WATER HEATER AND METHODS FOR MANUFACTURING THE SAME

Abstract

A water heater includes a tank including a tank wall that defines an opening, a heat exchanger disposed in the tank and terminating inboard of the tank wall, and a mount including a flange coupled to the tank wall and a cup extending from the flange and through the opening. The cup includes a receptacle configured to receive the heat exchanger in a passage defined by the receptacle.

Claims

1. A water heater, comprising: a tank including a tank wall that defines an opening; a heat exchanger disposed in the tank and terminating inboard of the tank wall; and a mount including a flange coupled to the tank wall and a cup extending from the flange and through the opening, wherein the cup includes a receptacle configured to receive the heat exchanger in a passage defined by the receptacle.

2. The water heater of claim 1, wherein the heat exchanger is coupled to the receptacle.

3. The water heater of claim 1, wherein the receptacle is recessed relative to the tank wall.

4. The water heater of claim 1, wherein the receptacle is disposed inboard of the tank wall.

5. The water heater of claim 1, wherein the tank extends along a longitudinal axis, and wherein the heat exchanger terminates radially inboard of the tank wall.

6. The water heater of claim 1, wherein the receptacle extends along a mount axis, and wherein the cup extends axially from the flange inboard of the tank wall to the receptacle, and wherein the receptacle extends axially from the cup toward the exterior.

7. The water heater of claim 1, wherein the heat exchanger includes a coil portion and an exhaust portion unitary with the coil portion and wherein the heat exchanger terminates at the exhaust portion.

8. The water heater of claim 1, wherein the flange couples with the tank wall at an exterior side of the tank wall.

9. The water heater of claim 1, wherein the mount is welded to the tank wall on an exterior surface of the tank wall.

10. The water heater of claim 1, wherein the heat exchanger is welded to the receptacle.

11. A water heater, comprising: a tank disposed on a longitudinal axis and including a tank wall extending axially along the longitudinal axis and defining an opening; a heat exchanger disposed in the tank and radially inboard of the tank wall; and a mount disposed in the opening and including: a flange coupled to the tank wall at an exterior side of the tank wall; and a cup extending radially inwardly from the flange and through the opening to a receptacle configured to receive an end of the heat exchanger at a position radially inboard of the tank wall.

12. The water heater of claim 11, wherein the receptacle extends along a mount axis, and wherein the cup extends axially from the flange inboard of the tank wall to the receptacle, and wherein the receptacle extends axially from the cup toward the exterior.

13. The water heater of claim 11, wherein the heat exchanger includes a coil portion and an exhaust portion unitary with the coil portion.

14. The water heater of claim 13, wherein the heat exchanger terminates at the exhaust portion.

15. A method for manufacturing a water heater, comprising: providing an opening in a tank wall of the water heater; moving the tank wall around and relative to a heat exchanger of the water heater without deformation of the tank wall during the moving of the tank wall around and relative to the heat exchanger; positioning a mount at the opening; and coupling the mount to each of the heat exchanger and the tank wall.

16. The method of claim 15, comprising: enameling the tank wall prior to moving the tank wall around the heat exchanger.

17. The method of claim 15, wherein the coupling of the mount to the heat exchanger includes welding the heat exchanger to the mount.

18. The method of claim 15, wherein the coupling of the mount to the tank wall includes welding the mount to the tank wall.

19. The method of claim 15, wherein the heat exchanger terminates within the tank.

20. The method of claim 15, wherein the mount extends inboard of the tank wall.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0027] In the drawings:

[0028] FIG. 1 is a perspective view of a water heater constructed according to a first construction of the present disclosure;

[0029] FIG. 2 is a perspective view of a water heater constructed according to a second construction of the present disclosure;

[0030] FIG. 3 is a partially-exploded side-elevational view of a tank of the water heater of FIG. 1;

[0031] FIG. 4 is a partially-exploded front-elevational view of a tank of the water heater of FIG. 2;

[0032] FIG. 5 is a functional block diagram of a method of manufacturing a water heater according to one aspect of the present disclosure;

[0033] FIG. 6 is a side elevational view of the tank of the first construction of the water heater with a tank wall of the tank being translucent;

[0034] FIG. 7A is a front view of an outlet tube disposed in an opening defined by the tank wall of the water heater of the first construction during a first stage of assembly with a first plate of a mount removed for clarity of demonstrating the opening and for demonstrating space between the tank wall and the outlet tube;

[0035] FIG. 7B is a front view of the outlet tube disposed in the opening defined by the tank wall of the water heater of the first construction with the first plate of the mount coupled with the tank wall proximate to the opening in the first stage;

[0036] FIG. 7C is a front view of the outlet tube disposed in the opening defined by the tank wall of the water heater of the first construction in a second stage with a second plate welded to the first plate and the outlet tube;

[0037] FIG. 8 is a lower perspective view of an outlet tube of the outlet tube of a heat exchanger coupled with a mount provided on the tank wall of the water heater of the first construction;

[0038] FIG. 9 is a bottom plan view of the mount and the base, with welding omitted, of the tank wall of the water heater of the first construction;

[0039] FIG. 10 is a cut-away view of a lower portion of the tank of the water heater of the first construction taken along the plane A-A of FIG. 6;

[0040] FIG. 11 is a side elevational view of the tank of the second construction of the water heater with a tank wall of the tank being translucent;

[0041] FIG. 12 is a front view of an outlet tube of a heat exchanger aligned with an opening defined by the tank wall of the water heater of the second construction demonstrating space between the outlet tube and the tank wall in the opening;

[0042] FIG. 13 is a lower perspective view of an outlet tube of a heat exchanger coupled with a mount provided on the tank wall of the water heater of the second construction;

[0043] FIG. 14 is a cut-away view of a lower portion of the tank of the water heater of the second construction taken along the plane B-B of FIG. 11; and

[0044] FIG. 15 is a rear perspective view of the mount for the tank according to the second construction.

[0045] The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles described herein.

DETAILED DESCRIPTION

[0046] Additional features and advantages of the disclosure will be set forth in the detailed description which follows and will be apparent to those skilled in the art from the description or recognized by practicing the disclosure as described in the following description, together with the claims and appended drawings.

[0047] As used herein, the term and/or, when used in a list of two or more items, means that any one of the listed items can be employed by itself, or any combination of two or more of the listed items can be employed. For example, if a composition is described as containing components A, B, and/or C, the composition can contain A alone; B alone; C alone; A and B in combination; A and C in combination; B and C in combination; or A, B, and C in combination.

[0048] In this document, relational terms, such as first and second, top and bottom, and the like, are used solely to distinguish one entity or action from another entity or action, without necessarily requiring or implying any actual such relationship or order between such entities or actions.

[0049] 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/or any additional intermediate members. Such joining may include members being integrally formed as a single unitary body with one another (i.e., integrally coupled) or may refer to joining of two components. Such joining may be permanent in nature, or may be removable or releasable in nature, unless otherwise stated.

[0050] The terms substantial, substantially, and variations thereof as used herein are intended to note that a described feature is equal or approximately equal to a value or description. For example, a substantially planar surface is intended to denote a surface that is planar or approximately planar. Moreover, substantially is intended to denote that two values are equal or approximately equal. In some embodiments, substantially may denote values within about 10% of each other, such as within about 5% of each other or within about 2% of each other.

[0051] As used herein, the terms the, a, or an, mean at least one, and should not be limited to only one unless explicitly indicated to the contrary. Thus, for example, reference to a component includes embodiments having two or more such components unless the context clearly indicates otherwise.

[0052] As used herein, the term axial and derivatives thereof, such as axially, shall be understood to refer to a direction along an axis for a given apparatus. Further, the term radial and derivatives thereof, such as radially, shall be understood in relation to the axis. For example, radially outboard refers to further away from the axis, while radially inboard refers to nearer to the axis. The term circumferential and derivatives thereof, such as circumferentially, shall be understood in relation to the axis. Further, axial, radial, and circumferential and derivatives thereof, as they relate to the axis, can be applied to components other than the apparatus.

[0053] Referring now to FIGS. 1-15, a water heater 10 and method 12 for assembling the same is provided. The water heater 10 can have various constructions to provide efficient assembly. Two exemplary constructions of the water heater 10 are shown and described herein, with each providing for limited or no deformation of a tank 14 during assembly and fastening/welding. In a first construction 16 of the water heater 10 depicted in FIGS. 1, 3, and 6-10, a heat exchanger 18 is provided in the tank 14 and includes an exhaust end 20 that is disposed outside of a wall 22 of the tank 14. The heat exchanger 18 can be unitary with the exhaust end 20, such as the exhaust end being a continuation of a coiled pipe. In a second construction 24 of the water heater 10 depicted in FIGS. 2, 4, and 11-15, the exhaust end 20 is disposed behind the wall 22 of the tank 14. In both constructions, the wall 22 of the tank 14 can be lowered onto a base 26 of the tank 14 without the wall 22 being temporarily deformed to fit over the exhaust end 20 during manufacturing of the tank 14. In this way, the wall 22 can be enameled prior to assembly with the base 26, thereby allowing for easier and more thorough application of the enamel on the wall 22 than applying the enamel after assembly of the wall 22 with the base 26.

[0054] Referring now to FIGS. 1 and 2, the water heater 10 includes a tank 14 for storing water and a combustion assembly 28 that is configured to heat the water stored in the tank 14. A jacket 30 can be provided around the tank 14 and define a void 32 in the space between the jacket 30 and the tank 14 for receiving insulation that limits heat transfer from the water through the tank 14. In some examples, a shroud 34 is provided covering at least part of the combustion assembly 28. The combustion assembly 28 can include a burner or other heat source and a blower 36 that is configured to force air over the heat source and into a combustion chamber 38 (FIGS. 3 and 4) centrally disposed in the tank 14. The combustion chamber 38 can be part of a heat exchanger 18 (FIGS. 3 and 4) and/or be in thermal and fluid communication with the combustion chamber 38. The heat exchanger 18 can include an exhaust end 20 that vents flue gas to a vent (not shown) operably coupled with the exhaust end 20. A mount 40 is provided on the tank 14 for providing access to the exhaust end 20 and coupling the heat exchanger 18 with the wall 22. The mount 40 can be unitary or be integrally-formed or be constructed of multiple pieces, as depicted. For example, the mount 40 can include a first plate 42 that couples with the wall 22 and a second plate 44 that couples with the first plate 42.

[0055] As will be described in detail with respect to FIGS. 6-15, the second plate 44 includes a receptacle 46 that defines a passage 48 extending between an ingress 50 and an egress 52 of the receptacle 46. The receptacle 46 interacts with an outlet tube 54 of the heat exchanger 18 via, for example, the passage 48 receiving the outlet tube 54. A sleeve 56 can be disposed around the outlet tube 54 and have different compositional properties than the outlet tube 54. For example, the sleeve 56 can provide a welding surface to interconnect the outlet tube 54 and the mount 40 via welding. While described as an outlet tube 54 herein, the outlet tube 54 can be referred to alternatively as a tube. The tube 54 can be configured for fluid flow (e.g., gas flow) into or out of the heat exchanger 18. Thus, the term outlet tube does not necessarily infer direction of flow.

[0056] In operation, and with particular reference to FIGS. 1 and 2, water enters and exits the tank 14 via an inlet 58 and an outlet 60, respectively, provided on the tank 14. For the constructions illustrated, the inlet 58 is provided in a lower portion 62 of the tank 14, and the outlet 60 is provided in a cap 64 of the tank 14.

[0057] Referring now to FIGS. 1-4, the tank 14 includes the base 26, the cap 64, and the wall 22 extending between the base 26 and the cap 64 to define an interior 66 of the tank 14 when the tank 14 is assembled. The wall 22 can form a friction fit, abut an outer surface 68 of the base 26, or otherwise fit with nominal spacing around the base 26, such that the wall 22 aligns with the base 26 when the wall 22 is lowered onto the base 26. The wall 22 extends along a longitudinal axis L that may be a central axis of the tank 14. For example, the tank 14 can be cylindrical, and the longitudinal axis L can be a center axis. In other examples, the tank 14 is rectangular or another shape, and the longitudinal axis L extends centrally through the tank 14.

[0058] Referring now to FIGS. 3 and 4, the heat exchanger 18 includes a coil 70, such as a helical coil 70, that extends along the longitudinal axis L and forms an outlet tube 54 that extends at an oblique angle relative to the longitudinal axis L to an exhaust end 20. A plurality of support members 72, or bars, can be coupled with the base 26 and extend upwardly to couple with the coil 70 of the heat exchanger 18. The support members 72 can maintain alignment of the heat exchanger 18. The wall 22 of each construction defines an opening 74 to allow external access to the exhaust end 20 when the tank 14 is assembled. In the first construction 16 (FIG. 3), the opening 74 extends from a lower edge 76 of the wall 22 forming a notched edge 78 and a gap 80 in the lower edge 76, while in the second construction 24, the opening 74 is bounded by the wall 22 forming an enclosed hole (FIG. 4).

[0059] With particular reference to FIG. 3, the outlet tube 54 extends through the opening 74. For example, during assembly, the wall 22 can be lowered onto the base 26 (or the base 26 lowered onto the wall 22) while the heat exchanger 18 is coupled with the base 26, and as the lower edge 76 passes the outlet tube 54, the outlet tube 54 moves into the opening 74. This arrangement limits deformation or squeezing of the wall 22 during assembly.

[0060] With particular reference to FIG. 4, the outlet tube 54 does not extend through the opening 74. For example, during assembly, the wall 22 can be lowered onto the base 26 (or the base 26 lowered onto the wall 22) while the heat exchanger 18 is coupled with the base 26, and as the lower edge 76 passes the outlet tube 54, the outlet tube 54 remains behind the opening 74 in the interior 66. This arrangement limits deformation or squeezing of the wall 22 during assembly.

[0061] Referring now to FIG. 5, a method 12 for manufacturing a water heater 10 includes providing an opening 74 in a wall 22 of the water heater 10 at step S10, moving the wall 22 around and relative to the heat exchanger 18 without deformation of the wall 22 at step S12, positioning a mount 40 at the opening 74 at step S14, and coupling the mount 40 to each of the heat exchanger 18 and to the wall 22 at step S16.

[0062] In some examples, step S12 can be limited to not deforming the wall 22 in a width-wise direction, a radial direction, or the like. For example, deformation of the wall 22 can occur in other directions (vertically). Thus, the wall 22 can be slid over the heat exchanger 18 without horizontal deformation or with limited horizontal deformation, without width-wise deformation or with limited width-wise deformation, and/or without radial deformation or with limited radial deformation.

[0063] While not illustrated in the figures, it is contemplated that the method 12 can include additional or alternative steps. For example, the coupling of the mount 40 to the wall 22 can include welding the mount 40 to the wall 22. In some examples, the method 12 includes coupling the heat exchanger 18 with the base 26. In some examples, the method 12 includes coupling the wall 22 to the base 26. For example, the wall 22 can be welded to the base 26. In some examples, moving the wall 22 around the heat exchanger 18 includes sliding the wall 22 over the heat exchanger 18 after the heat exchanger 18 is coupled to the base 26. In some examples, the method 12 includes enameling the wall 22 prior to moving the wall 22 around the heat exchanger 18. For example, the wall 22 can be enameled when the wall 22 is flat (e.g., planar), or otherwise prior to sliding the wall 22 around the heat exchanger 18 and over the base 26. In some examples, the method 12 includes aligning the exhaust end 20 with the opening 74. For example, the outlet tube 54 can be radially aligned with the opening 74, such that the exhaust can be viewed through a front of the opening 74.

[0064] Referring now to FIGS. 6-10, details of the first construction 16 are demonstrated. In this example, the opening 74 extends from the lower edge 76, as previously described. The mount 40 can therefore couple with both the wall 22 and the base 26 to seal the interior 66. For example, the mount 40 can be welded to the base 26 and the wall 22 around the opening 74, as shown in FIGS. 6, 7C, 8 and 10. In FIG. 7B, and 9, welds W are omitted for clarity.

[0065] With particular reference to FIG. 7A-7C, the lower portion 62 of the wall 22 interacting with the outlet tube 54 is shown at two stages A, B of the positioning and mounting process of the outlet tube 54 to the mount 40 and, via the mount 40, the wall 22. For clarity, FIGS. 7A and 7B illustrate the outlet tube 54 in the opening 74 to demonstrate a space 88 between the outlet tube 54 and the wall 22. During assembly, the first plate 42 can be mounted to the wall 22 prior to sliding the wall 22 over the base (see FIG. 7B), but the first plate 42 is omitted for clarity in FIG. 7A. In a first stage A (FIGS. 7A & 7B), the wall 22 has been moved over the base 26 with the opening 74 aligned with the outlet tube 54 having passed through the gap 80. The gap 80 can thus be larger than a width of the outlet tube 54. While the first plate 42 is not depicted in FIG. 7A, a footprint of the first plate 42 is shown in hidden lines to indicate the presence of the first plate 42 prior to coupling the wall 22 with the base 26. For example, when the wall 22 is laid flat (prior to forming a cylinder-shape), the opening 74 can be cut, drilled, or otherwise formed. Following rolling of the wall 22 and welding of the wall 22, end-to-end, to form the cylinder-shape, the first plate 42 can be mounted and welded to the wall 22. Then the wall 22 can be slid over the base 26.

[0066] The mount 40 and the opening 74 can be of any shape to allow the outlet tube 54 to pass through the gap 80 and into the opening 74 without deformation of the wall 22. In the present example, each of the mount 40 and the gap 80 form an at least partially arcuate shape, such as a U-shape, a stilted-arch shape, or a mouse hole shape. For example, the notched edge 78 can have side edges 82 that are substantially straight and extend orthogonally relative to the lower edge 76, as well as an arcuate edge 84 extending between the side edges 82. The arcuate edge 84 can be semicircular or have another arcuate shape to accompany the outlet tube 54. In the example depicted, the arcuate edge 84 has a radius of curvature substantially similar to a radius of curvature of an outer side of the outlet tube 54. The outlet tube 54 fills a portion of the opening 74 to form a space 88 between the tube and the wall 22 in the opening 74. This space 88 can provide tolerance in manufacturing and alignment. The space 88 can be covered by the mount 40, as shown in FIGS. 7A and 7B.

[0067] With particular reference to FIG. 7B, the first plate 42 is shown coupled with the wall 22 and includes an inner edge 90 that substantially aligns with, or is flush with, the notched edge 78. The first plate 42 can be U-shaped and provide outboard spacing from the wall 22 to allow the second plate 44 to cover the opening 74 and interact with the outlet tube 54 and sleeve 56. Thus, the first plate 42 can serve as an intermediate plate to provide a consistent welding surface for the first plate 42. As previously described, the first plate 42 can be coupled to the wall 22 prior to sliding the wall 22 onto the base 26.

[0068] With particular reference to FIGS. 7C-10, the second plate 44 can include the receptacle 46 that defines the passage 48 configured to receive the outlet tube 54. For example, at the second stage B, the second plate 44 can be slid over the exhaust end 20 and moved toward the first plate 42 to engage the first plate 42 and overlay the opening 74 and the second plate 44. The second plate 44 can then be welded to the first plate 42, the base 26, and the outlet tube 54. More particularly, the sleeve 56 can slide over the outlet tube 54 and provide a welding surface between the receptacle 46 and the outlet tube 54 adjacent the egress 52. For example, the sleeve 56 can be coupled with the outlet tube 54 but prior to mounting of the second plate 44, such as prior to assembly of the tank 14 with the base 26. Thus, the method 12 previously described can include the further steps of coupling the first plate 42 to the wall 22 along the notched edge 78 and coupling the second plate 44 to the first plate 42 and the outlet tube 54.

[0069] With continued reference to FIGS. 7C-10, the second plate 44 can include a flange 94 that extends about a periphery of the second plate 44 and a protrusion 96 that extends from the flange 94 toward the base 26. The protrusion 96, for example, can taper from the flange 94 and in a direction from the receptacle 46 and toward the base 26. For example, the relative depth, or lateral distance from the second plate 44 to the base 26 can be a sum of a thickness of the wall 22 and a thickness of the first plate 42, which the protrusion 96 compensates for by extending from a face 98 (e.g., a front surface) of the second plate 44. Accordingly, the protrusion 96 defines an indentation 100 in the front surface that increases in depth as the protrusion 96 approaches the base 26 at a tapered end 102.

[0070] Referring particularly to FIG. 9, the tapered end 102 abuts, or nearly abuts, the base 26 at the gap 80. The tapered end 102 is welded (not shown) to the base 26 along the gap 80 to generally align circumferentially, or peripherally, with welding between the tank 14 and the base 26. The receptacle 46 can extend outwardly from the face 98 of the second plate 44 away from the wall 22 and surround the sleeve 56 and/or the outlet tube 54.

[0071] Referring now to FIG. 10, the exhaust end 20 is disposed inside the receptacle 46 and outside of the interior 66 and outside of the tank 14. The egress 52 is disposed closer to the exhaust end 20 than the ingress 50. Stated another way, the ingress 50 is disposed closer to the longitudinal axis L than the egress 52 is. The ingress 50 can be larger than the egress 52. For example, the receptacle 46 can have an inner diameter, or inner width, that is greater at the ingress 50 than at the egress 52. For example, the inner diameter can narrow, or become smaller, toward the egress 52. For example, the receptacle 46 can be chamfered at the ingress 50 or otherwise filleted at the ingress 50 via a narrowing portion 104, or draw-necked portion. The size and shape of the ingress 50 can assist in guiding the mount 40 (e.g., the receptacle 46) over the exhaust tube. For example, as the ingress 50 receives the exhaust end 20 during mounting of the second plate 44, the exhaust end 20 can engage the receptacle 46 at the ingress 50, and the narrowing portion 104 of the receptacle 46 can guide the outlet tube 54 to align with an outlet axis N, which can be a central axis.

[0072] The outlet axis N can extend at an oblique angle, such as a downward angle, relative to horizontal. For example, when the tank 14 is upright (e.g., the base 26 is supported by a floor or ground), the outlet axis N and the receptacle 46 can slope downwardly relative to horizontal. This downward extension can allow condensate water to run into a condensate trap (not shown), which can be a part of the vent.

[0073] Referring now to FIGS. 11-15, details of the second construction 24 are demonstrated. In this example, the wall 22 entirely bounds the opening 74, and the outlet tube 54 is disposed inboard of the wall 22. The mount 40 therefore extends toward the interior 66 to couple with the outlet tube 54. The mount 40 can form a generally bundt-cake like shape. For example, the mount 40 can include the first plate 42 coupled to the wall 22, and the second plate 44 can include a flange 94 and a cup 108 extending from the flange 94 into the interior 66. The cup 108 can extend at an oblique angle relative to the wall 22 and include a receptacle 46 which can have a similar construction to the receptacle 46 of the first construction 16 (e.g., having a downward taper, chamfered construction, narrowing inner diameter, etc.) (see FIG. 14). The cup 108 can have any shape. In the present example, the cup 108 has an arcuate shape. The cup 108 can include any member that extends radially inboard of the tank wall 22. For example, the cup 108 can form an open-box shape that results in an aesthetic recess into the tank wall 22. It is contemplated that the mount 40 of the second construction 54 can be utilized to in the first construction 16, such that the cup 108 is provided in an opening that extends from the lower edge 76 of the wall 22.

[0074] During manufacturing, after the first plate 42 is installed (e.g., coupled and welded) to the wall 22 around the opening 74 to define a mounting surface for the second plate 44, the wall 22 is slid over the base 26. The second plate 44 is then inserted into the opening 74, and the receptacle 46 receives the outlet tube 54. The second plate 44 is then welded to the first plate 42 and the outlet tube 54 (e.g., to the sleeve 56 around the outlet tube 54).

[0075] Referring now to FIG. 12, the opening 74 can be substantially circular and/or have a warped circular shape. The opening 74 can have a width of approximately four times the width of the outlet tube 54. The space 88, or area/room, between the outlet tube 54 and the wall 22 (e.g., the portion of the opening 74 not taken up by the outlet tube 54), can provide for the cup 108 extending into the interior 66 and toward the outlet axis N. It is contemplated that, while appearing as a two-dimensional circular opening, when the wall 22 is formed in a cylinder, the arcuate shape of the wall 22 forms a warped-circular shape of the opening 74, which can be understood from the view of the mount 40 in FIG. 13 and in relation to the mount 40 shown in FIG. 15. Accordingly, the mount 40 can have a warped or contoured shape to provide continuous connection (via, e.g., welding) to the wall 22. Thus, the mount 40 can be formed in the shape of a Derby style hat. In some examples, the mount 40 can generally form a saddle-shape.

[0076] Referring now to FIGS. 13-15, the cup 108 can extend centrally inward from the flange 94 toward the outlet axis N and inboard toward the interior 66. As shown in FIGS. 14 and 15, the cup 108 can have an arcuate portion 110 that has a curved cross-section. The curved cross-section through the outlet axis N can have an inflection point 114 disposed approximately half-way between the flange 94 and the ingress 50. The arcuate portion 110 forms a recessed surface 116 from which the receptacle 46 extends. In this construction, the egress 52 is disposed inboard of the wall 22, and the exhaust end 20 is disposed inboard of the wall 22.

[0077] Referring particularly to FIG. 14, the shape of the mount 40 can provide for enhanced accessibility for welding. For example, one welder 118 is shown demonstrating the clearance, or welding access 120, provided by the cup 108 of the mount 40, with the welder 118 extending along a weld axis M. The shape of the mount 40 allows the welder 118 to access the sleeve 56 for welding the outlet tube 54 to the receptacle 46. As demonstrated, the welder 118 can have a width that can limit accessibility of the welder 118. However, due to the arcuate portion 110, approximately a 45-degree angle access 120 can be provided relative to the sleeve 56 and/or the receptacle 46. For example, the egress 52 and the flange 94 can be spaced apart by an angle greater than 45 degrees relative to the connection between the sleeve 56 and the receptacle 46 at the egress 52. Accordingly, this access angle 120 can be relative to the outlet axis N. Because the downward angle of the outlet axis N may not be orthogonal relative to the wall 22, the welding access 120 angle can vary based on the position along the arc of the cup 108. In other words, the angles provided by the access 120 may be greater at some angular positions relative to other angular positions (e.g., more room above the outlet tube 54 than below the outlet tube 54). The threshold access 120 angle can provide for access by the welder 118 to weld at a 45-degree angle. It is contemplated that, while one welder 118 is shown, the welding of the mount 40 to the sleeve 56 can include two, four, six, eight, or more welders 118 circumferentially spaced from one another. For example, the welders 118 can be provided on an end effector for concurrent welding of the sleeve 56 with the receptacle 46.

[0078] Referring now to FIG. 15, the saddle-shape of the mount 40 is demonstrated in a perspective view. As previously described, the shape of the mount 40 provides for connection with the outlet tube 54 and the tank wall 22 and welding access 120 for the outlet tube 54.

[0079] In some examples, the volume difference of the interior 66 of the tank 14 relative to the volume, or capacity, of the interior 66 of the tank accounting for the mount 40 extending into the interior 66 is between 0.1 and 0.6 gallons. In some examples, the volume difference of the interior 66 of the tank 14 relative to the volume, or capacity, of the interior 66 of the tank accounting for the mount 40 extending into the interior 66 is between 0.3 and 0.5 gallons. In some examples, the volume difference of the interior 66 of the tank 14 relative to the volume, or capacity, of the interior 66 of the tank accounting for the mount 40 extending into the interior 66 is less than 0.4 gallons. In some examples, the volume difference of the interior 66 of the tank 14 relative to the volume, or capacity, of the interior 66 of the tank accounting for the mount 40 extending into the interior 66 is about 0.3 gallons.

[0080] The interior 66 can be inboard of the tank wall 22, such that a volume bounded by the tank wall 22 (e.g., a cylindrical space) is considered inboard of the tank wall 22 relative to a region exterior to the tank wall 22. Stated another way, the heat exchanger 18 of the second construction 24 can be said to terminate in an inner side of the tank wall 22, as opposed to outside of the tank wall 22 (e.g., in the region exterior). Thus, the interior 66 can have less volume than space inboard, or on the inner side of, the tank wall 22, because the mount 44 can protrude inside the tank 14. The volume taken up by the mount 40 can thus be the volumetric difference between the volume of the interior 66 and the volume of space radially inboard of the tank wall 22.

[0081] It is contemplated that the mount 40 of the first construction 16 and/or the mount 40 of the second construction 24 may be integrally formed or unitary. For example, the first plate 42 and the second plate 44 can be provided as a common assembly that is then installed onto the tank 14. In other words, the order of welding the first plate 42 and the second plate 44 can vary from what is described above. It is also contemplated that the edge of a part may apply to a surface that is substantially thinner relative to the width or height of said part (e.g., an edgeof a sheet of 1/4-inch steel).

[0082] According to an aspect of the present disclosure, a method for manufacturing a water heater includes providing an opening in a tank wall of the water heater, moving the tank wall around and relative to the heat exchanger without deformation of the tank wall, positioning a mount at the opening, and coupling the mount to each of the heat exchangers and the tank wall.

[0083] According to another aspect of the present disclosure, the coupling of the mount to the heat exchanger includes welding the heat exchanger to the mount.

[0084] According to another aspect of the present disclosure, the coupling of the mount to the tank wall includes welding the mount to the tank wall.

[0085] According to another aspect of the present disclosure, the method includes aligning the heat exchanger with a base of a tank of the water heater.

[0086] According to another aspect of the present disclosure, the method includes coupling the tank wall to a base of a tank of the water heater.

[0087] According to another aspect of the present disclosure, the method includes moving the tank wall around the heat exchanger includes sliding the tank wall over the heat exchanger.

[0088] According to another aspect of the present disclosure, the tank wall and the base each extend along a longitudinal axis, and wherein the sliding of the tank wall over the heat exchanger is executed while the tank wall and the base are aligned on the longitudinal axis.

[0089] According to another aspect of the present disclosure, the heat exchanger includes a tube extending to the exhaust end, and the tube extends toward the tank wall.

[0090] According to another aspect of the present disclosure, the method includes enameling the tank wall prior to moving the tank wall around the heat exchanger.

[0091] According to another aspect of the present disclosure, the method includes aligning the exhaust end with the opening.

[0092] According to another aspect of the present disclosure, the tank wall defines an interior of the tank, and wherein the exhaust end is disposed outside of the interior.

[0093] According to another aspect of the present disclosure, the opening extends from a lower edge of the tank wall to form a gap in the lower edge.

[0094] According to another aspect of the present disclosure, the heat exchanger includes a tube extending to the exhaust end, and moving the tank wall relative to the heat exchanger includes the tube moving through the gap into the opening.

[0095] According to another aspect of the present disclosure, the gap is longer than a width of the tube.

[0096] According to another aspect of the present disclosure, the tube fills a portion of the opening to form a space between the tube and the tank wall in the opening.

[0097] According to another aspect of the present disclosure, the opening forms a notched edge.

[0098] According to another aspect of the present disclosure, the mount includes a first plate and a second plate.

[0099] According to another aspect of the present disclosure, positioning and coupling the mount includes coupling the first plate to the tank wall along the notched edge, and coupling the second plate to the first plate and the tube.

[0100] According to another aspect of the present disclosure, the second plate includes a receptacle configured to receive the tube.

[0101] According to another aspect of the present disclosure, coupling the second plate to the first plate and the tube includes sliding the receptacle over the tube and welding the second plate to the first plate.

[0102] According to another aspect of the present disclosure, the receptacle defines an ingress and an egress that each receive the tube, the egress disposed closer to the exhaust end than the ingress.

[0103] According to another aspect of the present disclosure, the ingress is larger than the egress.

[0104] According to another aspect of the present disclosure, the receptacle narrows from the ingress toward the egress.

[0105] According to another aspect of the present disclosure, the receptacle is chamfered at the ingress to guide the exhaust end through the receptacle.

[0106] According to another aspect of the present disclosure, the second plate includes a flange that engages the first plate and a protrusion that extends from the flange and into the opening and toward the gap.

[0107] According to another aspect of the present disclosure, the protrusion extends inwardly toward the base.

[0108] According to another aspect of the present disclosure, the method includes coupling the mount to the base of the tank at the protrusion.

[0109] According to another aspect of the present disclosure, coupling the mount to the base of the tank at the protrusion includes welding the protrusion to the base proximate the gap.

[0110] According to another aspect of the present disclosure, the second plate includes a front surface and defines an indentation on the front surface.

[0111] According to another aspect of the present disclosure, the indentation extends into the protrusion.

[0112] According to another aspect of the present disclosure, the notched edge forms an at least partially arcuate shape.

[0113] According to another aspect of the present disclosure, the at least partially arcuate shape is U-shaped.

[0114] According to another aspect of the present disclosure, the tank wall entirely bounds the opening.

[0115] According to another aspect of the present disclosure, the mount includes a first plate coupled to the tank wall, a second plate including an outer flange configured to engage the first plate, and a cup extending from the flange into an interior defined by the tank wall.

[0116] According to another aspect of the present disclosure, the cup extends at an oblique angle relative to the tank wall.

[0117] According to another aspect of the present disclosure, the heat exchanger includes a tube extending to the exhaust end.

[0118] According to another aspect of the present disclosure, the cup includes a receptacle configured to receive the tube.

[0119] According to another aspect of the present disclosure, coupling the mount to the heat exchanger includes sliding the receptacle over the tube, and welding the mount to the tube.

[0120] According to another aspect of the present disclosure, the receptacle defines an ingress and an egress that each receive the tube, the egress disposed closer to the exhaust end than the ingress.

[0121] According to another aspect of the present disclosure, the ingress is larger than the egress.

[0122] According to another aspect of the present disclosure, the receptacle narrows from the ingress toward the egress.

[0123] According to another aspect of the present disclosure, the receptacle is chamfered at the ingress to guide the exhaust end through the receptacle.

[0124] According to another aspect of the present disclosure, the cup includes an arcuate portion extending from the flange to a recessed surface from which the receptacle extends.

[0125] According to another aspect of the present disclosure, the egress is disposed inboard of the tank wall.

[0126] According to another aspect of the present disclosure, the mount forms a warped bundt-cake pan shape.

[0127] According to another aspect of the present disclosure, the exhaust end is disposed inboard of the tank wall.

[0128] According to another aspect of the present disclosure, the heat exchanger includes a heat exchanger coil extending along the longitudinal axis and is disposed inboard of the tank wall.

[0129] According to another aspect of the present disclosure, the heat exchanger coil is mounted to the base prior to moving the tank wall around and relative to the heat exchanger coil.

[0130] According to another aspect of the present disclosure, a sleeve is disposed at the exhaust end and serves as a welding surface for welding the heat exchanger to the mount.

[0131] According to another aspect of the present disclosure, the mounting plate defines at least one opening through which the exhaust end is received for coupling the mount to the heat exchanger.

[0132] According to another aspect of the present disclosure, a water heater includes a tank extending along a longitudinal axis and a tank wall that defines an opening, a heat exchanger including an exhaust end disposed between the longitudinal axis and the tank wall, and a mount disposed in the opening and extending toward the longitudinal axis, the mount operably coupling the heat exchanger with the tank wall.

[0133] According to another aspect of the present disclosure, the exhaust end extends at an acute angle relative to the longitudinal axis.

[0134] According to another aspect of the present disclosure, the tank wall entirely bounds the opening.

[0135] According to another aspect of the present disclosure, the mount includes an outer flange configured to engage the tank wall, and a cup extending from the flange and toward the longitudinal axis.

[0136] According to another aspect of the present disclosure, the cup extends at an oblique angle relative to the tank wall.

[0137] According to another aspect of the present disclosure, the heat exchanger includes a tube extending to the exhaust end.

[0138] According to another aspect of the present disclosure, the cup includes a receptacle configured to receive the tube.

[0139] According to another aspect of the present disclosure, the receptacle defines an ingress and an egress that each receive the tube, the egress disposed closer to the exhaust end than the ingress.

[0140] According to another aspect of the present disclosure, the ingress is larger than the egress.

[0141] According to another aspect of the present disclosure, the receptacle narrows from the ingress toward the egress.

[0142] According to another aspect of the present disclosure, the receptacle is chamfered at the ingress to guide the exhaust end through the receptacle.

[0143] According to another aspect of the present disclosure, the cup includes an arcuate portion extending from the flange to a recessed surface from which the receptacle extends.

[0144] According to another aspect of the present disclosure, the egress is disposed inboard of the tank wall.

[0145] According to another aspect of the present disclosure, the mount forms a bundt-cake pan shape.

[0146] According to another aspect of the present disclosure, the exhaust end is disposed inboard of the tank wall.

[0147] According to another aspect of the present disclosure, a water heater includes a tank including a tank wall having a lower edge, the tank wall defining an opening extending from the lower edge, a heat exchanger including an exhaust end extending through the opening, and a mount disposed covering the opening and operably coupling the exhaust end with the tank wall.

[0148] According to another aspect of the present disclosure, the tank includes a base operably coupled with the tank wall.

[0149] According to another aspect of the present disclosure, the tank wall defines an interior of the tank, and wherein the exhaust end is disposed outside of the interior.

[0150] According to another aspect of the present disclosure, the heat exchanger includes a tube extending to the exhaust end.

[0151] According to another aspect of the present disclosure, the gap is larger than a width of the tube.

[0152] According to another aspect of the present disclosure, the tube fills a portion of the opening to form a space between the tube and the tank wall in the opening.

[0153] According to another aspect of the present disclosure, the opening forms a notched edge.

[0154] According to another aspect of the present disclosure, the mount includes a first plate and a second plate.

[0155] According to another aspect of the present disclosure, the second plate includes a receptacle configured to receive the tube.

[0156] According to another aspect of the present disclosure, the receptacle defines an ingress and an egress that each receive the tube, the egress disposed closer to the exhaust end than the ingress.

[0157] According to another aspect of the present disclosure, the ingress is larger than the egress.

[0158] According to another aspect of the present disclosure, the receptacle narrows from the ingress toward the egress.

[0159] According to another aspect of the present disclosure, the receptacle is chamfered at the ingress to guide the exhaust end through the receptacle.

[0160] According to another aspect of the present disclosure, the second plate includes a flange that engages the first plate and a protrusion that extends from the flange and into the opening and toward the gap.

[0161] According to another aspect of the present disclosure, the protrusion engages the base of the tank.

[0162] According to another aspect of the present disclosure, coupling the mount to the base of the tank at the protrusion includes welding the protrusion to the base proximate the gap.

[0163] According to another aspect of the present disclosure, the second plate defines an indentation extending from the flange into the protrusion.

[0164] According to another aspect of the present disclosure, the notched edge forms an at least partially arcuate shape.

[0165] According to another aspect of the present disclosure, the at least partially arcuate shape is a stilted-arch shape.

[0166] According to another aspect of the present disclosure, a method for manufacturing a water heater includes providing an opening in a tank wall of the water heater, enameling the tank wall of a water heater, after enameling the tank wall, moving the tank wall around and relative to the heat exchanger without deformation of the tank wall, positioning a mount at the opening, and coupling the mount to each of the heat exchanger and the tank wall.

[0167] It is to be understood that variations and modifications can be made on the aforementioned structure without departing from the concepts of the present disclosure, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise.