STORED WATER HEATER WITH ADVANCED THERMAL LAYERING TECHNOLOGY

Abstract

An improved storage water heater is disclosed. The optimized storage water heater includes an inlet diffuser that is designed for enhancing the hot water stratification within the water heater tank. It features a single-part structure with a central, concentric inlet passage for cold water, creating a helical flow path formed by a spiral-shaped structure around the inlet. A conical inner core within the helical path decreases in diameter upwards, and downward-angled helical corners aid in shearing and redirecting water flow downwards in the tank. Another embodiment includes an inlet diffuser with an array of conical fins, supported by vertical ribs, and a central conical core with a decreasing diameter upwards resulting a formation of series of divergent nozzles shrouded around the conical inner core These designs improve heater efficiency, enabling users to extract more hot water with the same power, even at higher flow rates, compared to conventional designs.

Specification

Description:FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
As amended by the Patents (Amendment) Act, 2005
&
The Patents Rules, 2003
As amended by the Patents (Amendment) Rules, 2016 (as amended in 2024)

COMPLETE SPECIFICATION
(See Section 10 and Rule 13)

TITLE OF THE INVENTION:
STORED WATER HEATER WITH ADVANCED THERMAL LAYERING TECHNOLOGY

APPLICANT:
Name: M/s V-Guard Industries Ltd.
Address: 42/962, Vennala High School Road,
Vennala P.O., Kochi - 68202
Kerala State, India
Nationality: Indian


THE FOLLOWING SPECIFICATION PARTICULARLY DESCRIBES THE INVENTION AND THE MANNER IN WHICH IT IS TO BE PERFORMED.

A. FIELD OF INVENTION
[001] The present invention generally relates to storage water heaters. More particularly, the present invention relates to an inlet diffuser for optimizing hot water utilization within the water heater tanks.

B. BACKGROUND OF INVENTION
[002] Storage water heaters are widely used appliances for providing hot water in both domestic and commercial settings. These heaters typically consist of a well-insulated tank that stores heated water and an electric heating element responsible for maintaining the desired water temperature. One of the key challenges in the design of storage water heaters is optimizing hot water utilization. Ideally, the heated water should be efficiently used by the user before needing reheating. However, conventional storage water heaters often face challenges in achieving this goal due to the design of their inlet pipes.
[003] In conventional storage water heaters, the inlet pipe for introducing cold water into the tank is typically a straight, hollow tube. This design leads to several drawbacks. As cold water enters the tank through the straight inlet pipe, it creates turbulence within the heated water. This turbulence disrupts the natural stratification phenomenon where hot water rises and forms a layer at the top of the tank, while colder water settles at the bottom. The mixing of these water layers due to turbulence results in reduced usable hot water volume and increased energy consumption. Additionally, the turbulence tends to average the hot water temperature inside the tank, wasting the generated heat to the incoming cold water.
[004] Several existing solutions have been proposed to address the issue of hot water mixing in storage water heaters. These solutions include internal baffles within the tank to physically separate the hot and cold-water layers. However, these baffles can add complexity to the tank design and may affect overall water heater efficiency. Some water heaters also utilize features like angled inlet pipes or structurally complex diffusers to minimize turbulence and encourage stratification. However, the effectiveness of these methods may be limited.
[005] One example, US5137053A, discloses a storage tank that includes a vertical cylindrical tank, a fluid inlet, and a fluid outlet. It features an inlet diffuser for introducing cold water uniformly across the horizontal cross-section of the tank bottom, thereby preventing convection currents that cause mixing of hot and cold fluids, so that more hot fluid is recovered at the outlet over time.
[006] Another example, US11768012B2, discloses a diffuser for water heater fill tubes that includes a tube wall with an outer diameter. The diffuser features an elongated, flexible body designed for positioning at the outlet end of the fill tube.
[007] Yet another example, CN204739781U, discloses a water inlet pipe for a water heater, comprising a pipe body and a conical sealing head. Additionally, CN116336008A discloses a noise reduction structure for a water heater blower, which includes a blower main body with a fixedly mounted air inlet pipe and air outlet pipe. Furthermore, CN211716890U discloses an air inlet dust removal structure for a water heater. Lastly, WO2015007430A1 discloses an inlet nozzle for cold water in a water heater, designed to enhance efficiency by providing uniform, low-speed distribution of the cold-water flow.
[008] However, these inventions do not efficiently incorporate an inlet diffuser design for storage water heaters, diminishing their suitability for water heater utilization. Additionally, their intricate designs and structural disparities contribute to elevated production costs, rendering them less suitable for application in water heater systems.
[009] Therefore, there is a need in the art to provide an optimized storage water heater with an improved design for the inlet diffuser. This improved design should enhance stratification, minimize turbulence, and improve overall efficiency, thereby providing users with a efficient, reliable and maximum hot water supply.

C. OBJECTS OF THE INVENTION
[010] It is an object of the present invention to provide an improved storage water heater that avoids the drawbacks of known storage water heaters.
[011] It is another object of the present invention to provide an improved storage water heater with an inlet diffuser that optimizes the utilization of hot water by minimizing turbulence and promoting stratification within the storage water tank.
[012] It is yet another object of the present invention to provide an inlet diffuser that reduces turbulence and preserves the stratification of hot water within the tank. This is achieved by directing the water streamlines downwards using its innovative fin designs, even at higher flow rates under domestic usage conditions.
[013] It is yet another object of the present invention to provide an inlet diffuser that enhances energy efficiency.
[014] It is yet another object of the present invention to provide an inexpensive inlet diffuser for storage water heaters.
[015] It is yet another object of the present invention to provide an improved inlet diffuser that is durable, and easy to construct.

D. SUMMARY OF THE INVENTION
[016] According to an embodiment of the present invention, an improved storage water heater (200) comprises a tank (11) for storing hot water, a heating element for maintaining a desired water temperature within the tank (11), an outlet pipe (13), an inlet diffuser (100). The inlet diffuser (100) includes an inlet pipe (10) and a helical inlet diffuser design (12). The helical inlet diffuser design (12) includes a single-part structure that defining a central, concentric inlet passage for receiving cold water. A helical flow path is formed within the single part structure and the helical flow path is created by spiral-shaped structures (14) that wraps around the inlet passage. A conical inner core (16) is disposed within the helical flow path. The conical inner core (16) includes a diameter that progressively decreases in an upward direction, and downward-angled helical fins (18) are integrated with the spiral-shaped structures (14). The downward-angled helical fins (18) promote shearing of the water flow, and redirection towards a downward direction within the storage water tank (11).
[017] According to an embodiment, wherein the helical fins (18) are inclined.
[018] According to an embodiment, wherein the inlet diffuser (100) alternatively comprises an array of conical fins (24) and a plurality of vertical ribs (28), wherein plurality of vertical ribs (28) supporting the array of conical fins (24) while maintaining their positioning within the inlet diffuser (100)The said arrangement also functions as a series of divergent nozzles shrouded around the conical inner core.
[019] According to an embodiment, wherein a conical inner core (26) is positioned centrally within the inlet diffuser (100), wherein the conical inner core (26) includes a diameter that progressively decreases in an upward direction.
[020] According to an embodiment, wherein the single-part structure and /or conical inner core (26) are formed from a material selected from the group consisting of plastic and metal.
[021] According to an embodiment, wherein the inlet diffuser (100) is configured to minimize turbulence and promote stratification of hot and cold-water layers within the tank (11) when introducing cold water, thereby maintaining a stable stratification layer while maintaining an incoming dynamic energy of the flow.
[022] Features and advantages of the invention hereof will become more apparent in light of the following detailed description of selected embodiments, as illustrated in the accompanying FIGURES. As will be realised, the invention disclosed is capable of modifications in various respects, all without departing from the scope of the invention. Accordingly, the drawings and the description are to be regarded as illustrative in nature.

E. BRIEF DESCRIPTION OF THE DRAWINGS
[023] Further features and advantages of the present invention will become apparent from the following detailed description, taken in combination with the appended drawings, in which:
[024] FIG. 1 illustrates a perspective view of an inlet diffuser, in accordance with one embodiment of the present invention;
[025] FIG. 2 illustrates an environment in which the inlet diffuser implements, in accordance with one embodiment of the present invention;
[026] FIG. 3 illustrates a cross-sectional view of spiral-shaped structures of the inlet diffuser, in accordance with one embodiment of the present invention;
[027] FIG. 4 illustrates a perspective view of tapered inner core part of the inlet diffuser, in accordance with one embodiment of the present invention;
[028] FIG. 5 illustrates a flat top portion of the inlet diffuser, in accordance with one embodiment of the present invention;
[029] FIG. 6 illustrates a perspective view of an inlet diffuser, in accordance with another embodiment of the present invention;
[030] FIG. 7 illustrates an environment in which an inlet diffuser implements, in accordance with another embodiment of the present invention;
[031] FIG. 8 illustrates a cross-sectional view of pillars of the inlet diffuser, in accordance with another embodiment of the present invention;
[032] FIG. 9 illustrates a perspective view of conical inlet diffuser design, in accordance with another embodiment of the present invention; and
[033] FIG. 10 illustrates a perspective view of outlet portions of the inlet diffuser, in accordance with another embodiment of the present invention.
[034] It will be noted that throughout the appended drawings, like features are identified by like-reference numerals.

F. DETAILED DESCRIPTION OF THE EMBODIMENTS
[035] The detailed description set forth below in connection with the appended drawings is intended as a description of exemplary embodiments in which the presently disclosed invention may be practiced. The term "exemplary" used throughout this description means "serving as an example, instance, or illustration," and should not necessarily be construed as preferred or advantageous over other embodiments. The detailed description includes specific details for providing a thorough understanding of the presently disclosed inlet diffuser. However, it will be apparent to those skilled in the art that the presently disclosed invention may be practiced without these specific details. In some instances, well-known structures and devices are shown in functional or conceptual diagram form in order to avoid obscuring the concepts of the presently disclosed inlet diffuser design.
[036] The embodiments of the present invention provide an improved storage water heater. The storage water heater comprises an inlet diffuser, it is to be further understood that numerous changes may arise in the details of the embodiments of the inlet diffuser design. It is contemplated that all such changes and additional embodiments are within the true scope of this invention.
[037] Various features and embodiments of the storage water heater is explained in conjunction with the description of FIGURES (FIGs) 1-10.
[038] FIG. 1 illustrates a perspective view of an inlet diffuser 100, in accordance with one embodiment of the present invention. The inlet diffuser 100 includes an inlet pipe 10 and a helical inlet diffuser design 12. This embodiment features a helical structure designed to efficiently guide and manipulate the incoming flow of cold-water. The helical design effectively directs the water towards the bottom, optimizing its flow path for enhanced performance. By utilizing this configuration, the system ensures that the cold-water distribution is streamlined and effectively managed throughout the process.
[039] Now referring to FIG. 2, an environment is shown, in accordance with one embodiment of the present invention. The inlet diffuser 100 is implemented in the environment such as a storage water heater 200. Specifically, the storage water heater 200 includes the inlet diffuser 100, a tank 11, and an outlet pipe 13. Further, the storage water heater 200 includes a heating element (not shown) for maintaining a desired water temperature within the tank 11.
[040] In the present invention, the helical inlet diffuser design 12 includes spiral-shaped structures 14, conical or tapered inner core 16, and inclined helical fins 18. The spiral-shaped structures 14 are shown in the FIG. 3. The conical or tapered inner core 16, and inclined helical fins 18 are shown in the FIG. 4. In this innovative system, cold water initially enters the inlet pipe 10 through a central, concentric passage designed to direct it towards the top outlet end, which features a helically structured configuration. As the water enters, it begins its journey upwards along a meticulously engineered helical flow path. This path is meticulously crafted by the spiral-shaped structure 14 that envelops a conical inner core 16 passage. Within this carefully designed helical flow path, the conical inner core 16 gradually diminishes the cross-sectional area available for the water flow as it ascends.
[041] To further optimize the flow dynamics, the integrated inclined helical fins 18 within the structure are strategically angled downward. The inclined helical fins 18 play a crucial role in shearing and redirecting the upward-flowing water downward within the tank. This downward flow direction is essential for maintaining a stable layer of hot water at the uppermost part of the tank, thereby ensuring efficient stratification and thermal retention.
[042] The synergy of the helical flow path, conical inner core 16, and downward-angled inclined helical fins 18 collectively promotes a more uniform and swirling flow profile. This design not only minimizes turbulence within the tank but also enhances overall efficiency, reducing energy consumption and operational costs.
[043] From a fluid dynamics perspective, the structural transition is carefully engineered: the inner opening of the spiral restricts fluid discharge with a relatively smaller cross-sectional area, while the exit face of the structure widens to allow for a larger discharge area. According to Bernoulli's principle, this controlled transition results in a decrease in fluid velocity and an increase in pressure, effectively mitigating turbulence and optimizing thermal stratification.
[044] Overall, the carefully orchestrated combination of increased pressure and controlled flow direction significantly enhances the stability of thermal stratification within the tank. This improvement not only boosts system efficiency but also prolongs the lifespan of the heating equipment, ensuring consistent performance and energy savings over time.
[045] FIG. 5 shows a flat top portion 15 of the inlet diffuser 100, in accordance with one embodiment of the present invention.
[046] Now referring to FIG. 6, a perspective view of an inlet diffuser 100, is shown in accordance with another embodiment of the present invention. The inlet diffuser 100 includes an inlet pipe 10 and a conical inlet diffuser design 22. The conical inlet diffuser design 22 includes a conical fin array 24, and a conical or tapered inner core 26. This embodiment utilizes a conical fins array 24 supported by several vertical ribs 28, as shown in FIG. 9, to achieve its objectives.
[047] The conical shape of the fins facilitates a controlled heat transfer and fluid dynamics within the system, while the vertical ribs 28 provide structural support and enhance stability. Together, these elements work synergistically to optimize performance, ensuring optimal heat dissipation and operational efficiency across various conditions. The said arrangement also functions as a series of divergent nozzles shrouded around the conical inner core andnot only enhances thermal management but also contributes to the overall durability and reliability of the system.
[048] Now referring to FIG. 7, an environment is shown, in accordance with another embodiment of the present invention. The inlet diffuser 100 is implemented in the environment such as a storage water heater 200. Specifically, the storage water heater 200 includes the inlet diffuser 100, a tank 11, and an outlet pipe 13. Further, the storage water heater 200 includes a heating element (not shown) for maintaining a desired water temperature within the tank 11.
[049] FIG. 8 illustrates a cross-sectional view of ribs 28 (i.e. pillars), in accordance with another embodiment of the present invention. FIG. 9 illustrates a perspective view of conical inlet diffuser design 22, in accordance with another embodiment of the present invention. FIG. 9 shows the specific inlet portion 27 of the conical inlet diffuser design 22, in accordance with another embodiment of the present invention. In addition, FIG. 9 shows the top portion 23 of a conical fin and landing foot 25. The landing foot 25 provides structural stability to the conical fin array 24, anchoring it securely within the inlet diffuser 100.
[050] FIG. 10 illustrates a perspective view of outlet portion 29 of the conical inlet diffuser design 22, in accordance with another embodiment of the present invention.
[051] Cold water enters through an inlet diffuser 100, initiating its journey through a meticulously designed system. Inside the inlet diffuser 100, a precise arrangement of conical fins (i.e. conical fin array 24) promotes optimal heat transfer and fluid dynamics. The conical fin array 24, supported by vertical ribs 28, not only enhance structural integrity but also ensure consistent positioning within the inlet diffuser 100. Complementing these features, a centrally located conical inner core 26 further refines the water's path.
[052] As the cold water traverses the inlet diffuser 100, it encounters the conical fins (i.e. conical fin array 24), which induce a shearing effect. This effect disrupts the initial high velocity of the water, fostering a more uniform flow pattern crucial for optimized performance. Concurrently, the conical inner core progressively reduces water velocity and directs the flow downward within the tank 11, utilizing its inclined design to minimize turbulence and maintain stratification of the water layers.
[053] Strategically placed sharper wedges at the inner corners of the conical fins (i.e. conical fin array 24) intensify the shearing effect, effectively guiding the water flow downward while preventing unwanted mixing with the hotter upper layers. The combined configuration of vertical ribs 28 and conical fins (i.e. conical fin array 24) establishes a divergent channel from the inner to the outer fluid opening. According to Bernoulli's principle, this structure promotes a controlled decrease in fluid velocity and an increase in pressure as the water diverts downward and exits through the diffuser structure.
[054] This meticulous control of flow dynamics not only enhances thermal efficiency but also sustains a stable stratification layer within the tank, ensuring consistent availability of hot water. The comprehensive design approach not only optimizes operational performance but also reinforces the system's reliability and durability in various environmental conditions.
[055] The inlet diffuser 100 is made of metal alloys, plastic, or any other suitable material. It is preferable to use metal alloys for the inlet diffuser 100 due to its high strength and resistance, however a person skilled in the art understands that any other material can be used depending on the need. Further, the inlet diffuser 100 can come in different sizes and shapes. A person skilled in the art appreciates that the size of the inlet diffuser 100 varies depending on the need.
[056] The metal alloys used for the inlet diffuser 100 is typically selected for their durability and ability to withstand high temperatures and corrosive environments. In cases where weight is a critical factor, lightweight plastic materials might be preferred. Furthermore, the inlet diffuser 100 can be coated with protective layers to enhance its resistance to corrosion and wear. In some embodiments, the inlet diffuser 100 may include additional features such as integrated sensors to monitor flow rates or temperature. These sensors can provide real-time data to optimize the operation of the system. The versatility in the design of the inlet diffuser 100 allows it to be customized for a wide range of applications, from residential water heaters to industrial fluid systems.
[057] Moreover, the manufacturing process for the inlet diffuser 100 can involve advanced techniques such as 3D printing or precision casting, ensuring high accuracy and consistency in the final product. Regular maintenance and inspection of the inlet diffuser 100 are recommended to ensure its longevity and optimal performance over time.

G. ADVANTAGES OF THE INVENTION
[058] The presently disclosed inlet diffuser offers several advantages, including enhanced convenience and the ability to minimize turbulence and promote stratification in storage electric water heaters. This results in increased hot water availability and improved energy efficiency.
[059] The present invention introduces various embodiments of a novel inlet diffuser design tailored for storage electric water heaters. These innovative designs are crafted to optimize hot water utilization by minimizing turbulence and enhancing stratification within the tank. By reducing water turbulence, the designs ensure that hot water temperature remains stratified with minimal disturbance from incoming cold water. This significant reduction in heat loss leads to enhanced energy efficiency, translating into substantial power savings over time.
[060] Moreover, these advancements also contribute to water conservation and user convenience. With less disruption to the hot water temperature stratification, there is reduced need for frequent adjustments of the mixing valve to maintain a consistent water temperature. As a result, users experience minimized water wastage and save time previously spent on adjusting temperature settings. The design efficiently utilizes residual hot water stored in the upper portion of the tank, optimizing water usage and improving overall operational efficiency.
[061] A person skilled in the art appreciates that the inlet diffuser may come in a variety of sizes depending on the need. Further, different materials in addition to or instead of materials described herein may also be used and such implementations may be construed to be within the scope of the present invention. Further, many changes in the design and placement of components may take place without deviating from the scope of the presently disclosed inlet diffuser design.
[062] In the above description, numerous specific details are set forth such as examples of some embodiments, specific components, devices, methods, in order to provide a thorough understanding of embodiments of the present invention. It will be apparent to a person of ordinary skill in the art that these specific details need not be employed, and should not be construed to limit the scope of the invention.
[063] In the development of any actual implementation, numerous implementation-specific decisions must be made to achieve the developer's specific goals, such as compliance with system-related and business-related constraints. Such a development effort might be complex and time-consuming, but may nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill. Hence as various changes could be made in the above constructions without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
[064] The foregoing description of embodiments is provided to enable any person skilled in the art to make and use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the novel principles and invention disclosed herein may be applied to other embodiments without the use of the innovative faculty. It is contemplated that additional embodiments are within the scope of the disclosed invention.
, Claims:I/WE CLAIM:
1. An improved storage water heater (200), comprises:
a tank (11) for storing hot water;
a heating element for maintaining a desired water temperature within the tank (11);
an outlet pipe (13);
an inlet diffuser (100),
characterised in that:
the inlet diffuser (100) comprises an inlet pipe (10) and a helical inlet diffuser design (12), wherein the helical inlet diffuser design (12) comprises a single-part structure that defining a central, concentric inlet for receiving cold water,
wherein a helical flow path is formed within the single part structure and the helical flow path is created by spiral-shaped structures (14) that wraps around the inlet passage,
wherein a conical inner core (16) is disposed within the helical flow path,
wherein the conical inner core (16) includes a diameter that progressively decreases in an upward direction, and downward-angled helical fins (18) are integrated with the spiral-shaped structures (14),
wherein the downward-angled helical fins (18) and conical inner core (16) promote shearing of the water flow, and redirection towards a downward direction within the storage water tank (11).

2. The improved storage water heater (200) as claimed in claim 1, wherein the helical fins (18) are angled to direct a flow downward at an inclination.

3. The improved storage water heater (200) as claimed in claim 1, wherein the inlet diffuser (100) alternatively comprises an array of conical fins (24) and a plurality of vertical ribs (28), wherein plurality of vertical ribs (28) supporting the array of conical fins (24) while maintaining their positioning within the inlet diffuser (100), wherein a conical inner core (26) is positioned centrally within the inlet diffuser (100), wherein the conical inner core (26) includes a diameter that progressively decreases in an upward direction.

4. The improved storage water heater (200) as claimed in claim 1, wherein the single-part structure and/or conical inner core (16) are formed from a material selected from the group consisting of plastic and/or metal.

5. The improved storage water heater (200) as claimed in claim 1, wherein the inlet diffuser (100) is configured to minimize turbulence and promote stratification of hot and cold-water layers within the tank (11) when introducing cold water, thereby maintaining a stable stratification layer by efficiently managingan incoming dynamic energy of the water.

6. A method for optimizing hot water utilization in a storage electric water heater (200), comprises:
providing a storage electric water heater inlet diffuser (100), wherein the inlet diffuser (100) comprises an inlet pipe (10) and a helical inlet diffuser design (12), wherein the helical inlet diffuser design (12) comprises a single-part structure defining a central, concentric inlet passage for receiving cold water;
forming a helical flow path within the structure, wherein the helical flow path is created by a spiral-shaped structures (14) that wraps around the inlet passage;
providing a conical inner core (16) disposed within the helical flow path, wherein the conical inner core (16) having a diameter that progressively decreases in an upward direction;
integrating downward-angled helical fins (18) with the spiral-shaped structures (14), wherein the downward-angled helical fins (18) promote shearing of the water flow and redirection towards a downward direction within the storage water tank (11);
introducing cold water into the storage water heater tank (11) through the inlet diffuser (100); and
minimizing turbulence within the tank (11) by directing the cold-water flow downwardly through the helical flow path and the conical inner core (16).

7. The method of claim 6, wherein the inlet diffuser (100) alternatively comprises an array of conical fins (24) and a plurality of vertical ribs (28), wherein the plurality of vertical ribs (28) supporting the array of conical fins (24) while maintaining their positioning within the inlet diffuser (100), wherein a conical inner core (26) is positioned centrally within the inlet diffuser (100), and the conical inner core (26) includes a diameter that progressively decreases in an upward direction.

8. The method of claim 7, wherein the array of conical fins (24) and the conical inner core (26) are dimensioned to optimize water flow and minimize energy consumption in the storage electric water heater.

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