Instantaneous fluid heating device and process

• US 5,784,531 A
• Filed: 01/05/1996
• Issued: 07/21/1998
• Est. Priority Date: 01/05/1996
• Status: Expired due to Fees

• Current Assignee: Herman H. Hall Jr, Robert W. Mann
• Original Assignee: Herman H. Hall Jr, Robert W. Mann
• Inventors: Mann, Robert W., Hall, Herman H. Jr.
• Primary Examiner(s): HOANG, TU BA
• Application Number:
  US08/583,872
• Time in Patent Office: 928 Days
• Field of Search: 392/465, 392/485, 392/488, 392/490, 392/316, 392/491-494, 392/471, 219/497, 219/512, 219/509, 219/490, 200/81.9 R, 340/606
• US Class Current: 392/494
• CPC Class Codes: F24H 1/102 with resistance
• CPC Class Codes: F24H 15/174 Supplying heated water with desired temperature or desired range of temperature
• CPC Class Codes: F24H 15/212 Temperature of the water
• CPC Class Codes: F24H 15/37 of electric heaters
• CPC Class Codes: F24H 15/407 using electrical switching, e.g. TRIAC
• CPC Class Codes: F24H 9/2028 Continuous-flow heaters

Abstract

Instantaneous fluid heating device and process including an instantaneous fluid heating device which features forced fluid recirculation past/through heating elements/vessel featuring immersible electrical heating elements in a plurality of heating vessels arranged in series with all of said electrical heating elements/vessels being of equal electrical power/volume so as to be equal in overall heating capacity and receiving electricity simultaneously by on/off switching of electrical power via one or more solid state relays responsive to the minutest changes of temperature below/above the set point.

Claims

1. An electrical power distribution device for use in a fluid heating device, which said fluid heating device utilizes at least one electrical heating element receiving electricity from an external source of electrical power to heat fluid flowing film an external source of fluid while said fluid is passing through the fluid heating device so that said fluid is proximate a certain set-point temperature upon exiting from said fluid heating device, comprising:

at least one electrical heating element;

a heat exchange vessel formed of heat conducting materials, said heat exchange vessel (i) serves to relay a fluid being heated by said at least one electrical heating element, (ii) does not contain said at least one electrical heating element, and (iii) has at least one flat exterior surface wherein said at least one flat exterior surface forms an outer wall of said heat exchange vessel; and

at least one engageable electrical relay which is disposed upon said at least one flat exterior surface of said heat exchange vessel in such manner as to be in thermal communication with the fluid being heated flowing through said heat exchange vessel such that said at least one engageable electrical relay (i) is actively cooled by said fluid flow, and (ii) relays electrical power to said at least one electrical heating element only while engaged.

2. An electrical power distribution means for use in a fluid heating device, as described in claim 1, further comprising:

an engageable temperature control means responsive to the temperature of the fluid being heated, which engageable temperature control means must be engaged in order for said at least one engageable electrical relay to be engaged, and which engageable temperature control means regulates the fluid temperature of a fluid being heated is below the set-point temperature; and

an engageable master electrical control means responsive to the temperature of the fluid being heated, which engageable master electrical control means must be engaged in order for said engageable temperature control means to be engaged, and which engageable master electrical control means only engages said engageable temperature control means while the temperature of the fluid being heated is below the safety-point temperature.

3. An electrical power distribution means for use in a fluid heating device, as described in claim 2, wherein said engageable master electrical control means includes at least one bimetallic thermal safety switch in thermal communication with the fluid being heated for engaging said temperature control means only while the temperature of the fluid being heated is below the safety-point temperature.

4. An electrical power distribution means for use in a fluid heating device, as described in claim 2, further comprising a second engageable electrical relay, which second engageable electrical relay must be engaged in order for electrical power to flow to said at least one electrical heating element, and which second engageable electrical relay is engaged by the engageable temperature control means.

5. An electrical power distribution means for use in a fluid heating device, as described in claim 2, further comprising a second engageable electrical relay, which second engageable electrical relay must be engaged in order for electrical power to flow to said at least one electrical heating element, and which second engageable electrical relay is engaged by the engageable master electrical control means.

6. An electrical power distribution means for use in a fluid heating device as described in claim 1, wherein said at least one engageable electrical relay is a solid state electrical device.

7. An electrical power distribution means for use in a fluid heating device as described in claim 1, wherein said heat exchange vessel includes false activation suppression means based upon the inclusion of an air space within said heat exchange vessel.

8. An electrical power distribution means for use in a fluid heating device as described in claim 1, wherein the interior of said heat exchange vessel is provided with multiple interior heat exchange surfaces formed from heat conducting materials, which multiple interior heat exchange surfaces are in thermal communication with the heat conducting materials forming the heat exchange vessel in such manner that heat exchange takes place between the said heat exchange vessel and the said multiple interior heat exchange surfaces.

9. A temperature control device for use in a fluid heating device, said fluid heating device utilizes at least one electrical heating element receiving electricity from an external source of electrical power to heat fluid flowing from an external source of fluid while said fluid is passing through the fluid heating device so that said fluid is proximate a certain set-point temperature upon exiting from said fluid heating device, comprising:

at least one electrical heating element;

at least one electrical relay which serves to relay electrical power to said at least one electrical heating element and serves to relay electrical power equally and simultaneously to all electrical heating elements;

a temperature sensor which detects changes in the temperature of a fluid being heated and;

positioned so as to be in thermal communication with the fluid being heated; and

engageable relay control means which is instantaneously responsive to changes in the temperature of the fluid being heated and detected by said temperature sensor, said engageable relay control means engages all of said electrical relays simultaneously.

10. A temperature control means, as described in claim 9, wherein said temperature sensor is responsive to a low voltage input source, and said engageable relay control means includes a voltage linearization section responsive to a said temperature sensor, a differential amplification section responsive to said voltage linearization section, and a comparator section responsive to said differential amplification section, said comparator section including a potentiometer utilized for setting an output set point temperature/voltage equivalent.

11. A temperature control means, as described in claims 9 or 10, wherein said temperature sensor is an immersible micro-miniature thermistor assembly.

12. A temperature control means, as described in claims 9 or 10, wherein said engageable relay control means engages all electrical relays while the temperature of the fluid being heated is below the set-point temperature as detected by said temperature sensor.

13. An engageable master electrical control device for providing control voltages to low voltage electrically powered components of a fluid heating device, said fluid heating device heats fluid flowing from an external source of fluid while said fluid is passing through the fluid heating device so that said fluid is proximate a certain set-point temperature upon exiting from said fluid heating device, but not above a certain safety-point temperature, comprising:

at least one electrical heating element which is supplied with electrical power by an electrical circuit receiving electricity from an external source of electrical power;

an engageable temperature control means;

at least one electrical supply relay having a primary and a secondary;

an engageable regulated electrical power supply means which serves, while engaged, to (i) supply a first parallel control voltage to the primary of said at least one electrical supply relay, the secondary of said at least one electrical supply relay being part of the electrical circuit supplying electrical power to said at least one electrical heating element, and (ii) to supply a second parallel control voltage to said engageable temperature control means; and

an engageable safety means wherein said engageable safety means is not part of the said electrical circuit that supplies electrical power to said at least one electrical heating element and wherein said engageable safety means is engaged in order for said engageable regulated electrical power supply means to be engaged.

14. An engageable master electrical control means as described in claim 13, further comprising an engageable electrical start relay which must be engaged in order to relay electrical power to engage said engageable regulated electrical power supply means.

15. An engageable master electric control means, as described in claim 13, wherein said engageable safety means includes at least one bimetallic thermal safety switch in thermal communication with the fluid being heated.

16. An engageable master electric control means, as described in claim 13, further including overall engagement means, which means must be engaged in order for the said engageable master electrical control means to be engaged.

17. An engageable master electrical control means, as described in claim 16, wherein said overall engagement means includes a flow switch which only engages said master electrical control means in response to a fluid flow.

18. An engageable master electrical control means for use in an instantaneous fluid heating device, as described in claim 13, wherein said engageable master electrical control means includes false activation suppression means.

19. An engageable master electrical control means for use in an instantaneous fluid heating device, as described in claim 18, wherein said false activation suppression means includes the use of a time delayed electrical relay as said engageable electric start relay.

20. An engageable master electrical control means as described in claim 13, wherein said engageable safety means is responsive to the temperature of a fluid being heated, which engageable safety means must be engaged in order to relay electrical power to engage said electrical start relay, and which engageable safety means only engages said engageable electrical start relay while the temperature of the fluid being heated is below the safety point temperature.

21. An instantaneous fluid heating device that receives electricity from an external source of electrical power in order to heat fluid flowing from an external source of fluid while said fluid is passing through said instantaneous fluid heating device so that said fluid is proximate a certain set-point temperature upon exiting from said instantaneous fluid heating device, comprising:

(a) a fluid heating structure, said structure (i) having an inlet through which the fluid being heated enters the fluid heating structure, (ii) having an outlet through which the fluid being heated exits the fluid heating structure, and (iii) being further comprised of a plurality of vessels having hollow interiors, said plurality of vessels being arranged in series with each of said vessels having at least one electrical heating element such that the fluid being heated entering the inlet of the fluid heating structure flows through each of said plurality of vessels past at least one electrical heating element contained in each of said plurality of vessels before exiting through the outlet of said fluid heating structure;

(b) an exit port for emitting the fluid after it has been heated by the fluid heating structure;

(c) engageable electrical power distribution means comprising at least one engageable electrical relay which relays equal amounts of electrical power simultaneously to each electrical heating element while engaged; and

(d) an engageable temperature control means which (i) is responsive to the temperature of fluid exiting the fluid heating structure, and (iii only engages said at least one engageable electrical relay while said engageable temperature control means is engaged.

22. An instantaneous fluid heating device as set forth in claim 21, wherein said engageable temperature control means only engages said at least one engageable electrical relay while the temperature of the fluid being heated, when emitted from the exit port, is below the set point temperature.

24. An instantaneous fluid heating device as set forth in claim 21, 22 or 23, further comprising an electrical power distribution means having a heat exchange vessel with a hollow interior, said heat exchange vessel being formed of heat conducting materials, which said heat exchange vessel (i) serves to relay a fluid being heated to the inlet of said fluid heating structure, (ii) does not contain any electrical heating element, (iii) has at least one flat exterior surface which said at least one flat exterior surface forms an outer wall of the said heat exchange vessel, and (iv) has said at least one engageable electrical relay disposed upon said at least one flat exterior wall of said heat exchange vessel in such manner as to be in thermal communication with the fluid being heated flowing through said heat exchange vessel such that said at least one engageable electrical relay is actively cooled by said fluid flow.

25. An instantaneous fluid heating device as described in claim 24, further comprising an engageable temperature control means having:

a temperature sensor which detects changes in the temperature of a fluid being heated and is positioned so as to be in thermal communication with the fluid being heated; and

engageable relay control means which is instantaneously responsive to changes in the temperature of the fluid being heated detected by said temperature sensor, which engageable relay control means engages each of said at least one electrical relay simultaneously, and which engageable relay control means only engages each of said at least one electrical relays while engaged and while the temperature of the fluid being heated is below the set-point temperature as detected by said temperature sensor.

26. An instantaneous fluid heating device, as set forth in claim 24, further comprising engageable master electrical control means having:

an engageable regulated electrical power supply means which serves, while engaged, to (i) supply a first parallel control voltage to the primary of said at least one engageable electrical relay, the secondary of said at least one engageable electrical relay being part of the electrical circuit supplying electrical power to the at least one electrical heating element contained in each of said plurality of vessels, and (ii) to supply a second parallel control voltage to said engageable temperature control means; and

an engageable safety means, which engageable safety means is not part of the electrical circuit that includes the at least one electrical heating element in each of said plurality of vessels and which engageable safety means must be engaged in order for said engageable regulated electrical supply means to be engaged.

27. An instantaneous fluid heating device as set forth in claim 25, further comprising an engageable master electrical control means having:

an engageable regulated electrical power supply means which serves, while engaged, to (i) supply control voltages to the primary of said at least one engageable electrical relay, the secondary of said at least one engageable electrical relay being part of the electrical circuit supplying electrical power to the at least one electrical heating element contained in each of said plurality of vessels, and (ii) to supply control voltages to said engageable temperature control means; and

an engageable safety means, which engageable safety means is not part of the electrical circuit that includes the at least one electrical heating element contained in each of said plurality of vessels and which engageable safety means must be engaged in order for said engageable regulated electrical supply means to be engaged.

28. An instantaneous fluid heating device as described in claim 25, further including a flow switch which only engages said engageable master electrical control means when fluid is being emitted from said exit port.

29. An instantaneous fluid heating device as described in claim 26, further including a flow switch which only engages said engageable master electrical control means when fluid is being emitted from said exit port.

30. An instantaneous fluid heating device, as set forth in claim 21, wherein each of said vessels is equal in heating capacity.

23. An instantaneous fluid heating device as set forth in claim 54, further comprising an engageable fluid recirculation means, said engageable fluid recirculation means recirculating a majority of the fluid being heated exiting the fluid heating structure back to the inlet of the fluid heating structure before said fluid being heated can exit via the exit port while said engageable fluid heating means is engaged.

31. An instantaneous fluid heating device that receives electricity from an external source of electrical power in order to heat fluid flowing from an external source of fluid while said fluid is passing through said instantaneous fluid heating device so that said fluid is proximate a certain set-point temperature upon exiting from said instantaneous fluid heating device, comprising:

(a) a fluid heating stricture, said structure (i) having an inlet through which the fluid being heated enters the fluid heating structure, (ii) having an outlet through which the fluid being heated exit the fluid heating structure, and (iii) being further comprised of a plurality of vessels having hollow interiors, said plurality of vessels being arranged in series with each of said vessels having at least one electrical heating element such that the fluid being heated entering the inlet of the fluid heating structure flows through each of said plurality of vessels past at least one electrical heating element contained in each of said plurality of vessels before exiting through the outlet of said fluid heating structure;

(b) an exit port for emitting the fluid after it has been heated by the fluid heating structure;

(c) an engageable fluid recirculation means which when engaged recirculates a majority of the fluid being heated exiting the fluid heating structure back to the inlet of the fluid heating structure before said fluid being heated can exit via the exit port;

(d) engageable electrical power distribution means, said means comprising at least one engageable electrical relay, said at least one engageable electrical relay relays electrical power to each, of said electrical heating elements while engaged; and

(e) an engageable electronic temperature control means which (i) is responsive to the temperature of fluid exiting the fluid heating structure, and (ii) only engages said at least one engageable electrical relay while said engageable electronic temperature control means is engaged.

32. An instantaneous fluid heating device as described in claim 31, wherein said engageable electronic temperature control means only engages said at least one engageable electrical relay while the temperature of the fluid being heated when emitted from the exit port is below the set point temperature.

33. An instantaneous fluid heating device as described in claims 31 or 32, wherein said electrical power distribution means includes a heat exchange vessel formed of heat conducting materials, which said heat exchange vessel (i) serves to relay a fluid being heated to the inlet of the fluid heating structure, (ii) does not contain any electrical heating element, (iii) has at least one flat exterior surface which said at least one flat exterior surface forms an outer wall of the said heat exchange vessel, and (iv) has said at least one engageable electrical relay disposed upon said at least one flat exterior wall of said heat exchange vessel in such manner as to be in thermal communication with the fluid being heated flowing through said heat exchange vessel such that said at least one engageable electrical relay is actively cooled by said fluid flow.

34. An instantaneous fluid heating device as described in claim 31 or 32, wherein said engageable temperature control means includes:

a temperature sensor which detects changes in the temperature of a fluid being heated and is positioned so as to be in thermal communication with the fluid being heated; and

engageable relay control means which is instantaneously responsive to changes in the temperature of the fluid being heated detected by said temperature sensor, which engageable relay control means engages all of said electrical relays simultaneously, and which engageable relay control means only engages all electrical relays while engaged and while the temperature of the fluid being heated is below the set-point temperature as detected by said temperature sensor.

35. An instantaneous fluid heating device as described in claim 33, wherein said engageable temperature control means includes:

a temperature sensor which detects changes in the temperature of a fluid being heated and is positioned so as to be in thermal communication with the fluid being heated; and

engageable relay control means which is instantaneously responsive to changes in the temperature of the fluid being heated detected by said temperature sensor, which engageable relay control means engages all of said electrical relays simultaneously, and which engageable relay control means only engages all electrical relays while engaged and while the temperature of the fluid being heated is below the set-point temperature as detected by said temperature sensor.

36. An instantaneous fluid heating device as described in claim 31 or 32, further comprising an engageable master electrical control means having:

an engageable regulated electrical power supply means which serves, while engaged, to (i) supply control voltages to the primary of said at least one engageable electrical relay, the secondary of said at least one engageable electrical relay being part of the electrical circuit supplying electrical power to said at least one electrical heating element, and (ii) to supply control voltages to said engageable temperature control means; and

an engageable safety means, which engageable safety means is not part of the electrical circuit that includes said at least one electrical heating element and which engageable safety means must be engaged in order for said engageable regulated electrical supply means to be engaged.

37. An instantaneous fluid heating device, as described in claim 33, further comprising an engageable master electrical control means having:

an engageable regulated electrical power supply means which serves, while engaged, to (i) supply control voltages to the primary of said at least one engageable electrical relay, the secondary of said at least one engageable electrical relay being part of the electrical circuit supplying electrical power to said at least one electrical heating element, and (ii) to supply control voltages to said engageable temperature control means; and

an engageable safety means, which engageable safety means is not part of the electrical circuit that includes said at least one electrical heating element and which engageable safety means must be engaged in order for said engageable regulated electrical supply means to be engaged.

38. An instantaneous fluid heating device, as described in claim 34, further comprising an engageable master electrical control means having:

an engageable regulated electrical power supply means which serves, while engaged, to (i) supply control voltages to the primary of said at least one engageable electrical relay, the secondary of said at least one engageable electrical relay being part of the electrical circuit supplying electrical power to said at least one electrical heating element, and (ii) to supply control voltages to said engageable temperature control means; and

an engageable safety means, which engageable safety means is not part of the electrical circuit that includes said at least one electrical heating element and which engageable safety means must be engaged in order for said engageable regulated electrical supply means to be engaged.

39. An instantaneous fluid heating device, as described in claim 35, further comprising an engageable master electrical control means having:

an engageable regulated electrical power supply means which serves, while engaged, to (i) supply control voltages to the primary of said at least one engageable electrical relay, the secondary of said at least one engageable electrical relay being part of the electrical circuit supplying electrical power to said at least one electrical heating element, and (ii) to supply control voltages to said engageable temperature control means; and

an engageable safety means, which engageable safety means is not part of the electrical circuit that includes said at least one electrical heating element and which engageable safety means must be engaged in order for said engageable regulated electrical supply means to be engaged.

40. An instantaneous fluid heating device as described in claim 36, further including a flow switch which only engages said engageable master electrical control means when fluid is being emitted from said exit port.

41. An instantaneous fluid heating device as described in claim 37, further including a flow switch which only engages said engageable master electrical control means when fluid is being emitted from said exit port.

42. An instantaneous fluid heating device as described in claim 38, further including a flow switch which only engages said engageable master electrical control means when fluid is being emitted from said exit port.

43. An instantaneous fluid heating device as described in claim 39, further including a flow switch which only engages said engageable master electrical control means when fluid is being emitted from said exit port.

44. An instantaneous fluid heating device, as set forth in claim 31, wherein each of said vessels is equal in heating capacity.