Air Funnel for a Heat Pump System of a Water Heater

This application claims priority to and the benefit under 35 U.S.C. § 119(e) of U.S. Provisional Patent Application No. 63/568,486, filed Mar. 22, 2024, entitled AIR FUNNEL FOR A HEAT PUMP SYSTEM OF A WATER HEATER, the entire disclosure of which is hereby incorporated herein by reference.

The present disclosure generally relates to a heat pump system for a water heater, and more specifically, to an air funnel for directing a flow of process air through a heat exchanger of a heat pump system.

Water heaters are utilized for transferring heat into a reservoir of water for delivery throughout a structure. Certain water heaters utilize a heat pump system that utilizes a thermal exchange media for transferring heat between an evaporating device that absorbs heat from the surrounding area and to a condensing device which rejects heat into the water being heated. Blowers are typically utilized for producing an airflow through portions of the heat pump system.

According to one aspect of the present disclosure, a water heater includes a heat exchanger that absorbs heat from process air for delivery into a heat exchange media and that has an outer perimeter that defines a first dimension, a blower that selectively draws the process air through the heat exchanger, and a funnel that extends between the outer perimeter of the heat exchanger and the blower. The funnel includes a rounded port proximate the blower. The rounded port has an inner perimeter that defines a second dimension which is smaller than the first dimension. The funnel has an inner surface that maintains an air pressure of the process air to be generally consistent within the heat exchanger. A portion of the funnel forms a portion of a blower housing for the blower.

According to another aspect of the present disclosure, an airflow system for a water heater includes a heat exchanger that draws heat from process air and delivers the heat to a heat exchange media. The heat exchanger has a rectilinear cross-section defining a first area. The airflow system also includes a blower that delivers the process air through the heat exchanger. The airflow system further includes a funnel that directs the process air from the heat exchanger to the blower. The funnel manages an air pressure of the process air to be consistent within the heat exchanger, and the funnel regulates the air pressure of the process air to decrease evenly and consistently between a downstream surface of the heat exchanger and an outlet port that directs the process air into the blower. The outlet port has an inner perimeter that defines a second area that is smaller than the first area. The funnel includes a concave portion that is downstream of the heat exchanger and a convex portion that is downstream of the concave portion. The convex portion extends from the concave portion to the outlet port.

According to yet another aspect of the present disclosure, a heat pump system for a water heater includes an evaporator that draws heat from process air and delivers the heat to a heat exchange media. The evaporator has a generally rectilinear cross-section that defines a first area. The heat pump system also includes a blower that delivers the process air through the evaporator. The heat pump system further includes a funnel that at least partially surrounds an outer edge of the evaporator and includes a circular port that directs the process air from the evaporator to the blower. The circular port defines an inner perimeter that defines a second area which is smaller than the first area. The funnel manages an air velocity of the process air to be even and consistent within the evaporator. The funnel further regulates the air velocity of the process air to define a consistent increase as the process air moves between a downstream surface of the evaporator and the circular port.

These and other features, advantages, and objects of the present disclosure will be further understood and appreciated by those skilled in the art by reference to the following specification, claims, and appended drawings.

The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles described herein.

As required, detailed embodiments of the present disclosure are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to a detailed design; some schematics may be exaggerated or minimized to show function overview. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.

For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the concepts as oriented in. However, it is to be understood that the concepts may assume various alternative orientations, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.

The present illustrated embodiments reside primarily in combinations of method steps and apparatus components related to apparatus components related to an air funnel for a heat pump system that extends between a heat exchanger and a blower for generating a converging flow of process air through the air funnel and contemporaneously maintaining a consistent and even air pressure and air velocity of the process air as it moves through the heat exchanger and converges into a port of the air funnel for directing the process air into the blower for the heat pump system. Accordingly, the apparatus components and method steps have been represented, where appropriate, by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein. Further, like numerals in the description and drawings represent like elements.

As used herein, the term “and/or,” when used in a list of two or more items, means that any one of the listed items can be employed by itself, or any combination of two or more of the listed items, can be employed. For example, if a composition is described as containing components A, B, and/or C, the composition can contain A alone; B alone; C alone; A and B in combination; A and C in combination; B and C in combination; or A, B, and C in combination.

In this document, relational terms, such as “first” and “second,” “top” and “bottom,” and the like, are used solely to distinguish one entity or action from another entity or action, without necessarily requiring or implying any actual such relationship or order between such entities or actions. The terms “comprises,” “comprising,” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element preceded by “comprises . . . a” does not, without more constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises the element.

As used herein, the term “about” means that amounts, sizes, formulations, parameters, and other quantities and characteristics are not and need not be exact, but may be approximate and/or larger or smaller, as desired, reflecting tolerances, conversion factors, rounding off, measurement error and the like, and other factors known to those of skill in the art. When the term “about” is used in describing a value or an end-point of a range, the disclosure should be understood to include the specific value or end-point referred to. Whether or not a numerical value or end-point of a range in the specification recites “about,” the numerical value or end-point of a range is intended to include two embodiments: one modified by “about,” and one not modified by “about.” It will be further understood that the end-points of each of the ranges are significant both in relation to the other end-point, and independently of the other end-point.

The terms “substantial,” “substantially,” and variations thereof as used herein are intended to note that a described feature is equal or approximately equal to a value or description. For example, a “substantially planar” surface is intended to denote a surface that is planar or approximately planar. Moreover, “substantially” is intended to denote that two values are equal or approximately equal. In some embodiments, “substantially” may denote values within about 10% of each other, such as within about 5% of each other, or within about 2% of each other.

As used herein the terms “the,” “a,” or “an,” mean “at least one,” and should not be limited to “only one” unless explicitly indicated to the contrary. Thus, for example, reference to “a component” includes embodiments having two or more such components unless the context clearly indicates otherwise.

Referring to, reference numeralgenerally designates a heat pump system incorporated within a water heater, where the heat pump systemutilizes a heat exchange mediafor transferring heatcollected within an evaporatorand into waterthat is to be heated. The heat pump systemcan be utilized within a tank-type water heater, or within a tankless-type water heater. Additionally, certain hybrid configurations of water heaterscan utilize the heat pump systemthat may include a reservoirof heated water, as well as a tankless-component of a water heater.

As exemplified in, the water heatercan include the heat pump systemthat includes a heat exchanger, typically an evaporator, for absorbing heatfrom process air. The heatextracted by the heat exchangeris delivered into a heat exchange media. The evaporatorincludes an outer perimeterthat defines a first dimension. A blowerselectively draws the process airthrough the heat exchanger. The bloweroperates to move the process airthrough the heat exchanger. An air funnelextends between the outer perimeterof the heat exchangerand the blower. The air funnelincludes a rounded outlet porthaving an inner perimeterthat defines a second dimension. The second dimensionis smaller than the first dimension. In this manner, the air funnelprovides for a convergingof the flowof process airleaving the heat exchangerand moving through the outlet portof the air funneland into the blower. The air funnelincludes an inner surfacethat maintains an air pressureof the process airto be generally consistent within the heat exchanger. Typically, the heat exchangerincludes a rectilinear shape and the outlet portincludes a generally rounded, and typically circular, configuration. Accordingly, the air funnelmanipulates the flowof process airto converge from the larger size of the rectangular heat exchangerinto the smaller generally circular shape of the outlet port.

According to the various aspects of the device, as exemplified in, the air funnelis configured to maintain a consistent air pressureand air velocitywithin the heat exchanger. Therefore, to maximize the capture of heatfrom within the heat exchanger, the consistent movement of process airthroughout the entirety of the heat exchangerserves to increase the efficiency of the heat pump systemdelivering heatinto the waterto be heated. The air funnel, as will be described more fully below, includes a series of sections that operate sequentially to maintain the substantially consistent air pressurewithin the heat exchanger, and to also maintain a substantially consistent decline of air pressureof the process airas it moves between a downstream surfaceof the heat exchangerand through the outlet portof the air funneland into the blower. Accordingly, the process airmoving between an upstream surfaceof the heat exchangerand the downstream surfaceof the heat exchangermaintains a consistent and even air pressureand air velocity. This configuration minimizes the occurrence of a pressure drop of the process airwithin the heat exchanger. In this manner, the entirety of the heat exchangeris utilized for transferring heatfrom the process airand into a heat exchange mediamoving through the evaporatorof the heat pump system.

Referring again to, the heat exchangerincludes an outer housingthat encloses the various components of the water heater. As exemplified in, the water heaterincludes an upper housingthat encloses components of the heat pump system. The outer housingalso includes a lower housingthat encloses a reservoirfor storing waterand maintaining the temperature of the heated water. The upper housingof the water heaterincludes an air inletand an air outletthat are each positioned, typically, within a top wallof the upper housing. These apertures provide for the expedient movement of process airthrough the upper housingto be acted upon by the evaporatorof the heat pump system.

Referring now to, the heat pump systemincludes the evaporatorthat receives a heat exchange mediatypically from an expansion device. The heat exchange medialeaving the evaporatoris heated and is directed to a compressor. The heat exchange medialeaving the compressoris pressurized and heated and typically in the form of a gas. This form of the heat exchange mediais then directed to a condensing portionof the heat pump systemwhere heatis rejected into a separate media. In the case of the water heater, the condensing portionis typically in the form of the reservoirof waterto be heated, or a conduit of waterthat is heated as it moves through the condensing portionof the heat pump system. After leaving the condensing portionof the heat pump system, the heat exchange mediais delivered to the expansion devicewhere the heat exchange mediais now cooled in liquid form. This cooled liquid form of the heat exchange mediais then delivered to the evaporatorof the heat pump systemto receive additional amounts of heatthat can then be transferred to the condensing portionof the heat pump system. This process continues to move heatfrom the process airto the waterwithin the reservoir.

Typically, the compressor, evaporator, and expansion deviceare located within the upper housingof the water heater. The condensing portionof the heat pump systemis located in the lower housingproximate the reservoirof waterto be heated. Other locations of these components are also contemplated.

Referring now to, the evaporatorof the heat pump systemis positioned adjacent to the blowersuch that process aircan move through the evaporator. In this configuration, heatis extracted from the process airand delivered into the heat exchange mediamoving through the evaporator. The even movement of process airthrough the evaporator, which is generated by the air funnel, ensures that the process airmoves through the evaporatorin an even and consistent rate. In this manner, a maximum amount of heatcan be extracted from the process airand delivered into the heat exchange media.

It is contemplated that the heat exchange mediacan be in the form of a refrigerant, water, air, glycol, and other similar substances that are effective at absorbing and releasing heatwithin a heat pump system.

Referring now to, the air funnelthat is attached to the evaporatorincludes a transition sectionthat engages the heat exchanger. This transition sectionincludes a pressure maintenance portionand a pressure regulation portion. The pressure maintenance portionof the air funnelis positioned around the heat exchangersuch that the pressure maintenance portionoperates to maintain the air pressureand air velocityof the process airmoving through the heat exchangerto be at a consistent rate. The pressure regulation portionof the transition sectionoperates on the process airto manage the transfer of the process airbetween the downstream surfaceof the heat exchangerand the outlet portthat leads into the blower. The geometry of this pressure regulation portionof the air funnelcollects the flowof process airand generates a consistent and even decrease in air pressure, as well as a consistent and even increase in air velocity, of the process air. This phenomena is commonly referred to as a Venturi effect that is caused by a narrowing of a flow of a media moving through a space. The pressure regulation portionof the air funnelmanages the Venturi effect to ensure that as the process airmoves through the pressure regulation portion, each section of the flowof process airexperiences a similar decrease in air pressureand increase in air velocityas it approaches the outlet port.

Referring again to, the air funnelalso includes a converging sectionthat forms the rounded outlet portthat directs the process airinto the blower. This converging sectionof the air funneldirects the process airfrom the transition sectionand into the inner perimeterof the outlet port. Once through the outlet port, the process airis moved by the blowerthrough the air outletand out of the upper housing.

Referring again to, the pressure maintenance portionof the air funnelextends across the depthof the heat exchangerbetween the upstream surfaceof the heat exchangerand the downstream surfaceof the heat exchanger. It is contemplated that this pressure maintenance portionis substantially rectangular to match the profile of the heat exchanger. In certain aspects of the device, the pressure maintenance portioncan also extend at least partially into the space of the air funnelthat is immediately adjacent to the downstream surfaceof the heat exchanger. This pressure maintenance portionof the air funnelis typically defined by a flangeof the air funnelthat engages the rectangular outer edgeof the heat exchanger. This flangecan engage a single surface to the heat exchanger. Additionally, the flangecan extend around multiple surfaces of the outer edgeof the heat exchangerto encircle a portion of the heat exchangeror the entirety of the outer edgeof the heat exchanger. The flangeof the pressure maintenance portionoperates to secure the air funnelto the heat exchangerwhile also providing a guide through which the process airis directed through the heat exchangerat a consistent and even air pressureand air velocity.

The pressure regulation portionof the air funnelincludes a concave portionthat is positioned immediately adjacent to the downstream surfaceof the heat exchanger. This pressure regulation portionincludes a cross-sectional profile that is generally in the shape of a parabolic arc that proceeds from the rectangular downstream surfaceof the heat exchangerand toward the circular converging sectionof the air funnel. This parabolic curvature of the pressure regulation portionoperates to gradually and evenly decrease the air pressureof the process air, thereby managing the Venturi effect within the air funnel. Additionally, the pressure regulation portionmanipulates the flowof process airbetween the rectangular configuration of the heat exchangerand the round configuration of the converging section.

By managing the Venturi effect, sections of the flowof process airare prevented from moving at a greatly accelerated rate or decelerated rate, relative to adjacent portions of the flowof process air. Undesirable isolated changes in air pressureand air velocitymay result in a section of the process airthat experiences a pressure drop. These sections of pressure drop within the process aircan have impact upstream that may result in an uneven flowof process airthrough the heat exchanger.

Referring again to, the pressure regulation portionof the transition sectionmoves into the converging sectionof the air funneland transitions from the concave portionof the air funnelto a convex portionof the air funnelhaving a convex curvature. This convex portionof the converging sectionof the air funnelfurther directs the flowof process airthrough the outlet portand into the blower. Again, this transition of the air funnelbetween the pressure regulation portionand converging sectionof the air funnelmaintains a consistent and even decrease of air pressure, as well as a consistent and even increase in air velocityas the flowof process airmoves through the outlet portand into the blower housing.

In certain aspects of the device, the converging sectionof the air funnelcan be positioned in an eccentric position with respect to the transition section. Stated another way, the converging sectionand the outlet portcan be positioned in an off-axis or off-center position within the air funnelwith respect to the transition sectionas well as the heat exchanger. In this configuration, as described more fully herein, the curvature of the concave portionof the pressure regulation portiondirects the process airto maintain the consistent and even increase in air velocity, and corresponding decrease in air pressure. This eccentric position of the outlet portserves to align the outlet portwith the rotational axis of a fan of the blowerto funnel the process airdirectly into the middle of the blower. This configuration further minimizes turbulence and isolated changes in the air pressureand the air velocity.

To accommodate the off-center position of the outlet port, the pressure regulation portionincludes a non-symmetrical curvature of the concave portion. This non-symmetrical configuration of the concave portiondirects the process airin a consistent increase in air velocityand corresponding decrease in air pressure. In this manner, the curvature of the concave portioncan define a steeper curve on the short side of the air funnel, the short side being that side of the air funnelwhere the outlet portis closer to the outer edgeof the heat exchanger. Similarly, the long side of the air funnel, that portion of the concave portionwhere the outlet portis farther from the outer edgeof the heat exchanger, can have a shallower curve.

In certain aspects of the device, the outlet portand the converging sectioncan be centrally located within the air funnel. In such a configuration, the fan of the bloweris also centrally located within the air funnel.

According to the various aspects of the device, whether the outlet portis eccentrically positioned or centrally positioned, it is typically contemplated that the converging sectionof the air funnelis symmetrical about the outlet port.

As exemplified in, the configuration of the air funnelexemplified herein is modeled, showing the consistent and even increase in air velocitybetween the downstream surfaceof the heat exchangerand outlet portthat leads into the blower. As shown in this model, the various annotated benchmarks A-G show the velocity of the process airmoving through the air funnelto be substantially consistent across each benchmark. The benchmarks A-C show the consistent velocity of the process airwithin the area of the evaporatorand the pressure maintenance portion. The benchmarks D-G show the gradual and consistent increase in air velocityas the process airmoves through the pressure regulation portionand the converging section. Again, this increase in air velocityof the process aircoincides with a corresponding consistent decrease in air pressureas the process airmoves across the air funnelbetween the pressure maintenance portion, the pressure regulation portion, and the converging section. Accordingly, the configuration of the air funnelserves to converge the flowof process airfrom the heat exchangerand to the outlet portin an even configuration that results in a consistent decrease in air pressureand increase in air velocityof the process airas it moves through the air funnel.

Referring again to, an airflow systemfor a water heaterincludes the heat exchanger, typically in the form of the evaporator, that draws heatfrom the process air. The heat exchangerdelivers the heatto the heat exchange media. Typically, the heat exchangerincludes a rectilinear cross-section that defines a first area. The blowerdelivers the process airthrough the heat exchanger. The air funneldirects the process airfrom the heat exchangerinto the blower. The air funnelincludes a rounded outlet portwith an inner perimeterthat defines a second area. This second areais smaller than the first areasuch that the flowof process airneeds to be converged between the downstream surfaceof the heat exchangerand the outlet port. The outlet portdirects the process airfrom the air funneland into the blower. The air funnelmanages the air pressureof the process airto be consistent within the heat exchanger. Additionally, the air funnelregulates the air pressureof the process airto decrease evenly and consistently between the downstream surfaceof the heat exchangerand the rounded outlet portof the air funnel. As discussed herein, the pressure maintenance portionof the air funnelmaintains the air pressureof the process airto be consistent within the heat exchanger. The pressure regulation portionof the air funnelmanipulates the process airto gradually and evenly decrease the air pressureof the process airbetween the rectangular pressure maintenance portionand the circular converging sectionof the air funnel.

Referring again to, the heat pump systemfor the water heaterincludes the evaporatorthat draws heatfrom the process air. The heat exchangerdelivers this heatto the heat exchange media. The heat exchangerincludes a generally rectilinear cross-section that defines the first area. The blowerdelivers the process airthrough the evaporator. The air funnelat least partially surrounds the outer edgeof the evaporatorand directs the process airfrom the evaporatorto the circular outlet portof the air funnel. The circular outlet portincludes an inner perimeterthat defines the second area. The second areais smaller than the first area. The air funnelmanages the air velocityof the process airto be even and consistent within the heat exchanger. The air funnelalso regulates the air velocityof the process airto define a consistent increase in air velocityas the process airmoves between the downstream surfaceof the evaporatorand the circular outlet port.

Referring again to, the air funnelincludes the flangethat engages the heat exchangerof the heat pump system. The air funnelalso includes a platethat engages a blower housingof the blower. This platetypically mimics the shape of the blower housing. As exemplified herein, the blower housingcan include a generally cochlear shape. Accordingly, the plateof the air funnelincludes a similar cochlear profile to securely engage the blower housing.

As exemplified in, during operation of the heat pump system, the bloweractivates to move process airthrough the evaporator. Ambient airfrom the air inlet, in the form of process air, is directed into the evaporator. As discussed herein, the process airand the movement of the flowof process airthrough the heat exchangeris managed by the air funnel. Again, the air funnelmaintains the flowof process airto be consistent and even through the heat exchangerto minimize or eliminate pressure drop within the heat exchanger. This, in turn, also maintains the air velocityof the flowof process airthrough the heat exchangerto be even and consistent.

Referring again to, after leaving the heat exchanger, the flowof process airis now cooled process airthat moves through the air funneland to the outlet port, where the process airis directed into the blower housing. It is contemplated that the plateof the air funneldefines the outlet portthat leads into the blower housing. This platecan be formed as an integral part of the air funnelor can be a separate component that is attached to the air funnel.

The converging sectionof the air funneltransitions between the pressure regulation portionof the air funneland the outlet portof the air funneland directs the flowof process airthrough the convex configuration of the converging sectionto direct the flowof process airinto the blower housing. Stated another way, the air funnelregulates the flowof process airthrough the heat exchanger, and also through the space between the heat exchangerand the blower housingthat is defined by the inner surfaceof the air funnel. Accordingly, the flowof process airis managed by the air funnelto be an even and consistent flowof process airthat moves through the outlet portand is directed into the blower housing.

Referring again to, this cooled process airis then directed out of the upper housingfor the water heaterthrough operation of the blower. This now cooled process aircan be directed out of the top panel for the upper housingand directed to a downstream area for expulsion from a space or recaptured for later use.

Referring again to, the air funnelincludes a first attachment section, in the form of the flange, that attaches to the heat exchanger. The air funnelincludes a second attachment section, in the form of the plate, that attaches to the blower housing. Each of the first attachment sectionand the second attachment sectionof the air funnelassist in managing the movement of the flowof process airthrough the air funnelto be even and consistent through the various sections of the air funnel. In the case of the pressure maintenance portionof the air funnel, the air funnelmaintains the flowof process airto be even and consistent through the heat exchangerto minimize variations in the air pressureas well as variations in the air velocity. As the flowof process airmoves through the pressure regulation portionof the air funnel, the inner surfaceof the air funnelmanages the decline of air pressureand the increase in air velocityto be even and consistent as the flowof process airmoves toward the outlet port. Moreover, as the flowof process airmoves through the outlet port, this flowof process airis again maintained in an even and consistent level which minimizes excessive noise and turbulence within the air funneland within the blower housingas the flowof process airtransitions from the air funnelto the blower housing.

According to the various aspects of the device, the air funnelfor the heat pump systemoperates to maintain the flowof process airat a consistent and even air pressureand air velocityas the flowof process airmoves through the heat exchanger. Through this configuration, operation of the heat exchangerhas an increased efficiency due to the substantial elimination of pressure drop within a heat exchanger. This pressure drop, if not mitigated, can result in areas of a heat exchangerreceiving only limited amounts of process air, or no process air, thereby transferring little to no heatbetween the process airand the heat exchange media. By maintaining the flowof process airthrough the heat exchangerto be even and consistent, each section of the heat exchangeroperates contemporaneously to transfer heatfrom the process airto the heat exchange media. This maintenance of the flowof process airto be consistent within the heat exchangeris achieved through those portions of the air funnelthat are downstream of the pressure maintenance portionof the air funnel. The entire inner surfaceof the air funneloperates in cooperation to act upon the flowof process airto manage the Venturi effect of the process airas it moves between the downstream surfaceof the heat exchangerand the outlet portinto the blower housing.

As exemplified in, the air funnelcan include a configuration having a minimal converging section. Such an aspect of the device can be used where the heat exchangeris in closer proximity to the bloweror the blower housing. In such an aspect of the device, the transition sectionof the air funnelincludes the pressure maintenance portionwhich surrounds the outer edgeof the heat exchanger, as well as the pressure regulation portionthat extends between the downstream surfaceof the heat exchangerand the converging sectionof the air funnel. The converging sectionof the air funneldirects the process airthrough the outlet portwhich is also defined by the converging sectionof the air funnel. Additionally, the pressure regulation portionof the air funnelincludes the concave portionof the air funnelhaving a generally concave curvature and which directs the process airfrom the rectangular configuration of the heat exchangerto the circular configuration of the outlet port. As described herein, this pressure regulation portionoperates to increase the air velocityof the process airand, contemporaneously, decrease the air pressureof the process air.

Referring again to, the plateof the air funnelengages the blower housingof the blower. Additionally, the platecan be configured to extend across the entirety of the upper housing. Through this configuration, the plateseparates the volume of the upper housingbetween a heat exchange sectionand a blower section. Within the heat exchange sectionof the upper housing, various portions of the heat pump systemcan be located, including the heat exchanger, the compressor, and other components of the heat pump system. The blower sectionof the upper housingincludes the blower, including the fan of the blowerand the blower housing. By dividing the upper housinginto the heat exchange sectionand the blower section, operation of the blowerserves to efficiently direct process airfrom the air inlet, into the heat exchange section, and through the heat exchanger. Because the platedivides the upper housingbetween the heat exchange sectionand the blower section, all of the ambient airthat is drawn through the air inletis moved through the heat exchangeras process air.

As described herein, the process airmoving through the heat exchangeris manipulated through operation of the air funnelto maintain a consistent air velocityand air pressure. This consistent air velocityand air pressurecauses the process airto move evenly through the entirety of the heat exchanger. In turn, this maximizes the exchange of heatfrom the process airand into the heat exchange mediafor heating waterwithin the reservoirof the water heater. Use of the plateextending across the entirety of the upper housingalso serves to eliminate the unwanted movement of process airaround the heat exchanger. Preventing this bypass of process airincreases the efficiency of the heat pump systemfor the water heater.

As described herein, the outlet portfor the air funnelcan be positioned in an eccentric location within the pressure regulation portionof the air funnel. Accordingly, the shape of the pressure regulation portionof the air funnelis configured to manipulate the process airto maintain the consistent increase of air velocityand the consistent decrease of air pressureas the process airmoves through the air funnel, as exemplified inwith respect to the various benchmarks annotated therein.

According to various aspects of the device, the plateof the air funnelcan be integral with the converging sectionand the pressure regulation portionof the air funnel. In certain aspects of the device, the platecan be attached to at least one of the pressure regulation portionand the converging sectionof the air funnel.

According to the various aspects of the device, as exemplified in, the pressure regulation portionof the air funnelcan include tapered filletsthat assist in converting the rectangular outer perimeterof the pressure maintenance portionof the air funnelinto the circular profile of the converging sectionof the air funnel. The tapered filletsextend between parabolic panelsthat form the remainder of the pressure regulation portion. Together, the plurality of the tapered filletsand the plurality of the parabolic panelscooperate to regulate the manipulation of process airas it moves between the heat exchangerand the converging sectionof the air funnel. The tapered filletsand parabolic panelscooperate to consistently regulate the increase in air velocityof the process airas well as the consistent decrease in air pressureof the process air.