RESIDENTIAL HYBRID HOT WATER TANK AND CONTROL SYSTEM THEREFOR

Abstract

A hot water tank is provided. The hot water tank comprising: a tank which includes a bottom, a top, and sides therebetween to define an interior; a combustion chamber within the interior, proximate the bottom and sides, the combustion chamber terminating in a mouth where it connects to the side; a gas burner, which is a first heat source and is housed in the combustion chamber; a combustion fan located at the mouth of the combustion chamber and in gaseous communication with an ambient environment and the combustion chamber; a substantially spiral flue which extends upward through the interior and is in gaseous communication with the combustion chamber and a chimney, which is located proximate the top of the tank, such that in use flue gases travel from the combustion chamber upward to the chimney; a condensation trap, which is outside the tank and is in fluid communication with the combustion chamber or the flue proximate the combustion chamber; and a controller, the controller configured to control the burner.

Claims

1. A hot water tank, the hot water tank comprising: a tank which includes a bottom, a top, and sides therebetween to define an interior; a combustion chamber within the interior, proximate the bottom and sides, the combustion chamber terminating in a mouth where it connects to the side; a gas burner, which is a first heat source and is housed in the combustion chamber; a substantially spiral flue which extends upward through the interior and is in gaseous communication with the combustion chamber and a chimney, which is located proximate the top of the hot water tank, such that in use flue gases travel from the combustion chamber upward to the chimney; and a controller, the controller configured to control the burner.

2. The hot water tank of claim 1 further comprising at least one electrical element which is a second heat source and is housed in the interior and is under control of the controller.

3. The hot water tank of claim 2, further comprising a thermostat and a temperature sensor, the thermostat and temperature sensor in electronic communication with the controller.

4. The hot water tank of claim 3, wherein the controller includes a processor and a memory, the memory configured to modulate the first heat source and the second heat source based on parameters including one or more of a target temperature, a selected rate of heating, a current system load, a cost of a heat source and an availability of the heat source.

5. The hot water tank of claim 4, wherein the processor is configured to switch the first heat source on and off, switch the second heat source on and off and adjust an output of each of the first heat source and the second heat source.

6. (canceled)

7. (canceled)

8. (canceled)

9. A hybrid residential water heating system, the system comprising: a hot water tank which includes a bottom, a top, and sides therebetween to define an interior; a combustion chamber within the interior, proximate the bottom and sides, the combustion chamber terminating in a mouth where it connects to the side; a gas burner, which is a first heat source and is housed in the combustion chamber; a combustion fan located at the mouth of the combustion chamber and in gaseous communication with an ambient environment and the combustion chamber; a spiral flue which extends through the interior and is in gaseous communication with the combustion chamber and a chimney, which is located proximate the top of the hot water tank, such that in use, flue gases travel from the combustion chamber upward to the chimney; at least one electrical element which is a second heat source and is housed in the interior; a thermostat and a temperature sensor; and a controller which includes a printed circuit board and a microprocessor wherein the microprocessor is configured to modulate the first heat source and the second heat source and is in electronic communication with the thermostat and the temperature sensor.

10. The hybrid residential water heating system of claim 9, wherein one or more of the printed circuit board and the microprocessor include a wired link or a wireless link.

11. The hybrid hot water tank system of claim 10, further comprising a computing device which includes a wired link or a wireless link and is remote to the hot water tank, the printed circuit board and the microprocessor.

12. The hybrid residential water heating system of claim 11, wherein the computing device is a utilities company computing device.

13. The hybrid residential water heating system of claim 11, wherein the computing device is a third-party systems management company computing device.

14. The hybrid residential water heating system of claim 11, wherein the computing device includes a memory and a processor, the memory configured to instruct the processor to instruct the microprocessor to modulate the first heat source and the second heat source based on parameters including one or more of the target temperature, the selected rate of heating, the current system load, the cost of the heat source and the availability of the heat source.

15. The hybrid residential water heating system of claim 14, wherein the computing device memory is further configured to instruct the processor to determine a cost-effective heating mode and to instruct the microprocessor to modulate the first heat source and the second heat source based on the cost-effective heating mode.

16. (canceled)

17. (canceled)

18. (canceled)

19. A method of heating a domestic water supply, the method comprising: selecting the hybrid residential water heating system of claim 9; and modulating the first heat source and the second heat source with the microprocessor based on parameters including a target temperature, a selected rate of heating, a current system load, a cost of a heat source and an availability of the heat source by adjusting a gas flow and an electric current flow.

20. The method of claim 19, further comprising the microprocessor, in any order and in any number of times, switching the first heat source on and off, switching the second heat source on and off and adjusting an output of each of the first heat source and the second heat source.

21. The method of claim 20, further comprising the microprocessor communicating with a remote computing device.

22. The method of claim 21, further comprising the remote computing device instructing the microprocessor to modulate the first heat source and the second heat source based on parameters including one or more of the target temperature, the selected rate of heating, the current system load, the cost of the heat source and the availability of the heat source.

23. The method of claim 22, further comprising the remote computing device determining a cost-effective heating mode and instructing the microprocessor, the microprocessor adjusting the gas flow and the electric current flow such that the first heat source and the second heat source are operating in the cost-effective heating mode.

24. A hybrid hot water tank, the hybrid hot water tank comprising: a tank which includes a bottom, a top, and sides therebetween to define an interior; a combustion chamber within the interior, proximate the bottom and sides, the combustion chamber terminating in a mouth where it connects to the side; a gas burner, which is a first heat source and is housed in the combustion chamber; a combustion fan located at the mouth of the combustion chamber and in gaseous communication with an ambient environment and the combustion chamber; a substantially spiral flue which extends through the interior and is in gaseous communication with the combustion chamber and an externally disposed chimney; a condensation trap, which is outside the tank and is in fluid communication with the combustion chamber or the flue; a controller, the controller configured to control the burner; and at least one electrical element which is a second heat source and is housed in the interior and is under control of the controller, wherein the controller includes a processor and a memory, the memory configured to modulate the first heat source and the second heat source based on parameters including one or more of a target temperature, a selected rate of heating, a current system load, a cost of a heat source and an availability of the heat source.

25. (canceled)

26. (canceled)

27. (canceled)

28. (canceled)

29. (canceled)

30. (canceled)

31. (canceled)

32. (canceled)

33. (canceled)

Description

FIGURES

[0053] FIG. 1A is a schematic sectional view of the hot water tank of the present technology; FIG. 1B is an alternative embodiment of the condensation trap of the hot water tank of FIG. 1A.

[0054] FIG. 2 is a schematic sectional view showing the details of the combustion chamber, combustion fan and condensation trap.

[0055] FIG. 3 is a schematic sectional view of an alternative embodiment of FIGS. 1A and 1B.

[0056] FIG. 4 is a schematic sectional view of another alternative embodiment of FIGS. 1A and 1B.

[0057] FIG. 5 is a schematic of the flame ionization sensing system of the hot water tank of FIGS. 1A, 1B, 3 and 4.

[0058] FIG. 6 is a schematic of the gas control system of the hot water tank of FIGS. 1A, 1B, 3 and 4.

[0059] FIG. 7 is a schematic of the electricity control system of the hot water tank of FIGS. 1A, 1B, 3 and 4.

[0060] FIG. 8 is block diagram of autonomous operation of the hot water tank of FIGS. 1A, 1B, 3 and 4.

[0061] FIG. 9 is a block diagram of a utilities-controlled operation of the hot water tank of FIGS. 1A, 1B, 3 and 4.

[0062] FIG. 10 is a block diagram of the decision-making process for operating the hot water tank of FIGS. 1A, 1B, 3 and 4.

[0063] FIG. 11 is another alternative embodiment of FIGS. 1A and 1B.

DESCRIPTION

[0064] Except as otherwise expressly provided, the following rules of interpretation apply to this specification (written description and claims): (a) all words used herein shall be construed to be of such gender or number (singular or plural) as the circumstances require; (b) the singular terms “a”, “an”, and “the”, as used in the specification and the appended claims include plural references unless the context clearly dictates otherwise; (c) the antecedent term “about” applied to a recited range or value denotes an approximation within the deviation in the range or value known or expected in the art from the measurements method; (d) the words “herein”, “hereby”, “hereof”, “hereto”, “hereinbefore”, and “hereinafter”, and words of similar import, refer to this specification in its entirety and not to any particular paragraph, claim or other subdivision, unless otherwise specified; (e) descriptive headings are for convenience only and shall not control or affect the meaning or construction of any part of the specification; and (f) “or” and “any” are not exclusive and “include” and “including” are not limiting. Further, the terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted.

[0065] Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. Where a specific range of values is provided, it is understood that each intervening value, to the tenth of the unit of the lower limit unless the context clearly dictates otherwise, between the upper and lower limit of that range and any other stated or intervening value in that stated range, is included therein. All smaller sub ranges are also included. The upper and lower limits of these smaller ranges are also included therein, subject to any specifically excluded limit in the stated range.

[0066] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the relevant art. Although any methods and materials similar or equivalent to those described herein can also be used, the acceptable methods and materials are now described.

[0067] Definitions:

[0068] Heat source—in the context of the present technology, a heat source is an electrical power source or a gas source such as propane or natural gas.

[0069] First heat source and second heat source—in the context of the present technology, the use of “first” and “second” is interchangeable and is used simply to indicate that there is one heat source and there is another heat source.

[0070] Long flue—in the context of the present technology, a long flue is at least about twenty feet long and up to as long as about fifty feet long and all dimensions therebetween. The inside diameter is between about 1 inch inside diameter to about 2 inches inside diameter.

[0071] Substantially spiral flue—in the context of the present technology, a substantially spiral flue is one that is at least about 90% spiral, but may have one or more of a short section of horizontally disposed flue, a short section of vertically disposed flue and a short section of sloped flue.

DETAILED DESCRIPTION:

[0072] The usage ratio between fuel sources (gas and electricity), may be influenced directly, or indirectly by the occupant, a building management system (BMS), a third party energy management service, or via the utility provider(s), in order to increase operational efficiency, to lower operating costs, and/or to provide building or district wide load management capabilities.

[0073] A hybrid hot water tank, generally referred to as 8 is shown in FIG. 1A. The tank 10 has a top 12, a bottom 14, and a cylindrical side wall 16, all which define an interior 18. A gas line 20, which may carry natural gas or propane or the like, provides fuel to a burner 22. The burner 22 is housed in a combustion chamber 24 which is in the vicinity of the bottom 14 of the tank 10. Below the combustion chamber 24, outside of the tank and in fluid communication with the combustion chamber 24 is a condensation trap 28. The combustion chamber 24 has a condensation collection zone, generally referred to as 30, which is defined by a sloping end 32 and a base 34. In an alternative embodiment, shown in FIG. 1B the condensation collection zone 30 is defined by two flue sections members 36, both which slope downward towards the condensation trap 28, which is below the bottom 14. The condensation trap 28 may be extended via a pipe to the floor pan. A combustion fan 38 is located proximate the burner 22 to provide combustion air from the ambient to the burner 22. The combustion fan 38 is in gaseous communication with the combustion chamber 24 and is located at the combustion chamber mouth 26. The combustion chamber 24 is in gaseous communication with the flue 40. Thus, when the combustion fan 38 is operational, it forces air into the combustion chamber 24 and urges the flue gases through the flue 40. The placement and pushing the flue gases rather than pulling them reduces the chance of condensation within the flue 40. The combustion fan 38 acts as a shutter, thus when it is not operational, it covers the combustion chamber mouth 26 and reduces or eliminates gravity feed of cold, outside air into the building in which the hot water tank 8 is housed. The combustion chamber 24 is shown extending into the interior 18 from the side wall 16 in this embodiment. In an alternative embodiment it is located on the bottom 14.

[0074] The flue 40 is formed into a spiral 42 (helical coil, helix) which extends from the combustion chamber 24 up through the interior 18 of the tank 10, reaching a chimney 44 at or proximate the top 12. There is no vertically disposed flue, nor is there vertically disposed combustion chamber 24 extending substantially into the interior. Heat from combustion is primarily extracted from the flue 40 as it is urged upward through the spiral flue 40 to the chimney 44. We need to be careful because the prior art can be construed as having a combustion chamber with a spiral flue extending from the bottom to the top of the interior (even though the flue gases go from the top to the bottom rather than the bottom to the top). The prior art has a large chamber centrally located in the interior with the burner below.

[0075] An electrical line 46 provides power to one or more electrical elements 48 which are housed in the interior 18. The electrical elements 48 are preferably located on the side wall 16 and are spaced apart from one another such that different zones of water in the interior are being heated at the same time, or different times.

[0076] A smart controller 50 is in electronic communication with the burner 22, the combustion fan 38, the electrical elements 48, a temperature sensor 52 and a thermostat 54.

[0077] Water enters the hot water tank 10 through an inlet 56 in the top 12 of the tank 10. Hot water leaves the tank 10 through an outlet 58 in the top 12 of the hot water tank 10. A safety valve 60 is also located in the top 12 of the tank 10. A drain 62 is located either in the bottom 14 or proximate the bottom 14 of the tank 10.

[0078] The flue 40 is about 2 inches in inside diameter. This is half the diameter of a standard flue, thus the surface area per inch of length of flue 40 is 12.57 square inches versus 37.7 square inches, however, the ratio of surface area to volume per inch of length of flue is about 4 for the flue 40 compared to about 3 for a standard flue. The flue 40 is about 38 feet long as compared to 4 feet long, hence the ratio of surface area to volume is about 2 for the flue 40 versus about 1 for a standard flue. This greatly increases the efficiency of heat transfer between the flue gases and the water in the interior 18 of the tank 10. As the spiral 42 does not conform to the golden ratio, the flue gases have an increased tendency to cavitate and be slowed, thus further increasing the efficiency of heat transfer between the flue gases and the water in the interior 18 of the hot water tank 10. Similarly, as the spiral 42 is not a straight flue, and gases tend to travel in a straight line, the flue gases contact the inner surface of the flue 40 more often, thus increasing the potential for heat transfer.

[0079] Table 1 shows a range of exemplary dimensions of the tank and the flue (note that the tank volume is calculate as the tank volume minus the volume of the flue.

TABLE-US-00001 flue coil spiral tank inside flue spiral outside surface area inside tank tank diameter length height pitch diameter (square diameter height volume (inches) (feet) (inches) coils (inches) (inches) feet) (inches) (inches) (gallons) 1 40 30 14 2 10 10.5 16 36 32 1.25 40 40 15 2.5 12 13.1 18 48 53 1.5 40 45 14 3 14 15.7 20 50 68 1.75 40 52 14 3.5 16 18.3 22 60 99 2 40 60 14 4 18 20.9 23 65 117

[0080] The outside diameter of a coil of the spiral flue to a tank inside diameter has a ratio of about 0.6 to about 0.8. The ratio of spiral height to tank height may range from about 0.8 to about 0.95. The volume of the spiral flue to a volume of the hot water tank may have a ratio of about 0.05 to about 0.057. In comparison, the ratio of volume of a four foot long straight flue with an inside diameter of 4 inches to a volume of the hot water tank of 53 gallons is about 0.049. The surface area to tank volume ratio for a 1.25 inside diameter flue and a 53 gallons tank is about 0.15 versus 0.05 for the four foot straight flue with a diameter of 4 inches. The ratio of surface area to volume (gallons) for the spiral flues ranges from about 0.11 to about 0.21 and may range from about 0.09 to about 0.3. As would be known to one skilled in the art, as the length of the flue increases, one or more of the pitch decreases and the number of coils increases.

[0081] The controller 50 provides the following functionality: [0082] A—heating quickly with natural gas (high BTU input) 40K Btu [0083] B—heating slowly with natural gas 20K Btu [0084] C—heating quickly with electricity (2×4500 watt=40K Btu) [0085] D—heating slowly with electricity 0-20K Btu [0086] E—heating twice as fast with both electricity and natural gas running at same time 80K Btu [0087] F—overheating tank to store (usually done at night with cheap electricity) [0088] G—Allowing hot water to leave tank without replacing it, using either energy source [0089] H—vacation turndown, and turn on from Wi-Fi [0090] I—Safety mode where temperature kept below 130° F. if no mixing valve available.

[0091] FIG. 2 is a close-up view of the burner 22, fan 38 and trap 28. The burner 22 is housed in the combustion chamber 24. The combustion chamber 24 is lined with a ceramic liner 64. A condensate channel 65 is defined by the ceramic liner 64 and the base 34 of the combustion chamber 24. The condensate channel 65 is in fluid communication with a condensate line 67, which connects the condensate channel 65 to the condensation trap 28, through an aperture 69 in the side 16. The combustion fan 38 is located in the mouth 26 of the combustion chamber 24. A gas valve 94 controls the flow of gas to the burner 22 via a gas line 20.

[0092] In an alternative embodiment, shown in FIG. 3, the tank 10 has a top 12, a bottom 14, and a cylindrical side wall 16, all which define an interior 18. A gas line 20, which may carry natural gas or propane or the like, provides fuel to a burner 22. The burner 22 is housed in a combustion chamber 24 which is in the vicinity of the top 12 of the tank 10. Proximate the bottom 14, outside of the tank 10 and in fluid communication with the combustion chamber 24 is a condensation trap 28. The condensation trap 28 may be extended via a pipe to the floor pan. A combustion fan 38 is located proximate the burner 22 to provide combustion air from the ambient to the burner 22. The combustion fan 38 is in gaseous communication with the combustion chamber 24 and is located at the combustion chamber mouth 26. The combustion chamber 24 is in gaseous communication with the flue 40. Thus, when the combustion fan 38 is operational, it forces air into the combustion chamber 24 and urges the flue gases through the flue 40. The placement and pushing the flue gases rather than pulling them reduces the chance of condensation within the flue 40. The combustion fan 38 acts as a shutter, thus when it is not operational, it covers the combustion chamber mouth 26 and reduces or eliminates gravity feed of cold, outside air into the building in which the hot water tank 8 is housed. The combustion chamber 24 is shown extending into the interior 18 from the side wall 16 in this embodiment.

[0093] The flue 40 is formed into a spiral 42 (helical coil, helix) which extends from the combustion chamber 24 down through the interior 18 of the tank 10, reaching a chimney 44 in the side 16 proximate the bottom 14. The condensation trap 28 is in line with the flue 40 and the chimney 44. There is no vertically disposed flue, nor is there vertically disposed combustion chamber 24 extending substantially into the interior. Heat from combustion is primarily extracted from the flue 40 as it is urged downward through the spiral flue 40 to the chimney 44.

[0094] An electrical line 46 provides power to one or more electrical elements 48 which are housed in the interior 18. The electrical elements 48 are preferably located on the side wall 16 and are spaced apart from one another such that different zones of water in the interior are being heated at the same time, or different times.

[0095] A smart controller 50 is in electronic communication with the burner 22, the combustion fan 38, the electrical elements 48, a temperature sensor 52 and a thermostat 54.

[0096] Water enters the hot water tank 10 through an inlet 56 in the top 12 of the tank 10. Hot water leaves the tank 10 through an outlet 58 in the top 12 of the hot water tank 10. A safety valve 60 is also located in the top 12 of the tank 10. A drain 62 is located either in the bottom 14 or proximate the bottom 14 of the tank 10.

[0097] The flue 40 is about 2 inches in inside diameter. This is half the diameter of a standard flue, thus the surface area per inch of length of flue 40 is 12.57 square inches versus 37.7 square inches, however, the ratio of surface area to volume per inch of length of flue is about 4 for the flue 40 compared to about 3 for a standard flue. The flue 40 is about 38 feet long as compared to 4 feet long, hence the ratio of surface area to volume is about 2 for the flue 40 versus about 1 for a standard flue. This greatly increases the efficiency of heat transfer between the flue gases and the water in the interior 18 of the tank 10. As the spiral 42 does not conform to the golden ratio, the flue gases have an increased tendency to cavitate and be slowed, thus further increasing the efficiency of heat transfer between the flue gases and the water in the interior 18 of the hot water tank 10. Similarly, as the spiral 42 is not a straight flue, and gases tend to travel in a straight line, the flue gases contact the inner surface of the flue 40 more often, thus increasing the potential for heat transfer.

[0098] In another alternative embodiment, shown in FIG. 4, the tank 10 has a top 12, a bottom 14, and a cylindrical side wall 16, all which define an interior 18. A gas line 20, which may carry natural gas or propane or the like, provides fuel to a burner 22. The burner 22 is housed in a combustion chamber 24 which is in the vicinity of the top 12 of the tank 10. Proximate the bottom 14, outside of the tank 10 and in fluid communication with the combustion chamber 24 is a condensation trap 28. The condensation trap 28 may be extended via a pipe to the floor pan. A combustion fan 38 is located proximate the burner 22 to provide combustion air from the ambient to the burner 22. The combustion fan 38 is in gaseous communication with the combustion chamber 24 and is located at the combustion chamber mouth 26. The combustion chamber 24 is in gaseous communication with the flue 40. Thus, when the combustion fan 38 is operational, it forces air into the combustion chamber 24 and urges the flue gases through the flue 40. The placement and pushing the flue gases rather than pulling them reduces the chance of condensation within the flue 40. The combustion fan 38 acts as a shutter, thus when it is not operational, it covers the combustion chamber mouth 26 and reduces or eliminates gravity feed of cold, outside air into the building in which the hot water tank 8 is housed. The combustion chamber 24 is shown extending into the interior 18 from the side wall 16 in this embodiment.

[0099] The flue 40 is formed into a spiral 42 (helical coil, helix) which extends from the combustion chamber 24 down through the interior 18 of the tank 10, reaching a chimney 44 in the side 16 proximate the bottom 14. The condensation trap 28 is in line with the flue 40 and the chimney 44. There is no vertically disposed flue, nor is there vertically disposed combustion chamber 24 extending substantially into the interior. Heat from combustion is primarily extracted from the flue 40 as it is urged downward through the spiral flue 40 to the chimney 44.

[0100] An electrical line 46 provides power to one or more electrical elements 48 which are housed in the interior 18. The electrical elements 48 are preferably located on the side wall 16 and are spaced apart from one another such that different zones of water in the interior are being heated at the same time, or different times.

[0101] A smart controller 50 is in electronic communication with the burner 22, the combustion fan 38, the electrical elements 48, a temperature sensor 52 and a thermostat 54.

[0102] Water enters the hot water tank 10 through an inlet 56 in the top 12 of the tank 10. Hot water leaves the tank 10 through an outlet 58 in the top 12 of the hot water tank 10. A safety valve 60 is also located in the top 12 of the tank 10. A drain 62 is located either in the bottom 14 or proximate the bottom 14 of the tank 10.

[0103] The flue 40 is about 2 inches in inside diameter. This is half the diameter of a standard flue, thus the surface area per inch of length of flue 40 is 12.57 square inches versus 37.7 square inches, however, the ratio of surface area to volume per inch of length of flue is about 4 for the flue 40 compared to about 3 for a standard flue. The flue 40 is about 38 feet long as compared to 4 feet long, hence the ratio of surface area to volume is about 2 for the flue 40 versus about 1 for a standard flue. This greatly increases the efficiency of heat transfer between the flue gases and the water in the interior 18 of the tank 10. As the spiral 42 does not conform to the golden ratio, the flue gases have an increased tendency to cavitate and be slowed, thus further increasing the efficiency of heat transfer between the flue gases and the water in the interior 18 of the hot water tank 10. Similarly, as the spiral 42 is not a straight flue, and gases tend to travel in a straight line, the flue gases contact the inner surface of the flue 40 more often, thus increasing the potential for heat transfer.

[0104] As shown in FIG. 5, a flame ionization sensing element 66 or other suitable sensing element such as for example, but not limited to a thermocouple sensor, is part of a flame sensor system 68, which includes a capacitor 70. The controller 50 includes a printed circuit board 72 and a microprocessor 74 and is in electrical communication with the flame sensor system 68. The microprocessor 74 includes a memory 78, a processor 80 and a wireless communication link 82, which may be, for example, but not limited to Ethernet, WiFi or a Bluetooth® radio or a wired communication link. The printed circuit board 72 and the microprocessor 74 are also in electrical communication with a very rapidly switching, very high duty cycle on off switch 84 that is in electrical communication with the electrical element 48. The switch 84 cycles between on and off between about 30 times a second to about 10,000 times a second. The on off switch 84 is preferably a bidirectional triode thyristor (TRIAC). Switching is either via pulse-width modulation or phase control.

[0105] The printed circuit board 72 and the microprocessor 74 are also in electrical communication with an igniter 86 and an actuator 92, which may be a stepper motor, which in turn is in mechanical communication with a variable pressure gas valve 94. The printed circuit board 72 and the microprocessor 74 are also in wired or wireless communication with the thermostat 54.

[0106] As shown in FIG. 6, the gas valve 94 controls the flow of gas from the main gas supply line 98 through the gas line 20 to a nozzle 102 at the gas burner 22. The main gas supply line 98 is fed from a public gas utility 104. The public gas utility 104 has a wired or a wireless communication link 106, which may be, for example, but not limited to Ethernet, WiFi or a Bluetooth® radio for communicating with the microprocessor 74. The wireless communication link 106 is in a computing device 107, which includes a memory 108 and a processor 109.

[0107] If a stepper motor is used as the actuator 92, it can adjust the pressure of the gas at the outlet on the gas valve 94 from about 30% to about 100% in about 0.1% to about 1% increments or about 10% increments. In a preferred embodiment, the actuator 92 is a modulating actuator or a variable position actuator. These may be in communication with a variable current valve 94, which controls the amount of gas and the amount of air being drawn into the gas burner 22. Without being bound to theory, this modulates the thermal output based on feedback from the temperature sensor 52. This is unlike the prior art in which the gas pressure is in steps of low, medium and high, or has an “on” or “off” setting and is not being modulated in response to the actual room temperature.

[0108] As shown in FIG. 7, the electrical element 48 is connected to the electrical wire 46, which in turn is connected to a power line 112 from a public power utility 114. The on off switch 84 is located along the electrical wire 46. The public power utility 114 has a wired or wireless communication link 116, which may be Ethernet, WiFi or a Bluetooth® radio for communicating with the microprocessor 74. The wireless communication link 116 is in a computing device 118, which includes a memory 120 and a processor 122.

[0109] A user also has a computing device 124 with a memory 126, a processor 128 and a wireless communication link 130. The user's computing device 124 may be a desktop, tablet or a cellular phone or other mobile device, as would be known to one skilled in the art. It communicates with the microprocessor 74.

[0110] As shown in FIG. 8, one method of operating the hybrid hot water tank is autonomous operation, generally referred to as 200. The temperature is sourced 300 from an internal thermostat or internal temperature sensor. The desired temperature is set 302 in the microprocessor and is usually in the range of 55° C. The microprocessor signals 304 the on off switch to switch on the electrical element. The electrical element begins heating 306. This is the electrical heating mode, generally referred to as 310. Once the element (or elements) reaches about 30,000 for a small tank to about 88,000 British Thermal Units per hour (BTU/h) for a large tank, by way of example only, or the temperature sensor reports 312 a first selected and predetermined temperature increase to the microprocessor, the microprocessor signals 314 the modulating actuator to open 316 the valve to start the flow of gas and the ignitor to ignite 318 the gas. The microprocessor checks 320 the flame ionization sensor system to confirm that the flame is lit. In one mode the microprocessor signals 322 the electrical switch to shut down power to the electrical element, and the heating appliance runs solely on gas up to the maximum BTU of the gas valve. The flame can be maintained at the same height at 15000 BTUs as at 30000 BTU by the microprocessor signaling 324 the combustion fan to alter the air flow to the burner. Alternately, the electric element can be allowed to continue running 326. This is the dual heating mode 340. During this mode, the modulating actuator continues 342 to modulate the gas pressure to modulate the thermal output from the gas burner. This controls the rate of heating, which may be predetermined. Once it reaches a predefined heating rate, for example, about 50,000 BTU/h, or the temperature sensor reports 344 a second selected and predetermined temperature increase to the microprocessor, the microprocessor signals 346 the on off switch to switch off 348 and the electrical element is switched off 350. The microprocessor adjusts 352 the valve to adjust the pressure of the gas at the outlet of the valve and again adjusts the flow of air to the burner by signaling 354 the combustion fan. This controls the rate of heating. This is the gas heating mode, generally referred to as 360. Once it reaches about 60,000 BTU/h, by way of example only, or the temperature sensor reports 362 a third selected and predetermined temperature increase to the processor, the microprocessor may select one of three modes—the electrical heating mode 310, the dual heating mode 340 or the gas heating mode 360. Prior to entering the electrical heating mode 310, the gas burner is shut off by the microprocessor signaling 362 the modulating actuator, which then closes 364 the valve. In the electrical heating mode, the temperature sensor continually reports 370 the temperature to the microprocessor which then signals 372 the on off switch to switch 374 rapidly, for example at about 50 cycles per second, thus maintaining 378 the temperature at a plus or minus 1° C. In the dual heating mode 340 the temperature sensor continually reports 380 the temperature to the microprocessor which then signals 382 the on off switch to switch 384 rapidly, for example at about 50 cycles per second. The microprocessor also signals 386 the modulating actuator which modulates 388 the gas pressure. Both modulate the thermal output thus maintaining 390 the temperature within a predefined range, for example plus or minus 1° C. In the gas heating mode 360, the microprocessor also signals 392 the modulating actuator which modulates 394 the gas pressure, which modulates 396 the thermal output thus maintaining 398 the temperature within a predefined range, for example plus or minus 1° C.

[0111] As shown in FIG. 9, a second method of operating the hybrid hot water tank is a utility-controlled operation, generally referred to as 700. The utility selects 706 the heat source. The utility may, for example, instruct 708 their computing device, which then sends 710 a wireless message to the wireless link (or a wired message with a wired link) of the microprocessor to heat using gas. The microprocessor signals 714 the modulating actuator to open 716 the valve to start the flow of gas and the ignitor to ignite 718 the gas. The microprocessor checks 720 the flame ionization sensor system to confirm that the flame is lit. During this mode, the modulating actuator continues 722 to modulate the gas pressure to modulate the thermal output from the gas burner. This controls the rate of heating. The temperature sensor reports 724 the temperature to the microprocessor, which optionally then signals 726 the wireless link (or wired link) to communicate 728 the temperature to the utility's computing device. The microprocessor continues to signal 730 the modulating actuator which modulates 732 the gas pressure. This modulates 734 the thermal output thus maintaining 736 the temperature within a predefined range, for example, plus or minus 1° C.

[0112] Alternatively, the utility instructs 754 their computing device, which then sends 756 a wired or wireless message to the wired or wireless link of the microprocessor to heat using electricity. The microprocessor signals 758 the on off switch to switch on 760. The electrical element begins heating 762. The temperature sensor continually reports 770 the temperature to the microprocessor which then signals 772 the on off switch to switch 774 rapidly, for example at about 50 cycles per second, thus maintaining 778 the temperature within a predefined range allowing 780 the temperature to increase at a preselected rate or at a rate which the utility has instructed 782.

[0113] FIG. 10 shows the decision-making process at start up leading to operation in the hybrid mode and in the gas only mode. In one embodiment, the decisions are made locally, under control of a computing device in or proximate the user's residence. In another embodiment, the decisions are made remotely, under control of a computing device in a utility. Both the controller and the utility can independently control both the heat source and the temperature range. Thus, at night, when power costs are lower, the controller or the utility may increase the temperature of the water in the hot water tank to, for example 66° C. The hot water tank then functions as a thermal reservoir over the night and then returns to the normal operating temperature during the day. If needed, a cold water mixing valve may be included as a safety feature to reduce the water temperature back to 55° C., should there be an immediate requirement for hot water before the temperature has returned to the preferred temperature, for example, if a user needs hot water in the middle of the night. Further, the controller and the utility can determine when the cold water that replaces the hot water is heated. Again, for example, should the user use a lot of water around dinner time, the controller or the utility may postpone heating the now cooler water in the hot water tank until in the night, when power costs are lower.

[0114] In another embodiment, the flue is a vertically disposed serpentine.

[0115] In another alternative embodiment, shown in FIG. 11, the tank 10 has a top 12, a bottom 14, and a cylindrical side wall 16, all which define an interior 18. A gas line 20, which may carry natural gas or propane or the like, provides fuel to a burner 22. The burner 22 is housed in a combustion chamber 24 which is in the vicinity of the middle 13 of the tank 10. Proximate the bottom 14, outside of the tank 10 and in fluid communication with the combustion chamber 24 is a condensation trap 28. The condensation trap 28 may be extended via a pipe to the floor pan. A combustion fan 38 is located proximate the burner 22 to provide combustion air from the ambient to the burner 22. The combustion fan 38 is in gaseous communication with the combustion chamber 24 and is located at the combustion chamber mouth 26. The combustion chamber 24 is in gaseous communication with the flue 40. Thus, when the combustion fan 38 is operational, it forces air into the combustion chamber 24 and urges the flue gases through the flue 40. The placement and pushing the flue gases rather than pulling them reduces the chance of condensation within the flue 40. The combustion fan 38 acts as a shutter, thus when it is not operational, it covers the combustion chamber mouth 26 and reduces or eliminates gravity feed of cold, outside air into the building in which the hot water tank 8 is housed. The combustion chamber 24 is shown extending into the interior 18 from the side wall 16 in this embodiment.

[0116] The flue 40 is formed into a spiral 42 (helical coil, helix) which extends from the combustion chamber 24 down through the interior 18 of the tank 10, reaching a chimney 44 in the side 16 proximate the bottom 14. The condensation trap 28 is in line with the flue 40 and the chimney 44. There is no vertically disposed flue, nor is there vertically disposed combustion chamber 24 extending substantially into the interior. Heat from combustion is primarily extracted from the flue 40 as it is urged downward through the spiral flue 40 to the chimney 44.

[0117] An electrical line 46 provides power to one or more electrical elements 48 which are housed in the interior 18. The electrical elements 48 are preferably located on the side wall 16 and are spaced apart from one another such that different zones of water in the interior are being heated at the same time, or different times.

[0118] A smart controller 50 is in electronic communication with the burner 22, the combustion fan 38, the electrical elements 48, a temperature sensor 52 and a thermostat 54.

[0119] Water enters the hot water tank 10 through an inlet 56 in the top 12 of the tank 10 and down through a cold water pipe 110. The cold water pipe 140 is preferably aluminum. A heat conductive bar 142 is located in the interior 18. Hot water leaves the tank 10 through an outlet 58 in the top 12 of the hot water tank 10. In another embodiment, a heat pipe is located in the interior to destabilize the thermal layers of water 18. A safety valve 60 is also located in the top 12 of the tank 10. A drain 62 is located either in the bottom 14 or proximate the bottom 14 of the tank 10.

[0120] The flue 40 is about 2 inches in inside diameter. This is half the diameter of a standard flue, thus the surface area per inch of length of flue 40 is 12.57 square inches versus 37.7 square inches, however, the ratio of surface area to volume per inch of length of flue is about 4 for the flue 40 compared to about 3 for a standard flue. The flue 40 is about 38 feet long as compared to 4 feet long, hence the ratio of surface area to volume is about 2 for the flue 40 versus about 1 for a standard flue. This greatly increases the efficiency of heat transfer between the flue gases and the water in the interior 18 of the tank 10. As the spiral 42 does not conform to the golden ratio, the flue gases have an increased tendency to cavitate and be slowed, thus further increasing the efficiency of heat transfer between the flue gases and the water in the interior 18 of the hot water tank 10. Similarly, as the spiral 42 is not a straight flue, and gases tend to travel in a straight line, the flue gases contact the inner surface of the flue 40 more often, thus increasing the potential for heat transfer.

[0121] While example embodiments have been described in connection with what is presently considered to be an example of a possible most practical and/or suitable embodiment, it is to be understood that the descriptions are not to be limited to the disclosed embodiments, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the example embodiment. Those skilled in the art will recognize or be able to ascertain using no more than routine experimentation, many equivalents to the specific example embodiments specifically described herein. Such equivalents are intended to be encompassed in the scope of the claims, if appended hereto or subsequently filed.