WO2014097214A1

WO2014097214A1 - Water heater installation and components

Info

Publication number: WO2014097214A1
Application number: PCT/IB2013/061147
Authority: WO
Inventors: William Edwin SHAND; Roelof Mulder; Dylan Maynard COOPER
Original assignee: Conlagro Civils Cc
Priority date: 2012-12-20
Filing date: 2013-12-19
Publication date: 2014-06-26

Abstract

A water heater installation is provided in which a water heater includes a storage tank connected between a water inlet and a water outlet, a vacuum breaker valve typically associated with both the water inlet and water outlet, a shut-off valve connected to the water inlet supply line and configured to shut off a water supply to the water inlet of the storage tank upon receiving a trigger signal. At least one water sensor, and typically more, are operable to initiate a trigger signal upon detection of water leaked by any component of the installation. The installation includes a water containment arrangement that encloses the storage tank, and the vacuum breaker valves so as to obstruct any path whereby leaking water can be projected beyond the containment arrangement and wherein the containment arrangement includes a sump arranged to collect leaked water that may impinge on the containment arrangement.

Description

WATER HEATER INSTALLATION AND COMPONENTS

FIELD OF THE INVENTION

This invention relates to a water heater installation for water heaters having a hot water storage tank wherein a leak detection and automatic water shut off facility is provided. The invention also relates to components of such an installation.

BACKGROUND TO THE INVENTION

Storage tank water heaters are commonly used in residential dwellings as well as in commercial buildings. Storage tank water heaters are a popular choice where hot water is required intermittently at flow rates that are higher than can practically be achieved using tankless water heaters.

A conventional tank storage water heater typically comprises a cylindrical water tank that is configured to withstand hydrostatic pressures corresponding to those of incoming water supplies or water emanating from a pressure reducing valve. The tank is commonly manufactured from vitreous enamel-lined carbon steel, stainless steel, or copper and is fitted with a control mechanism configured to control one or more electrical resistance heating elements in contact with water inside the tank to heat it to a pre-set optionally adjustable temperature.

Consequent on the reactive nature of mains water, especially when hot, tanks may develop leaks over time and may have to be maintained and/or replaced periodically. While some leaks may manifest in a slow, gradual manner, others can manifest rapidly and result in aggressive leakage from the tank which may result in flooding of a building in which the water heater is installed.

As a result, water heater installations may include a shallow metal or plastic water collection tray, often referred to as a drip tray, fitted below the water heater to collect water when leaks occur. Water collection trays may be connected to a drain, or may be plumbed to discharge leaked water outdoors, commonly from a discharge outlet at ceiling height in the instance that a water heater is located within a roof above a ceiling. An alternative or additional precaution to reduce flood damage is to place some sort of water sensor on the floor near the water tank or in a water collection tray, possibly connected to an automatic water shutoff valve or to an alarm, or both.

Even with the precautions mentioned above in place, leakage from storage tank water heaters may still cause flooding in cases where leaks are so aggressive that an associated drip tray and discharge plumbing are not able to cope with the volumes of water leaking from the water heater. In some instances the water leaking may assume the form of a spurt, jet or spray that actually misses a water collection tray located beneath the water heater. As a water heater may be of considerable size, even with a shut-off valve secured to the inlet to the heater closed, the amount of water that may be expelled from a "burst" water heater can be sufficient to cause significant damage to property. Very often a water leak may go unnoticed for some time and considerable damage may already have been inflicted on property at the time that it is discovered.

SUMMARY OF THE INVENTION

In accordance with a first aspect of this invention there is provided a water heater installation comprising a water heater including a storage tank connected between a water inlet and a water outlet, a vacuum breaker valve associated with the water inlet or water outlet, or both; a shut-off valve connected to the water inlet supply line and configured to shut off a water supply to the water inlet of the storage tank upon receiving a trigger signal; at least one water sensor operable to initiate a trigger signal upon detection of moisture or water leaked by any component of the installation; the installation being characterised in that it includes a water containment arrangement that encloses the storage tank, and the vacuum breaker valves so as to obstruct any path whereby leaking water can be projected beyond the containment arrangement and wherein the containment arrangement includes a sump arranged to collect leaked water that may impinge on the containment arrangement.

In a first variation of the invention the containment arrangement includes an upper containment unit that covers the entire water heater tank including the usual elevated vacuum breaker valves and assumes the general form of a tent with the lower edge of the tent structure terminating in a water collection tray beneath the water storage tank. In a second variation of the invention the containment arrangement includes an upper containment unit that covers the entire water heater tank including the usual elevated vacuum breaker valves and has the lower edges of the containment arrangement joined together so that the containment arrangement envelops the entire water heater tank and associated elevated vacuum breaker valves.

In a third variation of the invention the containment arrangement includes separate containment units for each of the storage tank vacuum breaker valves with separate water sensors associated with each of the containment units.

In any of the first, second and third variations of the invention the containment arrangement preferably has opening seams releasably held in the closed condition for example by hook and loop fasteners such as that sold under the trade name VELCRO®. Alternatively, the opening seams may include inter-engaging tongues and grooves that create a generally satisfactory seal when closed such as are used on plastics ZIPLOC® bags.

In a fourth variation of the invention the containment arrangement includes an elongate band of water retaining material that can be wound around a water heater storage tank and vacuum breaker valve assembly so as to substantially totally enclosed the installation. In this instance a water sensor in the form of an exposed electrically conductive wire may be provided along the length of the elongate band that serves to function as a water sensor via a resistive or capacitive basis. In a fifth variation of the invention the containment arrangement may be a self-supporting closed housing that receives the entire water heater tank and vacuum breaker valves within its interior.

Further features of the invention provide for the installation to include a control unit to which the at least one water sensor is connected and that is connected to the shut-off valve in order to operate it by transmitting a trigger signal when the at least one water sensor is activated; for there to be multiple water sensors with a water sensor being associated with each component that is of a type having a tendency to leak; for water sensors to be associated with the storage tank, especially a sump or lower region thereof; for the shut- off valve to be an electromechanical shut-off valve configured to interrupt the water supply to the storage tank upon receiving a trigger signal from the control unit; and for the containment arrangement to be manufactured from a flexible composite sandwiched heat insulating material configured to contain water within the containment arrangement and also to limit heat transfer between the interior and exterior of the containment arrangement with the composite sandwich having an inner waterproof layer that may optionally be metalized for heat retention purposes, an intermediate heat insulating layer and an outer protective layer that may optionally be metalized for heat retention purposes. Yet further features of the invention provide for each sensor to be selected from a resistance based electrical sensor, a capacitance based electrical sensor and a mechanical sensor; for each sensor to be electrically connected to the control unit; for the control unit to be positioned either inside or outside the containment arrangement; and for the shut-off valve to be located either inside or outside the containment arrangement.

Still further features of the invention provide for the sump to be selected from a conventional water collection tray, a lower continuation of the containment arrangement and a separate flexible sump that is gathered to enclose and surround a lower periphery of an upper containment arrangement; for the water collection tray to be collapsible to the extent that an end wall or a side wall, or both may be folded to an approximately flat condition to facilitate its introduction between a water tank and a supporting structure for the water tank followed by folding any flattened end walls and sidewalls into their operative upright positions relative to a bottom to the water collection tray; and for the installation includes a superabsorbent polymer (SAP) or hydrogel for absorbing water that may leak from the storage tank or other components.

The shut-off valve may be electrically operated such as an electrically driven ball valve, a solenoid valve, or a manually charged mechanical valve in which a mechanical closure is biased towards a closed position and is held against the bias by a releasable catch that is released as a result of the action of a sensor and any control unit. In accordance of a second aspect of the invention there is provided a water collection tray for a water heater that is collapsible to the extent that an end wall or a side wall, or both may be folded to an approximately flat condition to facilitate introduction of the water collection tray between a water tank and a supporting structure for the water tank followed by folding any flattened end walls and sidewalls into their operative upright positions relative to a bottom of the water collection tray.

In order that the above and other features of the invention may be more fully understood, a more detailed description with particular reference to one embodiment of the invention will now follow with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:- Figure 1 is a generic schematic isometric view of a water heater installation to be enclosed within a containment arrangement in accordance with this invention;

Figure 2 is a block diagram of the circuit of the installation illustrated in Figure 1 ;

Figure 3 is a schematic side view of an embodiment of water heater installation according to the first variation of the invention; Figure 4 is a schematic end view of the water heater illustrated in

Figure 3;

Figure 5 is a schematic end view of an embodiment of water heater installation according to the second variation of the invention;

Figure 6 is a schematic side view of an embodiment of water heater installation according to the third variation of the invention;

Figure 7 is a schematic section through one form of flexible laminated material that is suitable for use in forming the enclosures of this invention;

Figure 8 is a schematic side view of an embodiment of water heater installation according to the fourth variation of the invention; Figure 9 is a schematic side view of an embodiment of water heater installation according to the fifth variation of the invention;

Figure 10 is a schematic side view of an embodiment of water heater installation wherein a collapsed water collection tray is being inserted between a water heater installation and a support therefor;

Figure 1 1 is a schematic plan view of one form of collapsible water collection tray;

Figure 12 is a schematic plan view of an alternative form of collapsible water collection tray; and,

Figure 13 is a schematic end view of an embodiment of the invention in which an alternative arrangement of sump is employed.

DETAILED DESCRIPTION WITH REFERENCE TO THE DRAWINGS

In all of the embodiments of the invention described in what follows, the water heater installation is described especially in one particular generic form thereof whereas it could be used in a number of different forms as will be quite apparent to those of ordinary skill in the art and as will be indicated at appropriate positions in the text.

In the instance of a water heater installation as illustrated in Figures 1 and 2, the water heater installation comprises a water heater having an externally heat insulated storage tank (1 ) connected between a water inlet (2) and a water outlet (3). The inlet is fitted with a vacuum breaker valve (4) and the water outlet is also fitted with a vacuum breaker valve (5), both of which are connected to the inlet and outlet pipes in a substantially conventional manner. It is to be noted that the description herein contained talks of a water storage tank in the sense that it is to be interpreted as meaning either a simple single walled water storage tank although it is more commonly an inner water storage tank (6) which is externally thermally insulated with a foamed insulation (7) that is in turn covered with an outer shell (8) protecting the outer surface of the insulating material. This construction is shown only in Figure 1. As the construction of the water storage tank is not of any significance to this invention it is simply described as a water storage tank (1 ) without any detail.

A water collection tray (9) is provided beneath the water storage tank, in the usual way. The water collection tray has a drainage outlet (1 1 ) that in many instances will simply deliver water at ceiling height to the outside of a house or other building in which the water heater storage tank is located in the roof space above a ceiling. The water collection tray may be provided with one or more bodies (12) of superabsorbent plastic or gel to absorb water reaching the water collection tray that serves as a sump, in this particular instance. Of course, such superabsorbent plastic or gel material may be included within the installation at any desired position both inside and outside the containment arrangement depending on the physical location of the various components.

A shut-off valve (13) is connected to the water inlet supply line and is configured to shut off a water supply to the water inlet of the storage tank upon receiving an appropriate trigger signal. As indicated above, it is expected that an electrically driven ball valve will be most appropriate as it can have two independent terminal positions, one being closed and the other being open. As an alternative, a solenoid valve may also be used.

The water inlet arrangement may also include a pressure reducing valve (14) although such a pressure reducing valve is usually employed to reduce the pressure throughout a water reticulation network or a part thereof. The water heater installation includes a control unit (15) arranged to control the shut off valve by sending out an appropriate trigger signal as may be determined according to the inputs received from multiple water sensors forming part of the installation. The multiple water sensors include one or more water sensors (16) strategically placed on the water collection tray (9) located beneath the water storage tank; one water sensor (17) associated with each of the vacuum breaker valves and a water sensor (18) associated with the shut off valve itself. There could also be a water sensor (19) associated with the control unit itself. In the event that a pressure reducing valve is present a further water sensor (20) can be included on that valve.

The water sensors may be connected to the control unit in any suitable way. The control unit itself is configured to initiate an appropriate trigger signal upon detection of moisture or water leaked by any component of the installation or any part of the installation that causes water to leak into the water collection tray. Each water sensor is selected from an electrical sensor and a mechanical sensor.

As provided by this invention, a water containment arrangement is provided in any suitable form and of which five variations are described in more detail below. The basis of the invention is that the water containment arrangement should enclose the storage tank as well as the vacuum breaker valves so as to obstruct any path whereby leaking water can be projected beyond or past the containment arrangement. The containment arrangement includes a sump that is itself arranged to collect leaked water that may impinge on the containment arrangement and that itself has a number of different configurations as will be quite apparent from what follows.

In a first variation of the invention, an embodiment of which is illustrated in Figures 3 and 4, the containment arrangement includes an upper containment unit (21 ) that covers the entire water heater tank including the elevated vacuum breaker valves and assumes the general from of a tent. The lower edge (22) of the tent structure terminates in the water collection tray beneath the water storage tank. The lower edge of the tent could simply terminate within the confines of the water collection tray or it may be gathered in under the water storage tank by means of a drawstring or the like.

In a second variation of the invention, an embodiment of which is illustrated in Figure 5, the containment arrangement includes an upper containment unit (24) that covers the entire water heater tank including the usual elevated vacuum breaker valves. However, in this instance, the lower edges of the containment unit are joined together, as indicated by numeral (25), so that the containment arrangement envelops the entire water heater tank and associated elevated vacuum breaker valves. The water containment unit may be fitted between the water heater storage tank and feet (26) on which it stands or it could be located beneath the feet.

In a third variation of the invention, an embodiment of which is illustrated in Figure 6, the containment arrangement includes a separate containment unit (28) for each of the storage tank and separate containment units (29) for each of the vacuum breaker valves. As indicated above each of the separate vacuum breaker valves has a water sensor (17) associated with it.

In each of these variations of the invention, as well as in those that follow, the containment arrangement has opening seams (31 ) (see Figure 4) held in the closed condition in a releasable manner for example by hook and loop fasteners such as that sold under the trade name VELCRO® or inter- engaging tongues and grooves that create a generally satisfactory seal when closed such as are used on plastics ZIPLOC® bags.

Also, the containment arrangement can in each instance be manufactured from a flexible composite sandwich of heat insulating material that is illustrated schematically in Figure 7 and that is configured to contain water within the containment arrangement. The containment arrangement is also preferably configured so as to limit heat transfer between the interior and exterior of the containment arrangement. The composite sandwich has an inner waterproof layer (32) that may optionally be metalized for heat retention purposes; an intermediate heat insulating layer (33) typically of foamed plastic material; and an outer protective layer (34) that may also optionally be metalized for heat retention purposes.

In a fourth variation of the invention an embodiment of which is illustrated in Figure 8, the containment arrangement includes an elongated band (36) of water retaining material that can be wound around a water heater storage tank and vacuum breaker valve assembly so as to substantially enclose the installation. In this instance a water sensor in the form of an exposed electrically conductive wire (37) may be provided along the length of the elongated band in order to serve the function of a water sensor via either a resistive or capacitive basis.

In a fifth variation of the invention an embodiment of which is illustrated in Figure 9, the containment arrangement may be a self-supporting closed housing that receives the entire water heater tank and vacuum breaker valves within its interior. In the instance of the illustrated embodiment of the invention the containment arrangement comprises a generally rigid bottom part (41 ) and a top part (42) with an overlap in a central region that causes the containment arrangement to be completely closed.

It may well happen that a water heater tank that is already installed in situ does not have a water collection tray and, in such an instance, and as shown in Figure 10, a special collapsible water collection tray (43) can be inserted between the water storage tank and a support (44) therefor with the surrounding sidewalls of the tray folded downwards to be generally flat so that it can easily be slid in between the water storage tank and the support (44).

Figure 1 1 illustrates one possibility in which a flat sheet (45) of plastic material is sulcated along lines defining side wall sections (46) and end wall sections (47) to the flat sheet so that the sidewalls can be folded up once the sheet has been installed in its operative position. Of course, a double gusset (48) will be formed at each corner and the double gusset can simply be permanently secured in this folded condition using adhesive, thermal welding, clipping or other fastening devices (not shown).

Figure 12 illustrates a second alternative in which the water collection tray is injection moulded or press moulded and is configured such that the sidewalls (51 ) can be folded inwards and down onto the bottom (52) of the water collection tray with the end walls (53) folded outwards approximately into the plane of the bottom (52). Prefabricated sulcations may be provided to enable the sidewalls and end walls to fold in this manner.

A still further sump arrangement is illustrated in Figure 13 wherein a lower region (55) of an upper containment arrangement (56) extends into a separate flexible sump (57) so that the two are overlapped. The sidewalls of the flexible sump may be gathered to enclose and surround a lower region of the upper containment arrangement. Numerous variations may be made to the embodiment of the invention described above without departing from the scope hereof, as will be quite apparent to those of ordinary skill in the art.

Claims

CLAIMS:

A water heater installation comprising a water heater including a storage tank connected between a water inlet and a water outlet; a vacuum breaker valve associated with the water inlet or water outlet, or both; a shut-off valve connected to the water inlet supply line and configured to shut off a water supply to the water inlet of the storage tank upon receiving a trigger signal; at least one water sensor operable to initiate a trigger signal upon detection of moisture or water leaked by any component of the installation; the installation being characterised in that it includes a water containment arrangement that encloses the storage tank, and the vacuum breaker valves so as to obstruct any path whereby leaking water can be projected beyond the containment arrangement and wherein the containment arrangement includes a sump arranged to collect leaked water that may impinge on the containment arrangement.

A water heater installation as claimed in claim 1 in which the containment arrangement includes an upper containment unit that covers the entire water heater tank including the elevated vacuum breaker valves and assumes the general from of a tent with the lower edge of the tent structure terminating in a water collection tray beneath the water storage tank.

A water heater installation as claimed in claim 1 in which the containment arrangement includes an upper containment unit that covers the entire water heater tank including the elevated vacuum breaker valves and wherein the lower edges of the containment arrangement are joined together so that the containment arrangement envelops the entire water heater tank and associated elevated vacuum breaker valves.

4. A water heater installation as claimed in claim 1 in which the containment arrangement includes separate containment units for each of the storage tank and vacuum breaker valves with separate water sensors being associated with each of the containment units.

5. A water heater installation as claimed in any one of claims 1 to 4 in which the containment arrangement has opening seams held in the closed condition in a releasable manner. 6. A water heater installation as claimed in claim 1 in which the containment arrangement includes an elongated band of water retaining material that is wound around a water heater storage tank and vacuum breaker valve assembly so as to substantially totally enclose the installation wherein a water sensor includes an exposed electrically conductive wire provided along the length of the elongated band and serving the function of a water sensor via a resistive or capacitive basis.

7. A water heater installation as claimed in claim 1 in which the containment arrangement is a self-supporting closed housing that receives the entire water heater tank and vacuum breaker valves within its interior.

8. A water heater installation as claimed in any one of the preceding claims in which the installation includes a control unit to which at least one water sensor is connected and that is connected to the shut-off valve in order to operate it by transmitting a trigger signal when at least one water sensor is activated. 9. A water heater installation as claimed in any one of the preceding claims in which there are multiple water sensors with a water sensor being associated with each component that is of a type having a tendency to leak together with at least one water sensor associated with the storage tank or sump.

10. A water heater installation as claimed in any one of the preceding claims in which the shut-off valve is an electromechanical shut-off valve configured to interrupt the water supply to the storage tank upon receiving a trigger signal from a control unit included in the installation.

1 1 . A water heater installation as claimed in any one of the preceding claims in which the containment arrangement is manufactured from a flexible composite sandwich heat insulating material configured to contain water within the containment arrangement and also to limit heat transfer between the interior and exterior of the containment arrangement with the composite sandwich having an inner waterproof layer, an intermediate heat insulating layer and an outer protective layer.

12. A water heater installation as claimed in any one of the preceding claims in which each sensor is selected from an electrical sensor and a mechanical sensor.

13. A water heater installation as claimed in any one of the preceding claims in which the sump is selected from a conventional water collection tray, a lower continuation of the containment arrangement and a separate flexible sump that is gathered to enclose and surround a lower periphery of an upper containment arrangement.

14. A water heater installation as claimed in any one of the preceding claims in which the water collection tray is collapsible to the extent that an end wall or a side wall, or both may be folded to an approximately flat condition to facilitate its introduction between a water tank and a supporting structure followed by returning any flattened end walls and sidewalls to their operative upright positions relative to a bottom to the water collection tray.

A water heater installation as claimed in any one of the preceding claims in which the installation includes a superabsorbent polymer (SAP) or hydrogel for absorbing water that may leak from the storage tank or other components.