Water heater and methods for manufacturing the same

Abstract

A water heater includes a tank including a tank wall that defines an opening, a heat exchanger disposed in the tank and terminating inboard of the tank wall, and a mount including a flange coupled to the tank wall and a cup extending from the flange and through the opening. The cup includes a receptacle configured to receive the heat exchanger in a passage defined by the receptacle.

What is claimed is: 
     
         1 . A water heater, comprising:
 a tank including a tank wall that defines an opening;   a heat exchanger disposed in the tank and terminating inboard of the tank wall; and   a mount including a flange coupled to the tank wall and a cup extending from the flange and through the opening, wherein the cup includes a receptacle configured to receive the heat exchanger in a passage defined by the receptacle.   
     
     
         2 . The water heater of  claim 1 , wherein the heat exchanger is coupled to the receptacle. 
     
     
         3 . The water heater of  claim 1 , wherein the receptacle is recessed relative to the tank wall. 
     
     
         4 . The water heater of  claim 1 , wherein the receptacle is disposed inboard of the tank wall. 
     
     
         5 . The water heater of  claim 1 , wherein the tank extends along a longitudinal axis, and wherein the heat exchanger terminates radially inboard of the tank wall. 
     
     
         6 . The water heater of  claim 1 , wherein the receptacle extends along a mount axis, and wherein the cup extends axially from the flange inboard of the tank wall to the receptacle, and wherein the receptacle extends axially from the cup toward the exterior. 
     
     
         7 . The water heater of  claim 1 , wherein the heat exchanger includes a coil portion and an exhaust portion unitary with the coil portion and wherein the heat exchanger terminates at the exhaust portion. 
     
     
         8 . The water heater of  claim 1 , wherein the flange couples with the tank wall at an exterior side of the tank wall. 
     
     
         9 . The water heater of  claim 1 , wherein the mount is welded to the tank wall on an exterior surface of the tank wall. 
     
     
         10 . The water heater of  claim 1 , wherein the heat exchanger is welded to the receptacle. 
     
     
         11 . A water heater, comprising:
 a tank disposed on a longitudinal axis and including a tank wall extending axially along the longitudinal axis and defining an opening;   a heat exchanger disposed in the tank and radially inboard of the tank wall; and   a mount disposed in the opening and including:
 a flange coupled to the tank wall at an exterior side of the tank wall; and 
 a cup extending radially inwardly from the flange and through the opening to a receptacle configured to receive an end of the heat exchanger at a position radially inboard of the tank wall. 
   
     
     
         12 . The water heater of  claim 11 , wherein the receptacle extends along a mount axis, and wherein the cup extends axially from the flange inboard of the tank wall to the receptacle, and wherein the receptacle extends axially from the cup toward the exterior. 
     
     
         13 . The water heater of  claim 11 , wherein the heat exchanger includes a coil portion and an exhaust portion unitary with the coil portion. 
     
     
         14 . The water heater of  claim 13 , wherein the heat exchanger terminates at the exhaust portion. 
     
     
         15 . A method for manufacturing a water heater, comprising:
 providing an opening in a tank wall of the water heater;   moving the tank wall around and relative to a heat exchanger of the water heater without deformation of the tank wall during the moving of the tank wall around and relative to the heat exchanger;   positioning a mount at the opening; and   coupling the mount to each of the heat exchanger and the tank wall.   
     
     
         16 . The method of  claim 15 , comprising:
 enameling the tank wall prior to moving the tank wall around the heat exchanger.   
     
     
         17 . The method of  claim 15 , wherein the coupling of the mount to the heat exchanger includes welding the heat exchanger to the mount. 
     
     
         18 . The method of  claim 15 , wherein the coupling of the mount to the tank wall includes welding the mount to the tank wall. 
     
     
         19 . The method of  claim 15 , wherein the heat exchanger terminates within the tank. 
     
     
         20 . The method of  claim 15 , wherein the mount extends inboard of the tank wall.