Fluid heater with low porosity thermal mass
First Claim
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1. A heater apparatus for heating fluid, the heater apparatus comprising:
- a one piece low porosity, thermally conductive mass formed of one of a thermally conductive semi-solid state cast material, a molded ceramic, and an extruded material formed of one of a ceramic material and a poltruded carbon;
heating means, disposed within and thermally coupled to the thermally conductive mass, for imparting heat to the thermally conductive mass; and
a fluid flow path formed in the mass between an inlet and an outlet, the fluid flow path coupled in heat transfer relation to the heating means so that fluid in the fluid flow path absorbs heat from the thermally conductive mass, the fluid flow path open to the exterior of the thermally conductive mass.
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Abstract
A fluid heater apparatus and method of making same includes a low porosity material, thermally conductive mass. A heat source is disposed in the thermally conductive mass for imparting heat to the mass. Fluid in a flow path through the mass absorbs heat from the mass. The thermally conductive mass is molded, cast or extruded from a material which, with the selected forming process, provides a low porosity mass. The mass may be formed of ceramic, aluminum and poltruded carbon. The mass can be cast from a material which is introduced into the casting mold in a semi-solid temperature state.
127 Citations
46 Claims
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1. A heater apparatus for heating fluid, the heater apparatus comprising:
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a one piece low porosity, thermally conductive mass formed of one of a thermally conductive semi-solid state cast material, a molded ceramic, and an extruded material formed of one of a ceramic material and a poltruded carbon; heating means, disposed within and thermally coupled to the thermally conductive mass, for imparting heat to the thermally conductive mass; and a fluid flow path formed in the mass between an inlet and an outlet, the fluid flow path coupled in heat transfer relation to the heating means so that fluid in the fluid flow path absorbs heat from the thermally conductive mass, the fluid flow path open to the exterior of the thermally conductive mass. - View Dependent Claims (2, 11, 12, 13, 14, 15, 16, 17, 18, 19)
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3. A heater apparatus for heating fluid, the heater apparatus comprising:
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a thermally conductive mass, the thermally conductive mass formed of an extruded, low porosity material; heating means, thermally coupled to the thermally conductive mass, for imparting heat to the thermally conductive mass; a fluid flow path formed in the mass between an inlet and an outlet, the fluid flow path coupled in heat transfer relation to the heating means so that fluid in the fluid flow path absorbs heat from the thermally conductive mass, the fluid flow path open to the exterior of the thermally conductive mass, the fluid flow path defined by a plurality of throughbores extending through first and second ends, the thermally conductive mass formed of a plurality of lamina, each lamina carrying an aperture defining a portion of the throughbores and an aperture defining a position of a bore for receiving the heater means therethrough; the heater means mounted in the thermally conductive mass concentrically within and surrounded by the plurality of throughbores; and means for coupling a fluid inlet to one end of each of a plurality of throughbores and a fluid outlet to each of the other ends of the plurality of throughbores to define the fluid flow path as at least one parallel flow path between the inlet and the outlet through the plurality of throughbores. - View Dependent Claims (4, 6, 7, 8, 9, 10)
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5. A heater apparatus for heating fluid, the heater apparatus comprising:
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a thermally conductive mass, the thermally conductive mass formed of an extruded, low porosity material; heating means, thermally coupled to the thermally conductive mass, for imparting heat to the thermally conductive mass; a fluid flow path formed in the mass between an inlet and an outlet, the fluid flow path coupled in heat transfer relation to the heating means so that fluid in the fluid flow path absorbs heat from the thermally conductive mass, the fluid flow path open to the exterior of the thermally conductive mass, the fluid flow path defined by a plurality of throughbores extending through first and second ends, the plurality of throughbores each having a helical path between opposed first and second ends; the heater means mounted in the thermally conductive mass concentrically within and surrounding by the plurality of throughbores; and means for coupling a fluid inlet to one end of each of a plurality of throughbores and a fluid outlet to each of the other ends of the plurality of throughbores to define the fluid flow path as at least one parallel flow path between the inlet and the outlet through the plurality of throughbores.
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20. A vehicle window wash apparatus comprises:
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a fluid source for supplying wash fluid; a fluid discharge device fluidically coupled to the fluid source for discharging fluid from the reservoir; a heater means disposed in fluid flow communication between the fluid source and the fluid discharge device; a controller, coupled to the heater means for supplying power to the heater means; the heater means including; a one piece low porosity thermally conductive mass having an inlet and an outlet; the thermally conductive mass formed of one of a material cast in a semi-solid state, a molded ceramic, and an extruded material formed of one of a ceramic material and a poltruded carbon; a heater element, disposed within and thermally coupled to the thermally conductive mass, for imparting heat to the thermally conductive mass; and a fluid flow path formed in the mass between the inlet and the outlet, the fluid flow path coupled in heat transfer relation to the heater means so that fluid in the fluid flow path absorbs heat from the thermally conductive mass, the fluid flow path open to the exterior of the thermally conductive mass.
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21. A heater apparatus manufactured by a process including the steps of forming a one piece low porosity, thermally conductive mass of one of a thermally conductive semi-solid state cast material, a molded ceramic, and an extruded material formed of one of a ceramic material and a poltruded carbon;
- associating at least one fluid channel in a thermally conductive relationship with the thermally conductive mass, the at least one fluid flow channel having at least one inlet and one outlet; and
associating heater means in a thermally conductive relationship with the thermally conductive mass, the heater means supplying heat, when activated, to the thermally conductive mass, the heater apparatus for heating fluid comprising;a one piece low porosity, thermally conductive mass formed of one of a thermally conductive semi-solid state cast material, a molded ceramic, and an extruded material formed of one of a ceramic material and a poltruded carbon; heating means, associated in a thermally conductive relationship with the thermally conductive mass, for imparting heat to the thermally conductive mass, when activated to the thermally conductive mass; and at least one fluid flow channel in a thermally conductive relationship with the thermally conductive mass, the at least one fluid flow channel having at least one inlet and at least one outlet to define a fluid flow path, wherein fluid within the fluid flow path absorbs heat from the thermally conductive mass. - View Dependent Claims (22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33)
- associating at least one fluid channel in a thermally conductive relationship with the thermally conductive mass, the at least one fluid flow channel having at least one inlet and one outlet; and
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34. A method for manufacturing a fluid heater comprising the steps of:
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providing a thermally conductive mass with a low porosity, the mass having at least one fluid flow channel extending therethrough, the fluid flow channel having first and second ends; mounting heater means in the thermally conductive mass, the heater means supplying heat, when activated, to the thermally conductive mass; and fluidically coupling a fluid inlet to one end of the fluid flow channel and a fluid outlet to the other end of the fluid flow channel to define a fluid flow path between the inlet and the outlet wherein fluid in the fluid flow path absorbs heat from the thermally conductive mass. - View Dependent Claims (35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46)
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Specification