Fluid Heater Penetration Sealing and Securing System

Abstract

A fluid heater penetration sealing and securing system that seals and secures operational components that must have a connection through a wall of a tank. The system comprises one or a plurality of each of a pass-through, a connector, a connector support, a pass-through seal, a connector support seal, an internal securing means, and an external securing means. The system may further comprise at least one anchor. Other embodiments do not include the connector. The invention relates to fluid heaters whose tank penetrations may be repurposed without modifying the penetration itself.

Description

BACKGROUND OF THE INVENTIONField of the invention

[0001] This invention relates to connections through the tank walls of fluid heaters, and more specifically to a system of collars, seals, supports, and / or other securing means. The invention also relates to how the system is used so that fluid cannot escape the fluid heater through the wall opening required by an operational component. The invention also relates to how the system is used to stabilize and reinforce the components of the system itself within the walls of the tank. This application claims the benefit of provisional application 63 / 761,934 filed Feb. 22, 2025.Description of Related Art

[0002] Fluid heaters are used everywhere in domestic, commercial, and industrial applications. One common feature of fluid heaters are tanks that contain water or any other working fluid. In almost all applications, there must be at least one opening in the tank(s). The opening must be sealed to prevent fluid from escaping or foreign fluids from entering the tank.

[0003] A variety of methods exist to prevent leakage and unwanted infiltration. The art teaches techniques such as welding, threading penetrations, close tolerance mating parts, gasket compression, ferrules, tapers, bellow seals, clamp collars, embedding parts in the tank walls, crimping, etc. The techniques themselves appear to be known in the art but the different features of the components in the application of the techniques have a great variation.

[0004] Modern homes may use electricity or a fossil fuel to heat water. In electrical domestic water heaters the penetration and sealing of the heating element may be achieved by threading the body of the heating element and compressing a gasket. A fossil fuel water heater may or may not have a penetration in the water tank. However, there are gas heaters that would require a seal such as ferrules and clamp collars at least at the joints of a heater to the plumbing system.

[0005] In commercial and industrial applications, heating a working fluid may also be accomplished by those same domestic energy sources; however, the volume of liquid to be heated is on a larger scale. Larger scale operations typically gravitate towards fossil fuel sources which are able to release a lot of heat in a short amount of time. The higher heat transfer rates mean that the working temperatures and pressures of the operational components within and outside the tank of a fluid heater may be different.

[0006] In addition, commercial and industrial (C&I) applications require larger operational components. The larger components increase fluid heating capacity but also increase the weight that needs to be supported by the tank wall penetration. Merely increasing the thickness of the tank wall may solve the weight issue but may not necessarily address the temperatures and pressures associated with the larger components. Notwithstanding corrosion and weathering considerations, there are many, many different sealing and securing methods for larger scale operations.

[0007] The sealing techniques used for domestic and C&I applications also differ because of fabrication costs. The optimum balancing of material and labor costs with application is vital for a homeowner or a public / private company. By increasing tank use flexibility by a viable amount, material and labor costs associated with larger endeavors or changing external infrastructure are reduced in addition to increasing real estate time horizons and reducing depreciation. However, the fabrication of a tank with a single purpose is typically cheaper because of standardization which allows for economies of scale.

[0008] Many of the specific built-in applications of sealing techniques for fluid heaters taught by the art may address the various aperture sizes inherent with any sort of fluid system. In addition, many do address an adaptable seal capable of being used with an existing penetration. However, the built-in sealing applications are stronger than the adaptable sealing applications, presenting yet another obstacle.

[0009] An existing patent by Swanson (U.S. Pat. No. 4,498,692) teaches one solution to sealing a tank penetration that is very similar to certain aspects of the present invention. However, increased operational scale may present larger obstacles for such a solution.SUMMARY OF THE INVENTION

[0010] Therefore, the objects of the present invention of a fluid heater penetration sealing and securing method are 1) to provide fluid tight sealing of a penetration in a wall of a tank of a fluid heater and 2) to provide adequate support for operational components that go through a wall of a tank of a fluid heater, 3) to lower maintenance costs by having a system with replaceable components, and 4) to increase the operational flexibility of a tank of a fluid heater enough to meet a viable range of operational parameters which increases the longevity of the tank.

[0011] The system comprises one or a plurality of each of a pass-through, a connector, a connector support, a pass-through seal, a connector support seal, an internal securing means, and an external securing means. The system may further comprise at least one anchor.

[0012] In one embodiment, the system is broadly adaptable by varying diameters of the connector supports and pass-through to provide a useful range for any fluid heating tank prefabrication. The system is specifically adaptable by a fluid heating tank being able to accommodate varying connectors post fabrication.

[0013] In another embodiment for relatively larger systems, the system maintains its adaptability by additional features on the pass-through and connector supports, so anchors may be used to strengthen penetrations.

[0014] In another embodiment, the system is the pass-through, connector support, and anchors themselves so that other custom connectors or other components can be used.BRIEF DESCRIPTION OF THE DRAWINGS

[0015] FIG. 1 is a depiction of an embodiment of the fluid heater penetration sealing and securing system (not all elements are visible).

[0016] FIG. 2 is a depiction of one embodiment of a pass-through.

[0017] FIG. 3 is a depiction of one embodiment of a connector support.

[0018] FIG. 4 is a cross-section depiction of different types of connectors: 4a, 4b, 4c.

[0019] FIG. 5 is an isometric view of a depiction of an embodiment of an electrical connector with a flanged external connection and an internal conduit holder connection (no insulation ring is shown).

[0020] FIG. 6 is an isometric view of a depiction of an embodiment of a “pipe” connector with an external mating flange connection and an internal mating flange connection (no insulation ring is shown).

[0021] FIG. 7 is a depiction of two different embodiments of a stud-screw.

[0022] FIG. 8 is a depiction of at least one embodiment of an unattached anchor made up of parts that physically attach the connector supports and pass-through using the additional features of the connector supports and pass-through.

[0023] FIG. 9 is a depiction of a corresponding grid associated with an anchor setup between a connector support and a pass-through which support the connector.

[0024] FIG. 10 is a depiction of another embodiment where the connector supports, pass-through, and connector of the electrical type take different shapes.DESCRIPTION OF THE ILLUSTRATED EMBODIMENT

[0025] The present invention of a fluid heater penetration sealing and securing system is best represented in the assembly of FIG. 1 and FIG. 10.Pass-Through

[0026] A hole in a wall of a tank (90) is supported by an embedded pass-through (20). The pass-through is a pipe with multiple outer diameters and with one or a plurality of circumferential ridges (25). Each circumferential ridge extends radially relative to the centerline of the pass-through, creating exposed surfaces (26) and unexposed surfaces (27). The exposed surfaces are intended to be parallel with the circumferential ends (22) of the pass-through and visible to an observer staring down either end of the pass-through. The unexposed surfaces are the surfaces of the circumferential ridge parallel to the exposed surfaces and embedded in the wall. The circumferential ridges may contain holes that may be but are not limited to being threaded. The ends of the pass-through are smaller in diameter (diameter 1) than the circumferential ridges (diameter 3) as shown in FIG. 1.

[0027] The diameter of the pass-through between each circumferential ridge (diameter 2) may be larger or smaller than the ends of the pass-through (diameter 1) and / or larger or smaller than the diameter of each circumferential ridge (diameter 3). Alternatively, the body of the pass-through may only have two diameters: the ends of the pass-through and the circumferential ridge. The body of the pass-through may also have additional features (29: holes, ribs, etc.) that are perpendicular to the centerline of the pipe body. The additional features may be located anywhere on the body including but not limited to the circumferential ridges. In some cases an end of the pass-through may be shaped with a pass-through lip as shown in FIG. 10.Connector Support

[0028] The structure of the connector support (30) is much like the pass-through structure except the connector support structure is relatively smaller in diameters in most cases (but can be relatively larger). The connector support has at least one circumferential ridge (35) and an inner cylindrical surface that is preferably non-threaded like that of the pass-through. However, the inner cylindrical surface of the connector support could be threaded in some embodiments. The connector support also has additional features (39), like that of the pass-through, that may be used to aid in installing, stabilizing, and providing rigidity of the fluid heater penetration sealing and securing system. The connector support has ends that may be threaded (32, FIG. 3). The connector may also be drilled and tapped on each end to avoid the need for seals.Connector

[0029] The connector (40) is cylindrical in nature but has different modifications based on the particular application of the tank of the fluid heater. The connector acts as a conduit between the exterior system components and the internal system components of the tank. The connector has a connection flange (41) in all cases, but may also have one or more mating flanges (42) and / or a conduit holder (43). The connection flange has holes that are preferably not threaded (FIGS. 5 and 6). The holes align with the placement of the connector supports in order to compress the pass-through seal (21, FIG. 1). The face of the connection flange that presses against the pass-through seal may also have a raised diameter or protrusion (44, FIG. 1) to aid in compression.

[0030] A “pipe” type connector (FIG. 6) would have a connection flange toward its center and have two mating flanges. Each mating flange of the “pipe” type connector could be modified to match whatever external or internal piping system was installed or going to be installed. Therefore, there are many types of “pipe” connectors.

[0031] An “electrical” type connector (FIG. 5) would have a connection flange toward its center. One end would be a mating flange for connection to an external electrical system while the other end would be either a mating flange for connection to an internal electrical system or a conduit holder. The conduit holder may take many shapes, but in at least one embodiment, the conduit holder may be rod or bar shaped that extends from the connection flange and has a portion that is halved or at least is flat in nature. Both halves may have holes in them and at least one half has a groove (as shown in FIG. 5, the other removable half is not shown). The groove is shaped to receive the shape of the internal conduit system, whatever that shape may be. The removable half is shaped to be able to sandwich or clamp the internal conduit system using the holes of the halves and readily available parts such as threaded rods, nuts, bolts, springs, etc. Like the “pipe” type connector, the mating flanges and / or conduit holder of the “electrical” type connector need only match the internal and external system connection points. Therefore, there are many types of “electrical” connectors as well. one of which is shown in FIG. 10.

[0032] In all cases, there is an air gap (51, FIG. 1) created between the connector's outer surface and the pass-through's inner surface. The air gap serves to insulate any type of connector but may be filled and / or plugged with a ring (or other shape) of insulation (FIGS. 4, 50) based on the conditions of any particular operation.Internal and External Securing Means

[0033] An external securing means compresses connector support seals on either side of the wall of the tank. The external securing means may be readily available parts such as threaded rods, nuts, bolts, washers, lock-nuts, etc. In the embodiment of FIG. 1, the external securing means may be a portion of a stud-screw, all of a stud-screw, or a stud-screw with additional parts. The stud-screw is either a threaded rod with constant diameter or a rod of two different diameters which are both threaded. The center of the stud-screw (FIG. 7) has a tightening means such as a nut-like feature, ends that are slotted, etc. The external securing means lines up with the connection flange holes of the connector which is then secured by an internal securing means. The internal securing means compresses the pass-through seals (21) between the circumferential edge of the pass-through and an associated surface of the connection flange of the connector (protrusion or surface of connection flange itself; FIG. 1). The connector support seals and the pass-through seals are each preferably a ring that has a “c-shaped” cross section but may take on other shapes in other embodiments (i.e. a ring with a flat profile, a ring with an “h-shaped” cross section, etc.). It is intended that the circumferential ends of the pass-through extend passed the installed external securing means, connector support circumferential ends, and connector support seals internally so that the pass-through seal can be adequately compressed to secure an interior side of the tank. The internal securing means may also be of readily available parts, similar to the external securing means. In the preferred embodiment, the internal securing means may be the stud-screw, a portion of the stud-screw, or readily available parts used in conjunction with the stud-screw.

[0034] FIG. 4 depicts different types of connectors differentiated by their mating flange(s). The different types of connectors allow the connectors to act as adapters to other systems. In other words, the mating flange(s) may take any shape that is conducive to a secure connection with a unique or common internal system structure and / or unique or common external system structure to preserve an owner's choice in selection of future system requirements.

[0035] FIG. 10 depicts another installation example that may only require pass-through seals.Anchors

[0036] Pass-throughs and connector supports use anchors to help install, stabilize, and provide rigidity of the fluid heater penetration sealing and securing system as a whole. The anchors themselves act as a connection means and may be collars, pins, rings, bars, rods, or any other common hardware known in the art or combination thereof (FIG. 8). The anchors may be used in conjunction with the additional features of the pass-throughs and connector supports (holes, keys, ribs, notches, etc.). The anchors may also be integral to the body of the pass-throughs and connector supports (not limited to but as an example: integrally casted). The anchors allow the pass-throughs to be physically attached to the connector supports. In some instances to ensure securement, the number of connector supports exceed the number of holes in the connection flange of the connector. The additional connector supports thereby reinforce the pass-through while the others provide securement of the seal. Relatedly, although some prior art teaches using an exterior plate or embedded plate to secure the exterior side of similar inventions for obvious reasons, the preferred embodiment does not require an exterior plate separate from the pass-through, connector supports, and connector because of the anchors.Example and Assembly

[0037] After taking into account likely future conditions and present considerations of any particular operation, an owner (business, homeowner, public entity, etc.) would be able to have a tank applicable for a range of solutions versus one specific solution.

[0038] In an exemplary embodiment, the pass-through and the connector supports are anchored and installed in the wall(s) of a tank. The connector supports are sealed from an exterior part of the tank wall first, without a side-sealing collar. They are spaced to provide support for the connector, which then is located and secured from the interior part of the tank wall. Securement of the connector compresses a pass-through seal and seals the connector without a side-sealing collar. Avoiding a side sealing collar helps limit wall thickness and diameters of the connectors and connector supports while also eliminating another potential leakage point in higher pressure and higher temperature applications. The connector supports are also spaced to increase the area of the tank wall that experiences any loading from the connector due to the internal and external conditions of the tank as shown in FIG. 9.

[0039] Should the owner desire to change only the interior system in the tank or only the exterior system to the tank, the owner would be able to uninstall the connector, the interior system's connection to the connector, and the external system's connection to the connector. This is opposed to removing the entire fluid heating tank and / or modifying the walls of the fluid heating tank. Additionally, if the owner were to want to change both the internal and external systems, the uninstalling would be the same to allow for the reinstallment of a new connector. Because the connectors all share similar features to ensure containment, the tank may have a more flexible, but not infinite, range of operating (steam heating, electrical heating, exhaust gas heat recovery, etc.) conditions and uses than its original intent.

[0040] In a preferred embodiment, all of the components are made of relatively corrosion resistant materials, such as but not limited to aluminum and stainless steel. In a preferred embodiment, the seals are made up of relatively softer metals / alloys but may also be high temperature polymers and are preferably non-toxic.

[0041] In all examples, pass-throughs may subvert seals and gaskets in lieu of welding the pass-through and connector together for fluid or electrical purposes.KEY FOR FIGURES20—pass-through

[0043] 21—pass-through seal

[0044] 22—pass-through end

[0045] 23—pass-through lip

[0046] 25—circumferential ridges

[0047] 26—exposed surface

[0048] 27—unexposed surface

[0049] 29—additional features

[0050] 30—connector support

[0051] 31—connector support seal

[0052] 32—connector support end

[0053] 35—circumferential ridges

[0054] 36—exposed surface

[0055] 37—unexposed surface

[0056] 39—additional features

[0057] 40—connector

[0058] 41—connection flange of connector

[0059] 42—mating flange of connector

[0060] 43—conduit holder of connector

[0061] 44—raised diameter or protrusion

[0062] 45—conductor

[0063] 50—ring of insulation

[0064] 51—air gap

[0065] 70e—external securing means

[0066] 70i—internal securing means

[0067] 72—stud-screw

[0068] 73—tightening means

[0069] 74—nut

[0070] 80—anchor

[0071] 90—walls of tank (not completely shown)

[0072] 90e—exterior of the fluid tank

[0073] 90i—interior of the fluid tank

[0074] 100—grid

Claims

1. A fluid tank penetration sealing and securing system comprising:At least one pass-through,At least one or a plurality of connector supports,At least one connector, andAt least one pass-through seal.

2. The system of claim 1, further comprising:At least one connector support seal.

3. The system of claim 1, wherein a relationship between the at least one pass-through and the at least one of plurality of connector supports allows for a connection flange of the at least one connector to compress the at least one pass-through seal against an end of the at least one pass-through.

4. The system of claim 3, wherein the relationship between the at least one pass-through and the at least one of plurality of connector supports allows for compressing at least one connector support seals separately from the connection flange of the connector.

5. The system of claim 4, wherein a stud-screw with tightening means is used to compress the at least one connector support seals.

6. The system of claim 5, wherein the stud-screw with tightening means is also used to compress the at least one pass-through seal.

7. The system of claim 1, wherein the at least one pass-through is a hollow tube with at least two different outer diameters and one inner diameter.

8. The system of claim 1, wherein the at least one connector supports is a hollow tube with at least two different outer diameters and one inner diameter.

9. The system of claim 8, wherein the at least one connector supports has two ends and each of the two ends have an overall diameter that is smaller than a separate outer diameter of the at least two different outer diameters.

10. The system of claim 9, wherein each of the two ends of the at least one connector supports is threaded.

11. The system of claim 1, wherein the at least one pass-through and the at least one or a plurality of connector supports have additional features for anchors that allow for the at least one-pass through to be physically attached to the at least one of a plurality of connector supports.

12. The system of claim 11, wherein each anchor supports the pass-through separately from a wall of the fluid tank.

13. A fluid tank penetration sealing and securing method using at least one connector support and at least one pass-through and one anchor to reinforce the at least one connector support.

14. A fluid tank wall penetration sealing and securing method comprising:installing at least one or a plurality of connector supports;connecting at least one pass-through with at least one or a plurality of connector supports using anchors; andsecuring at least one connector to the at least one of a plurality of connector supports so that a pass-through seal is compressed between one end of the at least one pass-through and one surface of the at least one connector.

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