Small diameter low watt density immersion heating element
First Claim
1. A method of heating a quantity of water within a storage container, comprising:
- providing a storage container having a storage capacity of at least one gallon, said storage container containing a substantially renewable supply of water, said storage container having a water inlet and a water outlet;
said water containing calcium, calcium carbonate, or both, in solution in a sufficient concentration to form a scale deposit during the heating of said quantity of water;
said storage container also including an electrical resistance immersion heating element disposed therein;
said immersion heating element including a resistance heating material disposed within an electrically insulating, substantially water impervious sheath;
self limiting an upper temperature of said immersion heating element due to scale deposit induced overheating thereof, by said resistance heating material having, a watt density of no greater than about 60 W/in2, and an overall wattage rating of at least about 1000 W;
said immersion heating element having a capability of fitting within an envelope of no greater than about 50 in3; and
electrically activating said immersion heating element to produce power for heating said water above ambient temperature, and self-limiting the upper temperature of said resistance heating material as induced by formation of said scale deposit.
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Accused Products
Abstract
The present invention provides immersion heating elements, water heaters and methods for their fabrication and use. In the first embodiment of this invention, a resistance heating element is provided which includes a resistance heating material and an electrically insulating, substantially water impervious sheath disposed over the resistance heating material to form an active element portion having an envelope of about 50 in3, a total wattage of at least 1000 W, and a watt density of no greater than 60 W/in2. Such an element has been demonstrated to substantially reduce scale reduction in water containing calcium, calcium carbonate, or both in solution.
239 Citations
21 Claims
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1. A method of heating a quantity of water within a storage container, comprising:
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providing a storage container having a storage capacity of at least one gallon, said storage container containing a substantially renewable supply of water, said storage container having a water inlet and a water outlet;
said water containing calcium, calcium carbonate, or both, in solution in a sufficient concentration to form a scale deposit during the heating of said quantity of water;
said storage container also including an electrical resistance immersion heating element disposed therein;
said immersion heating element including a resistance heating material disposed within an electrically insulating, substantially water impervious sheath;
self limiting an upper temperature of said immersion heating element due to scale deposit induced overheating thereof, by said resistance heating material having, a watt density of no greater than about 60 W/in2, and an overall wattage rating of at least about 1000 W;
said immersion heating element having a capability of fitting within an envelope of no greater than about 50 in3; and
electrically activating said immersion heating element to produce power for heating said water above ambient temperature, and self-limiting the upper temperature of said resistance heating material as induced by formation of said scale deposit. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
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10. In combination, a storage container capable of holding at least one gallon and an electrical resistance immersion heating element for heating water, comprising:
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a storage container having contained therein a substantially renewable supply of water, said water containing calcium, calcium carbonate, or both, in a sufficient concentration to form a scale deposit during the heating of said water;
an electrical resistance immersion heating element mounted through a wall of said storage container, said electrical resistance immersion heating element including a resistance heating material disposed within an electrically insulating, substantially water impervious sheath to form an active element portion;
said active element portion having a self limiting upper temperature due to scale deposit induced overheating thereof, by said resistance heating material having a cross-sectional dimension of no greater than about 0.25 inches (6.35 mm); and
having a watt density of no greater than about 60 W/in2, while providing a total wattage rating of at least about 2500-4500 W; and
said active element portion being capable of fitting within an envelope of less than about 50 in3. - View Dependent Claims (11, 12, 13, 14)
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15. A resistance heating clement comprising:
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a resistance heating material;
an electrically insulating, substantially water impervious sheath disposed over said resistance heating material to form an active element portion;
a pair of terminal ends extending from said resistance heating material for connecting said resistance heating element to an external source of electrical power;
said active element portion defining an envelope having an envelope length less than 30 in. and a cross-sectional envelope dimension of less than 1.5 in.;
said active element portion capable of generating a total wattage of at least about 1000 W and having a self limiting upper temperature due to scale deposit induced overheating thereof, by said resistance heating material having a watt density of no greater than 60 W/in2; and
said active element portion by having said self limiting upper temperature being capable of substantially reducing scale production in water containing calcium, calcium carbonate, or both. - View Dependent Claims (16, 17, 18, 19, 20)
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21. A water heater comprising:
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a storage container wall comprising a thermally conductive, water impervious polymeric material;
an electrical resistance heating element disposed within said storage container wall, said electrical resistance heating element including a resistance heating material which is electrically insulated from the contents of said storage container;
said electrical resistance heating element having a self limiting upper temperature due to scale deposit induced overheating thereof, by said resistance heating material having a watt density of no greater than about 60 W/in2 while providing a total wattage rating of at least about 1,000 watts; and
said electrical resistance heating element by having said self limiting upper temperature being capable of substantially reducing the growth of scale in said storage container.
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Specification