Patent Publication Number: US-2023141828-A1

Title: Leak detection in tankless water heater

Description:
TECHNICAL FIELD 
     The present disclosure relates, in general, to tankless water heater and, more specifically relates, to a leak detection device for the tankless water heater. 
     BACKGROUND 
     Typically, a water heater may be subject to deterioration over course of its life. Such deterioration may compromise integrity of the water heater and may, for example, cause water leak besides other issues. In case of tankless water heater, water may leak into a cabinet of the tankless water heater from fittings or couplings and eventually pool at a base of the tankless water heater. Since the tankless water heater has a sealed cabinet, leaked water may accumulate internally. If left undetected and unattended, progress of such water leaks may cause damage to electrical equipment and other components and may result in costly repairs. Therefore, it is important to detect the leak as early as possible in the tankless water heaters. 
     SUMMARY 
     According to one aspect of the present disclosure, leak detection device for a tankless water heater is disclosed. The leak detection device includes a leak sensor and at least one absorption arm extending from the leak sensor. The absorption arm is configured to (i) wick water and (ii) transport the wicked water towards the leak sensor. Further, the leak sensor is configured to generate a signal indicative of leakage in the tankless water heater, in response to sensing wetness. 
     In an embodiment, the absorption arm of the leak sensor extends along a base of the tankless water heater. The absorption arm absorption arm is made of one of polyester, polypropylene, merino wool, nylon, or micromodal. In some embodiments, diameter of the absorption arm is in a range of about 0.1 inches to about 0.2 inches and thickness of wall of the absorption arm is in a range of about 0.001 inches to about 0.1 inches. In some embodiments, the leak sensor in configured to generate the signal based on an electrical resistance change corresponding to the sensed wetness. In an embodiment, the leak sensor is configured to couple with a notification device. In some embodiments, the leak sensor is configured to operate in a temperature range of about 30° F. to about 200° F. 
     According to another aspect of the present disclosure, a tankless water heater is disclosed. The tankless water heater includes a leak detection device configured to detect a water leak in the tankless water heater. The leak detection device includes a leak sensor and at least one absorption arm extending from the leak sensor. The absorption arm is configured to (i) wick water and (ii) transport the wicked water towards the leak sensor. Further, the leak sensor is configured to generate a signal indicative of leakage in the tankless water heater, in response to sensing wetness. The tankless water heater also includes a controller coupled with the leak detection device and configured to receive the signal from the leak sensor and actuate a notification device to provide a notification regarding the detected leak in the tankless water heater. 
     In an embodiment, the leak detection device is disposed on a base of the tankless water heater. The absorption arm is coupled to the base of the tankless water heater with one or more coupling members, such as a magnetic clip, an adhesive, or a vacuum cup. In an embodiment, a free end of the absorption arm is located away from condensation regions in the tankless water heater. 
     According to yet another aspect of the present disclosure, method of detecting leak in a tankless water heater is disclosed. The method includes wicking water by at least one absorption arm, transporting wicked water towards a leak sensor, generating a signal indicative of leakage in the tankless water heater, in response to sensing wetness, and providing a notification regarding detected leak in the tankless water heater, corresponding to the sensed wetness. 
     In some embodiments, the method also includes causing a change in electrical resistance in the leak sensor in response to sensing wetness. 
     These and other aspects and features of non-limiting embodiments of the present disclosure will become apparent to those skilled in the art upon review of the following description of specific non-limiting embodiments of the disclosure in conjunction with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       A better understanding of embodiments of the present disclosure (including alternatives and/or variations thereof) may be obtained with reference to the detailed description of the embodiments along with the following drawings, in which: 
         FIG.  1    is an exemplary view of a base of a tankless water heater, according to an embodiment of the present disclosure; 
         FIG.  2    is an exemplary top view of a leak detection device, according to an embodiment of the present disclosure; 
         FIG.  3    is a an exemplary coupling member of the leak detection device, according to an embodiment of the present disclosure; 
         FIG.  4    shows a leak detection kit, according to an embodiment of the present disclosure; and 
         FIG.  5    is flowchart of a method of detecting leak in the tankless water heater, according to an embodiment of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     Reference will now be made in detail to specific embodiments or features, examples of which are illustrated in the accompanying drawings. Wherever possible, corresponding or similar reference numbers will be used throughout the drawings to refer to the same or corresponding parts. Moreover, references to various elements described herein, are made collectively or individually when there may be more than one element of the same type. However, such references are merely exemplary in nature. It may be noted that any reference to elements in the singular may also be construed to relate to the plural and vice-versa without limiting the scope of the disclosure to the exact number or type of such elements unless set forth explicitly in the appended claims. 
     As used herein, the terms “a”, “an” and the like generally carry a meaning of “one or more,” unless stated otherwise. Further, the terms “approximately”, “approximate”, “about”, and similar terms generally refer to ranges that include the identified value within a margin of 20%, 10%, or preferably 5%, and any values therebetween. 
     Aspects of the present disclosure are directed to a device and a method of detecting leak in a tankless water heater. Referring to  FIG.  1   , an exemplary view of a base  100  of a tankless water heater  102  is illustrated. The base  100  defines one or more apertures configured to allow piping connecting extending through the base  100  or connecting with the base  100 . For the purpose of the present disclosure, such apertures are considered as water outlets  104  defined in the base  100 . As used herein, the term “water outlets” includes (i) connections, such as piping connectors, coupled to the base  100 , configured to allow flow of water therethrough, and (ii) pipes extending through the apertures defined in the base  100 . In case of water leakage through such water outlets  104 , functioning of components located on the base  100  may be disturbed and may render the components non-functional. In order to detect the leakage, the tankless water heater  102  includes a leak detection device  106 . According to an aspect of the present disclosure, the leak detection device  106  is disposed on the base  100  of the tankless water heater  102 . However, location of the leak detection device  106  should not be construed limiting. In some embodiments, the leak detection device  106  may be located along walls of the tankless water heater  100 , albeit with few variations to the aspects described herein. 
       FIG.  2    illustrates an exemplary top view of the leak detection device  106 . In an embodiment, the leak detection device  106  includes a leak sensor  202  and at least one absorption arm  204  extending from the leak sensor  202 . Preferably, the leak sensor  202  is implemented as an electronic unit. As seen in the  FIG.  2   , two absorption arms, namely a first absorption arm  204 - 1  and a second absorption arm  204 - 2 . However, the number of absorption arms should not be considered as limiting and the leak detection device  106  may include more than two absorption arms  204 . In an embodiment, the absorption arms  204  are flexible in structure and may be made of polyester, polypropylene, merino wool, nylon, micromodal, or any equivalents thereof. 
     The first absorption arm  204 - 1  and the second absorption arm  204 - 2  extends along the base  100  of the tankless water heater  102 . Particularly, free ends of the first absorption arm  204 - 1  and the second absorption arm  204 - 2  are located proximal to the water outlets  104  defined in the base  100 . In an embodiment, one or more coupling members  206  are used to couple the first absorption arm  204 - 1  and the second absorption arm  204 - 2  on the base  100 , thereby retaining the arms intact during relocation of the tankless water heater  102 . Preferably, the coupling members  206  are embodied as a magnetic clip, an adhesive, a vacuum cup, or any other method known to a person skilled the art and may be coated with a chemical composition to eliminate rusting. In some embodiments, the base of the tankless water heater  102  may includes fixtures to secure the first absorption arm  204 - 1  and the second absorption arm  204 - 2 . 
     Each of the first absorption arm  204 - 1  and the second absorption arm  204 - 2  is configured to wick water and transport the wicked water towards the leak sensor  202 . In some embodiments, diameter of each of the first absorption arm  204 - 1  and the second absorption arm  204 - 2  may be in a range of about 0.1 inches to about 0.2 inches and thickness may be about 0.001 inches to about 0.1 inches. The leak sensor  202  is configured to generate a signal indicative of leakage in the tankless water heater  102 , in response to sensing wetness. In an embodiment, the leak sensor  202  is configured to generate the signal based on an electrical resistance change corresponding to the sensed wetness. 
     During leakage within the tankless water heater  102 , leaked water accumulates in the base  100 . As described earlier, the water outlets  104  are potential source of water leaks. Since the first absorption arm  204 - 1  and the second absorption arm  204 - 2  extend proximal to each of the water outlets  104 , the leaked water may be easily wicked by aid of capillary action. Over time, gradually amount of water leaked into the base  100  may increase and the absorption arms  204  continuously wick the leaked water from the base  100 . By virtue of characteristic of the absorption arm  204 , the wicked water moves along respective lengths of each of the first absorption arm  204 - 1  and the second absorption arm  204 - 2 , thereby wetting dry portions of the arms  204 . Such movement of the leaked water along the respective lengths of the arms  204  may be understood as “transport of wicked water”, as used in the present disclosure. Upon sensing presence of the leaked water or sensing wetness, the leak sensor  202  generates the signal indicative of leakage. In some embodiments, the leak sensor  202  is configured to operate in a temperature range of about 30° F. to about 200° F. 
     Often water carrying pipes in the tankless water heater  102  may be subjected to condensation, such as dropwise condensation. Condensed water may flow down along the length of such water carrying pipes and condensed water gets collected in the base  100  of the tankless water heater  102 . However, condensation may occur for a short time period, thereby resulting in low amount of water collected in the base  100 . As such, amount of the condensed water when wicked may not be sufficient to travel towards the leak sensor  202 . Therefore, instances of generating the signal in case of wicking condensation water may be eliminated, thereby overcoming false indications, and rendering the leak detection device  106  efficient. In some embodiments, the free ends of the first absorption arm  204 - 1  and the second absorption arm  204 - 2  may preferably be located away from condensation regions in the tankless water heater  102 . It is contemplated the free ends of the absorption arm  204  may not be necessarily located around the water outlets  104 , but more proximal to potential water leak locations within the tankless water heater  102 . 
     In an embodiment, the tankless water heater  102  includes a controller  208  coupled to the leak detection device  106 . The controller  208  may be integrated in the tankless water heater  102  and may be configured to perform multiple functions related to the tankless water heater  102 , as known a person skilled in the art. The leak sensor  202  includes a connecting member  212  configured to couple with the controller  208 . In an embodiment, the controller  208  may be implemented as a processor, such as one or more microprocessors, microcomputers, digital signal processors, central processing units, state machines, logic circuitries, or any devices that manipulate signals based on operational instructions. Among other capabilities the processor may be configured to fetch and execute computer-readable instructions stored in a memory  136  thereof. Various functions of the processor may be provided using dedicated hardware as well as hardware capable of executing software in association with appropriate software. When provided by the processor, the functions may be provided by a single dedicated processor, by a single shared processor, or by a plurality of individual processors. Moreover, explicit use of the term “processor” should not be construed to refer exclusively to hardware capable of executing software, and may implicitly include, but not limited to, digital signal processor (DSP) hardware, network processor, application specific integrated circuit (ASIC), field programmable gate array (FPGA), read only memory (ROM) for storing software, random access memory (RAM), and non-volatile storage. Other hardware known to a person skilled in the art may also be included. 
     The controller  208  is configured to receive the signal from the leak sensor  202  and actuate a notification device  210  to provide a notification regarding the detected leak in the tankless water heater  102 . The controller  208  may be configured to determine the water leak based on the signal from the leak sensor  202 . For example, a change in value associated with the signal from the leak sensor  202  may be indicative of the water leakage. The notification device  210  may be one of, for example, a display unit integrated with the tankless water heater  102 , a display unit mounted on the tankless water heater  102  but not considered as an integral component of the tankless water heater  102 , or a user device located remotely from the tankless water heater  102  and in wireless communication with the controller  208 . As such, besides other capabilities, the controller  208 , with aid of other components, may be configured to establish wireless communication with the remote user device to provide the notification, such as Econet notification, regarding the detected leak. In an example, the notification may an audio alert, or an audio alter combined with vibration alert. In some embodiments, multiple devices, such as display unit on the tankless water heater  102  and the remote user device, may be connected to the controller  208  to simultaneously receive the notification. Upon receiving such notification, user of the tankless water heater  102  may take corrective action to mitigate the water leakage within the tankless water heater  102 . Therefore, the leakage detection device  106  may help avoid damage to components of the tankless water heater  102  by providing real-time notification regarding the water leakage. In some embodiments, multiple tankless water heaters may be connected together to function as a single heating system and the signal indicative of leak in any of the tankless water heater may be provided to a master controller. In such an arrangement, the master controller may be configured to notify the user about the potential water leak and indicate tankless water heater in which the water leak is detected. 
       FIG.  3    illustrates an exemplary coupling member  206 , according to an embodiment of the present disclosure. The coupling member  206  includes a support portion  302  and a securing portion  304 . In cases where the coupling member  206  is implemented as the magnetic clips, the support portion  302  may be made of magnetic material, such as Neodymium magnets, configured to couple to the base  100  of the tankless water heater  102  with strong magnetic force. The securing portion  304  is configured to conform to an outer surface of the absorption arm  204 , thereby retaining the absorption arm  204  in position. Therefore, the coupling members  206  ensure that the absorption arm  204  is retained proximal to the water outlets  104  at all times. In cases where the coupling members  206  are implemented as vacuum cups, the support portion  302  may include a vacuum developing membrane configured to grip the support portion  302  at desired location on the base  100  of the tankless water heater  102 . Therefore, the coupling member  206  of the present disclosure eliminate need for screws in the tankless water heater  102 . Other known securing members may be apparent to the person skilled in the art from the description herein. 
       FIG.  4    illustrates an exemplary leak detection kit  400  for the tankless water heater  102 , according to an embodiment of the present disclosure. The leak detection kit  400  includes the leak detection device  106  and a plurality of coupling members  206 . In some embodiments, the leak detection kit  400  may include more than one leak detection device  106 . Besides the plurality of coupling members  206  and the leak detection device  106 , the leak detection kit  400  may include other components, for example, a dedicated control box for leak detection having a controller and a display unit. With such components in the leak detection kit  400 , the leak sensor  202  may be easily coupled to the dedicated controller. The leak detection kit  400 , therefore, allows retrofitting the leak detection device  106  to tankless water heaters  102  which do not include a built-in leak detection feature or allows replacing a faulty leak detection unit. To this end, the flexibility of the absorption arm  204  in addition to adjustable coupling members  206  allow the leak detection device  106  to be adapted to a range of different base portion of various devices or machines. 
       FIG.  5    illustrates a method  500  of detecting leak in the tankless water heater  102 . The method  500  is described in conjunction with  FIG.  1    to  FIG.  3   . In an embodiment, the method  500 , at step  502 , includes wicking water by at least one absorption arm  204 . Preferably, the absorption arm  204  is disposed on the base  100  of the tankless water heater  102 , such that portions of the absorption arm  204  is located proximal to the water outlets  104  defined in the base  100 . 
     At step  504 , the method  500  includes transporting the wicked water towards the leak sensor  202 . In an aspect, the transporting of the wicked water is aided by virtue of capillary action exhibited by material of the absorption arm  204 . At step  506 , the method  500  includes generating the signal indicative of leakage in the tankless water heater  102 , in response to sensing wetness. In an embodiment, the step of generating the signal may include causing a change in electrical resistance in the leak sensor  202  in response to sensing wetness. At step  508 , the method  500  includes providing a notification regarding detected leak in the tankless water heater  102 , corresponding to the sensed wetness. In an embodiment, the step of providing the notification may include actuating the notification device  210 , by the controller  208 , to provide the notification. 
     While aspects of the present disclosure have been particularly shown and described with reference to the embodiments above, it will be understood by those skilled in the art that various additional embodiments may be contemplated by the modification of the disclosed methods without departing from the spirit and scope of what is disclosed. For example, variations in orientation of the base  100  of the tankless water heater  102 , dimensional characteristics the absorption arms  204 , and number of coupling members  206  may be achieved through the additional embodiments. Such embodiments should be understood to fall within the scope of the present disclosure as determined based upon the claims and any equivalents thereof.