Heat pump water heater

Abstract

An implementation of the disclosed technology provides a base component for a modular heat pump compartment of a heat pump water heater. The base component includes a bottom portion forming a bottom surface of the base component, and a sidewall portion formed, in particular integrally, with the bottom portion and extending, at least in part, in a vertical or transverse direction from the bottom portion, at least along a segment of an outer edge of the bottom portion. The bottom portion includes a coupling structure formed, in particular integrally, with the bottom portion and / or the sidewall portion and having a shape configured for coupling with a corresponding positioning guide of a fluid movement module, to position the fluid movement module within the modular heat pump compartment. In some implementations, the base component is configured to be seated on or above a hot water tank of the heat pump water heater.

Description

HEAT PUMP WATER HEATERTECHNICAL FIELD

[0001] The disclosed technology relates to heat pump water heaters, and in particular to modular components for use in a heat pump water heater.BACKGROUND

[0002] Water heaters are means of producing domestic and / or sanitary hot water. A heat pump water heater is a water heater with at least one heat pump as a water heating element. A heat pump water heater may have other associated heating means such as an electric resistive element or heat exchangers associated with a hot water circuit.

[0003] Heat pump water heaters need an available energy / heat source to transfer heat to the water to be heated. Different sources can be used. The type of source can be used to differentiate and designate different types of heat pump water heaters.

[0004] Ambient air heat pump water heaters use ambient air as an energy source. Ambient air entering and leaving the heat pump is drawn in and returned to the volume of air available at the installation site. The place of installation is an unheated, frost-free room such as a utility room in a building (e.g., a cellar, garage, attic, etc.). Ambient air heat pumps provide a simplified product compared to other heat pump types. This is because, e.g., the ambient air used has a limited and positive temperature range. In addition, the pressure losses in the air flow are low as the air is pulled in and discharged in the same space as the product location.

[0005] Ducted air heat pump water heaters use outside air as an energy source - i.e., air that is drawn in and / or discharged from and / or to the outside. This type of heat pump water heater offers greater flexibility in installation modes and allows the user to choose a configuration that provides for comfort throughout the year. For example, it is possible to choose to discharge the air from the heat pump to the outside when the outside temperature is below the comfort temperature of theroom. Alternatively, one can choose to recirculate the air from the heat pump at the installation site when this provides comfort. This type of heat pump water heater may be susceptible to significant pressure drops due to lengths, bends, and height differences in the ducts.

[0006] Extracted air heat pump water heaters use air extracted from a ventilation network of the installation building as an energy source. This air has a relatively constant and high temperature, as it comes from living areas of a dwelling. In general, this air may be particularly humid and can contain significant levels of dust or other debris, because it may come from damp rooms, such as bathrooms or kitchens. Heat pumps using this type of air must be able to operate with a relatively low air flow rate (that of the building's ventilation system). A fan may be included in the heat pump water heater. Alternatively, the fan of the ventilation system of the installation building may be used, removing the need for a fan in the heat pump water heater.

[0007] Water source heat pump water heaters use a closed water circuit as an energy source. The water circuit may be the return of a heating circuit, a geothermal circuit or any other closed water circuit.

[0008] For all above-mentioned heat pump water heater types, the heat pump includes at least one closed refrigerant circuit. The refrigerant circuit includes a first heat exchanger with the source medium (an evaporator), a compressor, a second heat exchanger with the destination medium (a condenser), in particular domestic water, and an expansion device.

[0009] Depending on the type of heat pump water heater, different heat exchangers may be used. In the case of an air source heat pump water heater, the first heat exchanger is an air / refrigerant heat exchanger. In the case of a water source heat pump water heater, the first heat exchanger is a water / refrigerant heat exchanger.

[0010] Also, depending on the type of heat pump water heater, different fluid driving elements, in particular to move the source medium (pump, fan) are required. In the case of a water source heat pump water heater, a pump is used to move the water as a source medium. In the case of an air source heat pump water heater, a fan may be used to move the air.

[0011] Depending on the type of air heat pump water heater, different fan technologies and air ducts may be used. For example, it is preferable to use an axial fan for an ambient air heat pump water heater and a helicoidal or centrifugal fan for a ducted or extracted air heat pump water heater. Between ducted and extracted air heat pump water heaters, the air flow rates are different, and consequently, the fan diameters and rotation speeds are different, and so the fan and the ducts are different.

[0012] Since, depending on the type of heat pump water heater, several major components of the heat pump may change (e.g. the driving element / fan and the associated ducts, as well as the first heat exchanger), heat pump water heaters generally have different architectures. This requires different manufacturing lines for different heat pump water heaters.

[0013] EP3904783A1 for example discloses an appliance for heating water, in particular sanitary water. The appliance includes a water tank and a heat pump system for heating water in the water tank. EP3904783A1 is directed to providing an improved appliance for heating water which does not generate additional costs and does not require large, vibrating parts which can render the appliance unpleasant to have in a home. In addition, it is a goal to improve the tightness of the appliance and to optimize the appliance for use in ambient air. In order to at least partially achieve these goals, EP3904783A1 discloses a water heating appliance, in particular for heating sanitary water, comprising a water heater provided with a water tank, as well as a heat pump system provided with a condenser, an evaporator, and a compressor. The water heating appliance includes a housing compartment for the water tank, referred to as the water heater compartment, and a housing compartment for the evaporator, the compressor and the fan, referred to as the heat pump compartment. The appliance further includes a separation interface between the water heater and the heat pump compartments. The separation interface has the general shape of a bowl, including a bottom portion and a junction portion with the outer casing of the installation, the junction portion being secured to the side part of the outer casing. By way of the separation interface, the heat pump system is partially integrated into the body of the casing of the thermodynamic water heater, which providesboth easy access through the dedicated heat pump compartment on the one hand, and optimized operation in ambient air, due to the improved sealing by the two compartments.

[0014] As shown and described in EP3904783A1 , bottom portion of the separation interface has a relatively simple flat or slightly curved bowl shaped profile, on which various parts of the heat pump can rest. At least the evaporator and the compressor are said to rest on the bottom portion. The fan can also rest on the bottom portion, or, alternatively, does not rest directly on the bottom portion and is put in place (slid, clicked, etc.) into an intermediate piece, such as an air duct which rests on the bottom or is fixed to the evaporator.

[0015] Similar solutions to EP3904783A1 existed in the prior art at least since 2018 (Atlantic, Aquacosy Chauffe-Eau thermodynamique individual sur air extrait - notice utilisation 01 / 2018) which discloses a heating appliance allowing for a two in one solution for both ventilation and water heating. As shown in FIG. 11 , which shows shows an exploded view of the assembly of the Aquacosy heating appliance 1100, a heat pump compartment 1102 is contained within a casing 1104. An opening 1106 into the interior of the heat pump compartment 1102 allows for the insertion of a washable and front-accessible filter 1108. The opening 1106 is covered by a hatch 1110. The exploded view of FIG. 10 also shows assembly of a fan assembly 1140, including a heat pump fan 1142, housed within a fan housing 1144. The fan housing 1144 fits within the heat pump compartment 1102 within an opening 1112 formed by walls and guide structures of the base of the heat pump compartment 1102 and an evaporator 1114, but is not held rigidly secure by these structures. It should be noted that in some configurations, the Aquacosy heating appliance 1100 does not require a fan, in which case, the fan assembly 1140 may be omitted. The heating appliance 1100 further includes a resistive element 1116, an inverter card 1118, a cover 1120, a thermowell temperature sensor 1122, a heating body 1124, a pressure sensor 1126, a control panel 1128, a regulation card 1130, a front cover 1132, a cover 1134, and a bottom cap 1136.

[0016] FIG. 12 shows another view of the Aquacosy heating appliance 1100, showing the heat pump compartment 1102 seated within the casing 1104 abovea hot water tank 1202. Condenser coils 1204 wrap around the hot water tank 1202, and the space between the hot water tank 1202 and the casing 1104 may be filled with a thermal insulator (not shown). As can be seen, the heat pump compartment 1102 has a relatively deep profile.

[0017] FIG. 13 shows an interior view of the heat pump compartment 1102, showing interior walls and guiding structures, such as guiding structure 1302, which assist in placement of the evaporator 1114, and fan (not shown in FIG. 12), as well as providing guides for the filter (not shown in FIG. 12). The walls and guiding structures also form wells and openings, such as the opening 1112, which accommodates the fan.

[0018] These walls and guiding structures are integral to the heat pump compartment 1102, and provide the bottom portion of the heat pump compartment 1102 with a varied and complex profile. While the walls and guiding structures are shaped to accommodate particular parts of the heat pump, and to guide the removable filter into position, these parts are not intended to be interchanged for other parts to change the configuration of the Aquacosy heating appliance 1100, which is purpose designed specifically as an exhaust / extracted air system. Even the filter, which is removable for cleaning, is intended to be cleaned and placed back into its allotted space. The filter is not replacable with a differently configured filter, though this might be possible provided that the replacement had dimensions substantially the same as the original filter.

[0019] As noted with reference to FIGS. 11 -13, the front-accessible filter allows for easy and simplified maintenance and filter replacement. The heat pump compartment is secured to the outer casing. The heat pump compartment includes openings for the filter and for draining of condensate water. The separation interface - in other words bottom of the heat pump compartment - also includes guides formed integrally with the separation interface for guiding the evaporator and condensate flow and for keeping the fan housing in place.

[0020] WO2015004101 A1 is directed to simplifying the assembly of a thermodynamic machine by reducing the number of mechanical parts required. The invention also aims to simplify the production of the mechanical parts used in the assembly of the thermodynamic machine. WO2015004101 A1 relates moreparticularly to the assembly of the cold stage of the thermodynamic machine, which, according to WO2015004101 A1 , requires that air circulation is guided between the base and the cover. The base and the cap jointly seal the air circulation. FIG. 14 shows a view of the base 1400, and FIG. 15 shows a view of the cap 1500 of the device disclosed in WO2015004101 A1 . As can be seen in FIG. 14, several recessed shapes 1402, 1404, 1406, and 1408 made in the base 1400 are disclosed, which make it possible to accommodate the components of the cold stage. In particular, the recessed shapes 1402, 1404, 1406, and 1408 are configured to receive and position the compressor (not shown), the evaporator (not shown), the fan (not shown), and the bottle (not shown - used in WO201 5004101 A1 to trap the liquid still contained in the circuit at the outlet of the evaporator), respectively.

[0021] In greater detail for one of, these recessed shapes, the recessed shape 1402 - in other words a recess portion or bowl shaped portion - facilitates positioning the compressor. The recessed shape 1402 is disclosed having a triangular shape. In the vicinity of each vertex of the triangle, accessories for fixing the compressor, such as screws or rivets may be used. The recessed shapes 1402, 1404, 1406, and 1408 are complementary forms of the associated components to allow the positioning of each component after having engaged the component in the recessed shape which is dedicated to it.

[0022] Certain components of the cold stage, such as, for example, the compressor, can be fixed only on the base 1400. It is also possible to use the recessed shapes of the base 1400 only for positioning certain components, such as, in particular, the evaporator and the fan. The complete fixing of these components is obtained by associated shapes 1502 and 1504, for the evaporator and fan, respectively, made in the cap 1500. Fitting of the cap 1500 on the base 1400 is done by engaging the bore of the cap on the cylindrical part of the base. This relative position of the cap with respect to the base is the operational position of the water heater.

[0023] A drawback of the solutions of the prior art discussed above is the different architectures required in even those solutions, which do not allow for modularization of the parts of the architecture of a heat pump. To the extent thatreplacement of parts is contemplated, it is merely replacement with the same parts, for the same configuration. The prior art solutions do not allow for replacement of parts with differently configured parts, possibly changing the type of heat pump, the capacity, and / or other options. In other words, the prior art does not sllow for a standardized yet modularizable assembly which allows for predetermined implementation of parts which have a different type of heat pump component on the same base, for the heat pump components to allow a change of a source medium (ambient air, ducted, extracted or water), and / or associated components (plate or coil heat exchanger, diameter / power / speed of the fan etc..) needed to implement options for the same heat pump, without requiring additional tooling. This requires different manufacturing lines or use of sequential production (in which the manufacturing line is reconfigured between manufacturing batches of differently configured products) for different heat pump water heaters and does not allow for personalization during production or installation (i.e. , mix and match for a customer’s specific needs), or updating during maintenance.

[0024] A further example of a heat pump water heater of the prior art is disclosed in EP3462104B1. EP3462104B1 is directed to provide a hot water supply unit with a structure where pipes of the hot water supply unit can be easily connected to pipes arranged at an install destination and discloses a hot water supply unit, including a machinery unit that contains the heat pump parts the machinery unit including a main frame - in other words a housing frame structure - and a tank unit on which the machinery unit is mounted and separated from the tank unit by a support plate.

[0025] A further example of a heat pump water heater of the prior art is disclosed in EP3091305A1. EP3091305A1 is directed to partially remedy drawbacks regarding cleaning, deicing, and fouling of an evaporator due to humidity condensation and discloses a thermodynamic water heater, comprising a tank of water to be heated and at least one heat exchanger, said thermodynamic water heater comprising at least one water outlet conduit from the tank of water to be heated and at least one nozzle for spraying water from said at least one outlet duct.SUMMARY

[0026] Based on the above, it is an object to provide a heat pump water heater with a modular design. Such a heat pump water heater makes it possible to use, e.g., the same base component for the heat pump portion of the heat pump water heater, and therefore the same product architecture to make products with different technologies, i.e. , with different heat source medium driving elements, source medium guiding elements, and source medium / refrigerant heat exchangers. This makes it possible to standardize a large number of components, to facilitate industrialization, storage, logistics flows and part replacement flows. This modular design facilitates, for example, use of a single production line for a variety of configurations, since many of the parts are the same, and those that are different are set up as interchangeable modules. Furthermore, it allows for converting heat pump water heaters to use a different technology or to work with a different capacity. It further facilitates replacement of modular components at any time during the life of the heat pump water heater, e.g., for maintenance, late personalization, update of the product during production, etc.

[0027] This standardization also makes it possible to limit the number of tools involved in the production and installation of parts. This limits the ecological impact linked to the consumption of materials linked to the production of these tools. In this way, the economic and environmental cost is reduced.

[0028] In addition, this reduces the risks associated with being dependent on a single model of a heat pump water heater component (e.g., a fan, heat exchanger, compressor, pump, etc.): quality problems, logistical problems, dependence on one supplier, etc.

[0029] Implementations of a heat pump water heater in accordance with the disclosed technology make it possible to create a common modular heat pump compartment for different types of heat pump water heaters. Specifying the product destination can be done at a later stage, at the end of the production line. This delayed customization facilitates the organization of production and limits the number of scraps.

[0030] It is a further object to prevent errors in assembling modular components of a modular heat pump compartment of a heat pump water heater. In accordance with various implementations of the disclosed technology, this can be achieved by using a base component or other module of the modular heat pump compartment having at least one coupling structure that only permits compatible parts to be coupled with the coupling structure. For example, the coupling structure may have a shape that can only be coupled with a corresponding positioning guide on a compatible part. In some implementations, the shape of the coupling structure can be configured to permit only a compatible part to be coupled with the base component or other module in the correct position and orientation for that part.

[0031] It should be noted that the positioning guide on a compatible part is not the shape of the part itself. That is, as used herein, the positioning guide is an additional structure on the part, having a primary purpose of coupling to the corresponding coupling structure. The positioning guide is generally unrelated to the function or form of the part, other than coupling to the corresponding coupling structure. While this positioning guide could be seen as adding complexity to the form and manufacture of compatible parts, the modularity and prevention of errors can be seen as an overall benefit, or as a kind of reduction in the complexity of reconfiguring heat pump water heaters during design, manufacture, and maintenance.

[0032] The correct operation of a heat pump water heater generally requires a source medium driving element, such as a fan, a pump, or other driving element. In accordance with an implementation of the disclosed technology, these driving elements may be housed in a fluid movement module equipped with a positioning guide, configured to permit the fluid movement module to be coupled with a corresponding coupling structure on a base component of a modular heat pump compartment of a heat pump water heater. The fluid movement module may also include ducts and / or openings appropriate for the type of driving element being used. Additional modular components, such as an intermediate cover with appropriate ducts or openings may also be used to permit modularization of the heat pump compartment of a heat pump water heater. In some implementations,other components, such as the source fluid / refrigerant heat exchanger may also be built as interchangeable modules, with positioning guides corresponding to coupling structures on the base component, to facilitate proper compatibility, placement, and orientation of the heat exchanger within the modular heat pump compartment.

[0033] In particular an implementation of the disclosed technology provides a base component for a modular heat pump compartment of a heat pump water heater. The base component includes a bottom portion forming a bottom surface of the base component, and a sidewall portion formed, in particular integrally, with the bottom portion and extending, at least in part, in a vertical or transverse direction from the bottom portion, at least along a segment of an outer edge of the bottom portion. The bottom portion and / or the sidewall portion includes a coupling structure formed, in particular integrally, with the bottom portion and / or the sidewall portion and having a shape configured for coupling with a corresponding positioning guide of a fluid movement module, to position the fluid movement module within the modular heat pump compartment. In some implementations, the base component is configured to be seated on or above a hot water tank of the heat pump water heater.

[0034] In some implementations, the shape of the coupling structure is further configured for coupling only with a corresponding positioning guide of a compatible fluid movement module. In some implementations, the shape of the coupling structure is further configured to permit the fluid movement module to be coupled only in a predetermined orientation. In some implementations, the coupling structure includes a first opening passing through the bottom portion of the base component. While such an opening may permit fluids to pass through the bottom portion of the base component, in use, the opening may be effectively blocked by the presence of a compatible fluid movement module, and or by thermal insulation material, such as a foam material - as used commonly used in the prior art - which may be added into a compartment beneath the base component.

[0035] It should be noted that in view of the thermal insulation material commonly used to insulate the water tank, tightness of the bottom portion wasfound to be unnecessary, though blocking of openings at least during adding of the thermal insulation material may still be needed. It is possible to separate the thermal insulation material from the coupling structure during production by a barrier, such as a plastic film or separation foil. Advantageously, this facilitates replacement of the support portion of the fluid movement module at any time during the life of the modular heat pump compartment, e.g., for maintenance, late personalization, update of the product during production, etc. For instance, it allows a product to be updated at the installation site with another fan if needed. For example, the fan can be replaced with a more powerful fan, e.g., if there is a larger than expected pressure drop in the duct of the installation site (e.g., due to length, bent, height etc.). It can also be useful to replace the fan model and associated internal ducts if the previous fan model is not available (e.g., out of stock) or other reasons (e.g., quality issues, cost increases, phase out, etc.).

[0036] In some implementations, the base component may include one or more additional coupling structures, configured for coupling with corresponding different positioning guides on a heat exchange component and / or other component(s) of the heat pump water heater. Further coupling structures and positioning guides may be used, both on the base component, andon other components of the heat pump water heater.

[0037] In some implementations, the base component includes a condensate drain area. The sidewall portion includes a second opening providing access to the condensate drain area, the second opening having a size that facilitates cleaning the condensate drain area, and a shape configured to receive a corresponding condensate module. It should be noted that in a water source heat pump water heater, this second opening may be used for source water inlet and outlet tubes, avoiding the need for additional openings, e.g., in the cover of the modular heat pump compartment. In some implementations, the second opening may have a size and / or shape configured to receive other replaceable modules, such as a module having openings for source water inlet and outlet tubes and / or other configurations.

[0038] In some implementations, the base component is substantially circular, and is configured such that the bottom portion of the base component fits within a cylindrical tank housing of the heat pump water heater.

[0039] In some implementations, the base component includes an electrical connection box portion formed in the bottom portion and sidewall portion of the base component, the electrical connection box portion configured to at least partially house electronic components of the heat pump water heater. In some implementations, the electrical connection box portion includes a third opening between the electrical connection box portion and a main portion of the base component, the third opening configured to permit cables from electronic components to run between the electrical connection box portion and the main portion of the base component. In some implementations, the base component further includes a closure configured to substantially seal the third opening.

[0040] A further implementation of the disclosed technology provides a modular heat pump compartment of a heat pump water heater. The modular heat pump compartment includes a heat exchange component configured to transfer heat from a source fluid to a refrigerant that is used to transfer heat to water in the hot water tank of the heat pump water heater, and a fluid guiding assembly, configured to guide the source fluid through the heat exchange component. The modular heat pump compartment includes the base component as described above. The fluid guiding assembly includes a fluid movement module having a positioning guide that is coupled with the coupling structure of the base component. In some implementations, the modular heat pump compartment is configured to be seated on or above a hot water tank of the heat pump water heater.

[0041] In some implementations, the heat exchange component and / or other components of the heat pump water heater include different positioning guides that are coupled with corresponding additional coupling structures of the base component and / or other components of the heat pump water heater. It will also be noted that for any coupling structure, there may be multiple different components having a positioning guide that is compatible with the coupling structure, allowingany component having such a compatible positing guide to be used with that coupling structure.

[0042] In some implementations, the fluid movement module includes a driving element, including one of an axial fan, a centrifugal fan, a helical fan, a water pump, and / or another source fluid driving element.

[0043] In some implementations, the fluid movement module includes a support portion and a removable cover portion configured for coupling with the support portion, the support portion including the positioning guide. In some implementations, the removable cover portion includes a first duct that is configured to direct a flow of the source fluid, the configuration of the first duct varying based on the driving element. In some implementations, the modular heat pump compartment includes an intermediate cover, the intermediate cover including a second duct that directs the flow of the source fluid, and a third duct configured for coupling with the first duct. In some implementations, the modular heat pump compartment includes an outer cover configured to cover the modular heat pump compartment, the outer cover including a first opening configured for coupling with the second duct, and a second opening configured for coupling with the third duct.

[0044] A further implementation of the disclosed technology provides a heat pump water heater. The heat pump water heater includes a hot water tank and a tank housing enclosing the hot water tank. The heat pump water heater further includes the modular heat pump compartment as described above, seated on or above the hot water tank, such that at least a portion of the modular heat pump compartment fits within the tank housing.

[0045] In some implementations, a cavity is formed within the tank housing between the hot water tank and the base component of the modular heat pump component. The cavity is at least partially filled with a thermal insulation material, such that the base component is held in place, at least in part, by the thermal insulation material. In some implementations, the coupling structure of the base component of the modular heat pump component is configured so the positioning guide of the fluid movement module that is coupled to the coupling structure is in contact with the thermal insulation material in the cavity, such that the thermalinsulation material holds the positioning guide in place. In some implementations, if it is not desirable to have the positioning guide held in place by the thermal insulation, an additional interface part, such as a plastic film or foil may be used to prevent the thermal insulation from holding the positioning guide in place in the coupling structure. This may also be achieved in some implementations by using a coupling structure that does not fully pass through the base, so that the thermal insulation does not come into contact with the positioning guide.

[0046] A further implementation of the disclosed technology provides a method for assembling a heat pump water heater. The method includes: providing a hot water tank; providing a housing that substantially encloses the hot water tank to form a tank compartment; providing a heat pump compartment, including a base component as described above; placing a heat exchange component into the heat pump compartment, the heat exchange component configured to transfer heat from a source fluid to a refrigerant that is used to transfer heat to water in the hot water tank of the heat pump hot water heater; fitting a fluid guiding assembly into the heat pump compartment, the fluid guiding assembly configured to guide the source fluid through the heat exchange component; and installing the heat pump compartment above the hot water tank, such that the base component is seated on or above the hot water tank. Fitting the fluid guiding assembly into the heat pump compartment includes selecting a fluid movement module including a positioning guide having a shape configured to be coupled with the coupling structure of the bottom portion of the base component, and coupling the positioning guide of the fluid movement module with the coupling structure of the bottom portion of the base component.

[0047] In some implementations, coupling the positioning guide of the fluid movement module further includes orienting the fluid movement module such that the positioning guide fits with the coupling structure.

[0048] In some implementations, selecting a fluid movement module further includes selecting a fluid movement module having a support portion and a removable cover portion configured for coupling with the support portion, the support portion including the positioning guide, and the removable cover portion including a first duct that is configured to direct a flow of the source fluid in the fluidmovement module. In some implementations, fitting the fluid guiding assembly into the heat pump compartment further includes coupling the removable cover portion of the fluid movement module with the support portion. In some implementations, the method further includes installing an intermediate cover on at least a portion of the heat pump compartment, the intermediate cover including a second duct that directs the flow of the source fluid, and a third duct configured for coupling with the first duct. In some implementations, the method further includes installing an outer cover on the heat pump compartment, the outer cover including a first opening configured for coupling with the second duct, and a second opening configured for coupling with the third duct. In some implementations, the method further includes adding a thermal insulation material, such as a foam material, into the tank compartment, to at least partially fill the tank compartment with the thermal insulation material, such that the base component of the heat pump compartment is held in place, at least in part, by the thermal insulation material. It will be understood that the thermal insulation material may be added at any time after the tank compartment is assembled with the tank, housing, and a closing interface, such as the base part of the modular heat pump assembly. Once the tank compartment is assembled, the thermal insulation material may be added before, during, or after other tasks, such as mounting heat pump components, covers, electronics, refrigerant filling, etc.

[0049] It will be understood that although these manufacturing tasks are described and listed in an order, this is not intended to imply that the tasks must be completed in the order listed. For example, the heat pump compartment assembly can be produced in a separate production line, and added above the hot water tank before adding the thermal insulation material. This separate production line permits various of the listed tasks to be completed simultaneously, or in parallel. As a further example, the heat pump base could be placed on the tank and tank housing, followed by adding the thermal insulation material. After the thermal insulation material has been added, the heat pump elements may be added to the modular heat pump compartment. It will be apparent that assembly of a heat pump water heater could be completed with the tasks or steps carried out in many different orders.

[0050] A further implementation of the disclosed technology provides a method of heating water. The method includes: providing a heat pump water heater as described above; using the fluid guiding assembly to guide the source fluid through the heat exchange component, to transfer heat from the source fluid to a refrigerant; and transferring heat from the refrigerant to water in the hot water tank.

[0051] In the context of the present specification, unless expressly provided otherwise, the words “first”, “second”, “third”, etc. have been used as adjectives only for the purpose of allowing for distinction between the nouns that they modify from one another, and not for the purpose of describing any particular relationship between those nouns.

[0052] In the context of the present specification, unless expressly provided otherwise, directions indicated by terms such as “top”, “bottom”, “upper”, “lower”, “above”, “below”, etc., are used in their usual sense - i.e., relative to a gravitational direction or axis.

[0053] Additional and / or alternative features, aspects and advantages of implementations of the present technology will become apparent from the following description, the accompanying drawings and the appended claims.BRIEF DESCRIPTION OF THE DRAWINGS

[0054] In the figures, the subject-matter of the disclosure is schematically shown, wherein identical or similarly acting elements are usually provided with the same reference signs.

[0055] FIG.1 is a cutaway view of a heat pump water heater, in accordance with some implementations of the disclosed technology;

[0056] FIG. 2 shows a view of a base component, in accordance with some implementations of the disclosed technology;

[0057] FIG. 3 shows a view of a fluid movement module, in accordance with some implementations of the disclosed technology;

[0058] FIG. 4 shows another view of the fluid movement module;

[0059] FIG. 5 shows an assembly of parts of a modular heat pump compartment for use with a heat pump water heater, in accordance with some implementations of the disclosed technology;

[0060] FIG. 6 shows an alternative module configuration that may be fitted in an opening of the base component, in accordance with some implementations of the disclosed technology;

[0061] FIG. 7 shows an intermediate cover portion of the modular heat pump compartment, in accordance with some implementations of the disclosed technology;

[0062] FIG. 8 shows an assembly of the intermediate cover portion in combination with the base component;

[0063] FIG. 9 shows an assembly of components of a heat pump water heater, in accordance with some implementations of the disclosed technology;

[0064] FIG. 10 shows a block diagram of a method for assembling a heat pump water heater, in accordance with an implementation of the disclosed technology;

[0065] FIG. 11 shows an exploded view of the assembly of a prior art heat pump water heater;

[0066] FIG. 12 shows an additional view of the prior art heat pump water heater of FIG. 11 ;

[0067] FIG. 13 shows an interior view of the heat pump compartment of the prior art heat pump water heater of FIG. 11 ;

[0068] FIG. 14 shows a base of a heat pump compartment of a prior art heat pump water heater; and

[0069] FIG. 15 shows a cap of the heat pump compartment of the prior art heat pump water heater of FIG. 13.DETAILED DESCRIPTION

[0070] The examples and conditional language recited herein are principally intended to aid the reader in understanding the principles of the present technology and not to limit its scope to such specifically recited examples and conditions. It will be appreciated that those skilled in the art may devise variousarrangements that, although not explicitly described or shown herein, nonetheless embody the principles of the present technology.

[0071] Furthermore, as an aid to understanding, the following description may describe relatively simplified implementations of the present technology. As persons skilled in the art would understand, various implementations of the present technology may be of a greater complexity.

[0072] In some cases, what are believed to be helpful examples of modifications to the present technology may also be set forth. This is done merely as an aid to understanding, and, again, not to define the scope or set forth the bounds of the present technology. These modifications are not an exhaustive list, and a person skilled in the art may make other modifications while nonetheless remaining within the scope of the present technology. Further, where no examples of modifications have been set forth, it should not be interpreted that no modifications are possible and / or that what is described is the sole manner of implementing that element of the present technology.

[0073] Moreover, all statements herein reciting principles, aspects, and implementations of the present technology, as well as specific examples thereof, are intended to encompass both structural and functional equivalents thereof, whether they are currently known or developed in the future. Thus, for example, it will be appreciated by those skilled in the art that any block diagrams herein represent conceptual views of illustrative systems embodying the principles of the present technology.

[0074] With these fundamentals in place, we will now consider some nonlimiting examples to illustrate various implementations of aspects of the present disclosure.

[0075] FIG.1 is an illustrative cutaway view of a heat pump water heater 100 in accordance with some implementations of the disclosed technology. The heat pump water heater 100 includes a modular heat pump compartment 102 and a tank compartment 104. The tank compartment 104 includes a water tank 110 and a tank housing 112 that encloses the water tank 110. The water tank 110 stores heated water for later use, and may have a capacity that is selected according to the application of the heat pump water heater. For example, in domesticapplications, the water tank 110 will generally have a capacity between approximately 100 I and 400 I, depending on the size of the dwelling in which the heat pump hot water heater is installed. Tanks having lower or higher capacities may also be used, generally in specialized or commercial applications.

[0076] As will be described in greater detail below, space within the tank housing 112 that is not occupied by the water tank 110 or other components of the tank compartment 104 may be filled with a thermal insulation material 114, such as a foam material, for example an insulating polyurethane foam. In some implementations, the thermal insulation material serves to insulate the water tank 110, to slow the dissipation of heat in the stored hot water, and to hold components of the heat pump water heater 100 in place. It will be understood that although a foam material is shown in FIG. 1 , this is only one possible type of thermal insulation that could be used. In general, the water tank 110 should be surrounded by thermal insulation to slow thermal dissipation from the hot water stored in the water tank 110. Foam material, such as polyurethane foam, is the most common form of thermal insulation used for this purpose, but other forms of thermal insulation could also be used. For example, expanded polystyrene (EPS) insulation or void insulation (i.e. , removal of air or other material to reduce thermal conductivity) could be used.

[0077] The modular heat pump compartment 102 contains various components of the heat pump system of the heat pump water heater 100. As shown in FIG. 1 , the modular heat pump compartment 102 is seated on or above the water tank 110, and portions of the modular heat pump compartment 102 may fit within the tank housing 112. It will be understood that in some implementations, it is possible for the modular heat pump compartment 102 to be located in other positions relative to the water tank 110, such as below the tank. In some implementations, the modular heat pump compartment 102 may be a separate unit.

[0078] The modular heat pump compartment 102 includes a cover 120, a base component 122, a heat exchanger 124, a fluid movement module 126, an intermediate cover 128, and control electronics 130. The modular heat pump compartment 102 may also contain other components of a known heat pumpsystem, such as a compressor (not shown), an expansion valve (not shown), various piping (not shown) that directs a heat pump refrigerant (not shown) through the closed thermodynamic loop of the heat pump. These components are not shown in FIG. 1 for simplicity and due to the cutaway view selected to illustrate the layout of the modular heat pump compartment. The components that are not shown are well known to those skilled in the art, as is the operation of a heat pump.

[0079] The modular heat pump compartment 102 shown in FIG. 1 is configured as an air source heat pump, so the heat exchanger 124 is configured as an air / refrigerant heat exchanger. In particular, the modular heat pump compartment 102 shown in FIG. 1 is configured as an ambient air heat pump, so the fluid movement module 126 is configured to include an centrifugal fan 140 for moving air through the system, and the intermediate cover 128 is configured to fit with the centrifugal fan fluid movement module to direct air through the heat exchanger. Such a centrifugal fan is suitable for use with ambient air or with ducted air. It will be understood that other configurations may be used in various implementations. For example, the fluid movement module 126 could use a helicoidal fan, particularly if configured for ducted or extracted air, or an axial fan for ambient air. In some implementations, the fluid movement module 126 might not include a fan. For example, in a system that is connected to an external air circulation system, movement of the air through the heat exchanger 124 may be facilitated by the external air circulation system, without using a fan in the heat pump water heater 100. Additionally, in a water source heat pump system, the heat exchanger 124 would be configured as a water / refrigerant heat exchanger, and the fluid movement module 126 would include a pump for moving water, rather than a fan. In some configurations, where no fluid movement module is needed, the fluid movement module 126 could be replaced with a support (not shown), or may be absent, if no additional support is needed. As will be more fully described below, the modular nature of the modular heat pump compartment 102 makes it possible to use any of these variations, while keeping some of the same components, such as the base component 122. For air source heat pump configurations, a variety of configurations can be implemented by using different fluid movement modules and (depending on the configuration) the intermediate cover 128. Differentconfigurations can also be implemented by using different heat exchangers. For example, larger or smaller heat exchangers may be used to adjust the power of the heat pump water heater, depending, e.g., on tank capacity, refrigerant charge limitations, product range, etc.

[0080] In the implementation shown in FIG.1 , the fluid movement module 126 includes a support portion 142, which is configured to support, e.g., a fan (an centrifugal fan 140 in FIG. 1 ), and a removable cover portion 144. The support portion 142 couples to the base component 122, as will be described in greater detail below. The removable cover portion 144 as shown, may be removed to provide access to the fan, e.g., for repair or replacement. Additionally, the removable cover portion 144 also includes internal ducting appropriate for the air circulation system that is in use, so could be replaced to change the flow of air in some configurations. It will be understood that in some implementations, the fluid movement module may be a single pre-assembled unit, rather than a unit with a removable portion.

[0081] In the implementation shown in FIG. 1 , the intermediate cover 128 serves to direct air between openings in the cover 120, and internal portions of the modular heat pump compartment 102. In particular, the intermediate cover 128 includes internal ducting that directs air from an input opening 150 in the cover 120 to the heat exchanger 124, and from the fluid movement module 126 to an outlet opening (not shown in FIG. 1 ) of the cover 120. It will be understood that the configuration of the intermediate cover 128 depends on the fluid movement module and the cover that are used, and that the intermediate cover 128 is a modular component that can be changed or replaced as needed to accommodate a variety of configurations of the modular heat pump compartment 102.

[0082] In operation, an air source heat pump water heater, such as is shown in FIG. 1 , uses the centrifugal fan 140 to draw ambient air into and through the modular heat pump compartment 102. In some implementations, ambient air will pass through a fluid intake filter (not shown) before entering the modular heat pump compartment 102, or before passing through the heat exchanger 124. The air passes over coils in the heat exchanger 124 (also referred to as an evaporator). A refrigerant inside the coils of the heat exchanger 124 is at a lower temperaturethan the air. This causes the refrigerant to absorb heat from the air, causing the refrigerant to evaporate, changing state from a low-pressure liquid into a low- pressure gas. A compressor (not shown) compresses the low-pressure gas from the heat exchanger 124, increasing both the pressure and temperature of the refrigerant, changing it into a high-pressure gas.

[0083] The high-pressure, high-temperature gas then flows through a second heat exchanger (not shown, also referred to as a condenser), which is in close contact with the water tank 110. For example, coils of the second heat exchanger may be coiled around an exterior surface of the water tank 110 or may be placed inside the water tank 110. The hot refrigerant releases heat into the water in the tank, and in doing so, heats the water and condenses back into a high-pressure liquid. The high-pressure liquid refrigerant then passes through an expansion valve (not shown), which reduces its pressure and temperature. It then returns to the heat exchanger 124 (i.e., the evaporator) as a low-pressure liquid, ready to absorb more heat from the air, and restarting the heat pump cycle.

[0084] In some implementations, auxiliary heating, such as an electric resistance heating element (not shown) within the water tank 110, may be used as a backup to heat the water if the ambient temperature is too low for efficient operation of the heat pump, or during times of high hot water demand. As hot water is drawn from the water tank 110 for use in taps, showers, appliances, etc., cold water enters the tank to replace it. This cold water is then heated by the heat pump (and / or auxiliary heating) as described above. This process is controlled by the control electronics 130. It will be understood that in some implementations, additional features, such as a defrost cycle, energy efficiency monitoring, and other features may also be used, and may be controlled by the control electronics 130.

[0085] The operation of an ambient air heat pump, as described above, is well known. It will be understood that there may be many variations to this process, depending on the fluid being used in the heat pump (air, water, etc.), and the source of that fluid (ambient air, exterior air, ducted or extracted air, ground water, etc.). The refrigerants used in such heat pumps are also well known, and may include refrigerants such as hydrofluorocarbons, hydrofluoroolefins, and / or otherknown refrigerants such as propane (R-290), isobutane (R-600a), ammonia (R- 717), or carbon dioxide (R-744).

[0086] FIG. 2 shows a more detailed view of the base component 122. The base component 122 includes a bottom portion 202 a sidewall portion 204, and a electrical connection box portion 206, configured to at least partially house control electronics. In some implementations, the base component 122 may be formed as a single unit from a plastic and / or foam material. Advantageously, if the base component 122 is formed from a foam material, that foam material may absorb vibrations from various components of the heat pump which may be housed, at least in part, on the base component 122, and / or may act partly as a form of thermal insulation to limit thermal dissipation from the hot water tank.

[0087] The base component 122 also includes a coupling structure 210. The coupling structure 210 has a shape configured for coupling with a corresponding positioning guide on the fluid movement module 126 (not shown in FIG. 2). In some implementations, the shape of the coupling structure 210 is configured such that only the positioning guide of a compatible fluid movement module may be coupled to the coupling structure 210. In some implementations, the shape of the coupling structure 210 is configured such that the positioning guide of a compatible fluid movement module may only be coupled to the coupling structure 210 in a predetermined orientation. These features of the coupling structure 210 prevent errors in assembling a modular heat pump compartment by permitting only the use of compatible fluid movement modules placed in the heat pump compartment in a proper location and orientation. The coupling structure 210 also facilitates modularity by permitting the same base component 122 to be used with a variety of compatible fluid movement modules. For example, different types of fans or pumps that may be used in the system may include positioning guides that are compatible with the coupling structure 210, allowing various types of fans or pumps to be used with a single base component design, while also preventing incompatible fans or pumps from being used. These principles may also extend to the heat exchanger, since a given fluid movement module may be compatible with only some dimensions and positions of the heat exchanger. For example, if the heat exchanger surface is too small, air can bypass the heat exchanger. If the heatexchanger surface is too large, part of the heat exchanger will not be reached by the ducted air. The fluid movement module may also affect the position and thickness of compatible heat exchangers. Thus, although not shown, compatible heat exchangers could also be configured to include a positioning guide that couples with a corresponding coupling structure in the base component or other component of the of the modular heat pump compartment. For example, in some implementations, the coupling structure for the positioning guide of the heat exchanger could be formed in the fluid movement module, so that only a heat exchanger that is compatible with a particular fluid movement module may be used when that fluid movement module is installed in the system.

[0088] In some implementations, the coupling structure 210 may be formed with the bottom portion 202 of the base component 122. In some implementations, the coupling structure 210 may be formed as an opening passing through the bottom portion 202 of the base component 122. While such an opening may permit fluids to pass through the bottom portion 202 of the base component 122, in use, the opening may be effectively blocked by the presence of a compatible fluid movement module, or by thermal insulation material, such as a foam material - as commonly used in the prior art - which may be added into a compartment (not shown) beneath the base component 122. Additionally, in some implementations, raised portions of the bottom portion 202 surrounding such an opening may prevent fluids caught in the bottom portion 202 from passing through the opening.

[0089] It should be noted that in view of the thermal insulation material commonly used to insulate the water tank 110, tightness of the bottom portion 202 was found to be unnecessary, though blocking of openings at least during adding of the thermal insulation material may still be needed. It is possible to separate the thermal insulation material from the coupling structure 210 during production by a barrier (not shown), such as a plastic film or separation foil. Advantageously, this facilitates replacement of the support portion 142 of the fluid movement module 126 at any time during the life of the modular heat pump compartment, e.g., for maintenance, late personalization, update of the product during production, etc. For instance, it allows a product to be updated at the installation site with another fan if needed. For example, the fan can be replaced with a more powerful fan, e.g.,if there is a larger than expected pressure drop in the duct of the installation site (e.g., due to lenght, bent, height etc.). It can also be useful to replace the fan model and associated internal ducts if the previous fan model is not available (e.g., out of stock) or other reasons (e.g., quality issues, cost increases, phase out, etc.).

[0090] In some implementations, the base component 122 may include a second opening 212 formed in the sidewall portion 204, to facilitate draining condensate which may form, for example, around the heat exchanger coils during operation of the heat pump. The second opening 212 may also be used for clearing dust and debris that may be drawn into the heat pump during operation. During operation, the second opening 212 may be at least partially blocked by a corresponding condensate module (not shown in FIG. 2), which may, itself, include openings for draining, evaporating, or pumping out condensation. In some implementations, walls or barriers (not shown) formed on the bottom portion 202 of the base component 122 may enclose a condensate drain area, used to catch condensation from the heat exchanger coils. In some implementations, this condensate drain area may include most or substantially the whole of the bottom portion 202. The second opening 212 opens into any such condensate drain area, to facilitate draining condensate from the base component 122. In another implementation, the second opening 212 can be used and optionally covered with another module (not shown) to support and allow the passage of an inlet (not shown) and outlet (not shown) of the water circuit of a water source heat pump water heater.

[0091] In some implementations, the base component 122 may include a third opening 214 through which cables may pass between the electrical connection box portion 206 and the interior of the base component 122. These cables may, for example, be used to control components of the heat pump seated on and / or within the base component 122. The third opening 214 and / or additional openings 216 and 218 may also allow passage of wires or cables into the tank compartment, such as wires for a tank temperature sensor (not shown) and / or for powering and controlling resistance heating. In operation, any space around cables passing through the third opening 214 may be sealed, since it would be undesirable for moisture from the interior of the base component 122 to enter the electricalconnection box portion 206, which may house the control electronics for the system. Additionally, sealing any space around the cables passing through the third opening 214 prevents leaked refrigerant from reaching the electrical components housed in the electrical connection box portion 206, which could lead to a risk of an explosion if a flammable refrigerant is used.

[0092] It should be noted that the base component 122 and its bottom portion 202, as shown in FIG. 2, include features, ridges, and other contours that are not explicitly described. These may be used, for example, for seating a cover portion on top of the base component 122, for seating the base component 122 in a cover for the system, for facilitating the placement of other components on or in the base component 122, and / or for other similar purposes. It will be understood that these features may vary, depending on the detailed configuration of the system in which the base component 122 is used. These features give the base component 122, and the bottom portion 202 of the base component 122 a contoured cross-section.

[0093] FIG. 3 shows a view of the fluid movement module 126, in accordance with some implementations. The fluid movement module 126 includes a support portion 142 and a removable cover portion 144. As discussed above, the support portion 142 is configured to support, e.g., a fan or other driving element. The removable cover portion 144 may be removed to provide access to the fan or driving element, e.g., for repair or replacement. In some implementations, as shown in figure 3, the support portion and removable cover portion 144 have outer surfaces that are shaped, e.g., to direct air or other fluids into the fluid movement module 126. It will be understood that in some implementations, the fluid movement module 126 might not include a driving element or fan in its interior. For example, in a system that is connected to an external air circulation system, movement of air may be facilitated by the external air circulation system, without using a fan or other driving element in the fluid movement module 126.

[0094] As shown in FIG. 3, the support portion 142 includes a positioning guide 302, which has a shape configured for coupling with a corresponding coupling structure formed in the base component 122 (not shown in FIG. 3). In some implementations, the shape of the positioning guide 302 is configured such that only the coupling structure of a compatible base component may be coupled tothe positioning guide 302. In some implementations, the shape of the positioning guide 302 is configured such that the positioning guide 302 may only be coupled to the coupling structure of a compatible base component in a predetermined orientation. These features of the positioning guide 302 prevent errors in assembling a modular heat pump compartment by permitting only the use of compatible fluid movement modules placed in the heat pump compartment in a proper location and orientation. In some implementations, shape and associated counter shape connectors, such as coupling structures and positioning guides may be used on other parts, to enhance modularity of the system. For example, they could be used between the support portion 142 and removable cover portion 144 to allow only appropriate air duct assembly, and / or between the fluid movement module 126 and the heat exchanger, to allow use of only heat exchangers having an appropriate configuration with a particular air movement module.

[0095] FIG. 4 shows another view of the fluid movement module 126. As in FIG. 3, the fluid movement module 126 includes a support portion 142 and a removable cover portion 144. As seen in FIG. 4, the removable cover portion 144 includes an opening or duct 402, which is configured to direct a flow of the source fluid (e.g., air). The way in which the source fluid is directed, and the positioning of the opening or duct 402 may vary. For example, use of an axial fan as a driving element in the fluid movement module 126 may result in different fluid flow and different placement of the opening or duct 402 than would use of a helicoidal fan, a centrifugal fan, or a pump. For example, in some implementations, different modules may be used for the same fan, but with different angular positions of the opening or duct 402 to facilitate the ducting at the installation site. For example, the opening or duct 402 could be configured to provide an outlet on the top or on the side, depending on whether the ducting at the installation site runs to the top (e.g., to pass through a roof) or the side (e.g., to pass through a wall). Thus, having a removable cover portion 144 on the fluid movement module 126 facilitates modularity by permitting the same support portion to be used with a variety of fluid flow and opening or duct configurations. Additionally, a removable cover portion 144, such as is shown in FIG. 4, supports an ability to make repairs to the fluidmovement module 126. For example, if a fan or other driving element housed within the fluid movement module 126 needs repair, the removable cover portion 144 may be removed to provide access to the fan or other driving element. Despite these advantages, it will be understood that in some implementations, the fluid movement module 126 may be a single closed unit, without a removable cover portion 144. It will be further understood that in some implementations, the fluid movement module 126 may have more than two parts. For example, the removable cover portion 144 may be made up of two parts, including a common part, and a module that can be changed depending on the preferred angular position of the opening or duct 402.

[0096] FIG. 5 shows how parts of a modular heat pump compartment for use with a heat pump water heater in accordance with some implementations may fit together. As shown, the support portion 142 of a fluid movement module fits into the base component 122, and is coupled with the coupling structure 210. Additionally, a condensate module 502 fits into the second opening 212 of the base component 122. As discussed above, the condensate module 502 may be removed to facilitate cleaning and removal of condensation, and / or replaced or removed for water source inlet and outlet tubes.

[0097] FIG. 6 shows an example of a module 602 that fits into the second opening 212, and includes two openings, 604 and 606. The openings 604 and 606 may be used, for example, for water source inlet and outlet tubes. It will be understood that other configurations for modules for placement in the second opening 212 may also be used. For example, a module (not shown) having three openings - two openings for water tubes and one opening for evacuation of condensates could be used.

[0098] Referring now to FIG. 7, an intermediate cover portion of the modular heat pump compartment in accordance with some implementations is described. The intermediate cover 128 includes a duct or opening 702, a duct or opening 704, and an electrical connection box cover portion 706. The duct or opening 702 and the duct or opening 704 form portions of a fluid guiding assembly that guides the source fluid (e.g., air or water) through the modular heat pump compartment. This fluid guiding assembly may include ducts or openings for bringing the source fluidinto an out of the modular heat pump compartment, as well as components, such as the fluid movement module, which direct the source fluid through the heat exchanger. In some implementations, the duct or opening 704 may be used for the source fluid to enter an interior of the modular heat pump compartment. The duct or opening 702 may be connected to a duct or opening in the fluid movement module (not shown in FIG. 7), to facilitate the flow of the source fluid out of the modular heat pump compartment. It should be noted that for water source heat pumps, in some implementations, only a single opening may be used to accommodate both inlet and outlet tubes for source water. This single opening could be, e.g., the duct or opening 702, the duct or opening 704, or the second opening 212.

[0099] The intermediate cover 128 facilitates modularity by providing a removable and replaceable component that directs the flow of fluid into an out of the modular heat pump compartment. Various configurations of the intermediate cover 128 may be used, depending on the fluid movement module that is used in the modular heat pump compartment. In some implementations, the intermediate cover 128 may be used as a reconfigurable interface between the varying interior configurations of the modular heat pump compartment and a fixed exterior cover component. In some implementations, the intermediate cover may be removed or replaced with a smaller intermediate cover. In particular, in a water source heat pump water heater, there is no need to duct air and to enclose the heat exchanger, so a smaller intermediate cover or no intermediate cover may be used.

[0100] FIG. 8 shows the intermediate cover 128 in combination with the base component 122. When fitted together, as shown in FIG. 8, these components enclose the modular heat pump compartment, with a duct or opening 804 through which the source fluid enters the compartment and a duct or opening 802 through which the source fluid leaves the compartment after having passed through the heat exchanger. As discussed above, the second opening 212 may be used to remove condensation from the interior of the modular heat pump compartment, and to clear dust and debris from the interior of the modular heat pump compartment. The electrical connection box cover portion 806 forms, in combination with the electrical connection box portion 206 of the base component122, an electrical connection box that may be used to house an electronic controller, and other electric elements, such as capacitors.

[0101] FIG. 9 shows how these components fit together in an implementation of a heat pump water heater 100. As can be seen, the base component 122 fits within the tank housing 112. Cutouts in the tank housing 112 accommodate the electrical connection box portion of the base component 122 and the second opening of the base component 122. The condensate module 502 fits within the second opening of the base component 122. The support portion 142 of the fluid movement module, including its positioning guide, fit within the base component 122, and the removable cover portion 144 of the fluid movement module fits atop the support portion 142. The intermediate cover 128 fits with the base component 122 to enclose the modular heat pump compartment of the heat pump water heater 100.

[0102] FIG. 10 shows a block diagram 1000 of a method for assembling a heat pump water heater, in accordance with an implementation of the disclosed technology. At block 1002, the method includes providing a hot water tank. The volume and configuration of the hot water tank may depend on the model of the heat pump water heater being assembled, its intended use, etc.

[0103] At block 1004, the method includes providing a housing that substantially encloses the hot water tank to form a tank compartment. At block 1006, the method includes providing a heat pump compartment, including a base component as described above.

[0104] At block 1008, the method includes fitting a fluid guiding assembly into the heat pump compartment, the fluid guiding assembly configured to guide the source fluid through the heat exchange component. Fitting the fluid guiding assembly into the heat pump compartment includes selecting a fluid movement module including a positioning guide having a shape configured to be coupled with the coupling structure of the bottom portion of the base component (sub-block 1020), and coupling the positioning guide of the fluid movement module with the coupling structure of the bottom portion of the base component (sub-block 1022).

[0105] At block 1010, the method includes placing a heat exchange component into the heat pump compartment. The heat exchange component is configured totransfer heat from a source fluid to a refrigerant that is used to transfer heat to water in the hot water tank of the heat pump hot water heater.

[0106] In some implementations, selecting a fluid movement module further includes selecting a fluid movement module having a support portion and a removable cover portion configured for coupling with the support portion. The support portion may include the positioning guide, and the removable cover portion may include a first duct that is configured to direct a flow of the source fluid in the fluid movement module.

[0107] In some implementations, coupling the positioning guide of the fluid movement module includes orienting the fluid movement module such that the positioning guide fits with the coupling structure. In some implementations, fitting the fluid guiding assembly into the heat pump compartment includes coupling the removable cover portion of the fluid movement module with the support portion.

[0108] At block 1012, the method includes installing the heat pump compartment above the hot water tank, such that the base component is seated on or above the hot water tank.

[0109] At block 1014, the method includes adding a thermal insulation material, such as a foam material, into the tank compartment, to at least partially fill the tank compartment with the thermal insulation material, such that the base component of the heat pump compartment is held in place, at least in part, by the thermal insulation material. It will be understood that the thermal insulation material may be added at any time after the tank compartment is assembled with the tank, housing, and a closing interface, such as the base part of the modular heat pump assembly. Once the tank compartment is assembled, the thermal insulation material may be added before, during, or after other tasks, such as mounting heat pump components, covers, electronics, refrigerant filling, etc.

[0110] At block 1016, the method includes installing an intermediate cover on at least a portion of the heat pump compartment. The intermediate cover includes a second duct that directs the flow of the source fluid, and a third duct configured for coupling with the first duct.

[0111] At block 1018, the method further includes installing an outer cover on the heat pump compartment. The outer cover includes a first opening configuredfor coupling with the second duct, and a second opening configured for coupling with the third duct. It should be noted that in some implementations, the intermediate cover and outer cover may be a single part. In such implementations, the task of block 1018 would not be performed, since installing the intermediate cover would be the same as installing the outer cover.

[0112] It will be understood that although these manufacturing tasks are described and listed in an order, this is not intended to imply that the tasks must be completed in the order listed. For example, the heat pump compartment assembly can be produced in a separate production line, and added above the hot water tank before adding the thermal insulation material. This separate production line permits various of the listed tasks to be completed simultaneously, or in parallel. As a further example, the heat pump base could be placed on the tank and tank housing, followed by adding the thermal insulation material. After the thermal insulation material has been added, the heat pump elements may be added to the modular heat pump compartment. It will be apparent that assembly of a heat pump water heater could be completed with the tasks or steps carried out in many different orders.

[0113] It will be understood that, although the embodiments and / or implementations presented herein have been described with reference to specific features and structures, various modifications and combinations may be made without departing from the disclosure. For example, it is contemplated that in some implementations, the features described above may be used in different arrangements, or in other combinations. The specification and drawings are, accordingly, to be regarded simply as an illustration of the discussed implementations or embodiments and their principles as defined by the appended claims, and are contemplated to cover any and all modifications, variations, combinations or equivalents that fall within the scope of the present disclosure.REFERENCE SIGNS100 heat pump water heater102 modular heat pump compartment104 tank compartment110 water tank112 tank housing114 thermal insulation material120 cover122 base component124 heat exchanger126 fluid movement module128 intermediate cover130 control electronics140 centrifugal fan142 support portion (of fluid movement module)144 removable cover portion (of fluid movement module)150 input opening202 bottom portion (of base component)204 sidewall portion (of base component)206 electrical connection box portion (of base component)210 coupling structure212 second opening214 third opening302 positioning guide402 opening or duct502 condensate module602 module604 opening606 opening702 duct or opening704 duct or opening706 electrical connection box cover portion (of intermediate cover)1100 Aquacosy heating appliance (Prior Art)1102 heat pump compartment (Prior Art)1104 casing (Prior Art)1106 opening (Prior Art)1108 filter (Prior Art)1110 hatch (Prior Art)1112 opening (Prior Art)1114 evaporator (Prior Art)1116 resistive element (Prior Art)1118 inverter card (Prior Art)1120 cover (Prior Art)1122 thermowell temperature sensor (Prior Art)1124 heating body (Prior Art)1126 pressure sensor (Prior Art)1128 control panel (Prior Art)1130 regulation card (Prior Art)1132 front cover (Prior Art)1134 cover (Prior Art)1136 bottom cap (Prior Art)1140 fan assembly (Prior Art)1142 heat pump fan (Prior Art)1144 fan housing (Prior Art)1202 hot water tank (Prior Art)1204 condenser coils (Prior Art)1302 guiding structure (Prior Art)1400 base (Prior Art)1402 recessed shape (for compressor) (Prior Art)1404 recessed shape (for evaporator) (Prior Art)1406 recessed shape (for fan) (Prior Art)1408 recessed shape (for bottle) (Prior Art)1500 cap (Prior Art)1502 associated shape (for evaporator) (Prior Art)1504 associated shape (for fan) (Prior Art)

Claims

CLAIMS:1 . A base component (122) for a modular heat pump compartment (102) of a heat pump water heater (100), the base component (122) comprising: a bottom portion (202) forming a bottom surface of the base component (122); and a sidewall portion (204) formed, in particular integrally, with the bottom portion (202) and extending, at least in part, in a vertical or transverse direction from the bottom portion (202), at least along a segment of an outer edge of the bottom portion (202); characterised in that: the bottom portion (202) and / or the sidewall portion (204) comprises a coupling structure (210) formed, in particular integrally, with the bottom portion (202) and / or the sidewall portion (204), and having a shape configured for coupling with a corresponding positioning guide (302) of a fluid movement module (126), to position the fluid movement module (126) within the modular heat pump compartment (102).

2. The base component (122) of claim 1 , characterised in that the base component (122) is configured to be seated on or above a hot water tank (110) of the heat pump water heater (100).

3. The base component (122) of claim 1 or claim 2, characterised in that the shape of the coupling structure (210) is further configured for coupling only with acorresponding positioning guide (302) of a compatible fluid movement module (126).

4. The base component (122) of any one of the preceding claims, characterised in that the shape of the coupling structure (210) is further configured to permit the fluid movement module (126) to be coupled only in a predetermined orientation.

5. The base component (122) of any one of the preceding claims, characterised in that the coupling structure (210) comprises a first opening passing through the bottom portion (202) of the base component (122).

6. The base component (122) of any one of the preceding claims, characterised in that the base component comprises one or more additional coupling structures, configured for coupling with corresponding different positioning guides on a heat exchange component (124) and / or other component(s) of the heat pump water heater (100).

7. The base component (122) of any one of the preceding claims, further comprising a condensate drain area, the base component (122) further characterised in that the sidewall portion (204) comprises a second opening (212) providing access to the condensate drain area, the second opening (212) having a shape configured to receive a corresponding replaceable module (502, 602).

8. The base component (122) of claim 7, further characterised in that the second opening (212) has a size that facilitates cleaning the condensate drain area, and a shape configured to receive a corresponding condensate module (502).

9. The base component (122) of claim 7, further characterised in that the second opening (212) has a size and a shape configured to receive a corresponding replaceable module (602) comprising a first opening (604) for a source water inlet tube and a second opening (606) for a source water outlet tube.

10. The base component (122) of any one of the preceding claims, characterised in that the base component (122) is substantially circular, and is configured such that the bottom portion (202) of the base component (122) fits within a cylindrical tank housing (112) of the heat pump water heater (100).11 . The base component (122) of any one of the preceding claims, characterised in that the base component (122) comprises an electrical connection box portion (206) formed in the bottom portion (202) and sidewall portion (204) portion of the base component (122), the electrical connection box portion (206) configured to at least partially house electronic components of the heat pump water heater (100).

12. The base component (122) of claim 11 , characterised in that the electrical connection box portion (206) comprises a third opening (214) between the electrical connection box portion (206) and a main portion of the base component(122), the third opening (214) configured to permit cables from electronic components to run between the electrical connection box portion (206) and the main portion of the base component (122).

13. A modular heat pump compartment (102) of a heat pump water heater (100), the modular heat pump compartment (102) comprising: a heat exchange component (124) configured to transfer heat from a source fluid to a refrigerant that is used to transfer heat to water in the hot water tank (110) of the heat pump water heater (100); and a fluid guiding assembly, configured to guide the source fluid through the heat exchange component (124); characterised in that: the modular heat pump compartment (102) comprises the base component (122) of any one of claims 1 to 12; and the fluid guiding assembly comprises a fluid movement module (126) having a positioning guide (302) that is coupled with the coupling structure (210) of the base component (122).

14. The modular heat pump compartment (102) of claim 13, characterised in that the heat exchange component (124) and / or other components of the heat pump water heater (100) include different positioning guides that are coupled with corresponding additional coupling structures of the base component (122) and / or other components of the heat pump water heater (100).

15. The modular heat pump compartment (102) of claim 13 or claim 14, characterised in that the modular heat pump compartment (102) is configured to be seated on or above a hot water tank (110) of the heat pump water heater (100).

16. The modular heat pump compartment (102) of any one of claims 13 to 15, characterised in that the fluid movement module (126) comprises a driving element, comprising one of an axial fan, a centrifugal fan (140), a helical fan, a water pump, and / or another source fluid driving element.

17. The modular heat pump compartment (102) of any one of claims 13 to 16, characterised in that the fluid movement module (126) comprises a support portion (142) and a removable cover portion (144) configured for coupling with the support portion (142), the support portion (142) including the positioning guide (302).

18. The modular heat pump compartment (102) of claim 17, characterised in that the removable cover portion (144) comprises a first duct (402) that is configured to direct a flow of the source fluid, the configuration of the first duct (402) varying based on the driving element.

19. The modular heat pump compartment (102) of claim 17, characterised in that the removable cover portion (144) comprises a first duct (402) that is configured to direct a flow of the source fluid, at least one of a size, diameter, shape, position, and / or angular orientation varying depending on an installation of the heat pump water heater (100).

20. The modular heat pump compartment (102) of claim 18 or claim 19, characterised in that the modular heat pump compartment (102) comprises an intermediate cover (128), the intermediate cover (128) comprising a second duct (704) that directs the flow of the source fluid, and a third duct (702) configured for coupling with the first duct (402).21 . The modular heat pump compartment (102) of claim 20, characterised in that the modular heat pump compartment (102) comprises an outer cover (120) configured to cover the modular heat pump compartment (102), the outer cover (120) comprising a first opening (150) configured for coupling with the second duct (704), and a second opening configured for coupling with the third duct (702).

22. A heat pump water heater (100) comprising: a hot water tank (110); and a tank housing (112) enclosing the hot water tank (110): characterised in that: the heat pump water heater (100) further comprises the modular heat pump compartment (102) of any one of claims 13 to 21 , seated on or above the hot water tank (110), such that at least a portion of the modular heat pump compartment (102) fits within the tank housing (112).

23. The heat pump water heater (100) of claim 22, characterised in that a cavity is formed within the tank housing (112) between the hot water tank (110) and thebase component (122) of the modular heat pump compartment (102), and in that the cavity is at least partially filled with a thermal insulation material (114), such as a foam material, such that the base component (122) is held in place, at least in part, by the thermal insulation material (114).

24. The heat pump water heater (100) of claim 23, characterised in that the coupling structure (210) of the base component (122) of the modular heat pump component is configured so the positioning guide (302) of the fluid movement module (126) that is coupled to the coupling structure (210) is in contact with the thermal insulation material (114) in the cavity, such that the thermal insulation material (114) holds the positioning guide (302) in place.

25. A method for assembling a heat pump water heater (100), the method comprising: providing (1002) a hot water tank (110); providing (1004) a housing (112) that substantially encloses the hot water tank (110) to form a tank compartment (104); providing (1006) a heat pump compartment (102), comprising a base component (122) in accordance with any one of claims 1 to 12; placing (1010) a heat exchange component (124) into the heat pump compartment (102), the heat exchange component (124) configured to transfer heat from a source fluid to a refrigerant that is used to transfer heat to water in the hot water tank (110) of the heat pump water heater (100);fitting (1008) a fluid guiding assembly into the heat pump compartment(102), the fluid guiding assembly, configured to guide the source fluid through the heat exchange component (124); and installing (1012) the heat pump compartment (102) above the hot water tank (110), such that the base component (122) is seated on or above the hot water tank (110); wherein fitting (1008) the fluid guiding assembly into the heat pump compartment comprises: selecting (1020) a fluid movement module (126) including a positioning guide (302) having a shape configured to be coupled with the coupling structure (210) of the bottom portion (202) of the base component (122); and coupling (1022) the positioning guide (302) of the fluid movement module (126) with the coupling structure (210) of the bottom portion (202) of the base component (122).

26. The method of claim 25, wherein coupling (1022) the positioning guide (302) of the fluid movement module (126) further comprises orienting the fluid movement module (126) such that the positioning guide (302) fits with the coupling structure (210).

27. The method of claim 25 or claim 26, wherein selecting (1020) a fluid movement module (126) further includes selecting a fluid movement module (126) having a support portion (142) and a removable cover portion (144) configured for coupling with the support portion (142), the support portion (142) including the positioningguide (302), and the removable cover portion (144) including a first duct (402) that is configured to direct a flow of the source fluid in the fluid movement module (126).

28. The method of claim 27, wherein fitting (1008) the fluid guiding assembly into the heat pump compartment (102) further comprises coupling the removable cover portion (144) of the fluid movement module (126) with the support portion (142).

29. The method of claim 28, further comprising installing (1016) an intermediate cover (128) on at least a portion of the heat pump compartment (102), the intermediate cover (128) comprising a second duct (704) that directs the flow of the source fluid, and a third duct (702) configured for coupling with the first duct (402).

30. The method of claim 29, further comprising installing (1018) an outer cover (120) on the heat pump compartment (102), the outer cover (120) comprising a first opening (150) configured for coupling with the second duct (704), and a second opening configured for coupling with the third duct (702).31 . The method of any one of claims 25 to 30, further comprising adding (914) a thermal insulation material (114) into the tank compartment (104), to at least partially fill the tank compartment (104) with the thermal insulation material (114), such that the base component (122) of the heat pump compartment (102) is held in place, at least in part, by the thermal insulation material (114).

32. A method of heating water, comprising: providing a heat pump water heater (100) according to any one of claims 22-24; using the fluid guiding assembly to guide the source fluid through the heat exchange component (124), to transfer heat from the source fluid to a refrigerant; and transferring heat from the refrigerant to water in the hot water tank (110).

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