Clamshell Tankless Water Heater With Integrated Flow and Heat Control
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Solution Overview
Problem
Traditional water heaters require periodic reheating of stored hot water, while existing tankless designs are often complex with numerous parts, necessitating a simpler and more accessible solution.
Innovation Solution
A tankless water heater with a molded clamshell body featuring a channel with heating elements, sensors for temperature and flow measurement, and a controller to manage heat based on sensor input, offering a compact and efficient on-demand heating system with optional features like turbulent flow grooves and digital display.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional tank water heaters are used, then hot water is stored and readily available, but energy is wasted by periodic reheating of stored water
Solution Approach 1:
The patent merges multiple functional components (heating element, sensors, controller, flow channel) into a single integrated molded body. This consolidation eliminates the need for separate tanks, multiple tubing connections, and discrete mounting brackets, thereby reducing device complexity while maintaining the energy-efficient tankless operation that prevents periodic reheating waste
2Productivity
If tankless water heaters with multiple separate parts are used, then on-demand heating is achieved, but parts are difficult to access and assemble
Solution Approach 1:
The molded body is divided into an upper portion and a lower portion that can be separately manufactured and then assembled together. This segmentation allows for easier manufacturing of complex curved channels while maintaining the integrated design benefits, and the two portions can be conveniently accessed and assembled during installation or maintenance without requiring disassembly of the entire unit
3Adaptability or versatility
If complex tankless designs with multiple components are used, then heating functionality is enhanced, but manufacturing and assembly become more difficult
Solution Approach 1:
The patent combines multiple functional elements (heating element, temperature sensors, flow sensors, controller, and water channels) into a single molded body structure. This merging significantly simplifies manufacturing compared to assembling multiple separate components, while still maintaining advanced heating control functionality through the integrated sensor and controller system
Solution Approach 2:
The molded body serves multiple functions simultaneously: it provides structural housing, contains and directs water flow through molded channels, supports and positions heating elements, and integrates sensor mounting. This multi-functionality reduces the need for separate components while maintaining versatile heating control capabilities
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a simpler, more efficient on-demand water heating system that minimizes parts, optimizes energy use, and offers user-friendly control and monitoring, ensuring consistent water temperature without the need for storage tanks.
Implementation Method 1
At least one heating element extends through the channel to heat water
Data Source
AI summary
A tankless hot water heater has a molded body having an inlet and an outlet. The water heater has a clamshell design such that upper and lower portions are removably attached to one another. A channel extends from the inlet to the outlet. Heating elements extend through at least a portion of the channel and are configured to heat water flowing through the channel. Sensors are configured to measure temperature of water flowing through the channel prior to coming into contact with the heating element. Sensors measure flow rates, temperatures, presence of air, and/or other factors. A controller adjusts power supplied to heating elements using data from sensors.