Baffle structures for water heating systems and corresponding methods

Abstract

Water heating systems, associated components and devices, and methods of manufacturing the foregoing are provided. For example, a baffle structure for a water heating system may be designed to be located within a heating chamber of the water heating system along a longitudinal axis of a heating element of the water heating system. The heating chamber may be designed to receive a volume of fluid. The heating element may be designed to heat the volume of fluid. The baffle structure may include any number of baffles designed to direct fluid flow through the heating chamber. For example, the baffles may include side baffles designed to modify a velocity profile of the fluid flowing through the heating chamber and / or center baffles designed to divert the flow of fluid toward the heating element. The baffle structure may thereby improve heat transfer, corrosion resistance, and / or other performance characteristics of the water heating system.

Description

Baffle Structures for Water Heating Systems and Corresponding MethodsCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims priority to and the benefit of US provisional application No. 63 / 738,274, filed December 23, 2024, which is hereby incorporated by reference herein in its entirety.FIELD

[0002] The present disclosure generally relates to water heating systems, associated devices and components, and methods of manufacturing the foregoing. For example, systems, devices, components, and methods are provided herein for water heating systems including heating elements and baffle structures within heating chambers.BACKGROUND

[0003] Water heating systems heat volumes of water for use in residential, commercial, and industrial applications. For example, a water heating system may include a heating chamber designed to receive a volume of water and a heating element installed within the heating chamber and designed to heat the volume of water. Water heating systems may be electric, gas, heat pump, renewable (e.g., wind, solar, etc ), or hybrid heating systems and may further be tank-tased or tankless heating systems. The heating element included in a particular water heating system may correspond to the type of water heating system. For example, an electric water heating system may include one or more electric heating elements, a gas water heating may include one or more gas burner heating elements, and a hybrid heating system may include a combination of one or more different types of heating elements.

[0004] The heating chambers, heating elements, and nearby components in such water heating systems, and particularly in instantaneous or tankless electric water heating systems, may be subjected to very high operating temperatures, which may cause undesirable issues affecting longevity and / or performance of the water heating systems or their components (including heating chambers and heating elements installed therein). For example, heating elements, especially electric heating elements used in instantaneous or tankless electric water heating systems, may generate a significant amount of heat during operation, which may cause “baking” or other153910722.1premature damage to the heating elements when the generated heat cannot be effectively dissipated. Moreover, scale or mineral deposits accumulate on hot surfaces quickly. Accordingly, excessive heat generated within heating chambers may cause scale or mineral deposit buildups, for instance, on the walls of the heating chambers and / or on the heating elements installed within the heating chambers. Such buildups may detrimentally affect water heating system performance by decreasing fluid-heating efficiency, causing component corrosion or degradation, contaminating fluid in contact with the scale or mineral deposits, and / or any number of other performance or safety issues.BRIEF DESCRIPTION OF THE DRAWINGS

[0005] FIGS. 1 A and IB are perspective views of a water heating system in accordance with one or more example embodiments of the disclosure.

[0006] FIGS. 2A and 2B are side views of heating elements in accordance with one or more example embodiments of the disclosure.

[0007] FIGS. 3 A-3F are various views of a baffle structure and a heating element in accordance with one or more example embodiments of the disclosure.

[0008] FIGS. 4A-4C are various views of a baffle structure and a heating element in accordance with one or more example embodiments of the disclosure.

[0009] FIGS. 5 A and 5B are, respectively, perspective and cross-sectional views of a baffle structure and a heating element in accordance with one or more example embodiments of the disclosure.

[0010] FIG. 6 is a process flow diagram of an example method of manufacturing a baffle structure for a water heating system in accordance with one or more example embodiments of the disclosure.DETAILED DESCRIPTION

[0011] Improved water heating systems, associated devices and components, and methods of manufacturing the foregoing have been developed and may provide for directing a flow of fluid (e.g., water) through heating chambers of such water heating systems via baffle structures. As will be understood, the installation or incorporation of components designed to lessen the occurrence of issues such as those described above may prove challenging or problematic. For example, use253910722.1of dissimilar metals for different components in fluid communication within the fluid flow path of a water heating system may lead to galvanic corrosion of the components or other similar adverse electrochemical reactions, which may decrease the effective working life of the components. Accordingly, there is a need for improved water heating systems, as well as associated devices and components, for directing a flow of fluid (e.g., water) through a heating chamber of a water heating system so as to improve heat-transfer characteristics of water heating system components about the flow path of the fluid. There is further need for methods of manufacturing the foregoing systems, devices, and components in a manner that optimizes system performance while minimizing or eliminating the adverse effects of component incompatibility (e.g., galvanic corrosion caused by electrochemical dissimilarity of water heating system components).

[0012] Thus, for example, a baffle structure may be designed to be located or installed within a heating chamber of a water heating system, for example, along a longitudinal axis of a heating element of the water heating system. The heating chamber may be designed to receive a volume of fluid. The heating element may be designed to heat the volume of fluid. The baffle structure may include any number of baffles designed to direct the flow of the volume of fluid through the heating chamber. Redirecting the flow of the volume of fluid in such a manner may provide for improved heat-transfer and / or anti-corrosion performance characteristics with respect to the water heating system and its components, including the heating element and the heating chamber.

[0013] Although certain examples of the disclosed technology are explained in detail herein, it is to be understood that other examples, embodiments, and implementations of the disclosed technology are contemplated. Accordingly, it is not intended that the disclosed technology is limited in its scope to the details of construction and arrangement of components expressly set forth in the following description or illustrated in the drawings. The disclosed technology can be implemented in a variety of examples and can be practiced or carried out in various ways. In particular, the presently disclosed subject matter is described in the context of baffle structures for water heaters. The present disclosure, however, is not so limited, and can be applicable in other contexts. Accordingly, when the present disclosure is described in the context of baffle structures for water heaters, it will be understood that other implementations can take the place of those referred to.

[0014] Although the term “water” is used throughout this specification, it is to be understood that other fluids may take the place of the term “water” as used herein. Therefore, although353910722.1described as baffle structures for water heaters, it is to be understood that the system and method described herein can apply to fluids other than water. Further, it is also to be understood that the term “water” can replace the term “fluid” as used herein unless the context clearly dictates otherwise. Moreso, the terms “cold” and “hot” are relative and may mean different degrees of varying temperatures and ranges based on the context. Thus, the terms “cold” and “hot” should not be limited to any temperature or temperature range.

[0015] Referring now to FIGS. 1A and IB, and in brief overview, an example water heating system including a heating element located in a heating chamber is illustrated.

[0016] As shown in FIG. 1 A, water heating system 100 may include heating chamber 102 and / or heating element 104. Heating chamber 102 may be designed to receive heating element 104. For example, heating chamber 102 may have a substantially cylindrical (or any other) shape with a sufficient internal volume to accommodate heating element 104. Heating chamber 102 may further be designed to receive a volume of fluid (e.g., water) from an external source. For example, heating chamber 102 may include inlet 106 and / or outlet 108, which may be located at opposing ends of heating chamber 102. Inlet 106 may be designed to receive the fluid from another component of water heating system 100 or from an external fluid source, for instance, at a relatively cold temperature. The fluid may flow through heating chamber 102 along flow path 110, which may substantially follow longitudinal axis 112 of heating element 104 from inlet 106 toward outlet 108. Outlet 108 may be designed to provide the fluid to an external component of water heating system 100, such as piping, another heating chamber, or an external outlet, for delivery of fluid that has been heated by heating element 104. Heating element 104 may be designed to heat the fluid received within heating chamber 102, for example, via conduction, convection, or radiation. Heating element 104 may be any type of heating element, including but not limited to any type of electric heating element, heat pump heating element, or gas heating element.

[0017] Heating chamber 102, heating element 104, and / or any other component of water heating system 100 may each be formed, constructed, or manufactured from any fluid-compatible material. For example, heating chamber 102, heating element 104, and / or other components (e g., baffle structures) of water heating system 100 in fluid communication with the fluid traveling through water system 100 may be formed constructed, or manufactured from materials selected to minimize corrosion or galvanic reaction or to prevent creation of a significant thermal sink with respect to heat transfer from one component to another or between any component and the fluid453910722.1(e g., stainless steel such as 304 stainless steel or a low-cost alloy thereof, composite material, polymer material, or any other material or combination of materials known by those having ordinary skill in the art).

[0018] As shown in FIG. IB, water heating system 100 may further include controller 114 and / or additional heating chambers such as heating chamber 116 and / or heating chamber 118, each of which may include an additional heating element for further optimizing the heating profile of fluid traveling through water heating system 100. The heating elements, including heating element 104, may be controlled by controller 114. For example, controller 114 may be any computing device having a processor that is designed to receive input from a user (e.g., preferred fluid output temperature or heating schedule) and to cause the heating elements to heat the fluid received by the heating chambers, including heating chamber 102, in accordance with user input. Controller 114 may further be in communication with any number of sensors designed to detect or monitor various characteristics of the fluid or components of the water heating system (e.g., temperature, pressure, current, flow velocity, etc.) and may include software adapted to control or modify performance of various components of water heating system 100, including but not limited to the heating elements, based at least in part on sensor data received from the sensors.

[0019] Water heating system 100 may be any type of water heating system. For example, water heating system 100 may be an electric water heating system, a gas water heating system, a hybrid heating system including a combination of types of heating elements, or any other type of water heating system. Water heating system 100 may further be a tank-based or tankless water heating system. Moreover, although the present disclosure may generally refer to water heating systems, it will be understood by those having ordinary skill in the art that the present disclosure contemplates application of the technology described herein to heating systems designed to heat any number of fluids other than water.

[0020] Further still, for the sake of brevity, it will be understood that water heating system 100 may be the same as or similar to any one or more of the water heating systems described below with respect to FIGS. 2A and 2B, FIGS. 3A-3F, FIGS. 4A-4C, FIGS. 5 A and 5B, and / or FIG. 6 and / or or any other fluid heating system. Similarly, any of the components described herein with respect to any one embodiment may be the same as or similar to components described herein with respect to any one or more other embodiments or otherwise within the scope of the present disclosure. For example, heating chamber 104 of water heating system 100 may be the same as or553910722.1similar to any one or more of the heating chambers described below with respect to FIGS. 2A and 2B, FIGS. 3A-3F, FIGS. 4A-4C, FIGS. 5A and 5B, and / or FIG. 6 and / or any other heating chamber of any other fluid heating system.

[0021] Referring now to FIGS. 2A and 2B, and in brief overview, heating elements for use with water heating systems such as water heating system 100 (see FIGS. 1A and IB) are illustrated.

[0022] As shown in FIG. 2A, heating element 200 may be an existing heating element such as heating element 104 of water heating system 100 (see FIGS. 1A and IB). Heating element 200 may have any shape or configuration designed to fit within a heating chamber of a water heating system such as heating chamber 102 of water heating system 100 (see FIGS. 1A and IB). For example, heating element 200 may have a substantially cylindrical cross-sectional profile and may be formed having curvature 202 such that first portion 204 of heating element 200 may extend at an angle from curvature 202 with respect to longitudinal axis 206 of heating element 200, while second portion 208 of heating element 200 may be substantially parallel to longitudinal axis 206, or vice versa. First portion 204 may, for example, be a starting portion of heating element 200 designed to be mounted or connected to, or otherwise engage with, a heating chamber and / or other components or structural features of a water heating system. Second portion 208 may, for example, be an end portion of heating element 200 designed to be unattached, open-ended, or “free-floating” within the heating chamber. An angle of curvature 202 may be selected such that spacing 210 may be relatively tight or minimized between first portion 204 and second portion 208 of heating element 200. As such, heating element 200 may be insertable into the heating chamber for heating fluid as part of the water heating system.

[0023] As shown in FIG. 2B, heating element 212 may be a different heating element than heating element 200. Heating element 212 may have a modified shape compared to heating element 200 while also being designed to fit within a heating chamber of a water heating system such as heating chamber 102 of water heating system 100 (see FIGS. 1A and IB). For example, heating element 212 may have a substantially cylindrical cross-sectional profile and may be formed having curvature 214, which may be different than curvature 202 of heating element 200. First portion 216 and second portion 218 of heating element 212 may each be substantially parallel to longitudinal axis 220 of heating element 212, or at least may be angled to a lesser extend with respect to one another than are first portion 204 and second portion 208 of heating element 200. First portion 216 may, for example, be a starting portion of heating element 212 designed to be653910722.1mounted or connected to, or otherwise engage with, a heating chamber and / or other components or structural features of a water heating system. Second portion 218 may, for example, be an end portion of heating element 212 designed to be unattached, open-ended, or “free-floating” within the heating chamber. An angle of curvature 214 may be selected such that spacing 222 is sufficiently open or expanded to receive a baffle structure, such as any of baffle structure 300 (see FIGS. 3A-3F), baffle structure 400 (see FIGS. 4A-4C), or baffle structure 500 (see FIGS. 5A and 5B), for directing flow of fluid within a heating chamber in which heating element 212 might be installed. For example, spacing 222 may be greater than spacing 210 such that heating element 212 may be able to receive a baffle structure between first portion 216 and second portion 218, whereas heating element 200 might not be able to receive the same baffle structure between first portion 204 and second portion 208 due to spacing restrictions. Spacing 222 may further be selected such that heating element 212 may still be insertable into the heating chamber for heating fluid as part of the water heating system despite the increased spacing distance between the respective ends of first portion 216 and second portion 218.

[0024] Referring now to FIGS. 3A-3F, and in brief overview, a baffle structure for a water heating system is illustrated.

[0025] As shown in FIGS. 3A and 3B, baffle structure 300 may be designed to be located, inserted, or installed within a heating chamber of a water heating system such as heating chamber 102 of water heating system 100 (see FIGS. 1A and IB). For example, baffle structure 300 may be designed to be located along a longitudinal axis of a heating element within the heating chamber of the water heating system, such as along longitudinal axis 220 of heating element 212 (see FIG.2B), such that longitudinal axis 302 of baffle structure 300 may be substantially parallel to the longitudinal axis of the heating element. Baffle structure 300 may be located along a flow path of fluid (e.g., water) within the heating chamber of the water heating system, such as along flow path 110 within heating chamber 102 of water heating system 100 (see FIG. 1A).

[0026] Baffle structure 300 may include any number or combination of baffles 304 designed to direct the flow of fluid through the heating chamber and / or about the heating element. For example, baffles 304 may direct the flow of fluid by modifying a velocity profile of the fluid flowing through the heating chamber. The velocity profile may be selected, for example, to increase a rate of heat transfer away from the walls of the heating chamber and / or the heating element (or any other component) within the heating chamber.753910722.1

[0027] Benefits of directing fluid flow by baffle structure 300 may include improved heat transfer between the fluid and the various components of the water heating system. For example, fluid flow may be directed with respect to other components of the water heating system (e.g., the heating element and / or walls of the heating chamber) such that heat is more quickly transferred to the fluid from the other components than with existing systems. At the same time, heat may more rapidly be transferred away from those other components (and into the fluid) than with existing systems.

[0028] By more quickly removing heat from components of the water heating system such as the heating element and / or the walls of the heating chamber, longevity of those components may be increased. For example, the heating element may be protected from “baking” due to removal of excess heat, which may thereby prevent damage to the heating element. As another example, buildup of scale or mineral deposits, which generally occurs more quickly on hot surfaces, may be minimized with respect to the heating element and / or walls of the heating chamber by cooling their surfaces more rapidly and efficiently than with existing systems. As such, premature corrosion of critical components of the water heating system may be avoided. These and other results of including baffle structure 300 in a water heating system may prove particularly beneficial when the water heating system includes instantaneous electric heating elements (e.g., electric heating elements used with tankless water heating systems), which are known to generate substantial heat and, as a result, typically experience issues with baking and scale buildup as described above. However, as will be understood, the benefits of baffle structure 300 may be experienced with any water (or other fluid) heating system incorporating heating elements and heating chambers.

[0029] Baffle structure 300 may be formed, in whole or in part, from baffle material 306, which may be any material suitable for use as a baffle structure exposed to fluid in a fluid heating system. For example, baffle material 306 may be selected for cost-effectiveness, strength, heat-transfer characteristics, and / or to minimize galvanic corrosion between baffle material 306 and one or more materials of the heating chamber, the heating element, or other components of the water heating system when the baffle structure is in fluid communication with any such components via the fluid. Possible materials include metals such as stainless steel (e.g., 304 stainless steel) or low-cost alloys thereof, composite materials, or any other material known by those having ordinary skill in the art.

[0030] Certain materials, including stainless steel, may be preferable due to their superior heattransfer characteristics in the context of water heating systems. Forming baffle structure 300 from853910722.1a stainless steel such as 304 stainless steel, for example, may avoid creation of a significant thermal sink at baffle structure 300. In order to prevent or minimize galvanic corrosion, it will be understood that the material(s) selected as baffle material 306 should be compatible with the materials of other components (e.g., heating elements, heating chambers, piping, inlets, outlets, control valves, etc.) in fluid communication via the fluid traveling through the water heating system. Moreover, some materials may prove more cost-effective or economical than others while still providing acceptable performance characteristics. As will be further understood, baffle material 300 may be selected in conjunction with any number of other materials used in the construction of the water heating system to optimize various performance characteristics of the water heating system and its components.

[0031] Baffle structure 300 may be formed from any number of pieces or from a unitary piece of baffle material 306 using any known method of manufacturing or metalworking. For example, baffles 304 may be formed by punching or cutting and bending tabs 308 from the unitary piece of baffle material 306. Tabs 308 may be arranged in any shape, pattern, or orientation based on a preferred direction of flow for the fluid flowing through the heating chamber. For example, tabs 308 may be bent in alternating directions relative to plane 310 of baffle structure 300. Alternatively, baffle structure 300 may be manufactured by combining various pieces or components to achieve a desired shape, pattern, orientation, or configuration.

[0032] Baffles 304 may, for example, include any number of side baffles 312 located along one or more edges 314 of baffle structure 300. Side baffles 312 may have any shape or design selected to affect the flow of fluid through the heating chamber such that performance and / or longevity of the water heating system is improved. For example, side baffles 312 may each have a substantially “shark-tooth” shape (or any other shape) designed to modify the velocity profile of the flow of fluid through the heating chamber in a manner that improves heat transfer, minimizes corrosion, and / or achieves any other benefit of a modified velocity profile for the fluid flowing through the heating chamber. It will further be understood that any number of alternative designs, shapes, orientations, or other configurations of side baffles 312 may achieve an equally varied number of performance characteristics for the water heating system and / or components thereof (including but not limited to baffle structure 300, the heating chamber, and / or the heating element), all such alternatives being within the scope of the present disclosure.953910722.1

[0033] As shown in FIGS. 3C-3F, baffle structure 300 may be designed to be received by or within heating element 316 of a water heating system. For example, baffle structure 300 may be designed to be inserted via opening 318 of heating element 316 such that longitudinal axis 302 of baffle structure 300 may substantially align with longitudinal axis 320 of heating element 316. Side baffles 312 may extend beyond heating element 316 such that side baffles 312 may modify a direction of fluid flow about one or more external surfaces of heating element 316. For example, side baffles 312 may direct fluid away from heating element 316 as the fluid travels through a heating chamber within which heating element 316 and baffle structure 300 may be installed, which may offer improved heat transfer or anti-corrosion characteristics with respect to heating element 316. Baffle structure 300 may be substantially flat about plane 310, which may minimize the extent to which fluid flow is modified except by side baffles 312. Baffle structure 300 may be approximately the same length as heating element 316, may be any other length, and / or may be formed from a combination of multiple components each having any length or structure.

[0034] Referring now to FIGS. 4A-4C, and in brief overview, an alternative baffle structure for a water heating system is illustrated.

[0035] As shown in FIG. 4A, baffle structure 400 may be substantially similar in design to baffle structure 300 (see FIGS. 3A-3F). Baffle structure 400 may additionally or alternatively include one or more structures designed to facilitate engagement between baffle structure 400 and a heating element and / or a heating chamber of a water heating system. For example, baffle structure 400 may include mounting part 402, which may be designed to engage with heating element 404 and / or with one or more walls or other internal structures of the heating chamber such that baffle structure 400 may be fixedly installed within the heating chamber.

[0036] Where baffle structure 400 is formed from a unitary piece of baffle material 406, mounting part 402 may be formed from the unitary piece of baffle material 406. For example, mounting part 402 may be formed by punching or cutting and bending a mounting tab 408 from the unitary piece of baffle material 406 in a manner that retains sufficient structural strength for baffle structure 400 to be installed within the heating chamber in a fixed manner without undue yielding, bending, or other deformation. Alternatively, mounting part 402 may be a separate component designed to be attached to baffle structure 400 (e.g., via welding, riveting, or any other known method of attachment). Mounting part 402 may or may not noticeably affect the flow of1053910722.1fluid through the heating chamber depending on the particular location and / or profile of mounting part 402.

[0037] Referring now to FIGS. 5 A and 5B, and in brief overview, yet another alternative baffle structure for a water heating system is illustrated.

[0038] As shown in FIGS. 5A and 5B, baffle structure 500 may have any number of features in common with (or different from) baffle structure 300 (see FIGS. 3A-3F) and / or baffle structure 400 (see FIGS. 4A-4C). For example, baffle structure 500 may include any number of baffles 502, which may include any combination of side baffles 504 and / or center baffles 506. Similarly to side baffles 312 of baffle structure 300 (see FIGS. 3A-3F), side baffles 504 may be located along one or more edges 508 of baffle structure 500. Center baffles 506 may be located substantially along longitudinal axis 510 of baffle structure 500 in any pattern or configuration. Baffle structure 500 may, alternatively or in addition, include mounting part 512, which may be located at an end of baffle structure 500, for fixing baffle structure 500 to heating element 514 and / or one or more walls or other structures of the heating chamber of the water heating system.

[0039] Side baffles 504 and center baffles 506 may be designed to direct fluid flow through a heating chamber of a water heating system in the same or different manners from one another. For example, side baffles 504 may be designed to direct fluid flow by modifying a velocity profile of the flow through the heating chamber such that a rate of heat transfer away from the heating chamber and / or a heating element (e.g., heating element 514) of the water heating system may be increased. Center baffles 506 may be designed to divert fluid flow toward heating element 514 such that fluid received by the heating chamber may be heated to an acceptable temperature before being diverted away from heating element 514 and toward an outlet of the heating chamber.

[0040] Baffles 502 may have any shapes or designs selected to affect the flow of fluid through the heating chamber such that performance and / or longevity of the water heating system is improved. For example, side baffles 504 may each have the same or similar “shark-tooth” shape (or any other shape) as described above with respect to side baffles 306 of baffle structure 300 (see FIGS. 3A-3F). Center baffles 506 may each have a substantially “half-moon” shape (or any other shape) designed to divert the flow of fluid toward heating element 514 in a manner that improves heat transfer, minimizes corrosion, and / or achieves any other benefit of such a flow direction for the fluid flowing through the heating chamber.1153910722.1

[0041] As with baffle structure 300 (see FIGS. 3 A-3F), baffle structure 500 may be formed from any number of pieces or from a unitary piece of baffle material 516 using any known method of manufacturing or metalworking. For example, side baffles 504 and / or center baffles 506 may each be formed by punching or cutting and bending tabs 518 and / or tabs 520, respectively, from the unitary piece of baffle material 516. Mounting part 512 may be formed by punching or cutting and bending mounting tab 522 from the unitary piece of baffle material 516. Tabs 518, tabs 520, and / or mounting tab 522 may be arranged in any shape, pattern, or orientation allowing baffle structure 500 and heating element 514 to fit together within the heating chamber. Alternatively, baffle structure 500 may be manufactured by combining various pieces or components to achieve a desired shape, pattern, orientation, or configuration.

[0042] It will further be understood that any number of alternative designs, shapes, orientations, or other configurations of baffles 502 may achieve an equally varied number of performance characteristics for the water heating system and / or components thereof (including but not limited to baffle structure 500, the heating chamber, and / or heating element 514), all such alternatives being within the scope of the present disclosure.

[0043] Referring now to FIG. 6, and in brief overview, a process flow diagram of a method of manufacturing a baffle structure for a water heating system in accordance with one or more example embodiments of the disclosure is provided. The water heating system described herein may include a heating chamber and / or a heating element. The heating chamber may be designed to receive a volume of fluid (e.g., water) from another component of the water heating system and / or from an external fluid source. The heating element may be located within the heating chamber and designed to heat the volume of fluid.

[0044] As shown in FIG. 6, process 600 provides a method for manufacturing a baffle structure. It will be understood that the baffle structure described herein with respect to FIG. 6 may be the same as or similar to any of the baffle structures described herein (e.g., baffle structure 300 of FIGS. 3A-3F, baffle structure 400 of FIGS. 4A-4C, and / or baffles structure 500 of FIGS. 5A and 5B) or may be any other baffle structure in accordance with the principles of the present disclosure.

[0045] At step 602, one or more baffle materials may be selected. For example, a baffle material may be selected to minimize galvanic corrosion between the baffle material and one or more materials of the heating chamber and / or the heating element when the baffle structure is in fluid communication with the heating chamber and / or the heating element via the volume of fluid1253910722.1received by the heating chamber. The baffle material(s) may be any material already described herein (e.g., stainless steel, a low-cost alloy thereof, or a composite material) or may be any other material suitable for use as a baffle material.

[0046] At step 604, one or more preferred baffle shape(s), pattern(s), and / or orientation(s) for the baffle structure are selected. For example, it may be preferable in one or more scenarios to select a baffle structure design such as that of baffle structure 300 (see FIGS. 3A-3F) (including side baffles), baffle structure 400 (see FIGS. 4A-4C) (including side baffles and a mounting part), and / or baffle structure 500 (see FIGS. 5A and 5B) (including side baffles, center baffles, and a mounting part). The selected design may be chosen to improve heat transfer, minimize corrosion, and / or achieve any other benefit(s) of the baffle structures described or envisioned throughout the present disclosure.

[0047] At step 606, any number of baffles may be formed from the baffle material. For example, each baffle may be formed by punching or cutting and bending a tab from a unitary piece of the baffle material. The baffles may be designed to direct a flow of the volume of fluid through the heating chamber with the baffle structure installed in the heating chamber. The baffles may include, for example, any number of side baffles and / or center baffles. The side baffles may be located along one or more edges of the unitary piece of baffle material and / or may be designed to modify a velocity profile of the flow of the volume of fluid through the heating chamber. The center baffles may be located along a longitudinal axis of the unitary piece of baffle material and / or may be designed to divert the flow of the volume of fluid toward the heating element. For example, the side baffles may each have a substantially “shark-tooth” shape, while the center baffles may each have a substantially “half-moon” shape, to achieve the aforementioned results.

[0048] At step 608, one or more mounting parts are formed from, or attached to, the unitary piece of baffle material. The mounting part(s) may be designed to engage, for example, with the heating element and / or one or more walls of the heating chamber such that the baffle structure may be installed within the heating chamber of the water heating system in a fixed manner. For example, a mounting part may be formed by punching or cutting and bending a mounting tab at an end of the unitary piece of baffle material. The mounting tab may be designed to attach to the heating element and / or a corresponding mounting structure of the heating chamber.

[0049] At step 610, the baffle structure may be fixed to the heating element and / or the heating chamber of the water heating system. For example, the baffle structure may be inserted within an1353910722.1opening of the heating element. The baffle structure and the heating element may both be inserted or otherwise placed within the heating chamber. The heating element may be fixed, mounted, or attached to the heating chamber, for example, about a starting portion of the heating element. The baffle structure may be fixed, mounted, or attached, via the mounting part, to the heating element or the heating chamber. As such, the mounting part may restrict movement of the baffle structure with respect to the heating element and / or the heating chamber such that the flow of fluid through the heating chamber may be consistent and provide for reliable flow characteristics (e.g., heat transfer and corrosion resistance).

[0050] Although specific embodiments of the disclosure have been described, one of ordinary skill in the art will recognize that numerous other modifications and alternative embodiments are within the scope of the disclosure. For example, any of the functionality and / or processing capabilities described with respect to a particular device or component may be performed by any other device or component. Further, while various illustrative implementations and architectures have been described in accordance with embodiments of the disclosure, one of ordinary skill in the art will appreciate that numerous other modifications to the illustrative implementations and architectures described herein are also within the scope of this disclosure.

[0051] While embodiments have been described in language specific to structural features and / or methodological acts, it is to be understood that the disclosure is not necessarily limited to the specific features or acts described. Rather, the specific features and acts are disclosed as illustrative forms of implementing the embodiments. Conditional language, such as, among others, “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments could include, while other embodiments do not include, certain features, elements, and / or steps. Thus, such conditional language is not generally intended to imply that features, elements, and / or steps are in any way required for one or more embodiments or that one or more embodiments necessarily include logic for deciding, with or without user input or prompting, whether these features, elements, and / or steps are included or are to be performed in any particular embodiment.1453910722.1

Claims

THAT WHICH IS CLAIMED IS:

1. A baffle structure for a water heating system, the baffle structure comprising:a plurality of baffles, wherein:the baffle structure is configured to be disposed within a heating chamber of the water heating system along a first longitudinal axis of a heating element of the water heating system,the heating chamber is configured to receive a volume of water,the heating element is configured to heat the volume of water, and the plurality of baffles are configured to direct a flow of the volume of water through the heating chamber.

2. The baffle structure of claim 1, wherein:the plurality of baffles are further configured to direct the flow of the volume of water by modifying a velocity profile of the flow through the heating chamber, andthe velocity profile of the flow is selected to increase a rate of heat transfer away from the heating chamber or the heating element.

3. The baffle structure of claim 1, wherein the baffle structure is formed from a unitary piece of baffle material.

4. The baffle structure of claim 3, wherein the plurality of baffles are formed by punching or cutting and bending a plurality of tabs from the unitary piece of baffle material.

5. The baffle structure of claim 4, wherein the plurality of tabs are bent in alternating directions relative to a plane of the baffle structure.

6. The baffle structure of claim 4, wherein the plurality of baffles comprise a plurality of side baffles disposed along one or more edges of the baffle structure.1553910722.

17. The baffle structure of claim 6, wherein the plurality of baffles further comprise a plurality of center baffles disposed along a second longitudinal axis of the baffle structure.

8. The baffle structure of claim 7, wherein:the plurality of side baffles each have a substantially shark-tooth shape configured to modify a velocity profile of the flow of the volume of water through the heating chamber, and the plurality of center baffles each have a substantially half-moon shape configured to divert the flow of the volume of water toward the heating element.

9. The baffle structure of claim 1, wherein the baffle structure is configured to engage with the heating element or with one or more walls of the heating chamber.

10. The baffle structure of claim 1, wherein the baffle structure is formed from a baffle material selected to minimize galvanic corrosion between the baffle material and one or more materials of the heating chamber or the heating element when the baffle structure is in fluid communication with the heating chamber or the heating element via the volume of water.

11. A water heating system comprising:a heating chamber configured to receive a volume of water;a heating element disposed within the heating chamber and configured to heat the volume of water; anda baffle structure disposed within the heating chamber along a first longitudinal axis of the heating element, the baffle structure comprising a plurality of baffles configured to direct a flow of the volume of water through the heating chamber.

12. The water heating system of claim 11, wherein:the plurality of baffles are further configured to direct the flow of the volume of water by modifying a velocity profile of the flow through the heating chamber, andthe velocity profile of the flow is selected to increase a rate of heat transfer away from the heating chamber or the heating element.1653910722.

113. The water heating system of claim 11 , wherein:the baffle structure is formed from a unitary piece of baffle material, andthe plurality of baffles are formed by punching or cutting and bending a plurality of tabs from the unitary piece of baffle material.

14. The water heating system of claim 13, wherein the plurality of baffles comprise a plurality of side baffles disposed along one or more edges of the baffle structure.

15. The water heating system of claim 14, wherein the plurality of baffles further comprise a plurality of center baffles disposed along a second longitudinal axis of the baffle structure.

16. The water heating system of claim 15, wherein:the plurality of side baffles each have a substantially shark-tooth shape configured to modify a velocity profile of the flow of the volume of water through the heating chamber, and the plurality of center baffles each have a substantially half-moon shape configured to divert the flow of the volume of water toward the heating element.

17. The water heating system of claim 11, wherein:the heating element is further configured with an expanded opening to receive the baffle structure, andthe baffle structure is configured to engage with the heating element or with one or more walls of the heating chamber.

18. The water heating system of claim 10, wherein the baffle structure is formed from a baffle material selected to minimize galvanic corrosion between the baffle material and one or more materials of the heating chamber or the heating element when the baffle structure is in fluid communication with the heating chamber or the heating element via the volume of water.

19. The water heating system of claim 11, wherein:the water heating system is a tankless electric water heating system, andthe heating element is an electric heating element.1753910722.

120. A method of manufacturing a baffle structure for a water heating system, the water heating system comprising a heating chamber configured to receive a volume of water and a heating element disposed within the heating chamber and configured to heat the volume of water, the method comprising:selecting a baffle material, the baffle material selected to minimize galvanic corrosion between the baffle material and one or more materials of the heating chamber or the heating element when the baffle structure is in fluid communication with the heating chamber or the heating element via the volume of water;forming a plurality of baffles by punching or cutting and bending a plurality of tabs from a unitary piece of the baffle material, the plurality of baffles configured to direct a flow of the volume of water through the heating chamber with the baffle structure installed in the heating chamber, the plurality of baffles comprising one or more of:a plurality of side baffles disposed along one or more edges of the unitary piece of baffle material, ora plurality of center baffles disposed along a longitudinal axis of the unitary piece of baffle material; andforming a mounting part from, or attaching the mounting part to, the unitary piece of baffle material, the mounting part configured to engage with the heating element or with one or more walls of the heating chamber to install the baffle structure within the heating chamber of the water heating system.1853910722.1

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