GB2390143A

GB2390143A - Instantaneous water heater housing

Info

Publication number: GB2390143A
Application number: GB0314021A
Authority: GB
Inventors: Robin Craig Cocker; Jocelin Langford; Adrian Barclay Caroen
Original assignee: Aqualisa Products Ltd
Current assignee: Aqualisa Products Ltd
Priority date: 2002-06-24
Filing date: 2003-06-17
Publication date: 2003-12-31
Anticipated expiration: 2023-06-17
Also published as: GB0314021D0; GB2390143B; GB2390134A; GB0214535D0

Abstract

A front cover 2, such as for a shower, is attached to various functional components of the water heater. The functional components, including a heater can 14, water inlets 8 & 10, water outlet 19, and flow control button 22, are attached to one another rather than mounted onto a back plate. The self-supporting assembly of components is mounted to a wall via screw holes 30 & 32. The functional components may be grouped together in separate modules i.e. a heater module, an electrical module, and a valve module. Each module is self-supporting and interchangeable for versatility in the desired arrangement e.g. the mechanically-controlled valve module may be replaced with an electrically-controlled valve module. A splash guard (70 , figure 2) may be provided to shield the components of the electrical module.

Description

2390 1 43

-1 INSTANTANEOUS WATER HEATER

The present invention relates to an instantaneous water heater, in particular an instantaneous water heater for a shower whereby the overall construction is 5 simplified.

A great variety of different types of instantaneous water heater are known.

These may be used in conjunction with a shower such that when a user turns on a flow of water to the shower, the water is instantaneously heated to a desired temperature. Often, temperature control is achieved by varying the water flow rate 10 through a heater in the instantaneous water heater.

Instantaneous water heaters are often installed by mounting them on the wall in the region of the shower itself. However, due to the large number of components making up the water heater, including for instance heater elements, control valves, pipework, etc. the front cover of the water heater is undesirably large.

15 It will also be appreciated that different consumers have different tastes.

Therefore, retailers wish to stock instantaneous water heaters having different appearances. Unfortunately, with known types of instantaneous water heater, this is difficult to do. All of the various functional components within the instantaneous water heater have to be mounted and aligned carefully. Thus, the configuration of 20 the back plate to which the functional components are attached requires careful design and, furthermore, the front cover must mate with the back plate so as to prevent ingress of water and meet local safety standards.

According to the present invention, there is provided a method of constructing an instantaneous water heater for a shower including: 25 mounting the functional components of the instantaneous water heater to one another to form a self supporting structure; attaching a front cover directly to the functional components; and providing mounts on the functional components by which to mount the water heater on a wall; wherein 30 the water heater does not include a back plate.

According to the present invention, there is provided an instantaneous water heater for a shower including: functional components for providing heated water; mounts by which to mount the water heater on a wall; and 5 a front cover for covering the components: wherein the water heater does not include a back plate, the mounts being provided on the functional components and the front cover being attached directly to the functional components.

In this way, the functional components themselves allow mounting of the 10 water heater on a wall and attachment of a front cover. There is no need, therefore, for a back plate on which to mount the functional components. Thus, for the same arrangement of functional components, it is possible to provide easily and cheaply a large range of front covers having different appearances. The covers need only have attachment points in the same positions for attaching to the components.

15 Preferably, the functional components are attached to one another so as to form a self supporting structure.

In this way, the self supporting structure can easily be handled and mounted to a wall. Once mounted on the wall, the front cover can then be attached.

Preferably, groups of the functional components are provided together to 20 form respective modules and the modules are attached to one another so as to form a self supporting structure.

Thus, again, in the assembled condition, the self supporting structure can be handled and mounted as if it had a back plate.

By providing the functional components as modules, overall assembly can be 25 simplified. In particular, with individual modules assembled as respective self supporting structures, it is then only necessary to assemble the modules together.

Otherwise, simultaneously aligning and arranging a large number of individual functional components can be more difficult.

In this way too, greater variety may be offered to the consumer and retailer.

30 In particular, to provide functional variations to the instantaneous water heater, it is only necessary to replace a module. This is in comparison to known water heaters

-3 with back plates where entirely new back plates have to be provided to allow the use of different functional components or where the design of the back plate must be compromised or be overly complex in order to accommodate functional variants, for instance additional bosses for additional/alternative components.

5 Preferably, electrical components are provided together to form an electrical module, the electrical module including a splash guard for supporting the electrical components and shielding them from external water.

In this way, where known instantaneous water heaters required a back plate to prevent ingress of water, the splash guard of the electrical module takes the same 10 function. By moving all of the sensitive electrical components into the electrical module, it no longer becomes necessary to seal the entire water heater housing.

By providing an electrical module with a splash guard, it becomes possible to allow ingress of water to all other parts of the water heater. Other parts of the water heater may be attached to the electrical module in the mariner described above so as to 15 provide a self supporting structure having the advantages mentioned above.

In order to provide improved sealing of the electrical components, it is possible to provide a cover for the electrical module.

However, preferably, the splash guard of the electrical module includes peripheral walls and the front cover includes corresponding internally projecting 20 walls for forming a labyrinth seal with the peripheral walls.

In this way, although the range of front covers need include the internally projecting walls, their external appearance is still freely variable. Furthermore, the electrical module may be sealed in a manner to meet more strict local standards.

Preferably, the instantaneous water heater further includes a heater module 25 with a heater can including a heating element and also a valve module with valve components for controlling water flow wherein at least one of the heater module and the valve module is attached to the electrical module.

In other words, as described above, modules may be attached to one another to form the self supporting structure without the need of a back plate.

30 Preferably, the valve components connect directly to one another to form the valve module without the use of any intermediate pipework.

- In this way, the number of additional components is reduced, namely connecting pipework and necessary seals. It is only necessary to provide a seal between the components. An added advantage is that the overall length of flow through the instantaneous heater is reduced, such that the overall pressure drop is 5 also reduced.

Preferably, the valve module is connected to the heater module without the use of any intermediate pipework.

In other words, any inlet or outlet orifices may be aligned and sealed without any connecting pipes.

10 As described above, this reduces the number of components and simplifies assembly. Furthermore, by connecting the modules together without intermediate pipework, a more reliable and rigid connection may be made between the modules, enabling an improved overall self supporting structure.

Preferably, the front cover includes a side wall surrounding the functional 15 components and extending in a parallel direction so as to end adjacent the wall, a front wall extending between and beyond the side walls so as to form an overhanging lip around the periphery of the front cover wherein the overhanging lip also extends in the direction of said parallel direction, but not inwardly towards the side walls.

For aesthetic reasons, it is desirable to provide a housing to an instantaneous 20 water heater which attaches to the wall at the back over a smaller area than the largest area presented to the user. This is difficult to achieve by moulding.

It has now been recognised that by providing the overhanging lip which is separated from the wall to which the water heater is mounted, the same feel and appearance is given as if the lip did extend inwardly towards the side walls.

25 However, the housing of this design can be produced with a single moulding.

The invention will be more clearly understood from the following description, given by way of example only, with reference to the accompanying

drawings, in which: Figure 1 illustrates the front cover of an instantaneous water heater according 30 to the present invention;

-5 Figure 2 illustrates an exploded view of the functional components of an instantaneous water heater according to the present invention; Figures 3(a), (b) and (c) illustrate the heater module, electrical module and valve module of the instantaneous water heater of Figure 2; 5 Figure 4 illustrates the assembled modules of Figures 3(a), (b) and (c); Figure 5 illustrates an exploded view of the functional components of an alternative instantaneous water heater embodying the present invention; Figure 6(a), (b) and (c) illustrate the heater module, electrical module and valve module of the instantaneous water heater of Figure 5; 10 Figure 7 illustrates the assembled modules of Figures 6(a), (b) and (c); Figure 8 illustrates an on/off control module; Figure 9(a) illustrates a crosssection through a front cover; and Figure 9(b) illustrates a crosssection through a preferred front cover.

As illustrated in Figure l, an instantaneous water heater includes a front cover 15 2 including a water temperature control 4 and an on/off button 6.

The front cover 2 houses a number of functional components for providing hot water of a desired temperature.

Figures 2 and 5 illustrate suitable arrangements of components according to two similar embodiments of the present invention. However, it should be 20 appreciated that many other arrangements could be provided within the scope of the invention as defined by the claims.

Water is provided to one of two alternative inlets 8 and l O. With the water heater running, the water is then channelled via a flow rate control valve 12 to the Inside of a heater can 14. Within the heater can 14, the water flows up around the 25 outside of a chimney 16 in contact with a heater element 18. The water then flows down through the inside of the chimney 16 and out of an outlet 19.

A flow control valve 20 operates under the control of a button 22 to control whether or not there is any flow from the inlets 8 or to to the flow rate control valve 12. Dependant on the flow of water through the water heater, an arm 24 operates an 30 electrical switch 26 to turn on or off power to the heater element 18.

O

- The flow rate control valve 12 may be operated by a rotatable member 28 so as to vary the flow rate through the heater can 14 and, hence, the outlet temperature.

As Illustrated m Figures 4 and 8, with all of the various components connected together, a self supporting assembly is formed.

5 In contrast to previous instantaneous heater arrangements, there is no need to provide a back plate. In particular, all of the various functional components are attached to one another, rather than mounted on a dedicated back plate.

In order to enable the self supporting assembly to be mounted on a wall, mounts 30, 31 and 32 are provided. In particular, in the illustrated embodiment, 10 screw holes 30, 31 and 32 are provided to enable the assembly to be screwed to a wall. The assembly is also provided with means by which the front cover can be attached. Any suitable method of attachment may be used, for instance with screws, 15 resilient clips or the like.

As a preferred feature of the present invention, the various functional components are provided together as modules for assembly. Each module itself is self supporting.

Figures 3(a) and 6(a) illustrate heater modules 40 and 140. As illustrated, this 20 includes the heater can 14 with the heater element 18 and chimney 16 already fitted.

Figures 3(b) and 6(b) illustrate electrical modules 50 and 150 to be discussed further below and Figures 3(c) and 6(c) illustrate valve modules 60 and 160 including the on/off control valve 20, inlets 8 and I O and control button 22.

the embodiment of Figures 2 and 4 as illustrated in Figure 3(a), the flow 25 rate control valve 12 forms part of the heater module 40 so as to complete the heater can 14. However, alternatively, in the embodiment of Figures 5 and 7 as illustrated In Figure 6(c), the flow rate control valve 12 could be pre-assembled with the on/off control valve 20 to form part of the valve module 160.

With the modules so constructed, it becomes a simple matter to attach them 30 together to form the complete self supporting assembly. Furthermore, to introduce any desired functional variation in the range of products, it also becomes simple to

-7 provide an alternative module for alternative Functionality without changing the complete design.

For example, the flow rate control valve 12 could be replaced by a valve having thermostatic control. Similarly, the mechanical on/off arrangement of the 5 modules 60 and 160 could be replaced with an alternative module having solenoid operation. Indeed, the mechanical on/off arrangement could be provided as a separate module as illustrated in Figure 8.

Referring back to Figures 2 and 5, it will be seen that the various functional components connect directly to one another without the need for interconnecting 10 pipes. Similarly, the modules connect directly to one another without the need for such interconnecting pipes. This simplifies construction, reduces the number of components (since there are no interconnecting pipes and a reduced number of seals) and improves the connection between the components so as to provide a more rigid and stable self supporting structure. As an added benefit, it also reduces the total 15 flow path length through the device, thereby reducing the loss in pressure.

As illustrated in Figures 2 and 3(b), electrical components of the water heater are provided on a splash guard 70. Similarly, Figures 5 and 6(b) illustrate the electrical components of the water heater being provided on a splash guard 170.

The splash guard 70, l 70 provides protection to the electrical components 20 from water from the back of the assembly. In this regard, a cover for the splash guard 70 may also be provided so as to enclose the electrical components and seal them from external water to any degree necessary. However, in the preferred embodiments, side walls 80, 180 extend around the periphery of the splash guard 70, 170 and engage with corresponding walls (not illustrated) on the underside of the 25 front cover 2 to form a labyrinth seal.

By locating together all of the water sensitive electrical components in one module, it is possible to protect the electrical components without the need for a back plate as provided in previous instantaneous water heaters.

It has been found that a front cover having a cross-section of the general form 30 illustrated in Figure 9(a) gives the impression that the water heater is shallower and, hence, smaller. This is clearly advantageous.

-8 Unfortunately, it is not possible or is at least very difficult to produce a front cover having this cross-section as a single moulding. In particular, the undercut nature of the cross-section prevents the cover from being removed from the mould.

Where a back plate is provided, the lower portion (as illustrated in Figure 9(a)) of 5 the cross-section could be provided as part of the back plate. However, as described above, according to the present invention, no back plate is provided.

it has been recognised for the first time that a similar visual effect can be achieved without the complete undercutting cross-section of Figure 9(a). In particular, it is proposed to provide the front cover 2 with a cross-section of the 10 general form illustrated in Figure 9(b).

A side wall 2a is provided to enclose the functional components around their periphery. A front wall 2b extends between opposite sides of the side wall so as to complete the enclosure of the functional components. Furthermore, the front wall 2b extends beyond the side wall 2a so as to provide an overhanging lip 2c.

15 The side wall 2a is provided to extend to the wall on which the water heater is mounted, thereby generally enclosing the functional components. However, the overhanging lip gives the general impression of the crosssection of Figure 9(a) such that the water heater appears relatively shallow.

By designing the side wall 2a to extend in a generally parallel direction and 20 the overhanging lip to extend only downwardly and outwardly (and not inwardly), it is possible for the front cover 2 to be constructed easily as a single mould. In particular, it can be withdrawn easily from the mould.

It will be appreciated that the precise nature of the cross-section of the overhanging lip 2c can be varied according to other aesthetic considerations and that 25 the side wall 2a may include breaks or discontinuities around the periphery as required.

Claims

-9- CLAIMS

1. An instantaneous water heater for a shower including: functional components for providing heated water; 5 mounts by which to mount the water heater on a wall; and a front cover for covering the components: wherein the water heater does not include a back plate, the mounts being provided on the functional components and the front cover being attached directly to the functional components.

10

2. An instantaneous water heater according to claim 1 wherein the functional components are attached to one another so as to form a self supporting structure.

3. An instantaneous water heater according to claim 1 or 2 wherein groups of the functional components are provided together to form respective 15 modules and the modules are attached to one another so as to form a self supporting structure.

4. An instantaneous water heater according to claim 3 wherein electrical components are provided together to form an electrical module, the electrical module including a splash guard for supporting the electrical components and shielding them 20 from external water.

5. An instantaneous water heater according to claim 4 wherein the splash guard of the electrical module includes peripheral walls and the front cover includes corresponding internally projecting walls for forming a labyrinth seal with the peripheral walls.

25

6. An instantaneous water heater according to claim 4 or 5 further including: a heater module with a heater can including a heating element; and a valve module with valve components for controlling water flow; wherein at least one of the heater module and the valve module is attached to the 30 electrical module.

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7. An instantaneous water heater according to claim 6 wherein the valve components connect directly to one another to form the valve module without the use of any intermediate pipework.

8. An instantaneous water heater according to claim 6 or 7 wherein the 5 valve module is connected to the heater module without the use of any intermediate pipework.

9. An instantaneous water heater according to any preceding claim wherein the front cover includes: a front wall forming a front face of the instantaneous water heater; 10 side walls extending in a common direction from the front wall by a first distance so as to surround the functional components when mounted on a wall; wherein the front wall extends beyond the side walls so as to form an overhanging lip extending in a direction partly outwardly and partly in said cornnon direction and 15 extending in said common direction by a second distance less than said first distance.

10. A method of constructing an instantaneous water heater for a shower including: mounting the functional components of the instantaneous water heater to one another to form a self supporting structure; 20 attaching a front cover directly to the functional components; and providing mounts on the functional components by which to mount the water heater on a wall; wherein the water heater does not include a back plate.

11. An instantaneous water heater constructed and arranged substantially 25 as hereinbefore described with reference to and as illustrated by Figures I to 8 and 9(b) of the accompanying drawings.

12. A method of constructing an instantaneous water heater substantially as hereinbefore described with reference to and as illustrated by Figures I to 8 and 9(b) of the accompanying drawings.

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