The present invention relates to an electric boiler and particularly, but not exclusively, to an electric boiler suitable for heating sanitary water in a domestic or commercial premises, or suitable for use in a central heating system.
Generally, electric boilers have in the past tended to be predominantly used for single point of supply applications, for example electric showers, hot water supplies for single (or local) wash hand basins or similar, where it is not desired to install a traditional central emersion heater or fossil fuel boiler. This could be to avoid the expense and possible disruption associated with installing larger heating systems, or where there is a desire to ensure a reliable instantaneous supply of hot water. However, more recently electric boilers are also being used more commonly in place of the more traditional fossil fuel boiler, where they centrally provide hot water to a number of sanitary outlets and/or form the boiler of a central heating system. These new applications for electric boilers require far more powerful boilers than those traditionally used in the examples mentioned above.
It is an object of the present invention to provide a particularly compact arrangement of electric boiler which is capable of providing an instantaneous hot water supply, suitable for a sanitary hot water supply or for a central heating system.
According to the present invention there is provided an electric boiler comprising a heating element and a thermally conductive inner container, the inner container substantially surrounding the heating element to define an inner passage about the heating element, the inner container having an inlet and an outlet for a flow of water and being arranged such as to cause water received at the inner container inlet to flow along the inner passage in close proximity to a surface of the heating element to the inner container outlet, the boiler further comprising an outer container in which the inner container is substantially located, the outer container defining an outer passage about at least part of the inner container, the outer container having an inlet and an outlet for a flow of water, wherein the outer container outlet is fluidly connected to, or forms, the inner container inlet and wherein the outer container is arranged such as to cause water received at the outer container inlet to flow along the outer passage, in close proximity to a surface of the inner container, to the outer container outlet.
By having an inner container substantially surrounding the heating element, the inner container can be arranged to concentrate the flow of water over the surface of the heating element, providing only a small clearance between a surface of the container and a surface of the heating element and thus a low volume space through which water is forced to flow at high flow rates, providing a high heating surface area to volume ratio. The advantage of such an arrangement is that there is very little inertia within the boiler, due to the relatively low volume of water stored within the boiler and thus the boiler may function as an instantaneous hot water heater, at least at the point where the water leaves the boiler. This not only has the benefit of being able to quickly provide a source of hot water, without the need to have a cylinder of preheated hot water, but it may also minimise the residual energy stored within the boiler after hot water has been drawn from the boiler.
The provision of an outer container, in which the inner container is substantially located, enables water being drawn into an inlet of the boiler to be preheated, by first passing through the outer container and absorbing heat from the inner container, particularly if the inner container and outer container share a common thermally conductive wall, before being drawn through the inner container where it comes into contact with the heating elements. A boiler in accordance with the present invention can thus be used to increase the area of heated surface a relatively small volume of water comes into contact with, which may enable significantly more energy to be extracted from the heating elements without causing the water to boil at any point.
Preferably, the inner and outer passages are arranged such that in use water in the first inner passage progresses along the first passage in a direction opposite to the direction in which the water progresses along the second passage.
The above arrangement may provide a particularly compact arrangement of boiler that is relatively inexpensive to construct, but it can also be arranged to cause the coldest water, that entering the outer chamber, to come into contact with the hottest portion of the inner container, thus maximising heat transfer from the water in the inner container to the water in the outer container.
In one embodiment, the boiler may comprise a plurality of heating elements located in the common inner container. In this manner, the heating elements may be arranged in a compact arrangement while permitting the water within the inner container to freely flow between them. This also permits a number of standard heating elements to be employed, for example a number of standard, off the shelf, two kilowatt cartridge heating elements could be used as the heating elements.
In an alternative arrangement, the boiler may comprise a plurality of elongate heating elements and a plurality of tubular inner containers, each heating element being arranged concentrically within an associated inner container. In this manner, each of a plurality of heating elements has its own inner container forcing water entering that inner container to flow over the surface of the associated heating element. This maximises the volume of water that comes into contact with the surface area of the heating elements, by avoiding any “backwaters” that may otherwise occur. With this arrangement it may be preferable for the boiler to comprise a single outer container in which the plurality of inner containers are arranged, together with their associated heating elements.
The plurality of inner containers may be arranged side by side in a cylindrical pattern and connected to each other to define a central passage within the boiler, whereby the inner containers are aligned with a longitudinal axis of the boiler and wherein the boiler is arranged such that water enters through the outer container at or towards a first end of the boiler and travels in a first longitudinal direction along the outer passage, to exit the outer passage through the outer container outlet at or towards a second end of the boiler opposite to the first end. The water may then enter the inner containers through respective inner container inlets located at or towards a second end of the boiler, the water then passing along the respective inner passages to exit via respective outlets of the inner containers located at or towards the first end of the boiler. From there the water may enter the central passage and pass along the central passage towards the second end of the boiler. In this manner the inner containers may form a wall of the outer container, defining the outer passage, form the inner passages and also form a third central passage, thus causing the water to flow directly over the heating elements on one pass (a second pass) and to indirectly flow over the heating elements on two additional passes (a first pass and a third pass).
The outer container of the boiler may comprise at least two end portions and a cylindrical portion extending therebetween in which the plurality of inner containers are located, wherein each heating element is secured in place in one of the two end portions. This arrangement provides a particularly compact arrangement and may only require machining of the end portions, or just one end portion, to permit the heating elements to be correctly mounted.
The outer container inlet may be arranged to direct water tangentially into the outer passage, so that it spirals around the inner container as the water progresses along the passage to the outer container outlet. This arrangement ensures that the water in the outer container circulates around the whole of the inner container, cooling all the surface area of the inner container, without the need for mounting baffles in the outer container or otherwise directing flow.
An electric boiler as described above may further comprise one or more ultrasonic transducers arranged to break up or dislodge any scale accumulating on a surface within the boiler. This may be important in applications where the boiler is used for heating sanitary water and where it will not therefore be a sealed system. Thus the system will not be able to contain inhibitors and may be subjected to a continual fresh supply of impurities, such as limescale. Internal or external filters may though be used to reduce the number of impurities entering the boiler.
In one embodiment the outer container is a first outer container, the boiler further comprising a second outer container in which the first outer container is located, wherein the first outer container and second outer container share a common thermally conductive wall, the second outer container having an inlet and an outlet and defining a second outer container passage arranged to convey water in close proximity to the common thermally conductive wall from the inlet to the outlet of the second outer container, wherein the passage of the second outer container is in fluid isolation from the passage of the first outer container and the passages of the inner container, or inner containers.
With the above described arrangement of boiler, the first outer container and the inner container define a first flow path and the heating element or elements can be used to heat water flowing along that first flow path. However, when water is not being drawn through that first flow path, the water in that first flow path may still be heated, which will heat water flowing in the second outer container, defining a second flow path separate to the first flow path. In this manner, two fluidly isolated separate water supplies, or flow paths, may be heated without the need of diverter valves or the like. The above arrangement can be used to create a combination boiler of a central heating system in accordance with a second aspect of the present invention.
In accordance with a second aspect of the invention, a central heating system comprises a boiler as described above, where sanitary water to be heated enters through a first inlet of the boiler, before being received by and passing through the passage of the first outer container and the passage of the inner container where it is heated, before exiting through a first outlet of the boiler. The boiler additionally having a second inlet, to which a return of the central heating system is connected, with water entering the second inlet passing through the passage of the second outer container to exit the boiler through a second outlet of the boiler, to be recirculated around the central heating system.
With a central heating system, as described above, the electric boiler of the invention functions as a combination boiler, with sanitary water being drawn through and heated in the first outer container and the inner container. Then, when sanitary water is not being drawn through the boiler, this water in the boiler may be heated to transfer energy to the water of the central heating system passing through the second outer container. Thus the flow of sanitary water through the boiler can be used to control the transfer of energy from the heating elements to the central heating system without the use of valves, for when sanitary water is being drawn this will absorb the heat energy from generated by the heating elements. However, when sanitary water is not being drawn that energy may then be transferred to the central heating system. The major advantage of this arrangement is that the sanitary water automatically takes precedence for the available heat energy supplied by the heating elements.
With the above described central heating system it is preferable if this further comprises: a pump for circulating water around the central heating system; a temperature sensor for detecting the temperature of water returning to the boiler through the second inlet; a flow or pressure sensor for detecting the flow of sanitary water through the boiler; and a controller arranged to control the pump at least in part in dependence on signals received from the temperature sensor and the flow or pressure sensor. The controller may then be arranged to activate the pump when it is detected that sanitary water is being drawn through the boiler and the temperature of the central heating water returning to the boiler is above a predetermined temperature and to turn off the pump when it is detected that sanitary water is being drawn and the temperature of the water returning from the central heating system to the boiler is below a predetermined temperature.
With the above arrangement the central heating pump can be turned off when sanitary water is being drawn through the boiler such that all the heat generated in the boiler passes to the sanitary water passing through the boiler. However, where the water returning from the central heating system is above a predetermined temperature, then the heat stored in the central heating system may be utilised to heat the sanitary water as it passes on its first pass through the first outer container, so that the sanitary water is then preheated by the central heating return, before it passes through the inner container of the boiler.
Two embodiments of the present invention will now be described, by way of example only, with reference to the following drawings, of which:
Referring to
Although not shown, the boiler of
Referring now to the cross-section views of
Each of the heating element cartridges 10a to 10g contains an internal electrical conductor and may additionally have a temperature sensing device, such as a thermistor, to control and limit the internal temperature of the heating element cartridge, but the temperature may be controlled in any one of a number of known ways.
The first end plate 7 has six threaded apertures into which respective ones of the heating element cartridges 10a to 10f are threaded and sealingly engaged. A further central aperture 11 in the first end plate 7 has a threaded port 12 extending therefrom to provide the hot water outlet 3.
With reference to
External to the inner container 5 is the outer container 6. As previously mentioned, this shares the first end plate 7 with the inner container 5, but additionally comprises a scalloped shaped outer cylinder 15 and an outer end plate 16. The outer end plate 16 has a threaded central aperture 17 for the heating cartridge 10g.
The inner cylinder 8 and outer cylinder 15 define between their walls a small gap approximately 2 mm to 3 mm wide which defines a water jacket 18 about the inner cylinder 8. The separation between the inner end plate 9 and outer end plate 16 extends the water jacket 18 over the inner end plate 9. As can be seen from
On either side of the outer cylinder 15 there are located two ultrasonic transducers 21 and 22 housed within the outer casing 4 of the boiler 1, which outer casing 4 is filled with a thermally insulating material 23. The outer cylinder 15 is formed from copper tube having a wall thickness of between 1 mm to 2 mm. The inner cylinder 8 is formed of a similar thickness of copper and defining the water jacket 18 between them, which may be approximately 2 mm to 3 mm wide. When the heating element cartridges 10a to 10g are located within the inner cylinder 8 and the boiler is filled with water it will have a natural resonant frequency and the ultrasonic transducers 21 and 22 are tuned to approximately match this frequency, to maximise their effectiveness at preventing the build-up of scale and other deposits within the boiler 1. The boiler additionally comprises an over temperature sensor 24 which triggers should the temperature inside the boiler exceed a safe working threshold.
The cold water inlet 2, in the form of the threaded port 20, is directed tangentially to the walls of the inner and outer cylinders 8 and 15. Thus, in use, cold water entering the space between the outer cylinder 15 and inner cylinder 8 is directed circumferentially about the inner cylinder 8, so that it proceeds spirally as it is drawn downwards and through the apertures 13, 14 in the inner end plate 9. Then it travels through the inner cylinder 8, passing directly over the outer surfaces of the heating element cartridges 10a to 10g, before exiting the threaded port 12 to outlet 3. Thus, in use, when the heating element cartridges 10a to 10g are energised and water passing through the boiler 1 from the cold water inlet 2 to the hot water outlet 3, the water first passes around the outside of the inner container 5, preheating the water by absorbing heat from the inner container 5, prior to passing through apertures 13 and 14 into the inner container 5, where it is then heated, on a second pass, by directly coming into contact with the heating element cartridges 10a to 10g.
The double pass arrangement of the boiler 1 illustrated in
Referring now to
In the embodiment of
In this embodiment, each of the heating element cartridges 26a to 26f has a respective inner cylinder 28a to 28f joined at a first end to the first end plate 27 and joined at a second end to a common inner end plate 29. As in the previous embodiment, the inner end plate 29 has apertures, only two of which, 30 and 31, can be seen in
Each of the inner cylinders 28a to 28f has an aperture, only two of which, 33 and 34, can be seen in
In use, water enters the boiler 25 of
It will be appreciated that the same advantages are achieved with the boiler 25 of
Referring now to
The processor 38 is also connected to the over temperature sensor 24, via wire 41, and to an optional flow sensor 42, via wire 43. The flow sensor 42 is shown external to the boiler 1. However, it should be noted that
Referring now to
The above describes one process in which the processor 38 may control energisation of the heating element cartridges 10a to 10g, or 26a to 26f, but it will be apparent that any number of other arrangements of steps may be possible to achieve the same overall result. Particularly it should be noted that the flow sensor 42 of
Referring now to
Referring now to
Referring now to
The boiler 50 of
Referring now to
From the start 68, the processor 65 at step 69 determines whether or not there is a demand for hot water, by monitoring the signal from the flow sensor 42. If there is no demand for hot water, the processor 65 determines at step 70 whether there is a demand for central heating. This may be determined within the processor 65, where the processor 65 is part of a central heating controller. Alternatively, the processor 65 may receive a separate signal (not shown) indicating whether or not there is a demand for central heating.
If there is no demand for central heating at step 70 (and no demand for hot water) the processor 65 at step 79 turns off the central heating pump 63 and then turns off the heating element cartridges at step 80 before returning to the start 68.
However, if there is a demand for central heating at step 70 (but no demand for hot water) the processor 65 at step 71 turns on the central heating pump 63.
The processor 65 then determines at step 72 if the temperature of the heating element cartridges 10a to 10g is above 60° C. If the temperature of the appropriate heating cartridges is above 60° C. then the processor 65 proceeds to step 73 and turns off the heating elements cartridges 10a to 10g before returning to the start 68.
Alternatively, if at step 72 the processor the temperature of the heating element cartridges 10a to 10g is below 60° C., the processor 65 then proceeds to step 74 and determines whether or not the over temperature threshold for the boiler is exceeded, as determined by the over temperature sensor 24. If the over temperature threshold is not exceeded at step 74, then the processor proceeds to step 75 and turns on the heating element before returning to the start 68. If the over temperature is exceeded at step 74, then the processor 65 proceeds to step 73 and turns off the heating elements and proceeds again to the start 68.
If at step 69 the processor determines that there is a demand for hot water the processor proceeds to step 76, to determine if the central heating return is above 50° C. If it is not above 50° C. the processor proceeds to step 77 and turns off the central heating pump before proceeding again to step 72.
Alternatively, if at step 76 the processor 63 determines that the central heating return is above 50° C. then the processor proceeds instead to step 78 and turns on the central heating pump, before proceeding to step 72.
The purpose of step 76, (the processor determining if the central heating return is above 50° C. or not), when there is a demand for hot water, is that if the central heating return is above 50° C. then the central heating pump 63 should be on because, with reference for example to
In the above manner, the water within the central heating circuit can be used as a residual store of energy, to be depleted when there is a demand for hot water, with the energy in the central heating system being replenished when there is no demand for hot water. This may permit a relatively low powered boiler to satisfactorily supply both the demand for instantaneous hot water, whilst also providing the energy source for a central heating system.
As an alternative embodiment to the embodiment described above with reference to
Various embodiments of the present invention have been described above by way of example only and many alternative embodiments are possible which fall within the scope of the following claims.
Number | Date | Country | Kind |
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2001908.9 | Feb 2020 | GB | national |
2014928.2 | Sep 2020 | GB | national |
Filing Document | Filing Date | Country | Kind |
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PCT/GB2021/050308 | 2/10/2021 | WO |