Systems and methods for attaching a heat exchanger about a tank of a water heater

Abstract

A water heater including a water tank configured to store water is disclosed. The water heater may further include a heat exchanger disposed about the water tank. The heat exchanger may include a microchannel tube that is spiral-wrapped around the water tank. The microchannel tube may be configured to circulate a heat transfer fluid therein to transfer heat to the water stored in the water tank.

Description

COE-026-WO (92575-3075)SYSTEMS AND METHODS FOR ATTACHING A HEAT EXCHANGER ABOUT A TANK OF A WATER HEATERCROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 701,875, filed on October 1, 2024, which is hereby incorporated by reference herein in its entirety.FIELD

[0002] The present disclosure relates to water heaters and more specifically to systems and methods for attaching a heat exchanger about a tank of a water heater.BACKGROUND

[0003] Water heaters are generally used to provide a supply of heated water in a variety of applications, including residential, commercial, and industrial applications. Conventional water heaters use gas burners, electrical heating elements, heat pumps, and / or solar panels (or other renewable sources) to heat water. For example, a heat pump water heater may draw heat from ambient air to transfer heat to a refrigerant, which in turn may heat water stored in a tank of a water heater.SUMMARY

[0004] In one aspect, a water heater is provided, the water heater including a water tank configured to store water and a heat exchanger disposed about the water tank, where the heat exchanger comprises a first microchannel tube that is spiral-wrapped around the water tank, and where the first microchannel tube is configured to circulate a heat transfer fluid therein to transfer heat to the water. In some aspects, the first microchannel tube is a single continuous tube that is spiral-wrapped around the water tank. In some aspects, the first microchannel tube is a cuboidal- shaped tube or oval-shaped tube. In some aspects, the first microchannel tube comprises a plurality of turns that is spiral-wrapped around the water tank, where each turn is disposed at a predetermined distance from adjacent turns, and the first microchannel tube comprises a firstCOE-026-WO (92575-3075) inlet manifold and a first outlet manifold. The first inlet manifold and the first outlet manifold may be disposed vertically and parallel to a longitudinal axis of the water heater, and the first inlet manifold and the first outlet manifold may extend above a top end of the water tank.

[0005] In some aspects, the first microchannel tube further comprises a first microchannel bend portion located between a first turn of the plurality of turns and the first inlet manifold, and a second microchannel bend portion between a last turn of the plurality of turns and the first outlet manifold. In some aspects, the plurality of turns, the first inlet manifold, the first outlet manifold, the first microchannel bend portion, and the second microchannel bend portion form a unified structure of the first microchannel tube. In some aspects, the first inlet manifold and the first outlet manifold are connected to one or more water heater components via respective adaptors. In some aspects, the heat exchanger further comprises a second microchannel tube that is spiral-wrapped around the water tank. In some aspects, the second microchannel tube is disposed parallel to the first microchannel tube around the water tank. In some aspects, the second microchannel tube comprises a second inlet manifold and a second outlet manifold. In some aspects, the second inlet manifold is disposed parallel to the first inlet manifold, and the second outlet manifold is disposed parallel to the first outlet manifold.

[0006] In some aspects, the water heater further comprises an insulating sleeve disposed around at least a portion of the first microchannel tube to prevent heat transfer therefrom. In some aspects, the water heater further comprises one or more fasteners to secure the first microchannel tube to the water tank.

[0007] In another aspect, a water heater is provided, the water heater including a water tank configured to store water, and a heat exchanger disposed about the water tank, where the heat exchanger comprises a first microchannel tube that is spiral-wrapped around the water tank, wherein the heat exchanger further comprises a second microchannel tube that is spiral-wrapped around the water tank, and where the first microchannel tube and the second microchannel tube are configured to circulate a heat transfer fluid therein to transfer heat to the water. In some aspects, the first microchannel tube includes a first inlet manifold and a first outlet manifold, where the second microchannel tube includes a second inlet manifold and a second outlet manifold. In some aspects, the second inlet manifold is disposed parallel to the first inletCOE-026-WO (92575-3075) manifold, and the second outlet manifold is disposed parallel to the first outlet manifold. In some aspects, the first microchannel tube and the second microchannel tube are cuboidal-shaped tubes.

[0008] In some aspects, the water heater also includes an insulating sleeve disposed around at least a portion of the first microchannel tube to prevent heat transfer therefrom. In some aspects, the water heater also includes one or more fasteners to secure the first microchannel tube to the water tank.

[0009] In a further aspect, a method of assembling a heat exchanger to a water tank of a water heater. The method may include the steps of attaching the microchannel tube around the water tank, where the microchannel tube is spiral -wrapped around the water tank, and where the microchannel tube is configured to circulate a heat transfer fluid therein to transfer heat to water stored in the water tank.

[0010] In yet another aspect, a fluid heating system is provided, the fluid heating system having a fluid tank configured to store fluid, and a heat exchanger disposed about the fluid tank, where the heat exchanger comprises a first microchannel tube that is spiral-wrapped around the fluid tank, and where the first microchannel tube is configured to circulate a heat transfer fluid therein to transfer heat to the fluid. In some aspects, the first microchannel tube is a single continuous tube that is spiral -wrapped around the fluid tank. In some aspects, the first microchannel tube is a cuboidal-shaped tube. In some aspects, the first microchannel tube includes a plurality of turns that is spiral-wrapped around the fluid tank. In some aspects, each turn is disposed at a predetermined distance from adjacent turns. In some aspects, the first microchannel tube includes a first inlet manifold and a first outlet manifold. In some aspects, the first inlet manifold and the first outlet manifold are disposed vertically and parallel to a longitudinal axis of the fluid heating system. In some aspects, the first inlet manifold and the first outlet manifold extend above a top end of the fluid tank. In some aspects, the first microchannel tube also includes a first microchannel bend portion located between a first turn of the plurality of turns and the first inlet manifold, and a second microchannel bend portion between a last turn of the plurality of turns and the first outlet manifold. In some aspects, the plurality of turns, the first inlet manifold, the first outlet manifold, the first microchannel bend portion, and the second microchannel bend portion form a unified structure of the firstCOE-026-WO (92575-3075) microchannel tube. In some aspects, the first inlet manifold and the first outlet manifold are connected to one or more fluid heating system components via respective adaptors.

[0011] In some aspects, the heat exchanger also includes a second microchannel tube that is spiral-wrapped around the fluid tank. In some aspects, the second microchannel tube is disposed parallel to the first microchannel tube around the fluid tank. In some aspects, the second microchannel tube includes a second inlet manifold and a second outlet manifold. In some aspects, the second inlet manifold is disposed parallel to the first inlet manifold, and the second outlet manifold is disposed parallel to the first outlet manifold.

[0012] In some aspects, the fluid heating system also includes an insulating sleeve disposed around at least a portion of the first microchannel tube to prevent heat transfer therefrom. In some aspects, the fluid heating system also includes one or more fasteners to secure the first microchannel tube to the water tank.BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The detailed description is set forth with reference to the accompanying drawings. The use of the same reference numerals may indicate similar or identical items. Various embodiments may utilize elements and / or components other than those illustrated in the drawings, and some elements and / or components may not be present in various embodiments. Elements and / or components in the figures are not necessarily drawn to scale. Throughout this disclosure, depending on the context, singular and plural terminology may be used interchangeably.

[0014] FIG. 1 depicts a first example of a water heater in accordance with one or more embodiments of the present disclosure.

[0015] FIG. 2 depicts a second example of a water heater in accordance with one or more embodiments of the present disclosure.

[0016] FIG. 3 depicts a dual-wrap water heater in accordance with one or more embodiments of the present disclosure.COE-026-WO (92575-3075)

[0017] FIG. 4 depicts a flow diagram of an example method to dispose a microchannel tube around a water tank of a water heater in accordance with one or more embodiments of the present disclosure.

[0018] FIG. 5 depicts the water heater of FIG. 1 with an insulating sleeve in accordance with one or more embodiments of the present disclosure.

[0019] FIG. 6 depicts a partial view of the water heater of FIG. Iwith a plurality of fasteners in accordance with one or more embodiments of the present disclosure.DETAILED DESCRIPTION

[0020] Some modem water heaters include microchannels that are used to circulate the refrigerant around the tank of the water heater to heat water therein. In some instances, the microchannels are wrapped around the water tank to enable transfer of heat from the refrigerant to the water stored in the water tank. In some instances, a gap may be created or present between the surfaces of the microchannels and the water tank when the microchannels are wrapped around the water tank by using headers. The presence of the gap may result in reduced heat transfer and water heater thermal performance.

[0021] The present disclosure is directed towards a water heater having a water tank configured to store water therein. In certain embodiments, the water heater may include a heat source (such as a heat pump or the like) that may be configured to heat water in the water tank. Any suitable heat source may be used herein. In some aspects, the heat source may be configured to provide heat to a heat transfer fluid (such as a refrigerant), which may flow in a heat exchanger. In certain embodiments, the heat exchanger may be circumferentially and continuously wrapped around a water tank exterior surface and may be configured to transfer heat from the refrigerant to the water inside the water tank.

[0022] In some instances, the heat exchanger may include a microchannel tube (or a “first microchannel tube”) that may be spiral-wrapped around the water tank through a portion of the water tank length (e.g., 30-80% of the water tank length) or throughout the complete water tank length along a longitudinal axis of the water tank. The microchannel tube may be a single cuboidal-shaped tube or oval-shaped tube that may be continuously wrapped around the waterCOE-026-WO (92575-3075) tank to form a plurality of loops / turns along the water tank length. Each turn may be disposed at a predetermined distance / gap from adjacent turns. The single spiral-wrapped microchannel tube may effectively transfer heat to the water stored in the water tank, as there is no gap between the surface of the microchannel and the water tank when the microchannel tube is wrapped around the water tank.

[0023] In some aspects, the microchannel tube may include an inlet manifold (or a “first inlet manifold”) and an outlet manifold (or a “first outlet manifold”). The inlet manifold may be configured to receive the refrigerant from a water heater component (e.g., from a first compressor of the heat pump), and the outlet manifold may be configured to output the refrigerant to another water heater component (e.g., to a first evaporator of the heat pump). In some aspects, the inlet manifold and the outlet manifold may be disposed parallel to the longitudinal axis of the water tank.

[0024] In some aspects, the inlet manifold and the outlet manifold may be a part of the microchannel tube and may extend from the plurality of turns (or coils). The microchannel tube may include bends that may facilitate the inlet manifold and the outlet manifold to extend vertically (and parallel to the longitudinal axis of the water tank) from the plurality of turns (or spiral / circumferential turns). In some aspects, the inlet manifold and the outlet manifold may extend above a top end of the water tank. The inlet manifold and the outlet manifold may be connected to the water heater components (e.g., compressor / evaporator) via respective adapters that may facilitate connection between the cuboidal-shaped microchannel tube and the water heater components. In some aspects, the adapters facilitate connection between the cuboidal-shaped microchannel tube and a standard round tube typical of refrigerant systems.

[0025] In some aspects, the adapters comprise a round tube with a closed end, an open end, and a slot. The open end is configured to be attached to a round tube of a refrigeration system (e.g., tubing between the compressor and the adaptor). The open end may extend straight or at an angle relative to the closed end. The slot is configured to interface between the round tube of the adaptor and the cuboidal-shaped microchannel. The closed end facilitates directing refrigerant received from the compressor through the slot to the microchannel tube. OtherCOE-026-WO (92575-3075) configurations and structures of adaptors for interfacing a cuboidal-shaped microchannel tube with a round tube are contemplated by this disclosure.

[0026] In some instances, in addition to the first microchannel tube, the heat exchanger may include a second microchannel tube that may be spiral-wrapped around the water tank. The second microchannel tube may be wrapped in the similar manner as the first microchannel tube. In some aspects, the first microchannel tube may be wrapped around an upper portion of the water tank and the second microchannel may be wrapped around a lower portion of the water tank.

[0027] The second microchannel tube may include a second inlet manifold and a second outlet manifold, which may be similar to the first inlet manifold and the first outlet manifold described above. In some aspects, the second inlet manifold may be connected to a second compressor, and the second outlet manifold may be connected to a second evaporator via respective adaptors. Thus, the second microchannel tube may be connected in a second refrigerant circuit that may operate in parallel to a first refrigerant circuit having the first microchannel tube.

[0028] In alternative aspect, the second inlet manifold may be connected to the first compressor, and the second outlet manifold may be connected to the first evaporator. In such cases, the first inlet manifold and the second inlet manifold may be connected to the first compressor via a single adapter. Similarly, the first outlet manifold and the second outlet manifold may be connected to the first evaporator via a single adapter.

[0029] In yet another aspect, the first microchannel tube may be connected to a first heat source type (e.g., a heat pump) via the first inlet manifold and the first outlet manifold, and the second microchannel tube may be connected to a second heat source type (e.g., a solar heating source) via the second inlet manifold and the second outlet manifold.

[0001] Although certain examples of the disclosed technology are explained in detail herein, it is to be understood that other examples, embodiments, and implementations of the disclosed technology are contemplated. Accordingly, it is not intended that the disclosed technology is limited in its scope to the details of construction and arrangement of components expressly set forth in the following description or illustrated in the drawings. The disclosedCOE-026-WO (92575-3075) technology can be implemented in a variety of examples and can be practiced or carried out in various ways. In particular, the presently disclosed subject matter is described in the context of being a system and method for heating water with a heat pump and a microchannel heat exchanger. The present disclosure, however, is not so limited, and can be applicable in other contexts. The present disclosure, for example and not limitation, can be applied to heating water with heating sources. Furthermore, the present disclosure can include other fluid heating systems configured to heat a fluid other than water such as process fluid heaters used in industrial applications. Such implementations and applications are contemplated within the scope of the present disclosure. Accordingly, when the present disclosure is described in the context of being a system and method for heating water with a heat pump and a microchannel heat exchanger, it will be understood that other implementations can take the place of those referred to.

[0002] Although the term “water” is used throughout this specification, it is to be understood that other fluids may take the place of the term “water” as used herein. Therefore, although described as a system and method to heat water, it is to be understood that the system and method described herein can apply to fluids other than water. Further, it is also to be understood that the term “water” can replace the term “fluid” as used herein unless the context clearly dictates otherwise.

[0030] Turning now to the drawings, FIG. 1 depicts a first example of a water heater 100 in accordance with one or more embodiments of the present disclosure. The water heater 100 may include a water tank 102 for storing water. While describing FIG. 1, references will be made to FIG. 2.

[0031] The water tank 102 may be of any size, shape, or configuration based on the water heating device application. For example, the water tank 102 may be sized for common residential use or for commercial or industrial use that may require greater amounts of heated water. Furthermore, the water tank 102 can be made of any suitable material for storing and heating water, including copper, carbon steel, stainless steel, ceramics, polymers, composites, or any other suitable material. The water tank 102 can also be treated or lined with a coating to prevent corrosion and leakage. A suitable treating or coating will be capable of withstandingCOE-026-WO (92575-3075) the temperature and pressure of the water heater 100 and can include, as non-limiting examples, glass enameling, galvanizing, thermosetting resin-bonded lining materials, thermoplastic coating materials, cement coating, or any other suitable treating or coating for the application. In some aspects, the water tank 102 may be insulated to retain heat. For example, the water tank 102 may be insulated using an insulating material like polyurethane foam.

[0032] The water heater 100 may further include a water inlet (not shown) configured to receive water (e.g., tap water or water from a utility source) and transfer the water to the water tank 102. The water heater 100 may additionally include a water outlet (not shown) configured to output heated water from the water tank 102.

[0033] The water heater 100 may further include a heat source (not shown) configured to heat water in the water tank 102. In an exemplary aspect, the heat source may include a heat pump (or a heat pump assembly). In further aspects, the heat source may include a burner configured to heat a medium, a solar heating unit, or any other heating source. Any suitable heating source may be used herein.

[0034] The heat pump may include an evaporator, a compressor, a heat exchanger / condenser (including a heat exchanger 104 that may be externally wrapped around the water tank 102) and an expansion valve connected in series by a refrigerant tubing 106 through which, during heat pump operation, a refrigerant may flow. The components described herein may be part of a first refrigerant circuit of the water heater 100. In some aspects, the refrigerant may sequentially flow from a compressor outlet, through the heat exchanger 104, through the expansion valve, through the evaporator, and back to a compressor inlet. The refrigerant may be any suitable refrigerant, for example, R134A. The evaporator, the compressor, and the expansion valve of the water heater 100 may be conventional evaporator, compressor, and expansion valve and hence their functions are not described here in detail.

[0035] In certain embodiments, the heat exchanger 104 may include a microchannel tube (e g., a “first microchannel tube”, hereinafter referred to as a microchannel tube 104) that may be spiral -wrapped around the water tank 102 (e.g., around an external surface of the water tank 102), as shown in FIG. 1. In some aspects, “spiral-wrapped”, as described in the presentCOE-026-WO (92575-3075) disclosure, may mean that the elongated body of the microchannel tube 104 is wound around the external surface of the water tank 102 such that the body of the microchannel tube 104 encircles the external surface of the water tank 102 and makes a plurality of loops / turns around the external surface of the water tank 102 through a portion of the water tank 102 length (e.g., 30-80% of the water tank 102 length) or throughout the complete water tank 102 length along a longitudinal axis of the water tank 102.

[0036] The microchannel tube 104 may be configured to circulate the refrigerant therein to transfer heat to the water stored in the water tank 102. The microchannel tube 104 may be a single continuous tube that may be spiral-wrapped around the water tank 102. The microchannel tube 104 may be wrapped externally around the water tank 102. In some aspects, the thermal contact between the microchannel tube 104 and the exterior cylindrical surface of the water tank 102 is enhanced by using a thermal paste or thermal interface material. Some example thermal interface materials are contemplated in PCT Patent Application Nos. PCT / US2025 / 026657 and PCT / US2025 / 039491, which are hereby incorporated by reference herein in their entirety. Other thermal interface materials are contemplated by this disclosure. Although the present disclosure is described in the context of the water tank 102 being cylindrical in shape, the present disclosure is not limited to such an aspect. In alternative aspects, the water tank 102 may be cuboidal in shape. In this case, the shape / arrangement of the microchannel tube 104 may be altered so that the microchannel tube 104 may be effectively spiral-wrapped around the water tank 102.

[0037] In some aspects, the microchannel tube 104 may be a cuboidal-shaped tube and may have a flattened top surface “SI” (or a flattened exterior surface, which does not touch the surface of the water tank 102) and a flattened bottom surface “S2” (or a flattened inner surface, which touches the surface of the water tank 102 when the microchannel tube 104 is spiralwrapped around the water tank 102), as shown in zoom out view of a cross-section of the microchannel tube 104. Stated another way, a plane of the flattened top surface “SI” may be parallel to a plane of the flattened bottom surface “S2”. The flattened top and bottom surfaces may be attached to each other via microchannel side walls “S3” such that a predetermined small distance (e.g., a distance less than a width of the microchannel tube 104, a distance 10%COE-026-WO (92575-3075) of the width of the microchannel tube 104, a distance in a range of 5% to 20% of the width of the microchannel tube 104) may exist between the flattened top and bottom surfaces to form a fluid conduit. The refrigerant may flow through the predetermined small distance present in the microchannel tube 104 when the refrigerant may be circulated through the microchannel tube 104. Stated another way, the microchannel tube 104 may be a hollow elongated cuboidal tube through which the refrigerant may flow and heat the water stored in the water tank 102.

[0038] In certain embodiments, the dimensions of the microchannel tube 104 may be similar to the microchannels disclosed in PCT Patent Application No. PCT / US2024 / 040176, which is hereby incorporated by reference herein in its entirety. For example, the microchannel tube 104 may include ports “P” (e.g., inlet / outlet ports of the microchannel tube 104) that may enable the microchannel tube 104 to receive / output the refrigerant from / to the water heater component (e.g., compressor / evaporator) and circulate the refrigerant through the fluid conduit and around the water storage tank exterior surface. In an exemplary aspect, a count of ports in the microchannel tube 104 may be in a range of 16 to 32, which may enable the microchannel tube 104 to efficiently receive / output the refrigerant. In some embodiments, dimensions of each port may be in a range of 0.5mm * 0.5mm up to 2mm * 2mm (thus, forming “micro” channels through which the refrigerant may flow). In other embodiments, dimensions of each port may be in a range of 2mm * 2mm up to 5mm * 5mm. The above- mentioned dimensions are exemplary and not limiting. The microchannel tube 104 may be made using an extrusion process or folding process. The microchannel tube 104 may have a predetermined thickness / width. In some aspects, the width of the microchannel tube 104 (i.e., the widths of the flattened top and bottom surfaces) may be in a range of 12mm - 32mm. A length of the microchannel tube 104 may be based on the dimensions (e.g., the length and / or diameter) of the water tank 102.

[0039] As described above, the microchannel tube 104 may be spiral-wrapped around the water tank 102. The microchannel tube 104 may have a plurality of turns 106a, 106b ... 106n that may be spiral-wrapped around the water tank 102. Specifically, the plurality of turns 106a, 106b ... 106n may enable the microchannel tube 104 to be spiral -wrapped around the water tank 102. Each turn may be disposed at a predetermined distance / gap “D” from adjacentCOE-026-WO (92575-3075) turns. In some aspects, the predetermined distance “D” may be a non-zero distance, and may be in a range of 12 mm - 1.5 inches. In a preferred embodiment, the predetermined distance “D” may be 1.04 inches. In alternatively aspects, the predetermined distance “D” may be zero or tend to zero (as shown in FIG. 2). The predetermined distance “D” may be any suitable distance and not limited to the provided range of D. Stated another way, the microchannel tube 104 may be wrapped with wide gaps (as shown in FIG. 1) or narrow gaps (as shown in FIG. 2), which may depend on the usage requirements of the water heater 100, the length of the microchannel tube 104 and / or the dimensions of the water tank 102.

[0040] Furthermore, in some aspects, the gaps between adjacent turns may be the same. In alternative aspects, some gaps between adjacent turns may be greater or less than other gaps between adjacent turns of the microchannel tube 104. For example, a gap between two adjacent turns may be high as compared to other turns to accommodate other water heater components such as thermistors, water inlets / outlets, etc. in between the adjacent turns.

[0041] The microchannel tube 104 may be spiral-wrapped around the water tank 102 to cover a predetermined length of the water tank 102 along a longitudinal axis of the water tank 102, and may circulate the refrigerant around the water tank 102 to heat the water stored in the water tank 102. In some aspects, when the microchannel tube 104 may be spiral -wrapped around the water tank 102, the flattened inner surface of the microchannel tube 104 may face and touch the exterior cylindrical surface of the water tank 102 (e.g., via a thermal interface material), and the flattened outer surface may face away from (and not touch) the exterior cylindrical surface of the water tank 102.

[0042] A count of the turns 106a, 106b ... 106n may depend on the dimensions of the water tank 102 and the usage requirements of the water heater 100. As would be appreciated, increasing the count of turns 106a, 106b ... 106n may increase the available surface area on the water tank 102 for the heat transfer, thereby increasing the water heating capacity / efficiency.In some aspects, the count of turns 106a, 106b ... 106n of the microchannel tube 104 may be in range of 5-20. In one preferred embodiment, the count of turns 106a, 106b ... 106n may be 12. In another preferred embodiment, the count of turns 106a, 106b ... 106n may be 16.COE-026-WO (92575-3075)

[0043] In some aspects, the microchannel tube 104 may include an inlet manifold 108 and an outlet manifold 110. In some aspects, the inlet manifold 108 may be configured to receive refrigerant (shown as arrow “I” in FIG. 1) from a water heater component (e.g., the compressor) that supplies the refrigerant to the microchannel tube 104, and the outlet manifold 110 may be configured to output (shown as arrow “O” in FIG. 1) the refrigerant to a water heater component (e.g., the expansion valve, the evaporator) that receives the refrigerant from the microchannel tube 104. The inlet manifold 108 and the outlet manifold 110 may be a part of the microchannel tube 104, and hence may have the same cuboidal shape as the microchannel tube 104.

[0044] In an exemplary aspect, the inlet manifold 108 and the outlet manifold 110 may be disposed vertically, parallel to each other and parallel to the longitudinal axis of the water tank 102. In some aspects, the inlet manifold 108 may extend vertically “upwards” (and away from the water tank 102) from a starting point of a first turn 106a of the plurality of turns, and the outlet manifold 110 may extend vertically upwards (and away from the water tank 102) from an end point of a last turn 106n. The starting point may be a point at which the first turn 106a starts, and the end point may be a point at which the last turn 106b ends. For instance, when the microchannel tube 104 may be spiral -wrapped and has 12 turns / wraps, the inlet manifold 108 may extend vertically from the first turn and the outlet manifold 110 may extend vertically from the twelfth turn.

[0045] In some aspects, the inlet manifold 108 and the outlet manifold 110 may extend vertically above a top end 112 of the water tank 102, and may be connected to the compressor and the evaporator respectively (to receive and output the refrigerant, as described above). In some aspects, the inlet manifold 108 may be connected to the compressor via a first adaptor (not shown), and the outlet manifold 110 may be connected to the evaporator via a second adaptor (not shown). The first adaptor and the second adaptor may facilitate connection between the cuboidal-shaped microchannel tube 104 and a conventional refrigerant tubing through which the inlet manifold 108 and the outlet manifold 110 may be connected to the compressor and the evaporator.COE-026-WO (92575-3075)

[0046] The example arrangement of the inlet manifold 108 and the outlet manifold 110 relative to the water tank 102, as depicted in FIG. 1 and described above, should not be construed as limiting. In alternative aspects, the inlet manifold 108 and the outlet manifold 110 may also be arranged in any other manner relative to the water tank 102, without departing from the scope of the present disclosure. For example, in an exemplary aspect, the inlet manifold 108 and / or the outlet manifold 110 may be disposed perpendicular to (or aligned at any other angle relative to) the longitudinal axis of the water tank 102. In addition, one or more of the inlet manifold 108 and the outlet manifold 110 may not extend vertically above the top end 1 12 of the water tank 102.

[0047] In some aspects, the microchannel tube 104 may include a first bend portion 114 that may be located between the inlet manifold 108 and starting point of the first turn 106a. Similarly, the microchannel tube 104 may include a second bend portion 116 that may be located between the outlet manifold 110 and end point of the last turn 106n. The bend portions 114, 116 may enable the starting point of the first turn 106a (that may contact the cylindrical exterior surface of the water tank 102) to extend vertically and form the inlet manifold 108, and the end of the last turn 106n to extend vertically and form the outlet manifold 110. The bend portions 114, 116 may enable the inlet manifold 108 and the outlet manifold 110 to be disposed at a predetermined angle relative to the longitudinal axis of the plurality of turns 106a, 106b, ... 106n (which may all be aligned parallel to each other). In an exemplary embodiment, a longitudinal axis of the inlet manifold 108 may be positioned perpendicular to the longitudinal axis of the first turn 106a (and the plurality of turns). Similarly, a longitudinal axis of the outlet manifold 110 may be positioned perpendicular to the longitudinal axis of the last turn 106a (and the plurality of turns).

[0048] It may be appreciated from the description above that since the microchannel tube 104 is a single continuous tube, the plurality of turns 106a, 106b....106n, the inlet manifold 108, the outlet manifold 110, the first microchannel bend portion 114, and the second microchannel bend portion 116 may form a unified structure of the microchannel tube 104.

[0049] In some aspects, the bend portions 114, 116 may not be used. Instead, the microchannel tube 104 may simply terminate into an adaptor at each end that facilitatesCOE-026-WO (92575-3075) connection between the cuboidal-shaped microchannel tube 104 and a conventional round refrigerant tubing. A length of the round refrigerant tubing may then extend from the adaptor to the top of the water tank 102 (or elsewhere) for attachment to other refrigeration system components (e.g., compressor, expansion valve, evaporator, etc.).

[0050] During the water heater’ s operation, the refrigerant may enter the microchannel tube 104 from the compressor (e.g., via the adaptor(s)). The refrigerant may enter the microchannel tube 104 via the inlet manifold 108 (or inlet channel), move “downwards”, and may enter the first turn 106a (e.g., via the starting point of the first turn 106a). The refrigerant may then move in a circular or spiral direction (e.g., clockwise direction or counter-clockwise direction, as shown by arrow “F” in FIG. 1) around the water tank exterior surface, through the plurality of turns 106a, 106b....106n, and may come downwards (e.g., towards a bottom end of the water tank 102). When the refrigerant reaches the end point of the last turn 106n, the refrigerant may move “upwards” (e.g., towards the top end 112 of the water tank 102) via the outlet manifold 110 (or outlet channel) and may move towards the expansion valve and evaporator (e.g., via the adaptor(s)). In this manner, the refrigerant may flow through the microchannel tube 104. As described above, the refrigerant may transfer heat to the water stored in the water tank 102, when the refrigerant flows through the microchannel tube 104.

[0051] FIG. 3 depicts a dual -wrap water heater 300 in accordance with one or more embodiments of the present disclosure. The dual -wrap water heater 300 be similar to the water heater 100 described above, and may include a second microchannel tube 302 in addition to the microchannel tube 104 (or the first microchannel tube 104) described above in conjunction with FIGS. 1 and 2.

[0052] The second microchannel tube 302 may be similar to the first microchannel tube 104, and may include a plurality of turns 304a, 304b, ... 304n, a second inlet manifold 306, a second outlet manifold 308, and bend portions 310. The second microchannel tube 302 may be cuboidal in shape (with flattened top surface and bottom surface) and may have the same width as the width of the first microchannel tube 104. In some aspects, the second microchannel tube 302 may have a length that may be different from a first microchannel tube length. In other aspects, the second microchannel tube 302 may have a length that may be same as the firstCOE-026-WO (92575-3075) microchannel tube length. As above, in some aspects, the bend portions may be replaced with adaptors into which the ends of the second microchannel tube 302 may terminate.

[0053] The arrangement / structure of the plurality of turns 304a, 304b, ... 304n may be the same as the arrangement / structure of the plurality of turns 106a, 106b, .... 106n in the first microchannel tube 104. Furthermore, the arrangement / structure of the second inlet manifold 306 may be the same as the arrangement / structure of the inlet manifold 108 (or the first inlet manifold 108), the arrangement / structure of the second outlet manifold 308 may be the same as the arrangement / structure of the outlet manifold 110 (or the first outlet manifold 110), and the arrangement / structure of the bend portions 310 may be the same as the arrangement / structure of the first microchannel bend portion 114 and the second microchannel bend portion 116 in the microchannel tube 104.

[0054] In an exemplary embodiment, the first microchannel tube 104 may be located or disposed at an upper portion of the water tank 102, and the second microchannel tube 302 may be located or disposed at a lower portion of the water tank 102, as shown in FIG. 3. Stated another way, the first microchannel tube 104 may be disposed above (i.e., closer to the top end 112 of the water tank 102) the second microchannel tube 302 on the water tank 102. In other aspects, the positions of the first and second microchannel tubes 104, 302 may be reversed on the water tank 102. In yet another aspect (not shown), the first microchannel tube 104 and the second microchannel tube 302 may be disposed in a double helix manner around the water tank 102 to transfer heat to the water inside the water tank 102. The relative arrangement of the first and second microchannel tubes 104, 302 on the water tank 102 may be based on a plurality of parameters including, but not limited to, heating requirements of the water heater 300, the available lengths of the first and / or second microchannel tubes 104, 302, dimensions and / or shape of the water tank 102, and / or the like.

[0055] In some aspects, the second microchannel tube 302 may be arranged parallel to the first microchannel tube 104. In further aspects, when the first and second microchannel tubes 104, 302 are disposed on the water tank 102, the plurality of turns 304a, 304b, ... 304n may be parallel to the plurality of turns 106a, 106b, .... 106n. Further, the second inlet manifold 306 may be disposed parallel to the first inlet manifold 108, and the second outlet manifold 308COE-026-WO (92575-3075) may be disposed parallel to the first outlet manifold 110, when the first and second microchannel tubes 104, 302 are disposed on the water tank 102. In some aspects, the first inlet manifold 108, the first outlet manifold 110, the second inlet manifold 306, and the second outlet manifold 308 may be parallel to each other, when the first and second microchannel tubes 104, 302 are disposed on the water tank 102.

[0056] In some aspects, the second inlet manifold 306 may be connected to a second compressor (that may be different from the compressor described above in conjunction with FIG. 1), and the second outlet manifold 308 may be connected to a second expansion valve and evaporator (that may be different from the expansion valve and evaporator described above in conjunction with FIG. 1), via respective adaptors. Stated another way, the second microchannel tube 302 may be connected in a second refrigerant circuit that may operate in parallel with the first refrigerant circuit of FIG. 1 with the first microchannel tube 104.

[0057] In alternative aspects, the first inlet manifold 108 and the second inlet manifold 306 may be connected to the same compressor, and the first outlet manifold 110 and the second outlet manifold 308 may be connected to the same expansion valve and evaporator. In this aspect, the first inlet manifold 108 and the second inlet manifold 306 may be connected to the same compressor via a single first adapter, and the first outlet manifold 110 and the second outlet manifold 308 may be connected to the same evaporator via a single second adapter. In this case, both the first and second microchannel tubes 104, 302 may be part of the same refrigerant circuit.

[0058] In yet another aspect, the first microchannel tube 104 may be connected to a first heat source type (e.g., a heat pump) via the first inlet manifold 108 and the first outlet manifold 110, and the second microchannel tube 302 may be connected to a second heat source type (e g., a solar heating source) via the second inlet manifold 306 and the second outlet manifold 308. In alternative aspects, the second microchannel tube 302 may be arranged in series with the first microchannel tube 104, as opposed to disposed in parallel as described above.

[0059] The first and second microchannel tubes 104, 302 may be disposed on the water tank 102 in many other different ways, without departing from the scope of the present disclosure. The example arrangements described above should not be construed as limiting.COE-026-WO (92575-3075)

[0060] FIG. 4 depicts a flow diagram of an example method 400 to dispose / arrange a microchannel tube around the water tank 102 in accordance with one or more embodiments of the present disclosure. FIG. 4 may be described with continued reference to prior figures, including FIGS. 1-3. The following process is exemplary and not confined to the steps described hereafter. Moreover, alternative embodiments may include more or less steps than are shown or described herein and may include these steps in a different order than the order described in the following example embodiments.

[0061] The method 400 may start at step 402. At step 404, the method 400 may include applying a thermal paste on the microchannel tube 104 (specifically to the flattered inner surface of the microchannel tube 104). At step 406, the method 400 may include wrapping and attaching the microchannel tube 104 around the water tank 102, as described above in conjunction with FIGS. 1-3. In some aspects, the microchannel tube 104 may be attached via one or more brackets or fasteners, as shown in FIG. 6. The method 400 stops at step 408.

[0062] One or more additional features for enhancing the function of the water heaters and heat exchangers described herein may also be provided.

[0063] In embodiments, as shown in FIG. 5, an insulating sleeve 500 may be provided to thermally insulate at least a portion of the refrigerant tubing 106. The insulating sleeve 500 may be provided to prevent thermal transfer between overlapping portions of the refrigerant tubing 106, and may be made of any thermally insulative material known to those skilled in the art. As shown in FIG. 5, the insulating sleeve 500 is provided on the portion of the refrigerant tubing extending between the second bend portion 116 and the outlet manifold 110, to prevent heat transfer between the refrigerant tubing 106 wrapped around the body of the water tank 102 and the portion thereof extending vertically towards the outlet manifold 110 from the second bend portion 116. In this way, the insulating sleeve 500 may prevent transfer of heat to or from the respective portions of the refrigerant tubing 106 relative to the other portion. In some embodiments, an insulating sleeve 500 may also be provided to prevent heat transfer from portions of the refrigerant tubing 106 to the water tank 102, or vice versa. For example, an insulating sleeve 500 may be provided on the portion of the refrigerant tubing 106COE-026-WO (92575-3075) extending between the inlet manifold 108 and the first bend portion 114 to prevent heat transfer to or from the water tank 102 in this area.

[0064] In some embodiments, such as that shown in FIG. 5, the insulating sleeve 500 may is a single continuous sleeve extending between the second bend portion 116 and the outlet manifold 110. In other embodiments, however, the insulating sleeve 500 may include one or more segments, or one or more insulating sleeves 500 may be provided. For example, in embodiments where the water heater is a dual-wrap water heater 300 as shown in FIG. 3, one or more insulating sleeves 500 may be provided. In these embodiments, an insulating sleeve 500 may be provided on any vertical portion of the refrigerant tubing 106, 304 that overlaps with one or more coiled portions of the refrigerant tubing 106, 304. For example, an insulating sleeve 500 may be provided on the vertical portion of the refrigerant tubing 106 extending between the second inlet manifold 306 and the bend portion 310, between the bend portion 310 and the second outlet manifold 308, and / or the second bend portion 116 and the outlet manifold 110. In some embodiments, an insulating sleeve 500 may be provided on the portion of the refrigerant tubing 106 extending between the inlet manifold 108 and the first bend portion 114 to prevent heat transfer to or from the water tank 102 in this area.

[0065] In embodiments, as shown in FIG. 6, one or more fasteners 600 are provided to further secure the refrigerant tubing 106 to the water tank 102. Each fastener 600 may include a clip 602 that is sized and shaped to receive the refrigerant tubing 106 therethrough, and one or more screws 604 for securing the clip 602 to the water tank 102. According to preferred embodiments, each fastener 600 is provided with two screws 604 for securing the clip 602 on opposing sides of the refrigerant tubing 106. While the fasteners 600 are described and shown herein as clips 602, those skilled in the art would recognize that any fastening means may be implemented for securing the refrigerant tubing 106 to the water tank 102.

[0066] The fasteners 600 may be provided at various positions around the water tank 102 to secure the refrigerant tubing 106 thereto, or to reinforce the connection between the refrigerant tubing 106 and the water tank 102. Fasteners 600 may be provided in any number or in any configuration along the length of the refrigerant tubing 106 to appropriately secure the refrigerant tubing 106 to the water tank 102. For example, with reference to the waterCOE-026-WO (92575-3075) heater 100 of FIG. 1, one or both vertical portions (i.e., portions extending between the inlet manifold 108 and the first bend portion 114 and between the second bend portion 116 and the outlet manifold 110) of the refrigerant tubing may be secured with one or more fasteners 600. In some embodiments, each portion of the refrigerant tubing 106 wrapped around the water tank 102 (i.e., each coiled portion) may also be secured with one or more fasteners 600. In other embodiments, not every coiled portion of the refrigerant tubing 106 is secured with a fastener 600. For example, every other, every third, every fourth, etc. coiled portion of the refrigerant tubing 106 may be secured to the water tank 102 with one or more fasteners 600.

[0067] In the above disclosure, reference has been made to the accompanying drawings, which form a part hereof, which illustrate specific implementations in which the present disclosure may be practiced. It is understood that other implementations may be utilized, and structural changes may be made without departing from the scope of the present disclosure. References in the specification to “one embodiment,” “an embodiment,” “an example embodiment,” etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a feature, structure, or characteristic is described in connection with an embodiment, one skilled in the art will recognize such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described.

[0068] It should also be understood that the word “example” as used herein is intended to be non-exclusionary and non-limiting in nature. More particularly, the word “example” as used herein indicates one among several examples, and it should be understood that no undue emphasis or preference is being directed to the particular example being described.

[0069] With regard to the processes, systems, methods, heuristics, etc. described herein, it should be understood that, although the steps of such processes, etc. have been described as occurring according to a certain ordered sequence, such processes could be practiced with the described steps performed in an order other than the order described herein. It further should be understood that certain steps could be performed simultaneously, that other steps could be added, or that certain steps described herein could be omitted. In other words, the descriptionsCOE-026-WO (92575-3075) of processes herein are provided for the purpose of illustrating various embodiments and should in no way be construed so as to limit the claims.

[0070] Accordingly, it is to be understood that the above description is intended to be illustrative and not restrictive. Many embodiments and applications other than the examples provided would be apparent upon reading the above description. The scope should be determined, not with reference to the above description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. It is anticipated and intended that future developments will occur in the technologies discussed herein, and that the disclosed systems and methods will be incorporated into such future embodiments. In sum, it should be understood that the application is capable of modification and variation.

[0071] It should also be understood that, in addition to those embodiments and combinations of features specifically described herein and recited in the appended claims, any combination of features even if not explicitly disclosed is necessarily contemplated by the present disclosure.

[0072] All terms used in the claims are intended to be given their ordinary meanings as understood by those knowledgeable in the technologies described herein unless an explicit indication to the contrary is made herein. In particular, use of the singular articles such as “a,” “the,” “said,” etc., should be read to recite one or more of the indicated elements unless a claim recites an explicit limitation to the contrary. Conditional language, such as, among others, “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments could include, while other embodiments may not include, certain features, elements, and / or steps. Thus, such conditional language is not generally intended to imply that features, elements, and / or steps are in any way required for one or more embodiments.

Claims

COE-026-WO (92575-3075)CLAIMSThat which is claimed is:

1. A water heater comprising: a water tank configured to store water; and a heat exchanger disposed about the water tank, wherein the heat exchanger comprises a first microchannel tube that is spiral-wrapped around the water tank, wherein the first microchannel tube is configured to circulate a heat transfer fluid therein to transfer heat to the water.

2. The water heater of claim 1, wherein the first microchannel tube is a single continuous tube that is spiral-wrapped around the water tank.

3. The water heater of claim 1, wherein the first microchannel tube is a cuboidal-shaped tube or oval-shaped tube.

4. The water heater of claim 1, wherein the first microchannel tube comprises a plurality of turns that is spiral-wrapped around the water tank.

5. The water heater of claim 4, wherein each turn is disposed at a predetermined distance from adjacent turns.

6. The water heater of claim 4, wherein the first microchannel tube comprises a first inlet manifold and a first outlet manifold.

7. The water heater of claim 6, wherein the first inlet manifold and the first outlet manifold are disposed vertically and parallel to a longitudinal axis of the water heater.

8. The water heater of claim 6, wherein the first inlet manifold and the first outlet manifold extend above a top end of the water tank.COE-026-WO (92575-3075)9. The water heater of claim 6, wherein the first microchannel tube further comprises a first microchannel bend portion located between a first turn of the plurality of turns and the first inlet manifold, and a second microchannel bend portion between a last turn of the plurality of turns and the first outlet manifold.

10. The water heater of claim 9, wherein the plurality of turns, the first inlet manifold, the first outlet manifold, the first microchannel bend portion, and the second microchannel bend portion form a unified structure of the first microchannel tube.

11. The water heater of claim 6, wherein the first inlet manifold and the first outlet manifold are connected to one or more water heater components via respective adaptors.

12. The water heater of claim 6, wherein the heat exchanger further comprises a second microchannel tube that is spiral-wrapped around the water tank.

13. The water heater of claim 12, wherein the second microchannel tube is disposed parallel to the first microchannel tube around the water tank.

14. The water heater of claim 12, wherein the second microchannel tube comprises a second inlet manifold and a second outlet manifold.

15. The water heater of claim 14, wherein the second inlet manifold is disposed parallel to the first inlet manifold, and the second outlet manifold is disposed parallel to the first outlet manifold.

16. The water heater of claim 1, further comprising an insulating sleeve disposed around at least a portion of the first microchannel tube to prevent heat transfer therefrom.COE-026-WO (92575-3075)17. The water heater of claim 1, further comprising one or more fasteners to secure the first microchannel tube to the water tank.

18. A water heater compri sin : a water tank configured to store water; and a heat exchanger disposed about the water tank, wherein the heat exchanger comprises a first microchannel tube that is spiral-wrapped around the water tank, wherein the heat exchanger further comprises a second microchannel tube that is spiral-wrapped around the water tank, wherein the first microchannel tube and the second microchannel tube are configured to circulate a heat transfer fluid therein to transfer heat to the water.

19. The water heater of claim 18, wherein the first microchannel tube comprises a first inlet manifold and a first outlet manifold, and wherein the second microchannel tube comprises a second inlet manifold and a second outlet manifold.

20. The water heater of claim 19, wherein the second inlet manifold is disposed parallel to the first inlet manifold, and the second outlet manifold is disposed parallel to the first outlet manifold.

21. The water heater of claim 18, wherein the first microchannel tube and the second microchannel tube are cub oi dal -shaped tubes.

22. The water heater of claim 18, further comprising an insulating sleeve disposed around at least a portion of the first microchannel tube to prevent heat transfer therefrom.

23. The water heater of claim 18, further comprising one or more fasteners to secure the first microchannel tube to the water tank.COE-026-WO (92575-3075)24. A method of assembling a heat exchanger to a water tank of a water heater, the method comprising: attaching the microchannel tube around the water tank, wherein the microchannel tube is spiral-wrapped around the water tank, and wherein the microchannel tube is configured to circulate a heat transfer fluid therein to transfer heat to water stored in the water tank.

25. A fluid heating system comprising: a fluid tank configured to store fluid; and a heat exchanger disposed about the fluid tank, wherein the heat exchanger comprises a first microchannel tube that is spiral-wrapped around the fluid tank, wherein the first microchannel tube is configured to circulate a heat transfer fluid therein to transfer heat to the fluid.

26. The fluid heating system of claim 25, wherein the first microchannel tube is a single continuous tube that is spiral-wrapped around the fluid tank.

27. The fluid heating system of claim 25, wherein the first microchannel tube is a cuboidal- shaped tube.

28. The fluid heating system of claim 25, wherein the first microchannel tube comprises a plurality of turns that is spiral-wrapped around the fluid tank.

29. The fluid heating system of claim 28, wherein each turn is disposed at a predetermined distance from adjacent turns.

30. The fluid heating system of claim 28, wherein the first microchannel tube comprises a first inlet manifold and a first outlet manifold.COE-026-WO (92575-3075)31. The fluid heating system of claim 30, wherein the first inlet manifold and the first outlet manifold are disposed vertically and parallel to a longitudinal axis of the fluid heating system.

32. The fluid heating system of claim 30, wherein the first inlet manifold and the first outlet manifold extend above a top end of the fluid tank.

33. The fluid heating system of claim 30, wherein the first microchannel tube further comprises a first microchannel bend portion located between a first turn of the plurality of turns and the first inlet manifold, and a second microchannel bend portion between a last turn of the plurality of turns and the first outlet manifold.

34. The fluid heating system of claim 33, wherein the plurality of turns, the first inlet manifold, the first outlet manifold, the first microchannel bend portion, and the second microchannel bend portion form a unified structure of the first microchannel tube.

35. The fluid heating system of claim 30, wherein the first inlet manifold and the first outlet manifold are connected to one or more fluid heating system components via respective adaptors.

36. The fluid heating system of claim 30, wherein the heat exchanger further comprises a second microchannel tube that is spiral-wrapped around the fluid tank.

37. The fluid heating system of claim 36, wherein the second microchannel tube is disposed parallel to the first microchannel tube around the fluid tank.

38. The fluid heating system of claim 36, wherein the second microchannel tube comprises a second inlet manifold and a second outlet manifold.COE-026-WO (92575-3075)39. The fluid heating system of claim 38, wherein the second inlet manifold is disposed parallel to the first inlet manifold, and the second outlet manifold is disposed parallel to the first outlet manifold.

40. The fluid heating system of claim 25, further comprising an insulating sleeve disposed around at least a portion of the first microchannel tube to prevent heat transfer therefrom.

41. The fluid heating system of claim 25, further comprising one or more fasteners to secure the first microchannel tube to the water tank.

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