Heat Pump Assemblies for Water Heaters

Abstract

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

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