WO2020198782A1

WO2020198782A1 - An improved water heater cover assembly

Info

Publication number: WO2020198782A1
Application number: PCT/AU2020/050271
Authority: WO
Inventors: Brendan Bourke; Dean Clift; Ritesh BANKAPUR
Original assignee: Rheem Australia Pty Limited
Priority date: 2019-03-29
Filing date: 2020-03-20
Publication date: 2020-10-08
Also published as: AU2020252965A1

Abstract

A cover assembly (10) for a water heater (100). The cover assembly (10) includes an inner cover (12) and an outer cover (14). Each of the inner cover (12) and outer cover (14) has a cover portion (12.1, 14.1) and a skirt (12.2, 14.2) surrounding the cover portion (12.1, 14.1). A space (16) is defined between the inner cover (12) and outer cover (14) when assembled. At least one radiation shield (18) is included on at least one side of one or both of the inner cover (12) and the outer cover (14).

Description

An Improved Water Heater Cover Assembly

Field of the invention

[001 ] The present invention relates to water heaters and in particular to capping systems to cover fittings and components and to reduce heat loss from the tank through such fittings and components.

Background of the invention

[002] Various standards relating to water heaters proscribe the maximum heat loss allowance for domestic electric water heaters. These minimum energy performance standard requirements or (MEPS) may be reduced under government legislation. To meet new lower MEPS target, water heaters may require a more thermally efficient operation and this would result in an increase in manufacturing cost. Thus there is a need to identify and develop low cost heat loss reduction strategies and solutions.

[003] Any reference herein to known prior art does not, unless the contrary indication appears, constitute an admission that such prior art is commonly known by those skilled in the art to which the invention relates, at the priority date of this application.

Summary of the invention

[004] The present invention provides a water heater cover assembly having an inner cover and an outer cover, each cover having a cover portion and a skirt surrounding the cover portion, the inner cover and outer cover includes a space therebetween when the inner and outer cover are assembled or formed, the inner cover and or the outer cover including, on at least one side thereof, at least one radiation shield.

[005] The at least one radiation shield can be applied as a coating or a covering.

[006] The inner and outer cover can be manufactured separately and secured together, or are integrally formed together.

[007] The at least one radiation shield can be located between the inner and outer covers.

[008] The at least one radiation shield can be located adjacent to and or on the inner cover.

[009] The at least one radiation shield can be formed from aluminium, copper, or alloys thereof, and or polished aluminium, copper or alloys thereof, or combinations thereof if multiple radiation shields are present.. [010] The at least one radiation shield can be adhered to the cover.

[011] The at least one radiation shield can be made up of at least one panel of shield material which is or are to be located adjacent to the cover portion, and can be there secured in place by means of an adhesive coated shield material which will cover the skirt.

[012] The inner and outer cover can be manufactured from a polymeric material.

[013] The space between the inner cover and the outer cover can be substantially sealed.

[014] The cover assembly can be formed from a three dimensional printing process whereby the inner cover and outer cover are integrally formed. In this arrangement the at least one radiation shield can be located on a surface of the inner cover which is not between the inner cover and outer cover.

[015] The present invention also provides a water heater having a water heater cover assembly as described above.

[016] The cover assembly can be removeable from said water heater, thereby allowing access to service or repair water heater components under said cover assembly

Brief description of the drawings

[017] An embodiment or embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

[018] Figure 1 is an exploded perspective view of the components of a water heater assembly which includes a cover assembly at one tank end;

[019] Figure 2 is an enlarged view of the cover assembly of Figure 1 ;

[020] Figure 3 is an exploded view of the cover assembly with only the parts thereof, from a reverse location to the view of Figure 2;

[021] Figure 4 is an underside view of the outer cover of the cover assembly;

[022] Figure 5 is a left side view of the outer cover of Figure 4;

[023] Figure 6 is a plan view of the outer cover of Figures 4 and 5;

[024] Figure 7 is a cross section through the line A-A of Figure 4;

[025] Figure 8 is front elevation of the outer cover of Figure 4;

[026] Figure 9 is a cross section through the line B-B of Figure 4;

[027] Figure 10 is a cross section through the line C-C of Figure 4;

[028] [029] Figure 11 is a cross section through the line D-D of Figure 4;

[030]

[031] Figure 12 is a cross section through the line E-E of Figure 4;

[032] Figure 13 is a plan view of an inner cover;

[033] Figure 14 is a left side view of the inner cover of Figure 13;

[034] Figure 15 is an underneath view of the inner cover of Figure 13;

[035] Figure 16 is an inner perspective view of the inner cover of Figure 13.

[036] Figure 17 is a cross section through the line B-B of Figure 13;

[037] Figure 18 is a cross section through the line A-A of Figure 13;

[038] Figure 19 is a front elevation of the inner cover of Figure 13;

[039] Figure 20 is a plan view of an assembled cover assembly;

[040] Figure 21 is cross section through the assembled cover assembly of Figure 20 through the line B-B;

[041] Figure 22 is an enlarged view of the cross section of Figure 21 , in the region of circle C in Figure 21 ;

[042] Figure 23 is a plan view of an alternative cover assembly;

[043] Figure 24 is cross section through the assembled cover assembly of Figure 23 through the line D-D;

[044] Figure 25 is an enlarged view of the cross section of Figure 24, in the region of circle E in Figure 24;

[045] Figure 26 is a plan view of another alternative cover assembly;

[046] Figure 27 is cross section through the assembled cover assembly of Figure 26 through the line F-F;

[047] Figure 28 is an enlarged view of the cross section of Figure 27, in the region of circle G in Figure

Detailed description of the embodiment or embodiments

[048] Illustrated in Figure 1 is a water heater 100 which has a cover assembly 10 at one end of an outer jacket assembly which includes a cylindrical outer jacket 100.1 , a generally circular right side end cover 100.3 and a generally circular left side end cover 100.4. The water heater 100 is adapted for mounting in a generally horizontal condition to the roof side of ceiling joists or to the outside of angled rafters of a roof. To assist in this a mounting plate 100.6 is first secured to the outer jacket 100.1 of the water heater 100 by blind rivets during production. Then, at installation on site, the mounting plate 100.6 is secured to the joists or rafters or other building structure by means of an external frame (not illustrated) which will thus secure the water heater in-situ.

[049] The outer jacket 100.1 surrounds an inner cylindrical tank 100.2, which has a plus end 100.200 and a plus end 100.201. The end 100.200 includes outlet fittings 100.23 and 100.24, and an anode fitting 100.27 and an electric element mounting fitting 100.22 and a thermostat mount 100.21.

[050] The end 100.200 is covered by a generally circular insulation piece 100.5 which has a shaped aperture 100.51 which is of shape to accommodate the anode fitting 100.27 and the electric element mounting fitting 100.22 and a thermostat mount 100.21. The circular outer perimeter of the piece 100.5 provides a thermal seal with the inner surface of the outer jacket 100.1. The insulation piece 100.5 sits between the cover end 100.4 and the tank end 100.200, and the cover 100.4 includes a similarly shaped aperture 100.41 , which will overlie the aperture 100.51. The cover assembly 10 is shaped so as to match the apertures 100.41 and 100.51. The cover assembly 10 is provided so as to reduce the thermal losses which would otherwise occur through the anode fitting 100.27 and the element fitting 100.22.

[051] Illustrated in Figures 1 to 28 is a water heater cover assembly 10 which can be generally described as having an inner cover 12 and an outer cover 14, each cover 12 and 14 having a cover portion 12.1 , 14.1 respectively and a skirt 12.2, 14.2 respectively, surrounding the cover portion 12.1 , 14.1. The inner cover 12 and outer cover 14 includes a space 16 between them, when the inner cover 12 and outer cover 14 are assembled or formed. The inner cover 12 and or the outer cover 14 including, on at least one side thereof, a radiation shield 18. It will be understood that more than one radiation shield 18 can be assembled in the assembly. But for the sake of efficiency the following description will refer to a single radiation shield 18.

[052] The radiation shield 18 is applied as a coating or a covering. Most preferably, for assisting to keep costs to a minimum, the radiation shield 18 is made from polished aluminium foil and polished aluminium adhesive tape, as will be described in more detail below.

[053] The inner cover 12 and outer cover 14 are manufactured separately and secured or assembled together. With the advent of 3D printing and other depositing processes, the inner and outer covers can also be integrally formed together.

[054] The radiation shield 18 is most preferred to be located between the inner and outer covers.

[055] The radiation shield 18 as illustrated in Figures 20 to 22 is shown to be located adjacent to and or on the inner cover 12, on the side which faces the outer cover 14. Whereas in Figures 26 to 28 the radiation shield 18 is shown to be located adjacent to and or on the inner cover 12, on the side which is inboard of the outer cover 14 or adjacent the water tank, or on the side of the inner cover 12, which is the opposite side to that covered in Figures 20 to 22. Whereas in Figures 23 to 25, the radiation shield 18 is arranged on the outer cover 14, on an inboard surface thereof, which is on one side of the space 16 opposite to inner cover 12.

[056] The radiation shield 18 is preferably formed from aluminium or alloys thereof, or it could be made from copper, or alloys thereof, or similar material which can act as a radiation shield. Another appropriate material is polished aluminium, polished copper or polished alloys thereof.

[057] In order to keep manufacturing costs to a minimum, it is expected that the most cost effective manner to produce the radiation shield 18 and to assemble it to one or both of the inner cover 12 and or outer cover 14 is to adhere the reflective material to the cover 12, 14. The most effective way to do this is to have a cover shield 18.1 made from reflective aluminium foil, and this is secured to the cover portion 12.1 and or 14.1 by means of applying a surrounding band of reflective aluminium tape to form the skirt portion 18.2, which overlaps the cover portion 12.1 and or 14.1 and thus secures same in position to the cover portion 12.1 and or 14.1 via the respective skirts 12.2 and 14.2.

[058] The radiation shield 18, by being be made up of a cover panel 18.1 of shield material which is located adjacent to one or both cover portions 12.1 and or 14.1 , and securing it in place by means of an adhesive coated shield material 18.2 which will cover the skirts 12.2 and or 14.2, and by manufacturing the covers 12 and 14 from black UV stable polypropylene, a cost effective, and thermally efficient cover arrangement is produced which will result in low thermal losses, which are suited to a storage water heater. The cover assembly 10 will operate on the heat transfer principle that air has a very low thermal conductivity. The cover assembly 10 will limit convection (air circulation) and the presence of radiation barrier or shield 18 results in measurable heat loss reduction which saves energy in operation of the water heater.

[059] The black UV stable polypropylene was chosen due to it being a relatively cheap material, which is easily moulded, readily available, and has good UV resistance and good heat resistance.

[060] While black UV stable polypropylene is preferred, the inner cover 12 and outer cover 14 can be manufactured from a different polymeric material, which can have similar properties to those identified as being preferred.

[061] The space 16 between the inner cover 12 and the outer cover 14 are respectively shaped so that when they are assembled, they will be substantially sealed. The expression “substantially sealed” is used because the join and or contact between the inner cover 12 and outer cover 14 need not be airtight, as airtight generally implies greater manufacturing costs. The expression“substantially sealed” is more directed to there being a minimisation of the amount of convection or air circulation that will occur in use.

[062] The cover assembly 10 can be formed from a three dimensional printing process whereby the inner cover 12 and outer cover 14 are integrally formed. In this arrangement the radiation shield 18 can most easily be located on a surface of the inner cover 12 which is not between the inner cover 12 and outer cover 14. However, if the material deposition process or 3D printing process will allow a radiation shield material to be deposited to one or both of the surfaces on the covers which envelop the space 16, then an effective cover assembly 10 is expected to be able to be produced.

[063] To form the radiation shield 18 on to the inner cover 12 and or outer cover 14, alternative processes can be, but are thought to be currently more expensive than the above preferred method. One such process would be to coat or paint the selected inner cover and or outer cover surfaces with a radiation shield coating or paint. Another would be to co-mould or over mould a reflective polymer surface to the inner and or outer cover.

[064] Another method to produce the cover assembly 10, would be to manufacture the inner cover 12 and or outer cover 14 from a polymeric material, which is also actually a radiation shielding polymer, but this is expected to be quite expensive.

[065] The cover assembly 10 as best illustrated in Figures 3 and Figures 20 to 22 shows the outer cover 14 having the cover portion 14.1 and skirt 14.2 which surrounds the cover portion 14.1. The distal end of the skirt 14.2 terminates in an outwardly directed mounting flange 14.21 which peripherally surrounds the skirt 14.2. The flange 14.21 is not of constant width, so as to accommodate other fittings and formations related to the water heater.

[066] Through the flange 14.21 is a drainage aperture 14.21 1 , which is designed, when mounted to the water heater, and the water heater mounted to a roof, to be opening in a generally vertically downward direction. This ensures the skirt 14.2 in the vicinity of the drainage aperture 14.211 directs any condensation towards the drainage aperture for it to exit. The condensation can occur because the construction of cover assembly is not airtight between the points or lines of contact between inner cover 12 and outer cover 14. This means that with temperature variations water can sometimes condense.

[067] As is visible in the perspective view of Figure 3, the outer cover 14 has on its inboard side (relative to the tank 100.2) includes five raised screw receiving mounts 14.3 which are dimensioned to a height or distance of approx. 5mm from the level of the inner surface of cover portion 14.1 to the extremity of the mounts 14.3 into which is received a respective screw 14.31 as best seen in the cross section of Figure 22. [068] The shape of the cover assembly 10, and thus of each of the covers 12 and 14, can be generally described as an irregular pentagon, with a screw mount 14.3 located at each of the five apexes of the cover 14.1 , as is best viewed in Figure 20.

[069] As best seen in Figure 16, the inner cover 12 has five through holes 12.31 through the cover portion 12.1 so as to receive the screws 14.31 to thereby mount the cover 12 to the cover 14, and in so doing creates space 16 of approximately 5mm between the respective cover portions 12.1 and 14.1. The inner cover 12 also has the skirt 12.2 surrounding the cover portion 12.1 and a spacing flange 12.21 which extends away front the skirt 12.2. The skirt 12.2 also includes in one of it’s sides, a step change or cutaway formation 12.21 1 which is provided to allow for the fitment of the cover assembly 10 to the tank of the water heater to provide clearance for the thermostat and cable connections.

[070] The flange 12.21 is of approximately 5mm in depth, and as is best illustrated in the enlarged cross section of Figure 25, so that the outer wall of the skirt 12.2 will be spaced approx. 5mm from the inside wall of the outer cover 14 when the two covers 12 and 14 are assembled, so that the space 16 will have a shape which is similar in overall shape to that of the covers 12 and 14, as it is bounded by the respective surfaces thereof.

[071] The offset 14.33 in flange 14.21 of outer cover 14 as shown in Figure 5 and Figure

12 is used to ensure that the upper portions of the cover assembly 10 slide behind the side circular cover 100.4 and the lower portions of the cover assembly 10 are on the outside of side circular cover 100.4. This is done to ensure water ingress is minimised which may be due to atmospheric conditions enabling water precipitation. When assembling a water heater 100, all the components in Figure 1 , except those relating to the cover assembly 10 will be first assembled. Then cover assembly 10, having been pre-assembled or formed, by means of self-tapping screws and a series of six mounting apertures 14.5 located at spaced locations on the flange 14.21 , is secured to the left side cover 100.4. This ensures that service personnel are able to remove the cover assembly 10 where installed and make repairs to, or replace, the componentry, that the cover assembly 10 overlies. In the case of the above, this will include such componentry as the anode at fitting 100.27 the electric element at fitting 100.22 and the thermostat at mount 100.21. Once serviced or replace then the service personnel will replace the cover assembly 10.

[072] As explained earlier, it will be readily understood that multiple radiation shields 18 can be a part of the cover assembly 10, whether they are applied in the same location or surface of the cover assembly 10, or at different locations on the assembly 10 and its respective covers and their surfaces. [073] While a pentagonal shape is provided for the cover assembly 10 as described herein, it will be understood that any shape appropriate to cover the components which are located proud of the tank end 100.200 can be utilised.

[074] Another way to manufacture the cover assembly 10 is to replace or substitute the inner cover 12 made of polypropylene, with one made from aluminium foil. This can provide some benefits, but additional insulation benefits would be achieved if the non-tank side were coated or painted with a heat insulative coating or material such as those that are generally available under the brand MASCOAT.

[075] Where ever it is used, the word“comprising” is to be understood in its“open” sense, that is, in the sense of “including”, and thus not limited to its“closed” sense, that is the sense of “consisting only of”. A corresponding meaning is to be attributed to the corresponding words“comprise”,“comprised” and“comprises” where they appear.

[076] It will be understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text. All of these different combinations constitute various alternative aspects of the invention.

[077] While particular embodiments of this invention have been described, it will be evident to those skilled in the art that the present invention may be embodied in other specific forms without departing from the essential characteristics thereof. The present embodiments and examples are therefore to be considered in all respects as illustrative and not restrictive, and all modifications which would be obvious to those skilled in the art are therefore intended to be embraced therein.

Claims

1. A water heater cover assembly having an inner cover and an outer cover, each cover having a cover portion and a skirt surrounding said cover portion, said inner cover and outer cover includes a space therebetween when said inner and outer cover are assembled, said inner cover and or said outer cover including, on at least one side thereof, at least one radiation shield.

2. A water heater cover assembly wherein said at least one radiation shield is applied as one or more coatings or a coverings.

3. A water heater cover assembly as claimed in claim 1 or 2, wherein said inner and outer cover are manufactured separately and secured together, or are integrally formed together.

4. A water heater cover assembly as claimed in any one of claims 1 to 3, wherein said at least one radiation shield is located between said inner and outer covers.

5. A water heater cover assembly as claimed in claim 1 to 4, wherein said at least one radiation shield is located adjacent to and or on said inner cover.

6. A water heater cover assembly as claimed in any one of claims 1 to 5, wherein said at least one radiation shield is formed from aluminium, copper, or alloys thereof, and or polished aluminium, copper or alloys thereof; or combinations thereof if multiple radiation shields are present.

7. A water heater cover assembly as claimed in any one of claims 1 to 6, wherein said at least one radiation shield is adhered to said cover.

8. A water heater cover assembly as claimed in any one of claims 1 to 7, wherein said at least one radiation shield is made up of at least one panel of shield material which is to be located adjacent to said cover portion, and is there secured in place by means of an adhesive coated shield material which will cover said skirt.

9. A water heater cover assembly as claimed in any one of claims 1 to 8, wherein said inner and outer cover are manufactured from a polymeric material.

10. A water heater cover assembly as claimed in any one of claims 1 to 9, wherein said space between said inner cover and said outer cover is substantially sealed.

11. A water heater cover assembly as claimed in any one of claims 1 to 3, wherein said cover assembly is formed from a three dimensional printing process whereby said inner cover and outer cover are integrally formed.

12. A water heater cover assembly as claimed in claim 11 , wherein said at least one radiation shield is located on a surface of said inner cover which is not between said inner cover and outer cover.

13. A water heater having a water heater cover assembly as claimed in any one of claims 1 to 12.

14. A water heater as claimed in claim 13, wherein said cover assembly is removeable from said water heater, thereby allowing access to service , repair or replace components under said cover assembly.