that a temperature of water in the mixing tee is equal to a temperature setpoint; and

send, based on determining that the temperature is greater than the temperature setpoint, a signal to the motor to rotate the rotor to obstruct the second outlet.

9. The water heater of claim 4, wherein the controller is further configured to:

determine that a fault is detected in the water heater; and

send, based on determining that the fault is detected, a signal to the motor to rotate the rotor to obstruct the water inlet.

10. The water heater of claim 1, further comprising a backup battery to provide power to the motor.

11. A metering valve system for a water heater, the metering valve system comprising:

a metering valve comprising: a rotor; a motor connected to the rotor and configured to cause a rotation of the rotor; a water inlet in fluid communication with a water source; a first outlet in fluid communication with a water tank of the water heater; and a second outlet in fluid communication with a bypass shunt; and

a mixing tee in fluid communication with an outlet of the water tank and the bypass shunt, wherein at least one of the water inlet, the first outlet, or the second outlet is partially or fully obstructed by the rotor based on an angle of the rotor.

12. The metering valve system of claim 11, wherein the rotor further comprises:

a first portion including a first rounded surface and a first flat surface; and

a second portion including a second rounded surface and a second flat surface.

13. The metering valve system of claim 12, wherein the first flat surface and the second flat surface are non-parallel.

14. The metering valve system of claim 11, further comprising:

one or more sensors; and

a controller configured to provide a signal to the motor to rotate the rotor based on data received from the one or more sensors.

15. The metering valve system of claim 14, wherein the one or more sensors include a first temperature sensor provided at the mixing tee.

16. The metering valve system of claim 15, wherein the one or more sensors further include a second temperature sensor provided at the water inlet of the metering valve.

17. The metering valve system of claim 14, wherein the controller is further configured to:

determine, based on temperature data from the one or more sensors, that a temperature of water in the mixing tee is greater than a temperature setpoint; and

send, based on determining that the temperature is greater than the temperature setpoint, a signal to the motor to rotate the rotor to partially open the second outlet.

18. The metering valve system of claim 14, wherein the controller is further configured to:

determine, based on temperature data from the one or more sensors, that a temperature of water in the mixing tee is equal to a temperature setpoint; and

send, based on determining that the temperature is greater than the temperature setpoint, a signal to the motor to rotate the rotor to obstruct the second outlet.

19. The metering valve system of claim 14, wherein the controller is further configured to:

determine that a fault is detected in the water heater; and

send, based on determining that the fault is detected, a signal to the motor to rotate the rotor to obstruct the water inlet.

20. A metering valve for a water heater, the metering valve comprising:

a rotor;

a motor connected to the rotor and configured to cause a rotation of the rotor;

a water inlet in fluid communication with a water source;

a first outlet in fluid communication with a water tank of the water heater; and

a second outlet in fluid communication with a bypass shunt, wherein at least one of the water inlet, the first outlet, or the second outlet is partially or fully obstructed by the rotor based on an angle of the rotor.