System, device and associated methods for protection during over-temperature and over-pressure in a water heater

A water heater comprising:

• a tank configured to hold water and including an outlet;
• and
• a temperature and pressure relief valve connected to the outlet of the tank, the relief valve comprising:
• a valve casing including an open top with a flange, a valve seat, a threaded inlet port, a threaded outlet port and an internal tongue positioned between the inlet port and the valve seat,
• a valve assembly, carried by the valve casing, and including a moveable valve shaft and associated valve head sealingly biased against the valve seat by a valve spring which is sealed within a protective chamber configured to contain a first protective fluid, wherein the valve head is configured to be moved off the valve seat against a bias force of the valve spring when a pressure in the water heater tank exceeds a pressure threshold to allow water to flow from the water heater tank via the inlet port and the outlet port, and wherein the valve spring is protected, by the protective chamber and first protective fluid, from corrosion, calcification and/or mineral deposits which would affect the valve assembly,
• the protective chamber including a sealing flange at a top thereof,
• a thermal element assembly carried by the internal tongue of the valve casing and including an elongated plunger body having a lower end configured to extend out of the inlet port and into the water held in the water heater tank, and including a captive plunger extending out of an upper end of the elongated plunger body, opposite the lower end, and configured to push the valve head off the valve seat when a temperature of the water exceeds a temperature threshold,
• a plunger casing, encasing the upper end of the elongated plunger body and sealing around the captive plunger, and configured to contain a second protective fluid to protect the upper end and captive plunger from corrosion, calcification and/or mineral deposits which could affect the temperature sensor/actuator, and
• an end cap assembly comprising an end cap secured to the flange of the valve casing with the sealing flange of the protective chamber therebetween to define a casing seal for the protective chamber and the open top of the valve casing,
• wherein the end cap assembly also includes a release mechanism configured to manually release the valve head off the valve seat when actuated.

A relief valve for use with a water heater tank, the relief valve comprising:

• a valve casing including an open top, a valve seat, a threaded inlet port, a threaded outlet port and a flange surrounding the open top;
• a valve assembly, carried by the valve casing, and including a moveable valve shaft and associated valve head sealingly biased against the valve seat by a valve spring which is sealed within a protective chamber configured to contain a first protective fluid, wherein the valve head is configured to be moved off the valve seat against a bias force of the valve spring when a pressure in the water heater tank exceeds a pressure threshold to allow water to flow from the water heater tank via the inlet port and the outlet port, wherein the valve spring is protected, by the protective chamber and first protective fluid, from corrosion, calcification and/or mineral deposits which would affect the valve assembly, and wherein the moveable shaft of the valve assembly includes a spring limiter and mounts the moveable valve head and the valve spring;
• the protective chamber including a sealing flange at a top thereof;
• and
• an end cap assembly comprising an end cap secured to the flange of the valve casing with the sealing flange of the protective chamber therebetween to define a casing seal for the protective chamber and the open top of the valve casing;
• wherein the end cap assembly also includes a release mechanism configured to manually release the valve head off the valve seat when actuated.

A method of making a temperature and pressure relief valve for use with a water heater tank, the method comprising:

• providing a valve casing including an open top with a flange, a valve seat, a threaded inlet port, a threaded outlet port and an internal tongue positioned adjacent the inlet port and the valve seat;
• inserting a thermal element assembly into the valve casing to be carried by the internal tongue;
• inserting a valve assembly into the valve casing, the valve assembly including a moveable valve shaft and associated valve head sealingly biased against the valve seat by a valve spring which is sealed within a protective chamber to contain a first protective fluid, wherein the valve head is configured to be moved off the valve seat against a bias force of the valve spring when a pressure in the water heater tank exceeds a pressure threshold to allow water to flow from the water heater tank via the inlet port and the outlet port, and wherein the valve spring is protected, by the protective chamber and first protective fluid, from corrosion, calcification and/or mineral deposits which would affect the valve assembly;
• wherein the protective chamber includes a sealing flange at a top thereof;
• wherein the thermal element assembly carried by the internal tongue of the valve casing includes an elongated plunger body having a lower end configured to extend out of the inlet port and into the water held in the water heater tank, and includes a captive plunger extending out of an upper end of the elongated plunger body, opposite the lower end, and configured to push the valve head off the valve seat when a temperature of the water exceeds a temperature threshold;
• wherein a plunger casing, encases the upper end of the elongated plunger body and seals around the captive plunger, and contains a second protective fluid to protect the upper end and captive plunger from corrosion, calcification and/or mineral deposits which could affect the thermal element;
• securing an end cap assembly, comprising an end cap, to the flange of the valve casing with the sealing flange of the protective chamber therebetween to define a casing seal for the protective chamber and close the open top of the valve casing;
• and
• attaching a release mechanism to the valve shaft extending out of the end cap assembly, the release mechanism being configured to manually release the valve head off the valve seat when actuated.