WATER HEATER LIFE EXTENDER

Abstract

An improved anode rod assembly for removing corrosive elements from the water of the tank. The improved anode rod assembly is useful for providing a longer life span for water heater units. Further, an exemplary water intake assembly is presented. The water intake assembly is useful, it provides an extra port so that more anodes can be inserted into the tank. Also having the dip tube at the very bottom of the tank provides more hot water and increases the efficiency of the water heater. Having multiple anodes will give an indefinite life span for the water heater.

Claims

1. An improved water heater providing lengthened cathodic protection within substantially the entire interior volume thereof for lengthened life span of the water heater, the water heater comprising: a tank having an interior, a top surface, a bottom surface, side walls and a heating source mounted in the bottom thereof, said tank having a tank width measurement comprising the interior width of the tank between the side walls and a tank height measurement being the distance between the top surface and bottom surface thereof, and wherein the tank is taller than it is wide by virtue of the tank height measurement being longer than the tank width measurement; at least one top port extending through the top surface of the tank; a bottom drain port extending through a side wall of the tank in proximity to the bottom of the tank; a water intake assembly attached to the exterior of the tank at the bottom drain port whereby cold water to be heated is placed into the interior volume of the tank at a location near the bottom of the tank, said water intake assembly comprising: a three-way coupling-t-device having a left side port, a center port and a right side port; a water piping for coupling to a cold-water source, said water piping coupled to the center port of the coupling-t-device; a dip tube coupled at one end to the left side port of the coupling-t-device and extending horizontally through the bottom drain port of the tank for placement of cold water at a distal end thereof within the interior of the tank when coupled to the cold-water source via the coupling-t-device; and a tank drain valve coupled to the right side port of the coupling-t-device; and an anode rod assembly for attachment to a top port of the tank comprising: a plurality of unitary and non-flexible anode rods each having a top end and a bottom end, a width capable of insertion through a top port of the tank and a length longer than the tank width measurement and substantially equivalent to the tank height measurement; a cap engaging a top port of the tank and having an interior to which plurality of anode rods can be attached for suspension within the interior volume of the tank; an electrically-conductive attachment wire corresponding to each anode rod and being flexibly attached to the top end of said corresponding anode rod and to an interior of the cap, whereby the flexible attachment of each anode rod to the cap permits the attachment of more than one anode rod to the cap following insertion of said anode rods through a corresponding top port of the tank; wherein upon suspension of the plurality of anode rods within the tank the bottom ends of said plurality of anode rods are suspended in proximity to the bottom surface of the tank interior, to provide substantial cathodic protection to the entire vertical height of the tank interior over a lengthened period of time.

2. The water heater of claim 1 wherein the length of the anode rods is at least 75% of the height measurement of the tank.

3. The water heater of claim 1 wherein the anode rods each comprise a central steel rod coated with a sacrificial metal.

4. The water heater of claim 1 wherein the anode rods have a diameter of at least three-fourths (0.75) inches.

5. The water heater of claim 1 wherein a power source to remove sediments and other elements from water within the tank interior is created by cathodic action.

6. The water heater of claim 1 wherein the water piping comprises a poly-vinyl chloride (PVC) material.

7. The water heater of claim 1 wherein the dip tube comprises a poly-vinyl chloride (PVC) material.

8. The water heater of claim 1 further comprising at least one additional anode rod assembly comprising a cap and plurality of anode rods attached thereto via electrically-conductive attachment wires, corresponding to and inserted in an additional top port of the tank.

9. The water heater of claim 1 wherein the electrically-conductive attachment wire used to connect an anode rod to the interior of a corresponding cap is twenty (20) gauge bus bar.

10. A method for enhancing the lifespan of a water heater by providing lengthened cathodic protection within substantially the entire interior volume thereof, wherein the water heater comprises: a tank defining an interior of the tank and having a top surface, a bottom surface, side walls and a heating source mounted in the bottom thereof, said tank having a tank width measurement comprising the interior width of the tank between the side walls and a tank height measurement being the distance between the top surface and bottom surface thereof, and wherein the tank is taller than it is wide by virtue of the tank height measurement being longer than the tank width measurement; at least one top port extending through the top surface of the tank; and a bottom drain port extending through a side wall of the tank in proximity to the bottom of the tank; said method comprising: attaching a water intake assembly to the exterior of the tank at the bottom drain port whereby cold water to be heated is placed into the interior volume of the tank at a location near the bottom of the tank, said water intake assembly comprising: a three-way coupling-t-device having a left side port, a center port and a right side port; a water piping for coupling to a cold-water source, said water piping coupled to the center port of the coupling-t-device; and a dip tube coupled at one end to the left side port of the coupling-t-device and extending horizontally through the bottom drain port of the tank for placement of cold water at a distal end thereof within the interior of the tank when coupled to the cold-water source via the coupling-t-device; and a tank drain valve coupled to the right side port of the coupling-t-device; determining a desired plurality of unitary and non-flexible anode rods to be suspended within the interior of the tank to provide lengthened cathodic protection, each unitary and non-flexible anode rod having a top end and a bottom end, a width capable of insertion through a top port of the tank and a length longer than the tank width measurement and substantially equivalent to the tank height measurement; inserting each of the desired plurality of anode rods through a selected top port in the tank for suspension therein and attaching each inserted anode rod to a cap corresponding to each selected top port by an electrically-conductive attachment wire which is flexibly attached to the top end of said corresponding anode rod and to an interior of the cap, whereby the flexible attachment of the inserted anode rods to corresponding caps permits the attachment of more than one anode rod to a cap; wherein upon suspension of the plurality of inserted anode rods within the tank the bottom ends of said plurality of anode rods are suspended in proximity to the bottom surface of the tank interior, to provide substantial cathodic protection to the entire vertical height of the tank interior; and wherein the shorter length and horizontal orientation of the dip tube provides enhanced lifespan to the dip tube.

11. The method of claim 10 wherein the length of the anode rods is at least 75% of the height measurement of the tank.

12. The method of claim 10 wherein the anode rods each comprise a central steel rod coated with magnesium or another sacrificial metal.

13. The method of claim 10 wherein the electrically-conductive attachment wire used to connect each anode rod to the corresponding cap is twenty (20) gauge bus bar.

14. The method of claim 10 wherein the anode rods having a diameter between one-half (0.5) inches to (0.840) inches.

15. The method of claim 10, wherein the dip tube comprises a poly-vinyl chloride (PVC) material.

16. A retrofit kit for installation in a water heater to provide lengthened cathodic protection within substantially the entire interior volume thereof for lengthened life span of the water heater, the water heater comprising: a tank having an interior, a top surface, a bottom surface, side walls and a heating source mounted in the bottom thereof, said tank having a tank width measurement comprising the interior width of the tank between the side walls and a tank height measurement being the distance between the top surface and bottom surface thereof, and wherein the tank is taller than it is wide by virtue of the tank height measurement being longer than the tank width measurement; at least one top port extending through the top surface of the tank; and a bottom drain port extending through a side wall of the tank in proximity to the bottom of the tank; wherein the retrofit kit comprises: a water intake assembly for attachment to the bottom drain port of the tank of the water heater, whereby cold water to be heated is placed into the interior volume of the tank at a location near the bottom of the tank, said water intake assembly comprising: a three-way coupling-t-device having a left side port, a center port and a right side port; a water piping for coupling to a cold-water source, said water piping coupled to the center port of the coupling-t-device; a dip tube coupled at one end to the left side port of the coupling-t-device and extending horizontally through the bottom drain port of the tank for placement of cold water at a distal end thereof within the interior of the tank when coupled to the cold-water source via the coupling-t-device; and a tank drain valve coupled to the right side port of the coupling-t-device; and an anode rod assembly for attachment to a top port of the tank comprising: a plurality of unitary and non-flexible anode rods each having a top end and a bottom end, a width capable of insertion through a top port of the tank and a length longer than the tank width measurement and substantially equivalent to the tank height measurement; a cap engaging a top port of the tank and having an interior to which plurality of anode rods can be attached for suspension within the interior volume of the tank; an electrically-conductive attachment wire corresponding to each anode rod and being flexibly attached to the top end of said corresponding anode rod and to an interior of the cap, whereby the flexible attachment of the plurality of anode rods to the cap permits the attachment of more than one anode rod to the cap following insertion of said anode rods through a corresponding top port of the tank; wherein upon suspension of the plurality of anode rods within the tank the bottom ends of said plurality of anode rods are suspended in proximity to the bottom surface of the tank interior, to provide substantial cathodic protection to the entire vertical height of the tank interior over a lengthened period of time.

17. The retrofit kit of claim 16 wherein the length of the anode rods is at least 75% of the height measurement of the tank.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0026] FIG. 1 is an illustrated view of a currently used water heater.

[0027] FIG. 2A is an illustrated view of an exemplary anode rod assembly for use with the water heater shown in FIG. 1.

[0028] FIG. 2B is an illustrated view of two exemplary anode rod assemblies shown in FIG. 2A.

[0029] FIG. 2C is an illustrated view of four exemplary anode rod assemblies shown in FIG. 2A.

[0030] FIG. 3 is an illustrated view of an exemplary water intake assembly.

[0031] FIG. 4 is an illustrated view of the water heater shown in FIG. 1 with the anode rod assemblies shown in FIGS. 2A, 2B, 2C and the water intake assembly shown in FIG. 3.

DETAILED DESCRIPTION

[0032] Reference is now made in detail to the description of the embodiments as illustrated in the drawings. While embodiments are described in connection with the drawings and related descriptions, there is no intent to limit the scope to the embodiments disclosed herein. On the contrary, the intent is to cover all alternatives, modifications and equivalents. In alternate embodiments, additional devices, or combinations of illustrated devices, may be added to, or combined, without limiting the scope to the embodiments disclosed herein.

[0033] Referring to FIG. 1, an illustrated view of a prior-art water heater 100. The prior-art water heater 100 is useful for heating water for household or commercial use. The prior-art water heater 100 has a tank 110. The tank 110 holds and heats water that it receives through a cold-water pipe 111. A single rigidly attached anode rod 112 is inserted through a port 113 to attract corrosive elements of the water. The rigidly attached anode rod 112 has typically been made of magnesium material for chlorinated water, water that is not chlorinated uses other materials such as zinc or aluminum. A dip-tube 109 is useful for funneling the received water down to approximately half (½) way down the tank 110 to funnel the cold water closer to the heating device at the bottom of the tank 110. When water is heated it rises, therefore the hot water remains substantially near an upper portion 118 of the tank 110. An outlet 114 allows for the hot water to enter the water line 115 on the top 117 of the tank 110.

[0034] To heat the water received, a gas burner or electric element is controlled by a thermostat 120. The gas flue 103 is for the exhaust fumes from the prior-art water heater 100 that uses natural gas or propane. A chimney 104 is substantially coupled to the gas flue 103. The thermostat 120 controls the temperature of the water by selecting a desired temperature. The temperature of the water can be changed at any time by adjusting the thermostat. There also are other methods used to heat the water such as solar energy and geothermal energy, the principles however remain the same.

[0035] The prior-art water heater 100 further has a relief valve 101 and relief valve tubing 102. The relief valve 101 is coupled to the tank 110 and is useful for relieving excessive high pressure inside of the tank 110. The relief valve 101 has a metal spring that will expand and open the relief valve to release excessive pressure caused by very hot water or steam that is directed through the relief valve tubing 102 downwards to the floor so that it would prevent harm to anything being close by, such as children.

[0036] Water heaters typically come with one anode rod 112 which is installed through a port 113 on top 117 of the tank 110, if there is no separate port for the port 113, there will be a different type of anode used, this type of anode has a nipple on the top which connects to the hot water line, the bottom portion of the nipple extends into the tank, this part of the nipple has an open port that allows the hot water to flow through it to enter the hot water line 115. For the purpose of reference and description of the present invention, the typical water heater tank has a width dimension between the sidewalls thereof, and a height dimension between the top and the bottom interior surface.

[0037] In FIG. 2A, FIG. 2B and FIG. 2C, an illustrated view of an altered anode rod assembly 200 to attract corrosive elements from water being released into the tank 110. The altered anode rod assembly 200 is useful for providing a longer life span for the water heater unit 210. The anode rod assembly 200 comprises a plurality of unitary and nonflexible anode rods 210, each of which has a bottom end and a top end and a length of at least 75% of the length of the height dimension of the tank. Once suspended within the tank, the bottom end of the anode rods 210 will be positioned in proximity to the bottom surface of the interior volume of the tank, providing enhanced cathodic protection to the entirety of the interior volume of the metal vessel at the tank. This is an enhancement over the prior art in which shorter anode assemblies do not provide any cathodic protection in the bottom region of the tank vessel, resulting in enhanced likelihood of failure or corrosion and decay of the bottom area of the tank vessel.

[0038] Each of the plurality of anode rods 210 are attached to an electrically conductive attachment wire 230 at one end, the other end of the electrically conductive attachment wire is attached to the cap 220. The attachment wire 230 is preferably a twenty (20) gauge bus bar, however other types of attachment wires are further contemplated by this application. Each anode rod 210 might be attached to a separate electrically conductive attachment wire 230, or a single attachment wire 230 might be used in respect of each 220. Both such approaches are contemplated within the scope of the present invention.

[0039] A plurality of anode rods 210 are present at any time, thus the water heater unit 110 has an extended life span proportionate to the number of anode rods 210 installed—this represents a substantial enhancement over prior art systems in which a single anode rod 210 is deployed within the tank. Preferably there are four (4) anode rods 210, however the number of anode rods 210 may range from two to any higher number as determined to be optimal for a particular tank configuration. FIG. 2A shows a single anode rod 210 attached to the attachment wire 230 which attaches to the cap 220. FIG. 2B shows two (2) anode rods 210 attached to the attachment wire 230 which attaches to the cap 220. FIG. 2C shows four (4) anode rods 210 attached to the attachment wire 230 which attaches to the cap 220. One or more anode rod assemblies could be present in the water heater of the present invention, for the purpose of mounting the total of a plurality of anode rods 210.

[0040] Referring now to FIG. 3, an illustrated view of an altered water intake assembly 400 is presented.

[0041] The water intake assembly 400 has a cold-water piping 410, a dip tube 420 and a coupling-t-device 430. Note a coupling-t-device 430 allows for a three-way connection were as a normal coupling device allows for two connections.

[0042] The water piping 410 carries and delivers cold water to the water heater 500 of FIG. 4.

[0043] The water piping 410 is coupled to the coupling-t-device 430 at a center port 431. The water piping 410 is preferably made of a poly-vinyl chloride (PVC) material, however other materials are hereby contemplated and may be substituted as desired.

[0044] The dip tube 420 funnels the cold water received from the water piping 410 at the coupling-t-device 430 allows for three connections attached to the coupling 432 which attaches to near a bottom 513 of the tank 500 (shown in FIG. 4) where the drain valve connects to the tank. The placement of dip tube 420 attaching to a second connection 432 near the bottom 513 of the tank 500 (shown in FIG. 4) provides for enhanced life span of the dip tube 420. The dip tube 420 is preferably made of a poly-vinyl chloride (PVC) material, however other materials are hereby contemplated and may be substituted as desired. Further, the dip tube 420 is significantly shorter in length and supplies cold water to the very bottom of the tank which allows the water heater to operate at a higher efficiency level than a currently used dip tube.

[0045] An output port 433 of the coupling-t-device 430 has a valve 434 that is used to drain the water heater 500 of FIG. 4.

[0046] Moving now to FIG. 4, an illustrated view of an improved water heater 500 shown in FIG. 1 with the anode rod assembly 200 shown in FIG. 2A and the water intake assembly 400 shown in FIG. 3 is presented.

[0047] The water heater 500 has a tank 510, plurality of anode rod assemblies 200, a water intake assembly 400, a relief valve 520, an intake port 511 and a relief valve tubing 530.

[0048] The water intake assembly 400 delivering cold water to the water heater 500 for heating purposes. The water intake assembly 400 has a water piping 510 and a dip tube 420. The water intake assembly 400 being configured on an outside 515 of the tank 510.

[0049] The plurality of anode rods 210 are coupled to an inside 512 of the tank 510. The plurality of anode rods 210 may be deployed in groupings of 1 or more associated with an individual cap 220 and port 113, within the overall framework of the totality of anode rods 210 being more than one—that is to say the more than one anode rods 210 might be associated with one or more caps 220.

[0050] In many cases, the top port 113 of the tank which is used for the installation of the anode rod assembly 200 is the port in the top of the tank which would otherwise be used for the installation of a dip tube in a prior art water heater system. Other top ports 113 could also be used.

[0051] The plurality of anode rods 210 are placed in the port 113 where the dip tube (109 of FIG. 1) used to be. A cap 220 is coupled to the top 514 of the tank 510. The plurality of anode rods 210 preferably having a diameter of between three-fourth (0.75) and eight-four one-hundredths (0.840) inch, however other diameters are hereby contemplated, including, but not limited to, one-half (0.5) inch, one (1) inch, etc. The anode rods 210 are preferably made of a steel material and coated with a sacrificial metal. A power source is created by a cathodic action to remove sediments and other elements from the water.

[0052] Providing a system for enhanced cathodic protection of the water heater which can use the port 113 wherein dip tube is previously used in a prior configuration allows for the manufacture of a retrofit kit with the water coupler and anode assembly of the present invention as well and the retrofit kit for this purpose as claimed otherwise described herein is intended within the scope of the present invention.

[0053] The dip tube 420 is coupled to the coupling-t-device 430 at the intake port 511 of the tank 510. The water piping 410 is preferably made of a ploy-vinyl chloride (PVC) material however other materials are hereby contemplated as determined by a person of skill in the art. The dip tube 420 is preferably made of a ploy-vinyl chloride (PVC) material however other materials are hereby contemplated as determined by a person of skill in the art.

[0054] As can also be seen in this Figure, the length of the anode rods 210 is more than 75% of the interior height that mention of the tank. By positioning the bottom ends of the anode rods 210 in proximity to the bottom surface of the tank on this basis, complete cathodic protection is provided to the entirety of the interior of the tank vessel, versus prior art approaches which were limited by combinations of methods and means of insertion etc.

[0055] The anode rods 210 as shown are longer than the weight dimension of the tank. This results in a longer unitary and rigid anode rod 210 which provides enhanced cathodic protection to the tank, but also is a distinguishing point of the plurality of anode rods 210 over flexible anode rods and anode configurations which are inserted from a port on the side of the tank as seen in some of the prior art.

[0056] Those skilled in the art will appreciate that the foregoing specific exemplary processes and/or devices and/or technologies are representative of more general processes and/or devices and/or technologies taught elsewhere herein, such as in the claims filed herewith and/or elsewhere in the present application.

[0057] The features described with respect to one embodiment may be applied to other embodiments or combined with or interchanged with the features of other embodiments, as appropriate, without departing from the scope of the present invention. Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims.