WATER HEATING SYSTEMS AND METHODS

• US 20070246552A1
• Filed: 03/27/2007
• Published: 10/25/2007
• Est. Priority Date: 03/27/2006
• Status: Abandoned Application

• Current Assignee: A. O. Smith Corporation
• Original Assignee: A. O. Smith Corporation
• Inventors: Patterson, Wade, Phillips, Terry
• Application Number:
  US11/692,117
• Publication Number:
  US 20070246552A1
• Time in Patent Office: Days
• US Class Current: 236/21.B
• CPC Class Codes: F24H 15/174 Supplying heated water with desired temperature or desired range of temperature
• CPC Class Codes: F24H 15/225 at different heights of the tank
• CPC Class Codes: F24H 15/281 Input from user
• CPC Class Codes: F24H 15/296 Information from neighbouring devices
• CPC Class Codes: F24H 15/37 of electric heaters
• CPC Class Codes: F24H 15/407 using electrical switching, e.g. TRIAC
• CPC Class Codes: F24H 15/414 using electronic processing, e.g. computer-based
• CPC Class Codes: F24H 9/2014 using electrical energy supply

Abstract

A water heating system has a controller that is electronically actuated. In this regard, the controller controls an activation state of at least one heating element by providing an electrical control signal to a relay. In one embodiment, the controller has an emergency shut-off apparatus that is mechanically actuated. Further various features can be optionally implemented to help heat related problems plaguing many conventional water heater controllers that are electronically actuated.

Claims

1. A water heater controller, comprising:

a relay for controlling an activation state of a heating element;

an emergency shut-off apparatus for disabling the heating element if a temperature exceeds a threshold, the emergency shut-off apparatus having a temperature sensitive element that mechanically actuates based on the temperature, the emergency shut-off apparatus having a mechanical switch that is coupled to the relay, wherein actuation of the temperature sensitive element changes a state of the switch; and

logic configured to receive temperature data indicative of a temperature sensed by a temperature sensor, the logic further configured to control a state of the relay based on the temperature data.

2. The water heater controller of claim 1, wherein the logic is configured to perform a comparison between the temperature data and a threshold value, wherein the logic is configured to transmit an electronic signal to the relay based on the comparison, and wherein the relay transitions from an open state to a closed state in response to the electronic signal thereby activating the heating element.

3. The water heater controller of claim 1, wherein the logic is configured to perform a comparison between the temperature data and a threshold value, wherein the logic is configured to transmit an electrical signal to the relay based on the comparison, and wherein the relay transitions from a closed state to an open state in response to the electronic signal thereby deactivating the heating element.

4. The water heater controller of claim 1, wherein the emergency shut-off apparatus, upon disabling the heating element, is configured to ensure that the heating element remains disabled until at least the emergency shut-off apparatus receives a user input.

5. The water heater controller of claim 1, wherein the temperature sensitive element comprises a bimetallic disc.

6. The water heater controller of claim 1, further comprising an electrically conductive connection coupled to the emergency shut-off apparatus, the connection composed of a metallic alloy having an International Annealed Copper Standard (IACS) of greater than 80%, a stress relaxation temperature greater than 105 degrees Celsius, and a yield stress greater than 50 kilo-pounds per square inch (ksi).

7. The water heater controller of claim 1, further comprising:

a thermally conductive base;

a housing coupled to the base, the housing composed of electrically insulating material;

the temperature sensor, wherein the temperature sensor contacts the base.

8. The water heater controller of claim 7, wherein the relay is mounted on a first side of a printed circuit board (PCB), and wherein the temperature sensor is positioned on a second side of the PCB that is opposite to the first side.

9. The water heater controller of claim 7, wherein the temperature sensor is mounted on an element composed of thermally insulating material and is electrically coupled to the PCB.

10. The water heater controller of claim 1, further comprising an interface for electrically connecting an electrically conductive wire to an electrically conductive connection, the interface having a hole for receiving the wire.

11. The water heater controller of claim 10, wherein the connection is coupled to the emergency shut-off apparatus.

12. The water heater controller of claim 10, wherein the connection is coupled to the relay.

13. The water heater controller of claim 10, wherein the connection has at least one rib for guiding the wire as the wire is being inserted into the first hole.

14. The water heater controller of claim 10, further comprising a housing covering the logic, the housing having a hole, wherein the wire has a coating composed of insulating material, and wherein a portion of the coating passes through the hole of the housing.

15. The water heater controller of claim 14, wherein at least a portion of a wall of the housing contacts the coating, the portion defining the hole of the housing.

16. The water heater controller of claim 14, wherein the interface is composed of a metallic alloy having an International Annealed Copper Standard (IACS) of greater than 80%, a stress relaxation temperature greater than 105 degrees Celsius, and a yield stress greater than 50 kilo-pounds per square inch (ksi).

17. The water heater controller of claim 10, further comprising:

a thermally conductive base;

a housing coupled to the base, the housing composed of an electrically insulating material;

the temperature sensor,

wherein the temperature sensor contacts the base.

18. The water heater controller of claim 17, wherein the relay is mounted on a first side of a printed circuit board (PCB), and wherein the temperature sensor is positioned on a second side of the PCB that is opposite to the first side.

19. The water heater controller of claim 18, wherein the temperature sensor is mounted on an element composed of thermally insulating material and electrically coupled to the PCB.

20. A water heating system, comprising:

a tank;

a heating element mounted on the tank; and

a controller mounted on the tank, the controller comprising;

an emergency shut-off apparatus that is mechanically actuated, the emergency shut-off apparatus coupled to the heating element and having a temperature sensitive element that mechanically actuates due to thermal stresses such that the heating element is disabled if the temperature exceeds a threshold;

a relay coupled to the heating element; and

logic configured to receive temperature data indicative of a temperature sensed by a temperature sensor, the logic further configured to control a state of the relay based on the temperature data.

21. The system of claim 20, wherein the controller further comprises:

a thermally conductive base;

a housing coupled to the base, the housing composed of electrically insulating material;

the temperature sensor,

wherein the temperature sensor contacts the base.

22. The system of claim 21, wherein the relay is mounted on a first side of a printed circuit board (PCB), and wherein the temperature sensor is positioned on a second side of the PCB that is opposite to the first side.

23. The system of claim 20, further comprising an electrically conductive wire, wherein the controller further comprises:

an electrically conductive connection; and

an interface having a hole, the connection extending through the hole.

24. The system of claim 23, further comprising a housing covering the logic, the housing having a hole, wherein the wire has a coating composed of insulating material, and wherein a portion of the coating passes through the hole of the housing.

25. The system of claim 23, wherein the connection is composed of a metallic alloy having an International Annealed Copper Standard (IACS) of greater than 80%, a stress relaxation temperature greater than 105 degrees Celsius, and a yield stress greater than 50 kilo-pounds per square inch (ksi).

26. The system of claim 23, wherein the connection has at least one rib for guiding the wire as the wire is being inserted into the first hole.

27. A water heater controller, comprising:

an electromechanical switching means for controlling an activation state of the heating element;

means for disabling a heating element if a temperature exceeds a threshold, the disabling means having a mechanical switching means coupled to the relay and having a temperature sensing means that mechanically actuates based on the temperature, wherein actuation of the temperature sensing means changes a state of the mechanical switching means; and

means for receiving temperature data indicative of a temperature sensed by a temperature sensor, and for controlling a state of the relay based on the temperature data.

28. A method for controlling a water heating system having a tank and a heating element mounted on the tank, comprising the steps of:

disabling the heating element if a temperature exceeds a threshold, the disabling step comprising the step of mechanically actuating a temperature sensitive element based on the temperature;

sensing a temperature;

transmitting temperature data indicative of the sensed temperature; and

controlling an operational state of the heating element based on the temperature data, the controlling step comprising the step of electrically actuating a relay based on the temperature data.

29. The method of claim 28, wherein the disabling step comprises the step of ensuring that the heating element remains disabled until a user input is received.