DESC:FIELD OF THE INVENTION

The present invention provides an integrated pressure breaker Multi-Function Safety Valve (MFSV). More specifically, the present invention provides modified quick fitting, externally locking, scale reducing, and pressure breaking integrated MFSV.

BACKGROUND OF THE INVENTION
A storage water heater or geyser is used as a domestic appliance to heat and store hot water. The storage water heater comprises mainly of an inlet pipe bringing in the cold water to a heating and storing tank, an outlet pipe for draining the hot water, a jacket and cover assembly to insulate the storage tank and a bracket system to mount the water heater.
A typical storage water heater setup has safety measures to guarantee the safety of the system and its users, multiple layers of protection are integrated. The primary control in this safety hierarchy is the thermal cut-off switch. This switch is set to activate when the water temperature reaches a predetermined limit. If, for any reason, this switch fails to trigger, a secondary safeguard mechanism known as the high-limit switch comes into play. The high-limit switch acts as a failsafe by shutting down the system if the temperature exceeds recommended safety levels. The MFSV is the last line of defence in extremely rare scenarios where both the thermal cut-off switch and the high-limit switch fail to operate. If the pressure within the water heater tank becomes dangerously high due to a malfunction or other unforeseen circumstances, the MFSV is activated. It rapidly opens to release the excess pressure, preventing potential damage to the system and safeguarding against any potential hazards, such as tank rupture.
In summary, the Multi-Function Safety Valve (MFSV) is an integral component of a water heater, ensuring both energy efficiency, user safety, and acts as a non-return valve and a safety valve.
A MFSV comprises of a valve body or a housing, an inlet or nozzle customised to various shape and size to control the flow and pressure within the valve, a disc or poppet which is the movable component within the valve that opens and closes to control the flow of fluid and is specifically designed to lift off its seat when pressure exceeds the setpoint to relieve excess pressure, a spring to provide the force required to keep the valve closed and check the pressure within setpoint, when the spring force is overcome by the internal pressure the valve opens. Further, MFSV allows the setpoint adjustment, so that the technician could fine-tune the valve's opening pressure, and drainage means to safely release fluids or gases away from the valve and thereby regulating the pressure. Furthermore, when pressure or temperature surpasses the setpoint, the MFSV is designed to open automatically. The mechanism varies depending on the valve design. The mechanisms include direct spring loading, which has a spring that exerts force on a disc or poppet, and keeps it closed. When the pressure exceeds the spring force, the disc or poppet lifts off its seat, allowing fluid or gas to flow through the valve. Another mechanism is pilot systems which rely on a secondary pressure source (pilot pressure) to control the main valve. When the pilot pressure reaches a critical point, it triggers the main valve to open. Other control mechanisms, again depending on the design and complexity of the MFSV, may employ diaphragms, bellows, or electronic controls.
The MFSV prevents the undesired reverse flow of water and thus acting as a non-return valve. As water moves through the check valve, it permits the passage of water due to the high-water pressure compared to the resistance offered by the disc or poppet. Once the water flow ceases, the check valve automatically closes, preventing the backward flow of water. Additionally, the safety valve, maintains the internal pressure within the water heater and in case it surpasses predefined limits caused by factors such as excessive boiling, internal water pressure buildup, or malfunctioning cut-off switches, the safety valve activates at a specific set pressure. This activation leads to the release of surplus pressure, mitigating potential hazards.
A MFSV works by pressure relief mechanism which consists of a spring-loaded valve mechanism. The MFSV follow a design that uses an applied force (a spring) to directly oppose the system force, and maintains three states equilibrium, fully open or fully closed. In equilibrium state, the closing forces, applied by the spring and any back pressure, is in ‘equilibrium’ (balanced), i.e., applied by the system pressure. In fully open state, the valve can pass the maximum capacity at the specified overpressure and the valves open, when the system force exceeds the equilibrium force, i.e., overcome the applied spring and back pressure force. In fully closed state the valves are fully closed, i.e. no leakage. The closing force exceeds the opening force, i.e., the opening force is lower than the equilibrium force.
Pressure and Temperature Sensing: The safety valve is designed to monitor both pressure and temperature inside the tank. If either of these parameters exceeds a safe threshold, the valve activates. Activation criteria include pressure where the pressure inside the tank exceeds a predetermined limit, usually between 150 and 175 psi (pounds per square inch), the valve opens to release excess pressure. This prevents the tank from bursting. Similarly, if the temperature of the water rises excessively, typically above 210°F (99°C), due to a malfunctioning thermostat or other issues, the safety valve will also activate to release the overheated water. When the safety valve opens, it provides a discharge path for the excess pressure or overheated water. This path typically leads to a drain pipe or an open area where the hot water can safely escape without causing harm. Once the safety valve is opened it should undergo resetting. After the safety valve has relieved the excess pressure or temperature, it should reset itself automatically once the conditions return to normal. Therefore, it is essential to inspect and maintain the valve periodically to ensure it functions correctly and a trained practitioner should be hired.
One of the main concerns with improper working of the MFSV is the initial installation. The issues with installation may be due to unskilled technician providing improper installation services, not following manufacturer-specific installation guidelines, which can lead to misalignment, incorrect orientation, or improper seating of the MFSV within the water heater system.
Another issue may be incorrect adjustment or calibration, which is required to ensure that it activates at the correct pressure threshold. An unskilled technician might neglect this crucial step, rendering the valve ineffective in controlling pressure. Yet another issue may be use of inadequate usage of Teflon and thread sealant that leads to incomplete Sealing. If Teflon tape or thread sealant is not applied evenly or in the correct direction, it may not create a watertight seal. Even small gaps can result in water leaks around the MFSV or its associated connections. Yet another issue is incorrect torque during fastening that leads to over-tightening. Hence, applying excessive torque during the fastening of components can cause threads to strip, gaskets to deform, or even structural damage to the MFSV housing or breakage of the isolator. This can compromise its ability to maintain a secure and leak-free connection. Yet another issue is non installation of MFSV which can be a major safety issue.
Even after installation in order to maintain the function of the MFSV regular maintenance and inspection must be done. Homeowners should regularly inspect the safety valve to ensure it is not blocked or corroded. If the valve appears damaged, leaking, or shows signs of wear, it should be replaced immediately by a qualified technician. Further, there may be degradation over time, thread sealant and Teflon tape can degrade over time due to temperature and pressure fluctuations and water exposure. If not reapplied or maintained, the seals may deteriorate, allowing leaks. Any of these factors may create malfunction MFSV to malfunction and create serious injury to the users.
Thus, the conventional MFSV requires improvements and features for quick and easy fitting to improve the overall safety to help in avoid injuries during malfunction.
OBJECT(S) OF THE INVENTION
Accordingly, to overcome the drawbacks of the prior art, the main object of the present invention is to provide a multi-function safety valve for the electric water heater with breakaway safety release valve.
Yet another object of the invention is to provide a multi-function safety valve that can be easily and properly installed to an electric water heater.
Yet another object of the invention is to provide a multi-function safety valve for the electric water heater with breakaway safety release valve that acts as a failsafe mechanism.
SUMMARY OF THE INVENTION
In carrying out the above objects of the present invention, the present invention provides a multi-function safety valve for the electric heater comprises of a valve body having an inlet and outlet and around the center of the valve body a leakage receiving unit comprising a drain port and a pressure relief handle. The pressure relief handle is the first line of defense which is spring operated and is usually rendered inoperable due to scaling. The leakage receiving unit further comprising a safety release valve on one side to escape pressure build up in the valve body, which acts as the second line of defense. The safety release valve is automatically released or dislodged when the system pressure and temperature in greater than the safety limit of safety release valve. Further, the inlet and outlet are provided with spaces to seamlessly integrate plurality of retaining ring or clips to secure connection pipes.
In a preferred embodiment of the present invention, the invention provides a multi-function safety valve for the electric water heater is a simple and easy to mount and easy to fit structure, where the safety valve releases pressure in the valve body in case when drain port is choked with scaling or corrosion and malfunction of pressure relief handle.
In another preferred embodiment of the present invention, the invention provides a safety release valve comprising a fusible metallic material held within the bore of a metallic retainer member, wherein the fusible metal alloy is made of low melting temperature metal or metal alloy.
In another preferred embodiment of the present invention, the invention provides the safety release valve according to the prescribed safe pressure capability, satisfying the required different safe pressure values of different sizes of electric heater.
In another embodiment of the present invention, the invention provides customized rubberized seals to effectively bridge the gap between MFSV and the inlet pipes and outlet pipes. These seals are affixed to one component and are inserted into the other component through a linear motion to secure this arrangement, plurality of retaining rings or clips is seamlessly integrated into both components within predefined spaces. This meticulous arrangement ensures the cohesion of parts and precludes any leakage during the operational lifespan of the system. The mechanism not only simplifies the process of connecting and disconnecting residential water heaters without necessitating specialized skills. This design approach guarantees the MFSV's intrinsic integration within the water heater assembly. Importantly, without the successful connection of this assembly, the entire unit cannot be fully assembled, providing an inherent safeguard against incomplete installations. The water heater will function when the MFSV is integrated, and this ensures the safety.
In another embodiment of the present invention, the invention provides specific advantage over the prior art wherein the safety release valve comprises of a metallic retainer member, made up of non-corrosive high melting point such as but not limited stainless steel, etc. through bore along its center to affix a feasible metallic material. The feasible metallic material has a low melting point and pressure durability, and ruptures as the escapes when the system pressure and/or the temperature crosses the calibrated prescribed limit in the valve body and thereby preventing breach of system components, leaks, or even rupture. This acts as the failsafe mechanism and is the technical advantage of the present invention when the safety valve releases pressure in the valve body in case when drain port is choked with scaling or corrosion and/or malfunction of pressure relief handle and/or malfunction of the thermal cut off switch.
BRIEF DESCRIPTION OF THE DRAWING
The object of the invention may be understood in more details and more particularly description of the invention briefly summarized above by reference to certain embodiments thereof which are illustrated in the appended drawings, which drawings form a part of this specification. It is to be noted, however, that the appended drawings illustrate preferred embodiments of the invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective equivalent embodiments.
Fig. 1 illustrates perspective view of a multi-function safety valve of the electric heater according to the embodiments of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention will now be described more fully hereinafter with reference to the accompanying drawings in which a preferred embodiment of the invention is shown. This invention may, however, be embodied in many different forms and should not be construed as being limited to the embodiment set forth herein. Rather, the embodiment is provided so that this disclosure will be thorough, and will fully convey the scope of the invention to those skilled in the art.
Referring to Fig. 1 illustrates perspective view of a multi-function safety valve (100) of the electric heater according to the embodiments of the present invention. The multi-function safety valve (100) an electric heater comprises of a valve body (102) having an inlet (104) and outlet (106) and a leakage receiving unit (108) around the center of the valve body (102) incorporated with a drain port (110) and a pressure relief handle (112) at the end. The leakage receiving unit (108) is also incorporating a safety release valve (114) on one side to escape pressure build up in the valve body (102). Further, the inlet (104) and outlet (106) are provided with spaces (116) to seamlessly integrate plurality of retaining ring or clips (118) to secure connection pipes. The retaining ring or clips (118) secures the respective connector for forming a watertight connection and does not allow dislodging of the respective connector from the multi-function safety valve (100) without first removing retaining ring or clips (118).
In an embodiment of the present invention, the invention provides the retaining ring or clips (118) are designed to slide into spaces (116) of the multi-function safety valve (100). The retaining ring or clips (118) contains a holding portion and plurality of extending portions that extend transverse to the holding portion. In the illustrated embodiment, the retaining ring or clips (118) include two long extending portions, which are flexible, extend from the ends of holding portion, and are adapted to receive and hold connectors or adapters, connected to the inflow and outflow piping, into spaces (116).
In another embodiment of the present invention, the invention provides the leakage receiving unit (108), which is an opening with threads to assemble the safety release valve (114) into it. The safety release valve (114) comprises of a metallic retainer member having matching threads around its outer circumference according to the opening with threads of the leakage receiving unit (108). The metallic retainer member is made up of non-corrosive high melting point such as but not limited stainless steel, etc. and have a through bore along its center to fix a feasible metallic material. The feasible metallic material has low melting point and escapes when the system pressure and/or the temperature crosses the calibrated prescribed limit in the valve body (102) and thereby preventing breach of system components, leaks, or even rupture.
In preferred embodiment, the feasible metallic material is secured into the bore of the metallic retainer member through mechanical processes such as but not limited to press fitting, etc. Further, the feasible metallic material can be provided along the whole bore in the metallic retainer member or up to a certain depth according to the safety pressure/temperature requirements.
In preferred embodiment, the exposed face of the metallic retainer member has suitable grooves or cuts to allows its assembly into the leakage receiving unit (108) by means of a screwdriver or allen key.
In another preferred embodiment of the present invention, the MFSV provides specific advantage over the conventional water heater.
a. Heating Process and Energy Efficiency:
When a water heater is in operation, the heating element is supplied with electrical power. As the heating element warms up, its surface temperature increases. This heat energy is efficiently transferred to the water surrounding the element, causing the water temperature to rise. The overall efficiency of the water heater is gauged by evaluating how much heat is lost during this process. If there are any heat losses due to factors like backflow or leaks from the MFSV fitting, it can have a direct impact on the energy efficiency of the water heater. Preventing such heat losses is essential to maintain the water heater's optimal performance and reduce unnecessary energy consumption.
b. Pressure Buildup and Temperature Control:
As the water heats up within the tank, it begins to produce steam or water vapor. This increase in temperature leads to a rise in pressure within the tank. To ensure that the water doesn't reach unsafe pressure levels, the water heater system is designed to cut off the heating process once the desired temperature is attained. This control mechanism prevents over pressurization and the potential hazards associated with it.
c. Safety Measures:
To guarantee the safety of the system and its users, multiple layers of protection are integrated. The primary control in this safety hierarchy is the thermal cut-off switch. This switch is set to activate when the water temperature reaches a predetermined limit. If, for any reason, this switch fails to trigger, a secondary safeguard known as the high-limit switch comes into play. The high-limit switch acts as a failsafe, shutting down the system if the temperature exceeds safe levels.
d. MFSV as the Last Line of defence:
In extremely rare scenarios where both the thermal cut-off switch and the high-limit switch fail to operate, the pressure release mechanism of the MFSV becomes the final line of defense. If the pressure within the water heater tank becomes dangerously high due to a malfunction or other unforeseen circumstances, the MFSV activates. It rapidly opens to release the excess pressure, preventing potential damage to the system and safeguarding against any potential hazards, such as tank rupture.
In summary, the Multi-Function Safety Valve (MFSV) is an integral component of a water heater, ensuring both energy efficiency and user safety. Its dual role in preventing heat losses through backflow and maintaining safe pressure levels within the tank makes it a crucial element in the overall functionality of the water heater.
While certain exemplary embodiments have been described and shown in the accompanying drawings, it is to be understood that such embodiments are merely illustrative of, and not restrictive on, the broad invention, and that this invention not be limited to the specific constructions and arrangements shown and described, since various other changes, combinations, omissions, modifications and substitutions, in addition to those set forth in the above paragraphs, are possible. Those skilled in the art will appreciate that various adaptations and modifications of the just described embodiments can be configured without departing from the scope and spirit of the invention.
,CLAIMS:1. A multi-function safety valve (100) for the storage type electric water heater comprises of:
a valve body (102) having an inlet (104) and outlet (106);
a leakage receiving unit (108) around the center of the valve body (102);
a drain port (110) incorporated in the leakage receiving unit (108); and
a pressure relief handle (112) at the end of the leakage receiving unit (108);
wherein, the leakage receiving unit (108) is incorporated within the safety release valve (114) via an opening, comprises of a metallic retainer member through bore along its center to affix a feasible metallic material;
wherein, the metallic retainer member further comprises of matching threads around its outer circumference corresponding the opening threads of the leakage receiving unit (108), and
wherein the safety release valve (114) escapes when the system pressure and/or the temperature crosses the calibrated prescribed limit in the valve body (102) and thereby preventing breach of system components, leaks, or even rupture.
2. The multi-function safety valve (100) of the electric heater as claimed in claim 1, wherein the inlet (104) and outlet (106) are provided with spaces (116) to seamlessly integrate retaining ring or clips (118) to secure connection pipes.
3. The multi-function safety valve (100) of the electric heater as claimed in claim 1, wherein the spaces (116) and retaining ring or clips (118) allows quick and easy assembly to secure connection pipes.
4. The multi-function safety valve (100) of the electric heater as claimed in claim 1, wherein the multi-function safety valve (100) for the electric water heater is simple in structure and easy to mount and fit.
5. The multi-function safety valve (100) of the electric heater as claimed in claim 1, wherein the safety release valve (114) escapes pressure builds up in the valve body (102) in case when drain port (110) is choked with scaling or corrosion and malfunction of pressure relief handle (112).
6. The multi-function safety valve (100) of the electric heater as claimed in claim 1, wherein the spaces (116) and retaining ring or clips (118) simplifies the process of connecting and disconnecting residential water heaters without necessitating specialized skills.