WATER HEATING SYSTEMS AND METHODS

• US 20070248143A1
• Filed: 03/27/2007
• Published: 10/25/2007
• Est. Priority Date: 03/27/2006
• Status: Active Grant

• Current Assignee: A. O. Smith Corporation
• Original Assignee: A. O. Smith Corporation
• Inventors: Bullington, James, Phillips, Terry
• Granted Patent: US 8,245,669 B2
• Time in Patent Office: Days
• US Class Current: 374/141
• CPC Class Codes: G01K 1/20 Compensating for effects of temperature changes other than those to be measured, e.g. changes in ambient temperature
• CPC Class Codes: G01K 13/00 Thermometers specially adapted for specific purposes

Abstract

A water heating system, comprise a tank, a heating element, and a controller that is coupled to the heating element. The controller comprises a base, a housing, a relay, logic and, a temperature sensor. The base is composed of thermally conductive material, and the housing is composed of electrically insulating material. The housing is coupled to the base, and the logic is configured to control the a state of the relay. Further, the temperature sensor contacts the base and is coupled to the logic.

Claims

1. A water heater controller, comprising:

a base composed of thermally conductive material;

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

a relay;

an emergency shut-off apparatus;

logic for controlling the relay thereby controlling an operational state of a heating element that is coupled to the relay; and

a temperature sensor contacting the base and coupled to the logic.

2. The controller of claim 1, wherein the temperature sensor is mounted on a component composed of thermally insulating material.

3. The controller of claim 1, further comprising a printed circuit board having a first side and a second side, the first side opposite of the second side, wherein the relay is mounted on the first side of the PCB, and wherein the temperature sensor is positioned between the PCB and the base on the second side of the PCB.

4. The controller of claim 3, wherein the temperature sensor is mounted on a component composed of thermally insulating material.

5. The controller of claim 3, wherein the controller is mounted on a tank via a bracket, the bracket having notch, and wherein the temperature sensor is positioned in a portion of the controller inserted into the notch.

6. The controller of claim 3, wherein the emergency shut-off apparatus is mounted on the first side of the PCB.

7. The controller of claim 6, wherein the logic is mounted on the first side of the PCB.

8. The controller of claim 1, wherein the controller is mounted on a tank via a bracket, the bracket having a notch, and wherein the temperature sensor is positioned in a portion of the controller inserted into the notch.

9. The controller of claim 8, wherein the relay and the emergency shut-off apparatus are positioned in a portion of the controller outside of the notch.

10. A water heating system, comprising:

a tank;

a heating element; and

a controller coupled to the heating element, the controller comprising;

a base composed of thermally conductive material;

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

a relay coupled to the heating element;

logic configured to control a state of the relay; and

a temperature sensor contacting the base and coupled to the logic.

11. The system of claim 10, wherein the temperature sensor is mounted on a component composed of thermally insulating material.

12. The system of claim 10, further comprising a printed circuit board having a first side and a second side, the first side opposite of the second side, wherein the relay is mounted on the first side of the PCB, and wherein the temperature sensor is positioned between the PCB and the base on the second side of the PCB.

13. The system of claim 12, wherein the temperature sensor is mounted on a component composed of thermally insulating material.

14. The system of claim 12, wherein the controller is mounted on a tank via a bracket, the bracket having notch, and wherein the temperature sensor is positioned in a portion of the controller inserted into the notch.

15. The system of claim 12, wherein the logic is mounted on the first side of the PCB.

16. The system of claim 10, wherein the controller is mounted on a tank via a bracket, the bracket having a first arm and a second arm, and wherein the temperature sensor is positioned in a portion of the controller between the first and second arms.

17. The system of claim 16, wherein the relay is positioned in a portion of the controller that is outside of a notch formed by the first and second arms.