Securing Bracket for Maintaining a Position of Flexible Conduit Within a Water Heating Appliance

This application claims priority to U.S. 63/568,486, filed on Mar. 22, 2024, entitled “AIR FUNNEL FOR A HEAT PUMP SYSTEM OF A WATER HEATER,” the disclosure to which is hereby incorporated herein by reference in its entirety.

The present disclosure generally relates to a water heating appliance, and more specifically, to a securing bracket that maintains a position of flexible conduit within a water heating appliance during use and maintenance thereof.

Water heating appliances are utilized within various structures for providing heated water for various uses. These water heating appliances include heating elements for heating water within a reservoir or within a conduit of water. These heating elements can include electrically resistive heating elements, gas heating elements, and heat pump systems. For maintaining water heating appliances, access panels are provided within an outer housing. These access panels open to provide maintenance access to certain portions of the water heating appliance.

According to one aspect of the present disclosure, a water heating appliance that includes a fluid inlet that has an inlet retainer end, a fluid outlet that has an outlet retainer end, and a bracket that engages the inlet retainer end and the outlet retainer end. A rotational torque that is exerted on a threaded fastener of one of the fluid inlet and the fluid outlet is absorbed by the bracket and transferred from a torque receiving end proximate to the threaded fastener and distributed through the bracket to a torque distributing portion of the bracket.

According to another aspect of the present disclosure, a water heating appliance includes a fluid inlet that has a first flexible conduit and an inlet retainer end, a fluid outlet that has a second flexible conduit and an outlet retainer end, an outer enclosure that has a top cover through which the first flexible conduit and the second flexible conduit extend, and a bracket that engages the inlet retainer end and the outlet retainer end. A rotational torque that is exerted on a threaded fastener of one of the fluid inlet and the fluid outlet is absorbed by the bracket and transferred from a torque receiving end of the bracket proximate to the threaded fastener and distributed through the bracket to a torque distributing portion of the bracket, where the torque distributing portion is attached to the top cover.

According to yet another aspect of the present disclosure, a water heating appliance includes a flexible fluid inlet that has an inlet retainer end, a flexible fluid outlet that has an outlet retainer end, an outer enclosure that has a top cover through which the flexible fluid inlet and the flexible fluid outlet extend, and a bracket that engages the inlet retainer end and the outlet retainer end. The top cover and the bracket cooperate with the inlet retainer end and the outlet retainer end to maintain a position of the flexible fluid inlet and the flexible fluid outlet. A rotational torque that is exerted on a threaded fastener of one of the fluid inlet and the fluid outlet is absorbed by the bracket and transferred from a torque receiving end of the bracket proximate the threaded fastener and distributed through the bracket to a torque distributing portion of the bracket, where the torque distributing portion is attached to the top cover.

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 a support bracket for water heating appliance, where the support bracket maintains a position of flexible conduit within the water heating appliance when portions of the outer enclosure are removed, and to prevent deflection of the flexible conduit during maintenance of the water heating appliance. 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 water heating appliance that includes an outer enclosuremade up of a plurality of wall panelsand top panels. These wall panelsand top panelscan be removed from the outer enclosureto allow for maintenance within certain portions of the water heating appliance. According to the various aspects of the device, the water heating applianceincludes a fluid inlethaving an inlet retainer endand a fluid outlethaving an outlet retainer end. A support bracketengages the inlet retainer endand the outlet retainer end. When a rotational torqueis exerted on a threaded fastenerof one of the fluid inletand the fluid outlet, this rotational torqueis absorbed by a support bracket. This rotational torqueis then transferred from a torque receiving endof the support bracket. The torque receiving endbeing proximate to the threaded fastener, and typically at least partially surrounding the threaded fastener. This rotational torqueis then distributed through the support bracketto a torque distributing portionof the support bracket. This torque distributing portionis positioned between a first endof the support bracketand a second endof the support bracketthat oppose one another.

According to the various aspects of the device, the support bracketdisclosed herein is typically attached to a top coverthat is incorporated within the outer enclosure. The fluid inletand the fluid outletextend through the top cover. Additionally, the support bracketis attached to the top coverso that the rotational torquecan be distributed from the torque receiving endand into the torque distributing portionthat is attached to the top cover. It is contemplated that the distribution of the rotational torqueis then delivered into the top coveras well as the remainder of the outer enclosure. Using this configuration of the support bracket, portions of the top covercan be removed to allow for maintenance within the outer enclosureof the water heating appliance. The flexible conduitof the fluid inletand the fluid outlet, without support, tend to slump or deflect downward. This deflection of the flexible conduitcan interfere with certain maintenance operations within the outer enclosure. Use of this support bracket, in combination with the inlet retainer endand the outlet retainer end, helps to maintain the position of the flexible conduitof the fluid inletand the fluid outletin a static position during maintenance of the water heating appliance.

Additionally, tightening or loosening various threaded fastenerswith respect to the fluid inletand the fluid outletdoes not impact the structural integrity of the flexible conduitthrough use of the support bracket. As described herein, the support bracketreceives the rotational torquefrom a threaded fastenerand distributes this rotational torqueaway from the flexible conduitand into the support bracketand ultimately into the outer enclosureof the water heating appliance.

Referring again to, the water heating applianceincludes an outer enclosurethat surrounds portions of the water heating applianceand components contained therein. The outer enclosurecan include multiple components, such as a front wall paneland a rear wall panelthat can be positioned in a surrounding position. In the surrounding position, the wall panelssurround and protect the various aspects and components of the water heating appliance.

As exemplified in, the outer enclosurecan include a lower housingand an upper housing. The lower housingis configured to surround a reservoirand certain heating components that may surround the reservoir. It is contemplated that these heating components can include resistive heating elements, gas-powered heating elements, a heat pump system, and other heat exchangers for providing heat to the water within the reservoir. The upper housingcan include the heat pump systemand a blowerthat is in thermal communication with an evaporatorof the heat pump system. The heat pump systemcan operate as the primary heat source for the water heating appliance. Alternatively, it is contemplated that the heat pump systemcan act as a secondary or supplemental heat source for heating water to be delivered from the water heating appliance.

Referring again to, the outer enclosurecan include a plurality of panels that can be separable from the remainder of the outer enclosurefor providing access to certain locations of the water heating appliance. As described herein, the upper housingincludes the perimeter wallthat is made up of a plurality of wall panels. These wall panelsare typically made up of the front wall paneland the rear wall panel. The upper housingalso includes the first top paneland the second top panelthat can be attached to the plurality of wall panelsof the upper housing.

Referring again to, during operation of the heat pump systemfor the water heating appliance, an air inletis disposed within the second top panel, where the blowerdraws ambient air into the upper housingthrough the air inlet. This ambient air passes through a heat exchanger, typically in the form of the evaporator. Within the evaporator, heat is extracted from the ambient air and is directed into a thermal exchange mediaor directly into the water to be heated. After leaving the evaporator, the now cooled air is directed through the blower, and the cooled air is expelled through an air outletthat is defined within the first top panel. The air inletand the air outletcan each include a grillor other feature that provides support and structural integrity to each of the air inletand the air outlet, respectively. The air outletcan also include an air filterthat can be used for capturing particulate within the cooled process air leaving the evaporator. This filter can be separated from a filter slotof the grillfor the air outletfor periodic cleaning and/or replacement.

Referring again to, the heat exchanger for the heat pump systemextracts heat from the ambient air and delivers this heat to the reservoirof the water heating applianceor to another area where water is heated. The water to be heated is delivered into the water heating appliancethrough a fluid inlet. The heated water is then delivered from the water heating applianceto an external location via a fluid outlet. The fluid inletand the fluid outleteach pass through the top coverof the upper housing. As described herein, the top coverof the outer housing includes the first top paneland the second top panelthat combine to provide the top enclosure for the upper housing. The fluid inletand the fluid outletare typically in the form of a flexible conduit. This flexible conduitcan be a corrugated stainless-steel conduit, a flexible plastic conduit, a flexible metal conduit, or a flexible conduitthat includes pasting and metallic components. It is contemplated that more rigid conduits can be used for the fluid inletand the fluid outlet.

As exemplified in, the flexible conduitof the fluid inletincludes the inlet retainer end, which can be a rigid portion of the fluid inlet. Similarly, the flexible conduit of the fluid outletcan include the outlet retainer endthat can be a rigid portion of the fluid outlet. In this aspect of the device, the rigid components of the flexible conduit, in the form of the inlet retainer endand the outlet retainer endcan be supported by the support bracket. Additionally, the rigid inlet retainer endand the rigid outlet retainer endcan be the portions of the flexible conduitsthat extend through the cutout portionsof the top cover.

As exemplified in, the upper housingcan include a control panelfor operating the various components of the water heating appliance. The junction boxcan also be included within an area of the upper housingand attached to a base plateof the upper housing. According to the various aspects of the device, the junction boxis separate from the wall panelsof the upper housingsuch that removal of the various wall panelsof the upper housingdoes not affect the operation, location, or placement of the junction boxor the wiring that extends into or out from the junction box.

Referring again to, the outer enclosureof the water heating appliancealso includes a relief valvethat allows certain amounts of water from a reservoirto be released for decreasing the pressure within the water heating appliance. The water heating appliancecan also include a drainthat is positioned within a bottom portion of the outer enclosureto drain certain amounts of water from the reservoir.

Referring to, the blowerand the heat pump systemcan be mounted onto a base plate. This base plateoperates to separate the upper housingfrom the lower housingand to provide structural support for the blowerand the heat pump system. The components of the heat pump systemlocated within the upper housingcan include the heat exchanger, the compressor, at least one expansion device, and the blower. Various other components can also be included within the upper housing. A condensing portionof the heat pump systemis typically positioned adjacent to or in thermal communication with the reservoiror conduit where the water is heated for the water heating appliance.

During operation of the heat pump system, a thermal exchange media, such as a refrigerant, water, or other similar thermal exchange media, can be delivered from the compressorand through a refrigerant loop. The heat exchange media leaving the compressoris pressurized and heated, typically in the form of a gas. This form of a heat exchange media is then directed to a condensing portionof the heat pump systemwhere heat is rejected into a separate media. In the case of the water heating appliance, this separate media is the water to be heated. The condensing portionof the heat exchange system expels the heat from the thermal exchange mediaand directs this heat into the water to be heated. As discussed herein, this water to be heated can be within the reservoiror within a conduit of water that 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 media is delivered to an expansion device. Within the expansion device, the heat exchange media, which is now cooled, is expanded into a liquid form. This cooled liquid form of the heat exchange media is then delivered to the evaporatorof the heat pump system. Within the evaporator, the heat exchange media absorbs heat from the ambient air moving through the evaporatordue to operation of the blower. The heat exchange media leaving the evaporatoris in the form of a heated gas that is then returned to the compressorto begin this cycle of the refrigerant loopagain.

According to the various aspects of the device, as exemplified in, various outer panels of the outer enclosureare separable from the outer enclosurefor maintaining components of the heat pump system, the blower, and other components of the water heating appliance.

According to the various aspects of the device, as exemplified in, the water heating applianceincludes the fluid inlethaving a first flexible conduitand an inlet retainer end. The water heating appliancealso includes the second fluid outlet that includes a second flexible conduitand the outlet retainer end. The outer enclosureof the water heating applianceincludes the top coverthrough which the first flexible conduitand the second flexible conduitextend. The support bracketengages the inlet retainer endand the outlet retainer end, which are positioned within the outer enclosure. When a rotational torqueis exerted on a threaded fastenerof one of the fluid inletand the fluid outlet, typically through the inlet retainer endand the outlet retainer end, this rotational torqueis absorbed by the support bracketand is transferred from the torque receiving endof the support bracketto the torque distributing portion. As described herein, the torque receiving endof the support bracketis within the first endor the second endof the support bracketdepending upon where the threaded fasteneris being located. In either instance, the rotational torqueexerted upon the threaded fasteneris distributed from the inlet retainer endor the outlet retainer endand into the first endor the second end, through the support bracket, and into the torque distributing portionof the support bracket. This torque distributing portionis attached to the top coversuch that this rotational torquecan be distributed from the support bracketand into the top coverand the remainder of the outer enclosure.

Referring again to, the top coverof the outer enclosureis incorporated within the upper housing. The fluid inletand the fluid outletextend through the top cover. The support cover is attached to the top coverto provide for the distribution of the rotational torqueinto the outer enclosure. The top coverincludes the first top paneland the second top panelthat meet at a dividing edge. The first top panelincludes a seatthat receives a mountof the second top panel. The seatof the first top paneland the mountof the second top panelcooperate to define the dividing edgeand are attached to one another and the wall panelsvia fasteners. At this dividing edge, the first top paneland the second top panelalso define cutout portionsthrough which the fluid inletand the fluid outletpass through the top panel of the outer enclosure. Under typical operation, the at least one cutout portionof the first top paneland the second top panelcooperate to support the position of the flexible conduitof the fluid inletand the fluid outlet. During maintenance of the water heating appliance, the second top panelcan be removed from the first top panel. Removal of the second top panelalso removes a significant part of the cutout portionthat typically supports flexible conduits. Use of the support bracketprovides a supplemental support to the flexible conduitsof the fluid inletand the fluid outlet. In particular, during maintenance of the water heating appliance, when the second top panelis removed, a support bracketinteracts with the inlet retainer endand the outlet retainer endto maintain a position of the flexible conduitsduring maintenance of the water heating appliance.

During installation, maintenance, or other repair of the water heating appliance, threaded fasteners, such as from a fluid inlet linefrom a water source and a fluid outlet lineto the surrounding structure can be attached to the fluid inletand/or the fluid outlet. During attachment of these fluid lines, the threaded fastener, such as a threaded nut, must be tightened on to the fluid inletand/or the fluid outlet, typically via the inlet retainer endand the outlet retainer end. This requires exertion of the rotational torqueonto the fluid inletand the fluid outlet. The use of flexible conduitsis convenient for manipulating this flexible conduitduring manufacture, installation, and maintenance of water heating appliances. However, these flexible conduitscan be susceptible to damage through the exertion of the rotational torque. The use of the support bracketserves to absorb the rotational torqueexerted on to the fluid inletand the fluid outletso that this rotational torqueis not delivered into the flexible conduit. Rather, as described herein, this rotational torqueis delivered into a torque receiving endthat is proximate the threaded fastener. This rotational torqueis then distributed through a bodyof the support bracketand into the torque distributing portionof the support bracket. This torque distributing portionis attached to the top cover, typically the first top panelof the top cover, so that the rotational torquecan be distributed into the top coverand the outer enclosure.

Referring again to, the support bracketincludes the first endthat engages the inlet retainer end, and the second endthat engages the outlet retainer end. The torque distributing portionextends between the first endand the second end. The first endand the second endeach include a respective faceted edgethat form a faceted first endand a faceted second end, respectively. The faceted edgesof the first endand the second endengage, typically in a mating fashion, the inlet retainer endand the outlet retainer end, respectively. The first endand the second endof the support bracketeach include an open sidethrough which the inlet retainer endand the outlet retainer endcan be slidably engaged with the respective faceted edgeof the first end. In certain aspects of the device, the first endand the second endcan form a closed end. In such an aspect of the device, the faceted edgesof the first endand the second endare configured to surround the inlet retainer endand the outlet retainer end. Typically, the first end, and the second endwill include the open side.

Use of this faceted edgeallows for the first endand the second endof the support bracketto engage and support the fluid inletand the fluid outlet. By way of example, and not limitation, the faceted edgecan take the form of a four-sided open end, similar to that of a wrench, or other similar hex-type tool. It is contemplated that other configurations of the faceted edgecan be utilized. The faceted edgeof the first endand the second endare typically configured to matingly engage the outer profileof the inlet retainer endand the outlet retainer endof the fluid inletand the fluid outlet.

Referring again to, the torque distributing portionincludes an offset portionthat is in an offset configuration relative to the first endand the second endof the support bracket. Through this offset portion, the first endand the second endextend downward from the top coverand are offset from an undersideof the top cover. The offset portionof the torque distributing portionextends upward to engage the undersideof the top cover. Fastenersextend through the top coverand the support bracketto fix the torque distributing portionof the support bracketto the top cover. Through this engagement, the rotational torqueexerted on the threaded fastenerof the fluid inletand/or the fluid outletcan be transferred through the torque receiving endsand into the torque distributing portionto be distributed through the outer enclosurevia the top cover.

Referring again to, with the support bracketinstalled on the undersideof the first top panel, the offset portioncan be aligned with and in engagement with a portion of the seatfor the first top panel. In this manner, the seatcan operate as an alignment feature that positions the support bracketwith respect to the top coveras well as the inlet retainer endand the outlet retainer end. This engagement of the offset portionof the support bracketwith the seatprovides an additional interface through which the rotational torquecan be distributed into the top coverand the remainder of the outer enclosure.

In certain aspects of the device, the first endand the second endof the support bracketare configured to align with the interrupted portionsof the seatand the mount. Depending on the height of the offset portion, the first endand the second endcan be disposed within, and in some aspects journaled within, the interrupted portionsof the seatand the mount. This is the case where the offset portionof the support bracketis minimal or where the support bracketis a planar member that lacks the offset portion. Additionally, the alignment of the support bracketwith the interrupted portionsof the seatand the mountcan act as a temporary retaining mechanism to partially hold the support bracketin place as the fastenersare installed into the bodyof the support bracketand the first top panel.

Referring again to, the opening widthof the open sideof the first end, and the second endof the support brackethas a width that corresponds to the face-to-face widthof the inlet retainer end. By way of example, and not limitation, the inlet retainer endand the outlet retainer endcan include a hexagonal fastening bolt having the face-to-face widthand a point-to-point width. Accordingly, the inlet retainer endand the outlet retainer endare positioned in a particular rotational orientation with respect to the support bracketso that the first endand the second endof the support bracketcan engage the inlet retainer endand the outlet retainer endof the fluid inletand the fluid outlet. This engagement with the face-to-face widthof the inlet retainer endand the outlet retainer endprovides a secure rotational engagement that prevents rotation of the inlet retainer end, the outlet retainer end, and the flexible conduitsof the fluid inletand the fluid outlet. Through this engagement, the rotational torquecan be distributed from the threaded fastener, into a limited portion of the fluid inletand the fluid outlet, into the torque receiving endof the support bracketvia the inlet retainer endand the outlet retainer end, then to the top coverand the outer enclosurevia the torque distributing portionof the support bracket.

Moreover, use of the support bracketprevents rotational torquewithin one of the fluid inletor the fluid outletfrom passing to the other of the fluid inletand the fluid outlet. Positioning of the torque distributing portionof the support bracketprevents rotational torquefrom extending from the first endof the support bracketand into the second endof the support bracket. Again, the torque distributing portionprevents the transfer of this rotational torqueinto either of the fluid inletand the fluid outlet. Accordingly, all rotational torquethat is exerted by a threaded fasteneris directed into the top coverand the remainder of the outer enclosurefrom the water heating appliance.

Referring again to, the water heating applianceincludes the flexible fluid inletthat includes the inlet retainer end. The water heating appliancealso includes the flexible fluid outletthat includes the outlet retainer end. The outer enclosureincludes the top coverthrough which the flexible fluid inletand the flexible fluid outletextends. The support bracketengages the inlet retainer endand the outlet retainer end. The top coverand the support bracketcooperate with the inlet retainer endand the outlet retainer endto maintain a position of the flexible fluid inletand the flexible fluid outlet. The rotational torqueexerted on a threaded fastenerof one of the flexible fluid inletand the flexible fluid outletis absorbed by the support bracket. This rotational torqueis then transferred from the torque receiving endof the support bracket, which is proximate the threaded fastener. This rotational torqueis then distributed through the support bracketand into the torque distributing portionof the support bracket. The torque distributing portion, being attached to the top cover, allows the rotational torqueto be delivered into the outer enclosurevia the top cover.

As described herein, use of the support bracket provides for a convenient system of maintaining the positions of the flexible conduitsof the fluid inletand the fluid outlet. Additionally, the support bracket prevents rotational torquefrom causing damage to the flexible conduitsthrough the exertion of the rotational torquewithin the structure of the flexible conduits. The rotational torqueis directed through the support bracket and into the outer enclosureof the water heating appliancevia the top cover. Accordingly, use of the support bracket extends the life of certain components of the water heating applianceand also provides for a convenient mechanism for maintaining a clear space through which the water heating appliancecan be maintained.

It will be understood by one having ordinary skill in the art that construction of the described disclosure and other components is not limited to any specific material. Other exemplary embodiments of the disclosure disclosed herein may be formed from a wide variety of materials, unless described otherwise herein.