CONDENSER FOR WATER HEATER
A water heater comprises a tank, a cylinder coil section and a return-flow coil section. The cylinder coil section is in a heat transfer relationship with the tank and encircles a first portion of the tank. The return-flow coil section is in a heat transfer relationship with the tank and encircles a second portion of the tank. The cylinder coil section and the return-flow coil section are continuous over at least the first and second portions of the tank.
1 . A water heater comprising:
a tank;
a cylinder coil section in a heat transfer relationship with and encircling a first portion of the tank; and
a return-flow coil section in a heat transfer relationship with the tank and encircling a second portion of the tank;
wherein the cylinder coil section and the return-flow coil section are continuous over at least the first and second portions of the tank.
2 . The water heater of claim 1 , wherein the second portion of the tank is below the first portion of the tank.
3 . The water heater of claim 1 , wherein a thermal mastic compound is applied to at least one of the cylinder coil section and the return-flow coil section where the at least one of the cylinder coil section and the return-flow coil section make metal-to-metal contact with the tank.
4 . The water heater of claim 1 , wherein at least one of the cylinder coil section and the return-flow coil section is subject to a tension, wherein the tension is controlled as a function of the coefficient of thermal expansion between a material of the tank and a material of the at least one of the cylinder coil section and the return-flow coil section.
5 . The water heater of claim 1 , further comprising one or more clips which support a shape of a tube of at least one of the cylinder coil section and the return-flow coil section.
6 . The water heater of claim 5 , wherein a given one of the one or more clips has a length sufficient to distribute a contact stress of a bracket connecting the tube and the tank.
7 . The water heater of claim 1 , further comprising at least one spool placed at a point where a tube of at least one of the cylinder coil section and the return-flow coil section changes direction.
8 . The water heater of claim 7 , wherein the at least one spool has a radius controlled as a function of a minimum radius for preventing at least one of kinking and necking of the tube.
9 . The water heater of claim 1 , further comprising a foam layer surrounding the tank and at least a given portion of the cylinder coil section and the return-flow coil section.
10 . The water heater of claim 9 , wherein the cylinder coil section and return-flow coil section are continuous over the given portion.
11 . The water heater of claim 1 , wherein the cylinder coil section and return-flow coil section are formed of a non-copper material.
12 . The water heater of claim 11 , wherein the non-copper material is aluminum.
13 . The water heater of claim 11 , wherein the non-copper material is steel.
14 . The water heater of claim 13 , wherein at least a part of at least one of the cylinder coil section and the return-flow coil section are coated with a zinc/aluminum/chromium type coating.
15 . The water heater of claim 1 , wherein the tank, the cylinder coil section and the return-flow coil section are coated with a sealant.
16 . The water heater of claim 1 , further comprising a transition section extending between the cylinder coil section and the return-flow coil section, wherein a strip of foam separates at least a portion of the transition section and the cylinder coil section.
17 . A method for assembling a condenser of a heat pump water heater, comprising:
winding a first section of a coil around a first portion of a tank of the heat pump water heater; and
winding a second section of the coil around a second portion of the tank of the heat pump water heater,
wherein the first section of the coil comprises a cylinder coil section of the condenser and wherein the second section of the coil comprises a return-flow coil section of the condenser;
wherein the first section and the second section are continuous over at least the first and second portions of the tank.
18 . The method of claim 17 , wherein the first section of the coil is wound upwards around the tank and the second section is wound downwards around the tank.
19 . A condenser for a heat pump water heater, comprising:
a cylinder coil section configured to be in a heat transfer relationship with and encircle a first portion of a tank of the heat pump water heater; and
a return-flow coil section configured to be in a heat transfer relationship and encircle a second portion of the tank of the water heater,
wherein the cylinder coil section and the return-flow coil section form a continuous coil structure over at least the first and second portions of the tank.
20 . A heat pump water heater comprising:
a tank; and
a condenser comprising a cylinder coil section in a heat transfer relationship with and encircling a first portion of the tank and a return-flow coil section in a heat transfer relationship with the tank and encircling a second portion of the tank,
wherein the cylinder coil section and the return-flow coil section are continuously formed.