AIR FUNNEL FOR A HEAT PUMP SYSTEM OF A WATER HEATER

Abstract

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.

Claims

1. A water heater comprising: a heat exchanger that absorbs heat from process air for delivery into a heat exchange media, the heat exchanger having 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 including a rounded port proximate the blower, the rounded port having an inner perimeter that defines a second dimension, the second dimension being smaller than the first dimension, the funnel having an inner surface that maintains an air pressure of the process air to be generally consistent within the heat exchanger, wherein a portion of the funnel forms a portion of a blower housing for the blower.

2. The water heater of claim 1, wherein the heat exchanger includes a rectilinear shape.

3. The water heater of claim 1, wherein the rounded port is circular.

4. The water heater of claim 1, wherein the funnel includes a transition section that engages the heat exchanger, the transition section having a pressure maintenance portion and a pressure regulation portion.

5. The water heater of claim 4, wherein the funnel includes a converging section that defines the rounded port and directs the process air from the transition section to the inner perimeter of the rounded port, wherein the pressure regulation portion includes a concave curvature, and wherein the converging section includes a convex curvature.

6. The water heater of claim 4, wherein the pressure maintenance portion maintains the air pressure of the process air within the heat exchanger and within a portion of a space within the funnel that is immediately adjacent to the heat exchanger.

7. The water heater of claim 5, wherein the pressure regulation portion operates to gradually and evenly decrease the air pressure of the process air between the pressure maintenance portion and the converging section.

8. The water heater of claim 5, wherein the transition section and the converging section operate to evenly increase an air velocity of the process air as it moves between the heat exchanger and the blower, and wherein a depth of the converging section is approximately equal to a depth of the pressure regulation portion.

9. An airflow system for a water heater, the airflow system comprising: a heat exchanger that draws heat from process air, wherein the heat exchanger delivers the heat to a heat exchange media, the heat exchanger having a rectilinear cross-section defining a first area; a blower that delivers the process air through the heat exchanger; and a funnel that directs the process air from the heat exchanger to the blower, wherein the funnel manages an air pressure of the process air to be consistent within the heat exchanger, and wherein 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 having an inner perimeter that defines a second area that is smaller than the first area, wherein the funnel includes a concave portion that is downstream of the heat exchanger and a convex portion that is downstream of the concave portion, and wherein the convex portion extends from the concave portion to the outlet port.

10. The airflow system of claim 9, wherein the funnel includes a transition section that engages the heat exchanger, the transition section having a pressure maintenance portion and the concave portion, wherein the concave portion is at least partially defined by parabolic panels that extend between the pressure maintenance portion and the convex portion.

11. The airflow system of claim 10, wherein the pressure maintenance portion maintains the air pressure of the process air to be consistent within the heat exchanger and within a portion of a space within the funnel that is immediately adjacent to the heat exchanger.

12. The airflow system of claim 11, wherein the concave portion and the convex portion manipulate the process air to gradually and evenly decrease the air pressure of the process air between the pressure maintenance portion and the outlet port.

13. The airflow system of claim 9, wherein the outlet port is circular.

14. The airflow system of claim 10, wherein the pressure maintenance portion of the funnel at least partially surrounds an outer edge of the heat exchanger.

15. The airflow system of claim 10, wherein the concave portion includes tapered fillets that are positioned between adjacent parabolic panels of the parabolic panels.

16. A heat pump system for a water heater, the heat pump system comprising: an evaporator that draws heat from process air and delivers the heat to a heat exchange media, the evaporator having a generally rectilinear cross-section that defines a first area; a blower that delivers the process air through the evaporator; and 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 defining an inner perimeter that defines a second area, the second area being smaller than the first area, wherein the funnel manages an air velocity of the process air to be even and consistent within the evaporator, and wherein the funnel 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.

17. The heat pump system of claim 16, wherein the funnel includes a transition section that engages the evaporator, the transition section having a pressure maintenance portion and a pressure regulation portion, the pressure regulation portion including a plurality of parabolic panels that form a concave portion of the funnel.

18. The heat pump system of claim 17, wherein the funnel includes a converging section that defines the circular port and directs the process air from the transition section to the inner perimeter of the circular port.

19. The heat pump system of claim 18, wherein the pressure maintenance portion maintains the air velocity of the process air to be consistent within the evaporator.

20. The heat pump system of claim 19, wherein the pressure regulation portion operates to gradually and evenly increase the air velocity of the process air between the pressure maintenance portion and the converging section, wherein the plurality of parabolic panels extend from the pressure maintenance portion to the converging section.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] In the drawings:

[0009] FIG. 1 is a top perspective view of a water heater that incorporates an aspect of an air funnel;

[0010] FIG. 2 is a top plan view of the water heater of FIG. 1;

[0011] FIG. 3 is a cross-sectional view of the water heater of FIG. 1 taken along the line Ill-Ill;

[0012] FIG. 4 is a cross-sectional view of the water heater of FIG. 2 taken along the line IV-IV;

[0013] FIG. 5 is a cross-sectional view of an upper housing of the water heater of FIG. 1, and showing engagement of an aspect of the air funnel with a blower of the heat pump system;

[0014] FIG. 6 is a partial cross-sectional view of the water heater of FIG. 2 taken along the line VI-VI, and showing portions of the heat pump system contained within the upper housing;

[0015] FIG. 7 is a top perspective view of the air funnel for the heat pump system;

[0016] FIG. 8 is a bottom perspective view of the air funnel of FIG. 7;

[0017] FIG. 9 is a side elevation view of the air funnel of FIG. 7;

[0018] FIG. 10 is a side elevation view of the air funnel of FIG. 7;

[0019] FIG. 11 is a cross-sectional view of the air funnel of FIG. 7 taken along the line XI-XI;

[0020] FIG. 12 is a schematic perspective view of an aspect of the heat pump system incorporated within a water heater;

[0021] FIG. 13 is an exploded perspective view of the heat pump system of FIG. 12;

[0022] FIG. 14 is a schematic diagram illustrating airflow velocity of process air moving through the air funnel of FIG. 7;

[0023] FIG. 15 is an exploded perspective view of a heat pump system for a water heater that incorporates an aspect of the air funnel;

[0024] FIG. 16 is a cross-sectional view of a heat pump system for a water heater that incorporates an aspect of the air funnel;

[0025] FIG. 17 is a cross-sectional view of the heat pump system for a water heater that incorporates an aspect of the air funnel;

[0026] FIG. 18 is a cross-sectional view of the heat pump system of FIG. 17;

[0027] FIG. 19 is a cross-sectional view of the heat pump system of FIG. 18;

[0028] FIG. 20 is a perspective view of an aspect of the air funnel that can be incorporated within a heat pump system for a water heater;

[0029] FIG. 21 is a second perspective view of the air funnel of FIG. 20;

[0030] FIG. 22 is a side elevational view of the air funnel of FIG. 20;

[0031] FIG. 23 is a cross-sectional view of the air funnel of FIG. 22; and

[0032] FIG. 24 is a side elevational view of the air funnel of FIG. 20.

[0033] The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles described herein.

DETAILED DESCRIPTION

[0034] 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.

[0035] 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 FIG. 1. 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.

[0036] 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.

[0037] 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.

[0038] 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.

[0039] 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.

[0040] 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.

[0041] 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.

[0042] Referring to FIGS. 1-24, reference numeral 10 generally designates a heat pump system incorporated within a water heater 12, where the heat pump system 10 utilizes a heat exchange media 14 for transferring heat 16 collected within an evaporator 18 and into water 20 that is to be heated. The heat pump system 10 can be utilized within a tank-type water heater 12, or within a tankless-type water heater 12. Additionally, certain hybrid configurations of water heaters 12 can utilize the heat pump system 10 that may include a reservoir 68 of heated water 20, as well as a tankless-component of a water heater 12.

[0043] As exemplified in FIGS. 1-24, the water heater 12 can include the heat pump system 10 that includes a heat exchanger 30, typically an evaporator 18, for absorbing heat 16 from process air 32. The heat 16 extracted by the heat exchanger 30 is delivered into a heat exchange media 14. The evaporator 18 includes an outer perimeter 34 that defines a first dimension 36. A blower 38 selectively draws the process air 32 through the heat exchanger 30. The blower 38 operates to move the process air 32 through the heat exchanger 30. An air funnel 22 extends between the outer perimeter 34 of the heat exchanger 30 and the blower 38. The air funnel 22 includes a rounded outlet port 40 having an inner perimeter 42 that defines a second dimension 44. The second dimension 44 is smaller than the first dimension 36. In this manner, the air funnel 22 provides for a converging 46 of the flow 48 of process air 32 leaving the heat exchanger 30 and moving through the outlet port 40 of the air funnel 22 and into the blower 38. The air funnel 22 includes an inner surface 50 that maintains an air pressure 52 of the process air 32 to be generally consistent within the heat exchanger 30. Typically, the heat exchanger 30 includes a rectilinear shape and the outlet port 40 includes a generally rounded, and typically circular, configuration. Accordingly, the air funnel 22 manipulates the flow 48 of process air 32 to converge from the larger size of the rectangular heat exchanger 30 into the smaller generally circular shape of the outlet port 40.

[0044] According to the various aspects of the device, as exemplified in FIGS. 1-24, the air funnel 22 is configured to maintain a consistent air pressure 52 and air velocity 60 within the heat exchanger 30. Therefore, to maximize the capture of heat 16 from within the heat exchanger 30, the consistent movement of process air 32 throughout the entirety of the heat exchanger 30 serves to increase the efficiency of the heat pump system 10 delivering heat 16 into the water 20 to be heated. The air funnel 22, as will be described more fully below, includes a series of sections that operate sequentially to maintain the substantially consistent air pressure 52 within the heat exchanger 30, and to also maintain a substantially consistent decline of air pressure 52 of the process air 32 as it moves between a downstream surface 62 of the heat exchanger 30 and through the outlet port 40 of the air funnel 22 and into the blower 38. Accordingly, the process air 32 moving between an upstream surface 64 of the heat exchanger 30 and the downstream surface 62 of the heat exchanger 30 maintains a consistent and even air pressure 52 and air velocity 60. This configuration minimizes the occurrence of a pressure drop of the process air 32 within the heat exchanger 30. In this manner, the entirety of the heat exchanger 30 is utilized for transferring heat 16 from the process air 32 and into a heat exchange media 14 moving through the evaporator 18 of the heat pump system 10.

[0045] Referring again to FIGS. 1-6 and 15-19, the heat exchanger 30 includes an outer housing 80 that encloses the various components of the water heater 12. As exemplified in FIGS. 1-6, the water heater 12 includes an upper housing 82 that encloses components of the heat pump system 10. The outer housing 80 also includes a lower housing 66 that encloses a reservoir 68 for storing water 20 and maintaining the temperature of the heated water 20. The upper housing 82 of the water heater 12 includes an air inlet 70 and an air outlet 72 that are each positioned, typically, within a top wall 74 of the upper housing 82. These apertures provide for the expedient movement of process air 32 through the upper housing 82 to be acted upon by the evaporator 18 of the heat pump system 10.

[0046] Referring now to FIGS. 2-6 and 15-19, the heat pump system 10 includes the evaporator 18 that receives a heat exchange media 14 typically from an expansion device 90. The heat exchange media 14 leaving the evaporator 18 is heated and is directed to a compressor 92. The heat exchange media 14 leaving the compressor 92 is pressurized and heated and typically in the form of a gas. This form of the heat exchange media 14 is then directed to a condensing portion 94 of the heat pump system 10 where heat 16 is rejected into a separate media. In the case of the water heater 12, the condensing portion 94 is typically in the form of the reservoir 68 of water 20 to be heated, or a conduit of water 20 that is heated as it moves through the condensing portion 94 of the heat pump system 10. After leaving the condensing portion 94 of the heat pump system 10, the heat exchange media 14 is delivered to the expansion device 90 where the heat exchange media 14 is now cooled in liquid form. This cooled liquid form of the heat exchange media 14 is then delivered to the evaporator 18 of the heat pump system 10 to receive additional amounts of heat 16 that can then be transferred to the condensing portion 94 of the heat pump system 10. This process continues to move heat 16 from the process air 32 to the water 20 within the reservoir 68.

[0047] Typically, the compressor 92, evaporator 18, and expansion device 90 are located within the upper housing 82 of the water heater 12. The condensing portion 94 of the heat pump system 10 is located in the lower housing 66 proximate the reservoir 68 of water 20 to be heated. Other locations of these components are also contemplated.

[0048] Referring now to FIGS. 3-6 and 15-19, the evaporator 18 of the heat pump system 10 is positioned adjacent to the blower 38 such that process air 32 can move through the evaporator 18. In this configuration, heat 16 is extracted from the process air 32 and delivered into the heat exchange media 14 moving through the evaporator 18. The even movement of process air 32 through the evaporator 18, which is generated by the air funnel 22, ensures that the process air 32 moves through the evaporator 18 in an even and consistent rate. In this manner, a maximum amount of heat 16 can be extracted from the process air 32 and delivered into the heat exchange media 14.

[0049] It is contemplated that the heat exchange media 14 can be in the form of a refrigerant, water, air, glycol, and other similar substances that are effective at absorbing and releasing heat 16 within a heat pump system 10.

[0050] Referring now to FIGS. 5-11 and 19-24, the air funnel 22 that is attached to the evaporator 18 includes a transition section 110 that engages the heat exchanger 30. This transition section 110 includes a pressure maintenance portion 112 and a pressure regulation portion 114. The pressure maintenance portion 112 of the air funnel 22 is positioned around the heat exchanger 30 such that the pressure maintenance portion 112 operates to maintain the air pressure 52 and air velocity 60 of the process air 32 moving through the heat exchanger 30 to be at a consistent rate. The pressure regulation portion 114 of the transition section 110 operates on the process air 32 to manage the transfer of the process air 32 between the downstream surface 62 of the heat exchanger 30 and the outlet port 40 that leads into the blower 38. The geometry of this pressure regulation portion 114 of the air funnel 22 collects the flow 48 of process air 32 and generates a consistent and even decrease in air pressure 52, as well as a consistent and even increase in air velocity 60, of the process air 32. 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 portion 114 of the air funnel 22 manages the Venturi effect to ensure that as the process air 32 moves through the pressure regulation portion 114, each section of the flow 48 of process air 32 experiences a similar decrease in air pressure 52 and increase in air velocity 60 as it approaches the outlet port 40.

[0051] Referring again to FIGS. 5-11 and 19-24, the air funnel 22 also includes a converging section 120 that forms the rounded outlet port 40 that directs the process air 32 into the blower 38. This converging section 120 of the air funnel 22 directs the process air 32 from the transition section 110 and into the inner perimeter 42 of the outlet port 40. Once through the outlet port 40, the process air 32 is moved by the blower 38 through the air outlet 72 and out of the upper housing 82.

[0052] Referring again to FIGS. 5-11 and 19-24, the pressure maintenance portion 112 of the air funnel 22 extends across the depth 130 of the heat exchanger 30 between the upstream surface 64 of the heat exchanger 30 and the downstream surface 62 of the heat exchanger 30. It is contemplated that this pressure maintenance portion 112 is substantially rectangular to match the profile of the heat exchanger 30. In certain aspects of the device, the pressure maintenance portion 112 can also extend at least partially into the space of the air funnel 22 that is immediately adjacent to the downstream surface 62 of the heat exchanger 30. This pressure maintenance portion 112 of the air funnel 22 is typically defined by a flange 132 of the air funnel 22 that engages the rectangular outer edge 134 of the heat exchanger 30. This flange 132 can engage a single surface to the heat exchanger 30. Additionally, the flange 132 can extend around multiple surfaces of the outer edge 134 of the heat exchanger 30 to encircle a portion of the heat exchanger 30 or the entirety of the outer edge 134 of the heat exchanger 30. The flange 132 of the pressure maintenance portion 112 operates to secure the air funnel 22 to the heat exchanger 30 while also providing a guide through which the process air 32 is directed through the heat exchanger 30 at a consistent and even air pressure 52 and air velocity 60.

[0053] The pressure regulation portion 114 of the air funnel 22 includes a concave portion 140 that is positioned immediately adjacent to the downstream surface 62 of the heat exchanger 30. This pressure regulation portion 114 includes a cross-sectional profile that is generally in the shape of a parabolic arc that proceeds from the rectangular downstream surface 62 of the heat exchanger 30 and toward the circular converging section 120 of the air funnel 22. This parabolic curvature of the pressure regulation portion 114 operates to gradually and evenly decrease the air pressure 52 of the process air 32, thereby managing the Venturi effect within the air funnel 22. Additionally, the pressure regulation portion 114 manipulates the flow 48 of process air 32 between the rectangular configuration of the heat exchanger 30 and the round configuration of the converging section 120.

[0054] By managing the Venturi effect, sections of the flow 48 of process air 32 are prevented from moving at a greatly accelerated rate or decelerated rate, relative to adjacent portions of the flow 48 of process air 32. Undesirable isolated changes in air pressure 52 and air velocity 60 may result in a section of the process air 32 that experiences a pressure drop. These sections of pressure drop within the process air 32 can have impact upstream that may result in an uneven flow 48 of process air 32 through the heat exchanger 30.

[0055] Referring again to FIGS. 6-11 and 19-24, the pressure regulation portion 114 of the transition section 110 moves into the converging section 120 of the air funnel 22 and transitions from the concave portion 140 of the air funnel 22 to a convex portion 150 of the air funnel 22 having a convex curvature. This convex portion 150 of the converging section 120 of the air funnel 22 further directs the flow 48 of process air 32 through the outlet port 40 and into the blower 38. Again, this transition of the air funnel 22 between the pressure regulation portion 114 and converging section 120 of the air funnel 22 maintains a consistent and even decrease of air pressure 52, as well as a consistent and even increase in air velocity 60 as the flow 48 of process air 32 moves through the outlet port 40 and into the blower housing 172.

[0056] In certain aspects of the device, the converging section 120 of the air funnel 22 can be positioned in an eccentric position with respect to the transition section 110. Stated another way, the converging section 120 and the outlet port 40 can be positioned in an off-axis or off-center position within the air funnel 22 with respect to the transition section 110 as well as the heat exchanger 30. In this configuration, as described more fully herein, the curvature of the concave portion 140 of the pressure regulation portion 114 directs the process air 32 to maintain the consistent and even increase in air velocity 60, and corresponding decrease in air pressure 52. This eccentric position of the outlet port 40 serves to align the outlet port 40 with the rotational axis of a fan of the blower 38 to funnel the process air 32 directly into the middle of the blower 38. This configuration further minimizes turbulence and isolated changes in the air pressure 52 and the air velocity 60.

[0057] To accommodate the off-center position of the outlet port 40, the pressure regulation portion 114 includes a non-symmetrical curvature of the concave portion 140. This non-symmetrical configuration of the concave portion 140 directs the process air 32 in a consistent increase in air velocity 60 and corresponding decrease in air pressure 52. In this manner, the curvature of the concave portion 140 can define a steeper curve on the short side of the air funnel 22, the short side being that side of the air funnel 22 where the outlet port 40 is closer to the outer edge 134 of the heat exchanger 30. Similarly, the long side of the air funnel 22, that portion of the concave portion 140 where the outlet port 40 is farther from the outer edge 134 of the heat exchanger 30, can have a shallower curve.

[0058] In certain aspects of the device, the outlet port 40 and the converging section 120 can be centrally located within the air funnel 22. In such a configuration, the fan of the blower 38 is also centrally located within the air funnel 22.

[0059] According to the various aspects of the device, whether the outlet port 40 is eccentrically positioned or centrally positioned, it is typically contemplated that the converging section 120 of the air funnel 22 is symmetrical about the outlet port 40.

[0060] As exemplified in FIG. 14, the configuration of the air funnel 22 exemplified herein is modeled, showing the consistent and even increase in air velocity 60 between the downstream surface 62 of the heat exchanger 30 and outlet port 40 that leads into the blower 38. As shown in this model, the various annotated benchmarks A-G show the velocity of the process air 32 moving through the air funnel 22 to be substantially consistent across each benchmark. The benchmarks A-C show the consistent velocity of the process air 32 within the area of the evaporator 18 and the pressure maintenance portion 112. The benchmarks D-G show the gradual and consistent increase in air velocity 60 as the process air 32 moves through the pressure regulation portion 114 and the converging section 120. Again, this increase in air velocity 60 of the process air 32 coincides with a corresponding consistent decrease in air pressure 52 as the process air 32 moves across the air funnel 22 between the pressure maintenance portion 112, the pressure regulation portion 114, and the converging section 120. Accordingly, the configuration of the air funnel 22 serves to converge the flow 48 of process air 32 from the heat exchanger 30 and to the outlet port 40 in an even configuration that results in a consistent decrease in air pressure 52 and increase in air velocity 60 of the process air 32 as it moves through the air funnel 22.

[0061] Referring again to FIGS. 3-24, an airflow system 152 for a water heater 12 includes the heat exchanger 30, typically in the form of the evaporator 18, that draws heat 16 from the process air 32. The heat exchanger 30 delivers the heat 16 to the heat exchange media 14. Typically, the heat exchanger 30 includes a rectilinear cross-section that defines a first area 160. The blower 38 delivers the process air 32 through the heat exchanger 30. The air funnel 22 directs the process air 32 from the heat exchanger 30 into the blower 38. The air funnel 22 includes a rounded outlet port 40 with an inner perimeter 42 that defines a second area 162. This second area 162 is smaller than the first area 160 such that the flow 48 of process air 32 needs to be converged between the downstream surface 62 of the heat exchanger 30 and the outlet port 40. The outlet port 40 directs the process air 32 from the air funnel 22 and into the blower 38. The air funnel 22 manages the air pressure 52 of the process air 32 to be consistent within the heat exchanger 30. Additionally, the air funnel 22 regulates the air pressure 52 of the process air 32 to decrease evenly and consistently between the downstream surface 62 of the heat exchanger 30 and the rounded outlet port 40 of the air funnel 22. As discussed herein, the pressure maintenance portion 112 of the air funnel 22 maintains the air pressure 52 of the process air 32 to be consistent within the heat exchanger 30. The pressure regulation portion 114 of the air funnel 22 manipulates the process air 32 to gradually and evenly decrease the air pressure 52 of the process air 32 between the rectangular pressure maintenance portion 112 and the circular converging section 120 of the air funnel 22.

[0062] Referring again to FIGS. 3-24, the heat pump system 10 for the water heater 12 includes the evaporator 18 that draws heat 16 from the process air 32. The heat exchanger 30 delivers this heat 16 to the heat exchange media 14. The heat exchanger 30 includes a generally rectilinear cross-section that defines the first area 160. The blower 38 delivers the process air 32 through the evaporator 18. The air funnel 22 at least partially surrounds the outer edge 134 of the evaporator 18 and directs the process air 32 from the evaporator 18 to the circular outlet port 40 of the air funnel 22. The circular outlet port 40 includes an inner perimeter 42 that defines the second area 162. The second area 162 is smaller than the first area 160. The air funnel 22 manages the air velocity 60 of the process air 32 to be even and consistent within the heat exchanger 30. The air funnel 22 also regulates the air velocity 60 of the process air 32 to define a consistent increase in air velocity 60 as the process air 32 moves between the downstream surface 62 of the evaporator 18 and the circular outlet port 40.

[0063] Referring again to FIGS. 7-13 and 15-24, the air funnel 22 includes the flange 132 that engages the heat exchanger 30 of the heat pump system 10. The air funnel 22 also includes a plate 170 that engages a blower housing 172 of the blower 38. This plate 170 typically mimics the shape of the blower housing 172. As exemplified herein, the blower housing 172 can include a generally cochlear shape. Accordingly, the plate 170 of the air funnel 22 includes a similar cochlear profile to securely engage the blower housing 172.

[0064] As exemplified in FIGS. 12 and 13, during operation of the heat pump system 10, the blower 38 activates to move process air 32 through the evaporator 18. Ambient air 180 from the air inlet 70, in the form of process air 32, is directed into the evaporator 18. As discussed herein, the process air 32 and the movement of the flow 48 of process air 32 through the heat exchanger 30 is managed by the air funnel 22. Again, the air funnel 22 maintains the flow 48 of process air 32 to be consistent and even through the heat exchanger 30 to minimize or eliminate pressure drop within the heat exchanger 30. This, in turn, also maintains the air velocity 60 of the flow 48 of process air 32 through the heat exchanger 30 to be even and consistent.

[0065] Referring again to FIGS. 12 and 13, after leaving the heat exchanger 30, the flow 48 of process air 32 is now cooled process air 32 that moves through the air funnel 22 and to the outlet port 40, where the process air 32 is directed into the blower housing 172. It is contemplated that the plate 170 of the air funnel 22 defines the outlet port 40 that leads into the blower housing 172. This plate 170 can be formed as an integral part of the air funnel 22 or can be a separate component that is attached to the air funnel 22.

[0066] The converging section 120 of the air funnel 22 transitions between the pressure regulation portion 114 of the air funnel 22 and the outlet port 40 of the air funnel 22 and directs the flow 48 of process air 32 through the convex configuration of the converging section 120 to direct the flow 48 of process air 32 into the blower housing 172. Stated another way, the air funnel 22 regulates the flow 48 of process air 32 through the heat exchanger 30, and also through the space between the heat exchanger 30 and the blower housing 172 that is defined by the inner surface 50 of the air funnel 22. Accordingly, the flow 48 of process air 32 is managed by the air funnel 22 to be an even and consistent flow 48 of process air 32 that moves through the outlet port 40 and is directed into the blower housing 172.

[0067] Referring again to FIGS. 12-13, this cooled process air 32 is then directed out of the upper housing 82 for the water heater 12 through operation of the blower 38. This now cooled process air 32 can be directed out of the top panel for the upper housing 82 and directed to a downstream area for expulsion from a space or recaptured for later use.

[0068] Referring again to FIGS. 5-11 and 15-24, the air funnel 22 includes a first attachment section 190, in the form of the flange 132, that attaches to the heat exchanger 30. The air funnel 22 includes a second attachment section 192, in the form of the plate 170, that attaches to the blower housing 172. Each of the first attachment section 190 and the second attachment section 192 of the air funnel 22 assist in managing the movement of the flow 48 of process air 32 through the air funnel 22 to be even and consistent through the various sections of the air funnel 22. In the case of the pressure maintenance portion 112 of the air funnel 22, the air funnel 22 maintains the flow 48 of process air 32 to be even and consistent through the heat exchanger 30 to minimize variations in the air pressure 52 as well as variations in the air velocity 60. As the flow 48 of process air 32 moves through the pressure regulation portion 114 of the air funnel 22, the inner surface 50 of the air funnel 22 manages the decline of air pressure 52 and the increase in air velocity 60 to be even and consistent as the flow 48 of process air 32 moves toward the outlet port 40. Moreover, as the flow 48 of process air 32 moves through the outlet port 40, this flow 48 of process air 32 is again maintained in an even and consistent level which minimizes excessive noise and turbulence within the air funnel 22 and within the blower housing 172 as the flow 48 of process air 32 transitions from the air funnel 22 to the blower housing 172.

[0069] According to the various aspects of the device, the air funnel 22 for the heat pump system 10 operates to maintain the flow 48 of process air 32 at a consistent and even air pressure 52 and air velocity 60 as the flow 48 of process air 32 moves through the heat exchanger 30. Through this configuration, operation of the heat exchanger 30 has an increased efficiency due to the substantial elimination of pressure drop within a heat exchanger 30. This pressure drop, if not mitigated, can result in areas of a heat exchanger 30 receiving only limited amounts of process air 32, or no process air 32, thereby transferring little to no heat 16 between the process air 32 and the heat exchange media 14. By maintaining the flow 48 of process air 32 through the heat exchanger 30 to be even and consistent, each section of the heat exchanger 30 operates contemporaneously to transfer heat 16 from the process air 32 to the heat exchange media 14. This maintenance of the flow 48 of process air 32 to be consistent within the heat exchanger 30 is achieved through those portions of the air funnel 22 that are downstream of the pressure maintenance portion 112 of the air funnel 22. The entire inner surface 50 of the air funnel 22 operates in cooperation to act upon the flow 48 of process air 32 to manage the Venturi effect of the process air 32 as it moves between the downstream surface 62 of the heat exchanger 30 and the outlet port 40 into the blower housing 172.

[0070] As exemplified in FIGS. 15-24, the air funnel 22 can include a configuration having a minimal converging section 120. Such an aspect of the device can be used where the heat exchanger 30 is in closer proximity to the blower 38 or the blower housing 172. In such an aspect of the device, the transition section 110 of the air funnel 22 includes the pressure maintenance portion 112 which surrounds the outer edge 134 of the heat exchanger 30, as well as the pressure regulation portion 114 that extends between the downstream surface 62 of the heat exchanger 30 and the converging section 120 of the air funnel 22. The converging section 120 of the air funnel 22 directs the process air 32 through the outlet port 40 which is also defined by the converging section 120 of the air funnel 22. Additionally, the pressure regulation portion 114 of the air funnel 22 includes the concave portion 140 of the air funnel 22 having a generally concave curvature and which directs the process air 32 from the rectangular configuration of the heat exchanger 30 to the circular configuration of the outlet port 40. As described herein, this pressure regulation portion 114 operates to increase the air velocity 60 of the process air 32 and, contemporaneously, decrease the air pressure 52 of the process air 32.

[0071] Referring again to FIGS. 15-19, the plate 170 of the air funnel 22 engages the blower housing 172 of the blower 38. Additionally, the plate 170 can be configured to extend across the entirety of the upper housing 82. Through this configuration, the plate 170 separates the volume of the upper housing 82 between a heat exchange section 200 and a blower section 202. Within the heat exchange section 200 of the upper housing 82, various portions of the heat pump system 10 can be located, including the heat exchanger 30, the compressor 92, and other components of the heat pump system 10. The blower section 202 of the upper housing 82 includes the blower 38, including the fan of the blower 38 and the blower housing 172. By dividing the upper housing 82 into the heat exchange section 200 and the blower section 202, operation of the blower 38 serves to efficiently direct process air 32 from the air inlet 70, into the heat exchange section 200, and through the heat exchanger 30. Because the plate 170 divides the upper housing 82 between the heat exchange section 200 and the blower section 202, all of the ambient air 180 that is drawn through the air inlet 70 is moved through the heat exchanger 30 as process air 32.

[0072] As described herein, the process air 32 moving through the heat exchanger 30 is manipulated through operation of the air funnel 22 to maintain a consistent air velocity 60 and air pressure 52. This consistent air velocity 60 and air pressure 52 causes the process air 32 to move evenly through the entirety of the heat exchanger 30. In turn, this maximizes the exchange of heat 16 from the process air 32 and into the heat exchange media 14 for heating water 20 within the reservoir 68 of the water heater 12. Use of the plate 170 extending across the entirety of the upper housing 82 also serves to eliminate the unwanted movement of process air 32 around the heat exchanger 30. Preventing this bypass of process air 32 increases the efficiency of the heat pump system 10 for the water heater 12.

[0073] As described herein, the outlet port 40 for the air funnel 22 can be positioned in an eccentric location within the pressure regulation portion 114 of the air funnel 22. Accordingly, the shape of the pressure regulation portion 114 of the air funnel 22 is configured to manipulate the process air 32 to maintain the consistent increase of air velocity 60 and the consistent decrease of air pressure 52 as the process air 32 moves through the air funnel 22, as exemplified in FIG. 14 with respect to the various benchmarks annotated therein.

[0074] According to various aspects of the device, the plate 170 of the air funnel 22 can be integral with the converging section 120 and the pressure regulation portion 114 of the air funnel 22. In certain aspects of the device, the plate 170 can be attached to at least one of the pressure regulation portion 114 and the converging section 120 of the air funnel 22.

[0075] According to the various aspects of the device, as exemplified in FIGS. 4-24, the pressure regulation portion 114 of the air funnel 22 can include tapered fillets 210 that assist in converting the rectangular outer perimeter 34 of the pressure maintenance portion 112 of the air funnel 22 into the circular profile of the converging section 120 of the air funnel 22. The tapered fillets 210 extend between parabolic panels 212 that form the remainder of the pressure regulation portion 114. Together, the plurality of the tapered fillets 210 and the plurality of the parabolic panels 212 cooperate to regulate the manipulation of process air 32 as it moves between the heat exchanger 30 and the converging section 120 of the air funnel 22. The tapered fillets 210 and parabolic panels 212 cooperate to consistently regulate the increase in air velocity 60 of the process air 32 as well as the consistent decrease in air pressure 52 of the process air 32.

[0076] 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.

[0077] According to another aspect, the heat exchanger includes a rectilinear shape.

[0078] According to another aspect, the rounded port is circular.

[0079] According to another aspect, the funnel includes a transition section that engages the heat exchanger, and the transition section has a pressure maintenance portion and a pressure regulation portion.

[0080] According to another aspect, the funnel includes a converging section that defines the rounded port and directs the process air from the transition section to the inner perimeter of the rounded port, the pressure regulation portion includes a concave curvature, and the converging section includes a convex curvature.

[0081] According to another aspect, the pressure maintenance portion maintains the air pressure of the process air within the heat exchanger and within a portion of a space within the funnel that is immediately adjacent to the heat exchanger.

[0082] According to another aspect, the pressure regulation portion operates to gradually and evenly decrease the air pressure of the process air between the pressure maintenance portion and the converging section.

[0083] According to another aspect, the transition section and the converging section operate to evenly increase an air velocity of the process air as it moves between the heat exchanger and the blower, and a depth of the converging section is approximately equal to a depth of the pressure regulation portion.

[0084] 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.

[0085] According to another aspect, the funnel includes a transition section that engages the heat exchanger, the transition section has a pressure maintenance portion and the concave portion, and the concave portion is at least partially defined by parabolic panels that extend between the pressure maintenance portion and the convex portion.

[0086] According to another aspect, the pressure maintenance portion maintains the air pressure of the process air to be consistent within the heat exchanger and within a portion of a space within the funnel that is immediately adjacent to the heat exchanger.

[0087] According to another aspect, the concave portion and the convex portion manipulate the process air to gradually and evenly decrease the air pressure of the process air between the pressure maintenance portion and the outlet port.

[0088] According to another aspect, the outlet port is circular.

[0089] According to another aspect, the pressure maintenance portion of the funnel at least partially surrounds an outer edge of the heat exchanger.

[0090] According to another aspect, the concave portion includes tapered fillets that are positioned between adjacent parabolic panels of the parabolic panels.

[0091] 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.

[0092] According to another aspect, the funnel includes a transition section that engages the evaporator, the transition section has a pressure maintenance portion and a pressure regulation portion, and the pressure regulation portion includes a plurality of parabolic panels that form a concave portion of the funnel.

[0093] According to another aspect, the funnel includes a converging section that defines the circular port and directs the process air from the transition section to the inner perimeter of the circular port.

[0094] According to another aspect, the pressure maintenance portion maintains the air velocity of the process air to be consistent within the evaporator.

[0095] According to another aspect, the pressure regulation portion operates to gradually and evenly increase the air velocity of the process air between the pressure maintenance portion and the converging section, and the plurality of parabolic panels extend from the pressure maintenance portion to the converging section.

[0096] 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.