SYSTEM FOR HEATING WATER AND METHODS THEREOF

Abstract

A water heater system, the system comprising a water boiler including: a metallic spiral tube configured to receive at a top end thereof, from an external source, a fluid in a heated state; to output, at a bottom end thereof, the fluid in a cooled state; and a cylinder adapted to abut the metallic spiral tube; wherein the metallic spiral tube in the heated state, heats the cylinder which conducts the heat through the cylinder to heat water in the water boiler

Claims

1. A water heater system, the system comprising a water boiler including: a) a metallic spiral tube configured to receive at a top end thereof, from an external source, a fluid in a heated state; to output, at a bottom end thereof, the fluid in a cooled state; and b) a cylinder adapted to abut the metallic spiral tube; wherein the metallic spiral tube in the heated state, heats the cylinder which conducts the heat through the cylinder to heat water in the water boiler.

2. The system of claim 1, wherein the water boiler is a cylindrical tank comprising an upper wall, sidewalls and a bottom wall, wherein the bottom wall includes an opening adapted for receiving circular plate with openings therein.

3. The system of claim 1, wherein the water boiler is new or previously housed a different heating system.

4. The system of claim 1, wherein the external source heats the fluid and the fluid is injected, through a conduit, to the upper end of the metallic spiral tube.

5. The system of claim 1, wherein the metallic spiral tube is formed from a thermo-conductive material, such as copper.

6. The system of claim 1, wherein the water boiler further comprises a heating element disposed within an internal space defined by the metallic spiral tube.

7. The system of claim 1, wherein the external source includes a compressor.

8. The system of claim 1, wherein the cylinder is a two-layer hollow metallic cylinder comprising an inner layer and an outer layer, wherein an inner layer completely encircles an inner volume defined the metallic spiral tube, and the outer layer partially surrounds/envelops an outer face of the metallic spiral tube.

9. The system of claim 8, wherein an internal surface of the outer layer faces the metallic spiral tube and an external surface of the outer layer is in contact with the water.

10. The system of claim 1, wherein the cylinder is formed from a thermo-conductive material, such as copper.

11. The system of claim 1, wherein the heated water is outputted from a hot water output.

12. The system of claim 1, further comprising a control unit that includes a controller, a display and a software or a firmware embodied on a physical memory/storage.

13. The system of claim 12, wherein the control unit is configured by a user to control, to monitor or to determine the features of the system, temperature, what time the hot water will be available, and other related features.

14. The system of claim 12, wherein the control unit automatically recognizes which external source to use at a time and for how long the system will operate.

15. The system of claim 1, wherein the water is continuously generated.

16. A method for generating hot water, using a water heater system domestic household use, the system comprising a water boiler including: a) a metallic spiral tube; and b) cylinder adapted to surround the metallic spiral tube, the method comprising: a) heating a fluid at an external source; b) selecting, via a control unit, a desired temperature and time when hot water will be available; wherein the water heater system starts heating water by operating the water boiler which includes: c) receiving the fluid in a heated state at a top end of the metallic spiral tube; d) transferring heat from the heated fluid to a cylinder partially surrounding/enveloping the spiral and to the water; e) descending the heated fluid, now in a partially cooled state, on a bottom end of the metallic spiral tube; f) the fluid cooling as is winds down the metallic spiral tube; and g) the fluid exiting from the metallic spiral tube in a cooled state and flowing back to the external source through a conduit and restarting the process.

17. The method of claim 16, wherein the water boiler is a cylindrical tank comprising an upper wall, sidewalls and a bottom wall, wherein the bottom wall includes an opening adapted for receiving circular plate with openings therein.

18. The method of claim 16, wherein the water boiler is new or previously housed a different heating system.

19. The method of claim 16, wherein the external source heats the fluid and said fluid is injected, through a conduit, to the upper end of the metallic spiral tube.

20. The method of claim 16, wherein the metallic spiral tube is formed from a thermo-conductive material, such as copper.

21. The method of claim 16, wherein the water boiler further comprises a heating element disposed within an internal space defined by the metallic spiral tube.

22. The method of claim 16, wherein the external source includes a compressor.

23. The method of claim 16, wherein the cylinder is a two-layer hollow metallic cylinder comprising an inner layer and an outer layer, wherein an inner layer completely encircles an inner volume defined the metallic spiral tube, and the outer layer partially surrounds/envelops an outer face of the metallic spiral tube.

24. The method of claim 16, wherein an internal surface of the outer layer faces the metallic spiral tube and an external surface of the outer layer is in contact with the water.

25. The method of claim 16, wherein cylinder is formed from a thermo-conductive material, such as copper.

26. The method of claim 16, wherein the heated water is outputted from a hot water output.

27. The method of claim 16, further comprising a control unit that includes a controller, a display and a software or a firmware embodied on a physical memory/storage.

28. The method of claim 27, wherein the control unit is configured by a user to control, to monitor or to determine the features of the system, temperature, what time the hot water will be available, and other related features.

29. The method of claim 27, wherein the control unit automatically recognizes which external source to use at a time and for how long the system will operate.

30. The method of claim 16, wherein the water is continuously generated.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Some embodiments of the present invention are herein described, by way of example only, with reference to the accompanying drawings. With specific reference to the drawings in detail, it is stressed that the particulars shown are by way of example and for purposes of illustrative discussion of embodiments of the invention. In this regard, the description taken with the drawings makes apparent to those skilled in the art how embodiments of the invention may be practiced.

[0034] Attention is now directed to the drawings, where like reference numerals or characters indicate corresponding or like components. In the drawings:

[0035] FIG. 1 is an example of a prior art conventional heating element;

[0036] FIG. 2 is a real-life example model of the entire water heater system for generating hot water, according to embodiments of the present invention;

[0037] FIG. 3 is a schematic representation of the entire water heater system for generating hot water, according to embodiments of the present invention;

[0038] FIG. 4 is a schematic illustration of a sectional length of the internal structure of the water boiler 100, and subcomponents thereof, according to embodiments of the present invention;

[0039] FIGS. 4A and 4B are different views of a hybrid embodiment of the heating system;

[0040] FIG. 5 is a three-dimensional schematic representation of a sectional length of the water boiler 100, according to another embodiment of the present invention;

[0041] FIG. 6 illustrates the control unit 400 from the water heater system; and

[0042] FIG. 7 is a special connector for the tube-in-tube arrangements.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0043] The present invention is related to a fast and continuous water heater system that heats water up throughout the day. The system utilizes hot fluid to generate hot water quickly, continuously, and cheaply.

[0044] The main features of the water heater system are a water boiler having a thermo-conductive spiral tube surrounded by a thermo-conductive cylinder. Heated fluid flows through the spiral, entering at the top of the spiral and exiting the boiler at the bottom. The fluid cools and sinks down the spiral as it heats the water. The fluid is heated at an external source, such as compressor. The spiral has a differential heat gradient, being hottest at the top and coolest at the bottom. The spiral is in contact with the surrounding cylinder and transfers heat to the cylinder. Heat from the spiral spreads through the cylinder and distributes the heat throughout the cylinder. Water inside the space defined by the spiral/cylinder is heated by the heat from the fluid in the spiral.

[0045] In embodiments, a cylindrical (but not a complete cylinder) insulator (e.g., made of non-conductive or semi-conductive plastic or polymer) surrounds the outer face of the cylinder. As a result, the heat is concentrated on the water inside the internal space. The open area of cylindrical insulator exposes the external face of the cylinder to the water in the rest of the tank, warming that water in a somewhat slower process.

[0046] According to embodiments, the spiral is encased in a cylinder, closed in on both sides, the top and the bottom. Encasing the cylinder is a safety measure against the spiral tubing bursting, which would otherwise contaminate the water with the toxic heating fluid. The conduits for inputting and outputting the fluid are also encased by a tube-inside-tube arrangement. Special connectors connect to these arrangements at the bottom flange (circular plate) which all the pipes go through. The connectors screw into the tube-in-tube arrangements and are also attached to the flange. The connectors, on an outside section of the connector, include a number of holes to vent the fluid out of the boiler in the event of a pipe burst.

[0047] In embodiments, the water heating system also includes a legacy electrical heating element to form a hybrid system. The new and legacy components can work synergistically or individually, one at a time. A control unit is able to recognize which heating source or sources to use in order to provide hot water in the most efficient way (faster and consuming less energy), thus saving time and money.

[0048] The novel copper spiral tube conducts/circulates fluid in different states, generally referred to herein as a heated state and a cooled state. It is however understood that this is a generalization as the fluid starts its journey within the spiral in a more heated state and exits the spiral in a cooler state, having different temperatures at different stages.

[0049] In the embodiment where the novel copper spiral tube is encased/enveloped by a two-layer hollow metallic cylinder that conducts the heat from the spiral in a more even manner, providing a larger surface area that is in contact with the water. In such embodiments, the sheath/sleeve/envelope/encasement prevents scale from forming on the spiral tube and/or corrosion of the spiral. The water heater systems disclosed herein allow for faster and improved heat transfer to the water surrounding it.

[0050] Certain embodiments of the present invention provide a water heater system for domestic household. In other embodiments, the system can be used in large scale systems.

[0051] The principles and operation of the water heater system and method according to present invention may be better understood with reference to the drawings accompanying the description.

[0052] Before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not necessarily limited in its application to the details of construction and the arrangement of the components and/or methods set forth in the following description and/or illustrated in the drawings and/or the examples. The invention is capable of other embodiments or of being practiced or carried out in various ways.

[0053] Referring now to the drawings, FIG. 1 illustrates an example of a prior art conventional electric heater element. This well-known water heater produces and stores hot water and has the ability to control and monitor the water. The basic structure is comprised by a heating element 80. The metal heating element 80 heats water in legacy electrical water heaters. The heating element 80 is usually made from corrosion resistant material and is insulated from the metal sheath with a powder made of magnesium oxide. Solar panels (not represented herein) are also common heating systems. This represents the issue of water heater systems, since there are no external sources of heat (for heat-exchange purposes) that are pumped into the heating system. In addition, the conventional heater element as shown in FIG. 1, also lacks systems for cooling, pumping out and reusing of the external energy source. In other words, the internal space of these water heaters serves simply to store the hot water; so the previous water heater processes are done in different time/spaces, different from the claimed invention, being very time-consuming, costly and non-environmentally friendly.

[0054] FIG. 2 illustrates a real-life example model of the system for generating hot water, according to certain non-limiting embodiments of the present invention. Generally speaking, the water boiler 100 is connected to an external source 200 through conduits 300, from where the heated fluid enters into the water boiler 100. The water boiler 100 is formed from multiple internal subcomponents, which will be described with reference to FIG. 4. After the internal process in the boiler 100, the hot water is available at the hot water output 120 to the consumer for any desired purpose. In non-limiting embodiments, the external source can be a compressor, an electric source, solar panel energy source or any other source that can heats the fluid. Preferably, the external source is a compressor that heats gas by compressing it at high pressure. In some embodiments, the spiral heating element can work synergistically with legacy heating elements nder the control and direction of a control unit 400, which is connected both to the water boiler 100 and to the external source 200. The control unit 400 may include a controller, a display and a software/firmware embodied on a physical memory/storage and it will be described in more detail with reference to FIG. 6.

[0055] FIG. 3 illustrates a schematic representation of the entire system for generating hot water, according to embodiments of the present invention. FIG. 3 is a schematic representation of the entire system, similar to that of FIG. 2. Generally speaking, FIG. 3 represents the three elements for the whole system operation, namely, the water boiler 100, the external source 200, and the control unit 400. In a non-limiting example, the external source 200 is a compressor that heats up the fluid. In example embodiments, the compressor (and other necessary components) is housed in a repurposed external air-conditioning unit. The heated fluid will enter into the water boiler 100 through an input conduit 310 of conduits 300. The fluid circulates inside the metallic spiral tube 130 and heats the metallic spiral tube 130 which may be, for instance, a copper spiral tube/pipe. Then, the metallic spiral tube 130 in turn heats the cylinder 110 which surrounds, and is in contact with, the spiral 130. The cylinder 110 is adapted to heat water 70 in the water boiler.

[0056] Still referring to FIG. 3, the cylinder 110 is a two-layer hollow metallic cylinderfor instance, a two-layer hollow copper cylinder or pipe, that envelopes/encases the metallic spiral tube 130. The cylinder conducts heat from the top part of the spiral more or less evenly throughout the cylinder, thus providing a larger heated surface that is in contact with the water. The hollow pipe/cylinder also protects the metallic spiral tube 130 from corrosion and protects the boiler from fluid leakage which would otherwise result in contamination of the water. The heated water will be then available at the hot water output 120 for any desired purpose. The heated fluid enters the spiral at the top end and gradually cools as it descends downwards through the metallic spiral tube 130 and exits the water boiler via output conduit 320 of conduits 300. The fluid then returns to the external source 200 and the process of heating that fluid starts anew. There is a continuous flow of heated fluid during a water-heating process. The above description somewhat abstractly describes a portion of the fluid as it runs through the system.

[0057] FIG. 4 illustrates a sectional length of the internal structure of the water boiler 100 and its innovative operation. FIG. 4, represents an exploded schematic, cross-sectional view of the spiral heating arrangement with the cylinder 110 exploded away from the metallic spiral tube 130, since the cylinder 110 envelopes the metallic spiral tube 130 across the whole extent thereof. In the non-limiting embodiment illustrated in FIG. 4, the subcomponents of the water boiler 100 are a cylinder 110; and a metallic spiral tube 130. Each of these sub-components of the water boiler 100 can be implemented in various ways and perform different functions.

[0058] Still referring to the water boiler 100 operation of FIG. 4, the metallic spiral tube 130 is configured to receive at a top end 131 thereof, from an external source 200 and through an input conduit 310 (both illustrated in FIG. 3), a fluid in a heated state. The fluid is adapted to indirectly heat the water 70 surrounding heating arrangement (illustrated in FIG. 3). The fluid cools and sinks to a bottom end 132 and exits the fluid through an output conduit 320, in a cooled state. In some non-limiting embodiments, the cylinder 110 comprises two-layers 111A and 111B, where the inner layer 111A abuts the inside face of the metallic spiral tube 130 and the outer layer 111B abuts the outside face of the metallic the spiral 130 tube. The cylinder is sealed at the top and welded to the flange/circular plate at the bottom, thus completely protecting the metallic spiral tube 130 from corrosion, enlarging the heated contact surface with the water, especially in the internal volume/space defined by the cylinder 110.

[0059] As explained elsewhere herein, the spiral has a differential heat gradient, being hottest at the top and coolest at the bottom (where it would hardly be able to heat water). The spiral is in contact with the surrounding cylinder and transfers heat to the cylinder. Heat from the spiral spreads through the cylinder and distributes the heat throughout the cylinder.

[0060] Not shown in FIG. 4, and somewhat unclear from FIG. 3, in example embodiments, the heating arrangement further includes a cylindrical (but not forming a completely closed cylinder) insulator (e.g., made of non-conductive or semi-conductive material such as plastic or polymer) surrounds the outer face of the cylinder. As a result, the heat is concentrated on the water inside the internal space. The small open area of cylindrical insulator exposes [about 20% of] the external face of the cylinder to the water in the rest of the tank, warming that water in a somewhat slower process.

[0061] The spiral is encased in the cylinder 110 which is closed in on both sides, the top and the bottom. As mentioned, encasing the cylinder, inter alia, is a safety measure against the spiral tubing bursting, which would otherwise contaminate the water with the toxic heating fluid. The conduits for inputting 310 and outputting 320 the fluid are also encased by a tube-inside-tube arrangement.

[0062] FIG. 7 illustrates a special connector for the tube-in-tube arrangements. Special connectors 500 (see FIG. 7) connect to these arrangements at the bottom flange (circular plate) 102 which all the pipes go through. The connectors screw into the tube-in-tube arrangements and are also attached to the flange. The connectors, which are disposed through the flange, include a number of holes 510 on an outside part of the connector to vent the fluid out of the boiler in the event of a pipe burst.

[0063] FIG. 4A and FIG. 4B are different views of a hybrid embodiment of the heating system. The hybrid embodiment is the same as the embodiment described above, but with the addition of an electrical heating element 80. According to the present embodiment, the water boiler includes a cylinder 110, a metallic spiral tube 130, encased in the cylinder, and a legacy electric heating element 80 with a thermocouple 90 disposed on the bottom flange 102, inside the space defined by the metallic spiral tube 130/cylinder 110.

[0064] FIG. 4A is a top-down view of the heating arrangement with the top section of the encasing cylinder removed. FIG. 4B is an isometric view of the upper portion of the hybrid heating arrangement. Internal layer 111A is visible, having a slight wave form. The external layer 111B is also visible with indents corresponding to the spiral tubing also visible. A partially encircling insulator sheet 150 is also clearly shown. The cylindrical insulator piece does not cover the upper section of the heating arrangement, in order to allow this section to heat the water higher up in the tank in a more effective manner.

[0065] FIG. 5 is a three-dimensional schematic representation of a sectional length of the water boiler 100 according to another embodiment. FIG. 5, represents an exploded view of the cylinder 110 exploded away from the metallic spiral tube 130. The main features of the water heater system are a water boiler having a thermo-conductive spiral tube 130 surrounded (on the outside and/or on the inside) by a thermo-conductive cylinder 110 (having one or two layers). Heated fluid flows through the spiral 130, entering at the top 131 of the spiral and exiting the boiler at the bottom 132. The fluid cools and sinks down the spiral as it heats the water. Here too, the fluid is heated at an external source, such as compressor. The spiral has a differential heat gradient, being hottest at the top and coolest at the bottom. The spiral is in contact with the surrounding cylinder and transfers heat to the cylinder. Heat from the spiral spreads through the cylinder and distributes the heat throughout the cylinder. Water inside the space defined by the spiral/cylinder is heated by the heat from the fluid in the spiral.

[0066] With reference to FIG. 2, FIG. 6 illustrates in more detail the control unit 400. The control unit 400 includes a controller, a display and a software or a firmware embodied on a physical memory/storage. The control unit is connected both to the water boiler 100 and to the external source 200. In some non-limiting embodiments, the external source 200 is comprised by more than one source; the external source 200 can be a compressor, an electric source, solar panel energy source or any other source that can heats the water. The different external sources can work both synergistically with all the technologies together and also each external source at a time, what is defined by the control unit 400. The control unit 400 is connected both to the water boiler 100 and to the external source 200, and is automatically able to recognize which external source to usethe external source 200 that heats the metallic spiral tube 130; an electric external source and/or a solar panel external source that heat the heating element 90at determined moment in order to provide hot water in the most efficient way (faster and consuming less energy), thus saving time and money. The control unit 400 display the system status, such as the temperature and the operating time. Furthermore, the control unit 400 is automatically set up to never work below or above the configured temperature. The control unit 400 will operate the system only if needed and/or when there is no energy generation from a cheaper/natural/green source-such as electricity generation, solar energy and similar.

[0067] Therefore, the efficiency of this system will always be optimal: if there is enough hot water, the system will not work; if the solar energy will spend less energy, thus the system will use it; if both the electric energy and the hot gas energy, the system will synergistically use both.

[0068] The system according to the embodiments disclosed herein is simple to operate: turn on the whole system and, after a few minutes, hot water will come out of the consumer faucets. All the costumer/consumer needs to do is to select the desired configurations in the control unit 400such as temperature and what time the hot water will be available. The system then operates in a completely automated and independent manner and the control unit recognizes which external source will be the most efficient at the moment. Once the fluid is heated by the external source 200 (and/or other kind external sources, such as electricity or solar) and enters to the water boiler 100 through a conduit 300, the hot fluid inside the spiral tube 130 and/or the electric and/or solar energy for the heating element 80, quickly and continuously heats the water. While there is available water to the consumer from the hot water output 120, the hot fluid is continuously and gradually cooled and returned to the external source 200, starting the process anew.

[0069] The system disclosed herein is compact and practical, and heats water quickly in an environmentally friendly fashion. Any person or entity who needs hot water can acquire the system and, preferably, it works is inside a water boiler and/or works independently. Some non-limiting examples of deployment locations for the system include: houses, schools, hotels, restaurants, gyms and related places, shopping centers, shopping malls, supermarkets, industries and wherever hot water is needed.

[0070] The descriptions of the various embodiments of the present disclosure have been presented for purposes of illustration, but are not intended to be exhaustive or limited to the embodiments disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the described embodiments. The terminology used herein was chosen to best explain the principles of the embodiments, the practical application or technical improvement over technologies found in the marketplace, or to enable others of ordinary skill in the art to understand the embodiments disclosed herein.

[0071] As used herein, the singular form, a, an and the include plural references unless the context clearly dictates otherwise.

[0072] The word exemplary is used herein to mean serving as an example, instance or illustration. Any embodiment described as exemplary is not necessarily to be construed as preferred or advantageous over other embodiments and/or to exclude the incorporation of features from other embodiments.

[0073] External source herein is defined as any energy source that heats up water. Preferably, the external source is electric energy, solar energy, a compressor or any other energy source able to heat a quantity of water. Preferably, the external source is comprised by one or more different external sources working either together either separately.

[0074] Compressor herein is defined as a device that increases the pressure of a fluid (usually a gas) by reducing the volume of the substance, thus heating the fluid. Preferably, the compressor can be rotary screw compressor, vane compressor, reciprocating air compressor, axial compressor and centrifugal compressor. The compressor is preferably a reciprocating or a screw compressor.

[0075] Conduit herein is defined as a tube used to convey water, gas, oil, or other fluid or gaseous substances. Preferably, the conduit is made from different kinds of metal or other related material, as long as the material is a thermo-conductive material, such as copper. Preferably, the conduit is from a material comprising the intrinsic property of conducting heat.

[0076] Heating element herein is defined as an element that converts electrical or solar energy into heat through the process of Joule heating. Electric current through the element encounters resistance, resulting in heating of the element.

[0077] It is appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention, which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable subcombination or as suitable in any other described embodiment of the invention. Certain features described in the context of various embodiments are not to be considered essential features of those embodiments, unless the embodiment is inoperative without those elements.

[0078] Although the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, it is intended to embrace all such alternatives, modifications and variations that fall within the spirit and broad scope of the appended claims.