CENTERING BASE FOR SEALING AN INSULATION CAVITY OF A WATER HEATING APPLIANCE

Abstract

A water heating appliance includes a jacket wall, a tank base disposed within the jacket wall, and a centering base disposed under the tank base. The jacket wall engages an outer portion of the centering base to form a substantially liquid tight seal, and the substantially liquid tight seal at least partially prevents a flowable insulating material from traveling in between the jacket wall and the centering base to an exterior of the jacket wall.

Claims

1. A water heating appliance, comprising: a jacket including a jacket wall and a jacket base coupled to the jacket wall; a tank disposed within the jacket and including a tank base proximate to the jacket base, the tank being configured to contain a volume of liquid; and a centering base abutting the tank base, wherein a terminal portion of the jacket wall extends radially inward at an oblique angle relative to an engagement surface of the centering base, and wherein the terminal portion biases the centering base into a deformed condition, and wherein the deformed condition defines a substantially liquid tight seal between the jacket wall and the centering base, and wherein the substantially liquid tight seal at least partially prevents a flowable insulating material from traveling to an exterior of the jacket wall through a space defined between the engagement surface of the centering base and the terminal portion of the jacket wall.

2. The water heating appliance of claim 1, wherein the centering base is at least partially comprised of a deformable material.

3. The water heating appliance of claim 2, wherein the flowable insulating material cures into a substantially solid form.

4. The water heating appliance of claim 3, wherein a centering base diameter is greater than a tank diameter, and wherein the centering base is a unitary member.

5. The water heating appliance of claim 1, wherein the substantially liquid tight seal is formed without the use of fasteners.

6. The water heating appliance of claim 5, wherein an inner diameter of the jacket wall at the terminal portion is less than an inner diameter of the jacket wall above the terminal portion.

7. The water heating appliance of claim 6, wherein the terminal portion includes a crimped configuration.

8. The water heating appliance of claim 6, wherein the terminal portion is configured to engage the jacket base to cut off a portion of the centering base.

9. The water heating appliance of claim 6, wherein the terminal portion is generally frustoconical.

10. A water heating appliance, comprising: a jacket wall; a tank base disposed within the jacket wall; and a centering base disposed under the tank base, wherein the jacket wall engages an outer portion of the centering base to form a substantially liquid tight seal, and wherein the substantially liquid tight seal at least partially prevents a flowable insulating material from traveling in between the jacket wall and the centering base to an exterior of the jacket wall.

11. The water heating appliance of claim 10, wherein the jacket wall features a terminal portion that biases the centering base into a deformed condition that forms the substantially liquid tight seal.

12. The water heating appliance of claim 11, wherein a base diameter of the centering base is greater than a tank diameter of the tank base, and wherein the centering base is a unitary member.

13. The water heating appliance of claim 11, wherein a terminal portion diameter of the terminal portion is less than a jacket wall diameter of the jacket wall.

14. A method of assembling a water heating appliance comprising the steps of: aligning a jacket with respect to a centering base; engaging the jacket onto the centering base to define a deformed condition of the centering base, wherein the deformed condition defines a sealed interface between the centering base and the jacket; disposing a tank on the centering base to define an insulating volume between the jacket, the tank, and the centering base; disposing a flowable insulating material into the insulating volume; and solidifying the flowable insulating material to form an at least partially solid insulation layer between the jacket, the tank, and the centering base.

15. The method of claim 14, wherein the tank is installed before the jacket engages the centering base.

16. The method of claim 14, wherein the centering base is disposed on a jacket base that is coupled to the jacket.

17. The method of claim 14, wherein a weight of the jacket wall at least partially causes the deformed condition.

18. The method of claim 14, wherein the deformed condition is at least partially caused by a press exerting an external force onto the jacket wall.

19. The method of claim 14, wherein a terminal portion of the jacket is formed to define a crimped edge.

20. The method of claim 19, wherein engagement of the terminal portion with the jacket base cuts off a portion of the centering base.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] In the drawings:

[0008] FIG. 1 is a side perspective view of a water heating appliance;

[0009] FIG. 2 is an exploded perspective view of the water heating appliance;

[0010] FIG. 3 is a cross-sectional view of the water heating appliance of FIG. 1, taken along line III-III;

[0011] FIG. 4 is an enlarged cross-sectional view of the substantially liquid tight seal formed between the terminal portion of the jacket wall and the centering base of FIG. 3 taken at area IV, and including the substantially solid insulating material;

[0012] FIG. 5 is a cross-sectional view of the water heating appliance of FIG. 4 and showing the jacket wall being aligned with the centering base;

[0013] FIG. 6 is a cross-sectional view of the water heating appliance of FIG. 5 and showing the terminal portion of the jacket wall engaging the engaging surface of the centering base;

[0014] FIG. 7 is a cross-sectional view of the water heating appliance of FIG. 6 and showing the terminal portion engaging the centering base to define the deformed condition of the centering base that defines the substantially liquid tight seal;

[0015] FIG. 8 is a further enlarged cross-sectional view of FIG. 4 taken at area VIII and showing the deformed condition of the centering base that forms the substantially liquid tight seal;

[0016] FIG. 9 is an enlarged view of an aspect of the terminal portion of the jacket wall;

[0017] FIG. 10 is an enlarged view of an aspect of the centering base; and

[0018] FIG. 11 is a schematic flow diagram illustrating a method of assembling a water heating appliance.

[0019] The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles described herein.

DETAILED DESCRIPTION

[0020] The present illustrated embodiments reside primarily in combinations of method steps and apparatus components related to a water heating appliance that includes a jacket wall that engages a centering base to form a substantially liquid tight seal therebetween to contain a flowable insulation material within an insulating volume. 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.

[0021] For purposes of description herein, the terms upper, lower, right, left, rear, front, vertical, horizontal, and derivatives thereof shall relate to the disclosure as oriented in FIG. 1. Unless stated otherwise, the term front shall refer to the surface of the element closer to an intended viewer, and the term rear shall refer to the surface of the element further from the intended viewer. However, it is to be understood that the disclosure 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.

[0022] The terms including, 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.

[0023] Referring to FIGS. 1-4, reference numeral 10 generally designates a water heating appliance that includes a heating system 12 designed for heating a volume of fluid, typically a volume of liquid, that is to be delivered to a location or fixture that is external to the water heating appliance 10. In general, the water heating appliance 10 includes a jacket 14, a tank 16, and a centering base 18. The jacket 14 typically includes a jacket wall 20 and a jacket base 22 coupled to the jacket wall 20. Where the jacket base 22 is included, the jacket base 22 can be separately attached to the jacket wall 20 using some type of fastening mechanism or fastening method. The tank 16 typically includes a tank wall 24 and a tank base 26 coupled to the tank wall 24 that is proximate to the jacket base 22. The tank 16 is disposed inside the jacket 14 and is fitted to hold a volume of fluid to be heated. The centering base 18 is disposed between the jacket base 22 and the tank base 26. The jacket wall 20 also includes a terminal portion 28 that is typically located at a bottom edge of the jacket wall 20. Typically, a minority of the jacket wall 20 defines the terminal portion 28. The terminal portion 28 is configured to extend radially inward at an oblique angle 30 relative to an engagement surface 32 of the centering base 18. The engagement surface 32 of the centering base 18 typically includes a top surface 34 and, in some instances, a side surface 36 of the centering base 18. When the water heating appliance 10 is assembled, the terminal portion 28 is configured to bias the engagement surface 32 of the centering base 18 into a deformed condition 38. Once in the deformed condition 38, an interface 40, typically a sealed interface 40, between the terminal portion 28 and the engagement surface 32 of the centering base 18 forms a substantially liquid tight seal 42. This substantially liquid tight seal 42 at least partially prevents a flowable insulating material 44 from traveling to an exterior 46 of the jacket wall 20 through a space defined between the engagement surface 32 of the centering base 18 and the terminal portion 28 of the jacket wall 20. The space encircling an outer surface 48 of the tank 16 and inscribed within an inner surface 50 of the jacket wall 20 is an insulation volume 52 where the flowable insulating material 44 is typically disposed.

[0024] Referring to FIGS. 4-8, the centering base 18 abuts the tank base 26 and is typically displaced atop the jacket base 22. The tank base 26 is located at a central region 60 of the centering base 18. Similarly, the centering base 18 is centrally located within the jacket base 22. The terminal portion 28 of the jacket wall 20 is typically different from the rest of the jacket wall 20 in that the terminal portion 28 is positioned at the oblique angle 30 with respect to the remainder of the jacket wall 20. Using this angle 30, the terminal portion 28 is formed to interact with the engagement surface 32 of the centering base 18 to bias the engagement surface 32 of the centering base 18. This oblique angle 30 is typically from approximately 5 degrees to approximately 25 degrees in deviation from the rest of the jacket wall 20. When biased in this manner, the engagement surface 32 at least partially forms around the terminal portion 28 to form the substantially liquid tight seal 42. The geometry of the terminal portion 28 is typically angled inwards to define the exterior 46 of the jacket wall 20 (i.e., the water heating appliance 10) and simultaneously extend inward to engage the engagement surface 32 of the centering base 18. It is contemplated that the configuration of the terminal portion 28 can take the form of any one of various geometries to extend into a sealed engagement 62 with the centering base 18 and accomplish the interaction that forms the substantially liquid tight seal 42.

[0025] Referring again to FIGS. 4-8, the interaction between the terminal portion 28 and the centering base 18 typically occurs during assembly. This interaction causes the centering base 18 to deform around a part of the terminal portion 28. The deformation is caused by a force 70 acting on the jacket wall 20 and therefore the terminal portion 28. In some embodiments of the device, the jacket wall 20, and therefore the terminal portion 28, are pushed into the centering base 18. It is understood that not just downward force 70 can cause this deformation to occur. Other similar actions can be used to generate the biasing force 70 that creates the substantially liquid tight seal 42. These forces 70 can include, but are not limited to, an upward force applied to the centering base 18, a combination of upward and downward forces, and other similar forces 70 that can be used to cause this deformation of the centering base 18 to occur.

[0026] Referring again to FIGS. 4-8, the deformed condition 38 of the centering base 18 can take many forms. Typically, the deformed condition 38 reflects a condition where part of the engagement surface 32 that is biased by the terminal portion 28 is a sheared portion 82 that is deformed by the oblique angle 30 of the terminal portion 28. In some examples, the sheared portion 82 is severed, sheared, or otherwise cut off from a main portion of the centering base 18. For example, the centering base 18 can be a piece of unitary, or integrally formed, foam that, when deformed, is split into an outer portion (the sheared portion 82) and an inner portion, with the division occurring through the engagement surface 32 of the centering base 18. A compressed area 19 of the centering base 18, being cut off from the remainder of the centering base 18 in this aspect of the device, assists in forming the sealed engagement 62 that defines the substantially liquid tight seal 42. In this example, the terminal portion 28, which can include a circumferential bead, engages the jacket base 22 and at least partially deforms. A press that applies an external force 70 onto the jacket wall 20 can detect the engagement of the jacket wall 20 with the jacket base 22 (e.g., the terminal portion 28 with the jacket base 22) via a force sensor or a displacement sensor. For example, the press can include a control system having a controller that reads data from the sensor and, in response to detecting a high feedback force or lack of change in displacement of the jacket wall 20, can communicate signals indicative of assembly being complete. In this way, complete embedding of the jacket wall 22 with the centering base 18 can be consistently detected and controlled.

[0027] This sheared portion 82 is biased by the terminal portion 28 to form the compressed area 80 of the centering base 18. In this manner, the oblique angle 30 of the terminal portion 28 forms a void 84 left by the sheared portion 82 and the resulting compressed area 80. This configuration defines the substantially liquid tight seal 42. The combination of the compressed area 80 and the sheared portion 82 forms the generally sealed engagement 62 around the terminal portion 28 that forms the substantially liquid tight seal 42.

[0028] In certain aspects of the device, it is contemplated that the terminal portion 28 does not engage the jacket base 22 and the material of the centering base 18 is positioned therebetween. As described herein, it is also contemplated that the positioning of the terminal portion 28 of the jacket wall 20 with respect to the jacket base 22 can form a direct engagement that at least partially severs or cuts off the compressed area 80 of the centering ring 18.

[0029] It is understood that the deformed condition 38 that results from the sealed engagement 62 between the terminal portion 28 and the centering base 18 can reflect other conditions, not just compressed and sheared. Other examples of this deformation can include, but are not limited to, a condensation, a compaction, a reduction, a distortion, a cleave, combinations thereof, and other similar deflections of the centering base 18 proximate the engagement surface 32.

[0030] The area of the centering base 18 that is deformed interacts with the terminal portion 28 of the jacket wall 20 in such a way that the substantially liquid tight seal 42 is created. This substantially liquid tight seal 42 is typically created around the entire perimeter 92 of the terminal portion 28. This substantially liquid tight seal 42 prevents a vast majority of, or all of, the flowable insulating material 44 from escaping the insulation volume 52 once disposed within the insulation volume 52.

[0031] It should be understood that during assembly the terminal portion 28 and the engagement surface 32 may be placed out of alignment (i.e., misalignment 90). Where this misalignment 90 occurs during manufacture, limited amounts of the flowable insulating material 44 may be able to travel beyond the terminal portion 28 and the centering base 18. As discussed more fully herein, the interaction between the tank 16, the jacket wall 20, the jacket base 22, and the centering base 18 can provide for at least one supplemental seal, as described more fully herein, to prevent the flowable insulating material 44 that escapes the substantially liquid tight seal 42 from also escaping the jacket 14 via a seam between the jacket base 22 and the jacket wall 20.

[0032] According to the various aspects of the device, the deformed condition 38 can result in the terminal portion 28 cutting into the material of the centering base 18, within the engagement surface 32. In this manner, an outward facing surface 100 of the terminal portion 28, due to the oblique angle 30 of the terminal portion 28, pushes outward on the material of the centering base 18 to define the compressed area 80 of sealed engagement 62 that forms the substantially liquid tight seal 42. Additionally, an inward facing surface 102 of the terminal portion 28 cooperates with the centering base 18 to form a gutter or void 84 proximate to the substantially liquid tight seal 42. During manufacture of the appliance 10, the flowable insulating material 44 is disposed within the insulation volume 52. A portion of the flowable insulating material 44 is able to enter into this void 84. When disposed therein, the flowable insulating material 44 is able to cure within the void 84. As discussed herein, once cured, the sliding and flowable insulating material 44 forms a substantially solid form 106 of the insulating material. In this substantially solid form 106, the insulating material within the void 84 strengthens the sealed engagement 62 between the terminal portion 28 of the jacket wall 20 and the engagement surface 32 of the centering base 18. This configuration of the device strengthens the substantially liquid tight seal 42 formed between the terminal portion 28 of the jacket wall 20 and the engagement surface 32 of the centering base 18.

[0033] Referring again to FIGS. 1-3, the water heating appliance 10 is typically comprised of the jacket 14, the tank 16, and the centering base 18. The tank 16 includes the tank base 26 that is proximate to the jacket base 22 but is typically not in direct contact with the jacket base 22. According to various aspects of the device, the tank 16 may also include other elements such as a tank lid 120 that encloses the volume of fluid to be heated and protruded openings with sealed openings 122 for in-shroud compatibility with heating elements 124. According to the various aspects of the device, the water heating appliance 10 includes a fluid inlet 126 that receives fluid, typically in the form of water, from an external source, such as a well, a reservoir, or other municipal water supply. The water heating appliance 10 also includes a fluid outlet 128 that delivers water that has been heated from the tank 16 to the location or fixture that is external to the water heating appliance 10. The water heating appliance 10 also includes one or more heating elements 124. These heating elements 124 can include, but are not limited to, electrical heating elements, heat pump heating elements, gas heaters, combinations thereof, and other similar heating elements. It is to be understood that the heating system 12 is not limited to electrical and gas-powered heating elements.

[0034] Additionally, the tank 16 is typically directly involved in the water heating system 12. In some embodiments of the device, a coiled heat exchanger 140 is engaged with the outer surface 48 of the tank 16. Furthermore, heating elements 124 may extend inward from the tank 16. According to various aspects of the device, the jacket 14 may also include other elements such as a jacket lid 142 for enclosing and providing access to the tank 16 in the jacket 14 or additional heating elements 124 coupled to the jacket wall 20. In some embodiments of the device, the water heating appliance 10 may also include a control system 144 coupled to the jacket wall 20. It is to be understood that various alternative embodiments of the device may utilize non-cylindrical shrouds that may be used for applications that are different from water heating.

[0035] Referring to FIGS. 4-10, the centering base 18 is disposed between the tank base 26 and the jacket base 22 and at least partially prevents the flowable insulating material 44 from travelling through inner engagement 150 between the tank 16 and the centering base 18. This centering base 18 is typically unitary and is typically placed atop the jacket base 22 during assembly. In order to create the substantially liquid tight seal 42, the centering base 18 deforms in response to a sealed engagement 62 between the terminal portion 28 of the jacket wall 20 and the centering base 18. To form the substantially liquid tight seal 42, the centering base 18 is at least partially comprised of a deformable material. This deformable material may include polymeric content, elastomeric content, foam, rubber, natural fibers like cork, combinations thereof and other similar deformable materials. The material and its composition are at least partially dictated by its behavior and ability to deform in order to create the substantially liquid tight seal 42. The material may also dictate the type of deformation that occurs at the engagement surface 32 area that is biased by the terminal portion 28. More rigid materials are more likely to shear, whereas more pliable or elastic materials are more likely to deflect or compress.

[0036] Referring again to FIGS. 8-9, the flowable insulating material 44 is typically at least partially comprised of a foam-like material such as polyurethane foam. The polyurethane foam can be poured, injected, or otherwise disposed into the insulation volume 52 in a liquid or high-viscosity state. During disposition of the flowable insulating material 44 into the insulation volume 52, the insulation volume 52 is capped to form a substantially closed volume. Once disposed into the insulation volume 52, the polyurethane foam is cured using heat and humidity. During this curing stage, the flowable insulating material 44 expands to occupy the space of the insulation volume 52 into a substantially solid form 106. Because the insulation volume 52 is capped, the expansion of the flowable insulation material 44 substantially occupies or fully occupies the insulation volume 52. Vents can be included in the jacket 14 to allow air and other gases to escape so that the curing of the flowable insulating material 44 can operate to occupy most or all of the insulation volume 52.

[0037] In certain aspects of the device, the flowable insulating material 44 in an uncured form can be in various forms or states. These states can be liquid, small beads (such as polystyrene beads), and other flowable forms. Some forms of insulating material may behave like a fluid even if they are not liquids; however, in some embodiments, a liquid insulating material may be used. The flowable insulating material 44 is at least partially chosen based on thermodynamic properties such as thermal conductivity.

[0038] In some embodiment of the device, the flowable insulating material 44 expands and cures into a substantially solid form 106 in response to environmental factors such as humidity and/or heat. In such an aspect of the device, the flowable insulating material 44 is typically comprised of a liquid polyurethane foam in an uncured state that expands into the substantially solid form 106 after curing. During the curing process, the liquid polyurethane expands and forms throughout the insulation volume 52 into the substantially solid form 106. Once in the substantially solid form 106, the insulating material is at least partially unitary and in a substantially solid form 106, and occupies a substantial amount, or the entirety of, the insulation volume 52. Once the flowable insulating material 44 is cured into the substantially solid form 106, the likelihood of some of the flowable insulating material 44 leaking decreases. The cured, substantially solid form 106 of the flowable insulating material 44 may partially occupy gaps and spaces, such as the void 84 left by the sheared portion 82, within the space between the engagement surface 32 of the centering base 18 and the terminal portion 28 of the jacket wall 20 (i.e., the substantially liquid tight seal 42). By occupying these spaces, the substantially solid form 106 of the flowable insulating material 44 prevents further leaking. Additionally, due to the oblique angle 30 of the terminal portion 28, as the insulation material cures and expands, the force of expansion can further bias the terminal portion 28 of the jacket wall 20 against the centering base 18. Also, the inwardly crimped configuration of the terminal portion 28 that forms the oblique angle 30 can cause the force of expansion within the void 84 to further bias the terminal portion 28 and the remainder of the jacket wall 20 in a downward direction.

[0039] As discussed further herein, the configuration of the terminal portion 28, the centering base 18 and the jacket base 22 assist in maintaining the flowable insulating material 44 within the insulation volume 52. By maintaining the flowable insulating material 44 within the insulation volume 52 for a longer period of time, the flowable insulating material 44 has time to cure within the insulation volume 52 and before the flowable insulating material 44 has time to move through any gaps that may be present in a condition of misalignment 90 of the centering base 18. According to the various aspects of the device, where the areas of misalignment 90 are present, a labyrinth seal 160 is defined between the terminal portion 28, the centering base 18, the jacket base 22 and the jacket wall 20, as described more fully below.

[0040] In addition, an inner seal 170 between the tank 16 and the centering base 18 along with the labyrinth seal 160 between the jacket base 22, the jacket wall 20, and the centering base 18 decrease the likelihood of flowable insulating material 44 leakage underneath the tank 16 or through the substantially liquid tight seal 42 where an area of misalignment 90 may exist. The inner seal 170, formed during assembly of the tank 16 atop the centering base 18, is typically similar to the substantially liquid tight seal 42. In most cases, the centering base 18 deforms in response to an inner engagement 150 with the tank 16 and the tank base 26. Such engagement deforms an inner portion 202 of the centering base 18 and creates the inner seal 170, at least partially preventing the flowable insulating material 44 from travelling under the tank 16.

[0041] Furthermore, in areas of misalignment 90 that may exist, the engagement of the jacket base 22 with the jacket wall 20, forms the labyrinth seal 160. This labyrinth seal 160 creates a longer path between the insulation volume 52 and the exterior 46 of the jacket wall 20. This longer path is defined within the areas of misalignment 90 between the centering base 18 and the terminal portion 28 of the jacket wall 20. In these areas of misalignment 90, the flowable insulating material 44 may be able to flow downward around the centering base 18 and around the terminal portion 28, and then upward between the terminal portion 28 and the jacket base 22. Again, this circuitous path through the labyrinth seal 160 delays the movement of the flowable insulating material 44 so that the flowable insulating material 44 has time to cure into the substantially solid form 106, thereby sealing the circuitous path formed by the areas of misalignment 90. Stated another way, the labyrinth seal 160 delays the flowable insulating material 44 from traveling through the substantially liquid tight seal 42 by complicating the path of least resistance. Typically, where areas of misalignment 90 exist, the flowable insulating material 44 will cure into a substantially solid form 106 before making it to the exterior 46 of the jacket wall 20 through the labyrinth seal 160.

[0042] Along with the labyrinth seal 160 and the inner seal 170, the geometry of the centering base 18 can include a protruded area 180 encircling the central region 60 of the centering base 18. This protruded area 180 is positioned to direct the flowable insulating material 44 toward the tank 16 and the central region 60 of the centering base 18 and the inner seal 170. Additionally, the protruded area 180 directs the flowable insulating material 44 away from both the substantially liquid tight seal 42, and, where areas of misalignment 90 may exist, away from the labyrinth seal 160.

[0043] It should be readily understood that where the terminal portion 28 and the centering base 18 are properly aligned 190, there will be no areas of misalignment 90. In such a condition, the substantially liquid tight seal 42 will typically be a continuous seal that extends uninterrupted around the insulation volume 52 at the centering base 18.

[0044] Referring again to FIGS. 3-8, the centering base 18 is disposed between the tank base 26 and the jacket base 22. Typically, the tank 16 has a maximum diameter that is smaller than a maximum diameter of the centering base 18 to define the engaging surface 32 that receives the terminal portion 28. Additionally, it is typical that the maximum diameter of the centering base 18 is less than an inner diameter of the jacket 14. The centering base 18 is typically disposed underneath the tank base 26 but atop the jacket base 22. It is understood that the maximum diameter of the centering base 18 could be greater than, less than, or equal to the maximum diameter of the jacket base 22, the jacket wall 20, the tank base 26, the tank 16, or some combination thereof, depending on the design of the water heating appliance 10.

[0045] In some embodiments of the device, the diameter of the member that forms the centering base 18 may be greater than an outer diameter of the jacket 14. In such an aspect of the device, assembly of the centering base 18 onto the jacket base 22 may cleave off an outer section of this member. The cleaved outer section can fall away and the remaining portion can rest within the jacket base 22 to form the centering base 18 and achieve a flush engagement between the centering base 18 and the jacket base 22. This configuration can be used to maximize the extent of the engaging surface 32 of the centering base 18 onto which the terminal portion 28 is disposed to define the substantially liquid tight seal 42.

[0046] Referring again to FIGS. 3-8, because the centering base 18 is at least partially made of a deformable material, the action of placing the tank 16 on the centering base 18 can deform the area of the centering base 18 that engages with the tank 16 and therefore the tank base 26. This inner engagement 150 that results in deformation can resemble a shear, compression, condensation, compaction, reduction, distortion, cleave, or other deflection in the area engaged. This deformed condition 38 may also result from some type of force 70, such as a weight of the jacket 20 (e.g., gravity acting on the jacket wall 20), another external force 70 (e.g., pressing of a fixture of a hydraulic press), pushing the tank 16 down or pulling the jacket base 22 and/or the centering base 18 in an upward direction, or a combination of upward and downward movements. For example, a fixture configured to insert the insulating material 44 can also serve as the press for pushing the jacket wall 20 into the centering base 18. Thus, the assembly of the jacket wall 20 with the centering base 18 and the jacket base 22 can be performed on a common machine/press having at least one valve for dispensing the insulating material 44, a fixture for pressing the jacket wall 20, and a control system for controlling the assembly process for the jacket 14 (as described herein) and the foam dispensing process.

[0047] As discussed herein, the area that is deformed in response to an inner engagement 150 between the tank base 26 and the inner portion 202 of the centering base 18 can create the inner seal 170. This inner seal 170 may at least partially prevent a flowable insulating material 44 from traveling to an area underneath the tank base 26 through a space defined between a bottom edge 210 of the tank base 26 and the central region 60 of the centering base 18. If the flowable insulating material 44 enters this area and cures, the flowable insulating material 44 can expand and heave the tank base 26. This heaving may move the tank 16 into a misaligned orientation that can result in an insulation layer having an inconsistent thickness around the tank 16. The formation of the inner seal 170 prevents the flowable insulating material 44 from infiltrating the area between the tank 16 and the centering base 18 and, in turn, prevents the tank 16 from tipping and also ensures an at least partially central alignment of the tank 16 on the centering base 18.

[0048] The centering base 18 is typically a unitary member, making assembly and placement between the tank base 26 and the jacket base 22 relatively efficient. However, it is understood that alternative embodiments of the device may involve a non-unitary centering base, such as one formed through expanding polystyrene or polyurethane, or other similar insulating material.

[0049] Referring again to FIGS. 3-8, the jacket 14 has a maximum diameter similar to the maximum diameter of the centering base 18. However, it is understood that the maximum diameter of the jacket wall 20 may be less than, greater than, or equal to the maximum diameter of the centering base 18. The vast majority of the jacket wall 20 is defined above the terminal portion 28; however, in some embodiments the terminal portion 28 may be a majority of the jacket 14 and the jacket wall 20. The terminal portion 28 typically has different attributes than the rest of the jacket wall 20. By way of example, and not limitation, the terminal portion 28 diameter is smaller than the rest of the jacket wall 20 distal of the terminal portion 28. Typically, the diameter of the terminal portion 28 is also smaller than the diameter of the centering base 18. In this manner, engagement of the terminal portion 28 and the centering base 18 can form the substantially liquid tight seal 42.

[0050] Referring to FIG. 9, at least a partial amount of the terminal portion 28 of the jacket wall 20 can be of crimped configuration 220. In alternative embodiments of the device, this crimped configuration 220 can be generally frustoconical in shape. In this embodiment, the frustoconical part of the terminal portion 28 can be angled, typically inward, to engage with the centering base 18. As discussed herein, this sealed engagement 62 of the terminal portion 28 and the centering base 18 deforms the centering base 18 and creates the substantially liquid tight seal 42. In certain aspects of the device, the centering base 18 can have a height that extends through the terminal portion 28 and engages a portion of the jacket wall 20 above the terminal portion 28.

[0051] It is contemplated that the terminal portion 28 can be integrally formed with the jacket wall 20. In such an aspect of the device, the terminal portion 28 can be folded from the jacket wall 20 to either the inner surface 50 or the exterior 46 of the jacket wall 20. In an alternative aspect of the device, the terminal portion 28 can be attached to the jacket wall 20 through a fastening mechanism or some other fastening method. In such an aspect of the device, the terminal portion 28 may be attached to either the inner surface 50 or the exterior 46 of the jacket wall 20 where the terminal portion 28 may extend radially inward or outward at the oblique angle 30 in relation to the engagement surface 32 of the centering base 18. It is understood that in the typical case, the terminal portion 28 extends radially inward at the oblique angle 30.

[0052] In some embodiments of the device, the inner diameter of the jacket wall 20 at the terminal portion 28 is less than the inner diameter of the jacket wall 20 above the terminal portion 28. However, it is understood that in alternative embodiments, the inner diameter of the jacket wall 20 at the terminal portion 28 may be greater than the inner diameter of the jacket wall 20 above the terminal portion 28. In any case, the terminal portion 28 of the jacket wall 20 is responsible for engaging with and biasing the centering base 18 into the deformed condition 38 that defines the substantially liquid tight seal 42.

[0053] Referring again to FIGS. 3-8, the interface 40 between the terminal portion 28 of the jacket wall 20 and the centering base 18 is the substantially liquid tight seal 42. According to the various aspects of the device, no additional fastening mechanism or fastening method is required to establish this substantially liquid tight seal 42. In some embodiments of the device, the jacket base 22 can be fastened to the jacket wall 20 typically through the use of some type of fastening method as part of the assembly of the jacket 14. As described herein, the engagement between the jacket base 22 and the jacket wall 20 may act as a secondary seal, in the form of the labyrinth seal 160 to prevent leakage of the flowable insulating material 44 where a condition of misalignment 90 may exist. As discussed herein, this labyrinth seal 160 may improve the performance of the jacket wall 20 in areas of misalignment 90 between the centering base 18 and the terminal portion 28. The labyrinth seal 160 creates a longer path for the flowable insulating material 44 to travel such that the flowable insulating material 44 cures within the labyrinth seal 160. It is also understood that the jacket base 22 can be fastened to any part of the jacket wall 20, including the terminal portion 28 and parts of the jacket wall 20 above the terminal portion 28.

[0054] Referring again to FIG. 10, the centering base 18 is typically a circular, disk-like member that is unitarily formed. The diameter of the centering base 18 is typically larger than the diameter of the tank 16 and similar to that of the jacket wall 20 and jacket base 22. In various embodiments of the device, a rounded protrusion 230 is formed in the central region 60 of the centering base 18. This rounded protrusion 230 is similar in dimension to the underside 232 of the tank base 26. In this manner, the rounded protrusion 230 at least partially fits into the cavity (i.e., the underside 232) of the tank base 26 to assist in aligning the tank 16 onto the centering base 18. This fitting is intended to make the placement of the tank 16 onto the centering base 18 a consistent manufacturing operation that can be repeated for the manufacture of a plurality of water heating appliances 10. By making this assembly consistent and repeatable, the use of the centering base 18 and the geometries defined therein improve the overall insulation of the water heating appliance 10 and reduce heat loss to the surroundings. In various aspects of the device, the rounded protrusion 230 fits into the cavity (i.e., the underside 232) of the tank base 26 to form the inner seal 170 and further prevents the flowable insulating material 44 from entering and curing underneath the tank 16. In alternative embodiments of the device, the centering base 18 may not include the rounded protrusion 230 in the central region 60, making the centering base 18 a flat, disk-like member.

[0055] In some embodiments of the device, the centering base 18 includes the protruded area 180 that encircles the central rounded protrusion 230. The space in between the central rounded protrusion 230 and the protruded area 180 operates to direct the flowable insulating material 44 during manufacture of the water heating appliance 10. The protruded area 180 is configured to direct the flowable insulating material 44 toward the inner region of the insulation volume 52, which includes the tank 16 and the inner seal 170. Typically, the inner seal 170 will be a consistent and continuous seal defined between the tank 16 and the inner portion 202 of the centering base 18. The weight of the tank 16 is typically able to maintain the continuous inner seal 170. Accordingly, the protruded area 180 is designed to direct the pour of the flowable insulating material 44 toward the continuous inner seal 170 and away from the substantially liquid tight seal 42. As discussed herein, the substantially liquid tight seal 42, because of manufacturing tolerances, may include certain areas of misalignment 90. By directing the flowable insulating material 44 toward the inner seal 170, the flowable insulating material 44 is also directed away from any areas of misalignment 90 that may exist. This motion of the flowable insulating material 44 away from the labyrinth seal 160 allows for additional time for the flowable insulating material 44 to cure into the substantially solid form 106 and seal any areas of misalignment 90 in the labyrinth seal 160.

[0056] It is to be understood that these concepts may assume various alternative embodiments of the centering base 18. Such alternatives may include, but are not limited to, a rectangular or protrusion-less design. Alternative embodiments may also include more protrusions or angled protrusions to more efficiently direct the flowable insulating material 44 within the insulation volume 52. Additionally, the thickness of the centering base 18 is typically similar to that of the depth of the jacket base 22. However, it is to be understood that alternative embodiments of the device may utilize thicker, thinner, or gradient designs.

[0057] Referring again to FIGS. 1-4, the water heating appliance 10 is comprised of the jacket wall 20, the tank base 26, and the centering base 18. Typically, the centering base 18 is disposed underneath the tank base 26 and engages with the outer portion 200 of the centering base 18 to form the substantially liquid tight seal 42. The substantially liquid tight seal 42 is typically formed after engagement between the outer portion 200 of the centering base 18 and the jacket wall 20. The substantially liquid tight seal 42 at least partially prevents a flowable insulating material 44 from travelling in between the jacket wall 20 and the centering base 18 to the exterior 46 of the jacket wall 20.

[0058] Referring again to FIGS. 4-8, the terminal portion 28 of the jacket wall 20 typically extends radially inward at the oblique angle 30 relative to the engagement surface 32 of the centering base 18. It is understood that in certain aspects, the terminal portion 28 may extend radially outward at the oblique angle 30 relative to the engagement surface 32 of the centering base 18, depending on the design of the water heating appliance 10. The engagement surface 32 of the centering base 18 is defined as the general region of the centering base 18 where the terminal portion 28 of the jacket wall 20 engages with and biases the centering base 18 into a deformed condition 38. This extension engages the centering base 18 and biases the centering base 18 into a deformed condition 38. This deformed condition 38 may have a similar behavior as the condition defined by the inner engagement 150 between the tank base 26 and the inner portion 202 of the centering base 18 that forms the inner seal 170. This deformed condition 38 may also result from some type of force 70, such as the weight of the jacket wall 22 or another external force 70, pushing the jacket wall 20 down or pulling the centering base 18 toward the jacket wall 20. Once the centering base 18 is in the deformed condition 38, the interface 40 between the centering base 18 and the terminal portion 28 of the jacket wall 20 forms the substantially liquid tight seal 42. This substantially liquid tight seal 42 is meant to prevent any flowable insulating material 44 from leaking through the sealed engagement 62 between the engagement surface 32 of the centering base 18 and the terminal portion 28 of the jacket wall 20.

[0059] In some aspects of the device, this substantially liquid tight seal 42 is formed throughout the entire perimeter 92 of the terminal portion 28, protecting all areas that may be susceptible to leaks. During manufacture, tolerances in the assembly of the water heating appliance 10 may lead to the centering base 18 being out of alignment (i.e., misalignment 90) with the jacket wall 20. This misalignment 90 may result in gaps in the substantially liquid tight seal 42, exposing some portions to the possibility of flowable insulating material 44 leakage. The misalignment 90 can be the result of manufacturing tolerances and defects in the centering base 18, along with manufacturing tolerances and defects in the jacket wall 20 or tank 16. Typically, the perimeter 92 of the jacket wall 20 is disposed onto enough of the engagement surface 32 of the centering base 18 to bias the centering base 18 into a deformed condition 38. The general size and shape of the centering base 18 with respect to the jacket wall 20 results in the engagement surface 32 of the centering base 18 receiving substantially all of the terminal portion 28.

[0060] The term substantially, as used with respect to the completeness of the substantially liquid tight seal 42, typically refers to a seal that is from approximately 90% complete to approximately 100% complete. Additionally, the term substantially is intended to reflect that the flowable insulating material 44 is not able to pass through the substantially liquid tight seal 42 while other liquids having less viscosity or greater flowability may be able to pass therethrough. Assuring that both the tank 16 and jacket wall 20 are centered on the centering base 18 also ensures that the insulation volume 52 around the tank 16 will have a generally consistent thickness at each point around the tank 16, which is better for thermal efficiency of the water heating appliance 10.

[0061] Referring again to FIGS. 1-3, the water heating appliance 10 typically comprises the jacket wall 20, the tank base 26, and the centering base 18. In some embodiments of the device, the jacket wall 20 is coupled to the jacket base 22 and the jacket lid 142. The water heating appliance 10 may also include heating elements 124 attached to the jacket wall 20, pressure relief valves, inlet 126 and outlet 128 openings, the control system 144, temperature probes, or pressure probes. In certain aspects of the device, the tank base 26 can be coupled to the tank wall 24 and the tank lid 120. Additional aspects of the device can include heat exchanger 140 coiling or other methods of heating the water. It is to be understood that the shape of the jacket 14, the tank 16, and the centering base 18 does not have to be circular or cylindrical in order to work with the scope of the device.

[0062] Referring to FIGS. 4-8, the jacket wall 20 typically features the terminal portion 28 at the bottom edge of the jacket wall 20. This terminal portion 28 biases the centering base 18 into the deformed condition 38 upon engagement between the centering base 18 and the jacket wall 20. This deformed condition 38 forms the substantially liquid tight seal 42 that at least partially prevents a flowable insulating material 44 from leaking out of the insulation volume 52 during manufacture. The diameter of the centering base 18 is typically greater than the diameter of the tank 16. The centering base 18 is unitarily formed. The diameter of the terminal portion 28 is typically less than the diameter of the rest of the jacket wall 20.

[0063] Referring now to FIGS. 1-11, having described the various aspects of the centering base 18 and the substantially liquid tight seal 42 formed between the centering base 18 and the jacket wall 20, a method 400 is disclosed for assembling a water heating appliance 10. According to method 400, step 402 includes aligning a jacket wall 20 of a water heating appliance 10 with respect to a centering base 18. This jacket wall 20 is typically disposed in an outer portion 200 of the centering base 18 and outside the tank 16. In some embodiments of the device, the centering base 18 is first aligned into a jacket base 22 before the jacket wall 20 is aligned with respect to the centering base 18. However, it is understood that alignment of the centering base 18 into the jacket base 22 is not required to achieve the desired result.

[0064] Once aligned, the jacket wall 20 is engaged onto the centering base 18 (step 404). This sealed engagement 62 defines a deformed condition 38 of the centering base 18. This deformed condition 38 defines a sealed engagement 62 between the centering base 18 and the jacket wall 20. In some embodiments of the device, the act of engaging the jacket wall 20 onto the centering base 18 may be done through the weight of the jacket wall 20. In alternative embodiments of the device, external force 70 may be required to engage the jacket wall 20 onto the centering base 18. It is understood that the biasing force 70 that may be required can be upward, downward, angled, or some combination thereof.

[0065] In certain aspects of the device, the terminal portion 28 of the jacket wall 20 is formed to define a crimped edge (i.e., crimped configuration 220). This terminal portion 28 and its crimped edge (i.e., crimped configuration 220) are typically what directly engage with the centering base 18 in order to bias the centering base 18 into a deformed condition 38. It is understood that other embodiments of the device form terminal portions that are not crimped but still function the same way. Some examples of this include, but are not limited to, formation within a lower section of the jacket wall 20 or attachment of the terminal portion 28 onto the jacket wall 20.

[0066] According to the method 400, a step 406 includes disposing the tank 16 on the centering base 18 to define an insulation volume 52 between the jacket wall 20, the tank 16, and the centering base 18. This tank 16 is typically aligned in a central region 60 of the centering base 18. In some embodiments of the device, the tank 16 is disposed onto the rounded protrusion 230 on the centering base 18 located at the central region 60 of the centering base 18. In alternative embodiments of the device, the tank 16 is installed before the jacket wall 20 engages the centering base 18; however, it is understood that they can be installed before or after each other with no effect on the final product.

[0067] Once the insulation volume 52 is formed, a flowable insulating material 44 is disposed in the insulation volume 52 (step 408). The flowable insulating material 44 is then cured into a substantially solid form 106 (step 410). After at least partial solidification, the insulating material has formed an at least substantially solid form 106, layered between the jacket 14, the tank 16, and the centering base 18.

[0068] The flowable insulating material 44 typically expands in response to factors such as heat or humidity, so at least some of the insulation volume 52 is filled with flowable insulating material 44. In some embodiments of the device, after the flowable insulating material 44 expands into its final substantially solid form 106, a majority of the insulation volume 52 is filled with insulating material. The flowable insulating material 44 is typically at least partially comprised of a foam-like material such as expanding polyurethane. However, it is understood that other forms of insulation that are neither flowable nor foam-like are able to be used in place of the flowable insulating material 44.

[0069] According to the various aspects of the device, the sealed engagement 62 of the jacket wall 20 with the centering base 18 can be used to contain the flowable insulating material 44 within the insulation volume 52. In particular, the engagement of the terminal portion 28 with the engagement surface 32 forms the substantially liquid tight seal 42 to prevent the flowable insulating material 44 from escaping. Accordingly, use of the components described herein prevent waste of the flowable insulating material 44 during manufacture. By using the configuration of components, as described herein, the manufacturing process of a water heating appliance 10 can be made more efficient and cost effective by limiting the loss of the flowable insulating material 44. This loss of the flowable insulating material 44 is prevented through the use of the substantially liquid tight seal 42, as well as the labyrinth seal 160 that is defined in areas of misalignment 90 between the terminal portion 28 and the engagement surface 32 of the centering base 18.

[0070] The invention disclosed herein is further summarized in the following paragraphs and is further characterized by combinations of any and all of the various aspects described therein.

[0071] According to one aspect of the present disclosure, a water heating appliance includes a jacket including a jacket wall and a jacket base coupled to the jacket wall, a tank disposed within the jacket and including a tank base proximate to the jacket base, and a centering base abutting the tank base. The tank is configured to contain a volume of liquid. A terminal portion of the jacket wall extends radially inward at an oblique angle relative to an engagement surface of the centering base, and the terminal portion biases the centering base into a deformed condition, and wherein the deformed condition defines a substantially liquid tight seal between the jacket wall and the centering base. The substantially liquid tight seal at least partially prevents a flowable insulating material from traveling to an exterior of the jacket wall through a space defined between the engagement surface of the centering base and the terminal portion of the jacket wall.

[0072] According to another aspect, the centering base is at least partially comprised of a deformable material.

[0073] According to another aspect, the flowable insulating material cures into a substantially solid form.

[0074] According to another aspect, a centering base diameter is greater than a tank diameter, and wherein the centering base is a unitary member.

[0075] According to another aspect, the substantially liquid tight seal is formed without the use of fasteners.

[0076] According to another aspect, an inner diameter of the jacket wall at the terminal portion is less than an inner diameter of the jacket wall above the terminal portion.

[0077] According to another aspect, the terminal portion includes a crimped configuration.

[0078] According to another aspect, the terminal portion is configured to engage the jacket base to cut off a portion of the centering base.

[0079] According to another aspect, the terminal portion is generally frustoconical.

[0080] According to another aspect of the present disclosure, a water heating appliance includes a jacket wall, a tank base disposed within the jacket wall, and a centering base disposed under the tank base. The jacket wall engages an outer portion of the centering base to form a substantially liquid tight seal, and the substantially liquid tight seal at least partially prevents a flowable insulating material from traveling in between the jacket wall and the centering base to an exterior of the jacket wall.

[0081] According to another aspect, the jacket wall features a terminal portion that biases the centering base into a deformed condition that forms the substantially liquid tight seal.

[0082] According to another aspect, a base diameter of the centering base is greater than a tank diameter of the tank base, and wherein the centering base is a unitary member.

[0083] According to another aspect, a terminal portion diameter of the terminal portion is less than a jacket wall diameter of the jacket wall.

[0084] According to yet another aspect of the present disclosure, a method of assembling a water heating appliance includes the following steps: aligning a jacket with respect to a centering base; engaging the jacket onto the centering base to define a deformed condition of the centering base, wherein the deformed condition defines a sealed interface between the centering base and the jacket; disposing a tank on the centering base to define an insulating volume between the jacket, the tank, and the centering base; disposing a flowable insulating material into the insulating volume; and solidifying the flowable insulating material to form an at least partially solid insulation layer between the jacket, the tank, and the centering base.

[0085] According to another aspect, the tank is installed before the jacket engages the centering base.

[0086] According to another aspect, the centering base is disposed on a jacket base that is coupled to the jacket.

[0087] According to another aspect, a weight of the jacket wall at least partially causes the deformed condition.

[0088] According to another aspect, the deformed condition is at least partially caused by a press exerting an external force onto the jacket wall.

[0089] According to another aspect, a terminal portion of the jacket is formed to define a crimped edge.

[0090] According to another aspect, the engagement of the terminal portion with the jacket base cuts off a portion of the centering base.

[0091] 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.

[0092] For purposes of this disclosure, the term coupled (in all of its forms, couple, coupling, coupled, etc.) generally means the joining of two components (electrical or mechanical) directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two components (electrical or mechanical) and any additional intermediate members being integrally formed as a single unitary body with one another or with the two components. Such joining may be permanent in nature or may be removable or releasable in nature unless otherwise stated.

[0093] It is also important to note that the construction and arrangement of the elements of the disclosure as shown in the exemplary embodiments is illustrative only. Although only a few embodiments of the present innovations have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements shown as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and/or members or connector or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied. It should be noted that the elements and/or assemblies of the system may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of colors, textures, and combinations. Accordingly, all such modifications are intended to be included within the scope of the present innovations. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the desired and other exemplary embodiments without departing from the spirit of the present innovations.

[0094] It will be understood that any described processes or steps within described processes may be combined with other disclosed processes or steps to form structures within the scope of the present disclosure. The exemplary structures and processes disclosed herein are for illustrative purposes and are not to be construed as limiting.