Liquid heater and a method for manufacturing a liquid heater
Patent Information
- Application Number
- EP2023883238
- Authority / Receiving Office
- EP · EP
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2022-10-28
- Filing Date
- 2023-10-27
- Publication Date
- 2025-09-03
AI Technical Summary
Conventional liquid heaters have an inefficient heat transfer mechanism due to a low surface area to volume ratio, which hampers the effective transfer of heat from the energy source to the liquid being heated.
A liquid heater with a lattice structure metal body and a heating element surrounded by a plurality of baffles that split and redirect the liquid flow, creating a repetitive, partially circular trajectory to increase the surface area for heat transfer, along with a method for manufacturing using additive manufacturing to minimize assembly costs and maximize energy efficiency.
The design enhances energy efficiency by increasing the surface area to volume ratio, improving heat transfer and fluid flow performance, while reducing manufacturing complexity and costs.
Smart Images
Figure 1.1
Abstract
Description
[0001] LIQUID HEATER AND A METHOD FOR MANUFACTURING A LIQUID HEATER
[0002] TECHNICAL FIELD
[0003] The present disclosure relates to a liquid heater and a method for manufacturing a liquid heater.
[0004] BACKGROUND
[0005] Liquid heaters, such as water heaters are utilized to, by an energy source, heat a liquid above an ambient temperature thereof. Liquid heaters could be used to for example domestically or industrially.
[0006] A common drawback with liquid heaters of the present art is that the liquid is heated in an inefficient manner which prevents optimal heat transfer from the energy source to the liquid to be heated. Specifically, conventional liquid heaters utilize a low surface area to volume ratio thereby hampering heat transferring properties of the liquid heater. Thus, liquid heaters in the present art fail to fulfil requirements of providing sufficient heat transfer from an energy source to a liquid to be heated.
[0007] Accordingly, there is room for liquid heaters in the present art to explore the domain of providing a liquid heater that provides an improved heat transfer compared to conventional liquid heaters.
[0008] Even though previous solutions may work well in some situations, it would be desirable to provide a liquid heater that address requirements related to improving heat transfer efficiency. In other words, there is a need for a liquid heater with improved energy efficiency.
[0009] SUMMARY
[0010] It is therefore an object of the present disclosure to alleviate at least some of the mentioned drawbacks to provide an improved liquid heater that is improved in terms of heat transfer capabilities.
[0011] This and other objects, which will become apparent in the following, are achieved by a liquid heater and a method of manufacturing a liquid heater as defined in the appended claims. The present disclosure relates to a liquid / fluid heater comprising an enclosed metal body forming a lattice structure at an inner volume thereof. Further, the liquid heater comprises a heating element extending along a centre portion of said metal body, the heating element being circumferentially surrounded by said lattice structure. Moreover, the liquid heater comprises an inlet arranged at one of an upper portion and a lower portion of said metal body, the inlet being arranged to receive liquid to be heated. Further, the liquid heater comprises an outlet arranged at a lower portion of said metal body, the outlet being arranged to output heated liquid. Further, the lattice structure comprises a plurality of baffles for splitting paths of liquid received by the inlet, the baffles being formed as an extension of said inlet. The plurality of baffles extend from said upper portion to said outlet, wherein said plurality of baffles merge at said lower portion up-streams of said outlet. Furthermore, wherein each baffle of said plurality of baffles form a repetitive trajectory for transferring liquid from said upper portion to said lower portion, the repetitive trajectory comprising an at least partially circular path. The plurality of baffles (at least) jointly encircle said heating element along a vertical axis of said metal body. The liquid heater may also be referred to as a single-liquid heater.
[0012] An advantage of the liquid heater of the present disclosure is that it utilises a large surface area to volume ratio of the metal body, thereby increasing energy efficiency compared to conventional solutions. Increased energy efficiency may refer to at least improved fluid flow performance and heat transfer compared to conventional liquid heaters. The increased energy efficiency may be realized by, or at least advantageously affected by that the liquid in the inlet is split into a plurality of baffles each having a trajectory that at least jointly encircle the heating element. Accordingly, the heating element can spread heat about its circumference. Another advantage is that the liquid heater herein allows for only a single liquid to be put in the inlet, and let out the outlet. Thus, the lattice structure of the liquid heater may be arranged to receive a single liquid. Further, the liquid heater herein provides the advantage of manufacturing convenience as it requires few components (reducing assembly costs).
[0013] The liquid heater may function so to receive liquid in the inlet, wherein the heating element heats the metal body. Consequently, heat transfers from said metal body to the liquid. Thereafter, the liquid with a higher temperature can leave the metal body. The at least partially circular path may be a zigzag path, a spiral path or any combination thereof. The zigzag path or spiral path may extend from said upper portion to said lower portion.
[0014] An advantage of this is that it further increases the area to volume ratio, as the liquid trajectory is extended for each baffle.
[0015] The heating element may preferably be a heating cartridge. The metal body may be copper or aluminium. The liquid heater may comprise control circuitry and a power supply unit for regulating an applied electricity for heating. The liquid heater may further comprise flow and temperature sensors, wherein the control circuitry is configured to obtain liquid flow data and temperature data from said liquid heater, and based on said data, regulate the applied electricity to obtain e.g., a pre-determined heating temperature value of liquid exiting said liquid heater.
[0016] The at least partially circular path may have a radial extension being horizontally downwards (and at least non parallel with said vertical axis of said liquid heater, preferably forming an angle of <60° relative said vertical axis), allowing for the liquid to be transferred from the upper portion to the lower portion. The liquid may be transferred at least partly by gravitational force. Horizontally downwards may refer to that the radial extension is oriented towards said lower portion but that it is not parallel with a horizontal axis of the liquid heater, the horizontal axis being perpendicular to said vertical axis. The term "horizontally downwards" may be interchanged with "diagonal" or "declining".
[0017] Each baffle may transfer liquid from said upper portion to a merging section of said lower portion in which said plurality of baffles merge.
[0018] An advantage of said merging section is that it gathers all baffles into a common outlet subsequent to heating the liquid, thus the liquid heater is allowed to be more compact.
[0019] Moreover in one aspect of the present disclosure, each repetitive trajectory may be (circumferentially) delimited, so to not extend beyond pairs of radial planes extending from said centre portion, the planes may extend along the height of the liquid heater. Pairs of radial planes may jointly form a V-shape when viewed from a top-view. The delimitation be in the form of walls of the plurality of baffles. Each pair of radial planes may form an angle of 10-45°. Thus, a plurality of repetitive trajectories may be fitted within said liquid heater, allowing for a larger volume to be heated.
[0020] Each baffle may be arranged to, by said repetitive trajectory thereof, transfer liquid back and forth between said centre portion and a turning portion of said liquid heater.
[0021] Such a liquid transferring trajectory allows for further increased energy efficiency.
[0022] The lattice structure, may be a modified triply periodic minimal surfaces (TPMS) structure. Preferably the TPMS structure is based on a diamond TPMS structure, a gyroid TPMS structure or a Schwarz TPMS structure.
[0023] In another aspect of the present disclosure, each baffle of the plurality of baffles encircle a circumference of said heating element, encircling said heating element from said upper portion to said merging section.
[0024] Further, in said another aspect, each baffle of the plurality of baffles have differing radial distance from said heating element relative the other of said plurality of baffles. Thus, the baffles may be dividedly distributed at different radial distances from said heating element. E.g., one baffle may encircle the heating element from the upper portion to the lower portion at a constant distance of x mm from said heating element, wherein a second baffle may have a distance of x+y mm from said heating element, etc.
[0025] Thus, providing a structure that is simple in its design while maintaining a high energy efficiency.
[0026] Moreover, in any aspect herein, the walls of each baffle of the plurality of baffles may be wavy. Further, the walls may have a thickness of 0.1-1 mm.
[0027] The present disclosure further relates to a method for manufacturing the liquid heater according to any aspect herein. The method comprising the steps of, forming, by means of additive manufacturing, said metal body. Further, the method comprises positioning / attaching the heating element at / to a cavity within said metal body.
[0028] An advantage of the method is that it provides a convenient manufacturing that requires minimal assembly costs due to possibilities to consolidate parts. Also, produce complex geometries with less material waste that are expensive or even impossible to produce with conventional subtractive manufacturing. Generally, all terms used in the description are to be interpreted according to their ordinary meaning in the technical field, unless explicitly defined otherwise herein. All references to "a / an / the [element, device, component, means, step, etc.]" are to be interpreted openly as referring to at least one instance of said element, device, component, means, step, etc., unless explicitly stated otherwise.
[0029] BRIEF DESCRIPTION OF THE DRAWINGS
[0030] These and other features and advantages of the present disclosure will now be further clarified and described in more detail, with reference to the appended drawings;
[0031] Figure 1 illustrates an objective view of a liquid heater in accordance with aspects herein and a cut-out view of said liquid heater;
[0032] Figure 2 illustrates an enlarged partial view of the cut-out view of Figure 1 in accordance with aspects herein;
[0033] Figure 3 illustrates an objective view of a liquid heater and a cross-sectional side view of the liquid heater in accordance with aspects herein;
[0034] Figure 4 illustrates a side view of a liquid heater and a cross-sectional view
[0035] C-C of said liquid heater in accordance with aspects herein;
[0036] Figure 5 illustrates an objective view of a liquid heater in accordance with aspects herein and a cross-sectional view D of said liquid heater;
[0037] Figure 6 illustrates an objective view of a liquid heater in accordance with aspects herein; and
[0038] Figure 7 illustrates a flowchart of a method for manufacturing a liquid heater in accordance with some aspects herein. DETAILED DESCRIPTION
[0039] In the following detailed description, some embodiments / aspects of the present disclosure will be described. However, it is to be understood that features of the different embodiments / aspects are exchangeable between the embodiments / aspects and may be combined in different ways, unless anything else is specifically indicated. Even though in the following description, numerous specific details are set forth to provide a more thorough understanding of the present disclosure, it will be apparent to one skilled in the art that the present disclosure may be practiced without these specific details. In other instances, well known constructions or functions are not described in detail, so as not to obscure the present disclosure.
[0040] The term "liquid" as used herein may refer to water or any other suitable form of liquid.
[0041] The term "baffle" as used herein may refer to a water controlling element for directing the water flow in a specific direction / path / trajectory. The term "baffle" may be interchanged with "channel". In some aspects, the term "baffle" may refer to an enclosing element that forms a channel. In other words, a baffle may define a channel.
[0042] Figure 1 illustrates an objective view of a liquid heater 1 in accordance with some aspects herein. Further, figure 1 illustrates a cut-out view of a part A of the liquid heater.
[0043] Figure 1 illustrates that the liquid heater 1 comprises an enclosed (cylindric) metal body 2 forming a lattice structure 3 at an inner volume thereof. Further, comprising a heating element 4 extending along a centre portion cl of said metal body 2. The heating element 4 being circumferentially surrounded by said lattice structure 3. The heating element 4 may be square shaped, cylinder shaped or have any other suitable shape.
[0044] Further, as illustrated in Figure 1, the liquid heater 1 comprises an inlet 5a arranged at a lower portion u2 of said metal body 2. The inlet 5a being arranged to receive liquid to be heated.
[0045] Further, the liquid heater 1 comprise an outlet 5b also arranged at a lower portion u2 of said metal body 2, the outlet 5b being arranged to output heated liquid. The lattice structure 3 further comprises a plurality of baffles 6 for splitting paths of liquid received by the inlet 5a, the baffles 6 being formed as an extension of said inlet 5a. The plurality of baffles 6 may extend (at least) from said upper portion ul to said outlet 5b, wherein said plurality of baffles 6 merge at said lower portion u2 up-streams of said outlet 5b i.e. prior to reaching the outlet 5b. Each baffle 6 of said plurality of baffles may form a repetitive trajectory for transferring liquid from said upper portion ul to said lower portion u2, the repetitive trajectory comprises an at least partially circular path (shown in Figure 2). Further, figure 1 illustrates that the plurality of baffles 6 jointly encircle said heating element 4 along a vertical axis zl of said metal body 2.
[0046] As illustrated in Figure 1, the liquid heater 1 may transfer liquid from said inlet 5a, along outer portions 7 of said heater to said top portion ul - increasing energy efficiency.
[0047] Moreover, Figure 1 illustrates that each baffle transfers liquid from said upper portion ul to a merging section ml of said lower portion u2 in which said plurality of baffles 6 merge so to form the outlet. In other words, the baffles 6 may unite so to form a common baffle defining said outlet. In other words, the plurality of baffles 6 may lead / form path to a common outlet. The term "merge" may generally refer to that the baffles 6 unite / consolidate to form a common baffle which may define a common space. Further, Figure 1 shows that each repetitive trajectory 110 (that are schematically illustrated and denoted 110) may be delimited by pairs of radial planes ria, rib extending from said centre portion cl, thereby each repetitive trajectory can be radially spread out (forming a sunlike-shape when viewed from above) about the heating element 4.
[0048] The term "repetitive trajectory" may refer to a path / trajectory which defines a reocurrence / repetition. For example, if said repetitive trajectory is a zig-zag path, the repitition of said zig-zag path defines said repetitive trajectory. In some aspects herein, the term "repetitive trajectory" may be interchanged with "trajectory".
[0049] Figure 2 illustrates an enlarged view of the cut-out of Figure 1 in which said repetitive trajectory is illustrated by arrows, showing that the liquid may be transferred to the baffle 6 from said outer portion 7, and along the baffle 6 in a repetitive trajectory that e.g., partly by gravitational force transfers the liquid downwards. The repetitive trajectory is circular / spiral formed as shown in figure 2. The liquid transfers from il before it turns 180 degrees (see i2 in Figure 2) at said inner portion cl, further being transferred towards the outer portion 7 again (to i3) before going to i4 and subsequently being transferred similarly downwards to the merging section (not shown in Figure 2). In other words, each baffle 6 is arranged to, by said repetitive trajectory thereof, transfer liquid back and forth, spirally, between said centre portion cl and towards an outer portion 7 of said liquid heater 1 so to transfer liquid from said upper portion ul to said lower portion u2. The liquid may turn 180degrees at said inner portion cl and at a turning portion 7' associated to said outer portion 7 (forming a spiral path). The turning portion 7' may be part of a baffle 6 associated to the outer portion 7 that forces the liquid to turn 180 degrees. Figure 2 illustrates another baffle 6 of said plurality of baffles 6. Thus, the baffles may be arranged to circumferentially enclose said heating element 4.
[0050] Further, Figures 1 and 2 illustrates that the wherein the at least partially circular path has a radial extension rl being horizontally downwards, in other words, the radial extension thereof directed towards said centre portion cl is tilted away from said upper portion ul. As also illustrated in Figures 1 and 2, the lattice structure is a modified TPMS based structure. Further, Figure 2 illustrates that the walls are wavy.
[0051] Figure 3 illustrates an objective view of said liquid heater 1, and a cross-sectional side view of said liquid heater 1, the side view being denoted B. Figure 3 illustrates a movement of the liquid 120 downwards towards the merging section ml. It should be noted that from a side view the "back and forth" / spiral movement is not visible, only a "forth" trajectory in which the liquid 120 travels towards the cartridge 4 is therefore visible in "B". However, the full back and forth movement is shown in e.g. Figure 2.
[0052] Figure 4 illustrates a side view of said liquid heater and a cross-sectional view C-C of said liquid heater 1. The view C-C illustrates the back and forth movement of the liquid 120, showing that for each back and forth movement, the liquid 120 is transferred downwards, e.g, by a channel that acts as an interface between each trajectory of said repetitive trajectories.
[0053] Figure 5 illustrates an objective view of another aspect of the present disclosure in which the inlet 5a is positioned at said upper portion ul of said liquid heater. Further, Figure 5 illustrates a cross-sectional view D.
[0054] The cross-sectional view illustrates that the each baffle 6 of the plurality of baffles 6 encircle a circumference of said heating element 4. This is illustrated by the denotations fl-f3 and jl-j2 that show the encircling trajectory of the liquid in two different baffles. For example, the reference numerals fl-f3 illustrate sequentially that the liquid may travel from the inlet around said heating element 4 (or an axial extension thereof) in a spiral manner towards the outlet.
[0055] Further, as illustrated in Figure 5, each baffle of the plurality of baffles 6 (for at least 70% of a baffle length thereof) may have differing radial distance dl from said heating element 4 relative the other of said plurality of baffles 6, at least in said upper portion ul. The distance may be measured from centre point (not shown) in each baffle at an arbitrary point along the height of said liquid heater 1. Baffle length may be defined by the encircling distance (i.e. the total trajectory the liquid is transferred by each baffle) from the merging section to the inlet for each baffle. As the baffles in Figure 5 each have differing radial distances dl, also the encircling distances differ between each baffle shown in Figure 5.
[0056] Figure 6 illustrates an objective view of said liquid heater 1. Figure 6 illustrates that the inlet 5a and the outlet 5b are on different parts, the inlet being at an upper portion ul, the outlet being at a lower portion u2.
[0057] The liquid heater of any aspect herein may be formed by additive manufacturing.
[0058] Figure 7 schematically illustrates a flowchart of a method 100 for manufacturing a liquid heater according to any aspect herein.
[0059] The method comprises the steps of forming 101, by means of additive manufacturing, said metal body according to any aspect herein and positioning / attaching / fastening 102 the heating element at a cavity within said metal body.
Claims
CLAIMS1. A liquid heater (1) comprising an enclosed metal body (2) forming a lattice structure (3) at an inner volume thereof; a heating element (4) extending along a centre portion (cl) of said metal body (2), the heating element (4) being circumferentially surrounded by said lattice structure (3); an inlet (5a) arranged at one of an upper portion (ul) and a lower portion (u2) of said metal body (2), the inlet (5a) being arranged to receive liquid to be heated; an outlet (5b) arranged at a lower portion (u2) of said metal body (2), the outlet (5b) being arranged to output heated liquid; wherein the lattice structure (3) comprises a plurality of baffles (6) for splitting paths of liquid received by the inlet (5a), the baffles (6) being formed as an extension of said inlet (5a); wherein said plurality of baffles (6) extend from said upper portion (ul) to said outlet (5b), wherein said plurality of baffles (6) merge at said lower portion (u2) up-streams of said outlet (5b); wherein each baffle (6) of said plurality of baffles form a repetitive trajectory for transferring liquid from said upper portion (ul) to said lower portion (u2), the repetitive trajectory comprising an at least partially circular path; wherein the plurality of baffles (6) at least jointly encircle said heating element (4) along a vertical axis (zl) of said metal body (2).
2. The liquid heater (1) according to claim 1, wherein the at least partially circular path is a zigzag path and / or a spiral path.
3. The liquid heater (1) according to any one of the claims 1 or 2, wherein the at least partially circular path has a radial extension (rl) being horizontally downwards.The liquid heater (1) according to any one of the preceding claims, each baffle transfers liquid from said upper portion (ul) to a merging section (ml) of said lower portion (u2) in which said plurality of baffles (6) merge, wherein each repetitive trajectory is delimited by pairs of radial planes (ria, rib) extending from said centre portion (cl). The liquid heater (1) according to any one of the preceding claims, wherein the each baffle (6) is arranged to, by said repetitive trajectory thereof, transfer liquid back and forth between said centre portion (cl) and a turning portion (7') of said liquid heater (1), the turning portion being associated to an outer portion (7) of said liquid heater. The liquid heater (1) according to any one of the preceding claims, wherein the lattice structure is a triply periodic minimal surfaces, TPMS, based structure. The liquid heater (1) according to any one of the preceding claims, wherein each baffle (6) of the plurality of baffles (6) encircle a circumference of said heating element (4). The liquid heater (1) according to claim 7, wherein each baffle of the plurality of baffles (6) have differing radial distance (dl) from said heating element (4) relative the other of said plurality of baffles. The liquid heater (1) according to any one of the preceding claims, wherein walls of each of the plurality of baffles are wavy. A method (100) for manufacturing the liquid heater according to any one of the claims 1-9, the method (100) comprising the steps of: forming (101), by means of additive manufacturing, said metal body;- positioning (102) the heating element at a cavity within said metal body.