US20180094833A1

US20180094833A1 - Water heater appliance

Info

Publication number: US20180094833A1
Application number: US15/281,156
Authority: US
Inventors: Craig Iung-Pei Tsai; Shaun Michael Ward
Original assignee: Haier US Appliance Solutions Inc
Current assignee: Haier US Appliance Solutions Inc
Priority date: 2016-09-30
Filing date: 2016-09-30
Publication date: 2018-04-05

Abstract

A water heater appliance defining a vertical direction includes a tank for holding water. The water heater appliance further includes a shroud and a fan. The shroud may be positioned at a top portion of the tank. In addition, the shroud may define a chamber positioned over the tank along the vertical direction, and the shroud may further define a vent assembly extending through the shroud from the chamber of the shroud. The fan may be positioned within the chamber. In addition, the fan may include a hub and a plurality of blades extending from the hub. The plurality of fan blades may be rotatable in a first direction. Further, each of the plurality of blades may be positioned and oriented on the hub such that the fan discharges air in a direction that is substantially tangential to the first direction.

Description

FIELD OF THE INVENTION

The present subject matter relates generally to heat pump water heater appliances.

BACKGROUND OF THE INVENTION

Heat pump water heaters are gaining broader acceptance as a more economic and ecologically-friendly alternative to electric water heaters. These systems utilize a condenser configured in a heat exchange relationship with a water storage tank, for example wrapped around the tank in a series of coils. During operation of the vapor compression heat pump cycle, air flows across an evaporator and transfers energy to a refrigerant flowing through the evaporator. As such, the refrigerant exits the evaporator as a superheated vapor and/or high quality vapor mixture. Upon exiting the evaporator, the refrigerant enters a compressor where the pressure and temperature increase and the refrigerant becomes a superheated vapor. The superheated vapor from the compressor then enters the condenser, wherein the superheated vapor transfers energy to the water within a storage tank and returns to a saturated liquid and/or high quality liquid vapor mixture.
Certain heat pump water heaters include a shroud positioned over the storage tank. Various components of the heat pump water heater, such as the compressor, evaporator, and a fan, are disposed within the shroud. The fan generally circulates air directly out toward a back of the shroud. Thus, heat pump water heaters are preferably spaced apart from walls and other similar barriers to ensure proper airflow through the shroud. This diminishes the amount of usable space within a room or area in which a heat pump water heater is located, which is undesirable. In addition, the spacing between a heat pump water heater and a wall makes it difficult to secure the heat pump water heater to the wall, which certain localities require to prevent inadvertent movement of the heat pump water heater during an earthquake.
Accordingly, a heat pump water heater appliance with features for improving airflow would be beneficial. More specifically, a heat pump water heater appliance having improved airflow that reduces the amount of space consumed by the water heater appliance would be welcomed.

BRIEF DESCRIPTION OF THE INVENTION

The present disclosure provides a water heater appliance. The water heater appliance includes a fan positioned within a chamber of the water heater appliance. The fan can rotate in a first direction and direct air in a direction that is substantially tangential to the first direction. Additional aspects and advantages of the invention will be set forth in part in the following description, or may be apparent from the description, or may be learned through practice of the invention.
In a first exemplary embodiment, a water heater appliance defining a vertical direction includes a tank for holding water. The water heater appliance further includes a shroud and a fan. The shroud may be positioned at a top portion of the tank. In addition, the shroud may define a chamber positioned over the tank along the vertical direction, and the shroud may further define a vent assembly extending through the shroud from the chamber of the shroud. The fan may be positioned within the chamber. In addition, the fan may include a hub and a plurality of blades extending from the hub. The plurality of fan blades may be rotatable in a first direction. Further, each of the plurality of blades may be positioned and oriented on the hub such that the fan discharges air in a direction that is substantially tangential to the first direction.
In a second exemplary embodiment, a water heater appliance defining a vertical direction includes a tank for holding water. The water heater appliance further includes a shroud, an evaporator, and a fan. The shroud may be positioned at a top portion of the tank. In addition, the shroud may define a chamber positioned over the tank along the vertical direction, and the shroud may further define a first vent and a second vent both extending through the shroud from the chamber of the shroud. Further, the first vent may be defined at a top wall of the shroud, and the second vent may be defined at a side wall of the shroud. The evaporator and fan may both be positioned within the chamber. In addition, the fan may include a hub and a plurality of blades extending from the hub. The plurality of fan blades may be rotatable in a first direction. Further, each of the plurality of blades may be positioned and oriented on the hub such that the fan discharges air in a direction that is substantially tangential to the first direction.
These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures.

FIG. 1 provides a front elevation view of a water heater appliance according to an exemplary embodiment of the present disclosure;

FIG. 2 provides a perspective elevation view of the exemplary water heater appliance of FIG. 1;

FIG. 3 provides a front section view of the exemplary water heater appliance of FIG. 1;

FIG. 4 provides an elevated view of a chamber positioned over a tank of the exemplary water heater appliance of FIG. 1;

FIG. 5 provides a perspective view of a fan according to an exemplary embodiment of the present disclosure;

FIG. 6 provides a back view of the exemplary fan of FIG. 5;

FIG. 7 provides a cross-sectional view of a fan blade of the exemplary fan of FIG. 5; and

FIG. 8 provides a top down view of the of the exemplary fan of FIG. 5; and

FIG. 9 provides a cross-sectional side view of the exemplary fan of FIG. 5.

DETAILED DESCRIPTION

Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.
FIG. 1 provides a front elevation view of a water heater appliance 100 according to an exemplary embodiment of the present disclosure. The water heater appliance 100 defines a vertical direction V, and the water heater appliance 100 extends longitudinally between a top portion 102 and a bottom portion 104 along the vertical direction V. The water heater appliance 100 includes an outer shell or casing 106. The casing 106 generally surrounds a tank 108 (FIG. 2) such that the tank 108 is disposed within the casing 106. The tank 108 includes a top portion 110 and a bottom portion 112 spaced apart from one another along the vertical direction V. In addition, the tank defines an interior volume 114 extending between the top portion 110 and the bottom portion 112 along the vertical direction V.
The casing 106 may be formed from a variety of components. As illustrated, the casing 106 may include a wrapper 116, one or more covers, such as a top cover 118 and a bottom cover 120, and a shroud 122 as illustrated. The shroud 122 may be positioned at the top portion 110 of the tank 108 along the vertical direction V such that the shroud 122 defines a chamber 124 (FIG. 3) positioned over the tank 108 along the vertical direction V. Additionally, the shroud 122 may define a vent assembly comprising a first vent 126 (FIG. 4) and a second vent 128 (FIG. 3) that each extend through the shroud 122 from or to the chamber 124 of the shroud 122.
Upper and lower heating elements 130, 132 (FIG. 2) and a sealed system 134 (FIG. 2) may also be positioned within the casing 106 for heating water within the tank 108. The upper and lower heating elements 130, 132 can be any suitable heating elements. For example, the upper heating element 130 and/or lower heating element 132 may be an electric resistance element, a microwave element, an induction element, or any other suitable heating element or combination thereof. The lower heating element 132 may also be a gas burner. As will be understood by those skilled in the art and as used herein, the term “water” includes purified water and solutions or mixtures containing water and, e.g., elements (such as calcium, chlorine, and fluorine), salts, bacteria, nitrates, organics, and other chemical compounds or substances.
The water heater appliance 100 also includes an inlet or cold water conduit 136 and an outlet or hot water conduit 138 that are both in fluid communication with a chamber or interior volume 114 (FIG. 2) defined by the tank 108. As an example, cold water from a water source, e.g., a municipal water supply or a well, can enter the water heater appliance 100 through the cold water conduit 136. From the cold water conduit 136, such cold water can enter the interior volume 114 of the tank 108 wherein the water is heated with heating elements 130, 132 and/or sealed system 134 to generate heated water. Such heated water can exit the water heater appliance 100 at the hot water conduit 138 and, e.g., may be supplied to a bath, shower, sink, or any other suitable feature.
As mentioned above, the water heater appliance 100 extends longitudinally between the top portion 102 and the bottom portion 104 along the vertical direction V. Thus, the water heater appliance 100 is generally vertically oriented. The water heater appliance 100 can be leveled, e.g., such that the casing 106 is plumb in the vertical direction V, in order to facilitate proper operation of the water heater appliance 100. It should be understood that the water heater appliance 100 is provided by way of example only and that the present subject matter may be used with any suitable water heater appliance, including for example any heat pump water heater appliance.
FIG. 2 provides a front section view of the water heater appliance 100. As may be seen in FIG. 2, the water heater appliance 100 includes the sealed system 134 for heating water within the interior volume 114 of the tank 108. The sealed system 134 generally operates in a heat pump cycle. Thus, the water heater appliance 100 is commonly referred to as a “heat pump water heater appliance.” The water heater appliance 100 may additionally include one or more auxiliary heating elements, such as the upper heating element 130 and/or the lower heating element 132.
The sealed system 134 may include a compressor 140, a condenser 142 and an evaporator 144. The compressor 140 and/or evaporator 144 of the sealed system 134 may be disposed within the casing 106 at the top portion 102 of the water heater appliance 100, e.g., within the shroud 122. As is generally understood, various conduits may be utilized to flow refrigerant between the various components of the sealed system 128. Thus, e.g., the evaporator 144 may be between and in fluid communication with the condenser 142 and the compressor 140. During operation of the sealed system 134, refrigerant may flow from the evaporator 144 through the compressor 140. For example, refrigerant may exit the evaporator 144 as a fluid in the form of a superheated vapor and/or high quality vapor mixture. Upon exiting the evaporator 144, the refrigerant may enter the compressor 140. The compressor 140 may be operable to compress the refrigerant. Accordingly, the pressure and temperature of the refrigerant may be increased in the compressor 140 such that the refrigerant becomes a superheated vapor.
The condenser 142 may be assembled in a heat exchange relationship with the tank 108 in order to heat water within the interior volume 114 of the tank 108 during operation of the sealed system 134. In particular, the condenser 142 may be positioned downstream of and in fluid communication with the compressor 140, and may be operable to heat the water within the interior volume 114 using energy from the refrigerant. For example, the superheated vapor from the compressor 140 may enter the condenser 142 wherein it transfers energy to the water within the tank 108 and condenses into a saturated liquid and/or liquid vapor mixture.
The sealed system 134 may also include a throttling device 146 between the condenser 142 and the evaporator 144. Refrigerant, which may be in the form of high quality/saturated liquid vapor mixture, may exit the condenser 142 and travel through the throttling device 146 before flowing through the evaporator 144. The throttling device 146 may generally expand the refrigerant, lowering the pressure and temperature thereof. The refrigerant may then be flowed through the evaporator 144.
The throttling device 146 may be any suitable components for generally expanding the refrigerant. For example, in some exemplary embodiments, the throttling device 146 may be a Joule-Thomson expansion valve, also known as a “J-T valve.” In other exemplary embodiments, throttling device 146 may be an ejector. In still other exemplary embodiments, a capillary tube, fixed orifice, or other suitable apparatus may be utilized as throttling device 146.
The water heater appliance 100 may additionally include a temperature sensor 148. The temperature sensor 148 may be configured for measuring a temperature of water within the interior volume 114 of the tank 108. The temperature sensor 148 can be positioned at any suitable location within the water heater appliance 100. For example, the temperature sensor 148 may be positioned within the interior volume 114 of the tank 108 or may be mounted to the tank 108 outside of the interior volume 114 of the tank 108. The temperature sensor 148 may further be positioned within an upper portion of the tank 108. Alternatively, the temperature sensor 148 may be positioned within a lower portion of the tank 108. When mounted to the tank 108 outside of the interior volume 114 of the tank 108, the temperature sensor 148 can be configured for indirectly measuring the temperature of water within the interior volume 114 of the tank 108. For example, the temperature sensor 148 can measure the temperature of the tank 108 and correlate the temperature of the tank 108 to the temperature of water within the interior volume 114 of the tank 108. The temperature sensor 148 may be any suitable temperature sensor. For example, the temperature sensor 148 may be a thermocouple or a thermistor.
The water heater appliance 100 may further include a controller 150 that regulates operation of the water heater appliance 100. The controller 150 may be, for example, in operative communication with the sealed system 128 (such as compressor 122, and/or other components thereof), auxiliary heating elements, and/or temperature sensor 144. Thus, the controller 150 can selectively activate the sealed system 128 and/or auxiliary heating elements in order to heat water within interior volume 114 of tank 108.
The controller 150 includes memory and one or more processing devices such as microprocessors, CPUs or the like, such as general or special purpose microprocessors operable to execute programming instructions or micro-control code associated with operation of water heater appliance 100. The memory can represent random access memory such as DRAM, or read only memory such as ROM or FLASH. The processor executes programming instructions stored in the memory. The memory can be a separate component from the processor or can be included onboard within the processor. Alternatively, the controller 150 may be constructed without using a microprocessor, e.g., using a combination of discrete analog and/or digital logic circuitry (such as switches, amplifiers, integrators, comparators, flip-flops, AND gates, and the like) to perform control functionality instead of relying upon software.
Referring now to FIGS. 3 and 4, the sealed system 134 includes a fan 160 disposed within the chamber 124. More specifically, the fan 160 is positioned between the evaporator 144 and the second vent 128. In operation, the fan 160 draws air into the chamber 124 through the first vent 126. More specifically, the fan 160 draws the air across the evaporator 144 to cool the evaporator 144. Further, the fan 160 may direct the air out of the chamber 124 through the second vent 128.
The first vent 126 may be positioned above the compressor 140 along the vertical direction V. Further, the first vent 126 may be positioned proximate to the controller 150 at a front portion of the shroud 122. More specifically, the first vent 126 may be defined at a top wall of the shroud 122. The second vent 126 may be positioned between the first vent 126 and the controller 150 along the vertical direction V. Further, the second vent 128 may be spaced apart from the compressor 140 along a radial direction R. More specifically, the second vent 128 may be positioned proximate to a rear portion of the shroud 122. In one exemplary embodiment, the second vent 128 may be defined at a side wall of the shroud 122, wherein the side wall extends downwardly from the top wall of the shroud 122 along the vertical direction V.
FIGS. 5 through 9 depict an exemplary embodiment of the fan 160 in accordance with the present disclosure. The fan 160 defines a coordinate system comprising an axial direction A, a circumferential direction C, and a radial direction R. The fan 160 includes a hub 162, a plurality of fan blades 164, and a casing 166. The hub 162 extends along the axial direction A, and the casing 166 is spaced apart from hub 162 along the radial direction R. More specifically, the casing 166 surrounds the hub 162 along the circumferential direction C. Each of the plurality of fan blades 164 extends between the hub 162 and the casing 166 along the radial direction R. As such, each blade of the plurality of blades 164 defines a span along the radial direction R. Further, each of the plurality of fan blades 164 are spaced apart from one another along the circumferential direction C. More specifically, in one exemplary embodiment, a blade root of each fan blade 164 may be attached to the hub 162, and a blade tip of each fan blade 164 may be attached to the casing 166. Thus, the plurality of fan blades 164, specifically the blade tip of each fan blade 164, may not vibrate during rotation. Alternatively, or in addition to, the plurality of fan blades 164 are each spaced substantially equidistant from one another along the circumferential direction C.
The fan 160 may also include a motor (not shown), such as an electric motor, having an output shaft. The hub 162 may define an aperture sized to receive the output shaft. In operation, the motor may rotate the shaft and hub 162. In one exemplary embodiment, the hub 162, plurality of fan blades 164, and casing 166 may be integrally formed with one another. For example, the hub 162, plurality of fan blades 164, and casing 166 may be formed of or with a single, seamless piece of injection molded material. Thus, in such an embodiment, the motor may rotate the hub 162, plurality of fan blades 164, and casing 166 via the output shaft. More specifically, each of the plurality of fan blades 164 may be swept forward in a first direction 170, e.g., in the direction of rotation of fan 160. It should be appreciated, however, that the motor may be configured to rotate the shaft in a clockwise manner or a counterclockwise manner. Thus, the first direction 170 may correspond to either the clockwise direction or the counterclockwise direction.
FIG. 6 provides a back view of the fan 160. In particular, the plurality of fan blades 164 may each define a leading edge 168 and a trailing edge 169. Specifically, the leading edge 168 and trailing edge 169 may be spaced apart from one another along the circumferential direction C. As shown in FIG. 6, the trailing edge 169 trails the leading edge 168 when the plurality of blades 164 are swept in the first direction 170. In addition, the plurality of fan blades 164 may each define a chord 172 (FIG. 7) that extends between the leading edge 168 and the trailing edge 169.
The chord 172 defines a pitch angle β relative to the axial direction A. In the embodiment shown in FIG. 7, the trailing edge 169 is positioned above the leading edge 168 along the radial direction R. In an alternative embodiment, the trailing edge 169 is positioned below the leading edge 168 along the radial direction R. It should be appreciated that the pitch angle β includes any suitable range of angles. For example, the pitch angle β may be between seven (7) and fifteen (15) degrees.
The plurality of fan blades 164 may each also define a first width W1 and a second width W2. The first width W1 may be defined at or adjacent the hub 162, and the second width W2 may be defined at or adjacent the casing 166. Further, the first width W1 may be different than the second width W2. For example, in one embodiment, the first width W1 may be less than the second width W2. Specifically, the second width W2 may be no less than twice the first width W1.
When the fan 160 is rotating in the first direction 170, the plurality of fan blades 164 may draw air 180 into an air path defined between the casing 166 and the hub 162 along the radial direction R. Further, the plurality of fan blades 164 may each be positioned and oriented on the hub 162 such that each of the plurality of fan blades 164 discharges air 182 in a direction that is substantially tangential to the first direction 170. More specifically, the direction of the discharge air may be substantially tangential to the first direction 170 in a plane that is substantially perpendicular to the axial direction A. For example, in one exemplary embodiment, the fan 160 may discharge air 182 at an angle θ greater than about forty-five (45) degrees relative to the axial direction A. More specifically, the fan 160 may discharge air 182 at an angle greater than about forty-five (45) degrees but no greater than about sixty (60) degrees relative to the axial direction A. As used herein, the term “about” means within ten percent (10%) of the stated angle when used in the context of angles. As shown in FIG. 9, the hub 162 defines a length L along the axial direction A. In some embodiments, the length L of the hub 162 is less than the span of each of the plurality of blades 164.
In general, the exemplary embodiment of the fan 160 described herein improves airflow within the shroud 122. Specifically, the orientation and position of the plurality of blades 164 on the hub 162 reduce or eliminate the amount of discharged air that flows directly out a back of the shroud relative to known heat pump water heaters. Accordingly, heat pump water heater appliances with the fan 160 can be placed closer to wall or other barriers and will consume less space in an associated room or area relative to known heat pump water heaters. In addition, heat pump water heater appliances with the fan 160 will not require the use of an auxiliary duct to redirect air emitted from the second vent 128.
This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.

Claims

What is claimed is:

1. A water heater appliance defining a vertical direction, the water heater appliance comprising:

a tank for holding water;

a shroud positioned at a top portion of the tank, the shroud defining a chamber positioned over the tank along the vertical direction, the shroud further defining a vent assembly extending through the shroud from the chamber of the shroud; and

a fan positioned within the chamber, the fan comprising a hub and a plurality of blades extending from the hub, the plurality of blades rotatable in a first direction,

wherein each of the plurality of blades is positioned and oriented on the hub such that the fan discharges air in a direction that is substantially tangential to the first direction.

2. The water heater appliance of claim 1, wherein the vent assembly includes a first vent and a second vent, the first vent defined at a top wall of the shroud, the second vent defined at a side wall of the shroud.

3. The water heater appliance of claim 2, wherein the fan is positioned adjacent the second vent such that discharged air from the fan exits the chamber through the second vent.

4. The water heater appliance of claim 2, wherein the fan is positioned between the second vent and an evaporator positioned within the chamber.

5. The water heater appliance of claim 1, wherein the fan further comprises a casing surrounding the fan blades.

6. The water heater appliance of claim 5, wherein the hub, the plurality of blades and the casing are integrally formed with one another such that all of the hub, the plurality of blades and the casing are rotatable in the first direction.

7. The water heater appliance of claim 5, wherein each of the plurality of blades define a pitch angle between seven degrees and eighteen degrees.

8. The water heater appliance of claim 5, wherein each blade of the plurality of blades is swept forward in the first direction.

9. The water heater appliance of claim 8, wherein each blade of the plurality of blades is swept such that each blade of the plurality of blades defines a leading edge and a trailing edge, the leading edge of each blade of the plurality of blades has a common chord with a respective trailing edge.

10. The water heater appliance of claim 1, wherein each blade of the plurality of blades has a first width at the hub and a second width at the casing, the second width being no less than twice the first width.

11. The water heater appliance of claim 1, wherein the hub has a length along an axial direction of the fan, and each blade of the plurality of blades defines a span along a radial direction of the fan, the length of the hub being less than the span of each of the plurality of blades.

12. A water heater appliance defining a vertical direction, the water heater appliance comprising:

a tank for holding water;

a shroud positioned at a top portion of the tank, the shroud defining a chamber positioned over the tank along the vertical direction, the shroud further defining a first vent and a second vent extending through the shroud from the chamber of the shroud;

an evaporator positioned within the chamber;

wherein each of the plurality of blades is positioned and oriented on the hub such that the fan discharges air in a direction that is substantially tangential to the first direction,

wherein the first vent is defined at a top wall of the shroud and the second vent is defined at a side wall of the shroud.

13. The water heater appliance of claim 12, wherein the fan further comprises a casing surrounding the fan blades.

14. The water heater of appliance of claim 13, wherein the hub, the plurality of blades and the casing are integrally formed with one another such that all of the hub, the plurality of blades and the casing are rotatable in the first direction.

15. The water heater appliance of claim 13, wherein each of the plurality of blades defines a pitch angle between seven and fifteen degrees.

16. The water heater appliance of claim 13, where each blade of the plurality of blades has a first width at the hub and a second width at the casing, the second width being no less than twice the first width.

17. The water heater appliance of claim 12, wherein each of the plurality of blades are spaced substantially equidistant from one another.

18. The water heater appliance of claim 12, wherein the hub has a length along an axial direction of the fan, and each blade of the plurality of blades defines a span along a radial direction of the fan, the length of the hub being less than the span of each of the plurality of blades.