Thermosiphon system for hot water heater

Abstract

A thermosiphon system for hot water heaters. In an embodiment, the thermosiphon includes a multi-tubular structure which in an embodiment is insertable through the cold water connection in a hot water tank in order to provide for a thermosiphon action in the hot water heater, to keep water circulating and prevent temperature stratification of water in the tank. In another embodiment, a thermosiphon design is fabricated within a water heater tank at the factory.

Claims

1. A thermosiphon sized and shaped for use in combination with a residential water heater having a tank with internal sidewalls defining an internal space of height H, the tank adapted to be filled with water for heating of the water, the tank having a top portion with (1) a cold water inlet of internal diameter D.sub.C and (2) a hot water outlet, said thermosiphon comprising: a multi-tubular structure disposed along a longitudinal axis and having an outer diameter D.sub.T, wherein said outer diameter D.sub.T is less than said diameter D.sub.C so that said multi-tubular structure is insertable through said cold water inlet into said tank, said multi-tubular structure including (a) a hot water tube extending between a siphon inlet and a siphon exit, said siphon exit adapted for discharge of water therefrom, and (b) a cold water tube, said cold water tube spaced outwardly from and situated longitudinally along at least a portion of said hot water tube, said cold water tube extending between a cold water inlet end having a cold water inlet, and a cold water output end which is open and adapted for discharge of water therefrom; an external hot water tee, said external hot water tee having a hot water tee inlet fluidly attachable to said hot water outlet in said tank, a hot water tee outlet, and a hot water tee siphon outlet; a transition tube, said transition tube having a hot water inlet configured to receive a supply of hot water from said hot water tee siphon outlet and direct the supply of hot water to said hot water tube, said transition tube comprising (1) an inlet flange fluidly sealed with respect to said hot water tee siphon outlet, (2) a bend portion, and (3) a transition tube outlet, said transition tube having interior sidewalls defining a hot water receiving passageway for receiving hot water from said hot water tee siphon outlet and delivering hot water to said hot water tube; and wherein the hot water tube and the cold water tube of said multi-tubular structure form a pair of concentric tubes nested about said longitudinal axis, wherein said hot water tube provides a centrally located hot water passageway, and wherein said cold water tube is spaced outwardly from said hot water tube and provides an annular cold water passageway between an outer wall of said hot water tube and an inner wall of said cold water tube.

2. The thermosiphon as set forth in claim 1, wherein said multi -tubular structure has a length L.sub.I inside said tank and along said longitudinal axis, and wherein said length L.sub.I is greater than 50% of said height H.

3. The thermosiphon as set forth in claim 1, wherein said multi-tubular structure has a length L.sub.I inside said tank and along said longitudinal axis, and wherein said length L.sub.I is greater than 75% of said height H.

4. The thermosiphon as set forth in claim 1, wherein said multi-tubular structure has a length L.sub.I inside said tank and along said longitudinal axis, and wherein said length L.sub.I is greater than 90% of said height H.

5. A method for controlling biological growth in a residential hot water supply tank, said method comprising: (a) providing a hot water tank, said hot water tank comprising[:] a tank with sidewalls defining an internal space of height H between a bottom portion and a top portion, the tank adapted to be filled with water, the tank comprising a cold water inlet in the top portion and a hot water outlet in the top portion; a thermosiphon, said thermosiphon located within said tank and including a multi-tubular structure disposed along a longitudinal axis, said a multi-tubular structure thermosiphon having (a) a cold water tube extending between an upstream end and a downstream end, said upstream end fluidly connected to said cold water inlet in said top portion, and said downstream end adapted for discharge of water therefrom within said tank, and (b) a hot watertube, said hot water tube spaced outwardly from and situated longitudinally along at least a portion of said cold watertube, said hot water tube extending between a hot water inlet end having a hot water inlet, and a hot water output end which is open and adapted for discharge of water therefrom, said hot water tube further comprising an inlet cap substantially sealed to said cold water tube adjacent said cold water inlet, wherein the hot water tube and the cold water tube of said multi-tubular structure form a pair of concentric tubes nested about said longitudinal axis, wherein said cold water tube provides a centrally located cold water passageway, and wherein said hot water tube is spaced outwardly from said cold water tube and provides an annular hot water passageway between said cold water tube and said hot water tube; and a hot water collection tee within said tank, said hot water collection tee including a tee inlet, a first outlet fluidly connected to said hot water outlet in said top portion, and a second outlet fluidly connected to said hot water inlet of said thermosiphon; wherein said multi-tubular structure has a length L.sub.I inside said tank and along said longitudinal axis, and wherein said length L.sub.I is greater than 75% of said height H; (b) providing water to said hot water tank; (c) heating water in said hot water tank; circulating water in said hot water tank with said thermosiphon, to thereby substantially prevent vertical temperature stratification of water within said hot water tank; and (d) maintaining the temperature of the water in said tank at about 180 F., or more.

6. The method as set forth in claim 5, wherein said hot water tank comprises a generally cylindrical tank having an internal diameter D, and wherein height H is greater than diameter D.

7. A method for controlling biological growth in a hot water tank, said method comprising: providing a hot water tank; providing a thermosiphon as set forth in claim 1; providing water to said hot water tank; heating water in said hot water tank; circulating water in said hot water tank with said thermosiphon to thereby substantially prevent vertical temperature stratification of water within said hot water tank; and maintaining the temperature of the water in said tank at about 180 F., or more.

8. The method as set forth in claim 7, wherein said hot water tank comprises a generally cylindrical tank having an internal diameter D, and wherein height H is greater than diameter D.

Description

BRIEF DESCRIPTION OF THE DRAWING

(1) The present invention(s) will be described by way of exemplary embodiments, using for illustration the accompanying drawing in which like reference numerals denote like elements, and in which:

(2) FIG. 1 is a perspective of for an embodiment in which a thermosiphon is provided within a hot water tank.

(3) FIG. 2 is a conceptual vertical cross sectional view of an embodiment such as just illustrated in FIG. 1, where a thermosiphon is provided inside a hot water tank; those of skill in the art need not be provided with detailed mechanical details such as might be useful in assembly of threaded pipe or fabrication by brazing or welding components as illustrated in this or other figures of the drawing.

(4) FIG. 2A is an end view, of a multi-tubular thermosiphon, taken looking up at the location 2A-2A as indicated in FIG. 2.

(5) FIG. 3 is a perspective of for an embodiment in which a thermosiphon is provided separately and externally from a hot water tank; however, it should be appreciated that the multi-tubular structure component of the thermosiphon is configured for insertion though the cold water inlet to the tank, and extends downward into the tank upon assembly.

(6) FIG. 3A is an end view, of an insertable multi-tubular thermosiphon, taken looking up at the location 3A-3A as indicated in FIG. 4.

(7) FIG. 4 is a conceptual vertical cross sectional view of an embodiment such as just illustrated in FIG. 3, where a thermosiphon is provided for external insertion into a hot water tank.

(8) FIG. 5 is front perspective, partial cross-sectional view of a transition tube, showing a portion of the hot water T siphon outlet, an inlet flange fluidly sealed at the outer rim thereof to the inside of the hot water T siphon outlet, and fluidly sealed at the inner rim thereof to the outside of the inlet of the transition tube, as well as showing the bend portion which directs hot water to the hot water tube.

(9) FIG. 6 is rear perspective, partial cross-sectional view of a transition tube, showing a portion of the hot water T siphon outlet, an inlet flange fluidly sealed at the outer rim thereof to the inside of the hot water T siphon outlet, and the inlet flange fluidly sealed at the inner rim thereof to the outside of the inlet of the transition tube, as well as showing the bend portion which directs hot water to the hot water tube.

(10) The foregoing figures, being merely exemplary, contain various elements that may be present or omitted from a final configuration for an embodiment of a thermosiphon system for use with a hot water heater, or that may be implemented in various embodiments described herein for use either internally to, or assembled externally for use with, a hot water heater. Other variations in thermosiphon systems for hot water heaters may use slightly different mechanical structures, mechanical arrangements, or size and shape of components, and yet employ the principles described herein and as generally depicted in the drawing figures provided, and as more specifically called out in the claims set forth below. An attempt has been made to draw the figures in a way that illustrates at least those elements that are significant for an understanding of an exemplary thermosiphon system for use with hot water heaters, and suggestive embodiments for different approaches to using thermosiphonic devices with hot water heaters.

(11) It should be understood that various features may be utilized in accord with the teachings hereof, as may be useful in different embodiments as useful for various sizes and shapes of thermosiphon structures for hot water heaters, depending upon the specific requirements (such as typical height of a hot water heater tank) within the scope and coverage of the teachings herein as defined by the claims. Further, like features in various embodiments for thermosiphon system designs may be described using like reference numerals, or other like references, without further mention thereof.

DETAILED DESCRIPTION

(12) Attention is directed to FIG. 1, where a water heater 10 having an internal thermosiphon is illustrated. In an embodiment, the provision of these elements, factory built, is an important improvement in the art. Hot water heater 10 includes a tank 12 with internal sidewalls 14 defining an internal space of height H (see FIG. 2) between a bottom portion 16 and a top portion 18. The hot water tank 10 adapted to be normally filled with water, which is not separately illustrated. However, generally, arrows representing cold water are shown with arrows having tails with solid linessee reference CW in FIG. 2. Likewise, arrows representing hot water are shown with arrows having tails with broken linessee reference HW in FIG. 2. The tank 12 includes cold water inlet 20 in the top portion 18. A hot water outlet 22 is provided in the top portion.

(13) A thermosiphon 30 system is provided within tank 12. The thermosiphon system includes multi-tubular structure 32 and a hot water collection tee 34. The hot water collection tee 34 has a tee inlet 62, a first outlet 64 fluidly connected to the hot water outlet 22 in said top portion 18, and a second outlet 66 fluidly connected to a hot water inlet 42 on the multi-tubular structure 32.

(14) In an embodiment, a multi-tubular structure 32 may be located internal to the tank 12 and disposed along a longitudinal axis which is identified in FIG. 1 as centerline of axis A. In an embodiment the longitudinal axis of multi-tubular structure 32 may be parallel to the vertical axis of the water heater 10 (usually the same as vertical sidewalls of tank 12) in which the multi-tubular structure 32 is fabricated. The multi-tubular structure 32 of the thermosiphon 30 includes a cold water tube 40 extending between an upstream end 42 and a downstream end 44. The upstream end 42 is fluidly connected to the cold water inlet 20 in the top portion 18. The downstream end 44 is open (see FIGS. 2 and 2A) and adapted for discharge of cold water 46. A hot water tube 50 is provided. The hot water tube 50 is spaced outwardly from and situated longitudinally along at least a portion of the cold water tube 40. The hot water tube 50 extends between a hot water inlet end 52 having a hot water inlet 54, and a hot water output end 56 which is open and adapted for discharge of hot water 57 therefrom. The hot water tube 50 may further include an inlet cap 58 substantially sealed to the cold water tube 40 adjacent the cold water inlet 20.

(15) As better seen in FIG. 2A, the multi-tubular structure 32 may be fabricated in the form of a pair of concentric tubes nested about the longitudinal axis A. In an embodiment as shown in FIGS. 1, 2, and 2A, the cold water tube 40 provides a centrally located cold water passageway 41. In such embodiment, the hot water tube 50 is spaced outwardly from the cold water tube 40, thus providing an annular hot water passageway 60 between the cold water tube 40 and the hot water tube 50.

(16) In an embodiment, the hot water collection tee 34 is also located within the tank 12 of water heater 10. The hot water collection tee 34 includes a tee inlet 62, a first outlet 64 fluidly connected to the hot water outlet 22 in the top portion 18, and a second outlet 66 fluidly connected through orifice 68 which may be provided in an annular disk configuration having an outer radius (R) and an inner radius (r) so that it also serves as an orifice through which how water HW enters the hot water inlet 54 in the hot water tube 50.

(17) In various embodiments, the multi-tubular structure 32 has a length L.sub.I inside the tank 12 (see FIG. 2) along the longitudinal axis A, and the length L.sub.I is greater than fifty percent (50%) of the inside height H of tank 12.

(18) In various embodiments, the multi-tubular structure 32 has a length L.sub.I inside the tank 12 (see FIG. 2) along the longitudinal axis A, and the length L.sub.I is greater than seventy-five percent (75%) of the inside height H of tank 12.

(19) In various embodiments, the multi-tubular structure 32 has a length L.sub.I inside the tank 12 (see FIG. 2) along the longitudinal axis A, and the length L.sub.I is greater than ninety percent (90%) of the inside height H of tank 12.

(20) In various embodiments, the tank 12 may be provided as a cylindrical tank having an internal diameter D, and wherein height H is greater than diameter D.

(21) Attention is now directed to FIGS. 3, 3A, 4, 5, and 6, where another embodiment for a thermosiphon 130 is illustrated. A thermosiphon 130 includes a multi-tubular structure 132 sized and shaped for use in combination with a residential water heater 110 having a tank 112 with internal sidewalls 114 defining an internal space of height H. The tank 112 is adapted to be normally filled with water for heating of the water. The tank 112 has a top portion 118 with a cold water inlet 120 of internal diameter D.sub.C and a hot water outlet 122.

(22) The thermosiphon includes a multi-tubular structure 132 and an external hot water T 134. The multi-tubular structure 132 may be disposed along a longitudinal axis B and have an overall diameter D.sub.T. In order to size and shape the multi-tubular structure 132 so that the multi-tubular structure 132 is insertable through the cold water inlet 120 and thence into the tank 112, the multi-tubular structure 132 must have a diameter D.sub.T less than the inside diameter D.sub.C of the cold water inlet 120, as illustrated in FIG. 3A.

(23) The multi-tubular structure 132 includes a hot water tube 150 extending between a siphon inlet 152 and a siphon exit 154. The siphon exit 154 adapted for discharge of hot water 157 therefrom. The multi-tubular structure also includes a cold water tube 140. The cold water tube 140 is spaced outwardly from and situated longitudinally along at least a portion of the hot water tube 150. The cold water tube 140 extends between a cold water inlet end 142 having a cold water inlet 143, and a cold water output end 144 which is open and adapted for discharge of cold water 145 therefrom.

(24) An external hot water T 134 is provided for hot water HW return from the tank 112 to the multi-tubular structure 132 of thermosiphon 130. The external hot water T 134 includes a hot water T inlet 162 fluidly attachable to the hot water outlet 122 in the tank 112, a hot water T outlet 164, and a hot water T siphon outlet 166.

(25) For returning hot water HW to the multi-tubular structure 132, a transition tube 170 is provided. To accommodate the transition tube 170, an enlarged cold water tube portion 141 may be provided, and enlarged cold water tube portion 141 may have a larger outside diameter than cold water tube 140. The transition tube 170 having a hot water inlet 172 configured to receive a supply of hot water HW from the hot water T siphon outlet 166 and direct the supply of hot water HW to the hot water tube 150. The transition tube 170 includes (1) an inlet flange 173 which may be provided in an annular disk configuration having an outer radius (R) and an inner radius (r) so that it also serves as an orifice and may be fluidly sealed with respect to the hot water T siphon outlet 166, (2) a bend portion 174, and (3) a transition tube outlet 176. The transition tube 170 has interior sidewalls 178 defining a hot water receiving passageway 180 for receiving hot water HW from the hot water T siphon outlet 166 and delivering the hot water HW to the hot water tube 150.

(26) As seen in FIGS. 3A and 4, in an embodiment, the multi-tubular structure 132 may be provided as a pair of concentric tubes (140 and 150) nested about the longitudinal axis B. In this embodiment, the hot water tube 150 provides a centrally located hot water passageway 156. The cold water tube 140 is spaced outwardly from the hot water tube 150 and provides an annular cold water passageway 181 between an outer wall 182 of the hot water tube 150 and an inner wall 184 of the cold water tube 140, from which cold water 145 is discharged.

(27) In various embodiments, the multi-tubular structure 132 has a length L.sub.I inside the tank 112 (same parameters as shown in FIG. 2 apply) along the longitudinal axis B, and the length L.sub.I is greater than 50% of the inside height H of tank 112.

(28) In various embodiments, the multi-tubular structure 132 has a length L.sub.I inside the tank 112 (same parameters as shown in FIG. 2 apply) along the longitudinal axis B, and the length L.sub.I is greater than 75% of the inside height H of tank 112.

(29) In various embodiments, the multi-tubular structure 132 has a length L.sub.I inside the tank 112 (same parameters as shown in FIG. 2 apply) along the longitudinal axis A, and the length L.sub.I is greater than 90% of the inside height H of tank 12.

(30) In various embodiments, the tank 112 may be provided as a cylindrical tank having an internal diameter D, and wherein height H is greater than diameter D.

(31) In order to evaluate and confirm the advantages of a water heater design which incorporates a thermosiphon as taught herein, comparative testing was conducted at an accredited testing laboratory which is approved for United States Environmental Protection Agency Energy Star Testing. Two (2) water heaters were tested, each having a nominal fifty (50) gallon size, one water heater without, and one water heater with an internal thermosiphon as taught herein. All tests were conducted in accord with the procedures set out in the United States Code of Federal Regulations, as found at 10 C.F.R. Chapter II, Part. 430, Subpart B, Appendix E, entitled Uniform Test Method for Measuring Consumption of Water Heaters, which test procedures are incorporated herein in their entirety by this reference, as they existed on Mar. 22, 2016. A modified water heater having an internal thermosiphon as taught herein was tested, A modified fifty (50) gallon hot water heater, was provided for testing, Bradford White Model RE 350T1, Serial No. ME36250436. An unmodified hot water heater by the same manufacturer, Bradford White Model RE350T6, having Serial Number ME36218123 was also tested. Bradford White Corporation is a well-known manufacturer of hot water heaters, with corporate headquarters at 725 Talamore Drive, Ambler, Pa., 19002, United States of America. See http://www.bradfordwhite.com/ for more information.

(32) The full test results for the unmodified water heater are set out in Appendix A. Comparative test results are set out in Table 1 below.

(33) The full test results for a modified water heater using an internal thermosiphon system as taught herein are set out in Appendix B. Comparative test results are set out in Table 1 below.

(34) TABLE-US-00001 TABLE 1 COMPARATIVE TEST RESULTS Modified Unmodified Item Water Heater Water Heater Remarks Tank Storage 45.0 gallons 45.0 gallons Volume.sup.1 First Hour Rating 79.6 gallons 52.9 gallons 26.7 gallons increase Recovery 0.98 0.98 Allowed by Efficiency 10CFR Ch. II, 430(e) Daily Energy Use 42,196 BTUs 44,892 BTUs 2696 BTUs savings Annual Energy 15,402 BTU/yr 16,544 BTU/yr 335 kWh/yr savings Use or or 4,514 kWh/yr 4,849 kWh/yr Energy Factor 0.983 0.913 = 0.07 .sup.1Storage Tank water temperature was thermostatically maintained at 135 F. plus or minus 5 F.

(35) The test results set out in Table 1 speak for themselves when viewed by one of ordinary skill in the art and to whom this specification is directed. It is clear that in otherwise identical water heaters of nominal fifty (50) gallon capacity, the use of a modified water heater as taught herein would save a homeowner 335 kilowatt hours per year in energy costs. While the savings may be modest to the individual homeowner (for example about US$28.47 per year if the cost of electricity is 8.5 cents per kwH), such savings would be appreciable if such devices were installed in homes of large segments of the population. As an individual water heater of the same size produces more hot water (a 26.7 gallon increase in the First Hour Rating) while using less energy, the advantages provided by way of use of the inventive internal thermosiphon hot water heater becomes quite clear. Further, since energy savings based on hot water usage as projected by the test criteria noted above amounts to some 335 kilowatt hours per year per hot water heater, each installed hot water heater using the inventive apparatus disclosed herein would save 0.335 megawatt of energy usage over a year. In more basic terms, the use of a hot water heater with internal thermosiphon as disclosed herein by approximately 2400 homes would save about 800 megawatts per year of power. Such energy savings could significantly contribute to reducing new energy generation capacity required to serve a growing population. Where fossil fuels such as natural gas, oil, or coal are used for electrical power generation, such electricity savings as would be achievable by widespread use of the inventive internal thermosiphon hot water heater as disclosed herein would contribute to considerable greenhouse gas generation reductionsimply by using more efficient hot water heaters.

(36) Additionally, by using an embodiment of a thermosiphon in a hot water heater in accord with the teachings herein, biological growth in a residential hot water supply tank may be controlled or substantially eliminated. Such a method may be practiced by providing a hot water tank as set forth herein, then providing water to the hot water tank, and heating water in the hot water tank through conventional hot water heating equipment as may be normally supplied to residential hot water heaters. However, additionally, by circulating water in the hot water tank using a thermosiphon as set forth in one of the embodiments described herein, I have found that it is possible to substantially prevent vertical temperature stratification of water within a hot water tank. Consequently, by way of maintaining the temperature of the water in said tank above a selected temperature that inhibits or kills bacteria, it has been found that bacterial contamination is reduced or substantially eliminated. In an embodiment, setting the hot water temperature at about at about 180 F. may accomplish such a goal.

(37) It is to be appreciated that my thermosiphonic systems for hot water heaters is an appreciable improvement in the art of energy efficient hot water heaters. My novel design addresses the problem of how to provide for either a factory built hot water tank including a thermosiphon for continuous recirculation of water in the tank, or a field built thermosiphon design for use with a conventional factory built hot water tank which has not been provided with a thermosiphon system built therein.

(38) Although only a few exemplary embodiments have been described in detail, various details are sufficiently set forth in the drawings and in the specification provided herein to enable one of ordinary skill in the art to make and use the invention(s), which need not be further described by additional writing in this detailed description. It will be readily apparent to those skilled in the art that my thermosiphon system for hot water tanks may be modified from those embodiments provided herein, without materially departing from the novel teachings and advantages provided.

(39) The aspects and embodiments described and claimed herein may be modified from those shown without materially departing from the novel teachings and advantages provided by this invention, and may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. Therefore, the embodiments presented herein are to be considered in all respects as illustrative and not restrictive. As such, this disclosure is intended to cover the structures described herein and not only structural equivalents thereof, but also equivalent structures. Numerous modifications and variations are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention(s) may be practiced otherwise than as specifically described herein. Thus, the scope of the invention(s), as set forth in the appended claims, and as indicated by the drawing and by the foregoing description, is intended to include variations from the embodiments provided which are nevertheless described by the broad interpretation and range properly afforded to the plain meaning of the claims set forth below.