WO2011005684A1 - Système et procédé de chauffage électrique non-métal et chauffe-eau sans réservoir utilisant ces derniers - Google Patents

Système et procédé de chauffage électrique non-métal et chauffe-eau sans réservoir utilisant ces derniers Download PDF

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Publication number
WO2011005684A1
WO2011005684A1 PCT/US2010/040904 US2010040904W WO2011005684A1 WO 2011005684 A1 WO2011005684 A1 WO 2011005684A1 US 2010040904 W US2010040904 W US 2010040904W WO 2011005684 A1 WO2011005684 A1 WO 2011005684A1
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WO
WIPO (PCT)
Prior art keywords
tube
tubes
heating
heating layer
metallic
Prior art date
Application number
PCT/US2010/040904
Other languages
English (en)
Inventor
Shimin Luo
Su Chen
Original Assignee
American Hometec
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by American Hometec filed Critical American Hometec
Publication of WO2011005684A1 publication Critical patent/WO2011005684A1/fr

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
    • F24H1/00—Water heaters, e.g. boilers, continuous-flow heaters or water-storage heaters
    • F24H1/10—Continuous-flow heaters, i.e. heaters in which heat is generated only while the water is flowing, e.g. with direct contact of the water with the heating medium
    • F24H1/101—Continuous-flow heaters, i.e. heaters in which heat is generated only while the water is flowing, e.g. with direct contact of the water with the heating medium using electric energy supply
    • F24H1/102—Continuous-flow heaters, i.e. heaters in which heat is generated only while the water is flowing, e.g. with direct contact of the water with the heating medium using electric energy supply with resistance
    • F24H1/105—Continuous-flow heaters, i.e. heaters in which heat is generated only while the water is flowing, e.g. with direct contact of the water with the heating medium using electric energy supply with resistance formed by the tube through which the fluid flows
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
    • F24H1/00—Water heaters, e.g. boilers, continuous-flow heaters or water-storage heaters
    • F24H1/10—Continuous-flow heaters, i.e. heaters in which heat is generated only while the water is flowing, e.g. with direct contact of the water with the heating medium
    • F24H1/12—Continuous-flow heaters, i.e. heaters in which heat is generated only while the water is flowing, e.g. with direct contact of the water with the heating medium in which the water is kept separate from the heating medium
    • F24H1/14—Continuous-flow heaters, i.e. heaters in which heat is generated only while the water is flowing, e.g. with direct contact of the water with the heating medium in which the water is kept separate from the heating medium by tubes, e.g. bent in serpentine form
    • F24H1/142—Continuous-flow heaters, i.e. heaters in which heat is generated only while the water is flowing, e.g. with direct contact of the water with the heating medium in which the water is kept separate from the heating medium by tubes, e.g. bent in serpentine form using electric energy supply

Definitions

  • One or more embodiments disclosed herein relate to heaters.
  • Tankless water heaters have been developed in recent years and are known by a variety of names, including instantaneous, combination or "combi” boilers, continuous flow, inline, flash, or on-demand water heaters. This type of water heater is gaining in popularity mainly for space-saving and energy efficiency reasons. These advantages are achieved by heating water as it flows through the unitjsi].
  • tankless water heaters may be installed throughout a household at various points-of-use (POU) or at a centralized location. They also can be used alone or in combination with a centrally located water heater. In some cases, larger tankless models may be used to provide the hot water requirements for an entire house. Whether installed at one or multiple POUs, tankless water heaters provide a continuous flow of hot water and energy savings compared with tank-type heaters, which are only able to provide a finite supply of hot water limited by tank size and hot water recovery rates.
  • tankless water heaters on the market today suffer from significant disadvantages.
  • tankless water heaters tend to heat idle water in surrounding pipes through the process of convection. Also, tankless water heaters only heat water upon demand so that idle water in the piping is cold. Thus, there is a more apparent "flow delay" for hot water to reach a distant faucet.
  • tankless water heaters are inactive when hot water is not being used, they may be incompatible with hot water recirculation systems unless an expansion tank is added.
  • tankless water heaters often have minimum flow requirements before the heater is activated. This can create in a gap between the temperature of cold water and the coolest warm temperature that can be achieved with a hot-and-cold water mix. This gap can produce undesirable effects to the user.
  • the hot water temperature from a conventional tankless water heater is inversely proportional to the rate of water flow.
  • the faster the flow the less time water spends in the heating element.
  • a certain range of desirable hot water temperatures may not be achievable or achieving a desired temperature with precision may be difficult to control.
  • mixing hot and cold water to just the "right" temperature using a single-lever faucet e.g., while taking a shower
  • a user may therefore consider installing a temperature compensating valve under these circumstances, which can increase costs.
  • Tankless and other forms of water heaters are also disadvantageous in terms of their metallic heating elements. These elements tend to corrode over time, thereby necessitating their replacement over relatively short periods of time. This can be especially burdensome to homeowners in terms of cost and convenience. Also, conventional water heaters that use metallic heating elements have proven to be inefficient, unmanageable, or both, for many applications.
  • Figure IA shows one embodiment of a non-metallic heating element
  • Figure IB shows a cross-section of the element in Figure IA
  • Figure 2 shows one embodiment of a tankless water heater that uses one or more non-metallic heating elements such as shown in Figures IA and IB.
  • Figure 3 shows a second embodiment of a tankless water heater.
  • Figure 4 shows a third embodiment of a tankless water heater
  • One or more embodiments herein are directed to systems and methods for instantaneously generating heat in any one of a variety of residential, commercial, industrial, or medical applications.
  • the heat is generated using one or more non-metallic heating elements which prove to be safer, more efficient, and more cost effective than their metallic counterparts over the lifetime of the equipment.
  • die heating system and method may be applied to heating water, for example, for a user's faucet, shower, appliance, or other device.
  • the liquids different from water such as a gel may be heated.
  • the air or a solid may be heated.
  • non-metallic heating elements because non-metallic heating elements are used, the embodiments disclosed herein require less power due to no efficiency or capacity decay, making diem suitable for use in virtually any application that requires heat._Other types of metallic heating elements may build up lime scale over time, which reduces heating elements ability to heat water.
  • Figure IA shows one embodiment of a heating element having an electric heating layer 1 disposed on a non-metallic tube 2.
  • the heating layer may be in the form of a coating, film, or layer which generates heat when a voltage or other electrical signal is applied.
  • the coating, film, or layer may be applied directly to the exterior surface of die tube or an interior surface of non-metallic tube.
  • Such a coating, film, or layer may be made from electric heating membrane material agglutinated onto or embedded or burned into the exterior or interior surface of the non-metallic tube or otherwise applied to the tube surface. Examples of this material include carbon fiber, nylon, conductive polyimides, conductive indium-tin-oxide (ITO), kapton, and polymer thick-film inks that are screen printed onto a substrate.
  • ITO conductive indium-tin-oxide
  • the medium inside the tube to be heated may be air or another gas, water or another liquid, gel, or even a solid.
  • the size and quantity of electric heating material and the amount of voltage applied thereto (as well as other electrical properties such as frequency) may be varied or set to generate a predetermined amount of heat (e.g., temperature) and/or heating response time for the intended application.
  • Figure IB shows a sectional view of the heating element in Figure IA.
  • the medium 5 is shown as water passing through the tube at a predetermined rate. Because the heating layer is able to provide instantaneous heating, the water is immediately heated as a result of the signal applied through the electrodes.
  • insulating material (not shown) may be mounted proximate the heating layer.
  • the non-metallic tube 1 may be made of quartz, glass, or ceramic or another material capable of withstanding heat.
  • the use of a non-metallic tube is highly desirable for many applications in order to prevent corrosion which occurs in more traditional heaters that use metallic heating elements.
  • the thickness of the tube walls is preferably set to be strong enough to withstand breakage as a result of shock or other sudden forces, but thin enough to rapidly transfer heat from the heating layer to medium 5.
  • the thickness range may, for example, lie in the range of between 5 to 10 mm for many applications. Of course, in other applications, a different thickness range may be used.
  • the electrodes 4 and 5 may be attached to the heating layer using any one of a variety of connections including but not limited to lead wires, conductive terminals, and metallic traces.
  • the signal generator connected to the electrodes generates signals at a predetermined voltage, frequency, and/ or current to heat the medium inside the tube to the intended temperature, or temperature range.
  • FIG. 2 shows one embodiment of a tankless water heater which uses one or more heating tubes such as shown in Figures IA and IB.
  • the tankless water heater includes a heating section 10, a power source 11, one or more sets of terminals 12, and a controller 13, all of which are supported within a housing 20.
  • the power source may include a transformer for providing power to the controller, and the terminals are coupled to transfer the signals generated by the controller to the heating section at a predetermined voltage, current, and/ or frequency set based on the operational requirements of the heater and the temperature to be achieved by application of the heat.
  • the heating section contains a predetermined number of heating tubes for heating water.
  • two heating tubes 40 and 50 are used to provide heated water, for example, to different appliances in a house.
  • a different number of tubes may be used in other embodiments.
  • the heating tubes are held between upper and lower mounting sections 21 and 22 in a fixed position.
  • the mounting sections not only provide structural support for the tubes, but also include a water path between the tubes or electrodes for electrically connecting the heating layers of the tubes to different sets of terminals 12.
  • one or more support rods 23 are provided adjacent the tubes. Also, a number of sealing components are provided to seal the tubes from leaks, both along dieir lengths and also at the interface points.
  • the sealing components may, for example, be made of a pressurized silicon polymer or other suitable sealing material sustainable to, for example, over 3.0 MPa water pressure.
  • the heating tubes are coupled to different water pipes.
  • tube 40 is coupled to an inlet water pipe 41 and tube 50 is coupled to inlet water pipe 51.
  • Water passing through tubes 40 and 50 then exit through exit pipes 42 and 52, respectively.
  • the exit pipes carry the water to different destinations that have heating demands, e.g., dishwasher and clothes washer.
  • the sealing members may be made from nylon or another polymer-based material.
  • the controller 13 generates signals at one or more predetermined voltages, currents, and/or frequencies to the heating layers of the tubes.
  • the signals are applied to the electrodes of the tubes through the different sets of terminals 12. If the heating tubes are to heat water to different temperatures, then the controller signals will be proportionately different.
  • the tubes may be identically made or may be different. If different, the heating layer on the tubes may be different to provide different heating temperature ranges. For example, one tube may heat water to a first temperature range suitable for one type of appliance or faucet, and the other tube may heat water to a second temperature range greater than the first temperature range suitable for another type of appliance or application.
  • This two- temperature range configuration of the tankless water heater may be especially desirable for commercial applications where heated water in vastly different temperature ranges (e.g., a first range of 20° C to 100 0 C and a second range of 20 0 C to 500° C may be required).
  • insulation may be provided at various points within the heating section 10 to protect the components therein. This insulation may be especially desirable at a location between the tubes, to prevent a high-temperature range tube from adversely affecting a low-temperature range tube. Insulation may also be provided between the tubes and interior walls of the heating section.
  • Additional electrical components may be provided, for example, in the form of relays and/or timers to control the timing of when heated water is to be supplied, optionally, a silicon-controlled rectifier to control power and voltage requirements of the heating section, flow sensors to detect the rate of water flow at various positions relative to the heating tubes, a temperature sensor to form part of a protection circuit to prevent overheating, power regulators, water leakage protection circuits to detect water escaping from the tubes and/ or heating section housing, and dry heat protection circuits.
  • a ground for the electrical circuits may be provided, for example, in the form of a connection to one or more of the inlet or outlet water pipes.
  • a heating element box or other means of protection may also be included to protect the heating elements from physical damage.
  • Thermal insulation material may enhance the thermo efficiency of the equipment.
  • a control board box may be included to protect the control boards or circuits used for the heating tubes, for example, by preventing a high-voltage section of the system from being exposed when the unit is opened.
  • An outside jack may be included to meet visual design requirements.
  • the controller 13 and other circuits may also be equipped with or interfaced to one or more control panels and/or buttons to allow a user to adjust power, temperature, and/or other settings relating to heating.
  • the controller may modify the signals (e.g., voltage, current, or frequency) applied to the heating layer (s) of the tube(s) in accordance with the adjustments made through the control panel or buttons.
  • the embodiments of the non-metal water heater described herein may have one or more of the following advantages.
  • the non-metal tubes have higher sustainability to jvoltage than metal heating elements. Also, the non-metal tubes do not scale, have excellent insulation properties and therefore are safer. The tubes also will not age for over many- years, have a pure resistance load, heat up quickly, have high thermo efficiency, and long lifetime.
  • non-metallic heating element of the tubes in an electric water heater application demonstrate resistance to corrosion and are expected to have reduced power requirements and improved operational stability compared with their metallic counterparts.
  • FIG. 3 shows another embodiment of a tankless water heater which has a single heating tube 150 in a substantially U-shaped configuration.
  • different sections 160 and 170 of the tube are used to heat water from inlet pipe 180 before being discharged through outlet pipe 190.
  • water from the inlet pipe may be heated for a longer period of time.
  • the different tubes may be individually controlled based on signals from the controller to effect heating at different stages and/or at different temperatures.
  • a different number of heating tubes may be used from the tubes shown in Figures 2 and 3. Varying the number of heating tubes may have the effect of varying power capacity of the heating elements. Depending on the capacity required for a particular application, three or more heating tubes may be group together for purposes of generating heated water for discharge through a same or different outlet pipes. Also, the multiple heating tubes may be selectively and independently activated in order to satisfy heating requirements for a particular application.
  • FIG 4 shows another embodiment of a tankless water heater which uses multiple heating tubes 210 and 220 to heat water from a single inlet pipe 230. The heated water is then combined and passed through a single outlet pipe 240.
  • the heating tubes are independently and selectively activated based on signals from the controller to meeting different heating requirements.
  • the controller may supply signals to only heating tube 210 to heat the water to within a low-temperature range. In this case, signals are not supplied to heating tube 220. The controller may then supply signals to both heating tubes 210 and 220, to thereby activate both tubes to heat the water to within a high-temperature range. If the heating tubes have different heating material or heating capabilities, the controller may supply signals to only heating tube 220 to heat the water to a middle temperature range.
  • a three-way electronically controlled valve 240 may be located downstream of an inlet of the inlet pipe to shut off flow of water to a tube when the other tube is only to be selected for heating. Signals for controlling the configuration of the valve may be generated from the controller.
  • a water heating system which uses a tank to hold a supply of water may be provided.
  • This system may use one or more non-metallic heating tubes disposed within the tank to heat the supply of water.
  • one or more inlet pipes as previously discussed may carry a flow of water stored in the tank to one or more heating tubes with or without a water pump.
  • Such a system may, thus, correspond to a tank-based water heating system where the heating elements are located outside of die tank.
  • one or more intervening layers may be included between heating layer 1 and non-metallic tube 2. These layers may include, for example, an insulating layer, a sensing layer, a protective layer, an electrode layer or any combination thereof.
  • heating layer 1 may be formed over heating layer 1 including, for example, an insulating layer to prevent the heat generated by the heating layer from dissipating or escaping, a heat reflective layer to focus and/or redirect heating generated by layer 1 towards the tube to provide improved transfer of heat, a protective layer to prevent against damage from outside forces and/or to prevent the heat generated for one tube from migrating to another adjacent tube.
  • an insulating layer to prevent the heat generated by the heating layer from dissipating or escaping
  • a heat reflective layer to focus and/or redirect heating generated by layer 1 towards the tube to provide improved transfer of heat
  • a protective layer to prevent against damage from outside forces and/or to prevent the heat generated for one tube from migrating to another adjacent tube.
  • the tubes are shown to be substantially parallel to one another.
  • the tubes may, for example, be independently selected and perpendicular or otherwise angled relative to one another to meet the needs of a particular application and/or inlet pipe/outlet pipe configuration.
  • a heating system using one or more non-metallic tubes may be provided to heat a gelatin-type material.
  • the heated gelatin (as well as the water or liquids heated by the other embodiments described herein) may be used for a variety of home, commercial, industrial, or medical uses. Alternatively, blood, chemicals, or other substances may be heated in other embodiments.
  • all the heating elements of the heating tubes are located outside of the tube, e.g., on or adjacent an external surface of each tube. None of the heating elements are included inside the tube. This is beneficial in that if heating elements were included inside the tubes, then those elements over time would corrode or otherwise require replacement, thereby limiting the useful life of the entire system or increasing the maintenance costs thereof.
  • a heating element may be included inside of die tube to provide extra heating if necessary.
  • any reference to "one embodiment,” “an embodiment,” “example embodiment,” etc. means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the invention.
  • the appearances of such phrases in various places in the specification are not necessarily all referring to the same embodiment. Furdier, when a particular feature, structure, or characteristic is described in connection with any embodiment, it is submitted that it is within the purview of one skilled in the art to effect such feature, structure, or characteristic in connection witii other ones of the embodiments.
  • the features of any one embodiment may be combined with the features of the other embodiments.

Abstract

Le chauffe-eau sans réservoir selon la présente invention inclut au moins un tuyau non métallique, au moins une couche chauffante située sur une surface extérieure ou intérieure du tuyau ou adjacente à celle-ci, et un dispositif de commande permettant de générer un signal devant être appliqué à la couche chauffante. Le signal provenant du dispositif de commande est appliqué via une ou plusieurs électrodes couplées à la couche chauffante et la couche chauffante génère de la chaleur en réponse au signal. La chaleur est ensuite transférée à un liquide circulant dans le tuyau, un gel situé au sein du tuyau ou un solide situé à l’intérieur du tuyau pour chauffer le liquide, le gel ou le solide à une certaine plage de température, qui peut être ou ne pas être prédéterminée. En variante, la chaleur est transférée à un liquide, un gel ou un solide autour du tuyau en vue de le chauffer le liquide à une certaine température, qui peut être ou ne pas être prédéterminée. Dans une configuration à plusieurs tuyaux, les tuyaux peuvent être sélectionnés de façon indépendante et peuvent avoir différentes plages de température.
PCT/US2010/040904 2009-07-08 2010-07-02 Système et procédé de chauffage électrique non-métal et chauffe-eau sans réservoir utilisant ces derniers WO2011005684A1 (fr)

Applications Claiming Priority (2)

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US22396209P 2009-07-08 2009-07-08
US61/223,962 2009-07-08

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WO2011005684A1 true WO2011005684A1 (fr) 2011-01-13

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WO (1) WO2011005684A1 (fr)

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