Rheem Manufacturing Company

David L Henderson

Jozef Boros

Kenneth J Hicks

Timothy E Powell

Jacob H Hall

Jeffrey A Leep

Electrical components projecting outwardly from the storage tank portion of an electric water heater are shielded from foam insulation material being injected into an insulation space between the tank and an outer jacket portion of the water heater by a hollow, open sided foam dam structure extending through a jacket opening and circumscribing the electrical components. Force exerting projections on the dam engage the interior side surface of the jacket and forcibly hold the inner side of the dam structure in sealing engagement with the tank. The projections also hold an outer side peripheral lip of the dam in a an outwardly and resiliently deflected orientation in which it is sealingly pressed inwardly against the outer side surface of the jacket around the periphery of the opening therein to prevent injected foam from being forced outwardly through the jacket opening.

Water heater electrical enclosure insert/foam dam

A foam dam in the insulation cavity of an electric water heater comprises a plastic bag into which liquid foam insulation is injected, the bag having an essentially closed top edge portion with only a small opening for receiving the injected insulation. A small portion of the insulation injected into the bag is forced outwardly therefrom via small metering holes to form external protrusions on the bag that mechanically interlock with a second batch of insulation subsequently injected into the cavity and prevent the hardened second insulation batch from pulling away from the bag. The substantially closed top edge of the bag permits the insulation injected into the bag to pack therein and increase the top-to-bottom hardened foam density uniformity. Side edges of the bag may be pleated to increase the sealing area of the foam dam.

Water heater apparatus and associated manufacturing and insulation methods

Convective heat traps are installed at the cold water inlet and hot water outlet of a water heater. Each heat trap has a tubular body with two axially spaced apart resilient flapper members transversely extending across the interior of the body and being hinged on opposite sides thereof. The heat trap at the cold water inlet is coaxially disposed within a dip tube. In one alternate structure, flapper members are mounted directly on the dip tube, and in another alternate structure an external annular seal element is mounted on the dip tube or heat trap body, with a flapper member being integrally formed with the seal element.

Water heater heat trap apparatus

A water heater is provided with a specially designed molded bottom pad/foam dam member formed from a crushable material, such as polystyrene, which is received in a metal bottom pan and has concentric circular grooves formed in its top side to receive circular bottom end edge portions of the tank and outer jacket portions of the water heater. A circumferentially spaced plurality of rigid support members are imbedded in the bottom pad/foam dam member and underlie its tank groove to prevent the tank from crushing the member one of the support members is formed from an electrically conductive material and defines an electrical grounding path between the tank and the bottom pan, and the other support members are formed from a thermally insulative material to inhibit heat loss from the tank to the bottom pan.

Water heater bottom pad/foam dam apparatus with integrated tank support members

An electric water heater has upper and lower electric resistance type heating elements respectively controlled by a single pole, double throw upper thermostat and a single pole, single throw lower thermostat. The upper and lower thermostats are operatively interconnected by a wiring harness having outer wire end portions that may be connected in various orientations to the terminal block portion of an external junction box to provide the water heater with a variety of heating element operating modes without having to replace either of the thermostats or vary the wiring harness interconnections therebetween. The water heater may thus be advantageously manufactured in a single variant that may be easily and quickly modified in the field to selectively alter the heating element control mode of the water heater.

Field conversion electric water heater

An electric water heater is provided with simplified phase conversion apparatus including a terminal structure having replaceable line lug portions which are wired to a single phase row of multi-pin connector sockets by single phase routing circuitry, and to a three phase row of multi-pin connector sockets by three phase routing circuitry. Electrical supply wires from sets of fuse holders connected to multiple thermostat/heating element sets are grouped and connected to associated multi-pin connector plugs. To ready the water heater for single phase operation, the plugs are connected to the single phase row of sockets, and to convert the water heater to three phase operation the plugs are simply disconnected from the single phase sockets and connected to the three phase sockets. In this manner the necessity of individually repositioning all of the fuse holder wires on the terminal structure to change from single to three phase operation, or vice versa, is eliminated.

Electric water heater with simplified phase conversion apparatus

A fuel-fired water heater has a series of control and operating components which, with electrical power being supplied to the water heater circuitry via a power switch, are electrically actuatable in a predetermined sequence to supply combustion heat to water contained in a tank portion of the water heater to return the temperature of the water to a heated setpoint temperature in response to the water temperature falling below such setpoint temperature. LED diagnostic indicating lights are wired into the water heater circuitry in a manner such that each indicating light is associated with a different one of the electrically coupled components. As the components are sequentially actuated during a water heating cycle, the LED lights are successively illuminated. If one of the components malfunctions during such heating cycle, one or more of the indicating lights remains unilluminated, with the last illuminated light being indicative of the last component in the sequence which functioned properly, thereby facilitating the ready identification of the component which malfunctioned. The LED indicating lights are supported in a single row on a housing-mounted circuit board to which electrical indicating light leads from the water heater control circuit are connected. One of the LED lights is a power indicating light and, like the other indicating lights, has a resistor in an electrical trace leading to the light. The power indicating light and its associated resistor are physically isolated from the other indicating lights and their associated resistors by an interior housing barrier wall.

Growing community of inventors

Millbrook, AL, United States of America

David L Henderson