Abstract:
A water heater door assembly includes a base plate sized and shaped to substantially sealingly cover an access opening in a water heater combustion chamber and having at least one opening through which a fuel supply line extends at least partly between a burner in the combustion chamber and a fuel control valve, and a seal positioned at least partly within the opening and having a through hole that is sized and shaped to receive the fuel supply line, the seal comprising a plurality of complementary deformed seal pieces sealed together, to the opening and to the fuel supply line by a deforming force.

Description:
TECHNICAL FIELD 
       [0001]    This disclosure relates to water heaters, particularly to water heaters that have door assemblies, such as those for water heater combustion chambers. 
       BACKGROUND 
       [0002]    Gas fired water heaters traditionally have a water container placed above or adjacent to a combustion chamber and burner assembly. The burner assembly is controlled by a gas control valve which may be responsive to user input, such as a temperature setting. The burner assembly may have a main gas line extending from the gas control valve, through the combustion chamber wall or door, and to the burner. Gas lines have been constructed using various configurations and materials. By way of example, rigid tubing has been used where possible and in some cases threaded fittings are used to connect the rigid tubing to flexible tubing. 
         [0003]    It could be beneficial to provide a sealed door assembly that is simple, compact, durable, tamper-resistant and economical to construct. 
       SUMMARY 
       [0004]    We provide a water heater door assembly comprising a base plate sized and shaped to substantially sealingly cover an access opening in a water heater combustion chamber and having at least one opening through which a fuel supply line extends at least partly between a burner in the combustion chamber and a fuel control valve, and a seal positioned at least partly within the opening and having a through hole that is sized and shaped to receive the fuel supply line, the seal comprising a plurality of complementary deformed seal pieces sealed together, to the opening and to the fuel supply line by a deforming force. 
         [0005]    We also provide a water heater comprising a water container, a combustion chamber adjacent the water and having an access opening, a burner associated with the combustion chamber and arranged to combust fuel to heat water in the water container, a fuel control valve that regulates fuel flow from an external fuel source, and a door assembly comprising: 1) a base plate sized and shaped to substantially sealingly cover the access opening and having at least one opening through which a fuel supply line extends at least partly between a burner in the combustion chamber and the control valve; and 2) a seal positioned at least partly within the opening and having a through hole that is sized and shaped to receive the fuel supply line, the seal comprising a plurality of complementary deformed seal pieces sealed together, to the opening and to the fuel supply line by a deforming force. 
         [0006]    We further provide a method of producing a water heater door assembly comprising providing a base plate sized and shaped to substantially sealingly cover an access opening in a water heater combustion chamber and having at least one opening through which a fuel supply line extends at least partly between a burner in the combustion chamber and a fuel control valve, assembling a plurality of complementary seal pieces in the opening, passing the fuel supply line through a through hole formed by the complementary seal pieces and applying force to the complementary seal pieces sufficient to deform the seal pieces to substantially seal the seal pieces together, to the opening and to the fuel supply line. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]      FIG. 1  is a schematic front elevational view of a water heater. 
           [0008]      FIG. 2  is a schematic side elevational view of the water heater of  FIG. 1 . 
           [0009]      FIG. 3  is a schematic front elevational view, taken partly in section, of the lower portion of a water heater of the type shown in  FIGS. 1 and 2 . 
           [0010]      FIG. 4  is a schematic perspective view, partially cut away, of the lower portion of the water heater. 
           [0011]      FIG. 5  is a schematic perspective view of a pair of complementary fittings. 
           [0012]      FIG. 6  is a schematic perspective view of another pair of complementary fittings. 
           [0013]      FIG. 7  is a schematic perspective view of yet another shape of a complementary fitting. 
           [0014]      FIG. 8  is a schematic perspective view of a combustion chamber door having a portion of a fuel line extending through a through hole in the door and being held in place by a pair of complementary fittings. 
           [0015]      FIG. 9  is a schematic sectional view of the structure of  FIG. 8  subsequent to application of deformation force to the complementary fittings. 
           [0016]      FIG. 10  is a schematic perspective view of the exterior of a combustion chamber door showing a fuel line extending therethrough and being sealed into place. 
           [0017]      FIG. 11  is a perspective view of the structure shown in  FIG. 10  from the opposite side of the door. 
       
    
    
     DETAILED DESCRIPTION 
       [0018]    It will be appreciated that the following description is intended to refer to specific aspects of the representative structures selected for illustration in the drawings and is not intended to define or limit the substance of this disclosure, other than in the appended claims. 
         [0019]    Turning now to the drawings in general and  FIGS. 1-4  in particular, the number “2” designates a storage type gas water heater  2 . Water heater  2  includes jacket  4  which surrounds a water tank  6  and a main burner  14  in a combustion chamber  15 . The term “water tank” or “water container” can include conventional storage type water tanks. However, it can include other types of structures through which water passes and/or is retained for a period of time whether extended or just momentary. Thus, the water tank or container can also be as simple a structure as a pipe or conduit through which water flows. 
         [0020]    Passing through the center of the tank  6  is a flue  10 , in this instance incorporating a series of baffles  12  to better transfer heat generated by the main burner  14 . Water tank  6  is preferably of mains pressure capability and is capable of holding heated water. Water tank  6  is preferably insulated by foam insulation  8 . Alternative insulation may include fiberglass or other types of fibrous insulation, heating retaining material and the like. Fiberglass insulation  9  surrounds combustion chamber  15  and the lowermost portion of water tank  6 . It is possible that heat resistant foam insulation can be used if desired. A foam dam  7  separates foam insulation  8  and fiberglass insulation  9 . 
         [0021]    Located underneath the water tank  6 , within the combustion chamber  15 , is the main burner  14  which uses any type of fuel such as oil, natural gas or other gases such as LPG, for example. Other suitable fuels may be substituted. Fuel is provided to the main burner  14  through the fuel supply line  20 , which is fluidly connected to fuel control valve  21 . Fuel control valve  21  supplies fuel to burner  14  by way of fuel supply line  20 . Main burner  14  combusts a fuel and air mixture and the hot products of combustion resulting rise up through flue  10 , possibly with heated air. Water tank  6  is lined with a glass or other type of coating for corrosion resistance. Bottom  5  of water tank  6  is preferably coated on both its interior facing surface  3  and exterior facing surface  11 . The thickness of the coating of exterior facing surface  11  may be about half of the thickness of interior facing surface  3 . Also, the lower portion of flue  10  is preferably coated on both of its opposing surfaces. The surface exposed to the flue gases has a thickness about half the thickness of the surface exposed to water in water tank  6 . The glass coating helps to prevent scaling of the flue and water tank surfaces. 
         [0022]    Combustion chamber  15  also contains a pilot burner  49  connected to fuel control valve  21  by pilot fuel supply line  47 . A sheath  52 , preferably made of copper, contains wires (not shown) from a flame detecting thermocouple  51  to cause, in the absence of a flame at pilot burner  49 , fuel control valve  21  to shut off the gas supply. Thermocouple  51  may be selected from those known in the art. RobertShaw Model No. TS  7 50U may be used, for example. 
         [0023]      FIGS. 3 and 4  particularly show fuel supply line  20  and pilot fuel supply line  47  extending outwardly from a door  25 , which provides access to the combustion chamber  15 . Door  25  is removably sealable to skirt  60  that forms the side wall of combustion chamber  15 . Door  25  is held into position by a pair of screws  62  or by any other suitable means. Pilot fuel supply line  47  and fuel supply line  20  pass through door  25  in a substantially fixed and sealed condition. Sheath  52  also extends through door  25  in a substantially fixed and sealed condition as does igniter line  64 . Igniter line  64  connects on one end to an igniter button  22  and a piezo igniter. Igniter button  22  can be obtained from Channel Products, for example. Each of pilot fuel supply line  47 , fuel supply line  20  and sheath  52  are removably connectable to fuel control valve  21  by compression nuts  68 ,  70  and  72 , respectively. Each of compression nut  68 ,  70  and  72  are threaded and threadingly engage control valve  21 . Other means of connecting may be employed as alternatives. 
         [0024]    The products of combustion pass upwardly and out the top of jacket  4  via flue outlet  16  after heat has been transferred from the products of combustion. The flue outlet  16  discharges conventionally into a draft diverter  17  which in turn connects to an exhaust duct leading outdoors. 
         [0025]    Water heater  2  is preferably mounted on legs  24  to raise bottom pan  26  off the floor. Bottom pan  26  preferably has one or more apertures  27  or some other means that receive combustion air. Where bottom pan  26  meets jacket  4 , the mating surfaces (made up from surfaces of bottom pan  26  and jacket  4 ) can be sealed thoroughly to prevent ingress of air or any flammable gas or vapor. The cylindrical wall of jacket  4  (the majority of gas water heaters are cylindrical; however, a cubic or other shaped jacket  4  may be utilized) can be sealed substantially gas tightly so that no openings or breaks remain upon assembly and installation. 
         [0026]    In particular, gas, water, electrical, control or other connections, fittings or plumbing, wherever they pass through the jacket  4  or bottom pan  26  may be sealed substantially airtightly. The joining area of bottom pan  26  to jacket  4  and service entries or exits to the jacket  4  need not be sealed airtightly. It is preferred, however, that the space around burner  14  be substantially air/gas tight except for means to supply combustion air. 
         [0027]    Turning now to  FIG. 5 , a pair of complementary fittings  100  are shown in a perspective view and oriented apart from one another, but substantially positioned to be aligned adjacent to each other. Each fitting  100  comprises a substantially semi-circular barrel portion  102  and a substantially semi-circular flange  104 . The barrel portion is sized and shaped so that it approximately fits through a through hole in door  25  with just enough clearance so that distal end  106  of barrel portion  102  extends through the through hole and the outer surface of door  25  substantially contacts a surface of flange  104 . Flange  104  accordingly extends radially outwardly from barrel portion  102  in a substantially perpendicular direction. 
         [0028]    In the two structures shown in  FIG. 5 , a flange of one of the fittings has two ribs  108  that extend outwardly from that flange. Similarly, the complementary fitting has a flange with a pair of grooves  110  that are substantially sized and shaped to receive the ribs  108  from the opposed, complementary flange. 
         [0029]      FIG. 6  shows another type of a pair of complementary fittings  200 . They contain similar barrel portions  202  relative to the barrel portions  102  of fittings  100 . Fittings  200  also have flanges  204  that are similar to flanges  104  of fittings  100  as shown in  FIG. 5 . 
         [0030]    Fittings  200  each have a substantially cylindrically-shaped protrusion  208  that extends from the barrels  202 . Then, each fitting  200  on the opposed face of barrels  202  has a substantially cylindrically-shaped bore  210  that is sized and shaped to receive in a close fit the protrusions  208  from a complementary fitting  200 . 
         [0031]    It should be noted in the structure of  FIG. 6 , that the protrusions and bores are oriented on the barrels  202  of the fittings  200  as opposed to being located on the flanges  104  of the fittings  100  of  FIG. 5 . The location of the various ribs, grooves, protrusions and bores may be on various portions of the fittings so long as they are effective to serve as a means of aligning the respective fittings with respect to one another. 
         [0032]      FIG. 7  shows yet another structure of a fitting  300 . It also has a barrel  302  and a flange  304  similar to the barrels and flanges of the structures of  FIGS. 5 and 6 . The difference between fitting  300  and the fittings  100  of  FIG. 5  is that instead of having the ribs  108  located on a single fitting and the complementary grooves  110  located on the other complementary fitting, the grooves  310  of  FIG. 7  are located on different fittings as opposed to the same fitting  300 . Similarly, the ribs  308  are located on one of each of the two fittings  300  as opposed to both ribs  308  being located on the same fitting  308 . 
         [0033]      FIG. 8  shows a perspective view of a door  25  in a simplistic, flattened form for ease of understanding. Fuel supply line  20  extends through a through hole in door  25 . A pair of complementary fittings  300  also extend through the through hole such that barrels  302  extend through the thickness of door  25  and one of the surfaces of each of flanges  304  is substantially positioned against exterior surface  112  of door  25 . Ribs  308  from each of the complementary fittings  300  closely engages grooves  310 , so that the pair of complementary fittings  300  are closely aligned with one another. 
         [0034]    The arrangement in  FIG. 8  allows for the exterior surface of the barrels  302  to be sized and shaped slightly smaller than the diameter of the through hole to allow sufficient room for both the fittings  300  and fuel supply line  20  to pass through the through hole. The inner diameter of the barrels  302  is also sized and shaped to closely receive the exterior surface of fuel supply line  20 . It should be noted that the structure shown in  FIG. 8  is such that the complementary fittings  300  and fuel supply line  20  are all positioned together and within the through hole of door  25  such that a deforming force may be applied to the complementary fittings  300 . Such deforming force is applied to the flanges  304  of each fitting  300  at the exterior surface  112  of door  25  on the one hand and are applied to the exterior surface of barrel portions of fittings  300  from the interior surface of door  25 . 
         [0035]    The amount of deforming force may be varied depending on the material that is used to manufacture the fittings  100 ,  200  and  300 . Also, any number of different devices may be used to apply the deforming force. Any number of materials can be used so long as they are heat resistant, deform in response to deforming force and are capable of providing a seal between fuel supply line  20  and door  25 . Aluminum is a particularly preferred material. Of course, various aluminum alloys may be used as may be other metals such as copper, copper alloys, and mild steel. Non-metals may also be used such as, for example, silicon rubber. 
         [0036]    The assembly may be made by inserting the two complementary fittings  300  into the through hole with fuel supply line  20  having been inserted inside the complementary fittings. Then, the fittings are subjected to deforming force from both inside and outside of the door in the axial direction along the center line of fuel supply line  20 . The material used to form fittings  300  deforms or “flows” radially inwardly and outwardly. Inward flow affixes the material of the complementary fittings to fuel supply line  20 , while outward flow affixes the material of the complementary fittings to the through hole of the door. This achieves complete attachment of the fuel line to the door and also results in a substantially airtight seal. 
         [0037]    The resulting deformed structure is shown in  FIG. 9 .  FIG. 9  is a sectional view of door  25  having been provided with a pair of complementary fittings  300  and fuel supply line  20 . The complementary fittings  300  have been subjected to deforming force. Such deforming force results in “flow” of material from the fittings  300  into spaces between the edge  114  of the through hole to achieve a tight seal. Thus, the groove  116  provided in fuel supply line  20  is filled with “flowed” material from fittings  300 . Similarly, the groove  118  provided in door  25  is also filled with “flowed” material from complementary fittings  300 . This helps to ensure the stability of the fit between the fuel line and the door on the one hand and also assists in creating a substantially airtight seal. 
         [0038]      FIG. 10  shows fuel supply line  20  affixed to door assembly  25  substantially in the same manner as indicated in  FIG. 9 .  FIG. 10  shows the exterior surface  112  of door  25  and flanges  304 .  FIG. 11  shows an interior surface  120  of door  25  and the deformed portions of barrels  302 . 
         [0039]    It will be understood that water heater  2  may be constructed with a wide variety of materials, in a wide variety of shapes and sizes. For example, any number of types of burners  14  may be employed, along with various types of fuel control valves  21  and the like. Also, various types of insulation, water containers/tanks and jackets may be employed. 
         [0040]    Although the contents of this disclosure have been described in connection with specific representative forms thereof, it will be appreciated that a wide variety of equivalents may be substituted for the specified elements described herein without departing from the spirit and scope of this disclosure as described in the appended claims.