Electric water heater

• US 6,080,973 A
• Filed: 04/19/1999
• Issued: 06/27/2000
• Est. Priority Date: 04/19/1999
• Status: Expired due to Term

• Current Assignee: Global Heating Solutions, Inc.
• Original Assignee: Sherwood-Templeton Coal Company, Inc.
• Inventors: Thweatt, Carlisle Jr.
• Primary Examiner(s): PASCHALL, MARK H
• Application Number:
  US09/294,765
• Time in Patent Office: 435 Days
• Field of Search: 219/492, 219/497, 219/501, 219/505, 219/494, 392/465, 392/473, 392/485, 392/488, 392/489, 392/486, 392/497, 392/498, 392/544
• US Class Current: 219/497
• CPC Class Codes: F24H 15/124 Preventing or detecting electric faults, e.g. electric leakage
• CPC Class Codes: F24H 15/132 Preventing the operation of water heaters with low water levels, e.g. dry-firing
• CPC Class Codes: F24H 15/20 characterised by control inputs
• CPC Class Codes: F24H 15/212 Temperature of the water
• CPC Class Codes: F24H 15/37 of electric heaters
• CPC Class Codes: F24H 15/395 Information to users, e.g. alarms
• CPC Class Codes: F24H 9/2028 Continuous-flow heaters
• CPC Class Codes: F24H 9/45 for preventing galvanic corrosion, e.g. cathodic or electrolytic means
• CPC Class Codes: F24H 9/455 for water heaters
• CPC Class Codes: G05D 23/2401 using a heating element as a sensing element

Abstract

An electric water heater is provided which includes a polymeric body having an elongated hollow and an inlet opening and an outlet opening in communication with the hollow for flowing water to pass therethrough. An electrical resistance heater having a heating element of a material exhibiting a positive temperature coefficient of resistance is disposed in the hollow of the polymeric body and in heat transfer communication with water flowing through the hollow. An electrical source supplies electrical power to the heating element to generate heat. A controller senses current flow through the heating element and determines a resistance related value, such as current or resistance of the heating element. The controller also determines a first derivative of the resistance related value over time, and determines a second derivative of the resistance related value over time, and controls power supply to the heating element as a function of the first and second derivatives and/or absolute resistance.

Claims

1. A heater comprising:

a polymeric body having an elongated hollow, and an inlet opening and an outlet opening in communication with said hollow for flowing fluid therethrough;

an electrical resistance heater having a heating element of a material exhibiting a positive temperature coefficient of resistance, said heating element disposed in said hollow of said polymeric body and in heat transfer communication with fluid flowing through said hollow;

an input terminal for receiving electrical power and supplying said electrical power to said heating element to produce a current in said heating element to generate heat; and

a controller for sensing current flow through said heating element and determining a resistance related value of said heating element, said controller further determining a first derivative of said resistance related value as a function of time and controlling the electrical power supplied to said heating element as a function of said first derivative so that the controller prevents overheating of the polymeric body.

2. The heater as defined in claim 1, wherein said controller further computes a second derivative of said resistance related value as a function of time, said controller reducing electrical power supplied to said heating element as a function of said second derivative.

3. The heater as defined in claim 1 further comprising a pump for causing fluid to flow through said hollow of said polymeric body in heat transfer communication with said heating element.

4. The heater as defined in claim 1, wherein said polymeric body further has a first aperture formed therein for allowing a first terminal of said heating element to extend therethrough, and a compressed fitting disposed in said first aperture in a sealed relation between said polymeric body and said first terminal of said heating element.

5. The heater as defined in claim 4, wherein said polymeric body further has a second aperture formed therein for receiving a second terminal of said heating element, and a compressed fitting disposed in said second aperture in a sealed relation between said polymeric body and said second terminal of said heating element.

6. The heater as defined in claim 1 further comprising a conductive mounting member disposed in the hollow against inner walls of said polymeric body and in contact with said heating element, said conductive mounting member being in electrical contact with an outer conductive jacket of said heating element, wherein said conductive mounting member is adapted to collect stray currents and couple said stray currents to a ground fault detector for detecting a ground fault.

7. The heater as defined in claim 6, wherein said conductive mounting member mechanically engages said heating element to position said heating element within said hollow in the polymeric body and out of contact with said polymeric body.

8. The heater as defined in claim 1, wherein said fluid comprises water.

9. A water heater comprising:

a body having an elongated hollow, and an inlet opening and an outlet opening in communication with said hollow for flowing fluid therethrough;

an electrical resistance heater having a heating element of a material exhibiting a positive temperature coefficient of resistance, said heating element disposed in said hollow of said body and in heat transfer communication with fluid flowing through said hollow;

an input terminal for receiving electrical power and supplying said electrical power to said heating element to produce a current in said heating element to generate heat; and

a controller for sensing current flow through said heating element and determining a resistance related value of said heating element, said controller further determining a first derivative of said resistance related value as a function of time and a second derivative of said resistance related value as a function of time, and controlling said electrical power supplied to said heating element as a function of said first and second derivatives.

10. The heater as defined in claim 9, wherein said controller controls the electrical power supply to said heating element further as a function of absolute resistance.

11. The heater as defined in claim 9, wherein said controller cuts off said electrical power supplied to said heating element as a function of said first and second derivatives of said resistance related value.

12. The heater as defined in claim 9, wherein said resistance related value comprises resistance of said heating element.

13. The heater as defined in claim 9, wherein said resistance related value comprises current.

14. The heater as defined in claim 9 further comprising a temperature sensor disposed in said fluid for measuring temperature of said fluid, wherein said controller controls said heating element as a function of said sensed temperature.

15. The heater as defined in claim 9, wherein said body comprises a polymeric body.

16. The heater as defined in claim 15, wherein said polymeric body has a first aperture for allowing a first terminal of said heating element to extend therethrough, and a compressed fitting disposed in said first aperture in sealed relation between said polymeric body and said heating element.

17. The heater as defined in claim 9 further comprising a conductive mounting member disposed in the hollow in said polymeric body and in electrical contact with said heating element, said conductive mounting member being in electrical contact with an outer conductive jacket of said heating element and adapted to collect and couple stray current to a ground fault detector via said conductive shield.

18. The heater as defined in claim 17, wherein said conductive mounting member further engages said heating element to position said heating element within the hollow in the polymeric body and out of contact with the polymeric body.

19. A heater comprising:

a polymeric body having an elongated hollow, and an inlet opening and outlet opening in communication with said hollow for flowing fluid therethrough;

an electrical heater having a heating element disposed in said hollow of said polymeric body and in heat transfer communication with fluid flowing through said hollow said heating element having an inner conductor and an outer conductive jacket separated by a dielectric material;

an input terminal for receiving electrical power and supplying said electrical power to said heating element to produce a current in said heating element to generate heat;

a conductive member disposed in said hollow and in contact with said outer conductive jacket of said heating element for collecting stray currents in said fluid;

a ground fault detector in electrical contact with said outer conductive jacket for detecting a ground fault condition; and

a controller for controlling the electrical power to said heating element, said controller controlling said electrical power supplied to said heating element based on said ground fault detection.

20. The heater as defined in claim 19, wherein said conductive member mechanically supports and positions said electrical heating element within said hollow of said polymeric body.

21. A heater comprising:

a body having an elongated hollow, and an inlet opening and an outlet opening in communication with said hollow for flowing fluid therethrough;

a heater disposed in said hollow of said body and in heat communication with fluid flowing through said hollow;

an input for receiving power and supplying said power to said heater to generate heat;

a sensor for sensing a temperature dependent value indicative of temperature of said fluid; and

a controller for determining a first derivative of said temperature dependent value as a function of time and a second derivative of said temperature dependent value as a function of time, and controlling said power supplied to said heater as a function of said first and second derivatives.

22. A method of controlling a heating comprising:

sensing current flow through a heater element that is disposed in a hollow of a body having an inlet and an outlet in communication with the hollow flowing fluid therethrough, said heating element having a material exhibiting a positive temperature coefficient of resistance and providing heat transfer with fluid flowing through said hollow;

determining a resistance related value of said heating element as a function of said sensed current;

determining a first derivative of said resistance related value as a function of time;

determining a second derivative of said resistance related value as a function of time; and

controlling electrical power supplied to said heating element as a function of said first and second derivatives.

23. The method as defined in claim 22, wherein said step of controlling said electrical power supplied to said heating element is further supplied as a function of absolute resistance.

24. The method as defined in claim 22, wherein said step of controlling said electrical power supplied includes cutting off power supplied to said heating element as a function of said first and second derivatives of said resistance related value.

25. The method as defined in claim 22, wherein said resistance related value comprises current.

26. The method as defined in claim 22, wherein said resistance related value comprises resistance.