Systems and Methods for Attachment of Valve Assemblies in Water Heating Systems

[0001] The present application claims priority to and the benefit of U.S. provisional application No. 63/746,051, filed Jan. 16, 2025, which is hereby incorporated by reference in its entirety.

[0002] The present disclosure relates to systems and methods for attachment of valve assemblies in water heating systems and more specifically to systems and methods for attachment of a valve, a mixer, and a shunt of a valve assembly in a water heating system.

[0003] Water heaters are generally used to provide a supply of heated water in a variety of applications, including residential, commercial, and industrial applications. A tank based water heater typically includes a storage tank that stores water that is heated by a heating source. The hot water stored in the storage tank is output via an outlet port of the water heater. A conventional water heater also includes a mixing valve that mixes/blends cold water with the hot water output from the storage tank to increase the capacity of the water heating system and ensure that the outlet water is at an optimal water temperature.

[0012] The present disclosure is directed to a water heating system (“system”) that may include a water tank or a storage tank, a valve assembly, and a housing or a jacket. The valve assembly may include a mixing and shut-off combinational valve (“valve”) and a mixing tee or mixer, which may be connected with each other via a flexible shunt or tube. The valve may include an inlet port that may be configured to receive a supply of cold water (e.g., from a utility water source). The valve may be connected to the “cold side” of the system (i.e., to the inlet point of the system that supplies cold water to the valve). The valve may be configured to either enable the flow of cold water received from the inlet port to the water tank and/or the mixer or completely shut-off the flow of cold water to both the water tank and the mixer, based on an operating state in which the valve may be operating.

[0013] The water tank may be configured to receive the supply of cold water from the valve and heat the received water (via a heating source of the system). The water tank may not directly receive the supply of cold water from the utility water source and may instead receive the cold water via the valve. The water tank may be configured to supply the hot water stored in the water tank to the mixer.

[0014] The mixer may be in fluid communication with the water tank and the valve. The mixer may be configured to receive the hot water from the water tank, and the cold water from the valve (via the shunt). The mixer may not receive the supply of cold water directly from the utility water source but may instead receive the cold water via the valve. Since the mixer receives the hot water from the water tank, the mixer is connected to the “hot side” of the system. The mixer may be configured to mix/blend the hot water received from the water tank and the cold water received from the valve and output a “blended” water. A system user may use the water output from the mixer for various residential or commercial applications.

[0015] The valve may be configured to operate in a plurality of operating states, based on a plurality of parameters including, but not limited to, a temperature of hot water (“hot water temperature”) stored in the water tank, a temperature of water (“blended water temperature”) output by the mixer, a temperature of cold water (“cold water temperature”) received by the valve via the inlet port, a desired water temperature set by the system user, presence of water leak in the water tank, and/or the like. Based on an operating state in which the valve may be operating, the valve may either shut-off the supply of cold water to both the mixer and the water tank (e.g., when there may be a water leak in the water tank), or enable the flow of cold water to the mixer and/or the water tank (e.g., when there may be no water leak).

[0016] In some aspects, the housing may be configured to enclose one or more system components and protect them from ambient environment. For example, the water tank and one or more valve assembly components (e.g., the shunt) may be disposed in an interior portion of the housing. The housing may include a top pan or cover disposed on a top portion (or a side portion) of the housing. The cover may include a cover top surface and a cover bottom surface disposed opposite to the cover top portion. A space under or below the cover bottom surface and in the housing interior portion may be insulated (e.g., by using foam), and a space above the cover top surface may not be insulated (and exposed to ambient environment). In some aspects, the water tank and the shunt may be disposed in the housing interior portion under the cover bottom surface (i.e., in the “insulated area” of the housing interior portion).

[0017] In some aspects, the valve may include a valve stack and an actuator assembly that may be connected with each other. The valve stack may be configured to receive the cold water from the inlet port and divert the flow of cold water received from the inlet port to the water tank and/or the mixer, or completely shut-off the flow of cold water to both the water tank and the mixer, based on an operating state in which the valve may be operating.

[0018] The actuator assembly may include an actuator (which may be, e.g., a motor), a bracket and a first retainer clip. The actuator may be connected with the bracket via the first retainer clip. Further, the bracket may be attached to the valve stack, enabling the attachment/connection of the valve stack and the actuator assembly. A combined or connected structure of the valve stack and the actuator assembly may be connected with the valve body. In some aspects, the actuator, the bracket and the first retainer clip may be disposed above the cover top surface (i.e., above the cover).

[0019] The valve and the mixer may additionally include one or more temperature sensors that may also be disposed above the cover top surface (i.e., above the cover), thereby enabling the system operator to conveniently service the sensors (if required) without having to remove the cover.

[0020] In some aspects, the system may further include a first tank adapter and a second tank adapter, and the water tank may include a first coupler and a second coupler. The first tank adapter may be configured to be attached to the first coupler, and the second tank adapter may be configured to be attached to the second coupler. The valve assembly (specifically the valve and the mixer) may be conveniently attached to the water tank without requiring any external tools via the first tank adapter and the second tank adapter. For example, to attach the valve assembly to the water tank, the system operator may place or “drop” the valve on the first tank adapter (which may be connected to the first coupler of the water tank) and the mixer on the second tank adapter (which may be connected to the second coupler of the water tank). Responsive to placing the valve on the first tank adapter and the mixer on the second tank adapter, the system operator may secure the attachment of the valve and the mixer with respective tank adapters by inserting retainer clips (e.g., second and third retainer clips) in the bodies of the valve and the mixer. Once the retainer clips are inserted into the bodies of the valve and the mixer, the valve assembly may be securely connected with the water tank. In this manner, the system operator may conveniently attach the valve assembly to the water tank without requiring the use of any external tools. Stated another way, the valve assembly, as disclosed in the present disclosure, enables tool-less attachment of the valve assembly with the water tank, without requiring the system operator to use any attachment tools (e.g., wrenches, pliers, ratchet, etc.).

[0021] In the example described above, the system operator may be associated with a manufacturing/assembly facility where the valve assembly may be attached to the water tank in a “tool-less” manner. In certain embodiments, the first and second tank adapters (or the first and second couplers) described above may enable the system operator to attach the valve assembly (i.e., the valve and the mixer) to the water tank. In this case, the system operator may “swage” the valve and the mixer to the first and second tank adapters. In additional embodiments, the system may include a positive retention “lip” or structure that constrains the valve assembly from moving in the axial direction. In this case, the “flexible” shunt may force the valve flanges to stay under the lip. In yet another embodiment, the valve assembly and the water tank may be attached via an interference fit. The system operator may attach via interference fit by “pressing” the valve assembly onto the adapters or with a temperature differential. These different ways of attachment may enable the system operator to attach the valve assembly with the water tank in a tool-less manner.

[0022] The retainer clips described above (e.g., the second and third retainer clips) may be U-shaped clips. Other types of clips, e.g., c-clips, lock wires, clips like “hair pins,” etc. may also be used without departing from the scope of the present disclosure. In additional or alternative embodiments, the retainer clips may be replaced with a stamped sheet-metal part (made from a variety of materials) that provides spring-retained positive lock. In this case, the system may not require or have “loose” retainer clips.

[0023] It may appreciated that since a mixing valve is typically disposed at the “hot side” of a conventional water heating system (e.g., at a point where the hot water from the water tank mixes with the cold water), the mixing valve of a conventional water heating system is not equipped to completely shut-off the supply of cold water from the utility water source into the water tank in the event of a water leakage. Therefore, in some cases, a conventional water heating system may require two separate valves to operate optimally: one valve for mixing hot and cold water and a second valve for shutting off the supply of cold water in the event of a water leakage. On the other hand, in accordance with the present disclosure, since the valve is disposed at the “cold side” of the system and controls the flow of cold water towards the mixer and the water tank simultaneously, the valve, according to the present disclosure, is able to perform the operations of water mixing and shutting off the water supply within a single valve.

[0024] Further, since the valve is disposed on the “cold side” of the system and not on the “hot side,” the valve experiences considerably less scaling and structural degradation over time.

[0025] The present disclosure discloses a water heating system in which a mixing and shut-off combination valve of a valve assembly is disposed at the “cold side” of the system. Since the valve is disposed on the system's cold side, the valve may experience considerably less scaling and structural degradation over time, as compared to a mixing valve in a conventional heating system which is installed at the “hot side” of the system. Further, since the valve is disposed on the system's cold side, the valve can effectively function as a mixing valve as well as a shut-off valve, and the system is not required to have two separate valves for mixing and shutting-off operations. The system further enables the system operator to conveniently attach the valve assembly to the water tank without requiring use of any external tools (i.e., enables tool-less attachment of the valve assembly with the water tank).

[0026] Although certain examples of the disclosed technology are explained in detail herein, it is to be understood that other examples, embodiments, and implementations of the disclosed technology are contemplated. Accordingly, it is not intended that the disclosed technology is limited in its scope to the details of construction and arrangement of components expressly set forth in the following description or illustrated in the drawings. The disclosed technology can be implemented in a variety of examples and can be practiced or carried out in various ways. In particular, the presently disclosed subject matter is described in the context of systems and methods for installing a valve assembly in a water heating system. The present disclosure, however, is not so limited and can be applicable in other contexts. Accordingly, when the present disclosure is described in the context of systems and methods for installing a valve assembly in a water heating system, it will be understood that other implementations can take the place of those referred to.

[0027] Although the term “water” is used throughout this specification, it is to be understood that other fluids may take the place of the term “water” as used herein. Therefore, although described as systems and methods for installing a valve assembly in a water heating system, it is to be understood that the system and method described herein can apply to fluids other than water. Further, it is also to be understood that the term “water” can replace the term “fluid” as used herein unless the context clearly dictates otherwise. More so, the terms “cold” and “hot” are relative and may mean different degrees of varying temperatures and ranges based on the context. Thus, the terms “cold” and “hot” should not be limited to any temperature or temperature range.

[0028] Turning now to the drawings, FIG. 1 depicts a block diagram of an example water heating system 100 (or water heater 100 or system 100) and a view of a valve assembly 102 of the system 100 in accordance with one or more embodiments of the present disclosure. While describing FIG. 1, references will be made to FIGS. 2-5.

[0029] The system 100 may include a plurality of components including, but not limited to, the valve assembly 102, a storage tank 104 (or a water tank), a jacket or an enclosure or a housing 106, one or more first temperature sensors 108 (or first temperature sensor 108), a leak detector 110, a controller 112, and/or the like. The system 100 may include a plurality of additional components which are not shown in FIG. 1 for the sake of simplicity and conciseness, e.g., one or more heating sources configured to heat the water stored in the storage tank 104, heat exchangers or coils, and/or the like. The example depiction of the system 100 in FIG. 1 should not be construed as limiting.

[0030] The storage tank 104 may be configured to store water, which may be heated by the heating source(s) described above. The heating source(s) may be, for example, a gas burner, an electrical heating element, a heat pump, solar, and/or the like. The heating source(s) may heat the water stored in the storage tank 104 via one or more heating elements (e.g., heat exchanger coils, not shown) that may be disposed in an interior portion of the storage tank 104 or wrapped around an exterior surface of the storage tank 104. Alternatively, the heating source(s) may heat the water stored in the storage tank 104 via any other known means, without departing from the scope of the present disclosure.

[0031] The storage tank 104 may be of any size, shape, or configuration based on the water heating system application. For example, the storage tank 104 may be sized for common residential use or for commercial or industrial use that may require greater amounts of heated water. Furthermore, the storage tank 104 may be made of any suitable material for storing and heating water, including copper, carbon steel, stainless steel, ceramics, polymers, composites, or any other suitable material. The storage tank 104 may also be treated or lined with a coating to prevent corrosion and leakage. A suitable treating or coating will be capable of withstanding the temperature and pressure of the system 100 and may include, as non-limiting examples, glass enameling, galvanizing, thermosetting resin-bonded lining materials, thermoplastic coating materials, cement coating, or any other suitable treating or coating for the application.

[0032] In an exemplary aspect, the housing 106 may be shaped as a hollow cylinder or cuboid, with closed top and bottom portions. In other aspects, the housing 106 may have a similar shape as the storage tank 104. Although FIG. 2 depicts the housing 106 as a cylindrical structure, the example depiction of the housing 106 in FIG. 2 should not be construed as limiting. The housing 106 may be configured to enclose one or more system 100 components and protect them from ambient environment. For example, as shown in FIG. 1, the storage tank 104, the controller 112, one or more components of the valve assembly 102, the first temperature sensors 108, and/or the like may be located inside the housing 106 (or in a housing interior portion), and hence enclosed by the housing 106. The example depiction of the system 100 shown in FIG. 1 should not be construed as limiting, and one or more system 100 components shown to be located inside the housing 106 in FIG. 1 may be located outside the housing 106 in some embodiments, without departing from the scope of the present disclosure.

[0033] In an exemplary aspect, the housing 106 may include a top pan/lid or a cover 114 that may be disposed at a top portion of the housing 106. The cover 114 may be a removable cover, using which a system operator may access the housing interior portion. For example, the system operator may access the housing interior portion via the housing top portion (or a housing side portion if the cover 114 is installed at a sidewall of the housing 106) when the cover 114 is removed. Further, the housing interior portion may be inaccessible to the system operator when the cover 114 is placed/secured on the housing top portion. Although FIGS. 1 and 2 depict that the cover 114 is located at the housing top portion, the present disclosure is not limited to such an aspect. In alternative aspects, the cover 114 may be disposed on a housing sidewall.

[0034] The cover 114 may include a cover top surface 116 and a cover bottom surface 118, as shown in FIG. 1. The cover top surface 116 may be disposed opposite to the cover bottom surface 118. Further, the cover top surface 116 may be exposed to ambient environment. In some aspects, the storage tank 104 may be disposed/located in the housing interior portion, under or below the cover bottom surface 118. In some aspects, a space “A” (shown in FIG. 2) between the cover bottom surface 118 and the storage tank 104 may be insulated (e.g., via foam or any other insulating material). Stated another way, the space “A” below the cover bottom surface 118 may be insulated. On the other hand, a space “B” above or on top of the cover top surface 116 may not be insulated or be uninsulated. Since the storage tank 104 is disposed under the cover bottom surface 118, the storage tank 104 may be located in an “insulated area” of the system 100/housing interior portion. It may be appreciated that insulation in the housing interior portion prevents heat loss from the storage tank 104 (or other system components disposed in the housing interior portion), and hence facilitates in maintaining or enhancing the system efficiency.

[0035] In an exemplary aspect, the first temperature sensors 108 may be disposed along a length of the interior surface of the storage tank 104. Although FIG. 1 depicts two first temperature sensors 108, the system 100 may include more or less than two first temperature sensors 108. The first temperature sensor 108 may be configured to determine a water temperature (or “hot water temperature”) of the hot water stored in the storage tank 104. The first temperature sensor 108 may be communicatively coupled with the controller 112 and may share inputs associated with the hot water temperature with the controller 112 continuously or at a predefined frequency.

[0036] In certain embodiments, the leak detector 110 may be disposed on the storage tank 104 (e.g., at the interior surface or an exterior surface of the storage tank 104) or spaced apart from the storage tank 104 and may be configured to detect a water leak in the storage tank 104. Although FIG. 1 depicts that the leak detector 110 is disposed at a bottom portion of the storage tank 104, the present disclosure is not limited to such an arrangement. The leak detector 110 may be located anywhere on or in proximity to the storage tank 104, without departing from the scope of the present disclosure. In further aspects, in addition to detecting the water leak in the storage tank 104, in certain instances, the leak detector 110 may also be configured to detect water leak in other components of the system 100. Similar to the first temperature sensor 108, the leak detector 110 may also be communicatively coupled with the controller 112 and may share inputs associated with the water leak in the storage tank 104 (or other components of the system 100) with the controller 112 continuously or at a predefined frequency.

[0037] The controller 112 may be configured to control operation of the valve assembly 102 based on inputs obtaining from the first temperature sensor 108, the leak detector 110, and one or more temperature sensors included in the valve assembly 102, as described in the description later below.

[0038] The valve assembly 102 may be configured to receive a supply of cold water 120 (e.g., from a utility water source) and output water 122 at a desired water temperature (that may be set by a system user), which may be used by the system user for various residential, commercial or industrial applications. Although FIG. 1 depicts the valve assembly 102 being disposed in proximity to a top portion of the storage tank 104/housing 106, the present disclosure is not limited to such an arrangement. In some aspects, the valve assembly 102 may be disposed in proximity to a side portion of the storage tank 104/housing 106, without departing from the scope of the present disclosure.

[0039] The valve assembly 102 may include a plurality of components including, but not limited to, a valve 124, a mixing tee or a mixer 126, a connector or a shunt 128, and/or the like. The valve 124 may be in fluid communication with (or connected with) the mixer 126 and the storage tank 104. In some aspects, the valve 124 may be configured to receive the supply of cold water 120 and control a flow of cold water to the mixer 126 and the storage tank 104 based on an operating state in which the valve 124 may be operating. For example, the valve 124 may transfer the cold water 120 fully to the storage tank 104 when the valve 124 is operating in a first operating state, partially to the storage tank 104 and partially to the mixer 126 (via the shunt 128) when the valve 124 is operating in a second operating state, fully to the mixer 126 (via the shunt 128) when the valve 124 is operating in a third operating state, or completely shut-off the supply/flow of cold water to both the storage tank 104 and the mixer 126 when the valve 124 is operating in a fourth operating state. In any operating state, the valve 124 does not receive the hot water from the storage tank 104. The valve 124 is only configured to transfer the cold water to the storage tank 104 and/or the mixer 126, or completely shut-off the supply of cold water to both the storage tank 104 and the mixer 126.

[0040] In some aspects, the valve 124 may be connected with the mixer 126 via the shunt 128, which may be made of a flexible material. In an exemplary aspect, the shunt 128 may be made of copper, polyethylene (e.g., high density polyethylene), and/or the like. The mixer 126 may be configured to receive the cold water from the valve 124 via the shunt 128. Further, the storage tank 104 may be connected with both the valve 124 and the mixer 126 and configured to receive the cold water from the valve 124 (as described above) and supply the hot water to the mixer 126.

[0041] The mixer 126 may be configured to receive the hot water from the storage tank 104, blend the received hot water and the cold water (that the mixer 126 receives from the valve 124 via the shunt 128), and output the blended water 122 at the desired water temperature.

[0042] In some aspects, the shunt 128 may be disposed/located under or below the cover bottom surface 118 and above the storage tank 104, as shown in FIGS. 1 and 2. Stated another way, the shunt 128 may be disposed in the “insulated area” of the housing interior portion, thereby ensuring protection of the shunt 128 from ambient environment. In some aspects, since the area under the cover bottom surface 118 is already insulated with foam, separate or external insulation is not required to insulate the shunt 128 (and other valve assembly components that are disposed under the cover bottom surface 118). In some aspects, the shunt 128 may be omitted, and the valve 124 may be connected with the mixer 126 via one or more quick connect assemblies and pipes, which may be made of a flexible material. In such instances, the valve 124 and/or the mixer 126 may be disposed at any location about the tank 104, such as on top of the tank or on the side of the storage tank. For example, the valve 124 may be disposed at the top of the storage tank 104 as depicted, and the mixer 126 may be disposed on the side of the storage tank 104.

[0043] In some aspects, the valve 124 may include an inlet port 130, an inlet water conduit 302 (as shown in FIG. 3), a valve stack 304, an actuator assembly 306, a valve body 132, and/or the like, as shown in FIGS. 1, 2 and 3. The inlet port 130 may be configured to receive the supply of cold water 120 and transfer the cold water 120 to the inlet water conduit 302. In an exemplary aspect, both the inlet port 130 and the inlet water conduit 302 may be cylindrical in shape and may have similar diameters in a range of 0.5 to 1 inch. The inlet water conduit 302 may be configured to transfer the cold water 120 to the valve stack 304. Stated another way, the valve stack 304 may be configured to receive the cold water 120 via the inlet port 130 and the inlet water conduit 302. In some instances, the distal end of the inlet port 130 may include threads for attaching a water inlet for the supply of cold water 120. The inlet port 130 may include a flat surface (or cutout) feature adjacent to (e.g., below relative to the flow of water into the inlet port 130) the threads for applying a wrench to prevent torquing the valve assembly when attaching water lines thereto. Similarly, in some instances, the distal end of the mixer 126 may include threads for attaching a water outlet. The mixer 126 may include a flat surface (or cutout) feature adjacent to (e.g., upstream relative to the flow of water out of the mixer 126) the threads for applying a wrench to prevent torquing the valve assembly when attaching water lines thereto.

[0044] The valve stack 304 may include a plurality of components that may enable the valve stack 304 to control/regulate the flow of cold water 120 to the mixer 126 and the storage tank 104 based on the operating state of the valve 124/valve stack 304. Examples of the components included in the valve stack 304 include, but are not limited to, a shaft (not shown), a spool or one or more rotating discs (shown as rotating discs 308 in FIG. 3), a shunt check valve 310, and/or the like, which may enable the valve stack 304 to regulate the flow of cold water to the mixer 126 via the shunt 128 (shown by arrows 312) and the storage tank 104 (shown by arrows 314), based on the operating state of the valve stack 304. In an exemplary aspect, the operating state of the valve stack 304 is based on a state/position/configuration/arrangement of the spool or the rotating discs 308 in the valve stack 304.

[0045] The actuator assembly 306 may be connected with the valve stack 304 and may include a plurality of components including, but not limited to, an actuator 134, a bracket 136, a first retainer clip 138 (which may be made of plastic and/or metal), and/or the like (as shown in FIGS. 1, 2 and 3). In some aspects, the actuator 134 may be a motor (e.g., a servo motor, a linear motor, etc.), which may be configured to be attached to the bracket 136 via the first retainer clip 138. In an exemplary aspect, the first retainer clip 138 may be wrapped around the actuator 134, and the two ends of the first retainer clip 138 may be attached to the respective ends of the bracket 136 to enable the attachment between the actuator 134 and the bracket 136.

[0046] In some aspects, the actuator 134 may be connected to the spool or the rotating discs 308 via the shaft described above and configured to control the operating state of the valve stack 304 (and hence the valve 124). For example, the actuator 134 may cause a linear and/or rotatory motion of the spool or the rotating discs 308 to change the operating state of the valve stack 304, thereby controlling the flow of cold water into the mixer 126 and the storage tank 104. In some aspects, the actuator 134 may be communicatively coupled with the controller 112, and the actuator 134 may cause the linear and/or rotatory motion of the spool or the rotating discs 308 to change the operating state of the valve stack 304 based on command signals received from the controller 112.

[0047] In some aspects, the actuator 134 may be disposed above the cover top surface 116. Stated another way, the actuator 134 is not disposed in the “insulated area” of the housing interior portion but may instead be disposed/located above the cover top surface 116 which is an “uninsulated area” of the system 100.

[0048] In certain embodiments, the system 100 may include one or more additional components that may enable a system operator to conveniently attach/install the valve assembly 102 to the storage tank 104 in the example arrangement/configuration described above and conveniently detach one or more valve assembly 102 components whenever required (e.g., when servicing of the components may be required). For example, in an exemplary aspect, the system 100 may include a first tank adapter 402 and a second tank adapter 404 (as shown in FIG. 4A), which may enable the valve assembly 102 to be connected to the storage tank 104.

[0049] The first tank adapter 402 and the second tank adapter 404 may be made of the same material and may have the same dimensions. In an exemplary aspect, each tank adapter 402, 404 may have a hollow cylindrical shape (having a diameter in a range of 0.5-1.5 inches), having a first portion 406 and a second portion 408 separated by a hex-structure 410. In an exemplary aspect, the second portion 408 may be threaded, as shown in FIG. 4A.

[0050] The storage tank 104 may include or be connected with a first coupler 412 and a second coupler 414, which may be disposed at a top portion (or a side portion) of the storage tank 104. The first and second couplers 412, 414 may have hollow cylindrical shapes, and an internal diameter of the first and second couplers 412, 414 may be equivalent to the diameters of the first and second tank adaptors 402, 404. In some aspects, the inner surfaces of the first and second couplers 412, 414 may be threaded. The first coupler 412 may be configured to be attached or connected to the first tank adapter 402 via the threading of the second portion 408 and the threading of the inner surface of the first coupler 412. Similarly, the second coupler 414 may be configured to be attached or connected to the second tank adapter 404 via the threading of its second portion 408 and the threading of the inner surface of the second coupler 414.

[0051] In some aspects, the valve 124 (specifically the bottom end of the valve 124) may be configured to be attached to the first portion 406 of the first tank adapter 402 via a second retainer clip 416 (which may be similar to the first retainer clip 138). In this manner, when the first tank adapter 402 is attached to the first coupler 412, the attachment of the valve 124 with the first portion 406 of the first tank adapter 402 enables the valve 124 to be attached to the storage tank 104 (via the first tank adapter 402 and the second retainer clip 416). Similarly, the mixer 126 (specifically the bottom end of the mixer 126) may be configured to be attached to the first portion 406 of the second tank adapter 404 via a third retainer clip 418 (which may also be similar to the first retainer clip 138). In this manner, when the second tank adapter 404 is attached to the second coupler 414, the attachment of the mixer 126 with the first portion 406 of the second tank adapter 404 enables the mixer 126 to be attached to the storage tank 104 (via the second tank adapter 404 and the third retainer clip 418).

[0052] The retainer clips described above (e.g., the second and third retainer clips 416, 418) may be U-shaped clips. Other types of clips, e.g., c-clips, lock wires, clips like “hair pins,” etc. may also be used without departing from the scope of the present disclosure. In additional or alternative embodiments, the retainer clips may be replaced with a stamped sheet-metal part (made from a variety of materials) that provides spring-retained positive lock. In this case, the system may not require or have “loose” retainer clips.

[0053] The components described above enable the system operator to conveniently attach/install the valve assembly 102 to the storage tank 104 in a “tool-less attachment” manner (i.e., the system operator is not required to use any external tools such as wrenches, etc. to install the valve assembly 102 to the storage tank 104). In an exemplary aspect, to install the valve assembly 102 to the storage tank 104, the system operator may first attach the first tank adapter 402 with the first coupler 412 and attach the second tank adapter 404 with the second coupler 414, as shown in FIG. 4A. Once these components are attached, the system operator may place and push (or “drop”) the valve assembly 102 (which includes the valve 124, the mixer 126 and the shunt 128 in connected or assembled stated) onto the first portions 406 of the first and second tank adapters 402 and 404, as shown by arrows 420 in FIG. 4B. Specifically, the system operator may place the mixer 126 on the second tank adapter 404 and the valve 124 on the first tank adapter 402 and then push the valve assembly 102 downwards towards the storage tank 104 to attach the valve 124 with the first tank adapter 402 and the mixer with the second tank adaptor 404. In some aspects, the system operator may not need any tools to attach the valve assembly 102 to the first and second tank adapters 402, 404 and may instead just push the valve assembly 102 downwards to make the attachment with the first and second tank adapters 402, 404. In this manner, the components described above enable tool-less attachment of the valve assembly 102 with the storage tank 104, without requiring the system operator to use any attachment tools (e.g., wrenches, pliers, ratchet, etc.).

[0054] In alternative aspects (not shown) of the present disclosure, the system 100 may not include the first tank adapter 402 and the second tank adapter 404. In this case, the valve assembly 102 may be connected to the storage tank 104 via the first and second couplers 412, 414 and the second and third retainer clips 416, 418. Stated another way, in this case, the first and second couplers 412, 414 and the second and third retainer clips 416, 418 may enable tool-less attachment of the valve assembly 102 with the storage tank 104.

[0055] In certain embodiments, the first and second tank adapters 402, 404 (or the first and second couplers 412, 414) described above may enable a system operator to attach the valve assembly 102 (i.e., the valve 124 and the mixer 126) to the storage tank 104. In this case, the system operator may “swage” the valve 124 and the mixer 126 to the first and second tank adapters 402, 404. In additional embodiments, the system may include a positive retention “lip” or structure that constrains the valve assembly 102 from moving in the axial direction. In this case, the “flexible” shunt 128 may force the valve flanges to stay under the lip. In yet another embodiment, the valve assembly 102 and the storage tank 104 may be attached via interference fit. The system operator may attach via interference fit by performing pressing the valve assembly 102 onto the storage tank 104 or with a temperature differential. These different ways of attachment may enable the system operator to attach the valve assembly 102 with the storage tank 104 in a tool-less manner.

[0056] The process of attachment of the valve assembly 102 with the storage tank 104 described above (i.e., pushing or dropping the valve assembly 102 onto the adapters or the couplers, without requiring any external tools, as described above) may be considered as a tool-less attachment process of the valve assembly 102 with the storage tank 104.

[0057] In some aspects, the first portion 406 may include one or more O-rings 422 (as shown in FIG. 4A) that may be wrapped around the circumference of the first portion 406. The O-rings 422 may be configured to seal the valve 124/mixer 126 with the respective first and second tank adapters 402, 404 and ensure that no water gets leaked from the connection of the valve 124/mixer 126 with the respective first and second tank adapters 402, 404, when the system 100 is in operation. In some aspects, the hex-structure 410 enables the system operator to attach the valve 124/mixer 126 with the respective first and second tank adapters 402, 404 via automated drivers, without damaging the O-rings 422.

[0058] Furthermore, it may be appreciated that in some instances, the positions of the first and second couplers 412, 414 relative to each other may not exactly be the same in all storage tanks. Therefore, to factor-in or compensate for some variations in the relative positioning of the first and second couplers 412, 414, the shunt 128 is made of a flexible material. Therefore, while installing/pushing the valve assembly 102 onto the first and second tank adapters 402, 404, the system operator may manually adjust (shown by arrows 424 in FIG. 4B) the relative positions of the valve 124 and mixer 126 via the flexible shunt 128 to make them aligned with the first and second tank adapters 402, 404 (and hence aligned with the first and second couplers 412, 414), to enable secure and stable attachment of the valve assembly 102 with the storage tank 104.

[0059] After the valve 124 and mixer 126 are attached with the respective first and second tank adapters 402, 404 as described above, the system operator may insert the second retainer clip 416 into through-holes 426 present in proximity to the bottom end of the valve 124 (as shown in FIG. 4C) and the third retainer clip 418 into the through-holes present in proximity to the bottom end of the mixer 126 to secure the attachment of the valve assembly 102 with the storage tank 104. In this manner, the system operator may conveniently attach the valve assembly 102 with the storage tank 104 without the use of any external tools (i.e., perform “tool-less” attachment of the valve assembly 102 with the storage tank 104).

[0060] In some aspects, to protect the valve 124 and/or the mixer 126 from torque (due to water supply, or torque generated during installation/maintenance process), the bottom ends of the valve 124 and the mixer 126 (which mates with the first and second tank adapters 402, 404) may include a double-hex socket interface 502 (which may include a series of similarly-shaped triangular corrugations or isosceles “prism-shaped” structure, as shown in FIG. 5), which may prevent the valve 124 and the mixer 126 from rotating during system 100 operation. In other aspects, the valve 124 and/or the mixer 126 may not include the double-hex socket interface 502, and the system 100 may instead include/employ other measures to mitigate the effects of torque on the valve 124 and the mixer 126, e.g., by using an enforcement bracket (not shown) attached between the valve 124 and the mixer 126, welding the first and second couplers 412, 414 with hex features, welding one or more support structures on the storage tank 104, and/or the like. Examples of the measures described here should not be construed as limiting, and the system 100 may employ additional or alternative measures to mitigate the effects of torque on the valve 124 and the mixer 126.

[0061] In some aspects, after the valve assembly 102 is attached to the storage tank 104 as described above, the system operator may place the cover 114 on the top portion of the housing 106. After the cover 114 is placed on the housing top portion, one or more system/valve assembly components such as the shunt 128, the first tank adapter 402, the second tank adapter 404, the first coupler 412, the second coupler 414, the second retainer clip 416 and the third retainer clip 418 may get disposed under the cover bottom surface 118. Further, the cover 114 may include a first cut-out 202 and a second cut-out 204 (as shown in FIG. 2) through which one or more mixer and valve components may protrude out from the cover top surface 116, when the cover 114 is placed on the housing top portion. For example, a top portion 206 of the mixer 126 may protrude out of the cover top surface 116 via the first cut-out 202 when the cover 114 is placed on the housing top portion. In some aspects, the top portion 206 may include a mixer outlet 208 through which the blended water 122 may be dispensed by the mixer 126. In a similar manner, one or more valve components such as the actuator 134, the first retainer clip 138, and the bracket 136 may protrude out of the cover top surface 116 via the second cut-out 202 when the cover 114 is placed on the housing top portion.

[0062] In some aspects, the valve assembly 102 may additionally include foam structures or foam dams 140a, 140b that may be attached to the bodies of the mixer 126 and the valve 124, as shown in FIGS. 1 and 2. The foam dams 140a, 140b may be insulated plates that may enable secure attachment of the valve assembly 102 (specifically the mixer 126 and the valve 124) to the housing 106. In an exemplary aspect, the foam dams 140a, 140b may be lightly compressed between the flanges of the mixer 126 and the valve 124 and the underside of the cover 114 (or the cover bottom surface 118). In some aspects, the foam dams 140a, 140b may “rest” against the cover bottom surface 118 and cover/protect/insulate the mixer and valve components underneath the first and second cut-outs 202, 204, when the cover 114 is placed over the housing top portion. The foam dams 140a, 140b allow the mixer 126 and the valve 124 to be rotated (as shown by arrows 424 by approximately a maximum of 15 degrees) about their respective centerlines to accommodate for any geometric variation of the valve 124/mixer 126 with the storage tank assembly/geometry.

[0063] The foam dams 140a, 140b may be of any shape, and the example shapes of the foam dams 140a, 140b depicted in FIGS. 1 and 2 should not be construed as limiting. Further, in alternative aspects, the valve assembly 102 may not include the foam dams 140a, 140b and instead may include any other means of insulating the mixer and valve components underneath the first and second cut-outs 202, 204.

[0064] Although the description above describes an aspect where the system operator places the cover 114 on the housing top portion responsive to attaching the valve assembly 102 to the storage tank 104, the present disclosure is not limited to such an aspect. In some aspects, the system operator may first insulate the space “A” (shown in FIG. 2) between the cover bottom surface 118 and the storage tank 104 with foam, before placing the cover 114 on the housing top portion. Further, once the space “A” is insulated and the cover 114 is placed on the housing top portion, the valve assembly components underneath the cover bottom surface 118 may become inaccessible/un-serviceable, and the valve assembly components above the cover top surface 116 may be accessible/serviceable. However, in some instances, cutouts or access openings may be provided in the foam (e.g., lateral access ports) to access the retainer clips 416, 418.

[0065] In some aspects, the valve 124 may further include a second temperature sensor 142 that may be configured to determine a temperature of the cold water 120 (or cold water temperature) entering the valve 124 from the inlet port 130. Similarly, the mixer 126 may further include a third temperature sensor 144 that may be configured to detect the water temperature of the blended water 122 (or blended water temperature) that may be output from the mixer 126. Both the second and third temperature sensors 142, 144 may be communicatively coupled with the controller 112 and may share inputs associated with the cold water temperature and the blended water temperature respectively with the controller 112 continuously or at a predefined frequency. In some aspects, one or both the second and third temperature sensors 142, 144 may be disposed/located above the cover top surface 116, when the cover 114 may be placed on the housing top portion.

[0066] As described above, the system 100 further includes the controller 112 that may be configured to control operation of the valve assembly 102 (specifically, the valve 124) based on the inputs obtaining from the first temperature sensor 108, the leak detector 110, the second temperature sensor 142 and the third temperature sensor 144. Specifically, the controller 112 may be configured to obtain the inputs from the first, second, third temperature sensors 108, 142, 144, and the leak detector 110 and generate command signals to be transmitted to the actuator 134 to change/control the operating state of the valve 124 based on the obtained inputs and the desired water temperature (which may be set by the system user). In some aspects, the controller 112 may be configured to generate and transmit the command signals to the actuator 134 to cause the valve 124 to operate in the first, second, third or fourth operating state described above, based on the obtained inputs and the desired water temperature. An example controller operation is described below.

[0067] In some aspects, the controller 112 may be configured to determine a presence of water leak in the storage tank 104 (or other system components) based on the inputs obtained from the leak detector 110. Responsive to determining the presence of water leak, the controller 112 may cause, via the actuator 134, the valve 124 to operate in the fourth operating state. Stated another way, responsive to determining the presence of water leak, the controller 112 may cause the valve 124 to completely shut off the supply of cold water to both the mixer 126 and the storage tank 104.

[0068] On the other hand, responsive to determining that there is no water leak in the storage tank 104 (or other system components) based on the inputs obtained from the leak detector 110, the controller 112 may cause the valve 124 to enable a flow of cold water into the storage tank 104 and/or the mixer 126. Stated another way, responsive to determining that there is no water leak in the storage tank 104 (or other system components) based on the inputs obtained from the leak detector 110, the controller 112 may cause the valve 124 to operate in the first, second or third operating state. In some aspects, the controller 112 may cause the valve 124 to operate in the first, second, or third operating state based on the hot water temperature (i.e., the water temperature of the hot water stored in the storage tank 104 detected by the first temperature sensor 108), the cold water temperature (i.e., the water temperature of the cold water 120 received from the inlet port 130 detected by the second temperature sensor 142), the blended water temperature (i.e., the water temperature of the blended water 122 output from the mixer 126 detected by the third temperature sensor 144), and the desired water temperature set by the system user.

[0069] In an exemplary aspect, the controller 112 may cause the valve 124 to operate in the first operating state when the hot water temperature may be equivalent to the desired water temperature that the system user requires. Stated another way, the controller 112 may cause the valve 124 to transfer the cold water 120 fully to the storage tank 104 (and not transfer any cold water to the mixer 126) when the controller 112 determines that the hot water temperature may be equivalent to the desired water temperature.

[0070] Further, the controller 112 may cause the valve 124 to operate in the third operating state when the hot water temperature may be greater than the desired water temperature. Stated another way, the controller 112 may cause the valve 124 to transfer the cold water 120 fully to the mixer 126 (and not transfer any cold water to the storage tank 104) when the controller 112 determines that the hot water temperature may be substantially greater than the desired water temperature.

[0071] Furthermore, the controller 112 may cause the valve 124 to operate in the second operating state when the hot water temperature may be greater (but not substantially greater) than the desired water temperature. In some aspects, when the valve 124 operates in the second operating state, the controller 112 may be further configured to determine an “optimal” portion of the cold water received from the inlet port 130 to be transferred to the mixer 126 based on the hot water temperature, the blended water temperature, the cold water temperature, and the desired water temperature. The controller 112 may determine the optimal portion of the cold water such that the blended water temperature becomes equivalent to the desired water temperature. For example, the controller 112 may determine that 60% of the cold water received from the inlet port 130 should be transferred to the mixer 126 (and remaining 40% to the storage tank 104) based on the hot water temperature, the cold water temperature, the blended water temperature and the desired water temperature, to cause the blended water temperature to become equivalent to the desired water temperature.

[0072] In some aspects, the controller 112 may be a proportional-integral-derivative (PID) or proportional-integral (PI) controller that may utilize a closed-loop feedback control mechanism that continuously adjusts outputs (e.g., the optimal portion of the cold water described above) based on the real-time measured hot water temperature, the blended water temperature, and the cold water temperature. For example, if the real-time measured hot water temperature indicates that the temperature of the water stored in the storage tank 104 is gradually decreasing, the controller 112 may reduce the amount of cold water to be transferred to the mixer 126, so that the blended water temperature stays equivalent to the desired water temperature. It may be appreciated that during a hot water demand event when hot water is being drawn from the storage tank 104, the hot water temperature may change over time. Based on the real-time feedback from the first temperature sensor 108, the controller 112 may adjust the portion of water to be transferred to the mixer 126 to continue to discharge water at the desired water temperature.

[0073] Responsive to determining the optimal portion of the cold water, the controller 112 may cause the valve 124 to transfer the determined optimal portion of the cold water to the mixer 126.

[0074] In some aspects, the valve 124 operates in the fourth operating state whenever a water leak is detected in the storage tank 104 by the leak detector 110, regardless of the values of the hot water temperature, the cold water temperature, the blended water temperature and the desired water temperature. Stated another way, the valve 124 operates in the first, second or third operating states described above only when no water leak is detected by the leak detector 110. The valve 124 completely shuts off the supply of cold water to the mixer 126 and the storage tank 104 in the fourth operating state to prevent any damage to the system components because of the water leakage.

[0075] A person ordinarily skilled in the art may appreciate that since a mixing valve is typically disposed at the “hot side” of a conventional water heating system (e.g., at a point where the hot water from the storage tank mixes with the cold water from the inlet), the mixing valve of a conventional water heating system is not equipped to completely shut-off the supply of cold water from the inlet into the storage tank in the event of a water leakage. Therefore, in some cases, a conventional water heating system may require two separate valves to operate optimally: one valve for mixing hot and cold water and a second valve for shutting off the supply of cold water in the event of a water leakage. On the other hand, in the case of the system 100, since the valve 124 is disposed at the “cold side” of the system 100 (i.e., at the inlet port 130 that transfers the cold water 120 to the valve 124) and controls the flow of cold water towards the mixer 126 and the storage tank 104 simultaneously, the valve 124 is able to enable the operations of water mixing and shutting off the water supply within a single valve.

[0076] Further, it may be appreciated from the description above that since the “moving parts” of the valve 124 (i.e., the spool or the rotating discs 308) are disposed on the “cold side” of the system 100 (i.e., at the inlet port 130 that transfers the cold water 120 to the valve 124) and not on the “hot side” of the system 100 (i.e., at a point where the hot water from the storage tank 104 is received), the valve 124 experiences considerably less scaling and structural degradation over time. A person ordinarily skilled in the art may appreciate if the valve 124, including its moving parts, would have been disposed at the “hot side” of the system 100, the valve 124 would have experienced considerable scaling over time, and the hot water received from the storage tank 104 would have degraded the structural integrity of the valve 124. The system 100 alleviates this issue by having the valve 124 disposed at the “cold side” of the system 100, thus considerably increasing the life of the valve 124.

[0077] FIG. 6 depicts a block diagram of the controller 112 in accordance with one or more embodiments of the present disclosure. The controller 112 may include a plurality of components including, but not limited to, a processor 602, a memory 604, and a communication interface 606. The controller 112 may be a computing device configured to receive data, determine actions based on the received data, and output a control or command signal instructing one or more water heating system components (e.g., the actuator 134) to perform one or more actions. In some aspects, the controller 112 may be configured to receive the inputs from the first, second, third temperature sensors 108, 142, 144, the leak detector 110, etc., as described above.

[0078] In some aspects, the controller 112 may be configured to send and receive wireless or wired signals, and the signals may be analog or digital signals. The wireless signals may include Bluetooth™, BLE, WiFi™, ZigBee™, infrared, microwave radio, or any other type of wireless communication signals as may be suitable for a particular water heating system application. The hard-wired signals can include communication signals between any directly wired connections between the controller 112 and other water heating system components. For example, the controller 112 can be hard-wired to the first, second, third temperature sensors 108, 142, 144, and the leak detector 110.

[0079] Alternatively, the controller 112 may communicate with the first, second, third temperature sensors 108, 142, 144, and the leak detector 110 via a digital connection. The digital connection can include a connection such as an Ethernet or a serial connection and can utilize any suitable communication protocol for the water heating system application, such as Modbus, fieldbus, PROFIBUS, SafetyBus, Ethernet/IP, and/or the like. Furthermore, the controller 112 can utilize a combination of wireless, hard-wired, and analog or digital communication signals to communicate with and control the various water heating system components. A person ordinarily skilled in the art may appreciate that the above configurations are given merely as non-limiting examples and the actual configuration can vary depending on the particular water heating system application.

[0080] The memory 604 may be configured to store a program and/or instructions associated with the functions and methods described herein. The processor 602 may be configured to execute the program and/or instructions stored in the memory 604. The memory 604 can include one or more suitable types of memory (e.g., volatile or non-volatile memory, random access memory (RAM), read only memory (ROM), programmable read-only memory (PROM), erasable programmable read-only memory (EPROM), electrically erasable programmable read-only memory (EEPROM), magnetic disks, optical disks, floppy disks, hard disks, removable cartridges, flash memory, a redundant array of independent disks (RAID), and the like) for storing files including the operating system, application programs (including, for example, a web browser application, a widget or gadget engine, and or other applications, as necessary), executable instructions and data. One, some, or all of the processing techniques or methods described herein can be implemented as a combination of executable instructions and data within the memory 604.

[0081] The communication interface 606 may be configured to send or receive communication signals between the various water heating system components (e.g., the first, second, third temperature sensors 108, 142, 144, and the leak detector 110). The communication interface 606 can include hardware, firmware, and/or software that allows the processor 602 to communicate with the other components via wired or wireless networks, whether local or wide area, private or public, as known in the art. The communication interface 606 can also provide access to a cellular network, the Internet, a local area network, or another wide-area network as suitable for the particular water heating system application.

[0082] Additionally, the controller 112 may have or be in communication with a user interface (not shown) for receiving inputs from the user (e.g., the desired water temperature described above). The user interface may be installed locally on the system 100.

[0083] The operation of the controller 112 is described above in conjunction with FIG. 1 and hence not described again here for the sake of simplicity and conciseness.

[0084] FIG. 7 depicts a flow diagram of a method 700 for installing the valve assembly 102 in the system 100 in accordance with one or more embodiments of the present disclosure. FIG. 7 may be described with continued reference to prior figures. The following process is exemplary and not confined to the steps described hereafter. Moreover, alternative embodiments may include more or less steps than are shown or described herein and may include these steps in a different order than the order described in the following example embodiments.

[0085] The method 700 starts at step 702. At step 704, the method 700 may include attaching the first tank adapter 402 with the first coupler 412 and attaching the second tank adapter 404 with the second coupler 414, as shown in FIG. 4A. At step 706, the method 700 may include placing the valve assembly 102 on the first and second tank adapters 402, 404. Specifically, the mixer 126 may be placed on the second tank adapter 404 and the valve 124 may be placed on the first tank adapter 402, as shown in FIG. 4B. At step 708, the method 700 may include inserting the second retainer clip 416 into through-holes 426 present in proximity to the bottom end of the valve 124 (as shown in FIG. 4C) and the third retainer clip 418 into the through-holes present in proximity to the bottom end of the mixer 126 to secure the attachment of the valve assembly 102 with the storage tank 104.

[0086] The method 700 stops at step 710.

[0087] In the above disclosure, reference has been made to the accompanying drawings, which form a part hereof, which illustrate specific implementations in which the present disclosure may be practiced. It is understood that other implementations may be utilized, and structural changes may be made without departing from the scope of the present disclosure. References in the specification to “one embodiment,” “an embodiment,” “an example embodiment,” etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a feature, structure, or characteristic is described in connection with an embodiment, one skilled in the art will recognize such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described.

[0088] It should also be understood that the word “example” as used herein is intended to be non-exclusionary and non-limiting in nature. More particularly, the word “example” as used herein indicates one among several examples, and it should be understood that no undue emphasis or preference is being directed to the particular example being described.

[0089] With regard to the processes, systems, methods, heuristics, etc. described herein, it should be understood that, although the steps of such processes, etc. have been described as occurring according to a certain ordered sequence, such processes could be practiced with the described steps performed in an order other than the order described herein. It further should be understood that certain steps could be performed simultaneously, that other steps could be added, or that certain steps described herein could be omitted. In other words, the descriptions of processes herein are provided for the purpose of illustrating various embodiments and should in no way be construed so as to limit the claims.

[0090] Accordingly, it is to be understood that the above description is intended to be illustrative and not restrictive. Many embodiments and applications other than the examples provided would be apparent upon reading the above description. The scope should be determined, not with reference to the above description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. It is anticipated and intended that future developments will occur in the technologies discussed herein, and that the disclosed systems and methods will be incorporated into such future embodiments. In sum, it should be understood that the application is capable of modification and variation.

[0091] All terms used in the claims are intended to be given their ordinary meanings as understood by those knowledgeable in the technologies described herein unless an explicit indication to the contrary is made herein. In particular, use of the singular articles such as “a,” “the,” “said,” etc., should be read to recite one or more of the indicated elements unless a claim recites an explicit limitation to the contrary. Conditional language, such as, among others, “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments could include, while other embodiments may not include, certain features, elements, and/or steps. Thus, such conditional language is not generally intended to imply that features, elements, and/or steps are in any way required for one or more embodiments.