Controller valve coupling

#The present invention generally relates to controller valves that are used to regulate the water temperature within a water heater and more particularly pertains to the mechanism by which such controller valve is attached to a water heater.

#Controller valves are fitted to water heaters to perform a number of functions. In addition to sensing the water temperature within the water heater, the controller allows a set temperature to be selected, controls the flow of gas to the burner so as to maintain the water temperature at or near the set temperature and facilitates the ignition of the burner whether by pilot flame, or by electric or electronic means. Additionally, the device monitors the existence of a burner flame or pilot flame with the use of a thermocouple and/or thermopile for the purpose of shutting down the flow of gas in the event the gas fails to ignite or in the event an established flame becomes extinguished. Such controller device is typically situated on the exterior of the water heater so as to be readily accessible to allow a set temperature to be selected and in the event a pilot flame ignition system is employed, to allow manual valves to be operated during the start-up procedure. Additionally, the device includes a temperature sensor, usually in the form of an Invar rod/copper sleeve combination that extends into the interior of the water heater to sense water temperature directly. A conduit that supplies gas to the burner extends from the controller to the burner and in the event a pilot flame is relied upon for ignition, a second gas carrying conduit extends from the controller to supply gas to such pilot flame. Additionally, one or more electrical conductors may extend from the controller including interconnections to thermoccouples and/or thermopiles and to electric or electronic ignitors if present.

#Gas controllers have typically been attached to water heaters via a threaded interconnection between the controller and a fitting that is welded or otherwise permanently attached to the wall of the water tank and through which the Invar rod type sensor is extended into the interior of the water tank. A number of problems are inherent in such configuration including for example the need to apply a substantial torque load to the controller in order to achieve a water tight interconnection with the threaded fitting. This is further complicated by the necessity to achieve a proper rotational orientation of the controller valve while simultaneously avoiding an over-tightening or under-tightening of the connection. Additionally, because any rigid or semi-rigid conduits that extend from the controller would physically interfere with the structure of the water heater during the threading of the controller into place if such conduits were to be attached to the controller prior to its attachment to the water heater, the preassembly of such components to the controller is precluded. This in turn precludes the testing of such assembly prior to installation on the water heater. A leak or other malfunction that is discovered after the attachment of the controller to the water heater and the attachment of all the various conduits and wires thereto requires a labor intensive effort to disassemble, repair and reassemble the entire system on and in the water heater. A need to remove the controller for repair requires reapplying potentially damaging torque loads to the controller in order to remove it from the threaded fitting and again for refitment after its repair.

#FIG. 1 is perspective view of the gas controller of the present invention attached to a water heater;

#FIG. 2 is an enlarged cross-sectional view taken along lines II—II of FIG. 1;

#FIG. 3 is an enlarged perspective view of the spud component of the preferred embodiment shown in FIG. 2;

#The figures generally illustrate a embodiments of the gas controller device of the present invention that includes a mounting mechanism which allows the controller to be mounted to a water heater by simply pushing it into place. The controller may therefore be preassembled and pretested prior to its to the water heater. Moreover, the mounting mechanism allows the controller to be subsequently removed without the need to damage or sacrifice any of its components.

#FIG. 1 is a perspective view of the gas controller 12 of the present invention mounted to the side of a water heater 14. The gas controller includes a dial 16 with which a set temperature can be selected. Additionally visible is a gas feed line 18 by which a gaseous fuel is supplied to the controller. A gas conduit 20 extends from the controller to the burner (not visible) situated directly below the water tank. Additionally visible are several wires 22 that extend from the controller into the area below the tank. Such wires may connect to thermocouples and/or thermopiles in addition to an electric or electronic starter. In the event the water heater relies on a pilot flame to light the burner, an additional conduit 24 will extend from the controller into the burner area. The gas controller operates in the conventional manner to regulate the flow of gas to the burner as needed in order maintain a desired set temperature, monitors the existence of a flame and facilitates the ignition of the burner.

#FIG. 2 is a cross sectional view of the controller 12 illustrating the mechanism 26 by which the controller is attached to the side of the water heater 14. An opening 28 formed in the wall of the water heater 14 is surrounded by an internally threaded fitting 30 which is attached to the wall in a water tight manner such as by a weld 32. A spud 34, having an externally threaded surface 36, is received in the fitting. A bore38 formed in the interior of the spud has a proximal section 40 of increased internal diameter and a distal section 42 of reduced internal diameter with a chamfered transition 44 there between. A pair of diametrically opposed slots 46 are formed in spud near its proximal end and extend from its exterior surface completely through to its interior surface. The controller 12 has a shank 48 attached thereto and positioned so as to surround the base of the Invar rod temperature sensor 50. The shank has a stepped outer surface including a proximal section of increased outer diameter 52 and a distal section of reduced outer diameter 54. One or more circumferential grooves 56 are formed on the surface of the distal section of reduced diameter 54, each being dimensioned to support an O-ring 58 under slight tension. Another circumferential groove 60 is formed on the surface of the proximal section of increased diameter 52, positioned so as to be in alignment with the slots 46. A retainer spring clip 62 is positioned within slots 46 to extend into groove 60. Also visible in this illustration is a portion of a squared off lip 64 extending from the proximal end of the spud that cooperates with a squared off section 66 of the base of the shank to rotationally lock the two components to one another.