The invention relates to electric water heaters with resistive heating elements, which are located inside the heater and immersed into water.
A tubular electric heater (GB1360334) is known, in which a heating spiral made of a round resistive conductor is coated with insulating material and placed in a groove between two cylindrical pipes of the heater housing.
However, such a tubular electric heater has the following significant disadvantages:
Also an electric water heater (U.S. Pat. No. 3,898,428) is known comprising a cartridge heating element with a cylindrical spiral made of a round in cross section resistive conductor located under the shell of the heating element. The cartridge of the heating element is placed in a tubular housing, the inner side of which has a spiral-corrugated surface. In this water heater, compared with the above counterparts, the sequential removal of heat from the surface of the heating element is somewhat improved due to the turbulence created by the spiral-corrugated surface. In addition, it is possible to heat a small amount of liquid to a high temperature, due to the presence of a power regulator and two operating modes. However, it also has a number of significant drawbacks, namely:
The basis of the invention is the task of creating such an electric water heater where the heating element and the resistive conductor would be designed and arranged relative to each other in a way that to increase the heat-radiating surface, optimize the operating temperature, minimize heat losses, maximize the heat transfer rate of the heating element, and thereby increase the heater's thermal efficiency.
The problem is solved in that the resistive conductor of the heating element is made of a thin resistive tape, the cross-sectional perimeter of which exceeds the cross-sectional perimeter of a round wire of the same cross-sectional area, and the tape width exceeds its thickness, predominantly, more than ten times. Both wide sides of the resistive tape form two heat-radiating surfaces. The heating element is placed in the electric heater housing in such a way, that slotted gaps for the flow of the heated liquid are formed on both sides of its heat-radiating surfaces. The ratio between the width of the heat-radiating surface of the heating element and the slit size (height) of each gap for the flow of the heated liquid is selected from the condition of ensuring the optimal temperature head and thermal conductivity, at which the rate of heat transfer to the heated liquid will be maximal.
The heating element, fulfillment with a thin resistive tape, has more than doubles heat-radiating surface, compare to a round wire of equal cross-sectional area. This reduces the specific load and the heating temperature on its surface to the optimal values corresponding to the extremum rate of the heat transfer to the heated liquid. Since there is no massive central part in the cross-section of the thin tape, it is not being overheated. In this case, all the energy is transferred to the heated liquid circulating in the gaps formed on both sides of the heat-radiating surface of the heating element. At the same time, cavitation is decreased and the heat transfer rate increases is maximized, which reduces the heat loss of the heating element.
The formation of slotted gaps for the flow of the heated liquid adjacent to the heating element from two wide sides is optimizes the heat transfer conditions. On the one hand, the heat-radiating surfaces of the heating element and their high thermal conductivity are used to the maximum. On the other hand, by selecting the height of the gaps, it is possible to provide an optimal heat transfer mode. Given that the thermal conductivity of the heating element is much higher than the thermal conductivity of water, in a thin layer of water adjacent to the heat-radiating surface of the heating element the heat transfer rate is maximum. Therefore, for a heater of a certain capacity, a ratio between the heat-radiating surface width of the heating element and the height of the gap adjacent to it for the flow of the heated liquid, can be chosen that is meets the conditions for optimizing of the temperature pressure and achieving the maximum heat transfer rate.
Thus, the combination of the above features in the proposed water heater design provides a solution to the problem posed as the basis of the invention, namely: increasing the heat-radiating surface and optimizing the operating temperature of the heating element, maximizing the rate of heat transfer and reducing the inertia of the heater, minimizing heat losses of the heating element and the cavitation process. All this ensures the high thermal efficiency of such water heaters.
The fulfillment of the heating element from resistive tape as the rolled with the gaps, formed on both sides of its heat-radiating surface, allows to create efficient water heaters, as either volumetric or flat compact structures. The lowered temperature of the heater allows the usage of cheap materials (for example, enamel, PTFE and fiberglass) as an insulating coating and simplifies the heaters manufacturing technology. This reduces the manufacturing cost of such heaters and expands their application scope.
In one variation of the electric heater, its carcass is formed of a thin-walled cylindrical pipe, on which a cylindrical spiral from a thin resistive tape of the required length is wound. In this case, the opposite wide sides of the resistive tape adjacent to the cylindrical pipe form the external and internal heat-radiating surfaces of the cylindrical heating element. The resistive tape has a coating (for example, enamel) that insulates it from the heated liquid. This provides a direct contact of the heating element with the heated liquid (without the use of a protective tubular shell), which reduces the manufacturing cost of such heaters and further reduces heat losses.
In another variation of the electric heater, the heating element comprises a thin resistive tape of the required length, curved in the shape of a rectangular sinusoid (meander) and placed in a flat sectioning housing. The heating element is placed in sections of the electric heater housing in such a way that wave-like gaps for liquid flow are adjacent to both heat-radiating sides of the resistive tape. This ensures a direct contact of the resistive tape with the heated liquid and further reduction in heat losses. The flat shape allows creation of the high-power compact flow heaters.
In yet another variation of the electric heater, the heating element comprises a flattened tubular shell into which a thin resistive tape with an insulating coating is pressed and which is folded in a shape of a double Archimedes spiral. A spiral gap for the fluid flow is formed between the heat-emitting sides of adjacent turns of the spiral heating element.
The oblate cross-sectional shape of the tubular shell closely matches the cross-sectional shape of the resistive tape, which ensures optimal conditions for heat transfer from its opposite wide sides to the external and internal heat-radiating side of the tubular spiral. These features expand the technological capabilities and the scope of use of such heaters. At the same time, the compactness of the heating element, its increased efficiency and power output, is maintained.
The invention is illustrated by drawings, where:
The electric heater embodiment shown in
Resistive spiral 4 is made of thin resistive tape to increase the heat efficiency of the heater. Moreover, the perimeter of the section of the tape exceeds more than twice the perimeter of the cross section of a round wire with equal sectional area, that is, the width of the tape exceeds its thickness by more than ten times. In practice, thin tapes with an even larger aspect ratio can be used. For example, a 3 kW heater can be equipped with a tape with a cross-sectional area of 7×0.06 mm, in which the ratio of width to thickness is more than 100:1. This provides a six-fold increase in the heat-radiating surface of such a tape, compared with a round conductor of equal cross-sectional area.
The
The
Moreover, the diameters dimensions of cylindrical heating elements 1a. 2a and 1b, 2b are selected according to the condition of the equality between the sums of diameters of the cylinders of the connected pairs 1a, 2a and 1b, 2b. Contact cleats 6a, 7a and 6b, 7c are placed out to the cover 16 of the cylindrical housing 15. In the lower part of the housing 15 there is a branch pipe 11 for water inlet, and in the center of the lower end of the housing 15 there is a branch pipe 12 for water outlet, connected to the pipe 14 for water flow.
The
The
The electric heater operates as follows.
The variant shown in
An electric current causes the heating of the tape spirals 4. All the heating energy is transferred to the water through a thin layer of protective heat-conducting enamel coating 5, therefore, heat loss is minimized. The cylindrical gaps 11 for the liquid flow formed on both sides of each heating element 1 and 2, provide, on the one hand, a uniform heating of the entire liquid flow, and on the other hand, a high throughput of the heater. Due to the presence of passages between the heating elements and the ends of the housing 10, the heated liquid sequentially flows around all their external and internal heat-radiating surfaces. This increases the contact time of the liquid flow with the heater and provides intensive sequential heat removal from the entire area of these heat-radiating surfaces. Moreover, in the cylindrical gap between the heating elements 1 and 2, the liquid is surrounded on all sides by heat-radiating surfaces and heats up even more. The presence of the central tube 14 further increases the contact time of the liquid flow with the heater.
The cylindrical heating element can also be formed by means of a spiral shell made of a flattened tube into which a thin resistive tape 4 with an insulating heat-resistant coating is pressed. In this case, the turns of the tubular spiral adjoin each other with their short sides. This expands the scope of application of such cylindrical heating elements in instantaneous water heaters, in accordance with the available technological capabilities.
The variant shown in
If necessary (for example, for small volumes of liquid located in the heater housing), a variant of a heater containing one cylindrical heating element can be developed.
All this will expand the scope of such cylindrical heating elements and in storage water heaters.
The heater option shown in
Due to the sequential flow around of the liquid the external and the internal heat-radiating surfaces of all four heating elements, the contact time of the liquid flow with the heater is increased, and an intensive sequential heat harvest from the entire area of these heat-radiating surfaces also is ensured. The equality of the sum of the diameters of the connected pairs of cylindrical heating elements ensures the equality of their output powers. Moreover, by switching the connection between the pairs of heating elements 1a, 2a and 1b, 2b by means of contact leads, it is possible to control the total output power of the heater, the heating rate and the temperature of the liquid.
For three-phase electric networks, flow heaters containing at least three pairs of concentrically placed cylindrical heating elements can be made. Such heat-efficient water heaters, being compact, will provide almost any required performance.
A variant of a flat heater, presented in
A variant of the heater containing two tiers of flat heating elements, shown in
Due to the sequential flow around of the liquid along all the heat-emitting surfaces of both heating elements, the contact time of the liquid flow with the heater is increased and intensive sequential heat harvest from the entire area of these heat-radiating surfaces is ensured.
By switching the connection of the heating elements 21a and 21b by means of the contact cleats, the total output power of the heater, the heating speed and the liquid temperature can be adjusted.
For three-phase electrical networks, instantaneous heaters comprising at least three flat heating elements can be constructed. Such heat-efficient water heaters will provide practically any required performance, while being compact and having a low manufacturing cost.
The option of a disk spiral heater, shown in
The voltage from the current source is supplied to the spiral tape 4 of the heating element 41 only after the flow switch (not shown) is activated. An electric current causes heating of the spiral tapes 4.
The liquid being heated enters through the branch pipe 49, heats up in the spiral gaps formed between adjacent coils of the heating spirals, and exits through the branch pipe 50. In this case, the liquid stream flowing along the contour of each coil of the spiral heater 41 performs sequential intensive heat harvest from the entire area of both sides of their heat-radiating surfaces. The passage 46 under the place turnabout of the heating spiral provides a sequential liquid flow along the heat-radiating surfaces of its two branches. This provides an increase in the contact time of the liquid flow with the heater and stronger heating of the liquid.
Disc spiral heaters can also be effectively used in many submerged electric heating devices that are always filled with liquid, in particular such as, kettles, boilers and washing machines. In this case, passages for liquid should be provided from sides of the upper and the lower ends of the heating elements. The liquid located between the heating elements and in the center of the heater is surrounded on all sides by a heat-emitting surface and heats up more strongly. This causes a convective movement and circulation of the liquid in the heater housing, which further intensifies its rapid heating.
A variant of the heater containing two tiers of flat spiral heating elements, shown in
Due to the sequential flow around of the liquid along all the heat-radiating surfaces of both heating elements, the contact time of the liquid flow with the heater is increased and intensive sequential heat harvest from the entire area of these heat-radiating surfaces is ensured. By switching the connection between the heating elements 41a and 41b by means of the contact cleats, the total output power of the heater, the heating rate and the liquid temperature can be adjusted.
For three-phase electrical networks, flow heaters comprising at least three flat spiral heating elements can be constructed. Such heat-efficient water heaters will provide almost any required performance, while being compact and having a low manufacturing cost.
The proposed electric heaters with heating elements made from a thin resistive tape can be used in most various water heating devices, as an effective replacement of the known electric heaters with a round resistive conductor.
The main area of use of the proposed electric heaters is a variety of instantaneous water heaters of almost any capacity.
An additional area of use of the proposed electric heaters is any accumulation water heaters (for example, electric boilers), as well as immersed water heaters (for example, kettles and washing machines).
Thus, the proposed electric heaters, with volumetric (cylindrical) and flat (sinusoidal and spiral) heating elements of a thin resistive tape, can be used in a wide variety of devices for heating liquids. Such heating elements, in comparison with analogues, have a large heat-radiating surface, provide greater heat-efficiency and power output, as well as optimize the operating temperature, minimize heating time and heat losses of the heater. The widespread use of the proposed electric heaters will provide significant electrical energy savings in the respective countries.
Filing Document | Filing Date | Country | Kind |
---|---|---|---|
PCT/IL2020/050590 | 5/26/2020 | WO |