DESC:Water heater with single inlet/outlet port

Field of Invention:
The Invention relates to a water heater with single inlet/outlet port. Particularly, the Invention provides an efficient water heater with single inlet/outlet port with the advantages of reducing heat loss, increasing productivity and which is cost effective and simple to manufacture.
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.
Every household and many businesses require hot water for everyday use. These hot water consumers typically rely on conventional storage water heaters to store and constantly heat water for production upon demand.
It is common for water heaters to have separate inlet pipe and outlet pipe. Fig 1a and 1b show traditional design of inlet and outlet tubes in a water heater tank. Fig 1 is a vertically mounted water heater while Fig 1b is a horizontally mounted water heater.
In the conventional water heater, the inlet is designed to provide cold water to the bottom part of the tank so that it can get heated by taking heat energy from the heating element. Once the water gets heated, it’s density decreases so it rises to the top of the tank. The outlet is designed so that it will withdraw heated water from the top of the tank. In existing water heaters, inlet and outlet are 2 separate components that are mounted in 2 individual cavities in the water heater tank.
For instance, US9268342B2 discloses a water heater and thermal mixing valve assembly and method for providing a reduced discharge water temperature and a hot water temperature from the same tank. The assembly includes a tank adapted to accept and store an amount of cold water, a heater to heat the cold water held in the tank and increase the cold water temperature to a predetermined hot water temperature, at least one thermal mixing valve integrated with the tank in communication with a hot water passage and a cold water bypass conduit to provide a discharge water of a controlled temperature, the cold water bypass conduit being mounted to the cold water passage allowing the associated cold water to communicate with the tank and the thermal mixing valve. An adjustment member is mounted to the thermal mixing valve to adjust a temperature range of the discharge water, a discharge output passage and a hot output passage provide communication with an associated piping system oriented to supply discharge water from the thermal mixing valve and hot water from the tank to associated plumbing fixtures.
Further, EA022254B1 discloses a pipe connecting structure of a water heater, wherein individual parts in the water heater are integrally coupled with a pipe body, which is injection-molded, so as to form paths of direct water and hot water, thereby reducing the number of pipes connecting the individual parts and simplifying the connection structure of the pipes. In order to realize this, according to the present invention, the pipe connecting structure of a water heater comprising a direct water inlet pipe connected from a direct water inlet to a heat exchanger; a hot water supply pipe connected from the heat exchanger to a hot water outlet; a flow sensor for measuring the flow rate of the direct water introduced via the direct water inlet; a flow control valve for controlling the flow rate of the hot water discharged via the hot water outlet; is characterized in that the pipe body which connects the direct water inlet, the direct water inlet pipe, the hot water supply pipe and the hot water outlet is formed integrally therewith.
Further, US4282861A discloses a water heating system includes a solar collector panel, a hot water heater tank, a serpentine tube-in-sheet heat exchanger jacket built into the water tank assembly, pumping means, fluid transfer means and means for securing the heat exchanger jacket around the hot water heater. The solar collector panel has a first passageway which lies beneath the outer surface of the panel such that incident solar energy is used to elevate the temperature of an energy-absorbing fluid which is circulating through this first passageway. The heat exchanger jacket is constructed with second and third passageways which are positioned in a double serpentine coil arrangement. The energy-absorbing fluid from the collector panel flows through connecting conduits to and from the second passageway. Water within the hot water heater is coupled to the third passageway and, as it circulates through the third passageway, this water is elevated in temperature by means of conduction from the energy-absorbing fluid. The energy-absorbing fluid, by raising the temperature of the heat exchanger jacket, also elevates the temperature of the water within the hot water heater by conduction through the wall of the hot water heater. Thus, two modes of heat transfer are used to heat the water within the hot water heater. Suitable pumps and valves are provided in order to control the flow of the fluids during the various climatic conditions.
The conventional water heater having separate inlet and outlet port suffers with the drawback of heat loss, high manufacturing cost and lower productivity. The manufacturing process of such water heater are also complicated as it requires welding of the metal components.
Hence, there is needed an efficient water heater with single inlet/outlet port which reduces heat loss, increases productivity, which is simple to manufacture and is cost effective.

Objective of the Invention:
Primary object of the present invention is to overcome the limitation of prior art.
Another object of the present invention is to provide an efficient water heater that reduces heat loss.
Another object of the present invention is to provide an efficient water heater that increases productivity by reducing cycle time and reducing number of components to be welded and assembled.
Another object of the present invention is to provide an efficient water heater that is simple to be manufactured.
Another object of the present invention is to provide an efficient water heater that can be manufactured by injection moulded and extruded plastic components replacing the machined metal parts.
Another object of the present invention is to provide a cost effective efficient water heater.

Summary of the Invention:
In an aspect of the present invention there is provided a water heater comprising:
a) a water heater tank with a single cavity at the bottom of the tank for inlet and outlet of water;
b) a pipe assembly attached to the water tank through the single cavity, wherein the pipe assembly comprises:
i. an inlet/outlet manifold (A), wherein the inlet/outlet manifold of the pipe assembly comprises an inlet (A1) and an outlet (A2) section;
ii. a middle portion (B), the middle portion (B) of the pipe assembly configured to have two separate paths (B2, B3) for hot and cold water flow;
iii. a tube (C), wherein the tube is configured to pass hot water from the top of the water heater tank through (B2) and (A2);

wherein the inlet/outlet manifold (A) and the middle portion (B) are integrated into a single part;
wherein the pipe assembly is configured to receive the cold into the water heater tank through the inlet (A1) and the middle portion path (B3) and a heating element installed inside the water tank configured to heat the cold water to a predetermined temperature while said pipe assembly facilitates hot water to come out through the tube (C), the middle portion part path (B2) and the outlet (A2).
In an embodiment, the inlet/outlet manifold (A) and the middle portion (B) are integrated into a single part.
In an embodiment, the water heater tank comprises a welded flange around the cavity.
In an embodiment, inlet/outlet manifold (A) which is connected to a hose for supply of cold water from a water source.
In an embodiment, the middle portion (B) has a plurality of diffuser holes (B1) to ensure that cold water enters towards the bottom side of the tank and a protrusion (B4) to ensure that cold water flows only towards the bottom part of the tank and there is minimal mixing of cold water with hot water in the tank.
In an embodiment, the tube (C) is made of an extruded plastic or a metal where the tube is connected to the middle portion of the pipe assembly by a snap-fit connection.
In an aspect of the present invention there is provided a method of operation of the water heater, the method comprising steps of:
a) installing a water heater tank with a single cavity at the bottom of the tank for inlet and outlet of water;
b) attaching a pipe assembly to the water tank through the single cavity, wherein the pipe assembly comprises:
i. an inlet/outlet manifold (A), wherein the inlet/outlet manifold of the pipe assembly comprises an inlet (A1) and an outlet (A2) section,
ii. a middle portion (B), the middle portion (B) of the pipe assembly configured to have two separate paths (B2, B3) for hot and cold water flow,
iii. a tube (C), wherein the tube is configured to pass hot water from the top of the water heater tank through (B2) and (A2),

wherein the cold water enters into the water heater tank through the inlet (A1) and the middle portion path (B3) while the cold water is heated by a heating element installed inside the water tank to a predetermined temperature ;
and the hot water passes through the tube (C), the middle portion part path (B2) and the outlet (A2) for use.
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 Drawing:
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 its scope. The invention will be described and explained with additional specificity and detail with the accompanying drawings in which:
Figure 1 (a) and (b) illustrates traditional design of inlet and outlet tubes in a water heater tank.

Figure 2 (a) illustrates an overview of the complete inlet/outlet assembly 2(b) illustrates cross-section of inlet and outlet assembly with water flow paths 2 (c) illustrates bifurcated view of the 3 components of the assembly.

Figure 3 (a to g): (a) and (b) shows assembly of A-B-C with the water heater tank D for a water heater that is mounted vertically, Figure 3 (c) shows water heater tank D with cavity D1 for inserting the A-B-C assembly inside the tank, Fig 3 (d) shows a specially formed area in the tank D around cavity D1, Fig 3 (e) shows a steel flange D2 that is welded on the formed area shown in fig 3 (d), fig 3(f) shows leak proof connection, fig 3 (g) shows gasket E used between D2 and A3 to make it a leak proof connection as shown in fig 3 (f).
Figure 4 illustrates Part C as bent tube in horizontally mounted water heater.

Figure 5 (a) illustrates an overview of the complete inlet/outlet assembly where part A and B are integrated into a single part 5(b) illustrates part A, B assembled with part C 5(c) illustrates part A, B, C assembled together with water flow path.

Detailed description of the Invention:
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. Throughout the patent specification, a convention employed is that in the appended drawings, like numerals denote like components.

The Invention provides an efficient water heater with a single inlet and outlet port. Particularly, the Invention provides an efficient water heater with single inlet/outlet port with the advantages of reducing heat loss, increasing productivity and which is cost effective and simple to manufacture.

In an aspect of the present invention there is provided a water heater comprising:
a) a water heater tank with a single cavity at the bottom of the tank for inlet and outlet of water;
b) a pipe assembly attached to the water tank through the single cavity, wherein the pipe assembly comprises:
i. an inlet/outlet manifold (A), wherein the inlet/outlet manifold of the pipe assembly comprises an inlet (A1) and an outlet (A2) section;
ii. a middle portion (B), the middle portion (B) of the pipe assembly configured to have two separate paths (B2, B3) for hot and cold water flow;
iii. a tube (C), wherein the tube is configured to pass hot water from the top of the water heater tank through (B2) and (A2);

wherein the inlet/outlet manifold (A) and the middle portion (B) are integrated into a single part;
wherein the pipe assembly is configured to receive the cold into the water heater tank through the inlet (A1) and the middle portion path (B3) and a heating element installed inside the water tank configured to heat the cold water to a predetermined temperature while said pipe assembly facilitates hot water to come out through the tube (C), the middle portion part path (B2) and the outlet (A2).
In an embodiment, the inlet/outlet manifold (A) and the middle portion (B) are integrated into a single part. The water heater tank comprises a welded flange around the cavity.
In an embodiment, the pre-determined temperature is the temperature of the water as desired by the user.
In an embodiment, inlet/outlet manifold (A) which is connected to a hose for supply of cold water from a water source.
In an embodiment, the middle portion (B) has a plurality of diffuser holes and a protrusion, wherein the diffuser holes and the protrusion are configured to inject cold water at the bottom part of the water heater tank.
In an embodiment, the middle portion (B) has a plurality of diffuser holes (B1) to ensure that cold water enters towards the bottom side of the tank and a protrusion (B4) to ensure that cold water flows only towards the bottom part of the tank and there is minimal mixing of cold water with hot water in the tank.
In an embodiment, the tube (C) is made of an extruded plastic or a metal where the tube is connected to the middle portion of the pipe assembly by a snap-fit connection.
In an aspect of the present invention there is provided a method of operation of the water heater, the method comprising steps of:
a) installing a water heater tank with a single cavity at the bottom of the tank for inlet and outlet of water;
b) attaching a pipe assembly to the water tank through the single cavity, wherein the pipe assembly comprises:
i. an inlet/outlet manifold (A), wherein the inlet/outlet manifold of the pipe assembly comprises an inlet (A1) and an outlet (A2) section,
ii. a middle portion (B), the middle portion (B) of the pipe assembly configured to have two separate paths (B2, B3) for hot and cold water flow,
iii. a tube (C), wherein the tube is configured to pass hot water from the top of the water heater tank through (B2) and (A2),
wherein the cold water enters into the water heater tank through the inlet (A1) and the middle portion path (B3) while the cold water is heated by a heating element installed inside the water tank to a predetermined temperature;
and the hot water passes through the tube (C), the middle portion part path (B2) and the outlet (A2) for use.
In an embodiment, the inlet/outlet assembly creates independent cold-water path and hot-water path in the single cavity water heater tank.
In an embodiment, the cold water is injected into the bottom part of the tank while hot water is withdrawn from the top part of the tank.
In an embodiment, the Part B connects the middle part of the assembly to Part A so as to create atleast 2 separate paths, wherein separate paths comprises (B2) for hot water and (B3) for cold water, facilitating the cold water to travel to the bottom part of the tank while hot water to travel independently to outside the water heater.
In an embodiment, the diffuser holes (B1) ensures that cold water enters towards the bottom side of the tank.
In an embodiment, the protrusion (B4) ensures that cold water flows only towards the bottom part of the tank and there is minimal mixing of cold water with hot water in the tank.

In an embodiment, the water heater tank comprises a single cavity through which the inlet/outlet assembly is mounted. The inlet/outlet assembly used in the water heater is based on different components that are assembled using snap fit mechanism. The inlet/outlet assembly creates independent cold-water path and hot-water path where the cold water is injected into the bottom part of the tank while hot water is withdrawn from the top part of the tank.

In an embodiment, the water heater comprises an inlet and outlet assembly for water heater tanks where both the inlet and outlet tubes are integrated into one assembly that is assembled into the water heater tank through a single cavity.

In an embodiment, the inlet and outlet assembly comprise 3 different components as shown in Fig 2a, 2b and 2c. Fig 2a shows an overview of the complete assembly of the 3 components.

In an embodiment, Fig 2b shows cross-section of inlet and outlet assembly with water flow paths.

In another embodiment, Fig 2c shows bifurcated view of the 3 components of the assembly.

In an embodiment, 3 different components of inlet/outlet assembly parts are assembled using snaps or similar mechanism.

In an embodiment, Part A is the inlet/outlet manifold which is the outer most part of the assembly that has the inlet A1 and outlet A2 ports marked IN and OUT respectively. Cold water supply is through the inlet port A1 where a hose can be connected at the site of installation for supplying cold water. Hot water from the water heater flows out through the outlet port A2 to which another hose can be connected at the site of installation.

In an embodiment, Part B is the middle part of the assembly that connects to A. The connection of A and B is designed to make 2 separate paths (B2 for hot water and B3 for cold water) such that cold water can travel to the bottom part of the tank while hot water can travel independently to outside the water heater, as shown in fig 2b.

In an embodiment, the inlet path has diffuser holes B1 which ensures that cold water enters towards the bottom side of the tank. B4 is a protrusion designed specifically to ensure that cold water flows only towards the bottom part of the tank and there is minimal mixing of cold water with hot water in the tank.

In an embodiment, B5, B6 and B7 are O-rings that ensure that cold water flowing in path B3 does not mix with hot water flowing in path B2.

In an embodiment, the B5, B6 and B7 O-rings are optional.

In an embodiment, pipe assembly of the present invention does not require B5, B6 and B7 as O-rings to prevent mixing of hot and cold water in path B3 and path B2 as shown in Fig.5C.

In an embodiment, part C of the assembly is an extruded plastic tube. Part C is the outlet tube which is a cut-to-length tube, snap fit on B, with its main function being to bring hot water from the top part of the tank to the outlet port A2 through hot water path B2. In this embodiment, part A and B are made of plastic using injection moulding while part C is extruded plastic tube. These parts can also be made of any other material using any appropriate manufacturing technique.

In an embodiment, part C of the assembly can be a metal tube.

In an embodiment, Fig 3a and 3b shows the assembly of A-B-C with the water heater tank D for a water heater that is mounted vertically as show in fig 3b.

In an embodiment, Fig 3c shows water heater tank D with cavity D1 for inserting the A-B-C assembly inside the tank. Cavity D3 is for assembling heating element in tank D.

In an embodiment, Fig 3d shows a specially formed area in the tank D around cavity D1.

In an embodiment, Fig 3e shows a steel flange D2 that is welded on the formed area shown in fig 3d. The steel flange D2 and plastic flange A3 are assembled using bolts and nuts.

In an embodiment, a gasket E (fig 3g) is used between D2 and A3 to make it a leak proof connection as showing in fig 3f.

In an embodiment, part C comprises a bent tube C’ as shown in Fig 4 in horizontally mounted water heater. This helps part C’ reach till top of the tank to withdraw heated water from tank top.

In an embodiment, the water heater of the present invention provides several advantages like energy loss is minimized because there is a single inlet/outlet port instead of two so the path for heat loss is minimized.

In an embodiment, the water heater of the present invention is based on all the plastic components eliminating metal parts e.g., metal nipples. This also helps in reducing heat loss.

In an embodiment, the manufacturing of water heater of the present invention is simplified as the process of welding metal parts to tank is eliminated and stock keeping units (SKUs) are reduced.
Also, it reduces the cycle time of the production of water heater which leads to higher productivity.
,CLAIMS:We Claim:
1. A water heater comprising:
a) a water heater tank with a single cavity at the bottom of the tank for inlet and outlet of water;
b) a pipe assembly attached to the water tank through the single cavity, wherein the pipe assembly comprises:
i. an inlet/outlet manifold (A), wherein the inlet/outlet manifold of the pipe assembly comprises an inlet (A1) and an outlet (A2) section;
ii. a middle portion (B), the middle portion (B) of the pipe assembly configured to have two separate paths (B2, B3) for hot and cold water flow;
iii. a tube (C), wherein the tube is configured to pass hot water from the top of the water heater tank through (B2) and (A2);
wherein the inlet/outlet manifold (A) and the middle portion (B) are integrated into a single part;
wherein the pipe assembly is configured to receive the cold into the water heater tank through the inlet (A1) and the middle portion path (B3) and a heating element installed inside the water tank configured to heat the cold water to a predetermined temperature while said pipe assembly facilitates hot water to come out through the tube (C), the middle portion part path (B2) and the outlet (A2).
2. The water heater as claimed in claim 1, wherein the inlet/outlet manifold (A) and the middle portion (B) are integrated into a single part.
3. The water heater as claimed in claim 1, wherein the water heater tank comprises a welded flange around the cavity.
4. The water heater as claimed in claim 1, wherein inlet/outlet manifold (A) which is connected to a hose for supply of cold water from a water source.
5. The water heater as claimed in claim 1, wherein the middle portion (B) has a plurality of diffuser holes (B1) to ensure that cold water enters towards the bottom side of the tank and a protrusion (B4) to ensure that cold water flows only towards the bottom part of the tank and there is minimal mixing of cold water with hot water in the tank.

6. The water heater as claimed in claim 1, wherein tube (C) is made of an extruded plastic or a metal where the tube is connected to the middle portion of the pipe assembly by a snap-fit connection.
7. A method of operation of the water heater as claimed in claim 1, the method comprising steps of:
a) installing a water heater tank with a single cavity at the bottom of the tank for inlet and outlet of water;
b) attaching a pipe assembly to the water tank through the single cavity, wherein the pipe assembly comprises:
i. an inlet/outlet manifold (A), wherein the inlet/outlet manifold of the pipe assembly comprises an inlet (A1) and an outlet (A2) section,
ii. a middle portion (B), the middle portion (B) of the pipe assembly configured to have two separate paths (B2, B3) for hot and cold water flow,
iii. a tube (C), wherein the tube is configured to pass hot water from the top of the water heater tank through (B2) and (A2),

wherein the cold water enters into the water heater tank through the inlet (A1) and the middle portion path (B3) while the cold water is heated by a heating element installed inside the water tank to a predetermined temperature;
and the hot water passes through the tube (C), the middle portion part path (B2) and the outlet (A2) for use.
8. The method as claimed in claim 7, wherein the inlet/outlet assembly creates independent cold-water path and hot-water path in the single cavity water heater tank.
9. The method as claimed in claim 7, wherein the cold water is injected into the bottom part of the tank while hot water is withdrawn from the top part of the tank.
10. The method as claimed in claim 7, wherein Part B connects the middle part of the assembly to Part A so as to create atleast 2 separate paths, wherein separate paths comprises B2 for hot water and B3 for cold water, facilitating the cold water to travel to the bottom part of the tank while hot water to travel independently to outside the water heater.

11. The water heater as claimed in claim 7, wherein the diffuser holes B1 ensures that cold water enters towards the bottom side of the tank.
12. The water heater as claimed in claim 7, wherein the protrusion (B4) ensures that cold water flows only towards the bottom part of the tank and there is minimal mixing of cold water with hot water in the tank.