[001] The present invention relates to the field of Water Heater. The present invention in particular relates to a PUF blocker used for insulation in water heater which ensures low energy consumption of water heater during functioning. The present invention also relates to a PUF blocker used for insulation in water heater which improve standing loss of water heater.
DESCRIPTION OF THE RELATED ART
[002] In typical water heaters heat loss can occur in mainly three areas of the water heater namely, top of the water tank, bottom of the tank and cylindrical surface of the tank.
[003] Hot air always rises up due to which most of the heat loss is from the top of the tank. This is the reason why in typical water heaters insulation is provided on the top and cylindrical side of the tank. However, in general thermodynamic system heat transfer occur where there is a temperature gradient between two surfaces. During development of induction water heater, a study (test and thermal FEA simulations) revealed that there is temperature gradient between the bottom of the tank and air surrounding. This leads to heat loss from the bottom of the water heater.
[004] Five-star rating as specified by IS 2082 depends on standing loss (KWH) per 24 hours. This rating can be achieved by designing the system so as to reduce the amount of heat loss during the usage of water heater.

[005] Presently, insulation is provided on top side and cylindrical side of the tank. Some manufacturers also used molded polyurethane foam (PUF) in the bottom section of the water heater. However, this provision has some drawback such as:
> It does not create an air-tight compartment around the tank, which will lead to heat loss.
> Proximity to the electrical connections lead to possibility of fire.
[006] The patent application number 1775/MUM/2008 describes a Stationary Storage Type Water Heater with dual insulation of Glass Wool and Poly Urethane Formaldehyde to prevent the Heat Loss and thereby saving electricity and to conserve the natural resources and environment by way of reducing CO2 (Carbon di oxide) emission. The patent application uses two level of insulation i.e. Glass Wool and Poly Urethane Formaldehyde on the tank top surface and tank cylindrical surface. However, the patent application does not provide any design to cover bottom part of the water heater effectively.
[007] A Chinese patent application CN 00257709 discloses a utility model relating to a heat-insulating housing body structure for an electric water heater. In this utility model the edge surfaces of the top and the bottom ends are provided with jointing body, and the top cover and the bottom cover of the heat-insulating housing body can be jointed and locked with each other by the jointing body, and the heat-insulating body and the barrel can be stably positioned. However, the assembly

provided in the said Chinese application is not air tight and heat transfer can occur.
[008] The present subject matter discloses a PUF blocker used for providing insulation in water heater which overcome drawbacks associated with the related arts.
OBJECTS OF THE INVENTION
[009] The principal object of the present invention is to provide a PUF blocker used for providing insulation in water heater.
[010] Another object of the present invention is to provide a PUF blocker used for providing insulation in water heater which can lead to higher standing loss rating.
[Oil] Still another object of the present invention is to provide a PUF blocker used for providing insulation in water heater which can reduce heat loss from the bottom side by more than 20%.
[012] Another object of the present invention is to provide a PUF blocker used for providing insulation in water heater which can provide easy assembly/ disassembly of wire harness by providing a passage within injected PUF through which wire harness can be inserted and removed.
[013] Yet another object of the present invention is to provide a PUF blocker used for providing insulation in water heater which can provide structured PUF layer on bottom side so heat cannot escape during standing position of water heater.

[014] Yet still another object of the present invention is to provide a PUF blocker used for providing insulation in water heater which could not be accessible to technician for safety purpose.
SUMMARY OF THE INVENTION
[015] In accordance with the said objectives, the present invention provides a PUF blocker for insulation in water heater. The said PUF blocker is provided to effectively insulate the bottom section of the water heater. PUF blocker provides structured PUF layer on bottom side so heat cannot escape during standing position of water heater. Consecutively, the arrangement reduces power consumption by water heater and helps attaining commercial feature "5-star rating".
BRIEF DESCRIPTION OF THE DRAWINGS
[016] Figure: 1 depicts distinction between present water heater and new proposed design
[017] Figure: 2 depicts front view of bottom portion of water heater according to present design
[018] Figure: 3 depicts top view of PUF blocker
[019] Figure: 4 depicts bottom side of PUF blocker
[020] It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered for limiting of its scope, for the invention may admit to other equally effective embodiments.

DESCRIPTION OF THE PREFERRED EMBODIMENTS:
[021] It should be appreciated by those skilled in the art that any block
diagrams herein represent conceptual views of illustrative systems
embodying the principles of the present subject matter. Similarly, it will
5 be appreciated that any flow charts, flow diagrams, state transition
diagrams, pseudo code, and the like represent various processes which may be substantially represented in computer readable medium and executed by a computer or processor, whether or not such computer or processor is explicitly shown.
10 [022] In the present disclosure, the word "exemplary" is used herein to
mean "serving as an example, instance, or illustration." Any embodiment or implementation of the present subject matter described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other embodiments.
15 [023] While the present disclosure is susceptible to various
modifications and alternative forms, specific embodiment thereof has been shown by way of example in the drawings and will be described in detail below. It should be understood, however that it is not intended to limit the present disclosure to the particular forms disclosed, but on
20 the contrary, the present disclosure is to cover all modifications,
equivalents, and alternative falling within the spirit and the scope of the present disclosure.
[024] The terms “comprises”, “comprising”, or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a
6

setup, device or method that comprises a list of components or steps
does not include only those components or steps but may include other
components or steps not expressly listed or inherent to such setup or
device or method. In other words, one or more elements in a system or
5 apparatus proceeded by “comprises… a” does not, without more
constraints, preclude the existence of other elements or additional elements in the system or apparatus.
[025] In the following detailed description of the embodiments of the disclosure, reference is made to the accompanying drawings that form
10 a part hereof, and in which are shown by way of illustration specific
embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, and it is to be understood that other embodiments may be utilized and that changes may be made without
15 departing from the scope of the present disclosure. The following
description is, therefore, not to be taken in a limiting sense.
[026] The present invention will be described in detail below with reference to an embodiment as shown in the drawing.
[027] Accordingly, the present invention provides a PUF blocker (100)
20 for insulation in water heater. Reference may be made to Figure 3
showing the top view of the PUF blocker (100). The said PUF blocker
(100) comprises a rectangular hollow structure (101) with chamfered
corners, a base flange (102) extended perpendicularly away from the
rectangular hollow structure (101) and a hollow structure (103)
25 provided at one chamfered corner (105) of the rectangular hollow
7

structure (101) to allow passage for wire harness. This wiring harness
provide a passage to the wires and insulate wire from the PUF foam and
other components. The PUF blocker (100) makes the PUF inaccessible
to person using the water heater or technician during the service. Hence,
5 it provides safety to person using the water heater or technician during
the service.
[028] As most of the connections of the water heater is from the bottom
side of the water heater, plurality of holes (106) are provided in the base
flange (102) for tank inlet and outlet pipes and other connections as may
10 be needed.
[029] To provide strength to the PUF blocker (100) and strong
connection between PUF blocker (100) and the water heater, plurality
of vertical columns (109) are provided protruding from the outer
surface of the hollow structure (101) and one side of the said vertical
15 columns (109) are perpendicularly connected to the base flange (102).
These vertical columns (109) serves dual purpose i.e. provide firmness to the PUF blocker (100) structure and maintain a grip with the PUF, which in turn form an air tight seal, with the water heater, which reduces heat loss.
20 [030] The PUF blocker (100) is made up of fire-retardant plastic
which reduces accidents due to fire in case if there is sparking in wire.
[031] In other embodiment instead of rectangular shaped hollow structure (101) other shapes such as cylindrical, square, circular or elliptical are also possible.
8

[032] In yet another embodiment base flange (102) may have other shapes such as square, rectangular, circular or elliptical.
[033] In yet another embodiment hollow structure (103) may be square,
rectangular, circular, elliptical etc. and vertical columns (109) can be
5 various shapes and form depending of the strength requirements
(vertical, horizontal, at an angle, etc.)
[034] The PUF blocker (100) has following advantages:
• It helps to provide maximum injected PUF at bottom side which
reduces heating loss during working or standing position.
10 • The wire routing provided in PUF blocker (100) save the product
from fire hazard and can be used in all storage water heater.
• The PUF blocker (100) creates an air tight compartment around
the tank, which reduces the heat loss.
• Reduction in heat loss reduce power consumption leading to
15 higher standing loss rating.
• While use or during service, technician could not access PUF so, accidents like fire are eliminated.
• PUF blocker (100) can help to achieve commercial feature “5-star rating” for water heaters.
20 [035] It should be noted that the description and figures merely
illustrate the principles of the present subject matter. It should be appreciated by those skilled in the art that conception and specific
9

embodiment disclosed may be readily utilized as a basis for modifying
or designing other structures for carrying out the same purposes of the
present subject matter. It should also be appreciated by those skilled in
the art that by devising various assembly that, although not explicitly
5 described or shown herein, embody the principles of the present subject
matter and are included within its spirit and scope. Furthermore, all examples recited herein are principally intended expressly to be for pedagogical purposes to aid the reader in understanding the principles of the present subject matter and the concepts contributed by the
10 inventor(s) to furthering the art, and are to be construed as being without
limitation to such specifically recited examples and conditions. The novel features which are believed to be characteristic of the present subject matter, both as to its organization and method of operation, together with further objects and advantages will be better understood
15 from the aforementioned description when considered in connection
with the accompanying figures.
[036] These and other advantages of the present subject matter would
be described in greater detail with reference to the following figures. It
should be noted that the description merely illustrates the principles of
20 the present subject matter. It will thus be appreciated that those skilled
in the art will be able to devise various arrangements that, although not explicitly described herein, embody the principles of the present subject matter and are included within its scope.
[037] It will be further appreciated that functions or structures of a
25 plurality of components or steps may be combined into a single
10

component or step, or the functions or structures of one-step or component may be split among plural steps or components. The present invention contemplates all of these combinations. Unless stated otherwise, dimensions and geometries of the various structures depicted herein are not intended to be restrictive of the invention, and other dimensions or geometries are possible. In addition, while a feature of the present invention may have been described in the context of only one of the illustrated embodiments, such feature may be combined with one or more other features of other embodiments, for any given application. It will also be appreciated from the above that the fabrication of the unique structures herein and the operation thereof also constitute methods in accordance with the present invention. The present invention also encompasses intermediate and end products resulting from the practice of the methods herein. The use of "comprising" or "including" also contemplates embodiments that "consist essentially of or "consist of the recited feature.
[038] Although embodiments for the present subject matter have been described in language specific to structural features, it is to be understood that the present subject matter is not necessarily limited to the specific features described. Rather, the specific features and methods are disclosed as embodiments for the present subject matter. Numerous modifications and adaptations of the system/component of the present invention will be apparent to those skilled in the art, and thus it is intended by the appended claims to cover all such modifications and adaptations which fall within the scope of the present subject matter.

WE CLAIM:

A PUF Blocker (100) for insulation in water heater, the PUF Blocker (100) comprising:
A rectangular hollow structure (101) with chamfered corners;
A base flange (102) extended perpendicularly away from the rectangular hollow structure (101); and
A hollow structure (103) provided at one chamfered corner (105) of the rectangular hollow structure (101) to allow passage for wire harness.
The PUF blocker (100) as claimed in claim 1, wherein the base flange (102) comprises of plurality of holes (106) for tank inlet and outlet pipes.
The PUF blocker (100) as claimed in claim 1, wherein the hollow structure (103) is rectangular, cylindrical, square, circular or elliptical.
The PUF blocker (100) as claimed in claim 1, wherein the rectangular hollow structure (101) has plurality of vertical columns (109) protruding from the outer surface of the hollow structure (101) and are perpendicularly connected with the base flange (102).

The PUF blocker (100) as claimed in claim 1, wherein the chamfered corner (105), towards the base flange (102), has a gap (108) for the serviceability of the water heater.
The PUF blocker (100) as claimed in claim 1, wherein the vertical columns (109) grip the foam seal of the water heater to attach the PUF blocker structure (100) to the water heater.
The PUF blocker (100) as claimed in claim 1, wherein the base flange (102) is rectangular, square, circular or elliptical in shape.
The PUF blocker (100) as claimed in claim 1, wherein the PUF blocker structure (100) is made up of fire-retardant plastic.
The PUF blocker (100) as claimed in claim 1, wherein the PUF blocker structure (100) creates an air-tight compartment in the water geyser to decrease the heat loss.
).The PUF blocker (100) as claimed in claim 1, wherein hollow structure (103) provided at one chamfered corner (105) allows easy assembly and disassembly of the wire harness.
.The PUF blocker (100) as claimed in claim 1, wherein the PUF blocker (100) structure creates a barrier between the electrical connections and foam seal of the water heater to avoid spark induced fire.