US20110129205A1 - Flow-through heater - Google Patents
Flow-through heater Download PDFInfo
- Publication number
- US20110129205A1 US20110129205A1 US12/627,560 US62756009A US2011129205A1 US 20110129205 A1 US20110129205 A1 US 20110129205A1 US 62756009 A US62756009 A US 62756009A US 2011129205 A1 US2011129205 A1 US 2011129205A1
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- US
- United States
- Prior art keywords
- heater
- flow
- heating element
- cylindrical wall
- tubular housing
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 238000010438 heat treatment Methods 0.000 claims abstract description 116
- 239000012530 fluid Substances 0.000 claims abstract description 32
- 239000011248 coating agent Substances 0.000 claims abstract description 14
- 238000000576 coating method Methods 0.000 claims abstract description 14
- 230000000712 assembly Effects 0.000 claims description 24
- 238000000429 assembly Methods 0.000 claims description 24
- 230000002093 peripheral effect Effects 0.000 claims description 16
- 239000000463 material Substances 0.000 claims description 12
- 239000012212 insulator Substances 0.000 claims description 10
- 229910052782 aluminium Inorganic materials 0.000 claims description 9
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 8
- 238000004382 potting Methods 0.000 claims description 5
- 239000004033 plastic Substances 0.000 claims description 3
- 229920003023 plastic Polymers 0.000 claims description 3
- 239000007769 metal material Substances 0.000 claims 1
- 229910052751 metal Inorganic materials 0.000 description 5
- 239000002184 metal Substances 0.000 description 5
- 238000004519 manufacturing process Methods 0.000 description 4
- 238000000034 method Methods 0.000 description 4
- 239000007788 liquid Substances 0.000 description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 3
- 238000003466 welding Methods 0.000 description 3
- 238000005219 brazing Methods 0.000 description 2
- 238000005485 electric heating Methods 0.000 description 2
- 239000012777 electrically insulating material Substances 0.000 description 2
- 239000008236 heating water Substances 0.000 description 2
- 238000000465 moulding Methods 0.000 description 2
- 229920002492 poly(sulfone) Polymers 0.000 description 2
- 239000002861 polymer material Substances 0.000 description 2
- 238000005476 soldering Methods 0.000 description 2
- 229910001220 stainless steel Inorganic materials 0.000 description 2
- 239000010935 stainless steel Substances 0.000 description 2
- 238000011144 upstream manufacturing Methods 0.000 description 2
- 239000004593 Epoxy Substances 0.000 description 1
- 229920012266 Poly(ether sulfone) PES Polymers 0.000 description 1
- 239000004952 Polyamide Substances 0.000 description 1
- 239000004642 Polyimide Substances 0.000 description 1
- 229920000491 Polyphenylsulfone Polymers 0.000 description 1
- 239000004020 conductor Substances 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000001514 detection method Methods 0.000 description 1
- 238000010292 electrical insulation Methods 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 238000013021 overheating Methods 0.000 description 1
- 229920002647 polyamide Polymers 0.000 description 1
- 229920000728 polyester Polymers 0.000 description 1
- 229920001721 polyimide Polymers 0.000 description 1
- 239000004814 polyurethane Substances 0.000 description 1
- 229920002635 polyurethane Polymers 0.000 description 1
Images
Classifications
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B3/00—Ohmic-resistance heating
- H05B3/40—Heating elements having the shape of rods or tubes
- H05B3/42—Heating elements having the shape of rods or tubes non-flexible
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47L—DOMESTIC WASHING OR CLEANING; SUCTION CLEANERS IN GENERAL
- A47L15/00—Washing or rinsing machines for crockery or tableware
- A47L15/42—Details
- A47L15/4285—Water-heater arrangements
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06F—LAUNDERING, DRYING, IRONING, PRESSING OR FOLDING TEXTILE ARTICLES
- D06F39/00—Details of washing machines not specific to a single type of machines covered by groups D06F9/00 - D06F27/00
- D06F39/04—Heating arrangements
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H1/00—Water heaters, e.g. boilers, continuous-flow heaters or water-storage heaters
- F24H1/10—Continuous-flow heaters, i.e. heaters in which heat is generated only while the water is flowing, e.g. with direct contact of the water with the heating medium
- F24H1/101—Continuous-flow heaters, i.e. heaters in which heat is generated only while the water is flowing, e.g. with direct contact of the water with the heating medium using electric energy supply
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H9/00—Details
- F24H9/18—Arrangement or mounting of grates or heating means
- F24H9/1809—Arrangement or mounting of grates or heating means for water heaters
- F24H9/1818—Arrangement or mounting of electric heating means
Definitions
- the present disclosure relates to a fluid heater for an appliance.
- the present disclosure relates to an improved construction for a flow-through heater for heating water or other liquids and/or generating steam.
- Appliances such as dishwashers, clothes washers and water heaters, for example, employ a heater for heating water or other liquid that is used in the appliance.
- a flow-through heater An exemplary prior art flow-through heater is shown in FIG. 1 .
- the flow-through heater 10 includes a hollow, metal, cylindrical member 12 having a passageway 14 extending along its longitudinal axis 16 through which water or other liquid to be heated flows.
- An electric heating element 18 is generally spirally-wrapped around the circumference of the cylindrical member 12 for a length along its longitudinal axis 16 .
- the cylindrical member 12 is made from stainless steel and the electric heating element 10 is brazed or crimped to an exterior surface of the cylindrical wall 24 .
- the temperature sensor assemblies 20 and 22 can house a temperature sensor, like a thermostat device or NTC device.
- a temperature sensor like a thermostat device or NTC device.
- one temperature sensor assembly 20 provides an electrical connection to a power source for the heating element 10 and includes a thermostat.
- Another temperature sensor assembly 22 carries an NTC temperature sensor.
- the electrical heating element 18 generates heat that is transferred to the cylindrical member 12 and, ultimately, to the fluid passing through the heater 10 .
- a control system (not shown) regulates the temperature of the heating element 10 and/or fluid passing through the heater 10 based on feedback from the temperature sensor assemblies 20 and 22 .
- a shroud 24 is located over the heating element 18 to cover and protect the heating element 18 and shield the surrounding area from the heating element 18 .
- Conventional flow-through heaters like that shown in FIG. 1 have a heating element that is brazed to the cylindrical member 12 . Brazing the heating element 18 to the cylindrical member 12 ensures proper contact between the heating element 18 and the outer surface of the cylindrical member 12 and consequently optimum heat transfer from the heating element 18 to the cylindrical member 12 and the fluid flowing therethrough. Brazing the heating element 18 , however, is time consuming due to the spirally-wrapped structure of the heating element 18 . Moreover, the heating element 18 may have a slow response in heating the fluid due to indirect heating and/or heat loss to the cylindrical member 12 .
- a flow-through heater of the present disclosure includes a tubular housing and a heating element.
- the tubular housing defines a passageway.
- the heating element is provided in the passageway and attached to the tubular housing.
- the heating element includes a resistive wire housed within an electrically insulating coating.
- the heating element includes a coiled wire portion defining a channel extending in a direction along a longitudinal axis of the tubular housing.
- the coiled wire portion defines a channel extending along the longitudinal axis to enable a fluid to flow therethrough.
- the coiled wire portion contacts the fluid when the fluid flows through the channel.
- a flow-through heater of the present disclosure includes a metal cylindrical wall, a plurality of metal fin elements, and a heating element.
- the metal cylindrical wall includes an inner peripheral surface.
- the inner peripheral surface defines a passageway along a longitudinal axis of the cylindrical wall.
- the plurality of metallic fin elements extend inwardly from the inner peripheral surface and are located in the passageway.
- the heating element is provided on an outer peripheral surface of the metallic cylindrical wall.
- FIG. 1 is a front perspective view of a prior art flow-through heater
- FIG. 2A is a front perspective view of a flow-through heater according to a first embodiment of the present disclosure
- FIG. 2B is a front cross-sectional perspective view of a flow-through heater according to a first embodiment of the present disclosure
- FIG. 3 is an enlarged, partial end view showing a connection between a tubular housing and an insulator of the flow-through heater according to the first embodiment of the present disclosure
- FIG. 4 is an enlarged, partial cross-sectional view showing a connection between a terminal assembly and a tubular housing of a heater according to the first embodiment of the present disclosure
- FIG. 5 is a front perspective view of a flow-through heater according to a second embodiment of the present disclosure.
- FIG. 6A is a front cross-sectional perspective view of a flow-through heater according to a second embodiment of the present disclosure
- FIG. 6B is an end view of a flow-through heater according to a second embodiment of the present disclosure.
- FIG. 7 is an enlarged, partial cross-sectional view showing connection between a tubular housing and an electrical heating element of a flow-through heater according to a second embodiment of the present disclosure
- FIG. 8 is a perspective view of a flow-through heater according to a third embodiment of the present disclosure.
- FIG. 9 is an exploded perspective view of a flow-through heater according to a third embodiment of the present disclosure.
- FIG. 10 is an exploded perspective view of a flow-through heater according to a third embodiment of the present disclosure.
- FIG. 11 a partial cross-sectional perspective view of a flow-through heater according to a fourth embodiment of the present disclosure
- FIG. 12 is a perspective view of a flow-through heater according to a fifth embodiment of the present disclosure.
- FIG. 13 is a cross-sectional perspective view of a flow-through heater according to a fifth embodiment of the present disclosure.
- FIG. 14 an end view of a flow-through heater according to a fifth embodiment of the present disclosure.
- FIG. 15 is a perspective view of a flow-through heater according to a sixth embodiment of the present disclosure.
- FIG. 16 is an exploded perspective view of a flow-through heater according to a sixth embodiment of the present disclosure.
- FIG. 17 is an end view of a tubular housing of a flow-through heater according to a sixth embodiment of the present disclosure.
- FIG. 18 is a side view of a heating assembly of a flow-through heater according to a sixth embodiment of the present disclosure.
- FIG. 19 is a perspective view of a flow-through heater according to a seventh embodiment of the present disclosure.
- a flow-through heater 40 generally includes a tubular housing 42 , an electrical heating element 44 provided inside the tubular housing 42 , and a pair of terminal assemblies 46 mounted on the tubular housing 42 .
- the tubular housing 42 extends along a longitudinal axis 50 and includes a cylindrical wall 52 and a support member 53 provided inside the cylindrical wall 52 .
- the support member 53 includes a pair of fin elements 54 in the present embodiment.
- the cylindrical wall 52 defines a passageway 56 extending along the longitudinal axis 50 to enable a fluid to flow therethrough.
- the fin elements 54 extend radially inwardly from an inner surface of the cylindrical wall 52 .
- the fin elements 54 extend a predetermined length along the longitudinal axis 50 to support and position the heating element 44 in the passageway 56 .
- the fin elements 54 may be integrally formed with the cylindrical wall 52 or attached to the cylindrical wall 52 by any securing means known in the art.
- the fin elements 54 and the cylindrical wall 52 may be formed of the same material, for example, aluminum, in one molding process.
- the fin elements 54 may be made of a material different from that of the cylindrical wall 52 and attached to the cylindrical wall 52 by any conventional securing means, such as welding or riveting.
- the heating element 44 includes a coiled resistance wire and an electrically insulating coating 59 (shown in FIG. 4 ) over the wire surface to electrically insulating the resistance wire.
- the resistance wire may be made from metals such as Fe/Cr/Al or Ni/Cr.
- the electrically insulating coating 59 may include a corrosion-resistant, thermally conductive material.
- the materials for the electrically insulating coating 59 include, but are not limited to, epoxy, polyester, polyurethane, polyamide, polyimide, polyethersulfone (PES), polysulfone (PSU), and polyphenylsulfone.
- the heating element 44 includes a coiled wire portion 57 and a pair of connecting portions 58 .
- the coiled wire portion 57 includes a plurality of turns, each turn adjacent to one another to form a compact structure. Therefore, heat generated per unit length of the heating element 44 is increased as opposed to prior art heaters under similar operating conditions.
- the coiled wire portion 57 defines a channel therein and extends a predetermined distance along the length of the fin elements 54 . The channel is coaxially aligned with the passageway 56 of the cylindrical wall 52 .
- the pair of connecting portions 58 extend from opposing ends of the coiled wire portion 57 and connect the heating element 44 to an external power source (not shown).
- An insulator 60 is provided between the heating element 44 and each of the fin elements 54 to insulate the heating element 44 from the fin elements 54 .
- the insulators 60 provide further electrical insulation for the heating element 44 .
- the insulators 60 may be attached to the fin elements 54 in a snap-fit manner or in a sliding engagement.
- the insulators 60 each include a receiving portion 62 and a pair of clamping legs 64 .
- Each of the receiving portions 62 includes a base portion 61 extending along the longitudinal axis 50 of the tubular housing 42 and a pair of fingers 63 provided at longitudinal ends of the base portion 61 .
- the base portion 61 and the fingers 63 engage and receive the coiled wire portion 57 of the heating element 44 therebetween.
- the clamping legs 64 extend along the longitudinal axis 50 of the tubular member 42 and define a slot 65 for receiving a head 67 of the fin element 54 .
- the clamping legs 64 are secured to the respective one of the fin elements 54 by inserting the head 67 into the slot 65 .
- the heads 67 may be inserted into the slot 65 in a snap-fit manner along a radial direction relative to the cylindrical wall 52 .
- the insulators 60 may be attached by sliding the heads 67 into the slots 65 along the longitudinal axis 50 of the cylindrical wall 52 .
- the clamping legs 64 are shown to extend along the entire length of the base portion 61 , it is understood and appreciated that a plurality of clamping legs 64 may be formed at an interval along the length of the base portion 61 .
- the terminal assemblies 46 are inserted through openings 69 of the cylindrical wall 52 and connect the heating element 44 to an external power source (not shown).
- the terminal assemblies 46 each include a terminal housing 66 and a terminal pin 68 inserted through the terminal housing 66 .
- the terminal housing 66 is made of an electrically insulating material.
- a cavity 70 is defined at an end of the terminal housing 66 that is located inside the cylindrical wall 52 .
- the terminal pin 68 includes a contact end 72 extending into the cavity 70 .
- the connecting portions 58 of the heating element 44 each include a contact end 74 extending through the terminal housing 66 and into the cavity 70 .
- the contact ends 74 of the heating element 44 are not coated by the electrically insulating coating 59 .
- the contact end 72 of the terminal pin 68 contacts the contact end 74 of the heating element 44 in the cavity 70 to establish electrical connection between the heating element 44 and the terminal pins 68 .
- the contact ends 72 of the terminal pins 68 are soldered to the contact ends 74 of the heating element 44 to ensure proper contact and electrical connection.
- a potting material 76 may fill in the cavity 70 after the soldering process to embed and insulate the contact ends 74 of the heating element 44 and the contact ends 72 of the terminal pins 68 therein.
- the heater 40 according to the first embodiment of the present disclosure has a quick response and an improved heat transfer efficiency.
- the heating element 44 is located in the passageway 56 . Fluid, which enters the passageway 56 , flows around the heating element 44 and is in direct contact with the heating element 44 . The fluid flows inside and outside the coiled wire portion 57 . Heat generated by the heating element 44 is directly transferred to the fluid. No additional component is located between the heating element 44 and the fluid to absorb heat energy. Therefore, heat transfer efficiency of the heater 40 is improved.
- the heating element 44 can be more easily attached to the tubular housing 42 by using the fin elements 54 and the insulators 60 without time-consuming welding process. Therefore, manufacturing process becomes easier, resulting in reduced manufacturing costs and increased throughput.
- a heater 80 includes a tubular housing 82 and a heating element 84 .
- the tubular housing 82 includes a cylindrical wall 86 , a support member including a plurality of fin elements 88 , and a pair of hollow portions 90 .
- the cylindrical wall 86 , the fin elements 88 and the pair of hollow portions 90 are integrally formed from a polymer material.
- the cylindrical wall 86 defines a passageway 87 along the longitudinal axis 89 .
- the fin elements 88 extend from an inner surface 85 of the cylindrical wall 86 for supporting and positioning the heating element 84 in the passageway 87 .
- the fin elements 88 each include an elongated body 89 and a pair of lateral fingers 91 extending laterally from the elongated body 89 .
- the heating element 84 is provided between and clamped by the lateral fingers 91 .
- the tubular housing 82 is made from a polymer material. Therefore, the heating element 84 can be directly placed on the fin elements 88 . Because the fin elements 88 are made of an electrically insulating material, the heating element 84 can be attached directly to the elements 88 . The number of components that form the heater 80 may be further reduced, resulting in a more simplified structure.
- the hollow portions 90 extend radially outwardly from an outer surface 92 of the cylindrical wall 86 and are integrally formed with the cylindrical wall 86 .
- the hollow portions 90 are used as terminal housings and each define a cavity 94 .
- the connecting portions 96 of the heating element 84 extend through the cavity 94 and the hollow portions 90 to connect to an external power source.
- a potting material 76 may fill the cavity 94 to secure the connecting portions 96 of the heating element 84 to the hollow portions 90 .
- a heater 100 includes a tubular housing 102 , a heating element 104 , a pair of terminal assemblies 105 , a fuse assembly 106 , a temperature sensor assembly 108 , and a pair of securing members 110 .
- the tubular housing 102 includes a first part 112 and a second part 114 that jointly define a cylindrical shape and a passageway 116 .
- the first part 112 and the second part 114 are made of a plastic material.
- the first part 112 defines two openings 120 for receiving the fuse assembly 106 and the temperature sensor assembly 108 .
- An aluminum material is molded to the first part 112 of the tubular housing 112 in the openings 120 to provide an aluminum contact surface 121 .
- a fuse (not shown) of the fuse assembly 106 and a temperature sensor (not shown) of the temperature sensor assembly 108 are provided at the aluminum contact surface 121 .
- the temperature sensor may be a thermostat or an NTC device.
- the fuse assembly 106 is mounted adjacent to an inlet of the passageway 116 and upstream from the heating element 104 .
- the temperature sensor assembly 108 is mounted adjacent to an outlet of the passageway 116 and downstream from the heating element 104 .
- the fuse assembly 106 and the temperature sensor assembly 108 each include a casing 122 and a pair of terminals 124 attached to the casing 122 .
- the terminals 124 connect the fuse or the temperature sensor to a power source or a control device (not shown).
- the casings 122 of the fuse assembly 106 and the temperature sensor assembly 108 each define a slot 123 .
- the securing members 110 are in the form of a strap positioned in the slots 123 and wrapped around the tubular housing 102 .
- the securing members 110 press the casings 122 of the fuse assembly 106 and the temperature sensor assembly 108 against the aluminum contact surface 121 .
- the fuse and the temperature sensor can contact the aluminum contact surface 121 to ensure proper detection of the temperature of the tubular housing 102 and the fluid flowing therethough.
- the first part 112 further includes a pair of hollow portions 116 integrally formed with the first part 112 and between the fuse assembly 106 and the temperature sensor assembly 108 .
- the hollow portions 116 each define a cavity 122 .
- a terminal pin 125 is molded to each of the hollow portions 116 to form the terminal assembly 105 .
- the terminal pins 125 each have a contact end 119 extending into the cavity 122 of the respective one of the hollow portions 116 .
- the terminal pin 125 connects the heating element 104 to an external power source (not shown).
- a potting material may be provided in cavities 122 of the hollow portions 116 to insulate the contact ends 119 of the terminal pins 125 and the contact ends 117 of the heating element 104 .
- the heating element 104 may be attached to the tubular housing 102 by a pair of fin elements 131 .
- the two-piece structure of the tubular housing 102 facilitates soldering of the contact ends 117 of the heating element 104 to the contact ends 119 of the terminal pins 118 .
- the two-piece structure also facilitates mounting of the heating element 104 , the fuse assembly 106 and the temperature sensor assembly 108 to the tubular housing 102 .
- the first part 12 and the second part 114 of the tubular housing 102 are joined, for example, by high frequency welding.
- a heater 126 includes a tubular housing 125 having a cylindrical wall 127 and a heating element 128 .
- the cylindrical wall 127 is made of stainless steel.
- the heating element 128 includes a coiled wire portion defining an outside diameter substantially equal to the inside diameter of the cylindrical wall 127 .
- the heating element 128 is mounted inside the cylindrical wall 127 in an interference-fit manner and is in direct contact with an inner surface 129 of the cylindrical wall 127 .
- the heating element 128 is coated with an electrically insulating coating to electrically insulate the heating element 128 from the cylindrical wall 127 and the fluid flowing therethrough.
- a pair of terminal assemblies may be provided at the tubular housing 125 to connect the heating element 128 to an external power source.
- the terminal assemblies may have a structure similar to that in the first embodiment shown in FIGS. 2A to 4 .
- a heater 130 includes a tubular housing 132 and a heating element 134 .
- the tubular housing 132 includes a cylindrical wall 136 and a support member comprising a plurality of fin elements 138 extending inwardly from an inner peripheral surface 139 of the cylindrical wall 136 .
- the plurality of fin elements 138 are shown in the drawings and spaced apart equally (e.g., 3 fin elements at 120° apart) along the inner peripheral surface 139 of the cylindrical wall 136 .
- the cylindrical wall 136 and the fin elements 138 may be integrally formed from a plastic material in one molding process.
- the fin elements 138 jointly define a receiving space 141 (indicated by dashed line) for receiving the heating element 134 therein.
- the heating element 134 may be slid into the receiving space and supported by the fin elements 138 .
- the heating element 134 includes a coiled wire portion 140 and a pair of connecting portions 142 .
- the connecting portions 142 may extend through the cylindrical wall 136 of the tubular housing 132 to be connected to an external power source (not shown).
- the heating element 134 is covered with an electrically insulating coating to insulate the heating element 134 .
- the cylindrical wall 136 defines a passageway 137 .
- the passageway is generally divided by the coiled wire portion 140 into a first channel 144 and a plurality of second channels 146 .
- the first channel 144 is surrounded by the coiled wire portion 140 .
- the second channels 146 are defined by adjacent fin elements 138 and the outer surface of the coiled wire portion 140 . Fluid flows in the first channel 144 and the plurality of second channels 146 .
- a heater 150 includes a tubular housing 150 , a heating assembly 152 , a pair of terminal assemblies 154 , a fuse assembly 156 , and a temperature sensor assembly 158 .
- the tubular housing 152 includes a cylindrical wall 160 and two hollow portions 162 extending outwardly from an outer surface 157 of the cylindrical wall 160 .
- the cylindrical wall 160 defines a passageway 161 extending along a longitudinal axis 163 of the cylindrical wall 160 .
- the fuse assembly 156 and the temperature sensor assembly 158 are inserted into the hollow portions 162 and provided downstream from the terminal assemblies 154 .
- a connector housing 159 receives a terminal 161 from each of the fuse assembly 156 and the temperature sensor assembly 158 .
- the terminals 161 are connected to a control device (not shown).
- the terminal assemblies 154 are provided adjacent to an inlet of the passageway 162 and upstream from the fuse assembly 156 and the temperature sensor assembly 158 .
- the heating assembly 152 includes a heating element 164 and a support member comprising a plurality of support rails 166 attached to the heating element 164 .
- the support rails 166 each include an elongated body 168 and a pair of fingers 170 extending laterally from the elongated body 168 .
- the fingers 170 clamp the heating element 164 therebetween.
- the support rails 166 are matingly inserted into slots 172 of the cylindrical wall 160 .
- the slots 172 are formed on the inner surface 175 of the cylindrical wall 160 and extend along the length of the cylindrical wall 160 .
- the heating element 164 includes a coiled wire portion 174 and a pair of connecting portions 176 for connecting to the terminal assemblies 154 .
- the connecting portions 176 may be in the form of nuts.
- the connecting portions 176 are aligned with the terminal assemblies 154 .
- the terminal assemblies 154 are connected to the connecting portions 176 .
- a heater 200 includes a tubular housing 202 and a heating element 204 disposed around and outwardly of the tubular housing 202 .
- the tubular housing 202 includes a cylindrical wall 206 and a support member comprising a plurality of fin elements 208 extending radially inwardly from an inner surface 201 of the cylindrical wall 206 .
- the cylindrical wall 206 defines a fluid passageway 210 .
- the plurality of fin elements 208 are integrally formed with the cylindrical wall 206 and are disposed in the fluid passageway 210 .
- the cylindrical wall 206 and the fin elements 208 are made of aluminum.
- the heating element 204 is coiled around the cylindrical wall 206 and contacts an outer surface of the cylindrical wall 206 .
- the heating element 204 includes a resistive wire and an electrically insulating coating on the resistive wire.
- An outer surface of the cylindrical wall that is in contact with the heating element is coated with an electrically insulating layer 212 .
- a temperature sensor assembly 214 and a fuse assembly 216 are provided at each end of the tubular housing 202 .
- the temperature sensor assemblies 214 monitor the temperature of the cylindrical wall 206 and consequently the fluid flowing therethrough.
- the fuse assembly 216 protects the heating element 204 from overheating.
- Securing devices 220 are provided around the cylindrical wall 206 to secure the temperature sensor assembly 214 and the fuse assembly 216 on the tubular housing 202 .
- the heater 200 of this embodiment improves heat transfer efficiency by providing the plurality of fins elements 208 in the fluid passageway 210 . While heat from the heating element 204 is transferred indirectly to the fluid through the tubular housing 202 , the heater 200 has an advantage of increasing heat transfer efficiency by increasing surface area for heat transfer.
- the flow-through heater of the present disclosure provides a simplified structure to facilitate manufacturing of the flow-through heater, resulting in reduced manufacturing costs. Moreover, the simplified structure of the flow-through heater improves heater transfer efficiency and reduces heat loss and can more quickly heat the fluid to a desired temperature. While the flow-through heater has been described as a heater for heating fluids to a desired temperature, the flow-through heater may be configured as a steam generator without departing from the scope of the present disclosure.
- the flow-through heaters of the present disclosure may be used in, for example, dishwaters, laundry machines, or a SPA water heating systems.
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- General Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
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Abstract
A flow-through heater includes a tubular housing and a heating element. The tubular housing defines a passageway. The heating element is provided in the passageway and attached to the tubular housing. The heating element includes a resistive wire and an electrically insulating coating on the resistive wire. The heating element includes a coiled wire portion coiled along a longitudinal axis of the tubular housing. The coiled wire portion defines a channel extending in a direction along the longitudinal axis to enable a fluid to flow therethrough. The coiled wire portion contacts the fluid when the fluid flows through the channel.
Description
- The present disclosure relates to a fluid heater for an appliance. In particular, the present disclosure relates to an improved construction for a flow-through heater for heating water or other liquids and/or generating steam.
- The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.
- Appliances, such as dishwashers, clothes washers and water heaters, for example, employ a heater for heating water or other liquid that is used in the appliance. One type of heater used is a flow-through heater. An exemplary prior art flow-through heater is shown in
FIG. 1 . The flow-throughheater 10 includes a hollow, metal,cylindrical member 12 having apassageway 14 extending along itslongitudinal axis 16 through which water or other liquid to be heated flows. Anelectric heating element 18 is generally spirally-wrapped around the circumference of thecylindrical member 12 for a length along itslongitudinal axis 16. Typically thecylindrical member 12 is made from stainless steel and theelectric heating element 10 is brazed or crimped to an exterior surface of thecylindrical wall 24. - Mounted at locations on the exterior surface of the
cylindrical member 12 are one or moretemperature sensor assemblies FIG. 1 , onetemperature sensor assembly 20 provides an electrical connection to a power source for theheating element 10 and includes a thermostat. Anothertemperature sensor assembly 22 carries an NTC temperature sensor. - The
electrical heating element 18 generates heat that is transferred to thecylindrical member 12 and, ultimately, to the fluid passing through theheater 10. A control system (not shown) regulates the temperature of theheating element 10 and/or fluid passing through theheater 10 based on feedback from the temperature sensor assemblies 20 and 22. Ashroud 24 is located over theheating element 18 to cover and protect theheating element 18 and shield the surrounding area from theheating element 18. - Conventional flow-through heaters like that shown in
FIG. 1 have a heating element that is brazed to thecylindrical member 12. Brazing theheating element 18 to thecylindrical member 12 ensures proper contact between theheating element 18 and the outer surface of thecylindrical member 12 and consequently optimum heat transfer from theheating element 18 to thecylindrical member 12 and the fluid flowing therethrough. Brazing theheating element 18, however, is time consuming due to the spirally-wrapped structure of theheating element 18. Moreover, theheating element 18 may have a slow response in heating the fluid due to indirect heating and/or heat loss to thecylindrical member 12. - A flow-through heater of the present disclosure includes a tubular housing and a heating element. The tubular housing defines a passageway. The heating element is provided in the passageway and attached to the tubular housing. The heating element includes a resistive wire housed within an electrically insulating coating. The heating element includes a coiled wire portion defining a channel extending in a direction along a longitudinal axis of the tubular housing. The coiled wire portion defines a channel extending along the longitudinal axis to enable a fluid to flow therethrough. The coiled wire portion contacts the fluid when the fluid flows through the channel.
- A flow-through heater of the present disclosure includes a metal cylindrical wall, a plurality of metal fin elements, and a heating element. The metal cylindrical wall includes an inner peripheral surface. The inner peripheral surface defines a passageway along a longitudinal axis of the cylindrical wall. The plurality of metallic fin elements extend inwardly from the inner peripheral surface and are located in the passageway. The heating element is provided on an outer peripheral surface of the metallic cylindrical wall.
- Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
- The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
-
FIG. 1 is a front perspective view of a prior art flow-through heater; -
FIG. 2A is a front perspective view of a flow-through heater according to a first embodiment of the present disclosure; -
FIG. 2B is a front cross-sectional perspective view of a flow-through heater according to a first embodiment of the present disclosure; -
FIG. 3 is an enlarged, partial end view showing a connection between a tubular housing and an insulator of the flow-through heater according to the first embodiment of the present disclosure; -
FIG. 4 is an enlarged, partial cross-sectional view showing a connection between a terminal assembly and a tubular housing of a heater according to the first embodiment of the present disclosure; -
FIG. 5 is a front perspective view of a flow-through heater according to a second embodiment of the present disclosure; -
FIG. 6A is a front cross-sectional perspective view of a flow-through heater according to a second embodiment of the present disclosure; -
FIG. 6B is an end view of a flow-through heater according to a second embodiment of the present disclosure; -
FIG. 7 is an enlarged, partial cross-sectional view showing connection between a tubular housing and an electrical heating element of a flow-through heater according to a second embodiment of the present disclosure; -
FIG. 8 is a perspective view of a flow-through heater according to a third embodiment of the present disclosure; -
FIG. 9 is an exploded perspective view of a flow-through heater according to a third embodiment of the present disclosure; -
FIG. 10 is an exploded perspective view of a flow-through heater according to a third embodiment of the present disclosure; -
FIG. 11 a partial cross-sectional perspective view of a flow-through heater according to a fourth embodiment of the present disclosure; -
FIG. 12 is a perspective view of a flow-through heater according to a fifth embodiment of the present disclosure; -
FIG. 13 is a cross-sectional perspective view of a flow-through heater according to a fifth embodiment of the present disclosure; -
FIG. 14 an end view of a flow-through heater according to a fifth embodiment of the present disclosure; -
FIG. 15 is a perspective view of a flow-through heater according to a sixth embodiment of the present disclosure; -
FIG. 16 is an exploded perspective view of a flow-through heater according to a sixth embodiment of the present disclosure; -
FIG. 17 is an end view of a tubular housing of a flow-through heater according to a sixth embodiment of the present disclosure; -
FIG. 18 is a side view of a heating assembly of a flow-through heater according to a sixth embodiment of the present disclosure; and -
FIG. 19 is a perspective view of a flow-through heater according to a seventh embodiment of the present disclosure. - The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. Where applicable, corresponding reference numbers are used in the several Figures to identify like components.
- Referring to
FIGS. 2A and 2B , a flow-throughheater 40 according a first embodiment of the present disclosure generally includes atubular housing 42, anelectrical heating element 44 provided inside thetubular housing 42, and a pair ofterminal assemblies 46 mounted on thetubular housing 42. Thetubular housing 42 extends along alongitudinal axis 50 and includes acylindrical wall 52 and asupport member 53 provided inside thecylindrical wall 52. Thesupport member 53 includes a pair offin elements 54 in the present embodiment. Thecylindrical wall 52 defines apassageway 56 extending along thelongitudinal axis 50 to enable a fluid to flow therethrough. - The
fin elements 54 extend radially inwardly from an inner surface of thecylindrical wall 52. Thefin elements 54 extend a predetermined length along thelongitudinal axis 50 to support and position theheating element 44 in thepassageway 56. Thefin elements 54 may be integrally formed with thecylindrical wall 52 or attached to thecylindrical wall 52 by any securing means known in the art. Thefin elements 54 and thecylindrical wall 52 may be formed of the same material, for example, aluminum, in one molding process. Alternatively, thefin elements 54 may be made of a material different from that of thecylindrical wall 52 and attached to thecylindrical wall 52 by any conventional securing means, such as welding or riveting. - The
heating element 44 includes a coiled resistance wire and an electrically insulating coating 59 (shown inFIG. 4 ) over the wire surface to electrically insulating the resistance wire. The resistance wire may be made from metals such as Fe/Cr/Al or Ni/Cr. The electrically insulatingcoating 59 may include a corrosion-resistant, thermally conductive material. The materials for the electrically insulatingcoating 59 include, but are not limited to, epoxy, polyester, polyurethane, polyamide, polyimide, polyethersulfone (PES), polysulfone (PSU), and polyphenylsulfone. - The
heating element 44 includes a coiledwire portion 57 and a pair of connectingportions 58. The coiledwire portion 57 includes a plurality of turns, each turn adjacent to one another to form a compact structure. Therefore, heat generated per unit length of theheating element 44 is increased as opposed to prior art heaters under similar operating conditions. The coiledwire portion 57 defines a channel therein and extends a predetermined distance along the length of thefin elements 54. The channel is coaxially aligned with thepassageway 56 of thecylindrical wall 52. The pair of connectingportions 58 extend from opposing ends of the coiledwire portion 57 and connect theheating element 44 to an external power source (not shown). - An
insulator 60 is provided between theheating element 44 and each of thefin elements 54 to insulate theheating element 44 from thefin elements 54. In addition to the electrically insulatingcoating 59 of theheating element 44, theinsulators 60 provide further electrical insulation for theheating element 44. - Referring to
FIG. 3 , theinsulators 60 may be attached to thefin elements 54 in a snap-fit manner or in a sliding engagement. Theinsulators 60 each include a receivingportion 62 and a pair of clampinglegs 64. Each of the receivingportions 62 includes abase portion 61 extending along thelongitudinal axis 50 of thetubular housing 42 and a pair offingers 63 provided at longitudinal ends of thebase portion 61. Thebase portion 61 and thefingers 63 engage and receive the coiledwire portion 57 of theheating element 44 therebetween. The clampinglegs 64 extend along thelongitudinal axis 50 of thetubular member 42 and define aslot 65 for receiving ahead 67 of thefin element 54. The clampinglegs 64 are secured to the respective one of thefin elements 54 by inserting thehead 67 into theslot 65. For example, theheads 67 may be inserted into theslot 65 in a snap-fit manner along a radial direction relative to thecylindrical wall 52. Alternatively, theinsulators 60 may be attached by sliding theheads 67 into theslots 65 along thelongitudinal axis 50 of thecylindrical wall 52. While the clampinglegs 64 are shown to extend along the entire length of thebase portion 61, it is understood and appreciated that a plurality of clampinglegs 64 may be formed at an interval along the length of thebase portion 61. - Referring to
FIG. 4 , theterminal assemblies 46 are inserted throughopenings 69 of thecylindrical wall 52 and connect theheating element 44 to an external power source (not shown). Theterminal assemblies 46 each include aterminal housing 66 and aterminal pin 68 inserted through theterminal housing 66. Theterminal housing 66 is made of an electrically insulating material. Acavity 70 is defined at an end of theterminal housing 66 that is located inside thecylindrical wall 52. Theterminal pin 68 includes acontact end 72 extending into thecavity 70. The connectingportions 58 of theheating element 44 each include acontact end 74 extending through theterminal housing 66 and into thecavity 70. The contact ends 74 of theheating element 44 are not coated by theelectrically insulating coating 59. Thecontact end 72 of theterminal pin 68 contacts thecontact end 74 of theheating element 44 in thecavity 70 to establish electrical connection between theheating element 44 and the terminal pins 68. - The contact ends 72 of the terminal pins 68 are soldered to the contact ends 74 of the
heating element 44 to ensure proper contact and electrical connection. A pottingmaterial 76 may fill in thecavity 70 after the soldering process to embed and insulate the contact ends 74 of theheating element 44 and the contact ends 72 of the terminal pins 68 therein. - The
heater 40 according to the first embodiment of the present disclosure has a quick response and an improved heat transfer efficiency. Theheating element 44 is located in thepassageway 56. Fluid, which enters thepassageway 56, flows around theheating element 44 and is in direct contact with theheating element 44. The fluid flows inside and outside the coiledwire portion 57. Heat generated by theheating element 44 is directly transferred to the fluid. No additional component is located between theheating element 44 and the fluid to absorb heat energy. Therefore, heat transfer efficiency of theheater 40 is improved. Moreover, theheating element 44 can be more easily attached to thetubular housing 42 by using thefin elements 54 and theinsulators 60 without time-consuming welding process. Therefore, manufacturing process becomes easier, resulting in reduced manufacturing costs and increased throughput. - Referring to
FIGS. 5 , 6A and 6B, aheater 80 according to a second embodiment of the present disclosure includes atubular housing 82 and aheating element 84. Thetubular housing 82 includes acylindrical wall 86, a support member including a plurality offin elements 88, and a pair ofhollow portions 90. Thecylindrical wall 86, thefin elements 88 and the pair ofhollow portions 90 are integrally formed from a polymer material. Thecylindrical wall 86 defines a passageway 87 along thelongitudinal axis 89. - The
fin elements 88 extend from aninner surface 85 of thecylindrical wall 86 for supporting and positioning theheating element 84 in the passageway 87. Thefin elements 88 each include anelongated body 89 and a pair oflateral fingers 91 extending laterally from theelongated body 89. Theheating element 84 is provided between and clamped by thelateral fingers 91. Thetubular housing 82 is made from a polymer material. Therefore, theheating element 84 can be directly placed on thefin elements 88. Because thefin elements 88 are made of an electrically insulating material, theheating element 84 can be attached directly to theelements 88. The number of components that form theheater 80 may be further reduced, resulting in a more simplified structure. - Referring to
FIG. 7 , thehollow portions 90 extend radially outwardly from anouter surface 92 of thecylindrical wall 86 and are integrally formed with thecylindrical wall 86. Thehollow portions 90 are used as terminal housings and each define acavity 94. The connectingportions 96 of theheating element 84 extend through thecavity 94 and thehollow portions 90 to connect to an external power source. A pottingmaterial 76 may fill thecavity 94 to secure the connectingportions 96 of theheating element 84 to thehollow portions 90. - Referring to
FIGS. 8 to 10 , aheater 100 according to a third embodiment of the present disclosure includes atubular housing 102, aheating element 104, a pair ofterminal assemblies 105, afuse assembly 106, atemperature sensor assembly 108, and a pair of securingmembers 110. - The
tubular housing 102 includes a first part 112 and a second part 114 that jointly define a cylindrical shape and apassageway 116. The first part 112 and the second part 114 are made of a plastic material. The first part 112 defines twoopenings 120 for receiving thefuse assembly 106 and thetemperature sensor assembly 108. An aluminum material is molded to the first part 112 of the tubular housing 112 in theopenings 120 to provide analuminum contact surface 121. A fuse (not shown) of thefuse assembly 106 and a temperature sensor (not shown) of thetemperature sensor assembly 108 are provided at thealuminum contact surface 121. The temperature sensor may be a thermostat or an NTC device. - The
fuse assembly 106 is mounted adjacent to an inlet of thepassageway 116 and upstream from theheating element 104. Thetemperature sensor assembly 108 is mounted adjacent to an outlet of thepassageway 116 and downstream from theheating element 104. Thefuse assembly 106 and thetemperature sensor assembly 108 each include acasing 122 and a pair ofterminals 124 attached to thecasing 122. Theterminals 124 connect the fuse or the temperature sensor to a power source or a control device (not shown). - The
casings 122 of thefuse assembly 106 and thetemperature sensor assembly 108 each define aslot 123. The securingmembers 110 are in the form of a strap positioned in theslots 123 and wrapped around thetubular housing 102. The securingmembers 110 press thecasings 122 of thefuse assembly 106 and thetemperature sensor assembly 108 against thealuminum contact surface 121. As such, the fuse and the temperature sensor can contact thealuminum contact surface 121 to ensure proper detection of the temperature of thetubular housing 102 and the fluid flowing therethough. - Referring to
FIG. 10 , the first part 112 further includes a pair ofhollow portions 116 integrally formed with the first part 112 and between thefuse assembly 106 and thetemperature sensor assembly 108. Thehollow portions 116 each define acavity 122. Aterminal pin 125 is molded to each of thehollow portions 116 to form theterminal assembly 105. The terminal pins 125 each have acontact end 119 extending into thecavity 122 of the respective one of thehollow portions 116. Theterminal pin 125 connects theheating element 104 to an external power source (not shown). A potting material may be provided incavities 122 of thehollow portions 116 to insulate the contact ends 119 of theterminal pins 125 and the contact ends 117 of theheating element 104. Similar to the second embodiment, theheating element 104 may be attached to thetubular housing 102 by a pair offin elements 131. - The two-piece structure of the
tubular housing 102 facilitates soldering of the contact ends 117 of theheating element 104 to the contact ends 119 of the terminal pins 118. The two-piece structure also facilitates mounting of theheating element 104, thefuse assembly 106 and thetemperature sensor assembly 108 to thetubular housing 102. - After the
heating element 104, thefuse assembly 106, and thetemperature sensor assembly 108 are mounted, thefirst part 12 and the second part 114 of thetubular housing 102 are joined, for example, by high frequency welding. - Referring to
FIG. 11 , aheater 126 according to a fourth embodiment of the present disclosure includes atubular housing 125 having acylindrical wall 127 and aheating element 128. Thecylindrical wall 127 is made of stainless steel. Theheating element 128 includes a coiled wire portion defining an outside diameter substantially equal to the inside diameter of thecylindrical wall 127. Theheating element 128 is mounted inside thecylindrical wall 127 in an interference-fit manner and is in direct contact with aninner surface 129 of thecylindrical wall 127. Theheating element 128 is coated with an electrically insulating coating to electrically insulate theheating element 128 from thecylindrical wall 127 and the fluid flowing therethrough. - While not specifically shown in
FIG. 11 , a pair of terminal assemblies may be provided at thetubular housing 125 to connect theheating element 128 to an external power source. The terminal assemblies may have a structure similar to that in the first embodiment shown inFIGS. 2A to 4 . - Referring to
FIGS. 12 to 14 , aheater 130 according to a fifth embodiment of the present disclosure includes atubular housing 132 and aheating element 134. Thetubular housing 132 includes acylindrical wall 136 and a support member comprising a plurality offin elements 138 extending inwardly from an innerperipheral surface 139 of thecylindrical wall 136. The plurality offin elements 138 are shown in the drawings and spaced apart equally (e.g., 3 fin elements at 120° apart) along the innerperipheral surface 139 of thecylindrical wall 136. Thecylindrical wall 136 and thefin elements 138 may be integrally formed from a plastic material in one molding process. - The
fin elements 138 jointly define a receiving space 141 (indicated by dashed line) for receiving theheating element 134 therein. Theheating element 134 may be slid into the receiving space and supported by thefin elements 138. Theheating element 134 includes a coiledwire portion 140 and a pair of connectingportions 142. The connectingportions 142 may extend through thecylindrical wall 136 of thetubular housing 132 to be connected to an external power source (not shown). Similarly, theheating element 134 is covered with an electrically insulating coating to insulate theheating element 134. - The
cylindrical wall 136 defines apassageway 137. The passageway is generally divided by the coiledwire portion 140 into afirst channel 144 and a plurality ofsecond channels 146. Thefirst channel 144 is surrounded by the coiledwire portion 140. Thesecond channels 146 are defined byadjacent fin elements 138 and the outer surface of the coiledwire portion 140. Fluid flows in thefirst channel 144 and the plurality ofsecond channels 146. - Referring to
FIGS. 15 to 18 , aheater 150 according to a sixth embodiment of the present disclosure includes atubular housing 150, aheating assembly 152, a pair ofterminal assemblies 154, afuse assembly 156, and atemperature sensor assembly 158. Thetubular housing 152 includes acylindrical wall 160 and twohollow portions 162 extending outwardly from anouter surface 157 of thecylindrical wall 160. Thecylindrical wall 160 defines apassageway 161 extending along alongitudinal axis 163 of thecylindrical wall 160. - The
fuse assembly 156 and thetemperature sensor assembly 158 are inserted into thehollow portions 162 and provided downstream from theterminal assemblies 154. Aconnector housing 159 receives a terminal 161 from each of thefuse assembly 156 and thetemperature sensor assembly 158. Theterminals 161 are connected to a control device (not shown). - The
terminal assemblies 154 are provided adjacent to an inlet of thepassageway 162 and upstream from thefuse assembly 156 and thetemperature sensor assembly 158. - The
heating assembly 152 includes aheating element 164 and a support member comprising a plurality of support rails 166 attached to theheating element 164. The support rails 166 each include anelongated body 168 and a pair offingers 170 extending laterally from theelongated body 168. Thefingers 170 clamp theheating element 164 therebetween. The support rails 166 are matingly inserted intoslots 172 of thecylindrical wall 160. Theslots 172 are formed on theinner surface 175 of thecylindrical wall 160 and extend along the length of thecylindrical wall 160. - The
heating element 164 includes a coiledwire portion 174 and a pair of connectingportions 176 for connecting to theterminal assemblies 154. The connectingportions 176 may be in the form of nuts. When theheating assembly 154 is positioned inside thetubular housing 152, the connectingportions 176 are aligned with theterminal assemblies 154. By threading ascrew 178 into ahole 179 of thecylindrical wall 160 and engaging thescrew 178 to the nut-like connection portions 176, theterminal assemblies 154 are connected to the connectingportions 176. - Referring to
FIG. 19 , aheater 200 according to a seventh embodiment of the present disclosure includes atubular housing 202 and aheating element 204 disposed around and outwardly of thetubular housing 202. Thetubular housing 202 includes acylindrical wall 206 and a support member comprising a plurality offin elements 208 extending radially inwardly from aninner surface 201 of thecylindrical wall 206. Thecylindrical wall 206 defines afluid passageway 210. The plurality offin elements 208 are integrally formed with thecylindrical wall 206 and are disposed in thefluid passageway 210. Thecylindrical wall 206 and thefin elements 208 are made of aluminum. - The
heating element 204 is coiled around thecylindrical wall 206 and contacts an outer surface of thecylindrical wall 206. Theheating element 204 includes a resistive wire and an electrically insulating coating on the resistive wire. An outer surface of the cylindrical wall that is in contact with the heating element is coated with an electrically insulatinglayer 212. - A
temperature sensor assembly 214 and afuse assembly 216 are provided at each end of thetubular housing 202. Thetemperature sensor assemblies 214 monitor the temperature of thecylindrical wall 206 and consequently the fluid flowing therethrough. Thefuse assembly 216 protects theheating element 204 from overheating. - Securing
devices 220 are provided around thecylindrical wall 206 to secure thetemperature sensor assembly 214 and thefuse assembly 216 on thetubular housing 202. - The
heater 200 of this embodiment improves heat transfer efficiency by providing the plurality offins elements 208 in thefluid passageway 210. While heat from theheating element 204 is transferred indirectly to the fluid through thetubular housing 202, theheater 200 has an advantage of increasing heat transfer efficiency by increasing surface area for heat transfer. - The flow-through heater of the present disclosure provides a simplified structure to facilitate manufacturing of the flow-through heater, resulting in reduced manufacturing costs. Moreover, the simplified structure of the flow-through heater improves heater transfer efficiency and reduces heat loss and can more quickly heat the fluid to a desired temperature. While the flow-through heater has been described as a heater for heating fluids to a desired temperature, the flow-through heater may be configured as a steam generator without departing from the scope of the present disclosure. The flow-through heaters of the present disclosure may be used in, for example, dishwaters, laundry machines, or a SPA water heating systems.
- This description is merely exemplary in nature and, thus, variations that do not depart from the gist of the disclosure are intended to be included within the scope of the disclosure. Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the description and specific examples, while indicating the preferred embodiments of the invention, are intended for purposes of illustration only and are not intended to limit the scope of this disclosure.
Claims (32)
1. A flow-through heater comprising:
a tubular housing defining a passageway; and
a heating element provided in the passageway and attached to the tubular housing, the heating element including a resistive wire housed within an electrically insulating coating on the resistive wire,
wherein the heating element further includes a coiled portion defining a channel extending in a direction along the longitudinal axis to enable a fluid to flow therethrough and contacting the fluid when the fluid flows through the channel.
2. The flow-through heater of claim 1 wherein the passageway and the channel are coaxially aligned.
3. The flow-through heater of claim 1 wherein the tubular housing comprises a cylindrical wall and a support member extending inwardly from the cylindrical wall and wherein the heating element is attached to the support element.
4. The flow-through heater of claim 3 wherein the support member includes a plurality of fin elements extending radially inwardly from an inner surface of the cylindrical wall and extending a predetermined length along the longitudinal axis of the tubular housing.
5. The flow-through heater of claim 3 , further comprising a pair of terminal assemblies provided at the cylindrical wall.
6. The flow-through heater of claim 5 , wherein the terminal assemblies each include an insulating terminal housing inserted into an opening of the cylindrical wall.
7. The flow-through heater of claim 6 , wherein the cylindrical member is made of aluminum.
8. The flow-through heater of claim 5 , wherein the terminal assemblies each include a terminal housing integrally formed with the cylindrical wall.
9. The flow-through heater of claim 8 , wherein the terminal housing and the cylindrical wall are made of a plastic material.
10. The flow-through heater of claim 1 , wherein the fluid flows inside and outside the coiled portion of the heating element.
11. The flow-through heater of claim 1 , further comprising a support member for removably mounting the heating element to the tubular housing.
12. The flow-through heater of claim 11 , wherein the support member includes an elongated rail that is slidingly inserted in a slot of the cylindrical wall, the slot being formed on an inner peripheral surface of the cylindrical wall.
13. The flow-through heater of claim 12 , wherein the slot extends in a direction along the longitudinal axis of the tubular housing.
14. The flow-through heater of claim 12 , wherein the elongated rail comprises an elongated body and a pair of fingers extending laterally from the elongated body, the fingers securing the heating element therebetween.
15. The flow-through heater of claim 1 , wherein the tubular housing includes a cylindrical wall and a pair of hollow portions extending outwardly from the cylindrical wall for receiving at least one of a temperature sensor assembly and a fuse assembly.
16. The flow-through heater of claim 15 , wherein the hollow portions are integrally formed with the cylindrical wall.
17. The flow-through heater of claim 15 , wherein the cylindrical wall defines a pair of holes to enable a pair of terminal assemblies to pass through, the terminal assemblies including fasteners passing through the holes and the heating elements including connecting portions engaging a corresponding fastener.
18. The flow-through heater of claim 1 , wherein the cylindrical wall is a single-piece component.
19. The flow-through heater of claim 1 , wherein the cylindrical wall is a two-piece component.
20. The flow-through heater of claim 1 , further comprising an insulator provided between the cylindrical wall and the heating element to electrically insulate the heating element from the cylindrical wall.
21. The flow-through heater of claim 20 , wherein the insulator comprises a base portion extending in a direction along the longitudinal axis of the tubular housing and a pair of clamping legs extending from the base portion in a first direction toward the support member, the base portion engaging the heating element, the pair of clamping legs defining a slot for receiving the support member.
22. The flow-through heater of claim 21 , wherein the clamping legs extend an entire length of the base portion.
23. The flow-through heater of claim 21 , wherein each of the insulators further includes a pair of fingers extending from the base portion in a second direction and wherein the second direction is opposite to the first direction.
24. The flow-through heater of claim 1 , wherein the heating element contacts a peripheral inner surface of the tubular housing and is mounted to the tubular housing in an interference-fit manner.
25. The flow-through heater of claim 1 , wherein the tubular housing further comprises a cylindrical wall and a pair of hollow portions extending outwardly from an outer peripheral surface of the cylindrical wall, wherein the hollow portions are integrally formed with the cylindrical wall.
26. The flow-through heater of claim 25 , wherein the heating element further comprises a pair of connecting portions extending from the coiled portion, wherein the connecting portions extend through the hollow portions.
27. The flow-through heater of claim 26 , further comprising a potting material that fills cavities of the hollow portions and that electrically insulates a part of the connecting portions.
28. The flow-through heater of claim 27 , further comprising a pair of terminal pins extending through the hollow portions, wherein the heating element is connected to a power source through the terminal pins.
29. A flow-through heater comprising:
a cylindrical wall extending along a longitudinal axis and defining a passageway to allow a fluid to flow therethrough;
a fin element extending inwardly from an inner surface of the cylindrical wall and in the passageway;
a heating element provided in the passageway and attached to the fin element, the heating element including a resistive wire housed within an electrically insulating coating, the heating element including a coiled wire portion that defines a channel coaxially aligned with the passageway, the fluid flowing inside and outside the coiled wire portion;
a pair of terminal assemblies that connect the heating element to a power source, the terminal assemblies each including a terminal housing at the cylindrical wall and a terminal pin inserted through the terminal housing, the terminal pin connecting the heating element to the power source; and
a potting material provided in the terminal assemblies to embed a portion of the terminal pin therein.
30. A flow-through heater comprising:
an outer wall including an inner peripheral surface, the inner peripheral surface defining a passageway along a longitudinal axis of the outer wall;
a plurality of fin elements located in the passageway and extending inwardly from the inner peripheral surface; and
a heating element provided on an outer peripheral surface of the outer wall.
31. The flow-through heater of claim 30 , wherein the heating element includes a resistive wire coiled around the outer wall and an electrically insulating coating on the resistive wire.
32. The flow-through heater of claim 30 , wherein the outer wall is cylindrical in shape and made from a metal material and includes an outer peripheral surface and an insulating coating on the outer peripheral surface, the heating element being wrapped around the outer peripheral surface.
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
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US12/627,560 US20110129205A1 (en) | 2009-11-30 | 2009-11-30 | Flow-through heater |
PCT/US2010/047508 WO2011066019A2 (en) | 2009-11-30 | 2010-09-01 | Flow-through heater |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
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US12/627,560 US20110129205A1 (en) | 2009-11-30 | 2009-11-30 | Flow-through heater |
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US20110129205A1 true US20110129205A1 (en) | 2011-06-02 |
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US12/627,560 Abandoned US20110129205A1 (en) | 2009-11-30 | 2009-11-30 | Flow-through heater |
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US11913736B2 (en) * | 2017-08-28 | 2024-02-27 | Watlow Electric Manufacturing Company | Continuous helical baffle heat exchanger |
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US11933520B2 (en) * | 2015-09-09 | 2024-03-19 | Marelli Cabin Comfort Japan Corporation | Fluid-heating device and manufacturing method thereof |
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US20140112650A1 (en) * | 2012-10-19 | 2014-04-24 | Edwards Vacuum, Inc. | Cartridge heater apparatus |
US11933520B2 (en) * | 2015-09-09 | 2024-03-19 | Marelli Cabin Comfort Japan Corporation | Fluid-heating device and manufacturing method thereof |
WO2019046246A1 (en) * | 2017-08-28 | 2019-03-07 | Watlow Electric Manufacturing Company | Continuous helical baffle heat exchanger |
CN111247387A (en) * | 2017-08-28 | 2020-06-05 | 沃特洛电气制造公司 | Continuous spiral baffle heat exchanger |
US10941988B2 (en) | 2017-08-28 | 2021-03-09 | Watlow Electric Manufacturing Company | Continuous helical baffle heat exchanger |
US11913736B2 (en) * | 2017-08-28 | 2024-02-27 | Watlow Electric Manufacturing Company | Continuous helical baffle heat exchanger |
US11920878B2 (en) * | 2017-08-28 | 2024-03-05 | Watlow Electric Manufacturing Company | Continuous helical baffle heat exchanger |
TWI686581B (en) * | 2018-08-30 | 2020-03-01 | 美商瓦特洛威電子製造公司 | Continuous helical baffle heat exchanger |
CN114603322A (en) * | 2022-03-23 | 2022-06-10 | 广州熙安环控高科有限公司 | Method for manufacturing sheet type electric heater |
Also Published As
Publication number | Publication date |
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WO2011066019A3 (en) | 2011-07-21 |
WO2011066019A2 (en) | 2011-06-03 |
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Legal Events
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Owner name: EMERSON ELECTRIC CO., MISSOURI Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:SLAYTON, ALVIN L.;FOWLER, LUCAS L.;REEL/FRAME:023582/0559 Effective date: 20091110 |
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AS | Assignment |
Owner name: BACKER EHP INC., TENNESSEE Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:EMERSON ELECTRIC CO.;REEL/FRAME:027407/0507 Effective date: 20110912 |
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STCB | Information on status: application discontinuation |
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