Patent ID: 12235662

DETAILED DESCRIPTION

Throughout this disclosure, systems and methods are described with respect to mixing valve systems and assemblies and water heater units including a mixing valve system. Some implementations of the disclosed technology will be described more fully with reference to the accompanying drawings. This disclosed technology may, however, be embodied in many different forms and should not be construed as limited to the implementations set forth herein. The components described hereinafter as making up various elements of the disclosed technology are intended to be illustrative and not restrictive. Indeed, it is to be understood that other examples are contemplated. Many suitable components that would perform the same or similar functions as components described herein are intended to be embraced within the scope of the disclosed electronic devices and methods. Such other components not described herein may include, but are not limited to, for example, components developed after development of the disclosed technology.

Herein, the use of terms such as “having,” “has,” “including,” or “includes” are open-ended and are intended to have the same meaning as terms such as “comprising” or “comprises” and not preclude the presence of other structure, material, or acts. Similarly, though the use of terms such as “can” or “may” are intended to be open-ended and to reflect that structure, material, or acts are not necessary, the failure to use such terms is not intended to reflect that structure, material, or acts are essential. To the extent that structure, material, or acts are presently considered to be essential, they are identified as such.

Unless otherwise specified, all ranges disclosed herein are inclusive of stated end points, as well as all intermediate values. By way of example, a range described as being “from approximately 2 to approximately 4” includes the values 2 and 4 and all intermediate values within the range. Likewise, the expression that a property “can be in a range from approximately 2 to approximately 4” (or “can be in a range from 2 to 4”) means that the property can be approximately 2, can be approximately 4, or can be any value therebetween. Further, the expression that a property “can be between approximately 2 and approximately 4” is also inclusive of the endpoints, meaning that the property can be approximately 2, can be approximately 4, or can be any value therebetween.

It is to be understood that the mention of one or more method steps does not preclude the presence of additional method steps or intervening method steps between those steps expressly identified. Similarly, it is also to be understood that the mention of one or more components in a device or system does not preclude the presence of additional components or intervening components between those components expressly identified.

As used herein, unless otherwise specified, the use of the ordinal adjectives “first,” “second,” “third,” etc., to describe a common object, merely indicate that different instances of like objects are being referenced and are not intended to imply that the objects so described must be in a given sequence, either temporally, spatially, in ranking, or in any other manner.

Although the disclosed technology may be described herein with respect to various systems and methods, it is contemplated that embodiments or implementations of the disclosed technology with identical or substantially similar features may alternatively be implemented as methods or systems. For example, any aspects, elements, features, or the like described herein with respect to a method can be equally attributable to a system. As another example, any aspects, elements, features, or the like described herein with respect to a system can be equally attributable to a method.

Reference will now be made in detail to examples of the disclosed technology that are illustrated in the accompanying drawings and disclosed herein. Wherever convenient, the same reference numbers will be used throughout the drawings to refer to the same or like parts.

Referring in particular toFIGS.2-13, the disclosed technology includes a mixing valve assembly200, which can include a cold water connector210and a hot water connector220. As will be described in more detail herein, the cold water connector210can be configured to fluidly connect to a cold water inlet of a water heater (e.g., water heater300as described more fully herein), and the hot water connector220can be configured to fluidly connect to a hot water outlet of a water heater. The cold water connector210can be in fluid communication with the hot water connector220such that cold (i.e., unheated) water can be combined with hot (i.e., heated) water from the water heater, thereby providing mixed water having a temperature less than the temperature of the hot water from the water heater. The cold water connector210and hot water connector220can be fluidly connected by a hose230, one or more check valves232, and/or a fluid passage of a housing240. Optionally, additional components, nipples, fittings, and the like can be included to provide a desired configuration. For example, referring specifically toFIGS.3and11, an elbow fitting234can connect the hose230to the water passage of the housing240and/or other nipples, fittings, and the like can be used to connect the various components together to form a fluid passageway between the cold water connector210and the hot water connector220.

The cold water connector210can include a body and an aperture or through-hole212. As will be described more fully herein, the through-hole212can be configured to slidably receive a cold water inlet tube of a water heater. As a non-limiting example, the cold water inlet tube can be or include a heat trap. Thus, the cold water connector210can be or include a slip tee configured to slidably engage the cold water inlet tube. Optionally, the cold water connector210can include additional components, such as the illustrated temperature sensor214(e.g., to measure the temperature of water inside the through-hole212. As shown inFIG.11, the hot water connector220can optionally include one or more seals216(e.g., O-rings) inside the through-hole212. Alternatively or in addition, the seal(s) can be disposed on the tubular portion of the cold water inlet of the water heater. The cold water connector210can include one or more snap rings217and/or one or more washers218. The snap rings217can be used to connect one or more components or elements of the cold water connector210(and/or mixing valve assembly200). However, the disclosed technology is not so limited. For example, alternatively or in addition, components or elements of the mixing valve assembly200(e.g., the cold water connector210) can be connected via an open sided clip retained by a bolt or a snap fit connection between components.

Stated otherwise, the cold water connector210can have an inlet211, a tank outlet213, and a mixing outlet215. The inlet211and the tank outlet213can be axially aligned, thereby forming the through-hole212. A volume can be defined by the body of the cold water connector210and can extend between the inlet211and the tank outlet213. The mixing outlet215can fluidly communicate (e.g., be in direct fluid communication with) the internal volume of the cold water connector210, and the mixing outlet215can have an axis that intersects the axes of the inlet211and the tank outlet213. Accordingly, cold water can be permitted to flow from a cold water source, into the cold water connector210via the inlet211, and out of the of the cold water connector210via the tank outlet213to the tank of a water heater. In addition, cold water can be permitted to flow from the cold water source, into the cold water connector210via the inlet211, and out of the of the cold water connector210via the mixing outlet215toward the hot water outlet of the water heater.

Cold water exiting the cold water connector210via the mixing outlet can pass through a check valve232, which can prevent cold water from backflowing into the cold water connector210through the mixing outlet. Cold water can continue to flow from the check valve232through an electronic valve system260. Optionally, the electronic valve system can be located within housing240. The electronic valve system260can include a motor262configured to transition a valve264between an open configuration and a closed configuration. The motor262can be or include a stepper motor any other type of motor. The valve264can be or include a flap valve, a ball valve, or any other type of valve. Alternatively or in addition, the valve264can be a solenoid valve, in which case the motor262can be omitted. When the valve264is in the open configuration (which corresponds to active mixing of cold and hot water), cold water can be permitted to flow through the valve264, through the hose230, and into the hot water connector220. Optionally, a check valve232can be included between the hose230and the hot water connector220(e.g., in addition to or in place of a check valve232proximate the mixing outlet of the cold water connector210).

The hot water connector220can include a body and an aperture or through-hole222. As will be described more fully herein, the through-hole222can be configured to slidably receive a hot water outlet tube of a water heater. As a non-limiting example, the hot water outlet tube can be or include a heat trap. Thus, the hot water connector220can be or include a slip tee configured to slidably engage the hot water outlet tube. Optionally, the hot water connector220can include additional components, such as the illustrated temperature sensor224(e.g., to measure the temperature of water inside the through-hole222. As shown inFIG.11, the hot water connector220can optionally include one or more seals226(e.g., O-rings) inside the through-hole222. Alternatively or in addition, the seal(s) can be disposed on the tubular portion of the hot water outlet of the water heater. The cold water connector210can include one or more snap rings217and/or one or more washers218. The snap rings217can be used to connect one or more components or elements of the cold water connector210(and/or mixing valve assembly200). However, the disclosed technology is not so limited. For example, alternatively or in addition, components or elements of the mixing valve assembly200(e.g., the cold water connector210) can be connected via an open sided clip retained by a bolt or a snap fit connection between components.

Stated otherwise, the hot water connector220can have a hot water inlet221, an outlet223, and a mixing inlet225. The hot water inlet221and the outlet223can be axially aligned, thereby forming the through-hole222. A volume can be defined by the body of the hot water connector220and can extend between the hot water inlet221and the outlet223. The mixing inlet225can fluidly communicate (e.g., be in direct fluid communication with) the volume of the hot water connector220, and the mixing inlet225can have an axis that intersects the axes of the hot water inlet221and the outlet223. Accordingly, hot water can be permitted to flow from the tank of the water heater, into the hot water connector220via the hot water inlet221, and out of the of the hot water connector220via the outlet223. In addition, cold water can be permitted to flow from the hose230, into the hot water connector220via the mixing inlet225to mix cold water from the cold water source with hot water from the tank of the water heater, such that mixed water can flow out of the outlet223of the hot water connector220.

The hose230can comprise a rigid material (e.g., metal, a hard plastic such as PVC. Accordingly, the distance between the cold water connector210and the hot water connector220can be predetermined. Alternatively, the hose230can comprise a flexible material (e.g., a non-rigid plastic), such as PEX pipe or tubing. This can enable the distance between the cold water connector210and the hot water connector220to be variable, which can enable the mixing valve assembly200to be installable of multiple models of water heaters.

As can be seen inFIG.13, the mixing valve assembly200can include a controller250. The controller250can include one or more processors252, memory254storing data and/or instructions for operating the mixing valve assembly200, and/or a transceiver256configured to transmit and receive data with other devices and/or components. The memory254can have instructed stored thereon that, when executed by the one or more processors252, causes the one or more processors252to output instructions for operating the electronic valve system260, such as operating the motor262and/or valve264to transition the valve264between a closed configuration and an open configuration. Alternatively or in addition, the controller250can be in electronic communication with one or more water heater sensors358(e.g., temperature sensor(s)) and can receive sensor data (e.g., indicative of water temperatures measured by the water heater sensor(s)358); as such, the controller250can be configured to make determinations and output instructions based at least in part on the sensor data.

Alternatively or in addition, the controller250can be configured to communicate (e.g., via the transceiver256) with a controller350of the water heater (e.g., water heater300as described more fully herein). The controller250can be configured to receive instructions from the water heater controller350and can output instructions to components of the mixing valve assembly in accordance with the instructions from the water heater controller350. Alternatively, the controller250can be omitted, and the water heater controller350can be configured to directly control various components of the mixing valve assembly200(e.g., the motor262and/or the valve264). The controller250(or motor262/valve264, if the controller is omitted) can be in wired communication with the various other components, and/or the controller (or motor262/valve264if the controller250is omitted) can be in wireless communication with the various other components.

Alternatively or in addition, the controller250can be configured to communicate (e.g., via the transceiver256) with a user device360, such as a mobile computing device. The controller250can be configured to communicate directly with the user device360and/or indirectly via a network. The controller250can be configured to output data regarding the operational status of the mixing valve assembly200(e.g., whether an error or malfunction has been detected), how frequently and/or how much volume of cold water has been mixed with hot water over a given period, and the like.

Referring now toFIGS.14-18, a water heater300can include a tank302surrounded by a jacket, which is omitted fromFIGS.14-17for clarity of illustration. One or more heating elements can be configured to heat water inside the tank302, and the water heater300can include a cold water inlet310and a hot water outlet320. The cold water inlet310and hot water outlet320can each include a tubular portion, which can be or include a nipple and/or a heat trap. That is, both the cold water inlet310and hot water outlet320can include a tubular connector extending from the tank302. Although not necessarily shown inFIGS.14-18, the tubular portions of the cold water inlet310and hot water outlet320can include seals216(e.g., O-rings) (e.g., as illustrated inFIG.11) and/or porting threads. The seals216can be configured to prevent water leaks from occurring between the cold water connector210and the tubular portion of the cold water inlet310or between the hot water connector220and the hot water outlet320. (Alternatively or in addition, the seal(s) can be disposed within the through-holes212,222of the cold and/or hot water connectors210,220.) The porting threads of either tubular portion can be located one or both ends of the tubular portion. For example, one tubular portion can be configured to attach to (e.g., attached by threaded connections) an aperture of the cold water inlet310, and another tubular portion can be configured to attach to (e.g., attached by threaded connections) an aperture of the hot water outlet320. The opposite end of the tubular portion of the cold water inlet310can be configured to attach to (e.g., attached by threaded connections) tubing or pipes that are fluidly connected to a cold water source, and the opposite end of the tubular portion of the hot water outlet320can be configured to attach to (e.g., attached by threaded connections) tubing or pipes that are fluidly connected to a hot water use location (e.g., a sink).

The cold water inlet310and hot water outlet320can be located on the same face of the tank302and the same face of the water heater300. As illustrated inFIGS.14-18, the cold water inlet310and hot water outlet320can be located on a top surface of the tank302(and a top surface of the water heater300). However, it should be understood that the cold water inlet310and hot water outlet320can be located on a different surface of the tank302or water heater300(e.g., a side surface), or the cold water inlet310and hot water outlet320can be located on different surfaces (e.g., one on top and the other on a side).

The tubular portion of the cold water inlet310can include one or more apertures in the tubular portion's sidewall. Likewise, the tubular portion of the hot water outlet320can include one or more apertures in the tubular portion's sidewall. For example, as illustrated, the tubular portions of both the cold water inlet310and the hot water outlet320can include a plurality of apertures, with each aperture having an axis that is in a radial direction with respect to a central axis of the tubular portion. As such, the internal volume of each tubular portion can be in direct fluid communication, via the apertures, with a volume surrounding the tubular portion. When the mixing valve assembly200is installed on the water heater300, the tubular portion of the cold water inlet310can be inserted into the through-hole212of the cold water connector210and the tubular portion of the hot water outlet320can be inserted into the through-hole222of the hot water connector220. The through-hole212of the cold water connector210can be shaped and dimensioned such that a fluid passage is created between the mixing outlet215and the internal volume of the tubular portion of the cold water inlet310(e.g., via the apertures of the tubular portion and/or an internal volume created between one or more internal surfaces of the cold water connector210(e.g., surfaces of the through-hole212) and one or more external surfaces of the tubular portion of the cold water inlet310. Likewise, the through-hole222of the hot water connector220can be shaped and dimensioned such that a fluid passage is created between the mixing inlet225and the internal volume of the tubular portion of the hot water outlet320(e.g., via the apertures of the tubular portion and/or an internal volume created between one or more internal surfaces of the hot water connector220(e.g., surfaces of the through-hole222) and one or more external surfaces of the tubular portion of the cold water inlet320.

As will be appreciated by those having skill in the art, the mixing valve assembly200can simplify and expedite the manufacture of water heaters having an integrated mixing valve, which can, in turn, reduce the overall cost of the water heaters. For example, one tubular portion can be attached to (e.g., attached by threaded connections) an aperture of the cold water inlet310, and another tubular portion can be attached to (e.g., attached by threaded connections) an aperture of the hot water outlet320. This can result in the configuration illustrated inFIG.14.

The mixing valve assembly200can be installed by way of sliding the cold water connector210over the tubular portion of the cold water inlet310and sliding the hot water connector220over the tubular portion of the hot water outlet320. This can result in the configuration illustrated inFIGS.15-17.

The jacket304of the water heater300can be installed around the tank302(such as is shown inFIG.18), and a top pan306can be installed at the top of the jacket, thereby enclosing the tank302within an outer shell (which includes the jacket304and top pan306) of the water heater300. This can result in the configuration illustrated inFIGS.19and20. Thus, at least of the mixing valve assembly200can be located within the shell of the water heater300. As shown, a top portion of the cold water connector210, a top portion of hot water connector220, and at least some of the housing240are shown to be protruding above the top pan306, and the rest of the mixing valve assembly200is located within the shell of the water heater300. By positioning at least some of the mixing valve assembly200inside the shell of the water heater300, the overall height and size of the water heater300can be decreased (e.g., as compared to existing water heaters having traditional mixing valves installed thereon). Optionally, all of the mixing valve assembly200except for the housing240can be located within the shell of the water heater300(e.g., covered by the top pan306). The housing240can enable access to electrical ports and/or circuitry of the mixing valve assembly200, which can help facilitate easy electrical connection to the water heater300and/or an electricity source and/or easy access for maintenance or repairs. Alternatively, the housing240can also be located within the shell of the water heater300(e.g., covered by the top pan306); in such a case, the top plate can include an access panel or the like for accessing electrical ports and/or circuitry of the mixing valve assembly200.

As shown inFIGS.19and20, the upper end of the tubular portion of the cold water inlet310can protrude from the top plate306and can be attached to (e.g., attached by threaded connections) tubing or pipes that are fluidly connected to a cold water source. Likewise, the upper end of the tubular portion of the hot water outlet320can protrude from the top plate306and can be configured to attach to (e.g., attached by threaded connections) tubing or pipes that are fluidly connected to a hot water use location (e.g., a sink).

Insulation, such as insulative foam, can be inserted or injected in the space between the exterior of the tank302and the interior of the jacket. Optionally, the insulation can be an expanding foam. Some or all of the mixing valve assembly200can be located within the shell of the water heater300and surrounding by insulation. For example, some or all of the hose230can be surrounded by insulation (e.g., expanding foam insulation).

The cold water connector210and a hot water connector220have been discussed to this point as being configured to slideably receive a tubular portion protruding from the tank302(e.g., cold water inlet310and hot water outlet320). However, the cold water connector210and hot water connector220can be alternatively configured such that either has a protruding portion that slideably inserts into a corresponding receiving portion of the tank (e.g., cold water inlet310and hot water outlet320).

Referring toFIG.21, the cold water connector210can include a tubular portion2110that is configured to slideably insert into a receiving portion of the cold water inlet310. The cold water connector210can include a mount flange2112, which can be attached to the tubular portion2110, for example, and the mount flange2112can include a through-hole. The through-hole can be threaded. One or more seals226(e.g., O-rings) can be positioned on an external surface of the tubular portion2110.

The cold water inlet310of the tank302can include a bung2313, and the bung2313can be some or all of the receiving portion of the cold water inlet310. That is, bung2313can be configured to slideably receive the tubular portion2110. The bung2313can include a hole or recess, and the hole of the bung2313can be configured to align with the through-hole of the mounting plate2112when the tubular portion2110is inserted into the bung2313. The hole of the bung2313can be threaded, and the aligned holes of the mounting plate2112and bung2313can each be configured to receive at least part of a bolt2114.

Likewise, the hot water connector220can include a tubular portion2120that is configured to slideably insert into a receiving portion of the hot water outlet320. The hot water connector220can include a mount flange2122, which can be attached to the tubular portion2120, for example, and the mount flange2122can include a through-hole. The through-hole can be threaded. One or more seals226(e.g., O-rings) can be positioned on an external surface of the tubular portion2120.

The hot water outlet320of the tank302can include a bung2323, and the bung2323can be some or all of the receiving portion of the hot water outlet320. That is, bung2323can be configured to slideably receive the tubular portion2120. The bung2323can include a hole or recess, and the hole of the bung2323can be configured to align with the through-hole of the mounting plate2122when the tubular portion2120is inserted into the bung2323. The hole of the bung2323can be threaded, and the aligned holes of the mounting plate2122and bung2323can each be configured to receive at least part of a bolt2124.

Alternatively or in addition, the holes of the mounting plates2112,2122and bungs2313,2323and the bolts2114,2124can be omitted, and the mounting plates2112,2122can be attached to the respective bungs2313,2323by snap fits, latches, or any other attachment mechanism. Further, althoughFIG.21does not include the housing240, the configuration depicted and discussed can include the housing240and/or any other components discussed herein regarding the mixing valve assembly200.

As will be appreciated by on having skill in the art, the configuration illustrated inFIG.21can remove the need for threaded connections (e.g., at the fluid connection between the cold water connector210and the cold water inlet310and between the hot water connector220and the hot water outlet320).

While the mixing valve assembly200has been discussed herein as having an electronic valve system260, it is completed that the mixing valve assembly200can have a mechanical valve system, such as a valve system including a wax pill thermostatically mixing water.

In this description, numerous specific details have been set forth. It is to be understood, however, that implementations of the disclosed technology may be practiced without these specific details. In other instances, well-known methods, structures, and techniques have not been shown in detail in order not to obscure an understanding of this description. References to “one embodiment,” “an embodiment,” “one example,” “an example,” “some examples,” “example embodiment,” “various examples,” “one implementation,” “an implementation,” “example implementation,” “various implementations,” “some implementations,” etc., indicate that the implementation(s) of the disclosed technology so described may include a particular feature, structure, or characteristic, but not every implementation necessarily includes the particular feature, structure, or characteristic. Further, repeated use of the phrase “in one implementation” does not necessarily refer to the same implementation, although it may.

Further, certain methods and processes are described herein. It is contemplated that the disclosed methods and processes can include, but do not necessarily include, all steps discussed herein. That is, methods and processes in accordance with the disclosed technology can include some of the disclosed while omitting others. Moreover, methods and processes in accordance with the disclosed technology can include other steps not expressly described herein.

Throughout the specification and the claims, the following terms take at least the meanings explicitly associated herein, unless otherwise indicated. The term “or” is intended to mean an inclusive “or.” Further, the terms “a,” “an,” and “the” are intended to mean one or more unless specified otherwise or clear from the context to be directed to a singular form. By “comprising,” “containing,” or “including” it is meant that at least the named element, or method step is present in article or method, but does not exclude the presence of other elements or method steps, even if the other such elements or method steps have the same function as what is named.

While certain examples of this disclosure have been described in connection with what is presently considered to be the most practical and various examples, it is to be understood that this disclosure is not to be limited to the disclosed examples, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

This written description uses examples to disclose certain examples of the technology and also to enable any person skilled in the art to practice certain examples of this technology, including making and using any apparatuses or systems and performing any incorporated methods. The patentable scope of certain examples of the technology is defined in the claims and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.