Heating Assemblies for Water Heaters

Abstract

A heating assembly for a water heater may include a base, a first electric heating element secured to the base, and a second electric heating element secured to the base. The second electric heating element is electrically isolated from the first electric heating element. The first and second electric heating elements are independently switchable to provide a first heat rating of the heating assembly and a second heat rating higher than the first heat rating. A water heater assembly may include a tank defining a chamber for holding a volume of water, and the heating assembly coupled to the tank. The water heater assembly may include a second heating assembly, and may further include a controller configured to control the first and second heating assemblies to provide heating at same or different heat ratings.

Description

TECHNICAL FIELD

The present disclosure is generally in the field of water heaters, and more particularly related to heating assemblies for water heaters.

BACKGROUND

Water heaters may be used to heat water to a predetermined temperature. Some types of water heaters may include a tank for holding a volume of water and means for transferring heat to the water. Depending on the type of heating mechanism, water heaters may include a number of parts internal to and external to the tank. Other types of water heaters may be tankless heaters, and heat water traveling through a pipe or a conduit. Thus, a number of steps may be involved in assembling the water heater. Water heaters may need to be operated at different conditions and stages of external temperatures, target heating temperatures, and water usage.

SUMMARY

The present disclosure describes heating assemblies for water heaters, water heaters, and methods of making water heaters.

In embodiments, the present disclosure describes a heating assembly for a water heater. The heating assembly may include a base, a first electric heating element secured to the base, and a second electric heating element secured to the base. The second electric heating element may be electrically isolated from the first electric heating element. The first and second electric heating elements may be independently switchable to provide a first heat rating of the heating assembly and a second heat rating of the heating assembly that is higher than the first heat rating.

In embodiments, the present disclosure describes a water heater assembly. The water heater assembly may include a tank defining a chamber for holding a volume of water. The water heater may further include the heating assembly coupled to the tank and configured to heat the volume of water in the chamber.

In embodiments, the heating assembly is a first heating assembly, and the water heater assembly may include a second heating assembly. In embodiments, the water heater assembly may further include a controller configured to control the first and second heating assemblies to provide heating at same or different heat ratings.

BRIEF DESCRIPTION OF THE DRAWINGS

The detailed description is set forth with reference to the accompanying drawings. The use of the same reference numerals may indicate similar or identical items. Various embodiments may utilize elements and/or components other than those illustrated in the drawings, and some elements and/or components may not be present in various embodiments. Elements and/or components in the figures are not necessarily drawn to scale. Throughout this disclosure, depending on the context, singular and plural terminology may be used interchangeably.

FIG. 1A is a side view of a heating assembly including two electric heating elements.

FIG. 1B is a perspective view of the heating assembly of FIG. 1A.

FIG. 1C is rear view of the heating assembly of FIG. 1A.

FIG. 2A is a side view of a heating assembly including a first looped heating element and a second foldback heating element.

FIG. 2B is a perspective view of the heating assembly of FIG. 2A.

FIG. 3 is a block diagram shown a water heating assembly including a tank and at least one heating assembly.

FIGS. 4A to 4F are rear views of heating assemblies having different arrangements of electric heating elements.

The present disclosure provides a more detailed and specific description with reference to the accompanying drawings. The drawings and specific descriptions of the drawings, as well as any specific or other embodiments discussed, are intended to be read in conjunction with the entirety of this disclosure.

DETAILED DESCRIPTION

Example embodiments will now be described more fully hereinafter with reference to the accompanying drawings, in which example embodiments are shown. The concepts disclosed herein may, however, be embodied in many different forms and should not be construed as limited to the example embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the concepts to those skilled in the art. Like numbers refer to like, but not necessarily the same or identical elements throughout.

Water heaters may employ different techniques for generating heat to heat a volume of water. For example, some water heaters may employ resistive electrical heating, in which electrical energy is converted to thermal energy used to heat water. A heating element may be turned on or off, in response to water temperature sensed by a temperature sensor, for example, a thermostat. However, an on/off control may only provide a limited or simple scheme for controlling water temperature, and may not be able to account for water usage patterns, environmental conditions, and other external factors. Further, passing large amounts of current through a heating element may tend to cause thermal and electric fatigue, reducing the life of the heating element.

In embodiments, the present disclosure describes a heating assembly for a water heater. The heating assembly may include a base, a first electric heating element secured to the base, and a second electric heating element secured to the base. The second electric heating element may be electrically isolated from the first electric heating element. Providing two (or more) heating elements may distribute energy delivery along two (or more) heating elements, and thus, reduce energy density. Reducing the energy density may reduce thermal and electric fatigue. Further, providing multiple heating elements may also provide additional control schemes, for example, by permitting changes in the heat rating or wattage of the heating assembly. For example, the first and second electric heating elements may be independently switchable on and off to provide a first heat rating of the heating assembly and a second heat rating of the heating assembly higher than the first heat rating. For example, a higher heat rating of the heating assembly may be provided by switching on both of the electric heating elements, while a lower heat rating of the heating assembly may be provided by switching on one of the electric heating elements, and switching off another of the electric heating elements. The term “heat rating” refers to a heating power (for example, measured in Watts) supplied by the heating assembly.

In embodiments, the present disclosure describes a water heater assembly. The water heater assembly may include a tank defining a chamber for holding a volume of water. The water heater may further include the heating assembly coupled to the tank and configured to heat the volume of water in the chamber. Thus, the heating assembly may be used to provide different heating patterns (for example, low heat versus high heat) in the same water tank, in response to user needs.

In embodiments, the heating assembly is a first heating assembly, and the water heater assembly may include a second heating assembly. In embodiments, the water heater assembly may further include a controller configured to control the first and second heating assemblies to provide heating at same or different heat ratings. Providing two (or more) heating assemblies may provide an even greater breadth and variety of control schemes to be used. For example, different heating elements of different heating assemblies may be activated to heat different regions in the water tank. Further, if a heating element or a heating assembly is in need of replacement, energy can be diverted to other heating elements or heating assemblies so that the water heater may still be used while awaiting further maintenance.

In the present disclosure, the terms “upper” and “lower” denote components positioned higher or lower than other components with reference to gravity.

FIG. 1A is a side view of a heating assembly 10 including two electric heating elements 12 and 14. FIG. 1B is a perspective view of the heating assembly 10 of FIG. 1A.

The heating assembly 10 may be used in a water heater. For example, one or both of the heating elements 12 and 14 may be energized to provide different heat ratings of the heating assembly. Energizing only one of the heating elements 12 or 14 provides a lower heat rating, while energizing both of the heating elements 12 and 14 provides a higher heat rating. The heating assembly 10 may include a base 16. The first electric heating element 12 may be secured to the base 16. The second electric heating element 14 may also be secured to the base 16. For example, one or both of the heating elements 12 or 14 may be secured to the base by an interference fit, a brazed joint, a weld, a screw, a bolt, a fastener, an adhesive, a clip, or any suitable fastening means.

The second heating element 14 may be electrically isolated from the first heating element 12. For example, substantially no significantly conductive path may be present between the first and second heating element 12 and 14 (apart from any minor conduction provided by water occupying a surrounding volume).

The first and second heating elements 12 and 14 may be independently switchable to provide a first heat rating of the heating assembly 10 and a second heat rating higher than the first heat rating. Thus, the heating assembly 10 as a whole may be operable at the first heat rating to provide a lower heating power, and operable at the second heat rating to provide a higher heating power.

The heating assembly 10 may include electrical connections for coupling the first and second heating elements 12 and 14 to a power supply (not shown in FIG. 1A). For example, the electrical connections may include conductive pins, clips, sockets, plugs, or the like. The first and second heating elements 12 and 14 may be connectable to different power supplies, for example, dedicated power supplies for each sheath, or to a common power supply.

The first and second heating elements 12 and 14 may generate heat from electricity via the power supply, for example, by resistive heating. In embodiments, the first and second heating elements 12 and 14 may include one or more resistive elements that generate heat in response to passing an electric current. The heat power may be controlled by providing a predetermined resistance to the heating elements 12 and 14, and by controlling a magnitude of current passing through, or by controlling a voltage difference applied across respective sheaths.

The first and second heating elements 12 and 14 may include a metal, an alloy, or a ceramic. For example, a resistive core of a heating element may include a metal, an alloy, or a ceramic that generates heat in response to passage of electric current. The metal may include aluminum or copper. The alloy may include a nickel-chromium alloy or an iron-chromium-aluminum alloy. In embodiments, the first and second heating elements 12 and 14 may include metallic copper or an alloy including copper. In embodiments, the first and second heating elements 12 and 14 may be tubular and have a hollow core. In embodiments, the first and second heating elements 12 and 14 may include a resistive core surrounded by a metal or alloy sheath, shell, coating, or plating. The coating or plating may include one or more of magnesium oxide, tin, nickel, or zinc. In embodiments, the first and second heating elements 12 and 14 each may include tubing formed of copper, stainless steel, or titanium. The shell may include stainless steel. In embodiments, the first and second heating elements 12 and 14 may be coated with an anticorrosive coating.

The base 16 may be used to handle, manipulate, and orient the heating assembly 10, for example, during installation, removal, cleaning, or maintenance. The base 16 may be used to secure the heating assembly 10 to a water heater, for example, to a tank of the water heater. For example, the heating elements 12 and 14 may be introduced within an interior of the tank through an opening in a wall or open end of the tank, and the base 16 may be secured to the wall of the tank. In embodiments, the base 16 defines a threaded surface 18 configured to be secured to a tank of the water heater. Thus, the heating assembly 10 may be screwed onto the tank for installation, or unscrewed from the tank for removal. Instead of, or in addition to, the threaded surface 18, the base 16 may include one or more clips, tabs, or fasteners to secure the base 16 to the tank.

The base 16 may include insulating material or be formed of an insulating material. The insulating material may include one or more of a plastic, a glass, or a ceramic. The insulating material may facilitate electrically isolating the heating elements 12 and 14 from each other, and from the surrounding environment, such as a tank of the water heater.

Various connections, interfaces, or gaps may be made waterproof, for example, regions surrounding electrical couplings or connections, or about the base 16. One or more of a tape, a coating, a sealant, a seal, a gasket, or any suitable sealing means may be provided on or about the base 16.

FIG. 1C is rear view of the heating assembly of FIG. 1A. The first and second heating elements 12 and 14 may extend parallel to each other from the base 16, or may be transverse or in a crossed configuration, as shown in FIGS. 1A and 1C. For example, the first heating element 12 may extend at least partially or substantially along a first plane P1, and the second heating element 14 may extend at least partially or substantially along a second plane P2 transverse (angled relative) to the first plane P1, as shown in FIG. 1C. In some embodiments, the second plane P2 is normal (900 to the first plane). Such a configuration may promote compactness and may accommodate both heating elements in substantially the same form factor as a single heating element.

The heating assembly 10 may be operable to provide different heat ratings. For example, the first heat rating may be provided by switching on (or energizing or powering) only the first heating element 12, while the second heat rating may be provided by switching on only the second heating element 14. In such embodiments, the second heating element 14 has a different heating characteristic, for example, wattage, than the first heating element 12. Thus, operating different heating elements may provide different wattages. In embodiments, the first heat rating is provided by switching on only one of the first and second heating elements 12 and 14, and the second heat rating is provided by switching on both of the first and second heating elements 12 and 14. In such embodiments, the first and second heating elements 12 and 14 may have the same or different heating characteristics. For example, the first and second heating elements 12 and 14 may have the same wattage. In other embodiments, the second heating element 14 may have a higher wattage than the first heating element 12.

In this way, depending on whether one or both of the first and second heating elements 12 or 14 are powered, two or three different heat ratings may be achieved. If both heating elements 12 or 14 have the same wattage, then bi-level ratings may be achieved (for example, low power and high power). If the heating elements 12 and 14 differ in wattage, then tri-level ratings may be achieved by operating one or both of the heating elements 12 or 14 (for example, lowest power, medium power, and highest power).

Different heating characteristics or wattage may be provided in heating elements 12 and 14 by changing their geometric properties (for example, length, cross-section, area, shape) or electrical properties (for example, by selecting materials with different electrical resistances). In embodiments, the second heating element 14 is longer than the first heating element 12. Such a configuration may provide a greater wattage to the second heating element 14, by providing a longer resistive path, or a similar wattage as the first heating element 12, with a lower energy density (based on the energy delivered respectively through the first and second heating elements 12 and 14).

The heating elements 12 and 14 may extend as rods or bars, and may include one or more loops (e.g., turns or bends) for compactness, for example, by allowing a greater exposed surface area for a given volume of water. The heating elements 12 and 14 may have any suitable periphery in cross-section, such as circular, elliptical, ovoid, polygonal, or particular polygons such as hexagonal.

In embodiments, the first heating element 12 includes a first looped body 20, and the second heating element 14 includes a second looped body 22. The first looped body 20 may include a first bar and the second looped body 22 may include a second bar. Each of the first and second bar may have a circular cross-section. In embodiments, the first and second bars have a same diameter. In other embodiments, one of the heating elements 12 and 14 may have a larger cross-sectional diameter than the other.

At least one of the first looped body 20 and the second looped body 22 may be U-shaped, and define a single bend along a respective looped body. For example, as shown in FIG. 1B, the first looped body 20 includes only a single bend 24, while the second looped body 22 includes only a single bend 26. In embodiments, at least one of the first looped body 20 and the second looped body 22 respectively include a first bar and a second bar substantially parallel to the first bar, with the second bar being integral with or connected to the first bar by the bend (24 or 26).

In embodiments, one or both of first and second looped bodies 20 or 22 may have further bends. For example, at least one of the first looped body 20 and the second looped body 22 may define two or more bends. In other embodiments, the looped bodies may include a twist, coil, helix or other looped/bent structure.

FIG. 2A is a side view of a heating assembly 100 including a first looped heating element 12 and a second foldback heating element 111. A “foldback” heating element may be formed by folding back a U-shaped loop initially having two parallel bars into a structure including four substantially parallel bars. Thus, each of two parallel bars of a U-shaped bar may be bent or folded to provide a total of four parallel bars after the folding. Folding the element may provide an extended length and increased heating surface in a similar form factor as a U-shaped heating element including a single bend. FIG. 2B is a perspective view of the heating assembly 100 of FIG. 2A. The heating assembly 100 is similar to the heating assembly 10 in FIGS. 1A-1B, including the first heating element 12 and the base 16, but differs in the configuration of the second heating element 111. In particular, the second looped body 113 of the second heating element 111 includes a foldback heating element. In the foldback second heating element 111, the bend 115 is a first bend ultimately (indirectly) coupling first and second bars 117 and 119, with the second looped body 113 further including a third bar 121 coupled to the first bar 117 by a second bend 123 and a fourth bar 125 coupled to the second bar 110 by a third bend 127.

In embodiments, the fourth bar 125 is substantially parallel to the third bar 121. In embodiments, the fourth bar 125 is substantially parallel to the first bar 117. In some embodiments, the first, second, third, and fourth bars 117, 119, 121, and 125 are substantially parallel to each other.

The foldback heating element may provide a longer length in a similar form factor or volume as a U-shaped heating element with a single bend, and thus providing a greater wattage or similar wattage with a lower energy density (depending on the energy delivered through heating elements with different lengths).

FIG. 3 is a block diagram showing a water heating assembly 200 including a tank 205 and at least one heating assembly 10. Instead of, or in addition to, heating assembly 10 described with reference to FIGS. 1A to 1C, the water heating assembly 200 may include heating assembly 100 described with reference to FIGS. 2A and 2B.

In embodiments, the heating assembly 10 is a first heating assembly, and the water heater assembly 200 may be a second heating assembly (for example, the heating assembly 100). While FIG. 3 shows different heating assemblies 10 and 100 in the water tank 205, in other embodiments, the first and second heating assemblies may be identical. Thus, two or more of assemblies 10 or 100 may be provided.

The tank 205 defines a chamber 207 for holding a volume of water. The heating assembly (10 or 100 or variants thereof) may be coupled to the tank 205 and configured to heat the volume of water in the chamber 207.

The first and second heating assemblies 10 and 100 may differ in at least one characteristic such as a number of heating elements, a length of at least one heating element, an operational voltage of at least one heating element, a wattage of at least one heating element, a lower heat rating magnitude, or a higher heat rating magnitude. In embodiments, the first heating assembly is positioned higher along the tank than the second heating assembly. While assembly 100 is the lower assembly and assembly 10 is the higher assembly in FIG. 3, their locations may be reversed. In embodiments, the first and second heating assemblies are each operable at a lower heat rating and a higher heat rating.

In embodiments, the water heater assembly 200 may further include a controller 230 configured to control one or more heating assemblies, such as heating assembly 10 or 100. In embodiments, the controller 230 may individually control different heating elements of the one or more heating elements. For example, the controller 230 may be configured to operate one of the first or second electric heating elements (of the first or second heating assemblies 10 or 100) in response to detecting a failure of the other of the first or second electric heating elements.

In embodiments, the water heater assembly 200 further includes a temperature sensor 232 configured to sense a temperature of water within the chamber 207 and configured to send a signal to the controller 230 indicative of the temperature. The temperature sensor 232 may be positioned adjacent the first heating assembly 10, or spaced from the first heating assembly. In embodiments, the temperature sensor 232 is positioned at a height greater than that of the first heating assembly 10.

In embodiments, the temperature sensor 232 is a first sensor, and the water heater assembly further includes a second temperature sensor 234. For example, the first and second sensors 232 and 234 (and optionally, further sensors) may be located at different heights along the water tank, and the second sensor 234 may be a lower sensor, while the first sensor 232 may be an upper sensor. In embodiments, the second sensor 234 is positioned a height greater than that of the second heating assembly 100.

The assembly 200 may further include a power supply 240. The power supply 240 may supply appropriate electrical power supply (similar or different) to various components, for example, one or more of the heating assemblies 10 or 100, the controller 230, or the sensors 232 or 234.

In embodiments in which the assembly only includes a single heating assembly, the controller 230 may be configured to selectively energize one or more heating elements of the single heating assembly to provide a lower rating, a medium rating, or a higher rating. The ratings may be particular wattages at predetermined operating voltages. For example, at an operating voltage of 240V, the lower, medium, or higher rating may be at least 500 W, or at least 1000 W. The lower, medium, or higher rating may be less than 6000 W, or less than 5500 W, or less than 5000 W, or less than 4500 W, or less than 4000 W, at an operating voltage of 240 V. The lower, medium, or higher ratings may individually be in a range from 100 W to 6000 W, or from 500 W to 5500 W, or from 1000 W to 6000 W, end points inclusive, at an operating voltage of 240 V. The lower, medium, or higher ratings may individually be any of 1000 W, 1500 W, 2000 W, 2500 W, 3000 W, 3100 W, 3500 W, 3800 W, 4000 W, 4500 W, 5000 W, 5500 W, or 6000 W, at an operating voltage of 240 V.

The rating may change when the operating voltage is changed. For example, at an operating voltage of 120V, the lower, medium, or higher rating may be at least 200 W, at least 500 W, or at least 1000 W. The lower, medium, or higher rating may be less than 3000 W, or less than 2500 W, or less than 2000 W, or less than 1000 W, at an operating voltage of 120 V. The lower, medium, or higher ratings may individually be in a range from 100 W to 3000 W, or from 500 W to 2500 W, or from 1000 W to 2000 W, end points inclusive, at an operating voltage of 120 V. The lower, medium, or higher ratings may individually be any of 200 W, 500 W, 1000 W, 1440 W, 1500 W, 1700 W, 2000 W, 2500 W, or 3000 W, at an operating voltage of 120 V. Other operating voltages such as 110 V, 208 V, 277 V, 380 V, 480 V, or any other suitable operating voltages may be used, providing other wattage ratings.

Depending on the number and rating of the individual heating elements, the heating assembly as a whole may have a number of ratings, for example, two, three, four, five, six, or more numerically ordered ratings. Thus, the controller 230 may operate the heating assembly at a lower rating when the water temperature is greater than a first threshold and at a higher rating when the water temperature is lower than the first threshold. Selectively energizing different heating elements may extend the life of the heating assembly, by transferring energy along a larger area and with a lower energy density, which may reduce thermal and electric fatigue.

In embodiments in which more than one heating assembly is present, the controller 230 may be configured to selectively energize one or both of the first heating assembly and the second heating assembly to provide at least one of: (i) a lower heat rating of both the first and second heating assemblies; (ii) a lower heat rating of one of the first and second heating assemblies and a higher heat rating of the other of the first and second heating assemblies; or (iii) a higher heat rating of both the first and second heating assemblies. Further, where more than two heating elements are present in one or both of the first or second heating assemblies, the controller 230 may be configured to selectively energize one or more heating elements to provide a rating from a first, second, third, fourth, fifth, sixth, or higher rating of a plurality of numerically ordered ratings.

The water heating assembly 200 includes an inlet 250 and an outlet 260. The inlet 250 and outlet 260 may be positioned at any suitable position along the tank 205. In embodiments, as shown in FIG. 3, both the inlet 250 and the outlet 260 are positioned at a top of the tank 205. In other embodiments, one or both of the inlet 250 or the outlet 260 may be positioned at other locations, for example, at an upper section of the tank 205, at a central section of the tank 205, or at a lower section of the tank 205. In embodiments, one or both of the inlet 250 or the outlet 260 may be positioned at a bottom of the tank 205.

In embodiments, the controller 230 is configured to energize the first and second heating assemblies simultaneously over at least a first time period. In embodiments, the controller 230 is configured to energize the first and second heating assemblies non-simultaneously over at least a second time period. In embodiments, the controller 230 is configured to energize one of the first and second heating assemblies with a higher priority than the other of the first and second heating assemblies. For example, the controller 230 may prioritize heating an upper heating assembly when the first sensor 232 indicates that an upper volume of water has a temperature below a first threshold and when the second sensor 234 indicates that a lower volume of water has a temperature above the threshold. In this way, the lower volume need not be heated.

The upper volume may have a lower temperature, for example, if the outlet 250 is present at or adjacent a top of the water tank 205, which may result in frequent withdrawing of water from an upper region of the water tank 205.

In embodiments, the lower heating assembly (for example, assembly 100) may have a higher maximum rating that that of the upper assembly (for example, assembly 10). This may facilitate uniform heating, because water at a higher temperature tends to have a lower density and naturally tends to rise to the top. Thus, a fresh volume of water introduced through the inlet 260 may initially flow downward toward a bottom of the chamber 207 and be heated by the lower assembly 100, and then rise upward to be further heater by the upper assembly 10.

While heating assemblies including two electric heating elements have been described with reference to FIGS. 1A to 3, heating assemblies according to the present disclosure may include additional electric heating elements. For example, heating assemblies may include three, four, or more electric elements.

FIGS. 4A to 4F are rear views of heating assemblies having different arrangements of electric heating elements. FIG. 4A shows a heating assembly 300a including four heating elements, with the positions of the ends marked as A-A for a first heating element, B-B for a second heating element, C-C for a third heating element, and D-D for a fourth heating element. Any number of the heating elements may be similar to looped heating element 12 described with reference to FIGS. 1A to 1C or foldback heating element 111 described with reference to FIGS. 2A to 2B. As seen in FIG. 4A the heating elements may be arranged side-by-side with aligned ends.

FIG. 4B shows a heating assembly 300b including transverse pairs of heating elements. For example, the ends A-A of the first heating element are transverse to the ends B-B of the second heating element in a first pair of heating elements, and the ends C-C of the third heating element are transverse to the ends D-D of the fourth heating element in a second pair of heating elements.

FIG. 4C shows a heating assembly 300c including transverse pairs of heating elements. Similar to the arrangement in FIG. 4B, the ends A-A of the first heating element are transverse to the ends B-B of the second heating element in a first pair of heating elements, and the ends C-C of the third heating element are transverse to the ends D-D of the fourth heating element in a second pair of heating elements. However, the first pair and the second pair are in a diagonally opposed or offset configuration. Such a diagonally opposed configuration of pairs alternatively may include heating elements in a parallel configuration rather than a transverse configuration. Thus, the first pair of heating elements may include ends A-A and B-B in a parallel configuration, and the second pair of heating elements may include ends C-C and D-D in a parallel configuration.

FIG. 4D shows a heating assembly 300d including three diagonally aligned or offset heating elements. The ends A-A of the first heating element parallel to the ends B-B of the second heating element and the ends C-C of the third heating element, but all heating elements being diagonally aligned.

FIG. 4E shows a heating assembly 300e including circumferentially disposed heating elements. The ends A-A, B-B, C-C, and D-D may be arranged along a circular or other curved path, or along a polygonal path. In embodiments, “n” number of heating elements may be disposed at or along “n” vertices of a polygon.

FIG. 4F shows a heating assembly 300f including four heating elements in a crossed or “X-shape” arrangement. One set of ends A, B, C, and D may be disposed along an inner path, and the other set of ends A, B, C, and D may be disposed along an outer path.

Any of these configurations may be combined or further modified, for example, with fewer or more heating elements, and the heating elements may be arranged in symmetric or asymmetric arrangements.

Any such heating elements may be used as the first heating assembly 10 or the second heating assembly 100 in a water heating assembly, for example, the water heating assembly 200 of FIG. 3.

Turning back to FIG. 3, the controller 230 may selectively operate one or more heating elements of the upper or lower heating assemblies, or selectively operate the upper or lower heating assemblies, to provide different heating patterns or ratings, to extend the life of the heating elements, or in response to a detected failure of a heating element or heating assembly.

Modifications and variations of the assemblies, devices, and methods described herein will be obvious to those skilled in the art from the foregoing detailed description. Such modifications and variations are intended to come within the scope of the appended claims.

Claims

1. A heating assembly for a water heater, the heating assembly comprising: a base;a first electric heating element secured to the base; anda second electric heating element secured to the base,wherein the second electric heating element is electrically isolated from the first electric heating element, andwherein the first and second electric heating elements are independently switchable on or off to provide a first heat rating of the heating assembly and a second heat rating of the heating assembly that is higher than the first heat rating.

2. The heating assembly of claim 1, wherein the first heat rating is provided by switching on only the first heating element, and wherein the second heat rating is provided by switching on only the second heating element.

3. The heating assembly of claim 1, wherein the first heat rating is provided by switching on only one of the first and second heating elements, and wherein the second heat rating is provided by switching on both of the first and second heating elements.

4. The heating assembly of claim 1, wherein the first and second electric heating elements have a same wattage.

5. The heating assembly of claim 1, wherein the first electric heating element comprises a first looped body, and the second electric heating element comprises a second looped body; and wherein the first looped body comprises a first bar and the second looped body comprises a second bar, wherein the first and second bar each have a circular cross-section.

6. The heating assembly of claim 5, wherein at least one of the first looped body and the second looped body defines a single bend.

7. The heating assembly of claim 6, wherein at least one of the first looped body and the second looped body respectively comprises a first bar and a second bar substantially parallel to the first bar, and wherein the second bar is connected to the first bar by a bend.

8. The heating assembly of claim 7, wherein the second looped body comprises a foldback heating element, wherein the bend is a first bend, wherein at least one of the first looped body and the second looped body further comprises a third bar coupled to the first bar by a second bend and a fourth bar coupled to the second bar by a third bend.

9. The heating assembly of claim 1, wherein the second electric heating element is longer than the first electric heating element.

10. The heating assembly of claim 1, wherein the first electric heating element extends at least partially along a first plane, and wherein the second electric heating element extends at least partially along a second plane transverse to the first plane.

11. The heating assembly of claim 10, wherein the second plane is normal to the first plane.

12. The heating assembly of claim 1, wherein the first and second electric heating elements comprise a metal, an alloy, or a ceramic, and wherein the base comprises an insulating material.

13. A water heater assembly comprising: a tank defining a chamber for holding a volume of water; anda heating assembly coupled to the tank and configured to heat the volume of water in the chamber, the heating assembly comprising: a base;a first electric heating element secured to the base; anda second electric heating element secured to the base,wherein the second electric heating element is electrically isolated from the first electric heating element, andwherein the first and second electric heating elements are independently switchable on or off to provide a first heat rating of the heating assembly and a second heat rating of the heating assembly that is higher than the first heat rating.

14. The water heater assembly of claim 13, further comprising a controller configured to control the heating assembly.

15. The water heater assembly of claim 14, further comprising a temperature sensor configured to sense a temperature of water within the chamber and configured to send a signal to the controller indicative of the temperature.

16. The water heater assembly of claim 15, wherein the controller is configured to operate one of the first or second electric heating elements in response to detecting a failure of the other of the first or second electric heating elements.

17. The water heater assembly of claim 13, wherein the heating assembly is a first heating assembly, and wherein the water heater assembly further comprises a second heating assembly.

18. The water heater assembly of claim 17, wherein the first and second heating assemblies differ in at least one characteristic selected from a number of heating elements, a length of at least one heating element, an operational voltage of at least one heating element, a wattage of at least one heating element, or a heat rating magnitude.

19. The water heater assembly of claim 18, wherein the first heating assembly is positioned relatively higher along the tank than the second heating assembly.

20. The water heater of claim 13, wherein the controller is configured to selectively energize one or both of the first heating assembly and the second heating assembly to provide at least one of: (i) a lower heat rating of both the first and second heating assemblies;(ii) a lower heat rating of one of the first and second heating assemblies and a higher heat rating of the other of the first and second heating assemblies; and(iii) a higher heat rating of both the first and second heating assemblies.