DESC:AN EFFICIENT WATER HEATER WITH FLOW CONTROLLER AND METHOD THEREOF

FIELD OF THE INVENTION:
The present invention is in the field of a water heater. Particularly, the invention provides an efficient water heater which increases the hot water output by diverting the cold-water flow inside the water heater tank, reducing the velocity, decreasing the turbulence, and mixing the hot & cold water so that the thermocline layer/thickness is narrowed. The mixing layer between hot and cold water is known as “thermocline”. Thermocline thickness is one of the parameters found to characterize thermal stratification.

BACKGROUND OF THE INVENTION:
The following background discussion includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.

Water heaters are an essential commodity with usage on daily basis for house chores. It has been seen that mostly customer complaints of not enough hot water once he/she withdraws hot water from tank.
It may be due to various reason that the traditional water tank suffers with following defects:

1. Cold water and the hot water are mixed in uncontrolled manner: When the cold water of the traditional water tank enters the water tank, since the flow rate is relatively great, the cold water directly flushes into a hot water area of the water tank liner such that the cold water and the hot water are mixed, consequently the temperature of the hot water in the hot water area decreases, even the hot water cannot be used and the demand of the user cannot be better satisfied.

2. Output of hot water: Due to uneven mixing, operating flow rates, design of inlet stream diffuser, exit velocity at inlet stream, orientation of inlet stream, turbulence in water tank, heat conduction between hot and cold layer inside tank, position of inlet stream affect the hot water output rate of the water heater. Improving the hot water output rate of the water tank is a technical problem which always exists.

For instance, CN202835806U discloses an electric water heater water inlet pipe flow stopping structure which comprises a water inlet pipe arranged at the bottom end of an electric water heater liner and a stopping cap which is arranged at the top of the water inlet pipe. The electric water heater water inlet pipe flow stopping structure is characterized in that a filter screen cover is arranged between the water inlet pipe and the stopping cap. The filter screen cover comprises a filter screen cover body and a brim-shaped filter screen which integrally extends to all around from the filter screen cover body. The appearance of the filter screen body is consistent with the shape of the stopping cap, and part of the filter screen cover body is sleeved inside the stopping cap. The electric water heater inlet pipe flow stopping structure has the advantages that a layer of the filter screen cover is added between the water inlet pipe and the stopping cap so that water flow is stopped by the stopping cap arranged on the top of the water inlet pipe when the water flow enters into the electric water heater liner from the water inlet pipe, the water flow can only enters into the liner again along the direction of the filter screen cover, and flow splitting and pressure releasing of entered water can be effectively achieved. The influence and impact on high-temperature water inside the liner by the water flow are avoided, so that the output rate of hot water is improved. The utility model further provides the liner with the water inlet pipe flow stopping structure.

Further, DE102005062660A1 discloses a heater has a base container (5) for entry of water and including an inlet (40) for the water that is to be heated. The base container has an outflow (30) for the heated water and an outward opened support chamber (70) for removable accommodation of system components. The container has two halves (10, 20), where the inlet is formed as an inlet pipe that includes two sections (41, 42). The sections (41, 42) are connected with respective halves (10, 20) of the container. Independent claims are also included for the following: (1) a hot water tank for a water heater (2) a base container for a water heater.

There is a need of an improved water heater which has efficient hot water output achieved without increasing the heating element wattage, without changing the system thermostat/Hi-limit positions and without changing current product architecture, such that:
• Customer can get more hot water output in the same capacity tank
• Saves energy bills by delaying the heating element ON time by improving mixing factor achieved by delaying the thermal stratification inside the tank.

OBJECTIVE OF THE INVENTION:
The primary object of the present invention is to overcome the drawback associated with prior art.

Another object of the present invention is to provide a water heater which comprises flow controller/ an integrated structure of inlet based on a diffuser component, which will divert the flow of water from vertical to horizontal in case of vertical mount water heaters or from horizontal to vertical in case of horizontal mount water heaters (Wall mount or floor mount).

Another object of the present invention is to provide an improved water heater which has efficient hot water output achieved without increasing the heating element wattage, without changing the system thermostat/Hi-limit positions and without changing current product architecture, such that:
• Customer can get more hot water output in the same capacity tank
• Saves energy bills by delaying the heating element ON time by improving mixing factor achieved by delaying the thermal stratification inside the tank.
Another object of the present invention is to provide a water heater with a reduced velocity of cold water.

Another object of the present invention is to provide a water heater with a decreased turbulence of cold water before mixing in the hot water.

Another object of the present invention is to provide a water heater where mixing of hot & cold water is delayed.

Another object of the present invention is to provide a water heater which has delayed thermal stratification and in turn reducing the height/depth of thermocline layer inside the water heater tank.

Another object of the present invention is to provide a water heater which can be installed in various position like horizontal, vertical, floor mount and wall mount.

SUMMARY OF THE INVENTION:
In an aspect of the present invention there is provided a water heater, controlling the flow of water for diverting the direction of cold water from the hot water in the water tank of the water heater, comprising at least an inlet pipe (A7, A8) being connected to a nipple (A2, A6) with diffuser (A3, A4, A5) at its bottom end, through a spud, wherein the water heater comprises the components:
a) said nipple’s inlet (A2) connected to a hose pipe (A1), for receiving the cold water to be heated, wherein the nipple inlet cross section (A2) is greater than the cross-sectional area (A1) of the hose pipe;
a) said diffuser (A3, A4, A5) connected to the nipple by a threaded connection, wherein the diffuser comprises at least 3 openings through which the cold water passes through to the first area outside of diffuser (A4) and to the second area at the diffuser base (A5);
wherein the cross section area of inlet pipe opening area (A8) must be greater than Hose Pipe cross section area (A1), Nipple inlet cross section area (A2), Diffuser opening area (A3) and Nipple area after diffuser (A6);
and
the cross section area of area left at diffuser base (A5) must be greater than outside area of diffuser (A4).
In another aspect of the invention, there is provided a method of operation of the water heater, controlling the flow of water for diverting the direction of cold water from the hot water in the water tank, as claimed in claim 1, comprising the steps of:
Receiving the cold water by the inlet pipe (A7, A8) being connected to a nipple (A2, A6) with diffuser (A3, A4, A5) at its bottom end, such that the cold water diffuses from Diffuser opening area (A3) to first area outside of diffuser (A4) and to the second area at the diffuser base (A5), such that the area of inlet pipe opening area (A8) is greater than Hose Pipe cross section area (A1), Nipple inlet cross section area (A2), Diffuser opening area (A3) and Nipple area after diffuser (A6);
and
the area of diffuser base (A5) is greater than area outside of diffuser (A4).
This together with the other aspects of the present invention along with the various features of novelty that characterized the present disclosure is pointed out with particularity in claims annexed hereto and forms a part of the present invention. For better understanding of the present disclosure, its operating advantages, and the specified objective attained by its uses, reference should be made to the accompanying descriptive matter in which there are illustrated exemplary embodiments of the present invention.

DETAILED DESCRIPTION OF DRAWINGS:
To further clarify advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof, which is illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of their scope. The invention will be described and explained with additional specificity and detail with the accompanying drawings in which:

Figure 1: illustrates an embodiment of the water heater showing inlet pipe and outlet pipe.
Figure 2: illustrates an embodiment where inlet pipe, spud and Nipple with Diffuser of the water heater is shown. Here, the inlet pipe has a side opening for receiving the cold water.
Figure 3: illustrates an embodiment where inlet pipe, spud and Nipple with Diffuser of the water heater is shown. Here, the inlet pipe has multiple holes for receiving the cold water in the water tank. In this embodiment, different holes have variable size.
Figure 4: illustrates an embodiment where the inlet pipe can have an opening or multiple holes for the entry of cold water in the water tank.
Figure 5: illustrates integrated structure of nipple’s inlet and the diffuser
Figure 6: illustrates an embodiment showing the structure of the diffuser with multiple holes/ opening
Figure 7: illustrates an embodiment showing the structure of the diffuser where it has side openings and acts as a flow controller
Figure 8: illustrates an embodiment showing vertical water heater with inlet pipe having multiple holes for receiving the cold water to be heated
Figure 9: illustrates an embodiment showing vertical water heater with inlet pipe having a big opening for receiving the cold water to be heated
Figure 10: illustrates an embodiment showing horizontal water heater with inlet pipe having multiple holes for receiving the cold water to be heated
Figure 11: illustrates an embodiment showing horizontal water heater with inlet pipe having a big opening for receiving the cold water to be heated
Figure 12: illustrates an embodiment with the dimensions/ structure of all the components of the water heater of the present invention
Figure 13: illustrates results of the hot water output when the present water heater was compared with the other existing water heater, for evaluating the efficiency of heating the water.

DETAILED DESCRIPTION:
For the purpose of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated system, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates.
It will be understood by those skilled in the art that the foregoing general description and the following detailed description are exemplary and explanatory of the invention and are not intended to be restrictive thereof.

The present invention is in the field of a water heater. Particularly, the invention provides an efficient water heater which can control the flow of water by diverting the direction of cold water from the hot water in the water tank.

In an embodiment, the water heater diverts the flow of cold water in a specific direction, thus, increasing the hot water output by diverting the cold-water flow inside the water heater tank by reducing the velocity, decreasing the turbulence.
In an embodiment, the water heater comprises flow controller/ an integrated structure of inlet based on a diffuser component, which will divert the flow of water from vertical to horizontal in case of vertical mount water heaters or from horizontal to vertical in case of horizontal mount water heaters (Wall mount or floor mount).

In an embodiment, the inlet pipe (A7, A8) of the water heater is connected to a nipple (A2, A6) with diffuser (A3, A4, A5) at its bottom end, through a spud. The water heater comprises following components:

a) said nipple’s inlet (A2) is connected to a hose pipe (A1), for receiving the cold water to be heated, wherein the nipple inlet cross section (A2) is greater than the cross-sectional area (A1) of the hose pipe;
a) said diffuser (A3, A4, A5) connected to the nipple by a threaded connection, wherein the diffuser comprises at least 3 openings through which the cold water passes through to the first area outside of diffuser (A4) and to the second area at the diffuser base (A5).
In an embodiment, the cross section area of inlet pipe opening area (A8) must be greater than Hose Pipe cross section area (A1), Nipple inlet cross section area (A2), Diffuser opening area (A3) and Nipple area after diffuser (A6).
In another embodiment, the cross section area of area left at diffuser base (A5) must be greater than outside area of diffuser (A4). Figure 12 illustrates the water heater, of the present invention, with the details of dimensions/ structure of all the components.
In an embodiment, the hose pipe area (A1) is connected to the hose pipe for cold water supply by a threaded connection.
In an embodiment, the nipple is connected to the inlet pipe by a spud.
In an embodiment, the nipple is connected to the inlet pipe by the spud by a threaded connection.
In an embodiment, the inlet pipe comprises an opening or at least 3 holes of the varying dimensions, to receive the cold water.
In an embodiment, the inlet pipe is positioned at the bottom of the water heater such that the holes / opening faces the bottom corner wall of the water heater.
In an embodiment, the diffuser (A3, A4, A5) prevents the formation of bubbles.
In an embodiment, the spud is made of a metallic material.
Figure 1 illustrates an embodiment of the water heater showing inlet pipe and outlet pipe. Figure 2 shows configuration of the inlet pipe, spud and Nipple with Diffuser of the water heater. Here, the inlet pipe has a side opening for receiving the cold water. Figure 3 illustrates an embodiment where inlet pipe, spud and Nipple with Diffuser of the water heater is shown. Here, the inlet pipe has multiple holes for receiving the cold water in the water tank. In this embodiment, different holes have variable size.
Figure 4 illustrates an embodiment where the inlet pipe can have an opening or multiple holes for the entry of cold water in the water tank. Figure 5 shows integrated structure of nipple’s inlet and the diffuser.
In an embodiment, there are holes/slots in the diffuser, as shown in figures 6 and 7 which helps in diverting the flow. The opening area of the holes/slots are bigger than the area of pipe carrying the inlet cold water. Further the cross-section area is increased with connecting pipe/nipple which will connect to water heater. Thus, the increasing cross section helps in reducing the fluid velocity, lesser turbulence, and improves mixing of cold water into hot water of the operational water heater by delaying the depth/height of thermocline layer.
In an embodiment, the cross section is increased in four steps and because of higher density of cold inlet water, (not allowing to splash inside the fluid controller) will delay the mixing and hence delaying the thermal stratification layer inside the water heater tank. This will help achieve better hot water output. The flow controller/nozzle/device controls the thermal stratification inside the tank giving better hot water output. Basically, this invention reduces operating exit velocity at inlet stream, turbulence in water space.
In an embodiment, the flow controller/flow distributor/nozzle/device can be integrated into tank or assembled into inlet pipes of water heater, as shown in figure 1.
In an embodiment, water heater of the present invention provides more hot water to customers. This is achieved without increasing the heating element wattage, without changing the system thermostat/Hi-limit positions and their specifications, without changing current product architecture.
In an embodiment, the flow controller/flow distributor/nozzle/device can be integrated into tank or else can be assembled into inlet pipes of water heater.
In another aspect of the invention, there is provided a method of operation of the water heater, for controlling the flow of water for diverting the direction of cold water from the hot water in the water tank. The method of operation comprises the steps of:
Receiving the cold water by the inlet pipe (A7, A8) being connected to a nipple (A2, A6) with diffuser (A3, A4, A5) at its bottom end, such that the cold water diffuses from Diffuser opening area (A3) to first area outside of diffuser (A4) and to the second area at the diffuser base (A5), such that the volume of the cold water passing through inlet pipe opening area (A8) is greater than Hose Pipe cross section area (A1), Nipple inlet cross section area (A2), Diffuser opening area (A3) and Nipple area after diffuser (A6).
In another embodiment, the method comprises steps of:
a) connecting a nipple to a hose pipe, wherein the nipple inlet cross section (A2) is greater than the cross-sectional area (A1) of the hose pipe;
b) connecting a diffuser to the nipple by a threaded connection, wherein the diffuser comprises a proximal end and a distal end, wherein the proximal end has an inlet portion and an outside portion, wherein the inlet portion has a three opening with equal cross-sectional areas (A3);
c) forming a first outside area (A4) of the diffuser at an outer surface of the proximal end, wherein total cross-sectional area of the first outside area (A4) of the diffuser is greater than total cross-sectional area (A3) of the three openings;
d) forming a second outside area (A5) of the diffuser at an outer surface of the distal end, wherein total cross-sectional area of the second outside area (A5) of the diffuser is greater than the first outside area (A4) of the diffuser;
e) forming a nipple area (A6) in front of the second outside area (A5) of the diffuser, wherein cross-sectional area of the nipple area (A6) is greater than the second outside area (A5) of the diffuser; and
f) connecting an inlet pipe to the to the nipple area (A6). The top end of the inlet pipe has an opening having cross sectional area of (A8), wherein the inlet pipe opening cross sectional area of (A8) is greater than cross-sectional area of the nipple area (A6).
In an embodiment, the Invention provides a water heater with increased hot water output by diverting the cold-water flow inside the water heater tank by reducing the velocity, decreasing the turbulence. The water heater achieves hot water output increase where the fluid is diverted, turbulence is reduced, and velocity is reduced which leads to controlled mixing of cold and hot water inside the tank. The water heater advantageously helps in delaying the thermal stratification and in turn reducing the height/depth of thermocline layer inside the water heater tank.
In an embodiment, the water heater of the present invention can be installed at different position comprising horizontal, vertical floor mount, wall mount etc., as shown in Figures 8 to 11.
The Invention is further described with the help of non-limiting examples:

Example 1:
The experiment was performed to evaluate the efficiency of heating the water by the Vertical tank water heater, provided by the present invention as compared to the other existing / conventional water heater. The results are shown in the below mentioned Table 1 and Figure 13. The results shows that there is improvement of approx.18.84% in heating the water over existing water heater. The results in the table shows that Water Heater of the present Invention produces more hot water as compared to existing/ conventional water heater, when the comparison was done for the same time duration and same volume of water. The enhanced technical effect of heating the water is achieved due to the specific structure where the nipple’s inlet (A2) is connected to a hose pipe (A1), for receiving the cold water to be heated. The nipple inlet cross section (A2) is greater than the cross-sectional area (A1) of the hose pipe. The diffuser (A3, A4, A5) is connected to the nipple by a threaded connection, wherein the diffuser comprises at least 3 openings through which the cold water passes through to the first area outside of diffuser (A4) and to the second area at the diffuser base (A5). The cross section area of inlet pipe opening area (A8) must be greater than Hose Pipe cross section area (A1), Nipple inlet cross section area (A2), Diffuser opening area (A3) and Nipple area after diffuser (A6);and the cross section area of area left at diffuser base (A5) must be greater than outside area of diffuser (A4).

Output @3LPM Time Existing/ Conventional Water Heater (°C) Water Heater of Present Invention (°C)
3L 1 Minute 54.18 57.27
6L 2 Minute 55.4 57.59
9L 3 Minute 54.99 57.51
12L 4 Minute 52.01 57.33
15L 5 Minute 42.14 56.98
18L 6 Minute 36.15 55.36
21L 7 Minute 33 47.56
24L 8 Minute 0 0
Average 40.98 48.70
% improvement over existing water heater 18.8385
Table 1
,CLAIMS:We Claim:
1. A water heater, controlling the flow of water for diverting the direction of cold water from the hot water in the water tank of the water heater, comprising at least an inlet pipe (A7, A8) being connected to a nipple (A2, A6) with diffuser (A3, A4, A5) at its bottom end, through a spud, wherein the water heater comprises the components:

a) said nipple’s inlet (A2) connected to a hose pipe (A1), for receiving the cold water to be heated, wherein the nipple inlet cross section (A2) is greater than the cross-sectional area (A1) of the hose pipe;
b) said diffuser (A3, A4, A5) connected to the nipple by a threaded connection, wherein the diffuser comprises at least 3 openings through which the cold water passes through to the first area outside of diffuser (A4) and to the second area at the diffuser base (A5);
wherein the cross section area of inlet pipe opening area (A8) must be greater than Hose Pipe cross section area (A1), Nipple inlet cross section area (A2), Diffuser opening area (A3) and Nipple area after diffuser (A6);
and
the cross section area of area left at diffuser base (A5) must be greater than outside area of diffuser (A4).
2. The water heater as claimed in claim 1, wherein the inlet pipe comprises an opening or at least 3 holes of variable dimensions, to receive the cold water.
3. The water heater as claimed in claim 1, wherein the inlet pipe is positioned at the bottom of the water heater such that the holes / opening faces the bottom corner wall of the water heater.
4. The water heater as claimed in claim 1, wherein the diffuser (A3, A4, A5) presents the formation of bubbles.
5. The water heater as claimed in claim 1, wherein the spud is made of a metallic material.
6. A method of operation of the water heater, controlling the flow of water for diverting the direction of cold water from the hot water in the water tank, as claimed in claim 1, comprising the steps of:
Receiving the cold water by the inlet pipe (A7, A8) being connected to a nipple (A2, A6) with diffuser (A3, A4, A5) at its bottom end, such that the cold water diffuses from Diffuser opening area (A3) to first area outside of diffuser (A4) and to the second area at the diffuser base (A5), such that the volume of the cold water passing through inlet pipe opening area (A8) is greater than Hose Pipe cross section area (A1), Nipple inlet cross section area (A2), Diffuser opening area (A3) and Nipple area after diffuser (A6);