Water heater assembly having a condensate trap

Abstract

A water heater assembly includes a burner and an exhaust pathway. The exhaust pathway includes a condensate trap having a float and a housing. The housing includes an upper housing portion defining an upper chamber within which the float is disposed, an inlet through which exhaust gases and liquid condensate flow into the upper chamber, an exhaust outlet through which exhaust gases flow out of the upper chamber, a lower housing portion that defines a lower chamber positioned beneath the upper chamber, a divider that extends between the upper and lower chambers and includes an upper face and a lower face opposite the upper face, a port that extends through the divider from the upper chamber to the lower chamber, a condensate outlet through which liquid condensate flows out of the lower chamber, and a collar that projects downward from the lower face of the divider to a lower lip.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. 63 / 710,210, filed on Oct. 22, 2024, entitled “WATER HEATER ASSEMBLY HAVING A CONDENSATE TRAP,” the disclosure of which is hereby incorporated herein by reference in its entirety.FIELD OF THE DISCLOSURE

[0002] The present disclosure generally relates to a water heater. More specifically, the present disclosure relates to a water heater assembly that includes a condensate trap.BACKGROUND OF THE DISCLOSURE

[0003] Water heaters that heat water via combustion of fuel include flues or exhaust conduits. Liquid condensate often accumulates in the exhaust conduits.SUMMARY OF THE DISCLOSURE

[0004] A water heater assembly includes a burner configured to combust fuel to generate heat and an exhaust pathway that conveys exhaust gases from the burner to an exterior environment. The exhaust pathway includes a condensate trap. The condensate trap includes a float and a housing. The housing includes an upper housing portion that defines an upper chamber within which the float is disposed. The housing includes an inlet through which exhaust gases and liquid condensate flow into the upper chamber. The housing includes an exhaust outlet through which exhaust gases flow out of the upper chamber. The housing includes a lower housing portion that defines a lower chamber positioned beneath the upper chamber. A divider extends between the upper and lower chambers and includes an upper face and a lower face opposite the upper face. The upper face defines the upper chamber cooperatively with the upper housing portion, the lower face defines lower chamber cooperatively with the lower housing portion. A port extends to the divider from the upper chamber to the lower chamber. The housing includes a condensate outlet through which liquid condensate flows out of the lower chamber. A collar projects downward from the lower face of the divider to a lower lip of the collar that is distal from the lower face, such that the collar extends about the port. The lower lip of the collar is positioned below the condensate outlet, such that liquid condensate accumulated within the lower chamber to a level that is above the lower lip and below the condensate outlet cooperates with the collar to form a trap that isolates the port from the condensate outlet.

[0005] Embodiments of the first aspect of the present disclosure can include any one or a combination of the following features:

[0006] the float is pivotably coupled with the housing;

[0007] the float includes a float body and a float valve that extends outward from the float body and is configured to protrude into the port;

[0008] the divider includes a port wall that extends from the upper face of the divider to the lower face of the divider to form the port, and the port wall extends downward and port-inboard from the upper face of the divider to the lower face of the divider at an angle, and wherein a portion of the float valve is configured to abut the port wall in a closed condition of the float to restrict the flow of exhaust gases through the port from the upper chamber to the lower chamber, the portion of the float valve that is configured to abut the port wall in the closed condition of the float being angled, such that, in the closed condition of the float, the angle of the portion of the float valve is substantially complementary with the angle of the port wall of the divider;

[0009] the exhaust pathway is partially defined by a drain pan comprising: a side wall; a base coupled to the side wall to define an interior volume of the drain pan and including a recessed trough that slopes downward and drain pan-outboard; and a drain pan outlet that is aligned with the recessed trough and connected with the inlet of the housing of the condensate trap, such that exhaust gases flow from the interior volume of the drain pan into the upper chamber of the housing through the drain pan outlet and the inlet of the housing, and liquid condensate that enters the interior volume of the drain pan flows with gravity along the recessed trough of the base, into the drain pan outlet, and through the inlet of the housing into the upper chamber defined by the upper housing portion of the housing;

[0010] the housing of the condensate trap comprises: a first component that includes the inlet, the exhaust outlet, and the condensate outlet and that partially defines the upper chamber; a second component that includes the divider, the port, and the collar and that defines an aperture that is aligned with the condensate outlet formed by the first component; and a third component that partially defines the lower chamber and that contacts the first and second components;

[0011] the third component is in threaded engagement with the first component;

[0012] a sensor coupled with the housing of the condensate trap; and a controller in communication with the sensor configured to control a gas valve based on sensor data received from the sensor;

[0013] the sensor is a pressure sensor, and the controller is configured to close the gas valve based on the sensor data from the pressure sensor indicating at least one of a rate of pressure increase reaching a rate of pressure increase-threshold and a pressure level reaching a pressure level threshold;

[0014] the sensor is a temperature sensor, and the controller is configured to close the gas valve based on the sensor data from the temperature sensor indicating at least one of a rate of temperature increase reaching a rate of temperature increase-threshold and a temperature level reaching a temperature level-threshold;

[0015] the housing includes a connector portion that defines the exhaust outlet, the connector portion comprising: an inner surface that partially defines the exhaust pathway; an outer surface opposite the inner surface; a first flange that extends outward from the outer surface proximate to the exhaust outlet; and a second flange that extends outward from the outer surface, wherein the second flange is further than the first flange from exhaust outlet;

[0016] the first flange extends outward from the outer surface a first distance, the second flange extends outward from the outer surface a second distance, and the first distance is less than the second distance;

[0017] a flexible tubular coupling extending about and engaged with the outer surface of the connector portion, wherein the flexible tubular coupling is engaged with the connector portion such that the first flange is disposed within a hollow defined by the flexible tubular coupling and the second flange is outside of the hollow defined by the flexible tubular coupling; and

[0018] an exhaust conduit that partially defines the exhaust pathway and that extends within the hollow defined by the flexible tubular coupling, wherein the first flange extends outward from the outer surface of the connector portion, such that interference between the first flange and the exhaust conduit stops insertion of the connector portion into the exhaust conduit.

[0019] According to a second aspect of the present disclosure, a condensate trap includes a float and a housing. The housing includes an upper housing portion that defines an upper chamber within which the float is disposed. The housing includes an inlet through which exhaust gases and liquid condensate flow into the upper chamber. The housing includes an exhaust outlet through which exhaust gases flow out of the upper chamber. The housing includes a lower housing portion that defines a lower chamber positioned beneath the upper chamber. A divider extends between the upper and lower chambers and includes an upper face and a lower face opposite the upper face. The upper face defines the upper chamber cooperatively with the upper housing portion, the lower face defines lower chamber cooperatively with the lower housing portion. A port extends to the divider from the upper chamber to the lower chamber. The housing includes a condensate outlet through which liquid condensate flows out of the lower chamber. A collar projects downward from the lower face of the divider to a lower lip of the collar that is distal from the lower face, such that the collar extends about the port. The lower lip of the collar is positioned below the condensate outlet, such that liquid condensate accumulated within the lower chamber to a level that is above the lower lip and below the condensate outlet cooperates with the collar to form a trap that isolates the port from the condensate outlet.

[0020] Embodiments of the second aspect of the present disclosure can include any one or a combination of the following features:

[0021] the float is pivotably coupled with the housing;

[0022] the float includes a float body and a float valve that extends outward from the float body and is configured to protrude into the port;

[0023] the divider includes a port wall that extends from the upper face of the divider to the lower face of the divider to form the port, and the port wall extends downward and port-inboard from the upper face of the divider to the lower face of the divider at an angle, and wherein a portion of the float valve is configured to abut the port wall in a closed condition of the float to restrict the flow of exhaust gases through the port from the upper chamber to the lower chamber, the portion of the float valve that is configured to abut the port wall in the closed condition of the float being angled, such that, in the closed condition of the float, the angle of the portion of the float valve is substantially complementary with the angle of the port wall of the divider; and

[0024] the housing of the condensate trap comprises: a first component that includes the inlet, the exhaust outlet, and the condensate outlet and that partially defines the upper chamber; a second component that includes the divider, the port, and the collar and that defines an aperture that is aligned with the condensate outlet formed by the first component; and a third component that partially defines the lower chamber and that contacts the first and second components.

[0025] According to a third aspect of the present disclosure, a condensate trap includes a housing. The housing includes an upper housing portion that defines an upper chamber, an inlet through which exhaust gases and liquid condensate flow into the upper chamber, an exhaust outlet through which exhaust gases flow out of the upper chamber, a lower housing portion that defines a lower chamber positioned beneath the upper chamber, a divider that extends between the upper and lower chambers and includes an upper face that defines the upper chamber cooperatively with the upper housing portion, and a lower face opposite the upper face that defines the lower chamber cooperatively with the lower housing portion, a port that extends through the divider from the upper chamber to the lower chamber, and a condensate outlet through which liquid condensate flows out of the lower chamber. A float is disposed within the upper chamber and is pivotably coupled to the housing, such that the float is operable to pivot about a pivot axis within the upper chamber between a closed condition and an open condition. The float includes a float valve that, in the closed condition of the float, is configured to abut a port wall that extends from the upper face of the divider to the lower face of the divider to form the port, such that the float valve restricts the flow of exhaust gases through the port from the upper chamber to the lower chamber. The float further includes a float body that includes a lower surface from which the float valve extends, an upper surface, and a side surface that extends between the upper and lower surfaces, wherein, in the closed condition of the float, a first vertical line that intersects the pivot axis and extends within a plane that is perpendicular to the pivot axis extends a first distance from the lower surface to the upper surface of the float body, a second vertical line that extends within the plane between the float valve and the pivot axis extends a second distance from the lower surface to the upper surface of the float body, and a third vertical line that extends within the plane, such that the float valve is positioned between the third vertical line and the pivot axis, extends a third distance from the lower surface to the upper surface of the float body, and wherein the first distance is less than the second distance, and the second distance is less than the third distance.

[0026] These and other features, advantages, and objects of the present disclosure will be further understood and appreciated by those skilled in the art by reference to the following specification, claims, and appended drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0027] In the drawings:

[0028] FIG. 1 is a perspective view of a water heater assembly including a water heater and a condensate trap, according to one embodiment;

[0029] FIG. 2 is a cross-sectional view of a portion of the water heater assembly of FIG. 1, illustrating a combustion assembly, a flue, a drain pan, and a condensate trap, according to one embodiment;

[0030] FIG. 3 is a perspective view of a drain pan and a condensate trap of a water heater assembly, according to one embodiment;

[0031] FIG. 4 is a cross-sectional view of the drain pan and the condensate trap illustrated in FIG. 3, according to one embodiment;

[0032] FIG. 5 is a perspective view of an engagement feature and a receiver in a disengaged condition, according to one embodiment;

[0033] FIG. 6 is a perspective view of the engagement feature and the receiver in an engaged condition, according to one embodiment;

[0034] FIG. 7 is a perspective view of a condensate trap, according to one embodiment;

[0035] FIG. 8 is an exploded view of the condensate trap, illustrating a first component, a float, a second component, a third component, and a plurality of seals, according to one embodiment;

[0036] FIG. 9 is a cross-sectional exploded view of the condensate trap, according to one embodiment;

[0037] FIG. 10 is a cross-sectional view of a condensate trap, illustrating a float of the condensate trap that is positioned within an upper chamber defined by a housing of the condensate trap and is in a closed condition, wherein a float valve of the float abuts a port wall of a divider of the housing to restrict the flow of exhaust gases from an upper chamber of the housing to a lower chamber of the housing, according to one embodiment;

[0038] FIG. 11 is a cross-sectional view of the condensate trap, illustrating the float in an open condition, wherein the float is pivoted such that the float valve of the float is in a spaced relationship with the port wall to allow liquid condensate to drain through the port of the divider from the upper chamber to the lower chamber, according to one embodiment;

[0039] FIG. 12 is an enlarged view of Area XII taken from FIG. 10, illustrating the float valve in the closed condition of the float, according to one embodiment;

[0040] FIG. 13 is an enlarged view of Area XIII taken from FIG. 11, illustrating the float valve in the open condition of the float, according to one embodiment;

[0041] FIG. 14 is a partial cross-sectional view of a portion of a condensate trap, illustrating a float valve shaped as a spherical cap extending through a port defined by a divider of the housing of the condensate trap in a closed condition of the float, according to one embodiment;

[0042] FIG. 15 is a cross-sectional view of the condensate trap, illustrating the flow of exhaust gases into an inlet of the housing of the condensate trap and out of an exhaust outlet and the flow of liquid condensate into the inlet of the housing through the divider via the port from the upper chamber defined by the housing to the lower chamber defined by the housing and out of a condensate outlet defined by the housing, according to one embodiment;

[0043] FIG. 16 is a perspective view of a condensate trap, according to one embodiment;

[0044] FIG. 17 is a perspective view of a condensate trap having flexible tubular couplings engaged therewith and disposed respectively proximate an inlet and an exhaust outlet of the condensate trap;

[0045] FIG. 18 is a cross-sectional view of the condensate trap and flexible tubular couplings of FIG. 17, illustrating a conduit disposed within the flexible tubular coupling that extends about the exhaust outlet in phantom, according to one embodiment;

[0046] FIG. 19 is an enlarged view of area XIX of FIG. 19, illustrating first and second flanges that extend outward from a portion of the condensate trap, according to one embodiment; and

[0047] FIG. 20 is a block diagram illustrating components of a water heater assembly including a controller, one or more sensors, and a gas shutoff valve, according to one embodiment.DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0048] Additional features and advantages of the disclosure will be set forth in the detailed description which follows and will be apparent to those skilled in the art from the description, or recognized by practicing the disclosure as described in the following description, together with the claims and appended drawings.

[0049] As used herein, the term “and / or,” when used in a list of two or more items, means that any one of the listed items can be employed by itself, or any combination of two or more of the listed items can be employed. For example, if a composition is described as containing components A, B, and / or C, the composition can contain A alone; B alone; C alone; A and B in combination; A and C in combination; B and C in combination; or A, B, and C in combination.

[0050] In this document, relational terms, such as “first” and “second,”“top” and “bottom,” and the like, are used solely to distinguish one entity or action from another entity or action, without necessarily requiring or implying any actual such relationship or order between such entities or actions.

[0051] For purposes of this disclosure, the term “coupled” (in all of its forms: couple, coupling, coupled, etc.) generally means the joining of two components (electrical or mechanical) directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two components (electrical or mechanical) and / or any additional intermediate members. Such joining may include members being integrally formed as a single unitary body with one another (i.e., integrally coupled) or may refer to joining of two components. Such joining may be permanent in nature, or may be removable or releasable in nature, unless otherwise stated.

[0052] As used herein, the terms “the,”“a,” or “an,” mean “at least one,” and should not be limited to “only one” unless explicitly indicated to the contrary. Thus, for example, reference to “a component” includes embodiments having two or more such components unless the context clearly indicates otherwise.

[0053] Referring now to FIGS. 1-20, a water heater assembly 10 includes a burner 12 configured to combust fuel to generate heat and an exhaust pathway 14 that conveys exhaust gases 16 from the burner 12 to an exterior environment 18. The exhaust pathway 14 includes a condensate trap 20. The condensate trap 20 includes a float 22 and a housing 24. The housing 24 includes an upper housing portion 26 that defines an upper chamber 28 within which the float 22 is disposed. The housing 24 includes an inlet 30 through which exhaust gases 16 and liquid condensate 32 flow into the upper chamber 28. The housing 24 includes an exhaust outlet 34 through which exhaust gases 16 flow out of the upper chamber 28. The housing 24 includes a lower housing portion 36 that defines a lower chamber 38 positioned beneath the upper chamber 28. A divider 40 extends between the upper and lower chambers 28, 38 and includes an upper face 42 and a lower face 44 opposite the upper face 42. The upper face 42 defines the upper chamber 28 cooperatively with the upper housing portion 26, and the lower face 44 defines the lower chamber 38 cooperatively with the lower housing portion 36. A port 46 extends through the divider 40 from the upper chamber 28 to the lower chamber 38. The housing 24 includes a condensate outlet 48 through which liquid condensate 32 flows out of the lower chamber 38. A collar 50 projects downward from the lower face 44 of the divider 40 to a lower lip 52 of the collar 50 that is distal from the lower face 44. The collar 50 extends about the port 46. The lower lip 52 of the collar 50 is positioned below the condensate outlet 48, such that liquid condensate 32 accumulated within the lower chamber 38 to a level that is above the lower lip 52 and below the condensate outlet 48 cooperates with the collar 50 to form a trap that isolates the port 46 from the condensate outlet 48.

[0054] Referring now to FIGS. 1 and 2, the water heater assembly 10 includes a tank 54. In some examples, the tank 54 can be covered by a jacket 56 with insulation disposed between the tank 54 and the jacket 56 for insulating water in the tank 54. As illustrated in FIG. 1, a cold-water inlet 58 and a hot water outlet 60 may be coupled with the tank 54 of the water heater assembly 10. As shown in FIG. 2, the water heater assembly 10 includes a combustion assembly 62. The combustion assembly 62 may include the burner 12 that is configured to combust fuel to generate heat, an igniter 64, and / or a blower assembly 66 that is coupled to the burner 12. As illustrated, a flue conduit 68 extends downward from a mounting plate to which the burner 12 is coupled and defines an interior volume 70 into which a body of the burner 12 extends. In the illustrated embodiment, the water heater assembly 10 includes a top-fired water heater and the flue conduit 68 extends downward from the combustion assembly 62 to a plenum 72 that is partially defined by a drain pan 74, as described further herein. The interior volume 70 defined by the flue conduit 68 and the plenum 72 that is at least partially defined by the drain pan 74 forms portions of the exhaust pathway 14 that conveys exhaust gases 16 from the burner 12 to the exterior environment 18.

[0055] Referring now to FIGS. 2-4, the drain pan 74 includes a base 76 and a side wall 78 that extends upward from the base 76. As illustrated in FIG. 3, a flange 80 extends outward from the side wall 78 distally from the base 76 and includes a plurality of apertures. The plurality of apertures are configured to receive fasteners therethrough for fastening the drain pan 74 to another portion of the water heater assembly 10. In various implementations, the drain pan 74 is fastened in a substantially sealed manner, such that the interior volume defined by the drain pan 74 serves as a portion of the exhaust pathway 14. As illustrated in FIGS. 3 and 4, the base 76 of the drain pan 74 includes a recessed trough 82. The recessed trough 82 slopes downward and drain pan-outboard. As shown in FIG. 3, the recessed trough 82 initiates proximate to a center of the base 76. The base 76 may generally slope downward as it extends inboard toward the center, and the recessed trough 82 may slope downward away from the center as the recessed trough 82 extends drain pan-outboard toward the side wall 78. As further illustrated in FIGS. 3 and 4, the drain pan 74 includes a drain pan outlet 84. The drain pan outlet 84 is aligned with the recessed trough 82 and extends outward beyond the side wall 78 of the drain pan 74 to an opening. In various implementations, the drain pan outlet 84 is connected with the inlet 30 of the housing 24 of the condensate trap 20, such that exhaust gases 16 and liquid condensate 32 flow from the interior volume of the drain pan 74 into the upper chamber 28 of the housing 24, as described further herein.

[0056] Referring now to FIGS. 3-6, in various embodiments, the drain pan outlet 84 of the drain pan 74 is connected with the housing 24 of the condensate trap 20. As illustrated in FIGS. 3 and 4, the drain pan outlet 84 is connected with the inlet 30 of the housing 24 of the condensate trap 20. In operation of the water heater assembly 10, exhaust gases 16 flow from the interior volume of the drain pan 74 into the upper chamber 28 of the housing 24 through the drain pan outlet 84 and the inlet 30 of the housing 24, and liquid condensate 32 that enters the interior volume of the drain pan 74 flows with gravity along the recessed trough 82 of the base 76, into the drain pan outlet 84, and through the inlet 30 of the housing 24 into the upper chamber 28 defined by the upper housing portion 26 of the housing 24. As illustrated in FIGS. 3 and 4, the drain pan outlet 84 engages with the inlet 30 of the housing 24 of the condensate trap 20 in a nested manner.

[0057] In various implementations, the housing 24 includes one of a receiver 86 or an engagement feature 88 configured to be received by the receiver 86 for engagement therewith, and the drain pan 74 includes the other of the receiver 86 or the engagement feature 88. For example, as illustrated in FIG. 3, the drain pan 74 includes the engagement feature 88, which is coupled with the drain pan outlet 84, and the housing 24 of the condensate trap 20 includes the receiver 86 which is coupled with the inlet 30 of the housing 24. As shown in FIGS. 5 and 6, the engagement feature 88 includes a base portion 90 and an arm 92 that extends from the base portion 90 to a distal end thereof. The arm 92 includes an interior surface 94 and first and second fins 96, 98 that protrude relative to the interior surface 94 and extend along the interior surface 94 toward the distal end of the arm 92, such that the interior surface 94 is disposed between and recessed relative to the first and second fins 96, 98. Further, the arm 92 includes first and second catches 100, 102 that protrude from the first and second fins 96, 98, respectively, proximate to the distal end of the arm 92. The receiver 86 defines a hollow 104 having opposing open ends.

[0058] Referring now to FIGS. 5 and 6, the engagement feature 88 and the receiver 86 are operable between a disengaged condition (FIG. 5), wherein the arm 92 of the engagement feature 88 is disposed outside of the hollow 104 defined by the receiver 86, and an engaged condition (FIG. 6), wherein the arm 92 of the engagement feature 88 extends through the hollow 104 defined by the receiver 86. In the engaged condition, the first and second catches 100, 102 inhibit removal of the arm 92 from the hollow 104 defined by the receiver 86, the first and second fins 96, 98 abut the receiver 86, and the interior surface 94 of the arm 92 is in a spaced relationship with the receiver 86. In various implementations, the interior surface 94 being in a spaced relationship with the receiver 86 may allow for a user to insert a tool between the receiver 86 and the interior surface 94 to depress the arm 92 and release the first and second catches 100, 102 from their abutment with the receiver 86 to allow the engagement feature 88 to enter the disengaged condition.

[0059] Referring now to FIGS. 7-11, an exemplary embodiment of the condensate trap 20 is illustrated. In the illustrated embodiment, the condensate trap 20 includes the housing 24. The housing 24 includes the upper housing portion 26 that defines the upper chamber 28 within which the float 22 is disposed, the inlet 30 through which exhaust gases 16 and liquid condensate 32 flow into the upper chamber 28, the exhaust outlet 34 through which exhaust gases 16 flow out of the upper chamber 28, the lower housing portion 36 that defines the lower chamber 38 positioned beneath the upper chamber 28, the divider 40 that extends between the upper and lower chambers 28, 38, the port 46 that extends through the divider 40 from the upper chamber 28 to the lower chamber 38, the collar 50 that projects downward from the lower face 44 of the divider 40, and the condensate outlet 48 through which liquid condensate 32 flows out of the lower chamber 38.

[0060] As illustrated in FIGS. 7-11, the inlet 30 comprises a conduit that extends outward from the upper housing portion 26. As shown in FIG. 7, the conduit can include one or more sensor ports 106 that are configured to accommodate sensors 108 of the water heater assembly 10, as described further herein. In various implementations, the divider 40 includes the upper face 42 that defines the upper chamber 28 cooperatively with the upper housing portion 26 and the lower face 44 opposite the upper face 42 that defines the lower chamber 38 cooperatively with the lower housing portion 36. The divider 40 can include a port wall 110 that extends from the upper face 42 of the divider 40 to the lower face 44 of the divider 40 to form the port 46. The port wall 110 may extend downward and port-inboard from the upper face 42 of the divider 40 to the lower face 44 of the divider 40 at an angle, as illustrated in FIGS. 12 and 13, as described further herein.

[0061] Referring still to FIGS. 7-11, in various embodiments, the housing 24 of the condensate trap 20 includes a plurality of components. In the embodiment illustrated in FIGS. 7-11, the housing 24 includes a first component 112 that includes the inlet 30, the exhaust outlet 34, and the condensate outlet 48 and that partially defines the upper chamber 28. A second component 114 includes the divider 40, the port 46, and the collar 50 and defines an aperture 116 that is aligned with the condensate outlet 48 formed by the first component 112. A third component 118 partially defines the lower chamber 38 and contacts the first and second components 112, 114. As illustrated in FIGS. 8-11, the second component 114 is configured to be received within a hollow defined by the first component 112. As illustrated, the second component 114 includes a float pivot mount 120 that extends upward from the upper face 42 of the divider 40 that is formed by the second component 114. The third component 118 serves as an end cap of the housing 24 that is positioned at the bottom of the housing 24. The housing 24 further includes first and second seals 122, 124.

[0062] As illustrated in FIG. 10, in an assembled condition of the housing 24, the second component 114 is received within the hollow defined by the first component 112, and the first seal 122 is sandwiched between a portion of the first component 112 and the divider 40 of the second component 114 to provide a seal between the first and second components 112, 114. The third component 118 is in threaded engagement with the first component 112 at the bottom of the housing 24 and abuts the second component 114. The second seal 124 is disposed at a junction of the first, second, and third components 112, 114, 118. As illustrated in FIG. 10, in the assembled condition, the aperture 116 defined by the second component 114 is aligned with the condensate outlet 48 formed by the third component 118 of the housing 24. Further, in the assembled condition of the housing 24, the collar 50 that projects downward from the lower face 44 of divider 40 to the lower lip 52 of the collar 50 is positioned such that the lower lip 52 of the collar 50 is below the condensate outlet 48. As such, liquid condensate 32 that accumulates within the lower chamber 38 to a level that is above the lower lip 52 and below the condensate outlet 48 cooperates with the collar 50 to form a trap that isolates the port 46 from the condensate outlet 48.

[0063] Referring now to FIGS. 8-14, the condensate trap 20 includes the float 22. The float 22 may be disposed within the upper chamber 28 defined by the housing 24, as illustrated in FIGS. 10 and 11. In various implementations, the float 22 includes a float body 126 and a float valve 128 that extends outward from the float body 126. The float valve 128 may be configured to protrude into the port 46, as described further herein. In various implementations, the float 22 is pivotably coupled with the housing 24. As illustrated in FIGS. 8 and 9, the float 22 is configured to be pivotably coupled with the float pivot mount 120 that extends upward from the upper face 42 of the divider 40 of the second component 114 of the housing 24. In various implementations, the float 22 is operable to pivot between a closed condition and an open condition. In various embodiments, the float valve 128 of the float 22 is configured to abut the port wall 110 of the divider 40 in the closed condition of the float 22 to restrict the flow of exhaust gases 16 through the port 46 from the upper chamber 28 to the lower chamber 38, as illustrated in FIGS. 10 and 12. In the open condition of the float 22, the float 22 may be pivoted, such that the float valve 128 of the float 22 is in a spaced relationship with the port wall 110 to allow liquid condensate 32 to flow through the port 46 from the upper chamber 28 to the lower chamber 38, as illustrated exemplarily in FIGS. 11 and 13. The float 22 is buoyant and pivots from the closed condition to the open condition due to liquid condensate 32 accumulating in the upper chamber 28 and prompting the float 22 to float upward from the closed condition to the open condition, thereby allowing the liquid condensate 32 to drain through the port 46, which in turn causes the float 22 to return to the closed condition.

[0064] The float valve 128 of the float 22 may have a variety of shapes. For example, in some embodiments, the float valve 128 may be shaped as a spherical cap that extends outward from the float body 126 of the float 22, as illustrated in FIG. 14. In some implementations, a portion of the float valve 128 that is configured to abut the port wall 110 in the closed condition of the float 22 is angled. The portion of the float valve 128 that is configured to abut the port wall 110 in the closed condition of the float 22 may be angled in a frustoconical manner. In the embodiment illustrated in FIGS. 12 and 13, the port wall 110 extends downward and port-inboard from the upper face 42 of the divider 40 to the lower face 44 of the divider 40 at an angle. The portion of the float valve 128 that is configured to abut the port wall 110 in the closed condition of the float 22 is angled at an angle that is substantially complementary with the angle of the port wall 110 of the divider 40. The complementary angles of the float valve 128 and port wall 110 may result in a seal between the float valve 128 and the port wall 110 that is superior relative to a seal formed by non-complementary angles between the port wall 110 and the float valve 128.

[0065] Referring now to FIGS. 8-11, the float body 126 of the float 22 can be tapered to increase the mechanical advantage of the float 22 for adequately sealing the port 46 via the float valve 128 in the closed condition of the float 22. In the embodiment illustrated in FIGS. 8-11, the float body 126 of the float 22 includes a lower surface 140 from which the float valve 128 extends, an upper surface 142, and a side surface 144 that extends between the lower and upper surfaces 140, 142 of the float body 126. The cross-sectional view of the condensate trap 20 illustrated in FIGS. 10 and 11 is taken along a plane that intersects the float valve 128 and is a perpendicular to a pivot axis 146 about which the float 22 pivots between the open and closed conditions. As illustrated in FIG. 10, in the closed condition of the float 22, a first vertical line 148 extending within the plane and intersecting the pivot axis 146 extends a first distance from the lower surface 140 to the upper surface 142 of the float body 126. A second vertical line 150 extending within the plane between the float valve 128 and the pivot axis 146 extends a second distance from the lower surface 140 to the upper surface 142 of the float body 126. A third vertical line 152 extending within the plane such that the float valve 128 is positioned between the third vertical line 152 and the pivot axis 146 extends a third distance from the lower surface 140 to the upper surface 142 of the float body 126. The first distance is less than the second distance, and the second distance is less than the third distance.

[0066] In the embodiment illustrated in FIG. 10, the upper surface 142 of the float body 126 angles downward as the upper surface 142 extends generally toward the pivot axis 146 from a distal end of the float body 126. This angling of the upper surface 142 results in a tapering of the float body 126 as the float body 126 extends toward the pivot axis 146 from the distal end. Consequently, the center of mass of the float body 126 is further from the pivot axis 146 than would be the case were the taper absent. In operation, this increases the mechanical advantage of the system, as the increased torque afforded by the tapered float body 126 translates to a more forceful seal between the float valve 128 and the port wall 110. As illustrated in FIG. 10, the pivot axis 146 is nearer than the distal end of the float body 126 to float valve 128. The proximity of the float valve 128 to the pivot axis 146 further contributes to the mechanical advantage of the system. The float body 126 utilizing a tapered design rather than other means of gaining mechanical advantage (e.g., an untapered float body with a greater distance between the pivot axis and distal end of the float body) advantageously reduces the maximum radial dimension of the float 22 with respect to the pivot axis 146, which allows for a more compact condensate trap 20.

[0067] Referring now to FIG. 15, in operation of the water heater assembly 10, the combustion assembly 62 combusts fuel creating exhaust that includes water vapor. The exhaust travels along the exhaust pathway 14 and the water vapor condenses to liquid condensate 32. The liquid condensate 32 pools within the drain pan 74, flows down the recessed trough 82 and out of the drain pan outlet 84. The liquid condensate 32 flows from the drain pan outlet 84 into the inlet 30 of the housing 24 of the condensate trap 20 and enters the upper chamber 28 defined by the upper housing portion 26 of the housing 24 therefrom. As the liquid condensate 32 flows into the upper chamber 28 and accumulates on the upper face 42 of the divider 40, the float 22 is pivoted from the closed condition to the open condition due to the buoyancy of the float 22 that causes the float 22 to float upon the liquid condensate 32 within the upper chamber 28. As the float 22 moves from the closed condition to the open condition, the port 46 that extends through the divider 40 is revealed, allowing the liquid condensate 32 to flow from the upper chamber 28 to the lower chamber 38 via the port 46. When the float 22 is in the open condition, the liquid condensate 32 that is flowing between the float 22 and the divider 40 into the port 46 seals the upper chamber 28 from the lower chamber 38 until the float 22 pivots back to the closed condition when the liquid condensate 32 has drained.

[0068] The liquid condensate 32 that flows from the upper chamber 28 to the lower chamber 38 through the port 46 accumulates in the lower chamber 38 until it rises to the level of the aperture 116 defined by the second component 114 and the condensate outlet 48 that is aligned with the aperture 116. The liquid condensate 32 then flows out of the lower chamber 38 through the aperture 116 and condensate outlet 48 to drain from the water heater assembly 10. As illustrated in FIG. 15, the lower lip 52 of the collar 50 that extends about the port 46 and downward from the lower face 44 of the divider 40 is positioned below the condensate outlet 48, such that liquid condensate 32 accumulated within the lower chamber 38 to a level that is above the lower lip 52 and below the condensate outlet 48 cooperates with the collar 50 to form a trap that isolates the port 46 from the condensate outlet 48. Further, when the water level within the lower chamber 38 is above the level of the lower lip 52 of the collar 50, the collar 50 and the liquid condensate 32 cooperate to form a pocket 130 within which exhaust gases 16 that bypass the float valve 128 and flow into the lower chamber 38 can be accommodated.

[0069] Referring still to FIG. 15, exhaust gases 16 are conveyed from the burner 12 into the interior volume defined by the drain pan 74. The exhaust gases 16 travel through the drain pan outlet 84 and into the upper chamber 28 of the housing 24 via the inlet 30. The float valve 128 functions to restrict the flow of exhaust gases 16 from the upper chamber 28 to the lower chamber 38 via the port 46. As such, the exhaust gases 16 vent from the housing 24 of the condensate trap 20 through the exhaust outlet 34 that is in fluid communication with the upper chamber 28 and are conveyed onward through the exhaust pathway 14 before ultimately flowing to the exterior environment 18 (e.g., outdoors).

[0070] Referring now to FIGS. 16-19, in various embodiments, the condensate trap 20 includes a connector portion 160 that defines the exhaust outlet 34. The connector portion 160 may be a portion of the upper housing portion 26 of the housing 24 of the condensate trap 20. In the embodiment illustrated in FIGS. 16-19, the connector portion 160 is a portion of the first component 112 of the housing 24. In the illustrated embodiment, the connector portion 160 is substantially cylindrical and extends upward toward the exhaust outlet 34 which is defined at the top of the connector portion 160.

[0071] Referring still to FIGS. 16-19, the connector portion 160 includes an inner surface 162 and an outer surface 164. The inner surface 162 of the connector portion 160 partially defines the exhaust pathway 14. The outer surface 164 is opposite the inner surface 162. As illustrated in FIGS. 16, 18, and 19, a first flange 166 extends outward from the outer surface 164 of the connector portion 160 proximate to the exhaust outlet 34, and a second flange 168 extends outward from the outer surface 164 of the connector portion 160. The second flange 168 is further than the first flange 166 from the exhaust outlet 34 defined by the connector portion 160. In various embodiments, the distance that the first flange 166 extends outward from the outer surface 164 of the connector portion 160 is different than the distance that the second flange 168 extends outward from the outer surface 164 of the connector portion 160. For example, in the embodiment illustrated in FIGS. 16, 18, and 19, the first flange 166 extends outward from the outer surface 164 a first distance, the second flange 168 extends outward from the outer surface 164 a second distance, and the first distance is less than the second distance.

[0072] Referring now to FIGS. 17-19, the water heater assembly 10 may include a flexible tubular coupling 170. In various embodiments, the water heater assembly 10 may include a plurality of flexible tubular couplings 170. For example, in the embodiments illustrated in FIGS. 17 and 18, two flexible tubular couplings 170 are engaged with the inlet 30 of the housing 24 and the connector portion 160 of the housing 24, respectively. In an exemplary embodiment, the flexible tubular couplings 170 may be Fernco-style couplings. A variety of types of flexible tubular couplings 170 are contemplated. In the embodiment illustrated in FIGS. 17 and 18 one of the flexible tubular couplings 170 is engaged with the inlet 30 and the other flexible tubular coupling 170 is engaged with the connector portion 160 that defines the exhaust outlet 34. The flexible tubular coupling 170 that is engaged with the inlet 30 is configured to be engaged with the drain pan outlet 84 to allow for exhaust and condensate to flow into the condensate trap 20 from the water heater assembly 10. The flexible tubular coupling 170 that is engaged with the connector portion 160 is configured to be engaged with an exhaust conduit 172 that partially defines the exhaust pathway 14, as illustrated in FIGS. 18 and 19. As illustrated, both the connector portion 160 and the exhaust conduit 172 extend within a hollow 173 defined by the flexible tubular coupling 170. As such, exhaust that flows through the connector portion 160 and out of the exhaust outlet 34 can continue to be conveyed along the exhaust pathway 14 within the exhaust conduit 172 that is connected with the connector portion 160 via the flexible tubular coupling 170. In various embodiments, hose clamps 174 are utilized to maintain the engagement between the flexible tubular couplings 170 and the drain pan outlet 84, inlet 30, connector portion 160, and exhaust conduit 172, as illustrated in FIGS. 17 and 18. It is contemplated that the engagement may be maintained by a variety of features.

[0073] Referring now to FIGS. 16-19, in an exemplary implementation, the flexible tubular coupling 170 may extend about and be engaged with the outer surface 164 of the connector portion 160, as illustrated in FIGS. 18 and 19. In the illustrated embodiment, the flexible tubular coupling 170 is engaged with the connector portion 160 such that the first flange 166 is disposed within the hollow 173 defined by the flexible tubular coupling 170. As further illustrated, the second flange 168 is disposed outside of the hollow 173. In operation, the connector portion 160 and the first flange 166 may be inserted into the hollow 173 defined by the flexible tubular coupling 170, and the second flange 168, which extends outward further than the first flange 166, may serve as a stop that the flexible tubular coupling 170 abuts when assembled with the housing 24. The hose clamp 174 may then be tightened about the flexible tubular coupling 170 and the connector portion 160 at a location that is vertically between the first and second flanges 166, 168.

[0074] The presence of the first flange 166 may be advantageous for a variety of reasons. For example, the first flange 166 may interact with the flexible tubular coupling 170 engaged therewith to form a seal. In various embodiments, the first flange 166 being disposed proximate the exhaust outlet defined by the connector portion 160 adds structural rigidity to the cylindrical connector portion 160, thereby enabling the connector portion 160 to better withstand the inward force exerted by the hose clamp 174 when tightened. In some embodiments, the first flange 166 extends outward from the outer surface 164 of the connector portion 160, such that the interference between the first flange 166 the exhaust conduit 172 stops insertion of the connector portion 160 into the exhaust conduit 172. For example, in practice, a standard-sized exhaust conduit 172 may have an inner diameter slightly larger than the outer diameter of the connector portion 160. The first flange 166 extending outward from the outer surface 164 of the connector portion 160 may interfere with the exhaust conduit 172, thereby stopping insertion of the connector portion 160 into the exhaust conduit 172 that would be enabled but for the presence of the first flange 166. This may prevent unintended methods of connecting the exhaust conduit 172 and the connector portion 160 (e.g., inserting and adhering the connector portion 160 to the exhaust conduit 172) from being performed.

[0075] Referring now to FIGS. 2, 7, and 20, in various implementations, the water heater assembly 10 includes the sensor 108. The water heater assembly 10 can include a plurality of sensors 108. For example, the water heater assembly 10 can include a pressure sensor 132. The pressure sensor 132 may be configured to sense a pressure within the exhaust pathway 14 of the water heater assembly 10. A variety of types of pressure sensors 132 are contemplated (e.g., gauge pressure sensor, differential pressure sensor, pressure switch, etc.). In some implementations, the water heater assembly 10 can include a temperature sensor 134. The temperature sensor 134 may be configured to sense a temperature within the exhaust pathway 14 of the water heater assembly 10, in various embodiments. As illustrated in FIG. 7, the housing 24 of the condensate trap 20 includes sensor ports 106 that accommodate the pressure sensor 132 and / or the temperature sensor 134. As such, the pressure sensor 132 is configured to sense a pressure within the housing 24, and the temperature sensor 134 is configured to sense a temperature within the housing 24.

[0076] Referring still to FIGS. 2, 7, and 20, in various implementations, the water heater assembly 10 includes a controller 136. The controller 136 may be in communication with the one or more sensors 108 of the water heater assembly 10 and may be configured to control one or more components of the water heater assembly 10 based on sensor data received from the one or more sensors 108. In an exemplary implementation, the controller 136 is configured to control operation of a gas shutoff valve 138 of the water heater assembly 10. In some embodiments, the controller 136 is configured to close the gas shutoff valve 138 based on sensor data from the pressure sensor 132 indicating at least one of a rate of pressure increase reaching a rate of pressure increase-threshold and / or a pressure level reaching a pressure level-threshold. In some embodiments, the controller 136 is configured to close the gas shutoff valve 138 based on sensor data from the temperature sensor 134 indicating a rate of temperature increase reaching a rate of temperature increase-threshold and / or a temperature level reaching a temperature level-threshold.

[0077] It is to be understood that variations and modifications can be made on the aforementioned structure without departing from the concepts of the present disclosure, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise.

Examples

Embodiment Construction

[0048]Additional features and advantages of the disclosure will be set forth in the detailed description which follows and will be apparent to those skilled in the art from the description, or recognized by practicing the disclosure as described in the following description, together with the claims and appended drawings.

[0049]As used herein, the term “and / or,” when used in a list of two or more items, means that any one of the listed items can be employed by itself, or any combination of two or more of the listed items can be employed. For example, if a composition is described as containing components A, B, and / or C, the composition can contain A alone; B alone; C alone; A and B in combination; A and C in combination; B and C in combination; or A, B, and C in combination.

[0050]In this document, relational terms, such as “first” and “second,”“top” and “bottom,” and the like, are used solely to distinguish one entity or action from another entity or action, without necessarily requi...

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. 63 / 710,210, filed on Oct. 22, 2024, entitled “WATER HEATER ASSEMBLY HAVING A CONDENSATE TRAP,” the disclosure of which is hereby incorporated herein by reference in its entirety.FIELD OF THE DISCLOSURE

[0002] The present disclosure generally relates to a water heater. More specifically, the present disclosure relates to a water heater assembly that includes a condensate trap.BACKGROUND OF THE DISCLOSURE

[0003] Water heaters that heat water via combustion of fuel include flues or exhaust conduits. Liquid condensate often accumulates in the exhaust conduits.SUMMARY OF THE DISCLOSURE

[0004] A water heater assembly includes a burner configured to combust fuel to generate heat and an exhaust pathway that conveys exhaust gases from the burner to an exterior environment. The exhaust pathway includes a condensate trap. The condensate trap includes a float and a housing. The housing includes an upper housing portion that defines an upper chamber within which the float is disposed. The housing includes an inlet through which exhaust gases and liquid condensate flow into the upper chamber. The housing includes an exhaust outlet through which exhaust gases flow out of the upper chamber. The housing includes a lower housing portion that defines a lower chamber positioned beneath the upper chamber. A divider extends between the upper and lower chambers and includes an upper face and a lower face opposite the upper face. The upper face defines the upper chamber cooperatively with the upper housing portion, the lower face defines lower chamber cooperatively with the lower housing portion. A port extends to the divider from the upper chamber to the lower chamber. The housing includes a condensate outlet through which liquid condensate flows out of the lower chamber. A collar projects downward from the lower face of the divider to a lower lip of the collar that is distal from the lower face, such that the collar extends about the port. The lower lip of the collar is positioned below the condensate outlet, such that liquid condensate accumulated within the lower chamber to a level that is above the lower lip and below the condensate outlet cooperates with the collar to form a trap that isolates the port from the condensate outlet.

[0005] Embodiments of the first aspect of the present disclosure can include any one or a combination of the following features:

[0006] the float is pivotably coupled with the housing;

[0007] the float includes a float body and a float valve that extends outward from the float body and is configured to protrude into the port;

[0008] the divider includes a port wall that extends from the upper face of the divider to the lower face of the divider to form the port, and the port wall extends downward and port-inboard from the upper face of the divider to the lower face of the divider at an angle, and wherein a portion of the float valve is configured to abut the port wall in a closed condition of the float to restrict the flow of exhaust gases through the port from the upper chamber to the lower chamber, the portion of the float valve that is configured to abut the port wall in the closed condition of the float being angled, such that, in the closed condition of the float, the angle of the portion of the float valve is substantially complementary with the angle of the port wall of the divider;

[0009] the exhaust pathway is partially defined by a drain pan comprising: a side wall; a base coupled to the side wall to define an interior volume of the drain pan and including a recessed trough that slopes downward and drain pan-outboard; and a drain pan outlet that is aligned with the recessed trough and connected with the inlet of the housing of the condensate trap, such that exhaust gases flow from the interior volume of the drain pan into the upper chamber of the housing through the drain pan outlet and the inlet of the housing, and liquid condensate that enters the interior volume of the drain pan flows with gravity along the recessed trough of the base, into the drain pan outlet, and through the inlet of the housing into the upper chamber defined by the upper housing portion of the housing;

[0010] the housing of the condensate trap comprises: a first component that includes the inlet, the exhaust outlet, and the condensate outlet and that partially defines the upper chamber; a second component that includes the divider, the port, and the collar and that defines an aperture that is aligned with the condensate outlet formed by the first component; and a third component that partially defines the lower chamber and that contacts the first and second components;

[0011] the third component is in threaded engagement with the first component;

[0012] a sensor coupled with the housing of the condensate trap; and a controller in communication with the sensor configured to control a gas valve based on sensor data received from the sensor;

[0013] the sensor is a pressure sensor, and the controller is configured to close the gas valve based on the sensor data from the pressure sensor indicating at least one of a rate of pressure increase reaching a rate of pressure increase-threshold and a pressure level reaching a pressure level threshold;

[0014] the sensor is a temperature sensor, and the controller is configured to close the gas valve based on the sensor data from the temperature sensor indicating at least one of a rate of temperature increase reaching a rate of temperature increase-threshold and a temperature level reaching a temperature level-threshold;

[0015] the housing includes a connector portion that defines the exhaust outlet, the connector portion comprising: an inner surface that partially defines the exhaust pathway; an outer surface opposite the inner surface; a first flange that extends outward from the outer surface proximate to the exhaust outlet; and a second flange that extends outward from the outer surface, wherein the second flange is further than the first flange from exhaust outlet;

[0016] the first flange extends outward from the outer surface a first distance, the second flange extends outward from the outer surface a second distance, and the first distance is less than the second distance;

[0017] a flexible tubular coupling extending about and engaged with the outer surface of the connector portion, wherein the flexible tubular coupling is engaged with the connector portion such that the first flange is disposed within a hollow defined by the flexible tubular coupling and the second flange is outside of the hollow defined by the flexible tubular coupling; and

[0018] an exhaust conduit that partially defines the exhaust pathway and that extends within the hollow defined by the flexible tubular coupling, wherein the first flange extends outward from the outer surface of the connector portion, such that interference between the first flange and the exhaust conduit stops insertion of the connector portion into the exhaust conduit.

[0019] According to a second aspect of the present disclosure, a condensate trap includes a float and a housing. The housing includes an upper housing portion that defines an upper chamber within which the float is disposed. The housing includes an inlet through which exhaust gases and liquid condensate flow into the upper chamber. The housing includes an exhaust outlet through which exhaust gases flow out of the upper chamber. The housing includes a lower housing portion that defines a lower chamber positioned beneath the upper chamber. A divider extends between the upper and lower chambers and includes an upper face and a lower face opposite the upper face. The upper face defines the upper chamber cooperatively with the upper housing portion, the lower face defines lower chamber cooperatively with the lower housing portion. A port extends to the divider from the upper chamber to the lower chamber. The housing includes a condensate outlet through which liquid condensate flows out of the lower chamber. A collar projects downward from the lower face of the divider to a lower lip of the collar that is distal from the lower face, such that the collar extends about the port. The lower lip of the collar is positioned below the condensate outlet, such that liquid condensate accumulated within the lower chamber to a level that is above the lower lip and below the condensate outlet cooperates with the collar to form a trap that isolates the port from the condensate outlet.

[0020] Embodiments of the second aspect of the present disclosure can include any one or a combination of the following features:

[0021] the float is pivotably coupled with the housing;

[0022] the float includes a float body and a float valve that extends outward from the float body and is configured to protrude into the port;

[0023] the divider includes a port wall that extends from the upper face of the divider to the lower face of the divider to form the port, and the port wall extends downward and port-inboard from the upper face of the divider to the lower face of the divider at an angle, and wherein a portion of the float valve is configured to abut the port wall in a closed condition of the float to restrict the flow of exhaust gases through the port from the upper chamber to the lower chamber, the portion of the float valve that is configured to abut the port wall in the closed condition of the float being angled, such that, in the closed condition of the float, the angle of the portion of the float valve is substantially complementary with the angle of the port wall of the divider; and

[0024] the housing of the condensate trap comprises: a first component that includes the inlet, the exhaust outlet, and the condensate outlet and that partially defines the upper chamber; a second component that includes the divider, the port, and the collar and that defines an aperture that is aligned with the condensate outlet formed by the first component; and a third component that partially defines the lower chamber and that contacts the first and second components.

[0025] According to a third aspect of the present disclosure, a condensate trap includes a housing. The housing includes an upper housing portion that defines an upper chamber, an inlet through which exhaust gases and liquid condensate flow into the upper chamber, an exhaust outlet through which exhaust gases flow out of the upper chamber, a lower housing portion that defines a lower chamber positioned beneath the upper chamber, a divider that extends between the upper and lower chambers and includes an upper face that defines the upper chamber cooperatively with the upper housing portion, and a lower face opposite the upper face that defines the lower chamber cooperatively with the lower housing portion, a port that extends through the divider from the upper chamber to the lower chamber, and a condensate outlet through which liquid condensate flows out of the lower chamber. A float is disposed within the upper chamber and is pivotably coupled to the housing, such that the float is operable to pivot about a pivot axis within the upper chamber between a closed condition and an open condition. The float includes a float valve that, in the closed condition of the float, is configured to abut a port wall that extends from the upper face of the divider to the lower face of the divider to form the port, such that the float valve restricts the flow of exhaust gases through the port from the upper chamber to the lower chamber. The float further includes a float body that includes a lower surface from which the float valve extends, an upper surface, and a side surface that extends between the upper and lower surfaces, wherein, in the closed condition of the float, a first vertical line that intersects the pivot axis and extends within a plane that is perpendicular to the pivot axis extends a first distance from the lower surface to the upper surface of the float body, a second vertical line that extends within the plane between the float valve and the pivot axis extends a second distance from the lower surface to the upper surface of the float body, and a third vertical line that extends within the plane, such that the float valve is positioned between the third vertical line and the pivot axis, extends a third distance from the lower surface to the upper surface of the float body, and wherein the first distance is less than the second distance, and the second distance is less than the third distance.

[0026] These and other features, advantages, and objects of the present disclosure will be further understood and appreciated by those skilled in the art by reference to the following specification, claims, and appended drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0027] In the drawings:

[0028] FIG. 1 is a perspective view of a water heater assembly including a water heater and a condensate trap, according to one embodiment;

[0029] FIG. 2 is a cross-sectional view of a portion of the water heater assembly of FIG. 1, illustrating a combustion assembly, a flue, a drain pan, and a condensate trap, according to one embodiment;

[0030] FIG. 3 is a perspective view of a drain pan and a condensate trap of a water heater assembly, according to one embodiment;

[0031] FIG. 4 is a cross-sectional view of the drain pan and the condensate trap illustrated in FIG. 3, according to one embodiment;

[0032] FIG. 5 is a perspective view of an engagement feature and a receiver in a disengaged condition, according to one embodiment;

[0033] FIG. 6 is a perspective view of the engagement feature and the receiver in an engaged condition, according to one embodiment;

[0034] FIG. 7 is a perspective view of a condensate trap, according to one embodiment;

[0035] FIG. 8 is an exploded view of the condensate trap, illustrating a first component, a float, a second component, a third component, and a plurality of seals, according to one embodiment;

[0036] FIG. 9 is a cross-sectional exploded view of the condensate trap, according to one embodiment;

[0037] FIG. 10 is a cross-sectional view of a condensate trap, illustrating a float of the condensate trap that is positioned within an upper chamber defined by a housing of the condensate trap and is in a closed condition, wherein a float valve of the float abuts a port wall of a divider of the housing to restrict the flow of exhaust gases from an upper chamber of the housing to a lower chamber of the housing, according to one embodiment;

[0038] FIG. 11 is a cross-sectional view of the condensate trap, illustrating the float in an open condition, wherein the float is pivoted such that the float valve of the float is in a spaced relationship with the port wall to allow liquid condensate to drain through the port of the divider from the upper chamber to the lower chamber, according to one embodiment;

[0039] FIG. 12 is an enlarged view of Area XII taken from FIG. 10, illustrating the float valve in the closed condition of the float, according to one embodiment;

[0040] FIG. 13 is an enlarged view of Area XIII taken from FIG. 11, illustrating the float valve in the open condition of the float, according to one embodiment;

[0041] FIG. 14 is a partial cross-sectional view of a portion of a condensate trap, illustrating a float valve shaped as a spherical cap extending through a port defined by a divider of the housing of the condensate trap in a closed condition of the float, according to one embodiment;

[0042] FIG. 15 is a cross-sectional view of the condensate trap, illustrating the flow of exhaust gases into an inlet of the housing of the condensate trap and out of an exhaust outlet and the flow of liquid condensate into the inlet of the housing through the divider via the port from the upper chamber defined by the housing to the lower chamber defined by the housing and out of a condensate outlet defined by the housing, according to one embodiment;

[0043] FIG. 16 is a perspective view of a condensate trap, according to one embodiment;

[0044] FIG. 17 is a perspective view of a condensate trap having flexible tubular couplings engaged therewith and disposed respectively proximate an inlet and an exhaust outlet of the condensate trap;

[0045] FIG. 18 is a cross-sectional view of the condensate trap and flexible tubular couplings of FIG. 17, illustrating a conduit disposed within the flexible tubular coupling that extends about the exhaust outlet in phantom, according to one embodiment;

[0046] FIG. 19 is an enlarged view of area XIX of FIG. 19, illustrating first and second flanges that extend outward from a portion of the condensate trap, according to one embodiment; and

[0047] FIG. 20 is a block diagram illustrating components of a water heater assembly including a controller, one or more sensors, and a gas shutoff valve, according to one embodiment.DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0048] Additional features and advantages of the disclosure will be set forth in the detailed description which follows and will be apparent to those skilled in the art from the description, or recognized by practicing the disclosure as described in the following description, together with the claims and appended drawings.

[0049] As used herein, the term “and / or,” when used in a list of two or more items, means that any one of the listed items can be employed by itself, or any combination of two or more of the listed items can be employed. For example, if a composition is described as containing components A, B, and / or C, the composition can contain A alone; B alone; C alone; A and B in combination; A and C in combination; B and C in combination; or A, B, and C in combination.

[0050] In this document, relational terms, such as “first” and “second,”“top” and “bottom,” and the like, are used solely to distinguish one entity or action from another entity or action, without necessarily requiring or implying any actual such relationship or order between such entities or actions.

[0051] For purposes of this disclosure, the term “coupled” (in all of its forms: couple, coupling, coupled, etc.) generally means the joining of two components (electrical or mechanical) directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two components (electrical or mechanical) and / or any additional intermediate members. Such joining may include members being integrally formed as a single unitary body with one another (i.e., integrally coupled) or may refer to joining of two components. Such joining may be permanent in nature, or may be removable or releasable in nature, unless otherwise stated.

[0052] As used herein, the terms “the,”“a,” or “an,” mean “at least one,” and should not be limited to “only one” unless explicitly indicated to the contrary. Thus, for example, reference to “a component” includes embodiments having two or more such components unless the context clearly indicates otherwise.

[0053] Referring now to FIGS. 1-20, a water heater assembly 10 includes a burner 12 configured to combust fuel to generate heat and an exhaust pathway 14 that conveys exhaust gases 16 from the burner 12 to an exterior environment 18. The exhaust pathway 14 includes a condensate trap 20. The condensate trap 20 includes a float 22 and a housing 24. The housing 24 includes an upper housing portion 26 that defines an upper chamber 28 within which the float 22 is disposed. The housing 24 includes an inlet 30 through which exhaust gases 16 and liquid condensate 32 flow into the upper chamber 28. The housing 24 includes an exhaust outlet 34 through which exhaust gases 16 flow out of the upper chamber 28. The housing 24 includes a lower housing portion 36 that defines a lower chamber 38 positioned beneath the upper chamber 28. A divider 40 extends between the upper and lower chambers 28, 38 and includes an upper face 42 and a lower face 44 opposite the upper face 42. The upper face 42 defines the upper chamber 28 cooperatively with the upper housing portion 26, and the lower face 44 defines the lower chamber 38 cooperatively with the lower housing portion 36. A port 46 extends through the divider 40 from the upper chamber 28 to the lower chamber 38. The housing 24 includes a condensate outlet 48 through which liquid condensate 32 flows out of the lower chamber 38. A collar 50 projects downward from the lower face 44 of the divider 40 to a lower lip 52 of the collar 50 that is distal from the lower face 44. The collar 50 extends about the port 46. The lower lip 52 of the collar 50 is positioned below the condensate outlet 48, such that liquid condensate 32 accumulated within the lower chamber 38 to a level that is above the lower lip 52 and below the condensate outlet 48 cooperates with the collar 50 to form a trap that isolates the port 46 from the condensate outlet 48.

[0054] Referring now to FIGS. 1 and 2, the water heater assembly 10 includes a tank 54. In some examples, the tank 54 can be covered by a jacket 56 with insulation disposed between the tank 54 and the jacket 56 for insulating water in the tank 54. As illustrated in FIG. 1, a cold-water inlet 58 and a hot water outlet 60 may be coupled with the tank 54 of the water heater assembly 10. As shown in FIG. 2, the water heater assembly 10 includes a combustion assembly 62. The combustion assembly 62 may include the burner 12 that is configured to combust fuel to generate heat, an igniter 64, and / or a blower assembly 66 that is coupled to the burner 12. As illustrated, a flue conduit 68 extends downward from a mounting plate to which the burner 12 is coupled and defines an interior volume 70 into which a body of the burner 12 extends. In the illustrated embodiment, the water heater assembly 10 includes a top-fired water heater and the flue conduit 68 extends downward from the combustion assembly 62 to a plenum 72 that is partially defined by a drain pan 74, as described further herein. The interior volume 70 defined by the flue conduit 68 and the plenum 72 that is at least partially defined by the drain pan 74 forms portions of the exhaust pathway 14 that conveys exhaust gases 16 from the burner 12 to the exterior environment 18.

[0055] Referring now to FIGS. 2-4, the drain pan 74 includes a base 76 and a side wall 78 that extends upward from the base 76. As illustrated in FIG. 3, a flange 80 extends outward from the side wall 78 distally from the base 76 and includes a plurality of apertures. The plurality of apertures are configured to receive fasteners therethrough for fastening the drain pan 74 to another portion of the water heater assembly 10. In various implementations, the drain pan 74 is fastened in a substantially sealed manner, such that the interior volume defined by the drain pan 74 serves as a portion of the exhaust pathway 14. As illustrated in FIGS. 3 and 4, the base 76 of the drain pan 74 includes a recessed trough 82. The recessed trough 82 slopes downward and drain pan-outboard. As shown in FIG. 3, the recessed trough 82 initiates proximate to a center of the base 76. The base 76 may generally slope downward as it extends inboard toward the center, and the recessed trough 82 may slope downward away from the center as the recessed trough 82 extends drain pan-outboard toward the side wall 78. As further illustrated in FIGS. 3 and 4, the drain pan 74 includes a drain pan outlet 84. The drain pan outlet 84 is aligned with the recessed trough 82 and extends outward beyond the side wall 78 of the drain pan 74 to an opening. In various implementations, the drain pan outlet 84 is connected with the inlet 30 of the housing 24 of the condensate trap 20, such that exhaust gases 16 and liquid condensate 32 flow from the interior volume of the drain pan 74 into the upper chamber 28 of the housing 24, as described further herein.

[0056] Referring now to FIGS. 3-6, in various embodiments, the drain pan outlet 84 of the drain pan 74 is connected with the housing 24 of the condensate trap 20. As illustrated in FIGS. 3 and 4, the drain pan outlet 84 is connected with the inlet 30 of the housing 24 of the condensate trap 20. In operation of the water heater assembly 10, exhaust gases 16 flow from the interior volume of the drain pan 74 into the upper chamber 28 of the housing 24 through the drain pan outlet 84 and the inlet 30 of the housing 24, and liquid condensate 32 that enters the interior volume of the drain pan 74 flows with gravity along the recessed trough 82 of the base 76, into the drain pan outlet 84, and through the inlet 30 of the housing 24 into the upper chamber 28 defined by the upper housing portion 26 of the housing 24. As illustrated in FIGS. 3 and 4, the drain pan outlet 84 engages with the inlet 30 of the housing 24 of the condensate trap 20 in a nested manner.

[0057] In various implementations, the housing 24 includes one of a receiver 86 or an engagement feature 88 configured to be received by the receiver 86 for engagement therewith, and the drain pan 74 includes the other of the receiver 86 or the engagement feature 88. For example, as illustrated in FIG. 3, the drain pan 74 includes the engagement feature 88, which is coupled with the drain pan outlet 84, and the housing 24 of the condensate trap 20 includes the receiver 86 which is coupled with the inlet 30 of the housing 24. As shown in FIGS. 5 and 6, the engagement feature 88 includes a base portion 90 and an arm 92 that extends from the base portion 90 to a distal end thereof. The arm 92 includes an interior surface 94 and first and second fins 96, 98 that protrude relative to the interior surface 94 and extend along the interior surface 94 toward the distal end of the arm 92, such that the interior surface 94 is disposed between and recessed relative to the first and second fins 96, 98. Further, the arm 92 includes first and second catches 100, 102 that protrude from the first and second fins 96, 98, respectively, proximate to the distal end of the arm 92. The receiver 86 defines a hollow 104 having opposing open ends.

[0058] Referring now to FIGS. 5 and 6, the engagement feature 88 and the receiver 86 are operable between a disengaged condition (FIG. 5), wherein the arm 92 of the engagement feature 88 is disposed outside of the hollow 104 defined by the receiver 86, and an engaged condition (FIG. 6), wherein the arm 92 of the engagement feature 88 extends through the hollow 104 defined by the receiver 86. In the engaged condition, the first and second catches 100, 102 inhibit removal of the arm 92 from the hollow 104 defined by the receiver 86, the first and second fins 96, 98 abut the receiver 86, and the interior surface 94 of the arm 92 is in a spaced relationship with the receiver 86. In various implementations, the interior surface 94 being in a spaced relationship with the receiver 86 may allow for a user to insert a tool between the receiver 86 and the interior surface 94 to depress the arm 92 and release the first and second catches 100, 102 from their abutment with the receiver 86 to allow the engagement feature 88 to enter the disengaged condition.

[0059] Referring now to FIGS. 7-11, an exemplary embodiment of the condensate trap 20 is illustrated. In the illustrated embodiment, the condensate trap 20 includes the housing 24. The housing 24 includes the upper housing portion 26 that defines the upper chamber 28 within which the float 22 is disposed, the inlet 30 through which exhaust gases 16 and liquid condensate 32 flow into the upper chamber 28, the exhaust outlet 34 through which exhaust gases 16 flow out of the upper chamber 28, the lower housing portion 36 that defines the lower chamber 38 positioned beneath the upper chamber 28, the divider 40 that extends between the upper and lower chambers 28, 38, the port 46 that extends through the divider 40 from the upper chamber 28 to the lower chamber 38, the collar 50 that projects downward from the lower face 44 of the divider 40, and the condensate outlet 48 through which liquid condensate 32 flows out of the lower chamber 38.

[0060] As illustrated in FIGS. 7-11, the inlet 30 comprises a conduit that extends outward from the upper housing portion 26. As shown in FIG. 7, the conduit can include one or more sensor ports 106 that are configured to accommodate sensors 108 of the water heater assembly 10, as described further herein. In various implementations, the divider 40 includes the upper face 42 that defines the upper chamber 28 cooperatively with the upper housing portion 26 and the lower face 44 opposite the upper face 42 that defines the lower chamber 38 cooperatively with the lower housing portion 36. The divider 40 can include a port wall 110 that extends from the upper face 42 of the divider 40 to the lower face 44 of the divider 40 to form the port 46. The port wall 110 may extend downward and port-inboard from the upper face 42 of the divider 40 to the lower face 44 of the divider 40 at an angle, as illustrated in FIGS. 12 and 13, as described further herein.

[0061] Referring still to FIGS. 7-11, in various embodiments, the housing 24 of the condensate trap 20 includes a plurality of components. In the embodiment illustrated in FIGS. 7-11, the housing 24 includes a first component 112 that includes the inlet 30, the exhaust outlet 34, and the condensate outlet 48 and that partially defines the upper chamber 28. A second component 114 includes the divider 40, the port 46, and the collar 50 and defines an aperture 116 that is aligned with the condensate outlet 48 formed by the first component 112. A third component 118 partially defines the lower chamber 38 and contacts the first and second components 112, 114. As illustrated in FIGS. 8-11, the second component 114 is configured to be received within a hollow defined by the first component 112. As illustrated, the second component 114 includes a float pivot mount 120 that extends upward from the upper face 42 of the divider 40 that is formed by the second component 114. The third component 118 serves as an end cap of the housing 24 that is positioned at the bottom of the housing 24. The housing 24 further includes first and second seals 122, 124.

[0062] As illustrated in FIG. 10, in an assembled condition of the housing 24, the second component 114 is received within the hollow defined by the first component 112, and the first seal 122 is sandwiched between a portion of the first component 112 and the divider 40 of the second component 114 to provide a seal between the first and second components 112, 114. The third component 118 is in threaded engagement with the first component 112 at the bottom of the housing 24 and abuts the second component 114. The second seal 124 is disposed at a junction of the first, second, and third components 112, 114, 118. As illustrated in FIG. 10, in the assembled condition, the aperture 116 defined by the second component 114 is aligned with the condensate outlet 48 formed by the third component 118 of the housing 24. Further, in the assembled condition of the housing 24, the collar 50 that projects downward from the lower face 44 of divider 40 to the lower lip 52 of the collar 50 is positioned such that the lower lip 52 of the collar 50 is below the condensate outlet 48. As such, liquid condensate 32 that accumulates within the lower chamber 38 to a level that is above the lower lip 52 and below the condensate outlet 48 cooperates with the collar 50 to form a trap that isolates the port 46 from the condensate outlet 48.

[0063] Referring now to FIGS. 8-14, the condensate trap 20 includes the float 22. The float 22 may be disposed within the upper chamber 28 defined by the housing 24, as illustrated in FIGS. 10 and 11. In various implementations, the float 22 includes a float body 126 and a float valve 128 that extends outward from the float body 126. The float valve 128 may be configured to protrude into the port 46, as described further herein. In various implementations, the float 22 is pivotably coupled with the housing 24. As illustrated in FIGS. 8 and 9, the float 22 is configured to be pivotably coupled with the float pivot mount 120 that extends upward from the upper face 42 of the divider 40 of the second component 114 of the housing 24. In various implementations, the float 22 is operable to pivot between a closed condition and an open condition. In various embodiments, the float valve 128 of the float 22 is configured to abut the port wall 110 of the divider 40 in the closed condition of the float 22 to restrict the flow of exhaust gases 16 through the port 46 from the upper chamber 28 to the lower chamber 38, as illustrated in FIGS. 10 and 12. In the open condition of the float 22, the float 22 may be pivoted, such that the float valve 128 of the float 22 is in a spaced relationship with the port wall 110 to allow liquid condensate 32 to flow through the port 46 from the upper chamber 28 to the lower chamber 38, as illustrated exemplarily in FIGS. 11 and 13. The float 22 is buoyant and pivots from the closed condition to the open condition due to liquid condensate 32 accumulating in the upper chamber 28 and prompting the float 22 to float upward from the closed condition to the open condition, thereby allowing the liquid condensate 32 to drain through the port 46, which in turn causes the float 22 to return to the closed condition.

[0064] The float valve 128 of the float 22 may have a variety of shapes. For example, in some embodiments, the float valve 128 may be shaped as a spherical cap that extends outward from the float body 126 of the float 22, as illustrated in FIG. 14. In some implementations, a portion of the float valve 128 that is configured to abut the port wall 110 in the closed condition of the float 22 is angled. The portion of the float valve 128 that is configured to abut the port wall 110 in the closed condition of the float 22 may be angled in a frustoconical manner. In the embodiment illustrated in FIGS. 12 and 13, the port wall 110 extends downward and port-inboard from the upper face 42 of the divider 40 to the lower face 44 of the divider 40 at an angle. The portion of the float valve 128 that is configured to abut the port wall 110 in the closed condition of the float 22 is angled at an angle that is substantially complementary with the angle of the port wall 110 of the divider 40. The complementary angles of the float valve 128 and port wall 110 may result in a seal between the float valve 128 and the port wall 110 that is superior relative to a seal formed by non-complementary angles between the port wall 110 and the float valve 128.

[0065] Referring now to FIGS. 8-11, the float body 126 of the float 22 can be tapered to increase the mechanical advantage of the float 22 for adequately sealing the port 46 via the float valve 128 in the closed condition of the float 22. In the embodiment illustrated in FIGS. 8-11, the float body 126 of the float 22 includes a lower surface 140 from which the float valve 128 extends, an upper surface 142, and a side surface 144 that extends between the lower and upper surfaces 140, 142 of the float body 126. The cross-sectional view of the condensate trap 20 illustrated in FIGS. 10 and 11 is taken along a plane that intersects the float valve 128 and is a perpendicular to a pivot axis 146 about which the float 22 pivots between the open and closed conditions. As illustrated in FIG. 10, in the closed condition of the float 22, a first vertical line 148 extending within the plane and intersecting the pivot axis 146 extends a first distance from the lower surface 140 to the upper surface 142 of the float body 126. A second vertical line 150 extending within the plane between the float valve 128 and the pivot axis 146 extends a second distance from the lower surface 140 to the upper surface 142 of the float body 126. A third vertical line 152 extending within the plane such that the float valve 128 is positioned between the third vertical line 152 and the pivot axis 146 extends a third distance from the lower surface 140 to the upper surface 142 of the float body 126. The first distance is less than the second distance, and the second distance is less than the third distance.

[0066] In the embodiment illustrated in FIG. 10, the upper surface 142 of the float body 126 angles downward as the upper surface 142 extends generally toward the pivot axis 146 from a distal end of the float body 126. This angling of the upper surface 142 results in a tapering of the float body 126 as the float body 126 extends toward the pivot axis 146 from the distal end. Consequently, the center of mass of the float body 126 is further from the pivot axis 146 than would be the case were the taper absent. In operation, this increases the mechanical advantage of the system, as the increased torque afforded by the tapered float body 126 translates to a more forceful seal between the float valve 128 and the port wall 110. As illustrated in FIG. 10, the pivot axis 146 is nearer than the distal end of the float body 126 to float valve 128. The proximity of the float valve 128 to the pivot axis 146 further contributes to the mechanical advantage of the system. The float body 126 utilizing a tapered design rather than other means of gaining mechanical advantage (e.g., an untapered float body with a greater distance between the pivot axis and distal end of the float body) advantageously reduces the maximum radial dimension of the float 22 with respect to the pivot axis 146, which allows for a more compact condensate trap 20.

[0067] Referring now to FIG. 15, in operation of the water heater assembly 10, the combustion assembly 62 combusts fuel creating exhaust that includes water vapor. The exhaust travels along the exhaust pathway 14 and the water vapor condenses to liquid condensate 32. The liquid condensate 32 pools within the drain pan 74, flows down the recessed trough 82 and out of the drain pan outlet 84. The liquid condensate 32 flows from the drain pan outlet 84 into the inlet 30 of the housing 24 of the condensate trap 20 and enters the upper chamber 28 defined by the upper housing portion 26 of the housing 24 therefrom. As the liquid condensate 32 flows into the upper chamber 28 and accumulates on the upper face 42 of the divider 40, the float 22 is pivoted from the closed condition to the open condition due to the buoyancy of the float 22 that causes the float 22 to float upon the liquid condensate 32 within the upper chamber 28. As the float 22 moves from the closed condition to the open condition, the port 46 that extends through the divider 40 is revealed, allowing the liquid condensate 32 to flow from the upper chamber 28 to the lower chamber 38 via the port 46. When the float 22 is in the open condition, the liquid condensate 32 that is flowing between the float 22 and the divider 40 into the port 46 seals the upper chamber 28 from the lower chamber 38 until the float 22 pivots back to the closed condition when the liquid condensate 32 has drained.

[0068] The liquid condensate 32 that flows from the upper chamber 28 to the lower chamber 38 through the port 46 accumulates in the lower chamber 38 until it rises to the level of the aperture 116 defined by the second component 114 and the condensate outlet 48 that is aligned with the aperture 116. The liquid condensate 32 then flows out of the lower chamber 38 through the aperture 116 and condensate outlet 48 to drain from the water heater assembly 10. As illustrated in FIG. 15, the lower lip 52 of the collar 50 that extends about the port 46 and downward from the lower face 44 of the divider 40 is positioned below the condensate outlet 48, such that liquid condensate 32 accumulated within the lower chamber 38 to a level that is above the lower lip 52 and below the condensate outlet 48 cooperates with the collar 50 to form a trap that isolates the port 46 from the condensate outlet 48. Further, when the water level within the lower chamber 38 is above the level of the lower lip 52 of the collar 50, the collar 50 and the liquid condensate 32 cooperate to form a pocket 130 within which exhaust gases 16 that bypass the float valve 128 and flow into the lower chamber 38 can be accommodated.

[0069] Referring still to FIG. 15, exhaust gases 16 are conveyed from the burner 12 into the interior volume defined by the drain pan 74. The exhaust gases 16 travel through the drain pan outlet 84 and into the upper chamber 28 of the housing 24 via the inlet 30. The float valve 128 functions to restrict the flow of exhaust gases 16 from the upper chamber 28 to the lower chamber 38 via the port 46. As such, the exhaust gases 16 vent from the housing 24 of the condensate trap 20 through the exhaust outlet 34 that is in fluid communication with the upper chamber 28 and are conveyed onward through the exhaust pathway 14 before ultimately flowing to the exterior environment 18 (e.g., outdoors).

[0070] Referring now to FIGS. 16-19, in various embodiments, the condensate trap 20 includes a connector portion 160 that defines the exhaust outlet 34. The connector portion 160 may be a portion of the upper housing portion 26 of the housing 24 of the condensate trap 20. In the embodiment illustrated in FIGS. 16-19, the connector portion 160 is a portion of the first component 112 of the housing 24. In the illustrated embodiment, the connector portion 160 is substantially cylindrical and extends upward toward the exhaust outlet 34 which is defined at the top of the connector portion 160.

[0071] Referring still to FIGS. 16-19, the connector portion 160 includes an inner surface 162 and an outer surface 164. The inner surface 162 of the connector portion 160 partially defines the exhaust pathway 14. The outer surface 164 is opposite the inner surface 162. As illustrated in FIGS. 16, 18, and 19, a first flange 166 extends outward from the outer surface 164 of the connector portion 160 proximate to the exhaust outlet 34, and a second flange 168 extends outward from the outer surface 164 of the connector portion 160. The second flange 168 is further than the first flange 166 from the exhaust outlet 34 defined by the connector portion 160. In various embodiments, the distance that the first flange 166 extends outward from the outer surface 164 of the connector portion 160 is different than the distance that the second flange 168 extends outward from the outer surface 164 of the connector portion 160. For example, in the embodiment illustrated in FIGS. 16, 18, and 19, the first flange 166 extends outward from the outer surface 164 a first distance, the second flange 168 extends outward from the outer surface 164 a second distance, and the first distance is less than the second distance.

[0072] Referring now to FIGS. 17-19, the water heater assembly 10 may include a flexible tubular coupling 170. In various embodiments, the water heater assembly 10 may include a plurality of flexible tubular couplings 170. For example, in the embodiments illustrated in FIGS. 17 and 18, two flexible tubular couplings 170 are engaged with the inlet 30 of the housing 24 and the connector portion 160 of the housing 24, respectively. In an exemplary embodiment, the flexible tubular couplings 170 may be Fernco-style couplings. A variety of types of flexible tubular couplings 170 are contemplated. In the embodiment illustrated in FIGS. 17 and 18 one of the flexible tubular couplings 170 is engaged with the inlet 30 and the other flexible tubular coupling 170 is engaged with the connector portion 160 that defines the exhaust outlet 34. The flexible tubular coupling 170 that is engaged with the inlet 30 is configured to be engaged with the drain pan outlet 84 to allow for exhaust and condensate to flow into the condensate trap 20 from the water heater assembly 10. The flexible tubular coupling 170 that is engaged with the connector portion 160 is configured to be engaged with an exhaust conduit 172 that partially defines the exhaust pathway 14, as illustrated in FIGS. 18 and 19. As illustrated, both the connector portion 160 and the exhaust conduit 172 extend within a hollow 173 defined by the flexible tubular coupling 170. As such, exhaust that flows through the connector portion 160 and out of the exhaust outlet 34 can continue to be conveyed along the exhaust pathway 14 within the exhaust conduit 172 that is connected with the connector portion 160 via the flexible tubular coupling 170. In various embodiments, hose clamps 174 are utilized to maintain the engagement between the flexible tubular couplings 170 and the drain pan outlet 84, inlet 30, connector portion 160, and exhaust conduit 172, as illustrated in FIGS. 17 and 18. It is contemplated that the engagement may be maintained by a variety of features.

[0073] Referring now to FIGS. 16-19, in an exemplary implementation, the flexible tubular coupling 170 may extend about and be engaged with the outer surface 164 of the connector portion 160, as illustrated in FIGS. 18 and 19. In the illustrated embodiment, the flexible tubular coupling 170 is engaged with the connector portion 160 such that the first flange 166 is disposed within the hollow 173 defined by the flexible tubular coupling 170. As further illustrated, the second flange 168 is disposed outside of the hollow 173. In operation, the connector portion 160 and the first flange 166 may be inserted into the hollow 173 defined by the flexible tubular coupling 170, and the second flange 168, which extends outward further than the first flange 166, may serve as a stop that the flexible tubular coupling 170 abuts when assembled with the housing 24. The hose clamp 174 may then be tightened about the flexible tubular coupling 170 and the connector portion 160 at a location that is vertically between the first and second flanges 166, 168.

[0074] The presence of the first flange 166 may be advantageous for a variety of reasons. For example, the first flange 166 may interact with the flexible tubular coupling 170 engaged therewith to form a seal. In various embodiments, the first flange 166 being disposed proximate the exhaust outlet defined by the connector portion 160 adds structural rigidity to the cylindrical connector portion 160, thereby enabling the connector portion 160 to better withstand the inward force exerted by the hose clamp 174 when tightened. In some embodiments, the first flange 166 extends outward from the outer surface 164 of the connector portion 160, such that the interference between the first flange 166 the exhaust conduit 172 stops insertion of the connector portion 160 into the exhaust conduit 172. For example, in practice, a standard-sized exhaust conduit 172 may have an inner diameter slightly larger than the outer diameter of the connector portion 160. The first flange 166 extending outward from the outer surface 164 of the connector portion 160 may interfere with the exhaust conduit 172, thereby stopping insertion of the connector portion 160 into the exhaust conduit 172 that would be enabled but for the presence of the first flange 166. This may prevent unintended methods of connecting the exhaust conduit 172 and the connector portion 160 (e.g., inserting and adhering the connector portion 160 to the exhaust conduit 172) from being performed.

[0075] Referring now to FIGS. 2, 7, and 20, in various implementations, the water heater assembly 10 includes the sensor 108. The water heater assembly 10 can include a plurality of sensors 108. For example, the water heater assembly 10 can include a pressure sensor 132. The pressure sensor 132 may be configured to sense a pressure within the exhaust pathway 14 of the water heater assembly 10. A variety of types of pressure sensors 132 are contemplated (e.g., gauge pressure sensor, differential pressure sensor, pressure switch, etc.). In some implementations, the water heater assembly 10 can include a temperature sensor 134. The temperature sensor 134 may be configured to sense a temperature within the exhaust pathway 14 of the water heater assembly 10, in various embodiments. As illustrated in FIG. 7, the housing 24 of the condensate trap 20 includes sensor ports 106 that accommodate the pressure sensor 132 and / or the temperature sensor 134. As such, the pressure sensor 132 is configured to sense a pressure within the housing 24, and the temperature sensor 134 is configured to sense a temperature within the housing 24.

[0076] Referring still to FIGS. 2, 7, and 20, in various implementations, the water heater assembly 10 includes a controller 136. The controller 136 may be in communication with the one or more sensors 108 of the water heater assembly 10 and may be configured to control one or more components of the water heater assembly 10 based on sensor data received from the one or more sensors 108. In an exemplary implementation, the controller 136 is configured to control operation of a gas shutoff valve 138 of the water heater assembly 10. In some embodiments, the controller 136 is configured to close the gas shutoff valve 138 based on sensor data from the pressure sensor 132 indicating at least one of a rate of pressure increase reaching a rate of pressure increase-threshold and / or a pressure level reaching a pressure level-threshold. In some embodiments, the controller 136 is configured to close the gas shutoff valve 138 based on sensor data from the temperature sensor 134 indicating a rate of temperature increase reaching a rate of temperature increase-threshold and / or a temperature level reaching a temperature level-threshold.

[0077] It is to be understood that variations and modifications can be made on the aforementioned structure without departing from the concepts of the present disclosure, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise.

Examples

Embodiment Construction

[0048]Additional features and advantages of the disclosure will be set forth in the detailed description which follows and will be apparent to those skilled in the art from the description, or recognized by practicing the disclosure as described in the following description, together with the claims and appended drawings.

[0049]As used herein, the term “and / or,” when used in a list of two or more items, means that any one of the listed items can be employed by itself, or any combination of two or more of the listed items can be employed. For example, if a composition is described as containing components A, B, and / or C, the composition can contain A alone; B alone; C alone; A and B in combination; A and C in combination; B and C in combination; or A, B, and C in combination.

[0050]In this document, relational terms, such as “first” and “second,”“top” and “bottom,” and the like, are used solely to distinguish one entity or action from another entity or action, without necessarily requi...

Claims

1. A water heater assembly, comprising:a burner configured to combust fuel to generate heat; andan exhaust pathway that conveys exhaust gases from the burner to an exterior environment, the exhaust pathway being partially defined by a condensate trap that comprises:a float; anda housing comprising:an upper housing portion that defines an upper chamber within which the float is disposed;an inlet through which exhaust gases and liquid condensate flow into the upper chamber;an exhaust outlet through which exhaust gases flow out of the upper chamber;a lower housing portion that defines a lower chamber positioned beneath the upper chamber;a divider that extends between the upper and lower chambers and includes an upper face that defines the upper chamber cooperatively with the upper housing portion, and a lower face opposite the upper face that defines the lower chamber cooperatively with the lower housing portion;a port that extends through the divider from the upper chamber to the lower chamber;a condensate outlet through which liquid condensate flows out of the lower chamber; anda collar that projects downward from the lower face of the divider to a lower lip of the collar that is distal from the lower face, such that the collar extends about the port, wherein the lower lip of the collar is positioned below the condensate outlet, such that liquid condensate accumulated within the lower chamber to a level that is above the lower lip and below the condensate outlet cooperates with the collar to form a trap that isolates the port from the condensate outlet.

2. The water heater assembly of claim 1, wherein the float is pivotably coupled with the housing.

3. The water heater assembly of claim 2, wherein the float includes a float body and a float valve that extends outward from the float body and is configured to protrude into the port.

4. The water heater assembly of claim 3, wherein the divider includes a port wall that extends from the upper face of the divider to the lower face of the divider to form the port, and the port wall extends downward and port-inboard from the upper face of the divider to the lower face of the divider at an angle, and wherein a portion of the float valve is configured to abut the port wall in a closed condition of the float to restrict the flow of exhaust gases through the port from the upper chamber to the lower chamber, the portion of the float valve that is configured to abut the port wall in the closed condition of the float being angled, such that, in the closed condition of the float, the angle of the portion of the float valve is substantially complementary with the angle of the port wall of the divider.

5. The water heater assembly of claim 1, wherein the exhaust pathway is partially defined by a drain pan comprising:a side wall;a base coupled to the side wall to define an interior volume of the drain pan and including a recessed trough that slopes downward and drain pan-outboard; anda drain pan outlet that is aligned with the recessed trough and connected with the inlet of the housing of the condensate trap, such that exhaust gases flow from the interior volume of the drain pan into the upper chamber of the housing through the drain pan outlet and the inlet of the housing, and liquid condensate that enters the interior volume of the drain pan flows with gravity along the recessed trough of the base, into the drain pan outlet, and through the inlet of the housing into the upper chamber defined by the upper housing portion of the housing.

6. The water heater assembly of claim 1, wherein the housing of the condensate trap comprises:a first component that includes the inlet, the exhaust outlet, and the condensate outlet and that partially defines the upper chamber;a second component that includes the divider, the port, and the collar and that defines an aperture that is aligned with the condensate outlet formed by the first component; anda third component that partially defines the lower chamber and that contacts the first and second components.

7. The water heater assembly of claim 6, wherein the third component is in threaded engagement with the first component.

8. The water heater assembly of claim 1, further comprising:a sensor coupled with the housing of the condensate trap; anda controller in communication with the sensor configured to control a gas valve based on sensor data received from the sensor.

9. The water heater assembly of claim 8, wherein the sensor is a pressure sensor, and the controller is configured to close the gas valve based on the sensor data from the pressure sensor indicating at least one of a rate of pressure increase reaching a rate of pressure increase-threshold and a pressure level reaching a pressure level threshold.

10. The water heater assembly of claim 8, wherein the sensor is a temperature sensor, and the controller is configured to close the gas valve based on the sensor data from the temperature sensor indicating at least one of a rate of temperature increase reaching a rate of temperature increase-threshold and a temperature level reaching a temperature level-threshold.

11. The water heater assembly of claim 1, wherein the housing includes a connector portion that defines the exhaust outlet, the connector portion comprising:an inner surface that partially defines the exhaust pathway;an outer surface opposite the inner surface;a first flange that extends outward from the outer surface proximate to the exhaust outlet; anda second flange that extends outward from the outer surface, wherein the second flange is further than the first flange from exhaust outlet.

12. The water heater assembly of claim 11, wherein the first flange extends outward from the outer surface a first distance, the second flange extends outward from the outer surface a second distance, and the first distance is less than the second distance.

13. The water heater assembly of claim 12, further comprising:a flexible tubular coupling extending about and engaged with the outer surface of the connector portion, wherein the flexible tubular coupling is engaged with the connector portion such that the first flange is disposed within a hollow defined by the flexible tubular coupling and the second flange is outside of the hollow defined by the flexible tubular coupling.

14. The water heater assembly of claim 13, further comprising:an exhaust conduit that partially defines the exhaust pathway and that extends within the hollow defined by the flexible tubular coupling, wherein the first flange extends outward from the outer surface of the connector portion, such that interference between the first flange and the exhaust conduit stops insertion of the connector portion into the exhaust conduit.

15. A condensate trap, comprising:a float; anda housing comprising:an upper housing portion that defines an upper chamber within which the float is disposed;an inlet through which exhaust gases and liquid condensate flow into the upper chamber;an exhaust outlet through which exhaust gases flow out of the upper chamber;a lower housing portion that defines a lower chamber positioned beneath the upper chamber;a divider that extends between the upper and lower chambers and includes an upper face that defines the upper chamber cooperatively with the upper housing portion, and a lower face opposite the upper face that defines the lower chamber cooperatively with the lower housing portion;a port that extends through the divider from the upper chamber to the lower chamber;a condensate outlet through which liquid condensate flows out of the lower chamber; anda collar that projects downward from the lower face of the divider to a lower lip of the collar that is distal from the lower face, such that the collar extends about the port, wherein the lower lip of the collar is positioned below the condensate outlet, such that liquid condensate accumulated within the lower chamber to a level that is above the lower lip and below the condensate outlet cooperates with the collar to form a trap that isolates the port from the condensate outlet.

16. The condensate trap of claim 15, wherein the float is pivotably coupled with the housing.

17. The condensate trap of claim 16, wherein the float includes a float body and a float valve that extends outward from the float body and is configured to protrude into the port.

18. The condensate trap of claim 17, wherein the divider includes a port wall that extends from the upper face of the divider to the lower face of the divider to form the port, and the port wall extends downward and port-inboard from the upper face of the divider to the lower face of the divider at an angle, and wherein a portion of the float valve is configured to abut the port wall in a closed condition of the float to restrict the flow of exhaust gases through the port from the upper chamber to the lower chamber, the portion of the float valve that is configured to abut the port wall in the closed condition of the float being angled, such that, in the closed condition of the float, the angle of the portion of the float valve is substantially complementary with the angle of the port wall of the divider.

19. The condensate trap of claim 15, wherein the housing of the condensate trap comprises:a first component that includes the inlet, the exhaust outlet, and the condensate outlet and that partially defines the upper chamber;a second component that includes the divider, the port, and the collar and that defines an aperture that is aligned with the condensate outlet formed by the first component; anda third component that partially defines the lower chamber and that contacts the first and second components.

20. A condensate trap, comprising:a housing, comprising:an upper housing portion that defines an upper chamber;an inlet through which exhaust gases and liquid condensate flow into the upper chamber;an exhaust outlet through which exhaust gases flow out of the upper chamber;a lower housing portion that defines a lower chamber positioned beneath the upper chamber;a divider that extends between the upper and lower chambers and includes an upper face that defines the upper chamber cooperatively with the upper housing portion, and a lower face opposite the upper face that defines the lower chamber cooperatively with the lower housing portion;a port that extends through the divider from the upper chamber to the lower chamber; anda condensate outlet through which liquid condensate flows out of the lower chamber; anda float disposed within the upper chamber and being pivotably coupled to the housing, such that the float is operable to pivot about a pivot axis within the upper chamber between a closed condition and an open condition, the float comprising:a float valve that, in the closed condition of the float, is configured to abut a port wall that extends from the upper face of the divider to the lower face of the divider to form the port, such that the float valve restricts the flow of exhaust gases through the port from the upper chamber to the lower chamber; anda float body that includes a lower surface from which the float valve extends, an upper surface, and a side surface that extends between the upper and lower surfaces, wherein, in the closed condition of the float, a first vertical line that intersects the pivot axis and extends within a plane that is perpendicular to the pivot axis extends a first distance from the lower surface to the upper surface of the float body, a second vertical line that extends within the plane between the float valve and the pivot axis extends a second distance from the lower surface to the upper surface of the float body, and a third vertical line that extends within the plane, such that the float valve is positioned between the third vertical line and the pivot axis, extends a third distance from the lower surface to the upper surface of the float body, and wherein the first distance is less than the second distance, and the second distance is less than the third distance.

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