The present invention relates to electric water heaters, and more particularly to an instant electrode water heater that is compact and provides hot water at a substantially high speed and efficiency.
Due to high—and further increasing—energy costs, there is an increasing demand in energy efficient electric water heaters. In particular, there is an increasing demand in instant—or on-demand—electric water heaters that heat water only when hot water is being used. Since the instant electric water heaters are more energy efficient and use less space than storage tank electric water heaters, they are preferred for various household and industrial applications such as, for example, showers, and appliances such as, for example, coffee makers, dish washers, and washing machines.
Most prior art tankless water heater systems use resistance type electric heating elements to heat the water. A major disadvantage of tankless water heater systems utilizing resistance type electric heating elements is that the elements themselves have substantial thermal mass and thermal resistance, substantially reducing the speed the water is heated, especially when the water flow is started. Since the water must flow through the heater before the heating element is activated and the heating element requires time to heat the water, there is first cold water flowing out of the heater, which is particularly a disadvantage in applications without a drain such as, for example, coffee makers.
The alternative to using heating elements for heating the water is to pass an electric current through the water by passing it between two electrodes between which an AC voltage exists, known as Direct Electrical Resistance (DER) heating. Unfortunately, existing instant electrode water heaters have numerous disadvantages: they are highly complex, rendering them expensive to manufacture and difficult to implement in a compact fashion; the hot water temperature is difficult to control; and, they have a relatively high lifetime cost since the complete heater has to be replaced when the electrodes are no longer functional due to corrosion and/or mineral deposition.
It may be desirable to provide an instant electrode water heater that is simple and compact.
It also may be desirable to provide an instant electrode water heater that provides hot water at a substantially high start-up speed and efficiency.
It also may be desirable to provide an instant electrode water heater that enables substantially accurate control of the hot water temperature.
It also may be desirable to provide an instant electrode water heater that enables simple replacement of the electrodes.
Accordingly, in one case the present invention provides an instant electrode water heater that is simple and compact.
The present invention may also provide an instant electrode water heater that provides hot water at a substantially high start-up speed and efficiency.
The present invention may also provide an instant electrode water heater that enables substantially accurate control of the hot water temperature.
The present invention may also provide an instant electrode water heater that enables simple replacement of the electrodes.
According to one aspect of the present invention, there is provided an instant electrode water heater. The instant electrode water heater comprises a housing for containing water therein with the housing having a water inlet and a water outlet. A plurality of electrode plates is disposed inside the housing. The electrode plates are placed such that the electrode plates are oriented parallel to each other and have a predetermined distance between two successive electrode plates for directing water received at the water inlet through successive channels, with each channel being formed by two successive electrode plates, to the water outlet. A plurality of electric contacts is disposed in the housing such that each electric contact is in a touching relationship with a respective electrode plate for providing AC electric power thereto. Electric control circuitry is connected to the electric contacts for controllably providing electric power thereto.
According to one aspect of the present invention, there is provided an instant electrode water heater. The instant electrode water heater comprises a housing having a water inlet and a water outlet and forms a cavity therebetween. An electrode cartridge having a plurality of electrodes therein is removably disposed in the cavity. A cover is removably mounted to the housing in a water sealed fashion for covering the cavity with the electrode cartridge disposed therein. Electric control circuitry is connected to the electrodes for controllably providing AC electric power thereto.
According to one aspect of the present invention, there is provided an instant electrode water heater. The instant electrode water heater comprises a housing having a water inlet and a water outlet and forms a cavity therebetween. A plurality of electrodes is disposed in the cavity. Electric control circuitry is connected to the electrodes for controllably providing AC electric power thereto. The electric control circuitry comprises current sense circuitry for providing a current sense signal indicative of an electric power usage of the electrodes. A microcontroller is connected to the current sense circuitry, an AC electric power supply, and a user interface. The microcontroller determines supply of the AC electric power to the electrodes in dependence upon the current sense signal and the user input signal and provides a supply control signal indicative of the supply of the AC electric power to the electrodes to the AC electric power supply.
An advantage of the present invention is that it provides an instant electrode water heater that is simple and compact.
A further advantage of the present invention is that it provides an instant electrode water heater that provides hot water at a substantially high start-up speed and efficiency.
A further advantage of the present invention is to provide an instant electrode water heater that enables substantially accurate control of the hot water temperature.
A further advantage of the present invention is to provide an instant electrode water heater that enables simple replacement of the electrodes.
An embodiment of the present invention is described below with reference to the accompanying drawings, in which:
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the invention belongs. Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, certain methods and materials are now described.
While the description of certain embodiments hereinbelow is with reference to a wall mounted instant electrode water heater for providing hot water to, for example, a shower or tap, it will become evident to those skilled in the art that the embodiments of the invention are not limited thereto, but are also adaptable for use in appliances such as, for example, coffee makers, dish washers, and washing machines.
Referring to
Electrodes 130 can be contained in electrode cartridge 114 with the same being removably disposed in the cavity 112. Cover 104 is removably mounted to the housing 102—using, for example, conventional easy to open/close fasteners such as spring latches or magnetic latches 108—for covering the cavity 112 with the electrode cartridge 114 disposed therein in a water sealed fashion using for example, an O-ring seal 120 interacting with a respective sealing surface 122. The electrode cartridge 114, for example, comprises a cartridge housing having a bottom wall and sidewalls which, in concert with the cover 104, substantially completely enclose the electrodes 130. Inlet opening 116.1 and outlet opening 116.2 disposed in the sidewalls such that they align with the respective water inlet 150.1 and water outlet 150.2 of the cavity 112 when the electrode cartridge 114 is properly disposed therein, as illustrated in
AC electric power is provided to the electrodes 130 via electric cover connector elements 118 disposed in the cover 104 such as, for example, banana plugs or pin plugs, disposed in the cover 104 which are removably mated with respective electric housing connector elements 162 such as, for example, banana jacks or pin jacks disposed in the housing 102 and connected to electric control circuitry 170 disposed in control housing 124 mounted, for example, to the wall mounting plate 106, as illustrated in
A cover sensor 164 such as, for example, a Hall Effect sensor can be disposed in the housing 102 for providing a cover sensor signal indicating if the cover 104 or the spring latch is opened or closed to the microcontroller, as illustrated in
Optionally, the electric control circuitry 170 is adapted for sensing a resistance of the electrodes 130 and for providing a message, for example, displayed on user interface 110 when the sensed resistance is indicative of a need for replacing the electrode cartridge 114.
Further optionally, the electrode cartridge 114 is one of a set of different electrode cartridges 114 with the electrodes 130 thereof being adapted for heating water having different conductivity. For example, the electrodes 130 are adapted to different water conductivities by changing the distance DE between the electrodes 130 and/or the size—length LE and width WE—of the electrodes 130, as well as the number of the electrodes 130. With the electric control circuitry 170 being adapted for providing AC electric power to the electrodes 130 of any one of the set of different electrode cartridges 114, the instant electrode water heater 100 is easily adapted for heating water having specific water conductivity, enabling high speed and efficiency. For example, a user provides a water sample for testing the conductivity to his/her retailer of the water heater and can then purchase the appropriate electrode cartridge 114 in dependence upon the test result. This can be done prior purchasing the instant electrode water heater 100, as well as during the lifetime of thereof, for example, when purchasing a replacement electrode cartridge 114 in order to adapt to changes in the water conductivity.
The electrodes 130 can be provided as a plurality of electrode plates 130—having a predetermined length LE, width WE, and thickness TE—disposed inside the electrode cartridge 114, as illustrated in
The electrode plates 130 are secured to the electrode cartridge 114 such that the electrode plates 130 are enabled to vibrate in substantially all directions during provision of the AC electric power, which is achieved, for example, by accommodating the electrode plates 130 in respective grooves 134 disposed in the bottom and/or sidewalls of the electrode cartridge 114, with the grooves having a predetermined width WG which is greater than the thickness TE of the respective electrode plates 130 and a predetermined depth DG which is sufficient for securing the respective electrode plates 130 while vibrating, as illustrated in
Further alternatively, the electric contacts are disposed in the bottom with the electrode plates 130 placed thereupon and touching contact being ensured by placing a flexible material such as, for example, a foam insert between the top of the electrode plates 130 and the cover 104.
The electric contacts are connected to a neutral wire 146.1 and a live wire 146.2 in communication with the neutral electric cover connector element 118.1 and the live electric cover connector element 118.2, respectively, such that the electrode plates 130 are connected to neutral AC and live AC in an alternating fashion, as illustrated in
The housing 102, the cover 104, and the housing of the electrode cartridge 114 are made of a heat resistant and electrically non-conductive material, such as a plastic material such as, for example, Acetal using standard plastic molding techniques. The electrode plates 130 can be made of graphite, manufacturing and installation of which is facilitated by the simple shape of the electrode plates 130 and the touching contact for provision of the electric power. Alternatively, the electrode plates 130 are made of another electrically conductive material such as, for example, aluminum, stainless steel, or brass. Further alternatively, the electrode plates 130 have a different shape such as, for example, a circular shape to conform with a cylindrical housing.
The electrode plates 130 as described hereinabove provide a relatively large amount of electric power—large electrode surface area in contact with the water—to a relatively small amount of water—small channels between the electrode plates 130—compared to conventional instant electric water heaters, enabling a substantially compact instant electric water heater having a substantially high start-up speed and efficiency.
In an example implementation, 10 electrode plates 130 having length LE=57 mm, width WE=51 mm, and spaced at distance DE=1.5 mm are employed to heat 4.51/min of water by 40° C. using 240V at 40-45 A supply power.
Optionally, the electrode cartridge 114 is omitted and the electrode plates 130 are directly disposed in the housing 102.
It is noted that the cartridge assembly may also be implemented with other shapes, arrangements of the electrodes, as well as connecting mechanisms for providing the electric power thereto.
Further optionally, the electric control circuitry 170 disposed, for example, on a Printed Circuit Board (PCB), is cooled using a heatsink element 166 in thermal contact with the PCB, as illustrated in
Referring to
The current sense and power supply circuitry 170A can compromise the following components, as illustrated in
Microcontroller 170B drives the gate driver 170A.5 and reads the voltage output from the current sense amplifier 170A.6 and regulates the power provided to the electrodes 130 based on the voltage output from the current sense amplifier to achieve a set power based on the user input signal or preprogrammed into the microcontroller 170B. The microcontroller is, for example, a suitable off-the-shelf Field-Programmable Gate Array (FPGA) as well as the other components are also off-the-shelf components assembled on a PCB using standard technology.
Optionally, the microcontroller 170B is connected to: the cover sensor 164 via port 180; the solenoid valve 154 via port 182; inlet water temperature sensor 156 via port 184; outlet water temperature sensor 158 via port 186; water flow sensor 160 via port 188; and, water conductivity sensor 161 via port 190.
For example, the microcontroller 170B receives a cover sensor signal indicating if the cover 104 or the spring latch 108 is opened or closed to the microcontroller 170B. If the cover sensor signal is indicative of the cover/latch being opened, the microcontroller 170B stops provision of the AC electrical power to the electric housing connector elements 162 until the cover sensor signal is indicative of the cover/latch being closed in order to protect the user from electric shock when replacing the electrode cartridge 114. The microcontroller 170B may also send a signal to the solenoid valve 154 to shut off the water flow if the cover sensor signal is indicative of the cover/latch being opened. Furthermore, the microcontroller 170B may receive one or more signals indicative of the inlet water temperature, the outlet water temperature, the water flow rate, and the water conductivity in order to, for example: determine the start/stop and the amount of electrical power provide to the electrodes 130 based thereon in addition to the current sense signal to achieve a set hot water temperature; determine if the electrodes 130 need to be replaced and provide a message to the user interface 110 indicative thereof; determine one of the set of different electrode cartridges 114 in dependence upon the provided electrical power and provide a message to the user interface 110 indicative thereof; adjust the provision of electrical power to the electrodes 130 to changes in the water conductivity or to shut off the electrical power if the changes are greater than a predetermined threshold; adjust the provision of electrical power to changes in resistance of the electrodes 130; and, reduce the water flow if a set hot water temperature cannot be achieved.
As is evident to one skilled in the art, the electric control circuitry 170 may also be adapted for controlling other designs of instant electrode water heaters than the instant electrode water heater 100.
Alternatively, the current sense and power supply circuitry 170A described hereinabove is replaced by circuitry using a TRlode for Alternating Current (TRIAC) for sensing the AC voltages and regulate the provision of electrical power to the electrodes using Phase Controlled Dimming. While the TRIAC based circuitry is somewhat simpler it is less efficient, in particular, if not water-cooled.
Referring to
It is noted that the instant electrode water heater 200 may be implemented with the electrode plates 130 and/or the cartridge assembly as well as with various other designs of instant electrode water heaters.
The present invention has been described herein with regard to certain embodiments. However, it will be obvious to persons skilled in the art that a number of variations and modifications can be made without departing from the scope of the invention as described herein.
Number | Date | Country | Kind |
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2960258 | Mar 2017 | CA | national |
Filing Document | Filing Date | Country | Kind |
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PCT/CA2018/000051 | 3/7/2018 | WO | 00 |