Embossed Heads for Tanks and Tanks Including Same

Abstract

An embossed head for an end of a tank is disclosed. The embossed head can include one or more embossed features. The embossed feature(s) can extend generally upward or generally downward. The embossed features(s) can include an annular emboss. The embossed head can provide similar resistance to deformation as traditional heads while requiring less material as compared to such traditional heads

Claims

1. A tank head comprising: a skirt portion extending at least partially in an axial direction relative to a central axis of the tank head; a knuckle portion configured to transition between the skirt portion and a transition portion of the tank head, the knuckle portion extending at least partially in a radial direction relative to the central axis of the tank head; the transition portion configured to transition between the knuckle portion and a central portion of the tank head; and one or more embossed features, each having a side wall that extends at least partially in the axial direction.

2. The tank head of claim 1, wherein the tank head has a constant material thickness.

3. The tank head of claim 1, wherein the one or more embossed features comprises an annular emboss.

4. The tank head of claim 3, wherein the annular emboss extends at least partially in the radial direction such that the annular emboss is sloped.

5. The tank head of claim 1, wherein the one or more embossed features comprises a plurality of separate and distinct embosses.

6. The tank head of claim 1, wherein an embossed feature of the one or more embossed features extends in a generally direction.

7. The tank head of claim 1, wherein an embossed feature of the one or more embossed features extends in an upward direction.

8. The tank head of claim 1, wherein the one or more embossed features comprises: a first plurality of embosses, each having a first shape and a first size; and a second plurality of embosses, each having a second shape and a second size, wherein at least one of: the second shape is different from the first shape, or the second size is different from the first size.

9. The tank head of claim 8, wherein: each of the first plurality of embosses is located along a first circumference corresponding to a first radius extending from the central axis of the tank head, and each of the second plurality of embosses is located along a second circumference corresponding to a second radius extending from the central axis of the tank head, the second radius being greater than the first radius.

10. The tank head of claim 1, further comprising a secondary emboss located at least partially within an embossed feature of the one or more embossed features.

11. The tank head of claim 1, wherein the one or more embossed features comprise a first embossed feature proximate to the skirt portion, wherein the one or more embossed features comprise a first embossed feature of the skirt portion, wherein the one or more embossed features comprise a first embossed feature proximate to the knuckle portion, wherein the one or more embossed features comprise a first embossed feature of the knuckle portion, wherein the one or more embossed features comprise a first embossed feature proximate to the transition portion, or wherein the one or more embossed features comprise a first embossed feature of the transition portion.

12-16. (canceled)

17. A fluid heating tank comprising a tank head, the tank head comprising: a skirt portion extending at least partially in an axial direction relative to a central axis of the tank head; a knuckle portion configured to transition between the skirt portion and a transition portion of the tank head, the knuckle portion extending at least partially in a radial direction relative to the central axis of the tank head; the transition portion configured to transition between the knuckle portion and a central portion of the tank head; and one or more embossed features, each having a side wall that extends at least partially in the axial direction.

18. The fluid heating tank of claim 17, wherein the one or more embossed features comprises an annular emboss.

19. The fluid heating tank of claim 18, wherein the annular emboss extends at least partially in the radial direction such that the annular emboss is sloped.

20. The fluid heating tank of claim 17, wherein the one or more embossed features comprises a plurality of separate and distinct embosses.

21. The fluid heating tank of claim 17, wherein the one or more embossed features comprises: a first plurality of embosses, each having a first shape and a first size; and a second plurality of embosses, each having a second shape and a second size, wherein at least one of: the second shape is different from the first shape, or the second size is different from the first shape.

22. The fluid heating tank of claim 17, further comprising a secondary emboss located at least partially within an embossed feature of the one or more embossed features.

23. The fluid heating tank of claim 17, wherein the one or more embossed features comprise a first embossed feature proximate to the skirt portion.

24. A tank head comprising: a first portion extending at least partially in an axial direction relative to a central axis of the tank head; a second portion configured to transition between the first portion and a third portion of the tank head, the second portion extending at least partially in a radial direction relative to the central axis of the tank head; the third portion configured to transition between the second portion and a fourth portion of the tank head; and one or more embossed features of or in between at least one of the first portion, the second portion, the third portion, and the fourth portion.

25. The tank head of claim 19, wherein the one or more embossed features comprises an annular emboss.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Reference will now be made to the accompanying drawings, which are not necessarily drawn to scale. The drawings are incorporated into and constitute a portion of this disclosure, illustrating various implementations and aspects of the disclosed technology. Together with the description, the drawings serve to explain the principles of the disclosed technology.

[0016] FIGS. 1A and 1B illustrate cross-sectional views of an existing head.

[0017] FIG. 1C illustrates a bottom perspective view of a tank including the existing head.

[0018] FIG. 1D illustrates a visual representation of the existing head buckling, as shown by a deformation simulation.

[0019] FIGS. 2A and 2B illustrate cross-sectional views of a tank including an example embossed head, in accordance with the disclosed technology.

[0020] FIG. 2C illustrates a magnified cross-sectional view of an edge of a tank including an example embossed head, in accordance with the disclosed technology.

[0021] FIG. 2D illustrates a bottom perspective view of a tank including an example embossed head, in accordance with the disclosed technology.

[0022] FIG. 2E illustrates a top view of an example embossed head, in accordance with the disclosed technology.

[0023] FIG. 2F illustrates a visual representation of a deformation simulation of a tank including an example embossed head. in accordance with the disclosed technology.

[0024] FIG. 3 illustrates a graph comparing the relationship between material thickness and lineal deformation associated with a simulated hydrostatic test for both an existing head and an example embossed head, in accordance with the disclosed technology.

[0025] FIG. 4 illustrates an example embossed head including generally downward embossed features, in accordance with the disclosed technology.

[0026] FIG. 5 illustrates an example embossed head including generally downward embossed features, in accordance with the disclosed technology.

[0027] FIGS. 6A-6C illustrate example embossed heads including different configurations of embossed features, in accordance with the disclosed technology.

DETAILED DESCRIPTION

[0028] Throughout this disclosure, embossed heads are described in relation to tank-type water heaters. Those having skill in the art, however, will recognize that the disclosed technology can be applicable to multiple different scenarios and applications. For example, the disclosed technology can be applied to storage tanks or any other container that includes a generally concave end. Further, this disclosure generally illustrates and describes the disclosed technology in relation to a bottom head (e.g., a bottom side of a tank), but the disclosed technology is not so limited. For example, some or all of the concepts and elements described herein can be incorporated into a top head (e.g., a top side of a tank)

[0029] Some implementations of the disclosed technology will be described more fully with reference to the accompanying drawings. This disclosed technology may, however, be embodied in many different forms and should not be construed as limited to the implementations set forth herein. The components described hereinafter as making up various elements of the disclosed technology are intended to be illustrative and not restrictive. Indeed, it is to be understood that other examples are contemplated. Many suitable components that would perform the same or similar functions as components described herein are intended to be embraced within the scope of the disclosed devices and methods. Such other components not described herein may include, but are not limited to, for example, components developed after development of the disclosed technology.

[0030] Herein, the use of terms such as having, has, including, or includes are open-ended and are intended to have the same meaning as terms such as comprising or comprises and not preclude the presence of other structure, material, or acts. Similarly. though the use of terms such as can or may are intended to be open-ended and to reflect that structure, material. or acts are not necessary, the failure to use such terms is not intended to reflect that structure, material, or acts are essential. To the extent that structure, material, or acts are presently considered to be essential, they are identified as such.

[0031] Unless otherwise specified, all ranges disclosed herein are inclusive of stated end points, as well as all intermediate values. By way of example, a range described as being from approximately 2 to approximately 4 includes the values 2 and 4 and all intermediate values within the range. Likewise, the expression that a property can be in a range from approximately 2 to approximately 4 (or can be in a range from 2 to 4) means that the property can be approximately 2, can be approximately 4, or can be any value therebetween. Further, the expression that a property can be between approximately 2 and approximately 4 is also inclusive of the endpoints, meaning that the property can be approximately 2, can be approximately 4, or can be any value therebetween.

[0032] It is to be understood that the mention of one or more method steps does not preclude the presence of additional method steps or intervening method steps between those steps expressly identified. Similarly, it is also to be understood that the mention of one or more components in a device or system does not preclude the presence of additional components or intervening components between those components expressly identified.

[0033] As used herein, unless otherwise specified, the use of the ordinal adjectives first, second, third, etc., to describe a common object, merely indicate that different instances of like objects are being referred to and are not intended to imply that the objects so described must be in a given sequence, either temporally, spatially, in ranking, or in any other manner. Although the disclosed technology may be described herein with respect to various systems and methods, it is contemplated that embodiments or implementations of the disclosed technology with identical or substantially similar features may alternatively be implemented as methods or systems. For example, any aspects, elements, features, or the like described herein with respect to a method can be equally attributable to a system. As another example, any aspects, elements, features, or the like described herein with respect to a system can be equally attributable to a method.

[0034] Reference will now be made in detail to examples of the disclosed technology that are illustrated in the accompanying drawings and disclosed herein. Wherever convenient, the same reference numbers will be used throughout the drawings to refer to the same or like parts.

[0035] As discussed. the disclosed technology relates to improved head designs (e.g., for water heater tanks) that require a reduced amount of material while providing sufficient resistance to buckling during use of the resulting water heater. Certain rules and regulations can dictate the permissible resistance provided by a head design. For example, certain water heaters sold in the United States can be required to adhere to the regulations set forth in ANSI Z21.10.3 (2017)/CSA 4.3 (2017), entitled Gas-Fired Water Heaters, Volume III, Storage Water Heaters with Input Ratings Above 75,000 BTU Per Hour, Circulating and Instantaneous. As a more specific example, Section 5.28 of ANSI Z21.10.3/CSA 4.3 relates to allowable deformations of a head during a hydrostatic test. When comparing pre-test and post-test measurements, the allowable lineal deformation is

[00001]$\begin{array}{cc}{d}_{\mathrm{tank}-\mathrm{post}}0.5\%.Math.d_{\mathrm{tank}-\mathrm{pre}}& \left(1\right)\end{array}$

[0036] and the allowable circumferential deformation is

[00002]$\begin{array}{cc}{C}_{\mathrm{tank}-\mathrm{post}}0.2\%.Math.\left(.Math.d_{\mathrm{tank}-\mathrm{pre}}\right)& \left(2\right)\end{array}$

[0037] where d.sub.tank-pre is the pre-test diameter of the tank head, d.sub.tank-post is the post-test diameter of the tank head, and C.sub.tank-post is the post-tank circumference of the tank head. Stated otherwise, to satisfy ANSI Z21.10.3 (2017)/CSA 4.3 (2017), the diameter of the tank head is permitted to lineally deform during the hydrostatic test only by 0.5% or less as compared to the pre-test diameter of the tank head, and the circumference of the tank head is permitted to vary during the hydrostatic test only by 0.2% or less as compared to the pre-test circumference of the tank head.

[0038] Head designs for fluid heating tanks used to have two radiia knuckle radius that transitions a dish portion to a flange, and a dish/crown radius representing the major radius of the head. A transition portion was added to transition between the major portion and the knuckle portion, but stabilization of the transition radius (e.g., the radius of the transition portion) against internal pressure may be improved.

[0039] As illustrated in FIGS. 1A-ID, existing head designs typically have a generally concave shape. The head 10 typically includes a skirt portion 12, a knuckle portion 14, a transition portion 16, and a generally spherical portion 18. As illustrated, the skirt portion 12 can be a generally vertical portion (e.g., having a generally cylindrical shape) of the head 10. which, as shown perhaps most clearly in FIG. 1C, can be at least partially overlapped by the tank's shell 20 or sidewall. Stated otherwise, the skirt portion 12 can extend in a generally axial direction relative a central axis of the head 10. The knuckle portion 14 can have a knuckle radius and can effectively turn the corner from the generally axial direction of the skirt portion 12 to a generally radial direction associated with the transition portion 16 and the generally spherical portion 18. The generally spherical portion 18 can have a spherical shape or an approximately spherical shape, and the transition portion can serve to smoothly and/or gradually transition the head 10 from a non-spherical shape (e.g., at the skirt portion 12 and/or knuckle portion 14) to a generally spherical shape (e.g., at the spherical portion 18). Based at least in part on the requirements of ANSI Z21.10.3 (2017)/CSA 4.3 (2017), current head 10 designs having a 16-inch diameter can often have a head thickness of approximately 0.118 inches, with the tank often having a shell thickness of 0.48 inches. Buckling of a traditional head 10 is illustrated in FIG. 1D.

[0040] Buckling refers to a sudden change in shape of a structure under load, and buckling may occur even when the stresses in and/or on the structure are below those that would cause a failure in the material of the structure. The critical load to induce buckling is derived from Euler's formula and relates to the modulus of elasticity of the material and the area moment of inertia. The embossed features, and the resulting embossed head. disclosed herein can help increase the area moment of inertial of the embossed head to thereby increase the critical load of the embossed head.

[0041] To reduce the amount of required material while also providing sufficient resistance to buckling, an embossed head 200 is disclosed. The embossed head 200 can be formed from a single piece of material and can include one or more embossed features, as described herein. As illustrated in FIGS. 2A-2D, the embossed head 200 can include a skirt portion 202 (e.g., similar to the skirt portion 12 of a traditional head 10), a knuckle portion 204 (e.g., similar to the knuckle portion 14 of a traditional head 10). a transition portion 208 (e.g., similar to the transition portion 16 of a traditional head 10), and a generally spherical portion 210 (e.g., similar to the generally spherical portion 18 of a traditional head 10). As illustrated in FIGS. 2A-2D, the embossed head 200 can include an embossed feature in the form of an annular emboss 206. The annular emboss 206 can be or include a step or shoulder. The circumference and radius of the embossed head 200 may not be continuous due to the skirt portion 202, the knuckle portion 204, the transition portion 208, and a generally spherical portion 210 (e.g., central portion). As shown in FIGS. 2A-2D, the transition portion 208 may have a different radius than the skirt portion 202, the knuckle portion 204, and the generally spherical portion 210.

[0042] The annular emboss 206 can be generally vertical. That is to say, the annular emboss 206 can generally extend at least partially in the axial direction of the head 200.

[0043] Alternatively or in addition, the annular emboss 206 can extend at least partially in a radially inward direction. For example, the annular emboss 206 can extend partially in an axial direction and partially in a radially inward direction such that the annular emboss 206 is sloped or slanted. The depth and/or height of the annular emboss 206 can be any depth or height. For example, the annular emboss 206 can be located at and/or begin at a first radial location that is approximately 25% of the radius of the head 200, measured from a central axis of the head 200. As another non-limiting example, the annular emboss 206 can be located at and/or begin at a first radial location that is approximately 75% of the radius of the head 200, measured from a central axis of the head 200. Alternatively or in addition, the annular emboss 206 can be located at and/or end at the end of the knuckle portion 204 as the knuckle portion 204 transitions to the transition portion 208.

[0044] The annular emboss 206 can have an outer diameter (e.g., corresponding to the start of the annular emboss 206) and an inner diameter (e.g., corresponding to the end of the annular emboss 206). The difference between the inner and outer diameters can be approximately zero (or approximately equal to the material thickness at the annular emboss 206) such that the annular emboss 206 forms a generally vertical wall. Alternatively, the outer diameter can be greater than the inner diameter such that the annular emboss has a width. The width of the annular emboss 206 can be any width. For example, the width of the annular emboss 206 can be equal to the distance between a radial location at the boundary of the knuckle portion 204 and a radial location at the boundary of knuckle portion 204 on the opposite side of the head 200.

[0045] The thickness of the embossed head 200 can be substantially constant. That is to say, the thickness at any point along the embossed head 200 can approximately equal the thickness at any other point along the embossed head 200 (e.g., including an annular emboss 206, emboss 410, and/or secondary emboss 612, as described more fully herein). For example, the thickness of the embossed head 200 can be in a range between approximately 0.085 inch and approximately 0.10 inch. As another example, the thickness of the embossed head 200 can be less than or equal to approximately 0.096 inch. Alternatively, the thickness can vary at one or more locations along the embossed head. For example, the embossed head 200 can have an increased thickness at locations likely to fail. As non-limiting examples, the embossed head 200 can have a comparatively increased thickness at corners or transitions into, or out of, the annular emboss 206.

[0046] Numerous dimensional examples have been set forth herein. However, as will be appreciated, the specific dimensions of the element(s) of a particular embossed head 200 (e.g., a particular annular emboss 206. a particular emboss 410. and/or a particular secondary emboss 612) will depend on several factors, including, but not limited to, dimensions of the head 200 and the size or volume of the tank.

[0047] As illustrated, the annular emboss 206 can be located proximate the knuckle portion 204 and/or proximate the transition portion 208, but the disclosed technology is not so limited. That is to say, the annular emboss can be positioned at any location on the embossed head 200. For example, the embossed head 200 can include an annular emboss 206 in or proximate the knuckle portion 204, in or proximate the transition portion 208, and/or the in or proximate generally spherical portion 210. Further, while FIGS. 2A-2D illustrate the embossed head 200 as having only one annular emboss 206, the inclusion of multiple annular emboss 206 is contemplated. For example, the embossed head 200 can include two, three, four, or more annular embosses 206. The annular emboss(es) 206 can have a central axis that is generally aligned with a central axis of the embossed head 200 such that the embossed head 200 is symmetrical.

[0048] As illustrated in FIG. 2F, a deformation simulation of the embossed head 200 including an annular emboss 206 and having a substantially constant thickness was performed. And referring to the graph shown in FIG. 3, the embossed head 200 with the annular emboss 206 can provide approximately the same resistance to buckling as a traditional head 10 but can do so while having a material thickness that is substantially less than the material thickness of the traditional head 10.

[0049] Referring to FIGS. 4 and 5, the embossed feature of the embossed head 200 can be an emboss 410 that is extending generally downward (i.e., toward a surface defined by the edge of the skirt portion 202), as in FIG. 4, or generally upward (i.e., opposite the generally downward direction), as in FIG. 5. Depending on the system characteristics (e.g., head diameter, tank size), a generally upward emboss 410 can be preferable over a generally downward emboss 410, or vice versa. Alternatively or in addition, the embossed head 200 can include one or more generally upward embosses 410 and one or more generally downward embosses 410.

[0050] The embosses 410 can be of any shape. As illustrated in FIGS. 4-6C, the embosses 410 can be generally elongate and/or can have a generally arcuate shape. The ends of the embosses 410 can be rounded, as illustrated. Alternatively or in addition, one or more embosses can have a shape that is generally circular, generally spherical, generally ovular, generally triangular, generally square, generally rectangular, any other shape. The embosses 410 can have any desired length or width. The embosses 410 can all be of the same size (e.g., length, width). Alternatively, one, some, or all of the embosses 410 can have a different size (e.g., length, width). Similarly, the embosses can all have the same height or depth. For example, the height or depth (height for a generally upward emboss 410 and depth for a generally downward emboss 410) of the annular emboss 206 can be between approximately 0.02 inch and approximately 0.125 inch on a head 200 having a 16-inch diameter. For example, the annular emboss 206 can be between approximately 0.02 inch and approximately 0.05 inch, between approximately 0.05 inch and approximately 0.08 inch, between approximately 0.08 inch and approximately 0.1 inch, or between approximately 0.1 inch and approximately 0.125 inch.

[0051] The embosses 410 can be separate and distinct. Alternatively, at least some of the embosses 410 can at least partially overlap.

[0052] As shown in FIGS. 6A-6C, the embossed head 200 can include multiple embosses 410, and these embosses 410 can be arranged in any configuration. For example. a first plurality of embosses 410 can be located at and/or extend along a first radius (e.g., corresponding to the central axis of the embossed head 200), and a second plurality of embosses 410 can be located at and/or extend along a second radius that is greater than the first radius. Each of the first plurality of embosses 410 can have the same size and the same shape. Alternatively, one, some, or all of the first plurality of embosses 410 can have different sizes and/or different shapes. Each of the first plurality of embosses 410 can have the same size and the same shape. Alternatively, one, some, or all of the first plurality of embosses 410 can have different sizes and/or different shapes. As illustrated, the second plurality of embosses 410 can have a size that is greater than the size of the first plurality of embosses 410. Conversely, the second plurality of embosses 410 can have a size that is less than or approximately equal to the size of the first plurality of embosses 410.

[0053] The first and second pluralities of embosses 410 shown in FIGS. 6A-6C each include four embosses 410. but the disclosed technology is not so limited. That is to say, the first plurality of embosses 410 can include two, three, five, six, ten, twenty, or any other number of embosses 410. Similarly, the second plurality of embosses 410 can include two, three, five, six, ten, twenty, or any other number of embosses 410. The first and second plurality of embosses 410 can have the same number of embosses, or the first and second plurality of embosses 410 can have different numbers of embosses.

[0054] As described, a plurality of embosses 410 can extend along a circumference corresponding to a shared radius relative the central axis. Thus, gaps can exist between adjacent embosses 410 of the plurality of embosses 410. (However, it should be understood that embosses 410 are not required to be located along a circumference for the embosses 410 to form gaps therebetween.) The distance between adjacent embosses 410 (i.e., the length of the gap) can be approximately equal within a given plurality of embosses 410. The distance between adjacent embosses 410 of the first plurality of embosses 410 can be greater than the distance between adjacent embosses 410 of the second plurality of embosses 410. Conversely, the distance between adjacent embosses 410 of the first plurality of embosses 410 can be less than or approximately equal to the distance between adjacent embosses 410 of the second plurality of embosses 410.

[0055] Each gap can correspond to a sector, as shown in FIG. 6A. At least one emboss 410 of one plurality of embosses 410 can be configured to at least partially extend across the sector corresponding to a gap between embosses 410 of another plurality of embosses 410. As an example. the second plurality of embosses 410 can be rotated (e.g., 90 degrees) relative the first plurality of embosses 410. Alternatively or in addition. one or more embosses 410 of the first plurality of embosses 410 can extend entirely across a sector corresponding to a gap located between two adjacent embosses 410 of the second plurality of embosses 410, as illustrated in FIG. 6A.

[0056] The side walls of the emboss 410 can be generally vertical. That is to say, the side walls of the emboss 410 can generally extend at least partially in the axial direction of the embossed head 200. Alternatively or in addition, the side walls of the emboss 410 can extend at least partially in a radial direction relative a central axis of the emboss 410. For example, the side walls of the emboss 410 can extend partially in an axial direction and partially in a radial direction such that the side walls of the emboss 410 are sloped or slanted. The depth and/or height of the emboss 410can be any depth or height. For example, the axial distance between the start of the emboss 410and the top or bottom of the emboss 410 (top for a generally upward emboss 410 and bottom for a generally downward emboss 410) can be between approximately 0.02 inch and approximately 0.125 inch on a head 200 having a 16-inch diameter.

[0057] The embossed head 200 can include a secondary emboss 612, as illustrated in FIG. 6C. That is to say, a second embossed feature can be located within a first embossed feature. The secondary emboss 612 can extend generally upward or generally downward. For example, the secondary emboss 612 can be located within a generally downward emboss 410, and the secondary emboss 612 can extend generally upward. As another example, the secondary emboss 612 can be located within a generally downward emboss 410, and the secondary emboss 612 can extend generally downward. As another example. the secondary emboss 612 can be located within a generally upward emboss 410, and the secondary emboss 612 can extend generally downward. As yet another example, the secondary emboss 612 can be located within a generally upward emboss 410, and the secondary emboss 612 can extend generally upward.

[0058] The secondary emboss 612 can have any shape as described herein with respect to the embosses 410. The secondary emboss 612 can have approximately the same shape as the emboss 410 within which the secondary emboss is located.

[0059] While the present disclosure has been described in connection with a plurality of example aspects, as illustrated in the various figures and discussed above, it is understood that other similar aspects can be used, or modifications and additions can be made to the described subject matter for performing the same function of the present disclosure without deviating therefrom. In this disclosure, methods and compositions were described according to aspects of the presently disclosed subject matter. But other equivalent methods or compositions to these described aspects are also contemplated by the teachings herein. Therefore, the present disclosure should not be limited to any single aspect. but rather construed in breadth and scope in accordance with the appended claims. Moreover, various aspects of the disclosed technology have been described herein as relating to methods, systems, devices, and/or non-transitory, computer-readable medium storing instructions.

[0060] However, it is to be understood that the disclosed technology is not necessarily limited to the examples and embodiments expressly described herein. That is, certain aspects of a described system can be included in the methods described herein, various aspects of a described method can be included in a system described herein, and the like.