Water heater inlet fitting, flow sensor, shut off valve and diffuser
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Solution Overview
Problem
Existing water heaters face issues with improper diffuser positioning leading to reduced thermal efficiency, longer inlet fittings requiring more space, and the lack of integrated components for measuring water flow or shutting off the water flow.
Innovation Solution
An integrated flow sensor and diffuser assembly with a single set of threads for easy installation, combined with a shut off valve and heat trap, to ensure proper diffuser orientation and reduce installation space, utilizing a flow sensor with a turbine and Hall effect sensor for measuring water flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the diffuser is attached as a separate component to the water heater, then the diffuser can be positioned to optimize thermal efficiency, but the installer may not position the diffuser properly during installation thereby negatively affecting the thermal efficiency
Solution Approach 1:
The patent combines the diffuser and flow sensor into a single integrated assembly that is attached to the water heater as one unit. This integration ensures that the diffuser maintains its optimal orientation (e.g., 2 o'clock position) relative to the water heater tank while eliminating the risk of misalignment that occurs when separate components are installed independently. The integrated assembly includes a diffuser body with an outlet oriented at the optimal angle and a flow sensor housing that couples to the diffuser body, forming a unified structure that preserves thermal efficiency during installation.
2Ease of manufacture
If the diffuser and flow sensor are attached separately, then each component can be installed independently, but torque applied to the flow sensor causes the diffuser to shift from the optimal position
Solution Approach 1:
The patent integrates the flow sensor and diffuser into a single assembly where the flow sensor housing is coupled to the diffuser body through integrated attachment features. This merging ensures that when torque is applied to attach the assembly to the water heater, both components move together as one unit, preventing the diffuser from shifting out of its optimal orientation. The integrated design includes aligned thread patterns and coupling mechanisms that maintain the precise angular relationship between the diffuser outlet and the water heater tank during the installation process.
3Ease of manufacture
If the inlet fitting is made longer to accommodate separate components, then each component can be properly installed, but more space is required for water heater installation
Solution Approach 1:
The patent combines the diffuser and flow sensor into a compact integrated assembly that reduces the overall length of the inlet fitting required for water heater installation. By eliminating the need for separate attachment mechanisms and reducing the distance between components, the integrated design shortens the inlet fitting length while maintaining proper installation capability. The compact integration allows the assembly to fit within tighter spaces, accommodating the water heater in smaller installation environments without compromising the functionality or installability of individual components.
4Adaptability or versatility
If separate components are used for flow measurement and shut off, then each function can be independently designed, but the device complexity increases
Solution Approach 1:
The patent integrates the flow sensor, shut-off valve, and diffuser into a single unified assembly that performs multiple functions while reducing overall device complexity. The integrated design includes a flow sensor housing that contains both the flow measurement mechanism and the shut-off valve mechanism, with the diffuser body forming part of the same assembly. This consolidation eliminates the need for separate mounting brackets, attachment mechanisms, and alignment procedures that would be required if these components were installed independently, thereby reducing the total number of parts and simplifying the installation process while maintaining full functional capability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The integrated solution ensures optimal diffuser positioning for improved thermal efficiency, reduces installation space, and provides a single assembly for easier installation and accurate water flow measurement, while preventing heated water mixing with cold water.
Implementation Method 1
a flow sensor comprising a Hall effect sensor and a turbine disposed within the rotatable ball
Data Source
AI summary
An integrated valve and flow sensor for a water heater can have a valve body that includes a valve and a flow sensor for measuring the flow of water through the valve. The integrated valve and flow sensor can be disposed within a fitting that can be attached to a water heater. An actuator for opening and closing the valve can be attached to the fitting. A diffuser can also be attached to the fitting.