HIGH POWER ELECTRIC HEATER

Description

1 / 26 HIGH POWER ELECTRIC HEATER BACKGROUND

[001] Many industrial or other processes require a high-temperature heat source. Heat is often supplied by means of water or another fluid that is heated by a combustion process, such as in a boiler, furnace, or other heating device. Frequently, these heating devices are fueled by fossil fuels such as coal, oil, or natural gas.

[002] From an environmental perspective, a substitute heat source that does not use fossil fuels but is capable of providing the necessary level of heat, usually in the form of hot water or steam, or any other fluid, would be desirable. However, conventional means of electric heating currently available are not scalable to the high power levels required for most industrial processes. BRIEF SUMMARY

[003] In one aspect, an electric heater includes a core oriented to define a first surface and a second surface opposite the first surface. A primary winding is positioned around the core and operates at a power level greater than 1 MW to produce a primary current flow. A first flow member extends around a first portion of the core and defines an inlet; a second flow member extends around a second portion of the core and defines an outlet; the second portion is different from the first portion. A third flow member is arranged adjacent to the first surface and connected to the first flow member and the second flow member to complete a continuous flow path for the process fluid between the inlet and the outlet. The first flow member, the second flow member, and the third Petition 870250091551, dated 07 / 10 / 2025, page 7 / 65 2 / 26 flow members cooperate to define a portion of a secondary winding. The secondary winding is completed (closed) by a power-conducting connecting piece between the first and second flow members. A fluid flow is supplied at the inlet and collected from the outlet; the fluid flow is heated in response to a secondary current flow in the secondary winding, which is induced by the primary current flow.

[004] In another aspect, an electric heater includes a core oriented to define a first surface and a second surface opposite the first surface. A primary winding is positioned between the core surfaces and can be operated at a power level greater than 1 MW to produce a primary current flow. A first flow member extends around a first portion of the core and defines an inlet; a second flow member extends around a second portion of the core and defines an outlet; the second portion is different from the first portion. A third flow member is arranged adjacent to the first surface and connected to the first flow member and the second flow member to complete a continuous flow path for the process fluid between the inlet and the outlet. The first flow member, the second flow member, and the third flow member cooperate to define a portion of a secondary winding.The secondary winding is completed (closed) by a power-conducting connecting piece between the first and second flow members. A fluid flow is supplied at the inlet and collected from the outlet. The fluid flow is heated in response to a secondary current flow in the secondary winding, which is induced by the primary current flow.

[005] The electric heater may also contain a core with a plurality of laminations stacked in a first direction, where each lamination is formed of a magnetic material. Petition 870250091551, dated 07 / 10 / 2025, page 8 / 65 3 / 26

[006] The electric heater may also include a core in which magnetic material is wound from a continuous strip of magnetic material.

[007] The electric heater can also operate at a power level between 1 MW and 1000 MW.

[008] The electric heater may also include a third flow member with a first tube arranged along a serpentine path extending between the first flow member and the second flow member.

[009] The electric heater may also include a plurality of tubes and a plurality of end caps, wherein each tube of the plurality of tubes is straight, and wherein the plurality of tubes and the plurality of end caps cooperate to define a serpentine path that extends between the first flow member and the second flow member.

[0010] For a more uniform fluid flow distribution, the plurality of tubes in the third flow member allows each individual tube to remain completely separate. This can be combined with a first and second flow member consisting of a single, larger diameter tube connected to the plurality of individual tubes in the third flow member via a connecting piece.

[0011] The electric heater may also include an inlet manifold and an outlet manifold, where the inlet of the first flow member is connected to the inlet manifold and the outlet of the second flow member is connected to the outlet manifold.

[0012] The electric heater may also include a third flux member that is removable from the first flux member and the second flux member without disassembling the core and primary winding. Petition 870250091551, dated 07 / 10 / 2025, page 9 / 65 4 / 26

[0013] The electric heater may also include a core that defines three core bars and two core openings, wherein the primary winding includes a first phase winding extending around a first core bar, a second phase winding extending around a second core bar, a third phase winding extending around a third core bar, and wherein the secondary winding includes a first continuous flux path extending around the first core bar, a second continuous flux path extending around the second core bar and a third continuous flux path extending around the third core bar.

[0014] The electric heater may also include a first, a second, and a third phase primary winding, which is surrounded by a first, second, and third core.

[0015] The electric heater can also be composed of a single-phase or two-phase electrical arrangement. The two-phase arrangement can be operated as a three-phase system.

[0016] The electric heater may also include a first surface which is an upper surface and a second surface which is a lower surface, and where the first direction extends between the lower surface and the upper surface and is vertical.

[0017] The electric heater may also include a first surface which is a right surface and a second surface which is a left surface, and where the first direction extends between the right surface and the left surface and is horizontal.

[0018] The electric heater may also include a first flow member which is one of a plurality of first flow members, each first flow member including an inlet that is connected to the inlet manifold, and where the second flow member is one of a plurality of second flow members, each second Petition 870250091551, dated 07 / 10 / 2025, page 10 / 65 5 / 26 flow member including an output that is connected to the output collector.

[0019] The electric heater may also include a third flow member which is one of a plurality of third flow members, each third flow member connected to a corresponding first flow member and to one of the second flow members to define one of a plurality of continuous flow paths, each of the continuous flow paths being fluidically isolated from the other continuous flow paths between, but not including, the inlet manifold and the outlet manifold. Other technical attributes may be readily apparent to one skilled in the art from the following figures, descriptions, and claims.

[0020] The primary winding, core, and secondary winding of at least one phase are installed adjacent to each other, provided that the connection between the aforementioned items is purely by a magnetic field. This offers the advantage that the high-temperature secondary winding is not physically connected to the other parts of the electric heater, which operate at a lower temperature and therefore can avoid high voltages and allow for a long service life.

[0021] In another aspect, a method of heating a fluid flow includes applying a primary winding to a core, positioning a secondary winding around the core, the secondary winding defining a continuous flow path between an inlet and an outlet, and directing the fluid flow to the inlet, through the continuous flow path and out the outlet. The method also includes directing a primary current flow to the primary winding, the primary current flow having a primary voltage that results in a power level of at least 1 MW. The method also includes inducing a current flow. Petition 870250091551, dated 07 / 10 / 2025, page 11 / 65 6 / 26 secondary winding in response to primary current flow, heating of the secondary winding in response to secondary current flow, and heating of the fluid flow in response to secondary winding heating.

[0022] The method of heating a fluid flow also includes stacking a plurality of laminations in a first direction, where each lamination is formed from a magnetic material.

[0023] The method of heating a fluid flow may also include operation at a power level between 1 MW and 1000 MW.

[0024] The method of heating a fluid flow may also include a third flow member which includes a first tube arranged along a serpentine path that extends between the first flow member and the second flow member.

[0025] The method of heating a fluid flow further includes a plurality of tubes and a plurality of end caps, and where each tube is straight, the method further includes connecting one quarter of the plurality of tubes to the first flow member and to a first end cap, connecting a second quarter of the plurality of tubes to the first end cap and to a second end cap, connecting a third quarter of the plurality of tubes to the second end cap and to a third end cap, and connecting a fourth quarter of the plurality of tubes to the third end cap and to the second flow member, the plurality of tubes and the plurality of end caps cooperating to define a serpentine path between the first flow member and the second flow member.

[0026] The method of heating a fluid flow may also include a first flow member that is one of a plurality of first flow members and the second flow member is a Petition 870250091551, dated 07 / 10 / 2025, page 12 / 65 7 / 26 of a plurality of second flow members, each first flow member including an input and each second flow member including an output, the method further includes connecting each input of each of the first flow members to an input sink and connecting each output of the second flow members to an output sink.

[0027] The method of heating a fluid flow also includes removing the third flow member from the first flow member and the second flow member without disassembling the core and the primary winding.

[0028] The method of heating a fluid flow may also include the use of a core that defines three core bars and two core openings, and where the primary winding includes a first phase winding, a second phase winding and a third phase winding, and the secondary winding includes a first continuous flow path, a second continuous flow path and a third continuous flow path, the method further includes extending the first phase winding around a first core bar, the second phase winding around a second core bar, the third phase winding around a third core bar, the first continuous flow path around the first core bar, the second continuous flow path around the second core bar and the third continuous flow path around the third core bar.

[0029] The method of heating a fluid flow may also include a third flow member which is one of a plurality of third flow members; the method further includes connecting each third flow member to a corresponding first flow member and to one of the second flow members to define one of a plurality of continuous flow paths, each of the paths Petition 870250091551, dated 07 / 10 / 2025, page 13 / 65 8 / 26 continuous flow manifolds being fluidically isolated from each other between, but not including, the inlet manifold and the outlet manifold. Other technical attributes may be readily apparent to one skilled in the art from the following figures, descriptions, and claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] To easily identify the discussion of any specific element or act, the most significant digit(s) in a reference number refer(s) to the figure number in which that element is first introduced.

[0031] FIG. 1 is a perspective view of a high-power electric heater operable for heating a fluid flow.

[0032] FIG. 2 is a perspective view of a core for use in the electric heater of FIG. 1.

[0033] FIG. 3 is a cross-sectional view of the electric heater in FIG. 1.

[0034] FIG. 4 is a schematic illustration of the electric heater in FIG. 1.

[0035] FIG. 5 illustrates an arrangement of a high-power electric heater operable for heating a fluid flow.

[0036] FIG. 6 illustrates another arrangement of a high-power electric heater with a toroidal core and operable for heating a fluid flow.

[0037] FIG. 7 illustrates an aspect of the object according to a modality. DETAILED DESCRIPTION

[0038] Before any embodiments of the invention are explained in detail, it should be understood that the invention is not limited in its application to the construction details and component arrangement presented in this description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or Petition 870250091551, dated 07 / 10 / 2025, page 14 / 65 9 / 26 executed in various ways. Furthermore, it should be understood that the phraseology and terminology used here are for descriptive purposes only and should not be considered limiting. Moreover, although multiple modalities or constructions may be described here, any attributes, methods, steps, components, and the like described in relation to one modality are equally applicable to other modalities, unless specifically stated otherwise.

[0039] Various technologies pertaining to systems and methods will now be described with reference to the drawings, where similar reference numerals represent similar elements throughout the document. The drawings discussed below and the various embodiments used to describe the principles of the present invention in this patent document are merely illustrative and should not be interpreted in any way as limiting the scope of the invention. Those skilled in the art will understand that the principles of the present invention can be implemented in any suitably arranged apparatus. It should be understood that the functionality described as being performed by certain elements of the system can be performed by multiple elements. Similarly, for example, one element can be configured to perform a functionality described as being performed by multiple elements.The numerous innovative teachings of the present invention will be described with reference to exemplary, non-limiting embodiments.

[0040] Although terms such as first, second, third, and so forth may be used here to refer to various elements, information, functions, or acts, these elements, information, functions, or acts should not be limited by these terms. Instead, these numerical adjectives are used to distinguish different elements, information, functions, or acts from one another. For example, a first element, information, function, or act could be called... Petition 870250091551, dated 07 / 10 / 2025, page 15 / 65 10 / 26 a second element, information, function or act and, similarly, a second element, information, function or act could be called a first element, information, function or act, without departing from the scope of the present invention.

[0041] In addition, the term adjacent to may mean that an element is relatively close to, but not in contact with, an additional element, or that the element is in contact with the additional portion, unless the context clearly indicates otherwise. Furthermore, the expression based on is intended to mean based, at least in part, on, unless explicitly stated otherwise. The terms about or substantially or similar terms are intended to cover variations in a value that are within normal industry manufacturing tolerances for that dimension. If no industry standard is available, a twenty percent variation would fall within the meaning of these terms, unless otherwise indicated.

[0042] Many industrial processes require heat, which is typically supplied in the form of hot water or steam, hot gas, oil, or other hot fluids such as brine, molten salt, air, supercritical CO2, helium, hydrogen, hydrocarbons, molten metal, a particle-laden gas stream, and the like. Until now, most of this heat has been supplied by boilers or furnaces that burn fossil fuels such as coal, oil, or natural gas to produce steam or directly heat another fluid. In many cases, the energy required to produce the necessary heat exceeds one MW and can reach several hundred or even a thousand MWs.

[0043] FIG. 1 illustrates an arrangement of a high-power electric heater capable of operating in the range of 1 to 1,000 MW, preferably in the range of 10 to 100 MW, and at induction frequencies between 30 and 400 Hz to provide heat for any desired process. It is clear Petition 870250091551, dated 07 / 10 / 2025, page 16 / 65 11 / 26 that other arrangements can operate in different power ranges, including from 10 to 1,000 MW. The electric heater 100 includes a core 200, a primary winding 102, and a secondary winding 104. The core 200, best illustrated in Figure 2, includes a plurality of laminations 202 stacked in a first direction 204, or stacking. In the illustrated construction, the first direction 204 extends from a lower surface 206 of the core 200 to an upper surface 208 of the core 200 and is vertical, other orientations and arrangements being possible. Each of the laminations 202 has a desired shape and is formed from a magnetic or ferromagnetic material, such as iron, electrical steel, or carbon steel.

[0044] The core can be laminated in one direction, but we are proposing a specific type of toroidal core that is cheaper to stack because it is wound. We also want to advocate ferrite or powder cores, as these can offer low-quality but large and low-cost alternatives.

[0045] In the illustrated construction, each lamination 202 has a shape that, when stacked with the other laminations 202, cooperates to define a first core bar 210, a second core bar 212, and a third core bar 214. Core openings 216 are defined between adjacent core bars. This results in a core 200 suitable for use as a three-phase core. Lamination 202 can be formed as a single continuous piece or multiple pieces aligned to form the desired final lamination shape.

[0046] Returning to FIG. 1, the primary winding 102 includes a first phase winding 106 arranged around the first core bar 210, a second phase winding 108 arranged around the second core bar 212, and a third phase winding 110 arranged around the third core bar 214. When operating Petition 870250091551, dated 07 / 10 / 2025, page 17 / 65 In a 12 / 26 three-phase power supply, the first phase directs the current through the first phase winding 106, the second phase directs the current through the second phase winding 108, and the third phase directs the current through the third phase winding 110. In other constructions, a different arrangement may be used. For example, a single-phase power supply may include a single winding around a single core bar.

[0047] The secondary winding 104 includes a plurality of first continuous flux paths 112 arranged around the first central bus 210, a plurality of second continuous flux paths 114 arranged around the second central bus 212 and a plurality of third continuous flux paths 116 arranged around the third central bus 214.

[0048] Each of the first continuous flow paths 112, second continuous flow paths 114, and third continuous flow paths 116 includes a first flow member 118, a second flow member 120, and a third flow member 122, which connect to an inlet manifold 124 and an outlet manifold 126. For each continuous flow path, each of the first flow members 118 includes an inlet opening that is coupled to the inlet manifold 124 and a second end opposite the inlet opening. In the illustrated construction, each of the first flow members 118 is oriented vertically, substantially straight, and perpendicular to a central axis of the inlet manifold 124. The first flow members 118 are arranged along a first side of one of the respective central bars 210, 212, and 214.

[0049] In the illustrated construction, the inlet manifold 124 is a cylindrical duct or tube closed at one end and defining an inlet 128 at the opposite end. Each of the first flow members 118 for a specific phase joins the inlet manifold 124. Petition 870250091551, dated 07 / 10 / 2025, page 18 / 65 13 / 26 for that specific phase at a point along the outer wall of inlet manifold 124. In other arrangements, other shapes or layouts are used for inlet manifold 124, as desired.

[0050] For each continuous flow path, each of the second flow members 120 for a specific phase includes an outlet opening coupled to the outlet manifold 126 for that specific phase and a second end opposite the outlet opening. In the illustrated construction, each of the second flow members 120 is oriented vertically, substantially straight, and perpendicular to a central axis of the outlet manifold 126. The second flow members 120 are arranged along a second side of one of the respective core bars 210, 212, 214, opposite the first side.

[0051] In the illustrated construction, the outlet manifold 126 is a cylindrical duct or tube closed at one end and defining an outlet 130 at the opposite end. Each of the second flow members 120 joins the outlet manifold 126 at a point along the outer wall of the outlet manifold 126. In other arrangements, other shapes or arrangements are used for the outlet manifold 126, as desired.

[0052] Although the construction illustrated in FIG. 1 includes first flow members 118 and second flow members 120 arranged in a straight vertical orientation parallel to each other, other arrangements are possible.

[0053] For each continuous flow path, each of the third flow members 122 includes a first end that connects to the second end of the first flow member 118 and a second end that connects to the second end of the second flow member 120. Thus, each set of one of the first flow members 118, second flow members 120, and third flow members 122 completes a continuous flow path that Petition 870250091551, dated 07 / 10 / 2025, page 19 / 65 Route 14 / 26 extends between entry 128 and exit 130.

[0054] In another arrangement, the first flow member 118 and the second flow member 120 are formed as a single member with a single inlet 128 and outlet 130. This single member connects to the ends of the third flow member 122 to form a continuous flow path. The inlet and outlet manifolds for the fluid connections would move to one of the connections between this single member and the flow member 122.

[0055] To provide the most uniform flow distribution in the plurality of tubes of the third flow member, each tube can be completely separated from the other tubes. The flow to or from the various tubes can be combined using a first flow member 118 and / or a second flow member 120a which includes a single larger diameter tube that receives or directs the flow to all the tubes in the plurality of tubes.

[0056] As illustrated in FIG. 3, each third flow member 122 includes one or more ducts or tubes 132 arranged in a serpentine path 302 (also shown in FIG. 4) that extends between the first flow member 118 and the second flow member 120. In the construction illustrated in FIG. 3 and FIG. 4, each tube 132 (only one shown in FIG. 4) follows a serpentine path 302 that includes three 180-degree turns, with other turns being possible (e.g., one, five, seven, etc.). An end cap 304 is positioned at each 180-degree turn and acts as a collector to receive flow from tubes 132 flowing in one direction and redirect that flow to tubes 132 flowing in the opposite direction. This arrangement allows the use of straight 132 pipes instead of 132 pipes with actual curves formed in them. However, arrangements of both straight and curved pipes are possible.

[0057] As should be clear, other arrangements of tubes 132 and the Petition 870250091551, dated 07 / 10 / 2025, page 20 / 65 15 / 26 serpentine path 302 may include different turns (e.g., 45 degrees, 90 degrees, etc.), fewer than three 180-degree turns, or more than three 180-degree turns, or any combination thereof. Furthermore, curved tubes 132 may be employed instead of straight tubes 132. It should be clear that the serpentine path 302 may have any desired length or arrangement and is selected to achieve the desired level of current flow and heat transfer, as will be discussed in greater detail. Additionally, the first flow members 118, the second flow members 120, and / or the third flow members 122 may be surrounded by thermal insulation (not shown) to direct the generated heat to the process fluid and improve thermal efficiency.

[0058] Returning to FIG. 1, the primary winding 102, including the first-phase winding 106, the second-phase winding 108, and the third-phase winding 110, includes a series of primary coils, each extending around its respective core bars. Similarly, the secondary winding 104, including the first continuous flux path 112, the second continuous flux path 114, and the third continuous flux path 116, includes a series of first flux members 118, second flux members 120, and power connectors 306 that cooperate to define secondary coils in the form of continuous flux paths. The number of primary coils and the number of secondary coils are selected to allow the passage of the desired current, at the desired voltage, in the primary winding 102, as well as the generation of the desired current and voltage in the secondary winding 104.

[0059] For example, in one arrangement, there are significantly more primary coils than secondary coils, resulting in a step-down transformer arrangement. Thus, the secondary voltage of the winding Petition 870250091551, dated 07 / 10 / 2025, p. 21 / 65 The voltage in the secondary winding 104 is significantly reduced when compared to the voltage in the primary winding 102. Similarly, the secondary current in the secondary winding 104 is considerably increased when compared to the primary current in the primary winding 102.

[0060] With reference to FIGS. 3 and 4, the operation of electric heater 100 will be described in more detail. It should be noted that FIG. 3 illustrates a three-phase arrangement, while FIG. 4 illustrates only one phase of the arrangement in FIG. 1. The description in FIG. 3 is applicable to each phase in arrangements employing a multi-phase arrangement.

[0061] A fluid flow 402 is introduced into the secondary winding 104 through the inlet 128. The fluid flow 402 may include any suitable fluid, including but not limited to water, brines or molten salts, and is selected based on the desired process being supported. The fluid flow 402 flows through the secondary winding 104 entering first the inlet manifold 124 and then entering one of the first flow members 118. From the first flow members 118, the fluid flow 402 enters the third flow member 122 associated with the specific first flow member 118 and flows through one of the tubes 132 to one of the upper end caps 304, where the fluid flow 402 makes a 180-degree turn and enters another downward-flowing tube 132.Fluid flow 402 is again rotated 180 degrees in a lower end cap 304, returns upwards through another set of tubes 132, rotated again 180 degrees through another end cap 304 before finally entering a set of tubes 132 that direct fluid flow 402 downwards and into the second flow member 120 of the specific continuous flow path associated with the first flow member 118. Fluid flow 402 passes through the second flow member 120, enters the manifold. Petition 870250091551, dated 07 / 10 / 2025, page 22 / 65 17 / 26 output 126 and finally exits the secondary winding 104 through output 130.

[0062] The primary winding 102 includes a plurality of coils or windings, with each coil wound around one of the first core bars 210, the second core bars 212, or the third core bars 214. Electrical energy is applied to the primary winding 102 at a primary voltage and current. As noted, the power level of the electrical energy applied to the primary winding 102 is in the range of 1 MW to 1000 MW.

[0063] In operation, energy is applied to the primary winding 102 to induce similar energy through the core 200 in the secondary winding 104. The number of coils in the primary winding 102 and the number of first flux members 118 and second flux members 120 are selected to achieve the desired voltage and current levels in the secondary windings 104 for a given voltage and current in the primary winding 102. For example, if the primary winding operates at 45 kV and passes a primary current of 25 A, the power level would be about 1.1 MW. If the coil ratio between the primary winding 102 and the secondary winding 104 is 100 to 1, the resulting voltage of the secondary winding 104 would be about 450 volts with a secondary current flow of about 2500 A, with the current divided among the various parallel continuous flux paths.The large current passing through the continuous flux paths of the secondary winding 104 heats the first flux member 118, the second flux member 120, and the third flux member 122, which in turn heats the fluid flow 402 within the continuous flux paths. The extra length of the third flux member 122, produced by the inclusion of multiple bends (three 180-degree bends in the illustrated example), results in additional heating of the fluid flow 402. Furthermore, different. Petition 870250091551, dated 07 / 10 / 2025, page 23 / 65 18 / 26 tube lengths, tube counts, tube sizes, number of tube bends, and similar factors can be used to select the level of heating provided to the fluid flow 402 for a specific electric heater 100. Thus, the electric heater 100 can be sized to produce a desired quantity of fluid at a desired temperature.

[0064] To assemble the electric heater 100, the core 200 is first assembled by stacking a plurality of laminations 202 in a stacked direction. In the illustrated construction, the stacking direction is vertical, but other arrangements are possible. The laminations are formed and stacked according to the method known in the area of ​​large electrical machines and transformers. The primary winding 102 is then positioned around the core as desired. If a single-phase heater is used, a single primary winding 102 is applied to the core 200. In multi-phase arrangements, the primary winding 102 may include multi-phase windings, such as a first-phase winding, a second-phase winding, and a third-phase winding.The number of coils in each phase winding is selected in conjunction with the number of coils (continuous flux paths) in secondary winding 104 to achieve the desired secondary voltage and current in secondary winding 104.

[0065] The first flux members 118 and the second flux members 120 are positioned sequentially around the core 200 and around the primary winding 102. The first flux members 118 are connected to the input collector 124 and the second flux members 120 are attached to the output collector 126. In some constructions, the input collector 124 and the output collector 126 are connected to each other to allow the first flux members 118, the second flux members 120, the input collector Petition 870250091551, dated 07 / 10 / 2025, page 24 / 65 19 / 26 124 and the outlet manifold 126 are installed as a single unit with the inlet manifold 124 and the outlet manifold 126 positioned below the core 200 and the second open ends of the first flow members 118 and the second flow members 120 positioned near or above the top of the core 200.

[0066] The third flux members 122 are mounted separately with two open ends (one inlet and one outlet near their lower end). The third flux members 122 are then attached to the open ends of the first flux members 118 and the second flux members 120 to complete the continuous flux paths and the secondary winding 104.

[0067] The arrangement illustrated here is advantageous from a service standpoint for a number of reasons. The tubes 132 of the third flow members 122 are the components most likely to wear out and require periodic maintenance. These items are placed on top of the electric heater 100 in a position that allows for their easy removal. The next components most likely to require maintenance would be the first flow members 118, the second flow members 120, and the intake manifold 124 and the outlet manifold 126. These are also easily removable with minimal disassembly of other components. Finally, the most difficult-to-access components, namely the core 200 and the primary winding 102, are the only components that would require disassembly of other components for access, repair, or replacement. Thus, the illustrated arrangement is easy to maintain and repair.

[0068] FIG. 5 illustrates a continuous flux electric heater 500 that is similar to the constructions described in relation to FIGS. 1 to FIGS. 4. The continuous flux electric heater 500 includes a primary winding 502 formed around a core 522 very similar to Petition 870250091551, dated 07 / 10 / 2025, page 25 / 65 20 / 26 described in relation to FIG. 4 and a secondary winding 504 positioned adjacent to the primary winding 502 and the core 522.

[0069] The secondary winding 504 includes a first continuous flux member 506, a second continuous flux member 508, an upper connector 510, and a lower connector 512 that cooperate to form a complete winding. In the illustrated construction, the first continuous flux member 506 and the second continuous flux member 508 are substantially the same and include one or more inlets 514 at one end of the continuous flux electric heater 500 and one or more outlets 516 at the opposite end of the continuous flux electric heater 500. In the illustrated construction, the inlets 514 are located at the lower end of the continuous flux electric heater 500, but can be positioned at the upper end if desired. Similarly, the position of the outlets 516 can be reversed if desired.

[0070] The first continuous flow member 506 and the second continuous flow member 508 are enclosed by thermal insulation 518 to improve the efficiency of the heating process. In addition, support members 520 are periodically positioned along the vertical direction to provide additional support to the components of the continuous flow electric heater 500. A cover 524 may also be provided to protect the internal components from the environment.

[0071] The continuous flux electric heater 500 operates similarly to that described for the electric heater 100 previously described. When energy is applied to the primary winding 502, a current is induced in the secondary winding 504. The current flows through the first flux member 506 and the second flux member 508, causing them to be heated by the current flowing between the first flux member 506 and the second flux member. Petition 870250091551, dated 07 / 10 / 2025, page 26 / 65 21 / 26 508 via the upper connector 510 and the lower connector 512.

[0072] A fluid to be heated is introduced into the first flow member 506 and the second flow member 508 through the inlets 514. As the fluid passes through each of the first flow members 506 and the second flow member 508, it is heated by the heat generated by the resistance to the current passing through the secondary winding 504. The fluid then exits the first flow member 506 and the second flow member 508 through the outlets 516. In the illustrated construction, each of the first continuous flow members 506 and the second continuous flow member 508 includes two inlets 514 that feed four individual ducts within each of the continuous flow members 506 and the second continuous flow member 508, before exiting through four separate outlets 516. It should be noted that the number of inlets 514, the number of ducts, and the number of outlets 516 may vary and are not critical to the invention.Instead, the number of 514 inlets, 516 outlets, and ducts is selected based on convenience, efficiency, and other parameters.

[0073] The continuous flux electric heater 500 includes a complete secondary winding 504, without any ducts or other components attached to the top of the first continuous flux member 506 and the second continuous flux member 508. Thus, serpentine ducts, as illustrated in Figs. 1 to 4, may be included if desired. Furthermore, ducts that may not be electrically conductive may be connected if desired, since these ducts are not part of the secondary winding 504. Additionally, the outlets 516 may be connected to various other components or ducts where current flow is undesirable.

[0074] FIG. 6 illustrates another arrangement of a 600 toroidal electric heater that operates similarly to core constructions. Petition 870250091551, dated 07 / 10 / 2025, page 27 / 65 22 / 26 stacked laminations described in FIGS. 1 to 5. In the arrangement of FIG. 6, a magnetic core 606 is constructed by winding one or more strips of magnetic laminations to form an oval, rounded, or racetrack-shaped rectangle. The wound core 606 has a length direction oriented parallel to the longitudinal axis of the ducts 610 (i.e., in the plane of FIG. 6). The length of the core 606 for each lamination in the plane of FIG. 1 can be from 50 to 150 cm, with other lengths being possible. Several core modules 612, each defined by the stacking of one or more laminations in the length direction, can be stacked to extend the length of the core 606 as required for the specific application.

[0075] Continuing with the reference to FIG. 6, two core modules 612 are positioned adjacent to each other, with a long side of one of the core modules 612 positioned adjacent to a similar long side of the other core module 612 to define a central core bar 614 with two openings 616; one on each side of the central bar 614.

[0076] A primary winding 602 extends around the center bar 614 to form a closed primary winding 602. A secondary winding 604, in the form of a flux pipe 604, also forms a closed electrical circuit around the center bar 614.

[0077] Thermal insulation 608 is positioned around the secondary winding 604 to thermally separate the secondary winding 604 from the primary winding 602 and the laminations that make up the core modules 612. During operation, the electric current in the primary winding 602 induces a current in the secondary winding 604 and, in particular, in the ducts 610. The current in the secondary winding 604 heats the ducts 610 and any fluid flowing through them. Thermal insulation 608 protects the primary winding. Petition 870250091551, dated 07 / 10 / 2025, page 28 / 65 23 / 26 river 602 and the central modules 612 of this heat.

[0078] The electric heaters described here are suitable for efficient operation at very high power levels, exceeding 1 MW and up to approximately 1000 MW. In addition, the arrangements are inexpensive to produce and easy to maintain.

[0079] FIG. 7 illustrates another arrangement of an electric heater in the form of a single-phase 700 heater. Before proceeding, it should be noted that the term single-phase heater means that the primary winding is supplied as a single phase connected to a single-phase power supply or to a single phase of a multi-phase power supply. Thus, a single-phase 700 heater, as illustrated in FIG. 7, could be used with a single-phase power supply. Furthermore, if a three-phase power supply is available, three single-phase 700 heaters, as illustrated in FIG. 7, could be employed, with each single-phase 700 heater having a primary winding 706 powered by one of the available power phases. Thus, multiple independent single-phase 700 heaters can be used in conjunction with a single multi-phase or three-phase power supply. Obviously, a single core with three-phase windings similar to that illustrated in FIG. 7.1 can also be used with a multiphase or three-phase power supply.

[0080] With reference to FIG. 7, the single-phase heater 700 includes a core 702, a primary winding 706, and a secondary winding 708. The core 702 includes a plurality of laminations stacked in a stacking direction 716 to a desired height or length. The core 702 defines a core envelope 704 that surrounds the laminations and may extend slightly beyond them. Generally, the core envelope 704 is the area containing the laminations and may extend to a point where the magnetic field Petition 870250091551, dated 07 / 10 / 2025, p. 29 / 65 The 24 / 26 core remains strong enough to function as a magnetic core. The shape of the laminations, and therefore of the 702 core, is selected for the desired design, with the illustrated 702 core having a central bar 726 and two outer bars 728. Each outer bar 728 cooperates with the central bar 726 to define a core gap 730 between them. Thus, the 702 core looks very much like the 200 core and is capable of operating as a single-phase or three-phase core, as desired.

[0081] The primary winding 706 includes a plurality of wires, bars, or other conductors capable of carrying the desired amount of energy (e.g., 1-1000 MW and preferably 10100 MW) in the form of a primary current flow 732. As illustrated in FIG. 7, the primary winding 706 includes one or more loops extending around the central bar 726 such that a portion of each loop is disposed within each of the core openings 730 and most, if not all, of the primary winding 706 is disposed within the core sheath 704. As discussed, the primary winding 706 is connected to a power supply that operates to provide the desired energy.

[0082] The secondary winding 708 includes a central flux member 710 and an external flux member 712 that connect to each other to define a continuous flow path 724 for a fluid flow 714 and a secondary current flow 734. The central flux member 710 includes one or more ducts arranged in a U-shape, such that most, if not all, of the central flux member 710 is disposed within the central envelope 704. Specifically, the central flux member 710 includes two duct lengths that extend in the stack direction and are disposed within the core openings 730.

[0083] External flow member 712 includes one or more ducts Petition 870250091551, dated 07 / 10 / 2025, page 30 / 65 25 / 26 arranged in a serpentine pattern. The number, size, length, and arrangement of the ducts of the external flow member 712 are selected to achieve the desired level of heating of the fluid flow 714.

[0084] One end of the outer flow member 712 connects to the central flow member 710 by means of a power connector 722. The power connector 722 allows the passage of fluid flow 714 and also acts as a conductor to ensure that the central flow member 710 and the outer flow member 712, when connected, form a closed circuit. A second end of the outer flow member 712 connects to the central flow member 710 and defines an inlet 718 and an outlet 720. Each inlet 718 and the outlet 720 can be formed as part of the central flow member 710 or the outer flow member 712, or they can be formed as a single part, or two separate parts that connect to the central flow member 710 or the outer flow member 712.Although fluid flow 714 does not flow through outlet 720 and return to inlet 718, inlet 718 and outlet 720 must be electrically connected to each other to allow the formation of a closed circuit and the flow of secondary current 734.

[0085] In operation, the single-phase heater 700 of FIG. 7 receives energy from a single-phase power supply or receives a single phase from a multi-phase power supply and directs this energy to the primary winding 706, which results in the primary current flow 732.

[0086] The primary current flux 732 in the primary winding 706 produces a magnetic field in the core 702 which, in turn, induces a secondary current flux 734 in the secondary winding 708. Thus, the only interaction between the primary winding 706 and the secondary winding 708 occurs as a result of the magnetic interaction. Petition 870250091551, dated 07 / 10 / 2025, page 31 / 65 26 / 26 net connection between the primary winding 706, the secondary winding 708 and the core 702.

[0087] The secondary current flow 734 flows along the closed circuit or continuous flow path 724 defined by the inlet 718, the core flow member 710, the power connector 722, the outer flow member 712 and the outlet 720 and heats the ducts that define the central flow member 710 and the outer flow member 712.

[0088] Fluid flow 714 is introduced into secondary winding 708 at inlet 718 and flows through center flow member 710, power connector 722 and outer flow member 712 before exiting secondary winding 708 at outlet 720. As fluid flow 714 flows through secondary winding 708, it is heated by the various ducts in which it flows.

[0089] Although an exemplary embodiment of the present invention has been described in detail, those skilled in the art will understand that various alterations, substitutions, variations and improvements disclosed herein may be made without departing from the spirit and scope of the invention in its broadest form.

[0090] None of the descriptions contained in this application should be interpreted as implying that any particular element, step, act or function is an essential element that must be included in the scope of the claim: the scope of the patented object is defined only by the permitted claims. Furthermore, none of these claims is intended to invoke a means-plus-function claim construction unless the exact words "means to" are followed by a participle. Petition 870250091551, dated 07 / 10 / 2025, page 32 / 65

Claims

1 / 10 CLAIMS 1. An electric heater, characterized in that it comprises: a core with a first end and a second end spaced from the first end in a stacked direction to define a core envelope; a primary winding positioned around and magnetically coupled to the core, the operable primary winding being at a power level greater than 1 MW to produce a primary current flow; a magnetically coupled core flux member positioned to encircle a portion of the core; an external flux member positioned outside the core envelope and connected to the core flux member to define a continuous flux path between an inlet and an outlet, the core flux member and the external flux member cooperating to define a secondary winding;A fluid flow is supplied to the inlet and collected from the outlet, the fluid flow being heated in response to a secondary current flow in the secondary winding, which is induced by the primary current flow.

2. An electric heater, according to claim 1, characterized in that the core includes a plurality of laminations stacked in the stacking direction, the laminations arranged to define a central bar, a first outer bar and a second outer bar, and wherein the primary winding encircles the central bar and passes through a first core opening between the central bar and the first outer bar and a second core opening between the central bar and the second outer bar.

3. Electric heater, according to claim 2, as per Petition 870250091551, dated 07 / 10 / 2025, page 33 / 65 2 / 10 characterized by the fact that the core flow member surrounds a portion of the central bar and extends through the first core opening and the second core opening.

4. Electric heater, according to claim 1, characterized in that the inlet and outlet are arranged outside the core casing.

5. Electric heater, according to claim 1, characterized in that the external flow member includes a plurality of continuous ducts, each duct arranged along a serpentine path.

6. An electric heater, according to claim 1, characterized in that the core defines a first core bar, a second core bar, and a third core bar, and in that the first core bar and the second core bar cooperate to define a first core opening, and the second core bar and the third core bar cooperate to define a second core opening, and in that the primary winding includes a first phase winding extending around the first core bar, a second phase winding extending around the second core bar, a third phase winding extending around the third core bar, and in that the secondary winding includes a first continuous flux path extending around the first core bar.a second continuous flow path extending around the second core bar and a third continuous flow path extending around the third core bar.

7. Electric heater, according to claim 1, characterized in that the power level is between 10 MW and 100 MW.

8. Electric heater, according to claim 1, ca Petition 870250091551, dated 07 / 10 / 2025, p. 34 / 65 3 / 10 characterized in that the core includes a first core portion that defines a first core opening and a second core portion separate from the first core portion that defines a second core opening, the first core portion and the second core portion positioned adjacent to each other, a portion of the first core portion and a portion of the second core portion cooperating to define a central bar, the primary winding positioned to encircle the central bar.

9. Electric heater, according to claim 1, characterized in that the first core portion is made of a continuous strip of magnetic material wound to form an oval first core portion.

10. An electric heater, according to claim 1, characterized in that the core includes a central bar, a first outer bar and a second outer bar, and in that the primary winding encircles the central bar and passes through a first core opening between the central bar and the first outer bar and a second core opening between the central bar and the second outer bar, and in that the flux member of the core encircles a portion of the central bar and extends through the first core opening and the second core opening, the core, the primary winding and the secondary winding cooperating to define a single-phase heater.

11. Electric heater, according to claim 10, characterized in that the single-phase heater is a first single-phase heater, the electric heater further comprising a second single-phase heater separate from the first single-phase heater and a third single-phase heater separate from the first single-phase heater and the second single-phase heater, and wherein a first phase of a three-phase power supply provides energy to the primary winding of the first single-phase heater, a second phase of the three-phase power supply provides energy to the primary winding of the second single-phase heater and a third phase of the three-phase power supply provides energy to the primary winding of the third single-phase heater.

12. Electric heater, according to claim 1, characterized in that the only interaction between the primary winding and the secondary winding is a result of a magnetic interaction with the core.

13. Method for heating a fluid flow, the method characterized in that it comprises: applying a primary winding to a core with a core envelope; positioning a secondary winding adjacent to the core, the secondary winding including a central flux member encircling a portion of the core and an external flux member positioned outside a central envelope, the central flux member and the external flux member cooperating to define a continuous flow path between an inlet and an outlet; directing the fluid flow to the inlet, through the continuous flow path and out of the outlet; directing a primary current flow to the primary winding, the primary current flow having a primary voltage that results in a power level of at least 1 MW; inducing a secondary current flow in the secondary winding in response to the primary current flow;To heat the secondary winding in response to the secondary current flow; and to heat the fluid flow in response to the heating of the secondary winding. Petition 870250091551, dated 07 / 10 / 2025, page 36 / 65 5 / 10; 14. Method according to claim 13, characterized in that it further comprises stacking a plurality of laminations in a stacked direction, wherein each lamination is formed of a magnetic material.

15. Method according to claim 13, characterized in that it further comprises forming the core from a continuous strip of magnetic material wound in a toroidal shape.

16. Method according to claim 13, characterized in that it further comprises providing a core comprising a first core bar, a second core bar and a third core bar, wherein the first core bar and the second core bar cooperate to define a first core opening and the second core bar and the third core bar cooperate to define a second core opening, winding a first phase winding of the primary winding around the first core bar, a second phase winding of the primary winding around the second core bar, a third phase winding of the primary winding around the third core bar and positioning a first continuous flux path of the secondary winding around the first core bar,a second continuous flux path from the secondary winding around the second core bar and a third continuous flux path from the secondary winding around the third core bar.

17. Method, according to claim 13, characterized in that it further comprises forming the core to include a central bar, a first outer bar and a second outer bar, and wherein the primary winding application step includes encircling the central bar and passing the primary winding through a first core opening between the central bar and the first outer bar and a second core opening between the central bar and the second outer bar, and wherein the secondary winding positioning step includes encircling a portion of the central bar and extending the secondary winding through the first core opening and the second core opening, the core, the primary winding and the secondary winding cooperating to define a single-phase heater.

18. Method according to claim 17, characterized in that it further comprises connecting the single-phase heater to a first phase of a three-phase power supply, connecting a second single-phase heater to a second phase of the power supply and connecting a third single-phase heater to a third phase of the power supply, the single-phase heater, the second single-phase heater and the third single-phase heater being separated from each other.

19. Method according to claim 13, characterized in that it operates the electric heater at a power level between 10 MW and 100 MW.

20. Method according to claim 13, characterized in that the secondary winding includes a central flux member and an external flux member, and wherein the positioning step of the secondary winding includes positioning the central flux member to encircle a portion of the core and fixing the external flux member to the core flux member to define the continuous flux path between the inlet and outlet, with the external flux member disposed outside the core envelope.

21. Method according to claim 20, characterized in that it further comprises forming the outer flow member to include a serpentine path.

22. Electric heater, characterized in that Petition 870250091551, dated 07 / 10 / 2025, page 38 / 65 7 / 10 comprises: a core oriented to define a first surface and a second surface opposite to the first surface; a primary winding positioned adjacent to the core and operable at a power level greater than 1 MW to produce a primary current flow; a first flux member extending around a first portion of the core and defining an input; a second flux member extending around a second portion of the core and defining an output, the second portion being different from the first portion;a third flow member disposed adjacent to the first surface and connected to the first flow member and the second flow member to complete a continuous flow path between the inlet and outlet, the first flow member, the second flow member and the third flow member cooperating to define a portion of a secondary winding; and a fluid flow supplied to the inlet and collected from the outlet, the fluid flow being heated in response to a secondary current flow in the secondary winding, which is induced by the primary current flow.

23. Electric heater, according to claim 22, characterized in that the primary winding, the core and the secondary winding are arranged adjacent to each other and interact by means of a magnetic field.

24. Electric heater, according to claim 22, characterized in that it further comprises a power connector connected to the first flow member and to the second flow member.

25. Electric heater, according to claim 22, Petition 870250091551, dated 10 / 07 / 2025, page 39 / 65 8 / 10, characterized in that the core includes a plurality of laminations stacked in a first direction, and in that each lamination is formed of a magnetic material.

26. Electric heater, according to claim 22, characterized in that the core is made of a continuous strip of magnetic material wound to form a toroidal core.

27. Electric heater, according to claim 22, characterized in that the core defines three core bars and two core openings, wherein the primary winding includes a first phase winding extending around a first core bar, a second phase winding extending around a second core bar, a third phase winding extending around a third core bar, and wherein the secondary winding includes a first continuous flux path extending around the first core bar, a second continuous flux path extending around the second core bar and a third continuous flux path extending around the third core bar.

28. Electric heater, according to claim 22, characterized in that the core includes a central core bar, a first outer bar and a second outer bar, the central bar cooperating with the first outer bar to define a first core opening and cooperating with the second outer bar to define a second core opening, and wherein the primary winding includes a single-phase winding extending around the central core bar, and wherein the secondary winding includes a first continuous flux path extending around the central core bar, a portion of each primary winding and of the secondary winding passing through each of the openings of the first core and the second core opening. Petition 870250091551, 07 / 10 / 2025, p. 40 / 65 9 / 10 29. Electric heater, according to claim 22, characterized in that the power level is between 10 MW and 100 MW.

30. Electric heater, according to claim 22, characterized in that the third flow member includes a first tube arranged along a serpentine path extending between the first flow member and the second flow member.

31. An electric heater, according to claim 22, characterized in that the third flow member further comprises a plurality of tubes and a plurality of end caps, wherein each tube of the plurality of tubes is straight and wherein the plurality of tubes and the plurality of end caps cooperate to define a serpentine path extending between the first flow member and the second flow member.

32. Electric heater, according to claim 22, characterized in that it further comprises an inlet manifold and an outlet manifold, wherein the inlet of the first flow member is connected to the inlet manifold and the outlet of the second flow member is connected to the outlet manifold.

33. An electric heater, according to claim 32, characterized in that the first flow member is one of a plurality of first flow members, each first flow member including an inlet that is connected to the inlet manifold, and in that the second flow member is one of a plurality of second flow members, each second flow member including an outlet connected to the outlet manifold.

34. Electric heater, according to claim 33, characterized in that the third flow member is one of a plurality of third flow members, each third flow member connected to a corresponding first flow member and to one of the second flow members to define one of a plurality of continuous flow paths, each of the continuous flow paths being fluidically isolated from the other continuous flow paths between, but not including, the inlet manifold and the outlet manifold.

35. Electric heater, according to claim 22, characterized in that the third flux member is removable from the first flux member and the second flux member without disassembling the core and the primary winding. Petition 870250091551, dated 07 / 10 / 2025, pp. 42 / 65

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