US20250334296A1

US20250334296A1 - Blower assembly for heat pump water heater system

Info

Publication number: US20250334296A1
Application number: US19/192,879
Authority: US
Inventors: Jeevan Gnana Robinson; Abhishek Sharma; Saigeetha Padiri; Jeffrey C. Hutson; Chirag Sureshbhai Patel; Michael Braun; Steven A. Trimble
Original assignee: Regal Beloit America Inc
Current assignee: Regal Beloit America Inc
Priority date: 2024-04-30
Filing date: 2025-04-29
Publication date: 2025-10-30
Also published as: DE102025116524A1

Abstract

A blower assembly for a water heater includes a blower inlet shroud having an inlet opening and an outlet opening and a scroll housing defining an outer surface, an outlet, and a spiral feature. The scroll housing and the blower inlet shroud are connected to each other and define an inner volume. The blower inlet shroud outlet opening is fluidly connected to the scroll housing inner volume. The blower assembly further includes an impeller wheel positioned within the inner volume defined by the blower inlet shroud and the scroll housing. The impeller wheel is configured to move a fluid from the blower inlet shroud inlet opening to the scroll housing outlet opening.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent Application No. 63/640,656, filed Apr. 30, 2024, titled Blower Assembly for Heat Pump Water Heater System, and naming Steve Trimble et al. as inventors, the contents of which are hereby incorporated herein by reference.

FIELD OF THE DISCLOSURE

The invention described herein is directed to a water heater system and, more particularly, a heat pump water heater system including an advantageous blower assembly.

BACKGROUND OF THE DISCLOSURE

The water heater system utilizes an evaporator coil to extract heat from a heat pump system and transfer the heat to the fluid inside a tank. An axial fan is positioned at the coil such that ambient air is pushed/pulled through the coil and subsequently directed into HVAC (heating ventilation and air cooling) ducting. The cooled air may then be circulated in the ambient atmosphere or the surrounding space. The heat pump system, the coil, and the axial fan are commonly placed within an enclosure having a base, a shroud, and a lid. The base is positioned in proximity to a top surface of the tank. Traditional blower assemblies for the water heater system lack adjustability that can impact the functionality and efficiency of the water heater system. Therefore, a need exists to modify the blower assembly functionality and control to increase performance, efficiency, and reduce noise.
This background section is intended to introduce the reader to various aspects of art that may be related to various aspects of the present disclosure, which are described and/or claimed below. This discussion is believed to be helpful in providing the reader with supporting information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it should be understood that these statements are to be read in this light, and not as admissions of prior art.

SUMMARY OF THE DISCLOSURE

The exemplary embodiments disclosed herein describe a water heater system including an advantageous blower assembly.
In one embodiment, a blower assembly for a water heater is provided. The blower assembly includes a blower inlet shroud having an inlet opening and an outlet opening and a scroll housing defining an outer surface, an outlet, and a spiral feature. The scroll housing and the blower inlet shroud are connected to each other and define an inner volume. The blower inlet shroud outlet opening is fluidly connected to the scroll housing inner volume. The blower assembly further includes an impeller wheel positioned within the inner volume defined by the blower inlet shroud and the scroll housing. The impeller wheel is configured to move a fluid from the blower inlet shroud inlet opening to the scroll housing outlet opening.
In another embodiment, a water heater system is provided. The water heater system includes a body including a water storage tank and a heat pump system connected to the body and in thermal connection with the water storage tank. The water heater system further includes a blower assembly including a blower inlet shroud having an inlet opening and an outlet opening and a scroll housing defining an outer surface, an outlet, and a spiral feature. The scroll housing and the blower inlet shroud are connected to each other and define an inner volume. The blower inlet shroud outlet opening is fluidly connected to the scroll housing inner volume. The water heater system further includes an impeller wheel positioned within the inner volume defined by the blower inlet shroud and the scroll housing. The impeller wheel is configured to move a fluid from the blower inlet shroud inlet opening to the scroll housing outlet opening.
As used herein, “a”, “an”, and “the” refer to both singular and plural referents unless the context clearly dictates otherwise.
As used herein, the term “about” refers to a measurable value such as a parameter, an amount, a temporal duration, and the like and is meant to include variations of +/−15% or less, preferably variations of +/−10% or less, more preferably variations of +/−5% or less, even more preferably variations of +/−1% or less, and still more preferably variations of +/−0.1% or less of and from the particularly recited value, in so far as such variations are appropriate to perform in the invention described herein. Furthermore, it is also to be understood that the value to which the modifier “about” refers is itself specifically disclosed herein.
As used herein, spatially relative terms, such as “beneath”, “below”, “lower”, “above”, “upper”, “front”, “back”, “side”, “left”, “right”, “rear”, “top”, “bottom”, and the like, are used for ease of description to describe one element or feature's relationship to another element(s) or feature(s). It is further understood that the terms “front”, “back”, “left”, and “right” are not intended to be limiting and are intended to be interchangeable, where appropriate. Further, it should be noted that the terms “first,” “second,” and the like herein do not denote any order, quantity, or relative importance, but rather are used to distinguish one element from another.
As used herein, the terms “comprise(s)”, “comprising”, and the like, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
As used herein, the terms “configure(s)”, “configuring”, and the like, refer to the capability of a component and/or assembly, but do not preclude the presence or addition of other capabilities, features, components, elements, operations, and any combinations thereof.
All ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other. Each range disclosed herein constitutes a disclosure of any point or sub-range lying within the disclosed range.
All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”), is intended merely to better illustrate the invention and does not pose a limitation on the scope of the invention or any embodiments unless otherwise claimed.
Any combination or permutation of features, functions, and/or embodiments as disclosed herein is envisioned. Additional advantageous features, functions, and applications of the disclosed systems, methods, and assemblies of the present disclosure will be apparent from the description which follows, particularly when read in conjunction with the appended figures. All references listed in this disclosure are hereby incorporated by reference in their entireties.

BRIEF DESCRIPTION OF THE DRAWINGS

Features and aspects of embodiments are described below with reference to the accompanying drawings, in which elements are not necessarily depicted to scale. Corresponding reference characters indicate corresponding parts throughout the several views of the drawings. It is to be noted that the various features, steps and combinations of features/steps described below and illustrated in the figures can be arranged and organized differently to result in embodiments which are still within the scope of the present disclosure.

To assist those of ordinary skill in the art in making and using the disclosed assemblies and systems, reference is made to the appended figures, wherein:

FIG. 1 depicts a perspective view of a partial water heater system including a blower assembly, according to the present disclosure;

FIG. 2 depicts a rear perspective view of the blower assembly of FIG. 1 , according to the present disclosure;

FIG. 3 depicts a front perspective view of the blower assembly of FIG. 2 , according to the present disclosure;

FIG. 4 depicts a rear side view of the blower assembly of FIG. 2 , according to the present disclosure;

FIG. 5 depicts a cross-sectional view of the blower assembly of FIG. 4 taken along line A-A;

FIG. 6 depicts an exploded perspective view of the blower assembly of FIG. 2 , according to the present disclosure;

FIG. 7 depicts a front perspective view of a blower inlet shroud included in the blower assembly of FIG. 2 , according to the present disclosure;

FIG. 8 depicts a rear perspective view of the blower inlet shroud of FIG. 7 , according to the present disclosure;

FIG. 9 depicts a side view of the blower inlet shroud of FIG. 7 , according to the present disclosure;

FIG. 10 depicts a detailed view of the blower inlet shroud of FIG. 9 taken within box A;

FIG. 11 depicts a rear perspective view of a scroll housing included in the blower assembly of FIG. 2 , according to the present disclosure;

FIG. 12 depicts a front perspective view of the scroll housing of FIG. 11 , according to the present disclosure;

FIG. 13 depicts an outlet side view of the scroll housing of FIG. 11 , according to the present disclosure;

FIG. 14A depicts a cross sectional view of the scroll housing of FIG. 13 , according to the present disclosure;

FIG. 14B depicts a detailed cross sectional view of the scroll housing and the impeller wheel of FIG. 14A;

FIG. 15 depicts a perspective view of an impeller wheel included in the blower assembly of FIG. 2 , according to the present disclosure;

FIG. 16 depicts a front view of the impeller wheel of FIG. 15 , according to the present disclosure;

FIG. 17 depicts a side view of the impeller wheel of FIG. 15 , according to the present disclosure;

FIG. 18 depicts a cross-sectional view of the impeller wheel of FIG. 16 taken along line B-B;

FIG. 19 depicts a detailed view of the impeller wheel of FIG. 18 taken within box B;

FIG. 20A depicts a perspective view of a fan blade included within the impeller wheel of FIG. 15 , according to the present disclosure;

FIG. 20B depicts a front view of the fan blade shown in FIG. 20A;

FIG. 20C depicts a back view of the fan blade shown in FIG. 20A;

FIG. 20D depicts a top view of the fan blade shown in FIG. 20A;

FIG. 21A depicts a side view of a dimensioned fan blade according to the fan blade of FIG. 20A;

FIG. 21B depicts a side view of a dimensioned fan blade according to the fan blade of FIG. 20A;

FIG. 22A depicts a perspective view of an alternative impeller wheel including raised portions, according to the present disclosure;

FIG. 22B depicts a detailed perspective view of the impeller wheel of FIG. 22A;

FIG. 23 depicts a side view of a dimensioned impeller wheel according to the impeller wheel of FIGS. 22A and 22B;

FIG. 24A depicts a perspective view of an alternative impeller wheel including raised portions, according to the present disclosure;

FIG. 24B depicts a detailed perspective view of the impeller wheel of FIG. 24A;

FIG. 25 depicts a side view of a dimensioned impeller wheel according to the impeller wheel of FIGS. 24A and 24B;

FIG. 26 depicts a perspective view of an alternative impeller wheel including a plurality of slots, according to the present disclosure;

FIG. 27 illustrates a graph of the static pressure vs flow of the blower assembly of FIGS. 2-6 including the impeller wheel of FIG. 26 , where the pressure rise (inches×H₂ 0) is depicted along the Y-axis and the flow (CFM) is depicted along the X-axis;

FIG. 28 depicts a perspective view of an alternative impeller wheel including a plurality of openings, according to the present disclosure;

FIG. 29A depicts a front perspective view of an adapter included within the blower assembly of FIGS. 5 and 6 ;

FIG. 29B depicts a rear perspective view of the adapter of FIG. 29A;

FIG. 30A depicts a perspective view of an alternative impeller wheel including an opening for the adapter of FIG. 29A, according to the present disclosure;

FIG. 30B depicts a detailed view of the impeller wheel of FIG. 30A;

FIG. 31A depicts a front perspective view of an alternative adapter;

FIG. 31B depicts a rear perspective view of the adapter of FIG. 31A;

FIG. 31C depicts a cross-sectional view of the adapter of FIGS. 31A and 31B;

FIG. 32 depicts a cross-sectional view of an alternative impeller wheel including an opening for the adapter of FIG. 31A, according to the present disclosure;

FIG. 33 illustrates a graph of the pressure rise vs flow of three blower assemblies, including the blower assembly of FIGS. 2-6 , where the pressure rise (inches×H₂ 0) is depicted along the Y-axis and the flow (CFM) is depicted along the X-axis;

FIG. 34 illustrates a graph of the power output vs flow of three blower assemblies, including the blower assembly of FIGS. 2-6 , where the power output (watts) is depicted along the Y-axis and the flow (CFM) is depicted along the X-axis;

DETAILED DESCRIPTION OF THE DISCLOSURE

The present disclosure describes a water heater system and, more particularly, a heat pump water heater system including an advantageous blower assembly. Referring to FIG. 1 , a water heater system 10 includes a heat pump system 14. In some embodiments, water heater system 10 includes a heating element (not shown). Water heater system 10 includes a body (not shown) that at least partially includes a storage tank for holding a fluid (e.g., water). Heat pump system 14 is in thermal connection with the storage tank (not shown) of water heater system 10. For example, heat pump system 14 is in thermal connection with water within the storage tank (not shown) of water heater system 10.
Water heater system 10 includes a blower assembly 100 configured to transfer the heat from heat pump system 14 to the fluid inside the storage tank (not shown). Referring to FIGS. 2-6 , an advantageous blower assembly 100 includes a scroll housing 102 and an inlet component, or blower inlet shroud, 104. Scroll housing 102 and blower inlet shroud 104 are positioned relative to each other to define an inner volume, or volute, 106 (FIG. 5 ). Scroll housing 102 and blower inlet shroud 104 are coupled with respect to each other. In some instances, scroll housing 102 and blower inlet shroud 104 are removably coupled with respect to each other. Inner volume 106 is defined by at least a plate 108 of blower inlet shroud 104 and a cavity 122 (FIG. 12 ) of scroll housing 102. Inner volume 106 is sized and shaped to receive one or more components of blower assembly 100, including, for example, an impeller wheel 202.
Blower assembly 100 is configured to draw a fluid (e.g., air) into inner volume 106 through an outlet opening 110 of blower inlet shroud 104, an inlet opening 107 of blower assembly 100 and out outlet opening 128 of scroll housing 102. Referring to FIG. 5 , arrow A indicates the airflow entering blower assembly 100 through outlet opening 110 of blower inlet shroud 104 and leaving blower assembly 100 through outlet opening 128 of scroll housing 102. Impeller wheel 202 is positioned in axial alignment relative to outlet opening 110, as identified by axis C. Impeller wheel 202 is rotatably coupled to a motor 204 that is coupled to housing 102, either directly or indirectly. Impeller wheel 202 rotates about axis C to draw the fluid from inlet 107 of blower assembly 100 in the direction of arrow A and to move the fluid to scroll housing outlet opening 128 in the direction of arrow B.
It should be understood that modifications may be made to the various components of blower assembly 100 without departing from the spirit/scope of this disclosure. The individual components will be discussed in more detail below.
Referring to FIGS. 7-10 , blower inlet shroud plate 108 defines outlet opening 110 that opens to inner volume 106 of blower assembly 100. Plate 108 may be sized and shaped to engage with scroll housing 102 and may include features/components that limit fluid leakage from inner volume 106. Blower inlet shroud 104 defines mounting features 109 (FIGS. 3 and 8 ) that are positioned relative to plate 108 and sized and shaped to engage with mounting features 111 (FIG. 4 ) of scroll housing 102. Mounting features 109 are spaced around blower inlet shroud plate 108.
Blower inlet shroud 104 includes an entrance portion 112 that extends in a direction away from surface 108. Entrance portion 112 includes an upper edge 114 positioned opposite from outlet opening 110. Entrance portion 112 is configured to direct a fluid (e.g., air) through outlet opening 110 and into inlet opening 107. Outlet opening 110 may be centered with respect to Entrance portion 112 (FIG. 5 ). The shape and size of entrance portion 112 impacts the quality of flow, including but not limited to, increasing air flow, reducing turbulence, reducing noise and/or reducing air recirculation. Entrance portion 112 includes one or more side walls 116. The number of side walls 116 may depend, in part, on the shape of entrance opening 112.
Side walls 116 of entrance opening 112 may be angled, curved, or partially angled and partially curved. Upper edge 114 may define at least a portion of the shape of entrance portion 112. Inlet opening 110 may be circular, quadrilateral, triangular, and combinations thereof.
Outlet opening 110 of blower inlet shroud 104 may have a diameter that is in the range of about 5.5 inches to about 7.5 inches. However, alternative diameter sizes may be selected without departing from the spirit/scope of this disclosure. Scroll housing 102 of blower assembly 100 defines an outer surface 121 (FIG. 11 ) that is opposite from cavity 122 (FIG. 12 ). Outer surface 121 may be sized and shaped to resemble cavity 122. An opening 124 extends between outer surface 121 and cavity 122 of scroll housing 102. Opening 124 may be sized and shaped to interface with motor 204 (FIGS. 4-6 ). Motor 204 may extend at least partially into cavity 122 from outer surface 121. Scroll housing 102 includes mounting features (not shown) that are positioned in proximity to opening 124. The mounting features may be configured to couple motor 204 with scroll housing 102.
Scroll housing 102 defines a flange 130 that extends outwardly therefrom. Flange 130 may extend at least partially around a perimeter of scroll housing 102 (FIG. 12 ). Flange 130 defines mounting features 111 that are positioned at various points around the flange 130 and are configured to engage with mounting features 109 of blower inlet shroud 104.
Scroll housing 102 may include various rib features 126, 127 that create a web-like configuration relative to outer surface 121. Rib feature 126 is positioned perpendicular relative to opening 124 and, in some cases, extends to flange 130. Rib feature 127 is positioned axial with opening 124 at various distances from opening 124. Rib features 126, 127 provide support to scroll housing 102
Cavity 122 of scroll housing 102 defines a spiral feature 131 that is fluidly coupled to an outlet feature 132. Cavity 122 of scroll housing 102 transitions from spiral feature 131 to outlet feature 132 (FIGS. 12 and 14A). Outlet feature 132 is positioned in proximity to outlet opening 128 such that fluid flows through outlet feature 132 and out outlet opening 128.
Outlet feature 132 is sized and shaped to exhaust fluid from inner volume 106 of blower assembly 100 so as to improve airflow therethrough. In some embodiments, outlet feature 132 may define a cross-section that is at least partially rectangular. The cross-section of outlet feature 132 may include radiused features to reduce (or eliminate) sharp corners. Cavity 122, including spiral feature 131 and outlet feature 132, are sized and shaped to exhaust airflow with reduced turbulence, reduced recirculation, and/or reduced exhaust noise. Spiral feature 131 and/or outlet feature 132 define radiused portions 133 in proximity to a sidewall 134 of cavity 122. Radiused portions 133 may assist with directing the airflow smoothly by reducing turbulence. A reduction in turbulence may reduce the noise within scroll housing 102 during operation.
Spiral feature 131 and outlet feature 132 are sized and shaped to at least surround impeller wheel 202 (FIG. 14A). As depicted in FIGS. 14A and 14B, the distance between sidewall 134 of cavity 122 and sidewall 206 of impeller wheel 202 varies at different locations along the length of spiral feature 131 and outlet feature 132. For example, a neck portion 136 is a position where spiral feature 131 and outlet feature 132 meet. At neck portion 136, the distance D1 between sidewall 206 of impeller wheel 202 and sidewall 134 of cavity 122 may be one of the narrowest within the scroll housing 102 and along spiral feature 131. In one embodiment, distance D1 is the narrowest, or smallest, within scroll housing 102. The distance D1 may be between about 0.10 inches to about 0.40 inches. The distance D1 between sidewall 206 of impeller wheel 202 and sidewall 134 of cavity 122 may improve pressure within blower assembly 100 and reduce noise without affecting performance. The angle X1 of neck portion 136 shown in FIG. 14B may be between about 77 degrees and about 87 degrees. The angle X1 of neck portion 136 may improve pressure and reduce turbulence and recirculation of the airflow within blower assembly 100.
Outlet opening 128 of scroll housing 102 is sized and shaped to provide at least a smooth transition as the fluid is exhausted from cavity 122. For example, outlet opening 128 may provide at least a smooth transition from outlet feature 132. Outlet opening 128 may define a shape that is oval, quadrilateral, square with fillet corners, rectangular with fillet corners, hexagon, octagon, circular, and combinations thereof. Outlet feature 132 may taper to outlet opening 128 that has a diameter of about 6 inches to about 10 inches. Referring to FIG. 13 , outlet opening 128 is flared such that the opening is larger than the cross-sectional area of outlet feature 132. Outlet feature 132 and the outlet opening 128 define flared portions 138A, 138B, 138C, 138D that transition the cross-sectional area of outlet feature 132 to the cross-sectional area of outlet opening 128. For example, outlet feature 132 may define a cross-sectional shape that is at least partially rectangular. Flared portions 138A, 138B, 138C, 138D may provide a smooth transition as the fluid is exhausted from cavity 122, through the rectangularly-shaped outlet feature 132, and through outlet opening 128. Flared portions 138A, 138B, 138C, 138D may each be similarly-sized, differently-sized, or some may be similarly-sized and some may be differently-sized. Flared portions 138A, 138B, 138C, 138D may provide a smooth transition from cavity 122 to outlet opening 128 so as to reduce turbulence, thereby lowering the noise and improving the efficiency of blower assembly 100. Outlet opening 128 may define a first dimension measured between flared portions 138A and 138C that is in the range of about 5.0 inches to about 8.0 inches. Outlet opening 128 may define a second dimension that is measured between flared portions 138B and 138D that is in the range of about 1.0 inches to about 8.0 inches.
Referring to FIGS. 15-19 , impeller wheel 202 includes a base 208, an upper ring 210 and a plurality of fan blades 212 coupled between base 208 and upper ring 210. Upper ring 210 is positioned opposite base 208. The outer portions of base 208, upper ring 210, and the plurality of fan blades 212 define sidewall 206 of impeller wheel 202. Impeller wheel 202 includes the axis C which extends through the center between base 208 and upper ring 210. Impeller wheel 202 defines an opening 213 which is axial to the axis C. Opening 213 may be sized to receive a shaft, or the like, that is coupled motor 204. Referring to FIG. 17 , impeller wheel 202 may have a diameter D2 that is between about 7 inches to about 10 inches. The distance D3 between upper ring 210 and the base 208 may be between about 3 inches and about 4 inches.
Referring to FIGS. 15, 16, and 18 , base 208 defines a dome feature 214 that extends in the direction of upper ring 210. Dome feature 214 is concentric with sidewall 206 such that the axis C extends through the center of dome feature 214. Dome feature 214 may direct the airflow smoothly toward the plurality of fan blades 212. The shape of dome feature 214 may provide the airflow to move in a laminar nature thereby reducing the noise of the airflow. Referring to the cross-section of impeller wheel 202 (FIG. 18 ), dome feature 214 may define a shape that is partially semicircular or entirely semicircular. If partially semicircular, the cross-section of dome feature 214 may include one or more curves.
For example, referring to FIG. 19 , the cross-sectional shape of dome feature 214 may include about three (3) to about (7) distinct points, which in part, define the shape of dome feature 214. However, it should be understood that more points may be used, thereby producing, in some cases, a more detailed shape. In other instances, less points may be used.
Beginning with a first point 215A, which is positioned closest to the axis C, first point 215A has a horizontal dimension A3 from the axis C of about 0.72 inches to about 1.08 inches and a vertical dimension A4 from an offset of about 0.125 inches from dome 214, the vertical dimension A4 is about 0.20 inches to about 0.30 inches. For example, the horizontal dimension A3 of first point 215A may be about 0.90 inches and the vertical dimension A4 of first point 215A may be about 0.25 inches. A second point 215B, which is horizontally further from the axis C than first point 215A, has a horizontal dimension B3 from the axis C of about 1.5 inches to about 1.75 inches and a vertical dimension B4 from dome 214 of about 0.68 inches to about 1.02 inches. For example, the horizontal dimension B3 of second point 215B may be about 1.65 inches and the vertical dimension B4 of second point 215B may be about 0.85 inches. A third point 215C, which is horizontally further from the axis C than second point 215B, has a horizontal dimension C3 from the axis C of about 1.56 inches to about 2.34 inches and a vertical dimension C4 from dome 214 of about 1.08 inches to about 1.62 inches. For example, the horizontal dimension C3 of third point 215C may be about 1.95 inches and the vertical dimension C4 of third point 215C may be about 1.35 inches. A fourth point 215D, which is horizontally further from the axis C than third point 215C, has a horizontal dimension D3 from the axis C of about 1.96 inches to about 2.94 inches. Fourth point 215D may be situated in proximity to an inner surface of base 208. For example, the horizontal dimension D3 of fourth point 215D may be about 2.45 inches. A fifth point 215E, which is horizontally further from the axis C than fourth point 215D, has a horizontal dimension E3 from the axis C of about 2 inches to about 3 inches. Fifth point 215E may be situated in proximity to an outer surface of base 208. For example, the horizontal dimension E3 of fifth point 215E may be about 2.5 inches. The linear distance L1 between fourth point 215D and a sixth point 215F may be about 0.10 inches. The thickness T1 of dome feature 214 may be about 0.13 inches.
Fan blades 212 of impeller wheel 202 include a first surface 216 and an oppositely positioned second surface 218. Fan blades 212 include a first end 220 that extends between first and second surfaces 216, 218. Fan blades 212 include a second end 222 that is opposite from first end 220. In some instances, fan blades 212 may have a cross-sectional shape that is rectangular such that first and second surfaces 216, 218 are substantially parallel. In some instances and as depicted in FIGS. 20A-20D, first and second surfaces 216, 218 may each define a curve that extends between first end 220 and second end 222. Second end 222 is radiused and connects first surface 216 to second surface 218. Each fan blade 212 may have a cross-sectional shape that resembles an airfoil shape.
FIGS. 21A and 21B depict an advantageous fan blade 212 shape and design. The draft angle G1 of each fan blade 212 may be between about 0 degrees to about 5 degrees. However, it should be understood that the draft angle may vary depending on the number of fan blades 212. For example, the draft angle G1 may be greater when impeller wheel 202 includes fewer fan blades 212 and the draft angle G1 may be narrower when impeller wheel 202 includes more fan blades 212. The angle of attack G2 of each fan blade 212 may be between about 12 degrees to about 22 degrees. For example, the angle of attack G2 of each fan blade 212 may be between about 15 degrees to about 21 degrees. In a non-limiting example, the angle of attack G2 of each fan blade 212 is about 17 degrees. The diameter of first surface 216 may be between about 7 inches to about 11 inches. The diameter of second surface 218 may be between about 4.5 inches to about 8.5 inches. The sweeping direction diameter of each fan blade 212 may be between about 5.0 inches and about 7.0 inches. In a non-limiting example, angle G3-of each fan blade 212 is between about 0.25 degrees to about 1.5 degrees. In a non-limiting example, the angle G3 of each fan blade 212 is about 0.28 degrees. First surface 216 may define a radius R2 in proximity to second end 222 that is about 0.39 inches. Second surface 218 may define a radius R3 in proximity to second end 222 that is about 0.79 inches.
First and second surfaces 216, 218 are defined by three (3) or more points that extend along the length of first and second surfaces 216, 218 between first end 220 and second end 222. Measured from second end 222, a first point 217A along first surface 216, and a first point 219A along second surface 218 have a horizontal distance A5 of about 0.47 inches to about 0.70 inches. For example, the horizontal distance A5 of first points 217A, 219A may be about 0.59 inches. The distance A6 between first point 217A along first surface 216, and a first point 219A along second surface 218 may be about 0.08 inches to about 0.12 inches. For example, the distance A6 between first points 217A, 219A may be about 0.10 inches. A second point 217B along first surface 216, and a second point 219B along second surface 218, which are further away from second end 222 than first points 217A, 219A, may have a horizontal distance B5 of about 0.72 inches to about 1.09 inches. For example, the horizontal distance B5 of second points 217B, 219B may be about 0.91 inches. The distance B6 between second point 217B along first surface 216, and second point 219B along second surface 218 may be about 0.064 inches to about 0.096 inches. For example, the distance B6 between second points 217B, 219B may be about 0.08 inches. A third point 217C along first surface 216, and a third point 219C along second surface 218, which are further away from second end 222 than second points 217B, 219B, may have a horizontal distance C5 of about 1.04 inches to about 1.56 inches. For example, the horizontal distance C5 of third points 217C, 219C may be about 1.30 inches. The distance C6 between third point 217C along first surface 216, and third point 219C along second surface 218 may be about 0.048 inches to about 0.072 inches. For example, the distance C6 between third points 217C, 219C may be about 0.06 inches. A fourth point 217D along the first surface 216 and in proximity to first end 220, and a fourth point 219D along second surface 218 and in proximity to first end 220, which are further away from second end 222 than third points 217C, 219C, may have a horizontal distance D5 of about 1.13 inches to about 1.70 inches. For example, the horizontal distance D5 of fourth points 217D, 219D may be about 1.42 inches. The distance D6 between fourth point 217D along first surface 216, and fourth point 219D along second surface 218 may be about 0.04 inches to about 0.06 inches. For example, the distance D6 between fourth points 217D, 219D may be about 0.05 inches.
The number of fan blades 212 may depend on the size (e.g., diameter) of impeller wheel 202, or on one or more performance characteristics (e.g., static pressure, adjustment in cubic feet per minute (CFM), power consumption, noise level, and revolutions per minute (RPM)) required by blower assembly 100 of water heater assembly 10, and combinations thereof. In some embodiments, impeller wheel 202 may include about 41 fan blades 212. In other embodiments, impeller wheel 202 may include about 50 fan blades 212. In some embodiments, impeller wheel 202 may include between about 47 fan blades 212 to about 53 fan blades 212.
FIGS. 22A-23 illustrate an impeller wheel 302 that is a different embodiment of impeller wheel 202, as shown and described with respect to FIGS. 15-20 . Impeller wheel 302 includes features/components previously described with regard to impeller wheel 202. Thus, like parts/features will be numbered the same throughout the various embodiments. The features described with respect to one embodiment may apply to the other embodiments unless expressly stated otherwise.
Referring to FIGS. 22A and 22B, impeller wheel 302 includes a base 208, an upper ring 310 and a plurality of fan blades 212 coupled between base 208 and upper ring 310. Upper ring 310 is positioned opposite base 208. The outer portions of base 208, upper ring 310, and the plurality of fan blades 212 define sidewall 206 of impeller wheel 302. Impeller wheel 302 includes the axis C which extends through the center between base 208 and upper ring 310.
Upper ring 310 of impeller wheel 302 includes a plurality of raised portions 312 spaced around at least a portion of the circumference of upper ring 310. In one embodiment, upper ring 310 includes raised portions 312 spaced around the entirety of the circumference of upper ring 310. Raised portions 312 are spaced from each other and separated by a plurality of recessed portions including a first recessed portion 314 and a second recessed portion 316. In some embodiments, each fan blade 212 is spaced from an adjacent fan blade 212 by a pair of raised portions 312, including a first raised portion 312A and a second raised portion 312B. It should be understood that first and second raised portions 312A, 312B may be collectively referred to as reference number 312 and distinguishing between the two raised portions 312 enables a more thorough explanation of impeller wheel 302. It does not, however, inherently indicate differences between the two raised portions 312, unless otherwise expressly stated. The pair of raised portions 312 may include a pair of raised portions 312A, a pair of raised portions 312B, or a pair that includes the raised portion 312A and the raised portion 312B. In other embodiments, more or less raised portions 312A, 312B may be positioned relative to each fan blade 212.
Raised portions 312 are positioned on a first surface 311 of upper ring 310. As depicted, first surface 311 is a top surface of upper ring 310. Although depicted on top surface 311 of upper ring 310, raised portions 312 may be situated on a different surface of upper ring 310 (e.g., side surface, bottom surface). Raised portions 312 may be angled relative to sidewall 206 of impeller wheel 302. For example, raised portions 312 may not be perpendicular relative to sidewall 206 of impeller wheel 302. Upper ring 310 defines an outside surface 310A that is positioned proximate to sidewall 206 and an inside surface 310B positioned opposite from outside surface 310A. In some instances, outside surface 310A of upper ring 310 has a radius extending from the axis C that is equal to the radius of sidewall 206. In other instances, outside surface 310A has a radius extending from the axis C that is shorter or longer than the radius of sidewall 206. Raised portions 312 may extend at least between outside surface 310A and inside surface 310B of upper ring 310. In other instances, raised portions 312 extend beyond at least one of outside surface 310A and/or inside surface 310B of upper ring 310. In other instances, raised portions 312 extend a distance between outside surface 310A and/or inside surface 310B.
In some instances, raised portion 312A and raised portion 312B may be similarly sized and shaped. In other instances, raised portion 312A and raised portion 312B may be differently sized and shaped. Raised portions 312 define a first recessed portion 314 and a second recessed portion 316. Therefore, the size and shape of recessed portions 314, 316 may resemble the periphery of raised portions 312A, 312B. For example, a portion of the periphery of first raised portion 312A and a portion of the periphery of second raised portion 312B may define, at least in part, the size and shape of first recessed portion 314. A portion of the periphery of first raised portion 312A and a portion of the periphery of second raised portion 312B may define, at least in part, the size and shape of second recessed portion 316.
In operation, as airflow travels through recessed portions 314, 316, recessed portions 314, 316 create a disruption to the airflow. The disruption to the airflow reduces the noise emitted by blower assembly 100. In some instances, recessed portions 314, 316 have reduced the overall surface acoustic sound level of blower assembly 100 by about 4 percent.
In a non-limiting example, FIG. 23 depicts dimensions of the recessed portions 314, 316. As noted above, raised portions 312 define first recessed portion 314 and second recessed portion 316. For example, first raised portion 312A having a first side 318 defines a first side of first recessed portion 314 and second raised portion 312B having a second side 320 defines a second side of first recessed portion 314. The distance W1 between first side 318 of first raised portion 312A and second side 320 of second raised portion 312B in proximity to outside surface 310A of upper ring 310 may be about 0.10 inches to about 0.16 inches. For example, the distance W1 may be about 0.13 inches. The distance W2 between first side 318 of first raised portion 312A and second side 320 of second raised portion 312B in proximity to inside surface 310B of upper ring 310 may be about 0.16 inches to about 0.24 inches. For example, the distance W1 may be about 0.20 inches.
Second raised portion 312B having a first side 322 defines a first side of second recessed portion 316 and first raised portion 312A having a second side 324 defines a second side of second recessed portion 316. The distance W3 between first side 322 of second raised portion 312B and second side 324 of first raised portion 312A in proximity to outside surface 310A of upper ring 310 may be about 0.10 inches to about 0.16 inches. For example, the distance W3 may be about 0.13 inches. The distance W4 between first side 322 of second raised portion 312B and second side 324 of first raised portion 312A in proximity to inside surface 310B of upper ring 310 may be about 0.16 inches to about 0.24 inches. For example, the distance W4 may be about 0.20 inches.
FIGS. 24A-25 illustrate an impeller wheel 402 that is an alternative embodiment of impeller wheel 202, as shown and described with respect to FIGS. 15-20 , of blower assembly 100, as shown and described with respect to FIGS. 2-6 . Impeller wheel 402 includes features/components previously described with regard to impeller wheel 202. Thus, like parts/features will be numbered the same throughout the various embodiments. The features described with respect to one embodiment may apply to the other embodiments unless expressly stated otherwise.
Referring to FIGS. 24A and 24B, impeller wheel 402 includes a base 208, an upper ring 410 and a plurality of fan blades 212 coupled between base 208 and upper ring 410. Upper ring 410 is positioned opposite base 208. The outer portions of base 208, upper ring 410, and plurality of fan blades 212 define sidewall 206 of impeller wheel 402. Impeller wheel 402 includes the axis C which extends through the center between base 208 and upper ring 410.
Upper ring 410 of impeller wheel 402 includes a plurality of raised portions 412 spaced around at least a portion of the circumference of upper ring 410. In one embodiment, upper ring 410 of impeller wheel 402 includes a plurality of raised portions 412 spaced around the entirety of the circumference of upper ring 410. Raised portions 412 are spaced from adjacent raised portions 412 and separated therefrom by a first recessed portion 414 and a second recessed portion 416. In some instances, each fan blade 212 may be spaced from adjacent fan blades by a pair of raised portions 412, including a first raised portion 412A and a second raised portion 412B. It should be understood that first and second raised portions 412A, 412B may be collectively referred to as reference number 412 and distinguishing between the two raised portions 412 enables a more thorough explanation of the impeller wheel 402. It does not, however, inherently indicate differences between the two raised portions 412, unless otherwise expressly stated. The pair of raised portions 412, may include a pair of raised portions 412A, a pair of raised portions 412B, or a pair that includes raised portion 412A and raised portion 412B. However, more or less raised portions 412 may be positioned relative to each fan blade 212.
Raised portions 412 are positioned on a first surface 411 of upper ring 410. As depicted, first surface 411 is a bottom surface of upper ring 410. Although depicted on bottom surface 411 of upper ring 410, raised portions 412 may be situated on a different surface of upper ring 410 (e.g., side surface, top surface). Raised portions 412 may be angled relative to sidewall 206 of impeller wheel 402. For example, raised portions 412 may not be perpendicular relative to sidewall 206 of impeller wheel 402. Upper ring 410 defines an outside surface 410A positioned proximate sidewall 206 and an inside surface 410B positioned opposite outside surface 410A. In some instances, outside surface 410A of upper ring 410 has a radius extending from the axis C that is equal to the radius of sidewall 206. In other instances, outside surface 410A has a radius extending from the axis C that is shorter or longer than the radius of sidewall 206. Raised portions 412 may extend at least between outside surface 410A and inside surface 410B of upper ring 410. In other embodiments, raised portions 412 extend beyond at least one of outside surface 410A and/or inside surface 410B of upper ring 410. In still other embodiments, raised portion 412 extends a distance between outside surface 410A and/or inside surface 410B of upper ring 410.
In some embodiments, raised portion 412A and raised portion 412B are similarly sized and shaped. In other embodiments, raised portion 412A and raised portion 412B are differently sized and shaped. Raised portions 412 define first recessed portion 414 and second recessed portion 416. Therefore, the size and shape of recessed portions 414, 416 resemble the periphery of raised portions 412A, 412B. For example, a portion of the periphery of first raised portion 412A and a portion of the periphery of second raised portion 412B may define, at least in part, the size and shape of first recessed portion 414. A portion of the periphery of first raised portion 412A and a portion of the periphery of second raised portion 412B may define, at least in part, the size and shape of the second recessed portion 416.
In operation, as airflow travels through recessed portions 414, 416, recessed portions 414, 416 create a disruption to the airflow. The disruption to the airflow reduces the noise emitted by blower assembly 100. In some instances, recessed portions 414, 416 have reduced the overall surface acoustic sound level of blower assembly 100 by about 4 percent.
In a non-limiting example, FIG. 25 depicts dimensions of raised portions 412, 414. As noted above, raised portions 412 define first recessed portion 414 and second recessed portion 416. For example, first raised portion 412A having a first side 418 defines a first side of first recessed portion 414 and second raised portion 412B having a second side 420 defines a second side of first recessed portion 414. The distance W1 between first side 418 of first raised portion 412A and second side 420 of second raised portion 412B in proximity to outside surface 410A of upper ring 410 may be about 0.08 inches to about 0.12 inches. For example, the distance W1 may be about 0.10 inches. The distance W2 between first side 418 of first raised portion 412A and second side 420 of second raised portion 412B in proximity to inside surface 410B of the upper ring 410 may be about 0.12 inches to about 0.18 inches. For example, the distance W1 may be about 0.15 inches.
Second raised portion 412B having a first side 422 defines a first side of second recessed portion 416 and first raised portion 412A having a second side 424 defines a second side of second recessed portion 416. The distance W3 between first side 422 of second raised portion 412B and second side 424 of first raised portion 412A in proximity to outside surface 410A of upper ring 410 may be about 0.08 inches to about 0.12 inches. For example, the distance W3 may be about 0.10 inches. The distance W4 between first side 422 of second raised portion 412B and second side 424 of first raised portion 412A in proximity to inside surface 410B of upper ring 410 may be about 0.12 inches to about 0.18 inches. For example, the distance W4 may be about 0.15 inches.
FIG. 26 illustrates an impeller wheel 502 that is an alternative embodiment of impeller wheel 202, as shown and described with respect to FIGS. 15-20 , of blower assembly 100, as shown and described with respect to FIGS. 2-6 . Impeller wheel 502 includes features/components previously described with regard to impeller wheel 202. Thus, like parts/features will be numbered the same throughout the various embodiments. The features described with respect to one embodiment may apply to the other embodiments unless expressly stated otherwise.
Referring to FIG. 26 , impeller wheel 502 includes a base 508, an upper ring 210 and a plurality of fan blades 212 coupled between base 508 and upper ring 210. Upper ring 210 is positioned opposite base 508. The outer portions of base 208, upper ring 210, and the plurality of fan blades 212 define sidewall 206 of impeller wheel 502. Impeller wheel 502 includes the axis C which extends through the center between base 508 and upper ring 210. Impeller wheel 602 includes an adapter mating feature 752 configured to engage with a corresponding adapter (not shown) coupled to motor 204. Adapter mating feature 752 and the corresponding adapter (FIGS. 29A and 29B) will be discussed in more detail below.
Base 508 of impeller wheel 502 may define a plurality of slots 510 spaced around the axis C. The plurality of slots 510 may be equally spaced around the axis C. The plurality of slots 510 have a curved shaped. However, various elongated shapes may be utilized, for example, rectangles, ovals, straight lines and combinations thereof. The number of slots 510 may be similar to or equal to the number of fan blades 212. In some instances, each fan blade 212 may be spaced from adjacent fan blades 212 by a respective slot 510 of the plurality of slots 510. For example, the number of slots 510 may be equal to the number of fan blades 212. In another example, the number of slots 510 may be greater than the number of fan blades 212.
The impeller wheel 502 including base 508 with plurality of slots 510 may weigh less than a similar impeller wheel having a solid base. In one embodiment, impeller wheel 502 weighs about 10 percent less than a similar impeller wheel with a solid base. By reducing the mass of impeller wheel 502, material may be added (not shown) to a surface (e.g., inside surface) of fan blades 212, as needed, to assist with balancing impeller wheel 502. In addition, removing about 10 percent of the weight of impeller wheel 502 may produce a cost savings.
FIG. 27 illustrates a graph showing the static pressure versus the volume of air moved measured in cubic feet per minute (CFM) for impeller wheel 502 and an impeller wheel having a solid base. The X-axis identifies the flow in CFM and the Y-axis identifies the pressure rise in inches×H₂ 0. As illustrated, impeller wheel 502 produces a CFM increase of about 10 percent compared to the impeller wheel with the solid base.
FIG. 28 illustrates an impeller wheel 602 that is an alternative embodiment of impeller wheel 202, as shown and described with respect to FIGS. 15-20 , of blower assembly 100, as shown and described with respect to FIGS. 2-6 . Impeller wheel 602 includes features/components previously described with regard to impeller wheel 202. Thus, like parts/features will be numbered the same throughout the various embodiments. The features described with respect to one embodiment may apply to the other embodiments unless expressly stated otherwise.
Referring to FIG. 28 , impeller wheel 602 includes a base 608, an upper ring 210 and a plurality of fan blades 212 coupled between base 608 and upper ring 210. Upper ring 210 is positioned opposite base 608. The outer portions of base 208, upper ring 210, and the plurality of fan blades 212 define sidewall 206 of impeller wheel 602. Impeller wheel 602 includes the axis C which extends through the center between base 608 and upper ring 210. Impeller wheel 602 includes an adapter mating feature 752 that is configured to engage with a corresponding adapter (not shown) coupled to motor 204. Adapter mating feature 752 and the corresponding adapter (FIGS. 29A and 29B) will be discussed in more detail below.
Base 608 of impeller wheel 602 includes a plurality of openings 610 spaced around the axis C. Plurality of openings 610 are equally spaced around the axis C and have a circular shape. However, various shapes may be utilized, for example, squares, triangles, and combinations thereof. The number of openings 610 may be similar to or equal to the number of fan blades 212. In some embodiments, each fan blade 212 is spaced from adjacent fan blades 212 by a respective opening 610 of the plurality of openings 610. In one embodiment, the number of openings 610 is equal to the number of fan blades 212. In another embodiment, the number of openings 610 is greater than the number of fan blades 212.
In one embodiment, impeller wheel 602 including base 608 with plurality of openings 610 weighs less than a similar impeller wheel having a solid base. Impeller wheel 602 may weigh about 10 percent less than a similar impeller wheel with the solid base. By reducing the mass of impeller wheel 602, material may be added (not shown) to a surface (e.g., inside surface) of the fan blades 212, as needed, to assist with balancing the impeller wheel 602. In addition, removing about 10 percent of the weight of the impeller wheel 602 may produce a cost savings.
Referring to FIGS. 5, 6, 29A, and 29B, adapter 754 is sized and shaped to engage with adapter mating feature 752 (FIGS. 26 and 28 ). Adapter mating feature 752 may be included with any of the impeller wheels disclosed herein, including impeller wheel 202, 302, 402, 502, and 602. For ease of discussion, reference to impeller wheel 202 will be made, but it should be understood that any of the impeller wheels may be utilized.
Adapter 754 includes a body 756 and a plurality of ribs 758 extending outwardly therefrom. Each rib 758 is separated from adjacent ribs 758 by a respective slot 760. In one embodiment, plurality of ribs 758 extend outwardly from body 756 in a substantially perpendicular orientation relative to the axis C. Adapter 754 defines an impeller wheel side 762 and a motor side 764 opposite impeller wheel side 762. Impeller wheel side 762 of adapter 754 (FIG. 29A) is coupled with at least the corresponding adapter mating feature 752 of impeller wheel 202 (FIG. 5 ). Motor side 764 of adapter 754 (FIG. 29B) is coupled with at least motor 204 (FIG. 5 ). Adapter 754 provides for increased contact between impeller wheel 202 and motor 204. Thus, adapter 754 may decrease the wobble of impeller wheel 202 as motor torque is transferred to impeller wheel 202.
Adapter 754 includes a first neck 766 that extends outwardly from body 756 in the direction of impeller wheel side 762. In some embodiments, first neck 766 is sized and shaped to fit within opening 213 of dome feature 214 and ribs 758 of adapter 754 are sized and shaped to fit within corresponding features of adapter mating feature 752. Adapter 754 includes a second neck 768 that extends outwardly from body 756 in the direction of motor side 764. First neck 766 and second neck 768 extend outwardly from body 756 and are aligned with axis C. Second neck 768 defines an opening 770 that may be coupled with motor 204. Opening 770 is aligned with the axis C and may extend between second neck 768 and first neck 766. Opening 770 of second neck 768 is D-shaped. The D-shaped opening 770 couples with the motor 204. Adapter 754 defines a gear-shaped feature 772 extending outwardly from body 756 in the direction of motor side 764.
FIGS. 30A and 30B illustrate an impeller wheel 702 that is an alternative embodiment of impeller wheel 202, as shown and described with respect to FIGS. 15-20 , of the blower assembly 100, as shown and described with respect to FIGS. 2-6 . Impeller wheel 702 includes features/components previously described with regard to impeller wheel 202. Thus, like parts/features will be numbered the same throughout the various embodiments. The features described with respect to one embodiment may apply to the other embodiments unless expressly stated otherwise.
Referring to FIGS. 30A and 30B, adapter 754 may be embedded entirely within or at least partially within a dome feature 714 of impeller wheel 702. In the illustrated embodiment, an adapter mating feature 704 is sized and shaped to receive adapter 754. In some embodiments, adapter 754 is overmolded within impeller wheel 702. In other embodiments, adapter 754 is not overmolded into the impeller.
FIGS. 31A and 31B illustrate an alternative adapter 854. Adapter 854 is sized and shaped to engage with the adapter mating feature (e.g., adapter mating feature 752). The adapter mating feature may be included with any of the impeller wheels disclosed herein, including impeller wheel 202, 302, 402, 502, 602, and 702. For ease of discussion, reference to impeller wheel 202 will be made, but it should be understood than any of the impeller wheels may be utilized.
Adapter 854 includes a body 856 and a plurality of ribs 858 extending outwardly therefrom. Each rib 858 is separated from adjacent ribs 858 by a slot 860. In some embodiments, plurality of ribs 858 extend outwardly from body 856 in a curved orientation relative to the axis C. Adapter 854 defines an impeller wheel side 862 and a motor side 864 situated opposite impeller wheel side 862. In one embodiment, ribs 858 are curved (e.g., in an umbrella configuration) in the direction of motor side 864. Impeller wheel side 862 of adapter 754 (FIG. 31A) is coupled with at least the corresponding adapter mating feature (e.g., corresponding adapter mating feature 752) of impeller wheel 202. Motor side 864 of adapter 854 (FIG. 31B) is coupled with at least motor 204. Adapter 854 provides increased contact between impeller wheel 202 and motor 204 and may decrease the wobble of impeller wheel 202 as motor torque is transferred to impeller wheel 202.
Adapter 854 includes a first neck 866 that extends outwardly from body 856 in the direction of impeller wheel side 862. First neck 866 is sized and shaped to fit within opening 213 of dome feature 214. Ribs 858 of adapter 854 are sized and shaped to fit within corresponding features of the adapter mating feature. Adapter 854 includes a second neck 868 that extends outwardly from body 856 in the direction of motor side 864. First neck 866 and second neck 868 extend outwardly from body 856 and are aligned with axis C. Second neck 868 defines an opening 870 that may be coupled with motor 204. Opening 870 is aligned with the axis C and may extend between second neck 868 and first neck 866. Second neck 868 defines a keyed slot 872 that extends a distance within opening 870 in the direction of the axis C.
FIG. 32 illustrates an impeller wheel 802 that is an alternative embodiment of impeller wheel 202, as shown and described with respect to FIGS. 15-20 , of the blower assembly 100, as shown and described with respect to FIGS. 2-6 . Impeller wheel 802 includes features/components previously described with regard to impeller wheel 202. Thus, like parts/features will be numbered the same throughout the various embodiments.
The features described with respect to one embodiment may apply to the other embodiments unless expressly stated otherwise. It should be understood that any variation of wheel impellers 202, 302, 402, 502, 602, 702, 802 may be used within the blower assembly 100, unless expressly stated otherwise. Additionally, any variation and combination of components/features may be used without departing from the spirit/scope of this disclosure.
Referring to FIGS. 31A-31C, adapter 854 may be embedded entirely within or at least partially within dome feature 814 of impeller wheel 802. In this embodiment, an adapter mating feature 804 is sized and shaped to receive adapter 854. In some instances, adapter 854 may be overmolded within impeller wheel 802. Adapter 854 including the curved ribs 858 may promote a uniform wall thickness (see FIG. 32 ).
FIGS. 33 and 34 illustrate graphs comparing three different blower assemblies. The Rev-0 blower assembly, which is identified with the dot, is a blower assembly including a 41-fan blade impeller wheel. The Rev-1 blower assembly, which is identified with the triangle, is a blower assembly including a modified motor and a 50-fan blade impeller wheel. The Rev-2 blower assembly 100, which is identified with the diamond, is blower assembly 100 as depicted in FIGS. 2-6 . The Rev-2 blower assembly 100 includes scroll housing 102, blower inlet shroud 104, and impeller wheel 202 having 51 fan blades 212.
Referring to FIG. 33 , the X-axis captures the flow in CFM and the Y-axis captures the pressure rise in inches×H₂ 0. The Rev-2 blower assembly 100 produced a greater flow than the Rev-0 and Rev-1 blower assemblies and consumed less power than the Rev-0 and Rev-1 blower assemblies. The Rev-2 blower assembly 100 produced a noise level below 50 DbA, whereas the Rev-1 blower assembly produced a noise level above 50 DbA.
Referring to FIG. 34 , the X-axis captures the flow in CFM and the Y-axis captures the power output in watts. The Rev-2 blower assembly 100 produced a greater flow than the Rev-0 and Rev-1 blower assemblies and consumed less power than the Rev-0 and Rev-1 blower assemblies. The Rev-2 blower assembly 100 produced a noise level below 50 DbA, whereas the Rev-1 blower assembly produced a noise level above 50 DbA.
This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.

Claims

1. A blower assembly for a water heater, said blower assembly comprising:

a blower inlet shroud having an inlet opening and an outlet opening;

a scroll housing defining an outer surface, an outlet, and a spiral feature, wherein said scroll housing and said blower inlet shroud are connected to each other and define an inner volume, wherein said blower inlet shroud outlet opening is fluidly connected to the scroll housing inner volume; and

an impeller wheel positioned within the inner volume defined by said blower inlet shroud and said scroll housing, said impeller wheel configured to move a fluid from the blower inlet shroud inlet opening to the scroll housing outlet opening.

2. The blower assembly of claim 1, wherein said scroll housing comprises a cavity defined by a sidewall of said scroll housing, said scroll housing also including a neck portion extending from the location of where said scroll housing outlet and said spiral feature meet, wherein said impeller wheel includes a sidewall, and wherein a distance between said impeller wheel sidewall and said cavity sidewall is the smallest at the location of where said scroll housing outlet and said spiral feature meet.

3. The blower assembly of claim 2, wherein said outlet extends from said spiral feature at said neck at an angle of about 77 degrees to about 87 degrees.

4. The blower assembly of claim 1, wherein said impeller wheel includes a base, an upper ring and a plurality of blades extending between said base and said upper ring, said base includes a dome feature that extends toward said upper ring.

5. The blower assembly of claim 4, wherein each fan blade of said plurality of fan blades have surfaces that are one of rectangular or curved.

6. The blower assembly of claim 5, wherein said fan blades have a draft angle between and including 0 degrees and 5 degrees, and an angle of attack between and including 12 degrees and 22 degrees.

7. The blower assembly of claim 4, wherein said upper ring includes a plurality of raised portions.

8. The blower assembly of claim 4, wherein said base includes at least one opening between adjacent fan blades of said plurality of fan blades.

9. The blower assembly of claim 4, further comprising an adapter connecting a motor to the impeller wheel base.

10. A water heater system comprising:

a body including a water storage tank;

a heat pump system connected to said body and in thermal connection with said water storage tank; and

a blower assembly comprising:

a blower inlet shroud having an inlet opening and an outlet opening;

11. The water heater system of claim 10, wherein said scroll housing includes a cavity defined by a sidewall of said scroll housing, said scroll housing also including a neck portion extending from the location of where said outlet and said spiral feature meet, wherein said impeller wheel includes a sidewall, and wherein a distance between said impeller wheel sidewall and said cavity sidewall is the smallest at said neck portion.

12. The water heater system of claim 11, wherein said scroll housing outlet extends from said spiral feature at said neck portion at an angle of about 77 degrees to about 87 degrees.

13. The water heater system of claim 10, wherein said impeller wheel includes a base, an upper ring and a plurality of blades extending between said base and said upper ring, said base includes a dome feature that extends toward said upper ring.

14. The water heater system of claim 13, wherein each fan blade of said plurality of fan blades have surfaces that are one of rectangular or curved.

15. The water heater system of claim 14, wherein said fan blades have a draft angle between and including 0 degrees and 5 degrees, and an angle of attack between and including 12 degrees and 22 degrees.

16. The water heater system of claim 13, wherein said upper ring includes a plurality of raised portions.

17. The water heater system of claim 13, wherein said base includes at least one opening between adjacent fan blades of said plurality of fan blades.

18. The water heater system of claim 13, further comprising an adapter connecting a motor to said impeller wheel base.

19. A method of assembling a blower assembly for a water heater, the blower assembly including an inlet having an inlet opening and an outlet opening, the blower assembly also including an impeller wheel and a scroll housing defining an outer surface, an outlet, and a spiral feature, wherein said method comprises the steps of:

connecting the scroll housing to the blower inlet shroud to define an inner volume such that the blower inlet shroud outlet opening is fluidly connected to the scroll housing inner volume; and

positioning the impeller wheel within the inner volume defined by the blower inlet shroud and the scroll housing, such that the impeller wheel is configured to move a fluid from the blower inlet shroud inlet opening to the scroll housing outlet opening.

20. The method of assembling of claim 19 wherein the blower assembly further includes adapter, said method further comprising connecting a blower motor to the impeller wheel with the adapter.