Patent Publication Number: US-2022214077-A1

Title: Water heater inlet fitting, flow sensor, shut off valve and diffuser

Description:
RELATED APPLICATIONS 
     The present application is a divisional application of U.S. patent application Ser. No. 16/042,386 filed Jul. 23, 2018, which claims priority to U.S. Provisional Patent Application No. 62/535,592, filed Jul. 21, 2017, the entire contents of which are incorporated herein by reference. 
    
    
     TECHNICAL FIELD 
     The present disclosure relates generally to water heaters and particularly to water heater inlet fittings. 
     BACKGROUND 
     Boilers, water heaters, and other similar devices have various types of water inlet fittings. For example, gas water heaters typically have an inlet with a diffuser that extends into the water heater. The diffuser can be designed and positioned within the water heater to optimize the thermal efficiency of the water heater. The proper orientation and geometry of the diffuser will deliver cold inlet water to the proper location within the water heater allowing mixing and counter-flow and preventing the cold inlet water from being directed at one or more heat exchanger pipes which could cause thermal stress. In one example, the optimum orientation for the diffuser is the 2 o&#39;clock position for the diffuser outlet, assuming the diffuser is positioned extending vertically downward into the cylindrically shaped water heater tank, the diffuser outlet is on a side of the diffuser pointing outward toward a wall of the water heater tank, the 12 o&#39;clock position is pointing inward toward a gas flue running through the central longitudinal axis of the cylindrically shaped water heater tank, and the 6 o&#39;clock position is pointing outward directly towards the closest section of the outer wall of the water heater tank. Because the diffuser is a separate component that must be attached to the gas water heater during installation, there is an increased likelihood the installer may not position the diffuser properly during the installation thereby negatively affecting the thermal efficiency of the water heater. For example, if the diffuser is attached to the water heater and then the separate flow sensor is attached to the diffuser, torque is separately applied to both the diffuser and the flow sensor. When torque is applied to the flow sensor, there is a tendency for the diffuser to shift from the optimal position. 
     Another drawback in some existing water heaters is the length of the diffuser and the inlet fitting because longer components require more space in which to install the water heater. 
     Yet another drawback of some existing water heaters is that the inlet fittings lack integrated components for measuring the flow of water through the fitting or shutting off the flow of water through the fitting. 
     The following disclosure describes example water inlet fittings, flow sensors, shut off valves, and diffusers that can address one or more of the foregoing limitations associated with water heaters and other similar devices. 
     SUMMARY 
     The present disclosure is directed to a flow sensor for a water heater. In one embodiment, an integrated flow sensor and diffuser for a water heater include a flow sensor body with a diffuser attachment mechanism and a diffuser with a complementary attachment mechanism. An inlet of the flow sensor body includes an inlet attachment mechanism for attaching the flow sensor body to a water supply pipe. The diffuser attachment mechanism is located on an extended cylindrical flange at an outlet of the flow sensor body. The complementary diffuser attachment mechanism is configured to couple to the diffuser attachment mechanism of the extended cylindrical flange. The flow sensor body includes a cavity for retaining a flow sensor. The integrated flow sensor and diffuser can have a single set of threads on the outer surface of the extended cylindrical flange so that the integrated flow sensor and diffuser can be attached to the water heater as a single assembly. 
     In another example embodiment, an integrated valve and flow sensor include a valve body, a rotatable ball disposed within the valve body, a flow sensor comprising a Hall effect sensor and a turbine disposed within the rotatable ball, a stem extending from the rotatable ball and comprising a lead from the Hall effect sensor, and an actuator coupled to the stem for controlling the operation of the rotatable ball. The lead from the Hall effect sensor can be coupled to a meter that measures a flow of water through the integrated valve and flow sensor. An outlet of the integrated valve and flow sensor can include an attachment mechanism for mating with a complementary attachment mechanism of a diffuser. 
     In yet another example, a fitting for a water heater comprises a valve, an actuator coupled to the valve for opening and closing the valve, a flow sensor, and a heat trap. The flow sensor can comprise a turbine and a Hall effect sensor for measuring the flow of water through the fitting. The heat trap can prevent undesirable mixing or loss of heated water. The fitting can be coupled to either an inlet fitting or an outlet fitting on a water heater. 
     These and other aspects and examples will be described in the following description and the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein: 
         FIG. 1  is a cross-sectional illustration of separate flow sensor and diffuser components joined with a coupler as known in the prior art. 
         FIG. 2  is a cross-sectional illustration of an inlet fitting that is a combined flow sensor and diffuser assembly in accordance with an example embodiment of this disclosure. 
         FIG. 3  is a cross-sectional illustration of an inlet fitting that is a combined flow sensor, diffuser, and shut off valve assembly in accordance with an example embodiment of this disclosure. 
         FIG. 4  is a perspective, partial cross-sectional illustration of an inlet fitting that is a combined flow sensor, diffuser, and shut off valve assembly in accordance with an example embodiment of this disclosure. 
         FIG. 5  is a schematic illustration of an electric water heater with a shut off valve and flow sensor located at the inlet in accordance with an example embodiment of this disclosure. 
         FIGS. 6, 7, 8, and 9  are views from different angles of an inlet fitting that is a combined flow sensor and shut off valve in accordance with an example embodiment of this disclosure. 
         FIG. 10  is a partial cross section of the inlet fitting of  FIGS. 6-9  that is a combined flow sensor and shut off valve showing a heat trap insert in accordance with an example embodiment of this disclosure. 
     
    
    
     DESCRIPTION OF EXAMPLE EMBODIMENTS 
     The example embodiments discussed herein are directed to systems, apparatuses, and methods for water heaters with optimized inlet structures, diffusers, flow sensors and shut off valves. The following embodiments are non-limiting examples and those working in this field should understand that various modifications can be applied to the examples described herein without departing from the scope of this disclosure. 
     The components described herein can be made of one or more of a number of suitable materials to allow the component or other associated components to meet certain standards and/or regulations. Examples of such materials can include, but are not limited to, aluminum, stainless steel, copper, fiberglass, plastic, PVC, ceramic, and rubber. 
     Components described herein can be made from multiple pieces that can be mechanically coupled to each other using one or more of a number of coupling methods, including but not limited to epoxy, welding, soldering, fastening devices, compression fittings, mating threads, and slotted fittings. One or more pieces that are mechanically coupled to each other can be coupled to each other in one or more of a number of ways, including but not limited to fixedly, hingedly, removeably, slidably, and threadably. An attachment or coupling feature can include, but is not limited to, a swage, a snap, a clamp, a portion of a hinge, an aperture, a recessed area, a protrusion, a slot, a spring clip, a tab, a detent, a compression fitting, and mating threads. 
     Any component described in one or more figures herein can apply to any other figures having the same label. In other words, the description for any component of a figure can be considered substantially the same as the corresponding component described with respect to another figure unless otherwise noted. For any figure shown and described herein, one or more of the components may be omitted, added, repeated, and/or substituted. Accordingly, embodiments shown in a particular figure should not be considered limited to the specific arrangements of components shown in such figure. 
     Referring to  FIG. 1 , a cross-sectional illustration is shown of separate flow sensor  105  and diffuser  110  components joined with a coupler  115  as known in the prior art. As described above in the Background Section, the separate flow sensor  105  and diffuser  110  components have drawbacks due to their length and difficulty with installing the diffuser at the optimal position for thermal efficiency. For example, the flow sensor and diffuser would typically be attached to a water heater fitting located on a top surface of a cylindrically shaped gas water heater so that the diffuser extends down into the water heater tank. Installation requires first attaching the diffuser  110  and coupler  115  to the water heater with a first application of torque. When the diffuser is attached to the water heater, it can be disposed at a particular position, such as 2 o&#39;clock for the diffuser outlet  112 , that affects the circulation of the incoming water to optimize thermal efficiency. Second, the flow sensor  105  is attached to the coupler  115  with a second application of torque. When attaching the flow sensor  105  to the coupler  115 , the second application of torque can cause the diffuser to be rotated from its optimal position. 
     In contrast,  FIG. 2  is a cross-sectional illustration of an inlet fitting that is a combined flow sensor and diffuser assembly  200  in accordance with an example embodiment of this disclosure. In the example assembly of  FIG. 2 , the flow sensor body  205  includes an integral attachment mechanism  206  and an extending cylindrical flange  207  that extends from the integral attachment mechanism  206  and outward away from the flow sensor body  205 . The diffuser  210  attaches to the flow sensor body  205  with a complementary attachment mechanism  214  that is integral to the diffuser so that the flow sensor and diffuser assembly  200  forms a single component and can be installed as a single component in a water heater. As shown in  FIG. 2 , the attachment mechanism  206  can be a protrusion and the complementary attachment mechanism  214  can be a notch. In alternate embodiments, the protrusion and notch can be reversed or can be any other readily know attachment mechanism such as a swage fitting. 
     The combined flow sensor and diffuser assembly  200  can have a single set of threads on the outer surface of the extended cylindrical flange  207  so that the combined flow sensor and diffuser assembly  200  can be attached to the water heater as a single assembly. Because only one tightening procedure is required to attach the single flow sensor and diffuser assembly  200 , the installer is better able to ensure that the diffuser  210  is in the correct orientation to optimize the flow of the cold inlet water entering the water heater from the diffuser outlet  212 . The combined flow sensor and diffuser assembly  200  also comprises an inlet  202  that is configured to couple to a water supply pipe. 
     The single flow sensor and diffuser assembly  200  is also an improvement over the prior art components shown in  FIG. 1  because it has a shorter length thereby allowing for installation in smaller spaces. Referring to the non-limiting prior art example shown in  FIG. 1 , the joined flow sensor  105 , diffuser  110 , and coupler  115  have a combined length ranging from 10.25 to 10.50 inches. In contrast, the example combined flow sensor and diffuser assembly  200  of  FIG. 2  has a length of 7.25 inches thereby making it easier to install in small spaces. In other examples, the length of the combined flow sensor and diffuser assembly can vary within a range of 5 to 8 inches. All dimensions shown in the figures herein are in inches and should be considered non-limiting examples of the embodiments described herein. 
       FIGS. 3 and 4  illustrate a cross-sectional view and a perspective, partial cross-sectional view, respectively, of an inlet fitting  300  that is a combined flow sensor, diffuser, and shut off valve assembly in accordance with an example embodiment of this disclosure. Similar to the embodiment shown in  FIG. 2 , the embodiment shown in  FIGS. 3 and 4  includes a diffuser  310  with a complementary attachment mechanism  314 , and the flow sensor body  305  with an extending cylindrical flange  307  and an attachment mechanism  306 . The attachment mechanism  306  and complementary attachment mechanism  314  can comprise a protrusion and a notch that lock together as shown in  FIG. 3  or can comprising other known attachment mechanisms. The flow sensor body  305  shown in  FIGS. 3 and 4  can also include male threads  308  on the outer surface of the extending cylindrical flange  307  for mating with a female fitting on the water tank. 
     The example embodiment shown in  FIGS. 3 and 4  is similar to the embodiment shown in  FIG. 2 , except that it shows more details of the flow sensor and shows a shut off valve in the form of a ball valve that is integrated with the flow sensor. While the diffuser  310  is shown in  FIGS. 3 and 4 , it should be understood that the combined flow sensor and shut off valve can be used without the diffuser  310  in certain example embodiments. The combined flow sensor and shut off valve shown in  FIGS. 3 and 4  provides advantages over the prior art in that the components are integrated into a single assembly thereby simplifying installation and reducing the space required when a shut off valve and flow sensor are separate components. 
     In the embodiment shown in  FIGS. 3 and 4 , the flow sensor comprises a turbine  318  a Hall effect sensor  320  and a sensor lead  322 . The turbine  318  is positioned inside the ball  324  of the ball valve and the Hall effect sensor  320  and the sensor lead  322  are located in the stem  326  of the ball valve. The flow sensor measures the flow of water through the inlet fitting  300  and, in conjunction with the Hall effect sensor  320 , provides a signal via the sensor lead  322  to a meter that gathers data indicating the flow of water into the water heater. In alternate embodiments, other types of flow sensors can be implemented in the valve. A motor, not shown in  FIGS. 3 and 4 , can control the opening and closing of the ball valve via the stem  326 . Placing a shut off valve at the entrance to the water heater provides advantages that include controlling the flow of water at the entrance to the water heater and being able to maintain a vacuum seal within the water heater. 
     Referring now to  FIGS. 5-10 , another example embodiment of an integrated inlet fitting, flow sensor and shut off valve is illustrated. The embodiment illustrated in  FIGS. 5-10  is in connection with an electric water heater, however, the same concepts can also be applied to a gas water heater.  FIG. 5  shows a schematic illustration of an electric water heater  500  with an inlet  502 , an outlet  530 , and two heating elements  535 . An inlet fitting  504  comprises an integrated shut off valve  524  and flow sensor  518  in accordance with an example embodiment of this disclosure. In contrast to the previously described fittings for gas water heaters that included an optional diffuser, the electric water heater  500  shown in  FIG. 5  includes an optional dip tube  540  attached to the inlet fitting  504 . 
       FIGS. 6-10  show different views of an example inlet fitting  604  comprising an integrated flow sensor and shut off valve in accordance with the embodiment shown in  FIG. 5 .  FIG. 6  is a top view of the fitting,  FIG. 7  is a top perspective view of the fitting,  FIG. 8  is a back view of the fitting, and  FIG. 9  is a side view of the fitting.  FIG. 10  is a partial cross-sectional view of the fitting showing the flow sensor integrated into the shut off valve, but that omits, for purposes of clarity, the external components of the fitting shown in  FIGS. 6-9 . While the example shown in  FIG. 610  is an inlet fitting, it should be understood that the same components can also be implemented in an outlet fitting for a water heater. 
       FIGS. 6-10  show the inlet fitting  604  with an inlet  602 , inlet threads  603 , an outlet  612 , and outlet threads  608 . The outlet threads  608  permit the inlet fitting  604  to be attached to a fitting on the water heater. The inlet threads  603  permit the inlet fitting  604  to be attached to a water supply pipe. 
     As shown in  FIGS. 6-10 , the integrated inlet fitting  604  combines a flow sensor and shut off valve into a single assembly that simplifies installation. The integrated inlet fitting also requires less space than if one were to install a separate flow sensor and a separate shut off valve at a water heater inlet.  FIGS. 6-9  show the shut off valve  624  located inside the inlet fitting  604  and an electronic actuator  645  connected to the inlet fitting via a valve stem  626 . The electronic actuator  645  can be connected to a separate controller and/or power source via lead  623  and the electronic actuator  645  controls the opening and closing of the shut off valve  624 . The shut off valve  624  can be a ball valve similar to the valve described in connection with  FIGS. 3 and 4 , or another type of valve. Located within the shut off valve is a turbine  618  for measuring the flow of water through the inlet fitting  604 . The turbine  618  works with a Hall effect sensor  620 , located on the outer surface of the inlet fitting  604 , to provide signals to a meter, via lead  622 , indicating the flow of water through the inlet fitting  604 . The integrated inlet fitting can also include a heat trap  650  located inside the inlet fitting and downstream of the shut off valve  624 . The heat trap  650  is a valve that prevents the heated water within the water tank from flowing back through the inlet fitting and mixing with the cold water from the water supply. 
     While example embodiments of integrated inlet fittings are discussed herein, the principles of the described embodiments can be applied to a variety of types of water heaters. Accordingly, many modifications of the embodiments set forth herein will come to mind to one skilled in the art having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that water inlet structures, flow sensors, shut off valves, and diffusers are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of this application. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.