WO2024076776A1

WO2024076776A1 - Heat pump assemblies for water heaters

Info

Publication number: WO2024076776A1
Application number: PCT/US2023/034735
Authority: WO
Inventors: Govinda Mahajan; David Adler
Original assignee: Rheem Manufacturing Co
Current assignee: Rheem Manufacturing Co
Priority date: 2022-10-07
Filing date: 2023-10-09
Publication date: 2024-04-11
Anticipated expiration: 2025-04-07
Also published as: AU2023356716A1; EP4612443A1

Abstract

A heat pump assembly may be securable to a tank of a water heater. The heat pump assembly may include a base pan, and inlet and outlet tubes including flanges. The base pan defines inlet and outlet openings each extending between upper and lower faces. The tubes extend through the openings, and are configured to secure the heat pump assembly to the tank by securing the base pan to an upper pan of the tank. A water heater may include a tank and the heat pump assembly secured to the upper pan of the tank by the tubes. A method for making a water heater may include introducing inlet and outlet tubes through openings in an upper pan of a tank. The method may further include introducing the tubes through openings in a base pan of a heat pump assembly to secure the heat pump assembly to the tank.

Description

HEAT PUMP ASSEMBLIES FOR WATER HEATERS

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of U.S. Application No. 63/378,717, filed October 7, 2022, the entirety of which is hereby incorporated by reference.

TECHNICAL FIELD

[0002] The present disclosure is generally in the field of water heaters, and more particularly related to heat pump assemblies for water heaters.

BACKGROUND

[0003] Water heaters may be used to heat water to a predetermined temperature. Heaters may include a tank for holding a volume of water, and means for transferring heat to the water. Depending on the type of heating mechanism, water heaters may include a number of parts internal to and external to the tank. Thus, a number of steps may be involved in assembling the water heater.

SUMMARY

[0004] The present disclosure describes heat pump assemblies for water heaters, water heaters, and methods of making water heaters.

[0005] In embodiments, the present disclosure describes a heat pump assembly securable to a tank of a water heater. The heat pump assembly may include a base pan, and inlet and outlet tubes. The base pan has opposed upper and lower faces. The base pan defines an inlet opening and an outlet opening each extending between the upper and lower faces. The inlet tube extends through the inlet opening of the base pan and includes an inlet flange. The outlet tube extends through the outlet opening of the base pan and includes an outlet flange. The inlet flange and the outlet flange may be configured to secure the base pan to the upper pan. The inlet tube and the outlet tube may be configured to secure the heat pump assembly to the tank by securing the base pan to an upper pan of the tank.

[0006] In embodiments, the present disclosure describes a water heater. The water heater includes a tank and the heat pump assembly. The tank includes an upper pan. The heat pump assembly is secured to the upper pan of the tank by the inlet and outlet tubes. [0007] In embodiments, the present disclosure describes a method for making a water heater. The method includes introducing inlet and outlet tubes through openings in an upper pan of a tank. The method further includes introducing the inlet and outlet tubes through openings in a base pan of a heat pump assembly to secure the heat pump assembly to the tank.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The detailed description is set forth with reference to the accompanying drawings. The use of the same reference numerals may indicate similar or identical items. Various embodiments may utilize elements and/or components other than those illustrated in the drawings, and some elements and/or components may not be present in various embodiments. Elements and/or components in the figures are not necessarily drawn to scale. Throughout this disclosure, depending on the context, singular and plural terminology may be used interchangeably.

[0009] FIG. 1 is an exploded view of a water heater assembly including a heat pump assembly securable to a tank by inlet and outlet tubes.

[0010] FIG. 2 is an exploded view of the heat pump assembly of FIG. 1 adjacent a vibration pad and an upper pan of the tank.

[0011] FIG. 3 A is a partial side view of the water heater assembly of FIG. 1 in an unassembled configuration including the inlet tube with a lower face of a flange facing an upper face of a base pan of a heat pump assembly.

[0012] FIG. 3B is a partial side view of the water heater assembly of FIG. 3 A in an assembled configuration.

[0013] FIG. 4A is a partial side view of a water heater assembly of FIG. 1 in an unassembled configuration including the inlet tube with an upper face of the flange opposing a lower face of the base pan of a heat pump assembly.

[0014] FIG. 4B is a partial side view of the water heater assembly of FIG. 4A in an assembled configuration.

[0015] FIGS. 5A-5B are exploded front and rear views of another heat pump assembly adjacent a vibration pad and an upper pan of a tank.

[0016] The present disclosure provides a more detailed and specific description with reference to the accompanying drawings. The drawings and specific descriptions of the drawings, as well as any specific or other embodiments discussed, are intended to be read in conjunction with the entirety of this disclosure. DETAILED DESCRIPTION

[0017] Example embodiments will now be described more fully hereinafter with reference to the accompanying drawings, in which example embodiments are shown. The concepts disclosed herein may, however, be embodied in many different forms and should not be construed as limited to the example embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the concepts to those skilled in the art. Like numbers refer to like, but not necessarily the same or identical elements throughout.

[0018] Water heaters may employ different techniques for generating heat to heat a volume of water. For example, some water heaters may employ resistive electrical heating, in which electrical energy is converted to thermal energy used to heat water, or fuel combustion to generate thermal energy. Other types of heaters may use heat pumps. The present disclosure describes heat pump assemblies for water heaters, water heaters, and methods of making water heaters. For example, the heat pump assemblies described herein may be modular heat pump units that are able to be secured to an existing or separately installed tank water heater.

[0019] In the present disclosure, the terms “upper” and “lower” denote components positioned higher or lower than other components with reference to gravity.

[0020] While heating elements or exchangers may be provided within the tank itself, heat pumps may typically be external to the tank. Heat pump assemblies according to the present disclosure may be securable to tanks in a relatively easy manner (for example, with fewer components or steps) to make water heaters. In embodiments, a heat pump assembly may include a base pan, and inlet and outlet tubes. The inlet and outlet tubes introduce water into or withdraw water from a tank. The base pan has opposed upper and lower faces, and defines inlet and outlet openings extending between the upper and lower faces. The inlet and outlet tubes extend through the inlet and outlet openings, and may ultimately extend to the tank. The inlet tube and the outlet tube are configured to secure the heat pump assembly to the tank by securing the base pan to an upper pan of the tank. For example, the inlet tube may include an inlet flange, the outlet tube may include an outlet flange, and the inlet and outlet flanges may secure or hold the base pan against the upper pan. In this way, the water heater may use the inlet and outlet tubes themselves to secure the heat pump assembly to the tank (in addition to their normal function of introducing and withdrawing water). Thus, additional dedicated components may not be needed to secure the assembly, allowing a fewer number of components to be used, reducing complexity and cost of the assembly. In some embodiments, only the inlet and outlet tubes (or additional components associated with only the inlet and outlet tubes) are used to secure the heat pump assembly to the tank. In such embodiments, further fasteners or clips or other means for securing may be absent. [0021] A fewer number of manufacturing steps may be required to assemble the tanks, or manufacturing may be relatively simpler than methods that require additional components and fastening steps. For example, a method for making a water heater may include introducing inlet and outlet tubes through openings in the upper pan of the tank, and through openings in the base pan of the heat pump assembly to secure the heat pump assembly to the tank. The inlet and outlet tubes may be provided with one or more of flanges, bolts, nuts, or washers to facilitate securing the base pan of the heat pump assembly to the upper pan of the tank. In some embodiments, fastening or securing means not associated with the inlet or outlet tubes may not be used in the method of making the water heater.

[0022] FIG. 1 is an exploded view of a water heater assembly 10 including a heat pump assembly 12 secured to a tank 14 by inlet and outlet tubes 16 and 18. The tank 14 holds a volume of water to be heated, and the inlet and outlet tubes 16 respectively introduce water into and withdraw water from the tank 14. The heat pump assembly 12 provides heat transfer to ultimately heat the water in the tank 14.

[0023] The tank 14 may be cylindrical, or have any other suitable shape. The tank 14 may be formed of one or more materials, such as a metal, or alloy, or a polymer, and may be coated with protective or ornamental coatings, for example, paint or anti-corrosion coatings. The tubes 16 and 18 may be formed of the same or similar materials, and also be coated in the same or similar manner. The tubes 16 and 18 may be circular in cross-section, or have any other suitable crosssection.

[0024] The tank 14 may have a generally vertical aspect, for example, having a height greater than a width. The tank 14 includes an upper pan 20. The upper pan 20 may define an uppermost surface of the tank 14 (and an internal surface of the water heater assembly 10). In some embodiments, at least one more component or element of the tank 14 may be provided over the upper pan 20, for example, a covering, or some other layer. In embodiments, the heat pump assembly 12 is secured to the upper pan 20 of the tank 14 to assembly the water heater assembly 10 into a single unit. [0025] FIG. 2 is an exploded view of the heat pump assembly 12 of FIG. 1 securable to the upper pan 20 of the tank 14 by inlet and outlet tubes 16 and 18.

[0026] The heat pump assembly 12 includes a base pan 22. The base pan 22 may be formed of any suitable material, for example, a metal or an alloy or a polymer. The base pan 22 may be similar in size, shape, or peripheral geometry to the upper pan 20. For example, both the upper pan 20 and the base pan 22 may be substantially circular or disc-shaped. There may be some divergence or deviation in their geometries, for example, differences in openings, notches, or tabs, or the like, even though the overall geometries and configurations may be similar. Further, their thicknesses may be similar or different. The upper pan 20 and the base pan 22 may be formed of the same material, or differ in material of construction. The respective pans 20 and 22 may further be provided with same, similar, or different one or more protective, functional, or ornamental coatings. Providing similar geometries may facilitate aligning the heat pump assembly 12 with the tank 14 during assembly, and may facilitate a streamlined or uniform external appearance for the assembly 10 as a whole.

[0027] The base pan 22 has opposed upper and lower faces 24 and 26. The base pan 22 defines an inlet opening 28 and an outlet opening 30 each extending between the upper and lower faces. Like the base pan 22, the upper pan 20 also may define an inlet opening 32 and an outlet opening 34, for example, substantially aligned with the inlet opening 28 and the outlet opening 30 of the base pan 22.

[0028] The inlet tube 16 extends through the inlet opening 28 of the base pan 22 (and through the inlet opening 32 of the upper pan 20), when assembled in the water heater assembly 10. The outlet tube 18 extends through the outlet opening 30 of the base pan 22 (and through the outlet opening 32 of the upper pan 20), when assembled. The inlet tube 16 and the outlet tube 18 are configured to secure the heat pump assembly 12 to the tank 14 by securing the base pan 22 to the upper pan 20 of the tank 14. For example, the inlet tube 16 and the outlet tube 18 may extend through the upper pan 20 and the base pan 22, and end portions of the inlet tube 16 and the outlet tube 18 may hold the base pan 22 in place relative to the upper pan 22. The end portions of the inlet tube 16 and the outlet tube 18 may be provided with flanges or fasteners to facilitate securing the base pan 22 to the upper pan 22. Thus, in the assembled water heater assembly 10, the heat pump assembly 12 is secured to the upper pan 20 of the tank 14 (at least partially) by the inlet and outlet tubes 16 and 18. For example, the base pan 22 of the heat pump assembly 12 may secure the heat pump assembly 12 as a whole to the upper pan 20, and ultimately, to the tank 14. [0029] In embodiments, the heat pump assembly 12 is secured to the tank 14 only by the inlet tube 16 and the outlet tube 18. For example, a fastener, a clip, a weld, or any other means of securing the heat pump assembly 12 may be absent, except for the inlet tube 16 and the outlet tube 18, and except for any means of securing associated with the inlet tube 16 and the outlet tube 18. For example, a washer, nut, bolt, or another means for fastening the heat pump assembly 12 to the tank 14 may be present only in association with the inlet tube 16 and the outlet tube 18, and with components in contact with the inlet tube 16 and the outlet tube 18.

[0030] In embodiments, the upper pan 20 and the base pan 22 may each comprise a plurality of alignment indentations 36. The alignment indentations 36 may define one or more ridges, channels, protrusions, tabs, grooves, or other features that may facilitate aligning the upper pan 20 and the base pan 22. In embodiments, one or more of the alignment indentations 36 may follow a partial circular arc. In embodiments, each of the upper pan 20 and the base pan 22 has four circular arc indentations. In embodiments, cut-outs or slots may be present instead of, or in addition to, the alignment indentations 36. For example, the cut-outs or slots may have a similar shape as the alignment indentations, but extend completely across the thickness of the upper pan 20 or the base pan 22.

[0031] In embodiments, the alignment indentations 36 may each define a recess in a first surface, and a protrusion in an opposing second surface. For example, protruding surfaces of a first set of the alignment indentations 36 of the base pan 22 may be nested or received in recesses of a second set of the alignment indentations 36 of the upper pan 20 only when the upper pan 20 and the base pan 22 are aligned. If the upper pan 20 is not substantially aligned with the base pan 22, the second set of alignment indentations 36 of the upper pan 20 do not receive the first set of alignment indentations 36 of the base pan 22, and the first set of the alignment indentations 36 rest against a flat surface of the base pan 22. Such a resting of the first set of the alignment indentations 36 would space apart the opposing surfaces of the upper pan 20 and the base pan 22 when the upper pan 20 and the base pan 22 are not aligned. Thus, the alignment indentations 36 may respectively space the upper pan 20 and the base pan 22 away from each other when the respective indentations 36 are not aligned, and may allow a distance between the upper pan 20 and the base pan 22 to be reduced to a minimum when substantially aligned. Such alignment indentations 36 may ultimately allow the upper pan 20 and the base pan 22 to be quickly oriented relative to each other such that respective inlet openings 28 and 32 and the respective outlet openings 30 and 34 are aligned, even if these openings are not visible during assembly.

[0032] In embodiments, the base pan 22 is directly secured to the upper pan 20. For example, the lower face 26 of the base pan 22 may directly contact the upper pan 20. However, such contact may transfer vibrations or sound between the heat pump assembly 12 and the tank 14. In other embodiments, the water heater assembly 10 further includes a vibration dampener pad 38 configured to be secured between the base pan 22 and the upper pan 20. The vibration dampener pad 38 may include one or more of a foam, a woven fabric, a nonwoven fabric, a paper, a polymeric film, a composite, or combinations thereof. The vibration dampener pad 38 may be sandwiched at the interface between the upper pan 20 and the base pan 22. The indentations 36 may press and hold the vibration dampener pad 38 in place, for example, reducing or preventing lateral movement of the vibration dampener pad 38. For example, the first set of the alignment indentations 36 of the base pan 22 may press and hold portions of the vibration dampener pad 38 received in the second set of the alignment indentations of the upper pan 20.

[0033] The heat pump assembly 12 may include at least one heat pump component 40. The at least one heat pump component 40 may include one or more of an evaporator coil, a condenser coil, a condensation collector, an expansion valve, a fan, or a compressor. In embodiments, the heat pump assembly 12 may include a refrigerant piping circuit in which the compressor, the condenser coil, the expansion valve, the evaporator coil, and an evaporator fan.

[0034] The at least one heat pump component may facilitate transfer of heat to ultimately raise a temperature of water held in the tank 14 to a predetermined temperature or within a predetermined temperature range.

[0035] The heat pump assembly 12 may further include a shroud assembly 42. The shroud assembly 42 may receive, surround, cover, or protect at least one pump component 40. A lower surface of the shroud assembly 42 may oppose the upper face 24 of the base pan 22. The inlet tube 16 and the outlet tube 18 extend through the shroud assembly 42 when the water heater assembly 10 is assembled. For example, the shroud assembly 44 may define at least one channel or cavity through which the inlet and outlet tubes 16 and 18 may extend. In some embodiments, at least one pump component 40 may be present in the same at least one channel or cavity. [0036] The shroud assembly 42 may include a plurality of foam sections. In embodiments, the plurality of foam sections includes a first foam section 44, a second foam section 46, and a third foam section 48. Thus, the plurality of foam sections are collectively configured to receive, surround, or cover the at least one component 40 of the heat pump. The foam sections may include or be formed of a plastic, for example, a polyethylene, a polyurethane, or the like, or a combination thereof. The foam may be a rigid or a semi-rigid foam.

[0037] The plurality of foam sections may define tabs, protrusions, channels, grooves, or the like to facilitate securing the plurality of foam sections to each other. For example, the first, second, and third foam sections 44, 46, and 48 may be securable to each other by sliding protrusions into complementary grooves. In embodiments, the first foam section 44 may be securable to the second foam section 46, and the second foam section in turn may be securable to the third foam section 48. In embodiments, the first foam section 44 is securable to the third foam section 48 with the second foam section 36 retained between the first and third foam sections 44 and 48. In some embodiments, the first foam section 42 is above the second foam section 46, and the second foam section is above the third foam section 48.

[0038] The heat pump assembly 14 may be covered by a heat pump cover (not shown in the figures), for example, surrounding or covering the shroud assembly 42. The heat pump cover may be formed of one or more suitable materials, for example, for providing insulation and/or ornamentation. In embodiments, the heat pump cover may include a metal or an alloy.

[0039] The inlet and outlet tubes 16 or 18 may include features to facilitate securing the base pan 22 of the heat pump assembly 12 to the upper pan 20 of the tank. In embodiments, the inlet tube 16 includes an inlet flange 50, and the outlet tube 18 includes an outlet flange 52, where the inlet and outlet flanges 50 and 52 are configured to secure the base pan 22 to the upper pan 20. The flanges 50 and 52 may be formed of any suitable material, for example, a metal, alloy, or polymer. The flanges 50 and 52 may be welded or fastened to the tubes 16 and 18, or may be integrally formed with the tubes 16 or 18.

[0040] The flanges 50 or 52 may extend sufficiently outward from the respective inlet or outlet tubes 16 or 18 to provide adequate securing force or pressure to press or hold the upper pan 20 against the base pan 22. In embodiments, the flanges 50 or 52 may extend outward to a diameter that is at least 1%, at least 5%, at least 10%, at least 15%, at least 20%, at least 25%, or at least 30%, of a total height of a respective tube. The diameter of the flanges 50 or 52 may be in a range from 1% to 50%, or from 10% to 50%, or from 1% to 30%, or from 10% to 30%, or from 15% to 30%, or from 25% to 50%, end points of the ranges included, of a total height of the respective tube.

[0041] In embodiments, one or both of the inlet and outlet flanges 50 and 52 may be spaced from respective lower ends of the inlet and outlet tubes 16 and 18 by a predetermined spacing. In embodiments, the predetermined spacing of the flanges 50 or 52 from the lower ends of the inlet or outlet tubes 16 or 18 is at least 1%, at least 5%, at least 10%, at least 15%, at least 20%, at least 25%, or at least 30%, of a total height of a respective tube. The predetermined spacing may be in a range from 1% to 50%, or from 10% to 50%, or from 1% to 30%, or from 10% to 30%, or from 15% to 30%, or from 25% to 50%, end points of the ranges included, of a total height of the respective tube.

[0042] In embodiments, the predetermined spacing of the flanges 50 or 52 from the lower ends of the inlet or outlet tubes 16 or 18 is at least 10%, at least 25%, at least 30%, at least 50%, at least 75%, at least 100%, at least 110%, at least 120%, or at least 150%, of a respective diameter of the flange 50 or 52. The predetermined spacing may be in a range from 10% to 150%, or from 25% to 100%, or from 50% to 75%, or from 50% to 150%, or from 30% to 120%, or from 30% to 100%, or from 25% to 75%, or 25% to 125%, end points of the ranges included, of the diameter of the respective flange.

[0043] Instead of, or in addition to the flanges 50 and 52, the inlet and outlet tubes 16 and 18 may be secured by inlet and outlet bolts 54 and 56. The orientation and configuration of flanges and bolts are further described with reference to FIGS. 3 and 4. While the inlet tube 16 is described only as an example in FIGS. 3 A to 4B, the outlet tube 18 may also be similarly configured as the inlet tube 16 in FIGS. 3A to 4B.

[0044] FIG. 3 A is a partial side view of the water heater assembly 10 in an unassembled configuration 10a including the inlet tube 16, with a lower face of the flange 50 opposing the upper face 24 of the base pan 22 of the heat pump assembly 12. FIG. 3B is a partial side view of the water heater assembly of FIG. 3A in an assembled configuration 10b.

[0045] In the configuration 10a, the inlet tube 16 can be introduced from an upper side of the base pan 22, and toward the base pan 22, so that the inlet flange 50 ultimately presses against the upper face 24 of the base 22. For example, the inlet flange 50 may be offset from a lower end 58 of the inlet tube 16, so that a portion of the inlet tube 16 below the inlet flange 50 may extend through the base pan 22 and the upper pan 20. This pressure or weight promotes the pressing of the base 22 against the upper pan 20, ultimately facilitating the securing of the heat pump assembly 12 to the tank 14.

[0046] In some embodiments, the inlet bolt 54 may be secured into the lower end 58 of the inlet tube 16. For example, the inlet bolt 54 may be pushed or screwed into an internal threaded bore of the inlet tube 16, or pushed or screwed about an external surface of the inlet tube 16 at the lower end 58. Thus, the base pan 22 and the upper pan 20 are securable between the inlet and outlet bolts 54 and 56 and inlet and outlet flanges 50 and 52.

[0047] In some embodiments, an inlet washer 60 may be provided between the bolt 54 and the upper pan 20. The inlet washer 60 may promote a secure fit between the base pan 22 and the upper pan 20. Another washer may be provided at the upper surface 24 of the base pan 22. An outlet washer 60 may be similarly provided about the outlet tube 18. Thus, the base pan 22 and the upper pan 20 may be securable between the inlet and outlet washers 60 and inlet and outlet flanges 50 and 52.

[0048] In some embodiments, the tank 14 may be preassembled such that an interior of the tank 14 may not be accessible, and the inlet tube 16 may be introduced from above the base pan 22. Thus, the inlet tube 16 may be introduced from above the base pan 22, resulting in the assembled configuration 10b of FIG. 3B. Placing the inlet bolt 54 or the inlet washer 60 may not be possible from the interior of the tank 14 in some embodiments, and only the inlet tube 16 may be introduced from above the base pan 22.

[0049] In some embodiments, an interior of the tank 14 may be accessible during assembly, and the inlet tube 16 may be introduced from below the base pan 22 and the upper pan 20.

[0050] In embodiments, as shown in FIG. 3A, the inlet flange 50 is offset from the lower end 58 of the inlet tube 16. The outlet flange 52 may also be offset from a lower end of the outlet tube 18.

[0051] FIG. 4A is a partial side view of a water heater assembly 10 of FIG. 1 in an unassembled configuration 10c including the inlet tube 16, with an upper face of the flange 50opposing a lower face 26 of the base pan of a heat pump assembly. FIG. 4B is a partial side view of the water heater assembly of FIG. 4A in an assembled configuration lOd.

[0052] As shown in FIG. 4B, the inlet flange 50 may be positioned at the lower end 58 (instead of being offset) of the inlet tube 16. For example, the inlet flange 50 may be flush with the lower end 58. In embodiments, the inlet flange 50 may be within a predetermined distance of the lower end to constitute being positioned at the lower end 58. For example, the inlet flange 50 may be positioned at a distance less than 10%, less than 5%, less than 3%, or less than 1%, of a total height of the inlet tube. Likewise, the outlet flange 52 may be positioned at (flush with or within a predetermined distance from) a lower end of the outlet tub 18. In embodiments, both the inlet and outlet flanges 50 and 52 are positioned at the respective lower ends of inlet and outlet tubes 16 and 18. Alternatively, one of the inlet and outlet flanges 50 or 52 may be positioned at a lower end of a respective tube and the other of the inlet and outlet flanges 50 or 52 may be offset from the lower end of the respective tube.

[0053] The inlet tube 16 may be introduced from below the upper pan 20 (for example, within an accessible interior of the tank 14), and the heat pump assembly 12 and the inlet tube 16 may be brought together, to secure the upper pan 20 to the base pan 22.

[0054] In some embodiments, an external surface of the inlet tube 16 near the inlet flange 50 may be threaded, and a nut 62 may be introduced from above the base pan 22 and threaded about the inlet tube 16. Using the nut 62 may facilitate a secure fit between the base pan 22 and the upper pan 20, and ultimately, between the heat pump assembly 12 and the tank 14.

[0055] In embodiments, the present disclosure describes a method for making a water heater. The method includes introducing inlet and outlet tubes through openings in an upper pan of a tank. The method further includes introducing the inlet and outlet tubes through openings in a base pan of a heat pump assembly to secure the heat pump assembly to the tank.

[0056] The method may further include coupling one or both of an inlet washer or an inlet bolt to the inlet tube. The method may further include coupling and or both of an outlet washer or an outlet but to the washer tube. The method may further include extending the inlet and outlet tubes through the shroud assembly.

[0057] The method may include coupling the heat pump assembly to the tank without using any means for securing or fastening other than the inlet tube and the outlet tube, or other than components associated with the inlet tube or the outlet tube.

[0058] FIGS. 5A-5B are exploded front and rear views of another heat pump assembly 70. The heat pump assembly 70 may be disposed adjacent a vibration pad and an upper pan 20 of a tank, such as tank 14 of FIG. 1. [0059] The heat pump assembly 70 may be similar to the heat pump assembly described with respect to FIGS. 1-4B; however, the heat pump assembly 70 may have a different arrangement of the vibration dampener pad 38, the base pan 22, and the upper pan 20. For example, as depicted in FIGS. 5A-5B, the heat pump assembly 70 may have the vibration dampener pad 38 disposed relatively higher than the base pan 22, such that the base pan 22 is disposed between the vibration dampener pad 38 and the upper pan 20. Such an arrangement may have relatively improved vibration dampening effects. In addition, the heat pump assembly 70 may include valves at the end of the heat pump piping that allow for increased functionality as a replacement part, as well as a tank modification part for existing tanks without heat pumps, thereby allowing for retrofitting of existing systems.

[0060] Also depicted in FIGS. 5A-5B for illustrative purposes is an evaporator 80 and corresponding refrigerant compressor 82. The evaporator 80 may have a liquid line that couples the evaporator 80 and the compressor 82, and a compressor discharge line may lead downstream from the compressor 82. Valves may be disposed along the liquid line and/or discharge line. The compressor 82 and evaporator 80 depict example location of the piping and valves. With the valves added, as depicted in FIGS. 5A-5B, the heat pump assembly 70 may be independently sealed.

[0061] The heat pump assembly 70 may be configured to be charged independent of the tank via one or more sealing valves, such as ball valves or other types of valves. The heat pump assembly 70 may therefore be charged prior to being secured to the tank. In some instances, the heat pump assembly 70 may be independently sealed and disconnected from the tank. This may allow for the entire heat pump system to be replaced as a standalone component in an instance of failure. In some embodiments, the heat pump assembly 70 may include an external condenser coupled to a recirculating system tank, where the heat pump assembly 70 can be coupled to the external condenser. The heat pump assembly 70 can be added to a tank system that was not provided with a heat pump originally, with the addition of the external condenser to a tank that utilizes a recirculating system with the original non-heat pump tank system. As a result of the configuration depicted in FIGS. 5A-5B, the heat pump assembly 70 may be independently leak tested, such as leak tested before being added to the tank system. The heat pump assembly 70 can also be independently functionally tested, such as functionally tested before being added to the tank system. [0062] Modifications and variations of the methods and devices described herein will be obvious to those skilled in the art from the foregoing detailed description. Such modifications and variations are intended to come within the scope of the appended claims.

[0063] Embodiment 1 includes a heat pump assembly securable to a tank of a water heater, the heat pump assembly comprising: a base pan having opposed upper and lower faces, the base pan defining an inlet opening and an outlet opening each extending between the upper and lower faces; an inlet tube extending through the inlet opening of the base pan and comprising an inlet flange; and an outlet tube extending through the outlet opening of the base pan and comprising an outlet flange, wherein the inlet flange and the outlet flange are configured to secure the base pan to an upper pan of the tank, and wherein the inlet tube and the outlet tube are configured to secure the heat pump assembly to the tank by securing the base pan to the upper pan.

[0064] Embodiment 2 includes Embodiment 1, wherein lower faces of the inlet and outlet flanges oppose the upper face of the base pan.

[0065] Embodiment 3 includes Embodiment 1, wherein upper faces of the inlet and outlet flanges oppose the lower face of the base pan.

[0066] Embodiment 4 includes any of Embodiments 1 to 3, wherein the inlet flange is positioned at a lower end of the inlet tube, and wherein the outlet flange is positioned at a lower end of the outlet tube.

[0067] Embodiment 5 includes any of Embodiments 1 to 3, wherein the inlet flange is offset from a lower end of the inlet tube, and wherein the outlet flange is offset from a lower end of the outlet tube.

[0068] Embodiment 6 includes any of Embodiments 1 to 5, further comprising an inlet bolt coupled to the inlet tube and an outlet bolt coupled to the outlet tube, wherein the base pan and the upper pan are securable between the inlet and outlet bolts and inlet and outlet flanges.

[0069] Embodiment 7 includes any of Embodiments 1 to 6, further comprising an inlet washer about the inlet tube and an outlet washer about the outlet tube, wherein the base pan and the upper pan are securable between the inlet and outlet washers and inlet and outlet flanges.

[0070] Embodiment 8 includes any of Embodiments 1 to 7, further comprising a shroud assembly having a lower face opposing the upper face of the base pan, wherein the inlet tube and the outlet tube extend through the shroud assembly. [0071] Embodiment 9 includes any of Embodiments 1 to 8, wherein the shroud assembly comprises a plurality of foam sections configured to receive, surround, or cover at least one component of the heat pump.

[0072] Embodiment 10 includes any of Embodiments 1 to 9, wherein the at least one component comprises an evaporator, a condensation collector, a fan, or a compressor.

[0073] Embodiment 11 includes any of Embodiments 1 to 10, further comprising a vibration dampener pad configured to be secured between the base pan and the upper pan.

[0074] Embodiment 12 includes any of Embodiments 1 to 11, wherein the base pan comprises a metal or an alloy.

[0075] Embodiment 13 includes any of Embodiments 1 to 12, wherein the heat pump assembly is secured to the tank by the inlet tube and the outlet tube without a fastener.

[0076] Embodiment 14 includes any of Embodiments 1 to 1 , wherein the heat pump assembly is configured to be charged independent of the tank via one or more sealing valves, such that the heat pump assembly is charged prior to being secured to the tank.

[0077] Embodiment 15 includes any of Embodiments 1 to 14, wherein the heat pump assembly is configured to be independently sealed and disconnected from the tank.

[0078] Embodiment 16 includes any of Embodiments 1 to 15, further comprising an external condenser coupled to a recirculating system tank, wherein the heat pump assembly is coupled to the external condenser.

[0079] Embodiment 17 includes any of Embodiments 1 to 16, wherein the heat pump assembly is configured to be independently leak tested.

[0080] Embodiment 18 includes any of Embodiments 1 to 17, wherein the heat pump assembly is configured to be independently functionally tested.

[0081] Embodiment 19 includes a water heater comprising: a tank comprising an upper pan that is formed of a metal or an alloy; and a heat pump assembly secured to the upper pan of the tank by the inlet and outlet tubes, the heat pump assembly comprising: a base pan having opposed upper and lower faces, the base pan defining an inlet opening and an outlet opening each extending between the upper and lower faces; an inlet tube extending through the inlet opening of the base pan and comprising an inlet flange; and an outlet tube extending through the outlet opening of the base pan and comprising an outlet flange, wherein the inlet flange and the outlet flange are configured to secure the base pan to an upper pan of the tank, and wherein the inlet tube and the outlet tube are configured to secure the heat pump assembly to the tank by securing the base pan to the upper pan.

[0082] Embodiment 20 includes Embodiment 19, wherein the upper pan defines inlet and outlet openings through which the inlet and outlet tubes extend.

Claims

CLAIMS We claim:

1. A heat pump assembly securable to a tank of a water heater, the heat pump assembly comprising: a base pan having opposed upper and lower faces, the base pan defining an inlet opening and an outlet opening each extending between the upper and lower faces; an inlet tube extending through the inlet opening of the base pan and comprising an inlet flange; and an outlet tube extending through the outlet opening of the base pan and comprising an outlet flange, wherein the inlet flange and the outlet flange are configured to secure the base pan to an upper pan of the tank, and wherein the inlet tube and the outlet tube are configured to secure the heat pump assembly to the tank by securing the base pan to the upper pan.

2. The heat pump assembly of claim 1, wherein lower faces of the inlet and outlet flanges oppose the upper face of the base pan.

3. The heat pump assembly of claim 1, wherein upper faces of the inlet and outlet flanges oppose the lower face of the base pan.

4. The heat pump assembly of any of claims 1 to 3, wherein the inlet flange is positioned at a lower end of the inlet tube, and wherein the outlet flange is positioned at a lower end of the outlet tube.

5. The heat pump assembly of any of claims 1 to 3, wherein the inlet flange is offset from a lower end of the inlet tube, and wherein the outlet flange is offset from a lower end of the outlet tube. The heat pump assembly of any of claims 1 to 5, further comprising an inlet bolt coupled to the inlet tube and an outlet bolt coupled to the outlet tube, wherein the base pan and the upper pan are securable between the inlet and outlet bolts and inlet and outlet flanges. The heat pump assembly of any one of claim 1 to 6, further comprising an inlet washer about the inlet tube and an outlet washer about the outlet tube, wherein the base pan and the upper pan are securable between the inlet and outlet washers and inlet and outlet flanges. The heat pump assembly of any of claims 1 to 7, further comprising a shroud assembly having a lower face opposing the upper face of the base pan, wherein the inlet tube and the outlet tube extend through the shroud assembly. The heat pump assembly of claim 8, wherein the shroud assembly comprises a plurality of foam sections configured to receive, surround, or cover at least one component of the heat pump. The heat pump assembly of claim 9, wherein the at least one component comprises an evaporator, a condensation collector, a fan, or a compressor. The heat pump assembly of any of claims 1 to 10, further comprising a vibration dampener pad configured to be secured between the base pan and the upper pan. The heat pump assembly of any of claims 1 to 11, wherein the base pan comprises a metal or an alloy. The heat pump assembly of any of claims 1 to 12, wherein the heat pump assembly is secured to the tank by the inlet tube and the outlet tube without a fastener. The heat pump assembly of any of claims 1 to 13, wherein the heat pump assembly is configured to be charged independent of the tank via one or more sealing valves, such that the heat pump assembly is charged prior to being secured to the tank. The heat pump assembly of any of claims 1 to 14, wherein the heat pump assembly is configured to be independently sealed and disconnected from the tank. The heat pump assembly of any of claims 1 to 15, further comprising an external condenser coupled to a recirculating system tank, wherein the heat pump assembly is coupled to the external condenser. The heat pump assembly of any of claims 1 to 16, wherein the heat pump assembly is configured to be independently leak tested. The heat pump assembly of any of claims 1 to 17, wherein the heat pump assembly is configured to be independently functionally tested. A water heater comprising: a tank comprising an upper pan that is formed of a metal or an alloy; and a heat pump assembly secured to the upper pan of the tank by the inlet and outlet tubes, the heat pump assembly comprising: a base pan having opposed upper and lower faces, the base pan defining an inlet opening and an outlet opening each extending between the upper and lower faces; an inlet tube extending through the inlet opening of the base pan and comprising an inlet flange; and an outlet tube extending through the outlet opening of the base pan and comprising an outlet flange, wherein the inlet flange and the outlet flange are configured to secure the base pan to an upper pan of the tank, and wherein the inlet tube and the outlet tube are configured to secure the heat pump assembly to the tank by securing the base pan to the upper pan. The water heater of claim 19, wherein the upper pan defines inlet and outlet openings through which the inlet and outlet tubes extend.