Electrical hot water processing system
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Solution Overview
Problem
Conventional electric hot water treatment systems face issues such as high thermal mass and poor thermal conductivity in tubular heaters, and limitations in water quality and flow pressure losses in blank wire heaters, necessitating an efficient and reliable alternative.
Innovation Solution
A double-walled electric hot water treatment system with a thermally sprayed electrically conductive and insulating layer on a substrate, providing high ohmic resistance for efficient heat transfer and minimizing flow pressure losses, using materials like alumina and titanium suboxide for thermal stability and corrosion protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a tubular radiator heating system is used, then heating is provided through electrical energy flowing through ohmic resistance, but the system has high thermal mass and poor thermal conductivity resulting in sluggish response and significant energy losses
Solution Approach 1:
The patent applies a thin-film heating element (heating foil) with thickness of 0.05-0.5 mm instead of traditional tubular radiators. This thin-film structure dramatically reduces thermal mass while maintaining heating capability, enabling rapid response and reduced energy losses through improved thermal conductivity and direct heat transfer to the medium.
Solution Approach 2:
The invention changes the physical parameters of the heating system by transitioning from bulky tubular structures to thin-film configurations. This parameter change in geometry and mass directly improves transient thermal behavior and reduces the time constant of the heating system, eliminating the sluggish response characteristic of traditional systems.
2Speed
If a blank wire heating system is used, then excellent transient temperature behavior and high surface load are achieved, but the system is limited by water quality with low electrical conductivity and requires leaks before and after the blank wire causing high flow pressure losses
Solution Approach 1:
The patent introduces an intermediary substance (dielectric fluid or air gap) between the heating element and the water medium. This intermediary allows the heating element to be electrically isolated from the water, eliminating the need for leaks while still transferring heat efficiently. The heating element can be positioned close to the water flow without direct electrical contact, maintaining excellent transient response without requiring pressure-compromising leaks.
Solution Approach 2:
The thin-film heating element design allows for compact integration into the flow path without requiring long leak sections. The film can be positioned optimally close to the water flow for maximum heat transfer efficiency while maintaining electrical isolation, thus achieving excellent transient temperature behavior without the flow pressure losses associated with traditional leak-based systems.
3Power
If a thin electrical layer with high ohmic resistance is used for heating, then efficient heat generation is achieved, but the layer requires protection from corrosion, deposits and particle removal by the medium
Solution Approach 1:
The patent employs a composite structure consisting of a thin electrical heating layer combined with a protective coating layer. The heating layer provides efficient Joule heating with high ohmic resistance, while the protective coating (such as ceramic or corrosion-resistant material) shields it from water corrosion, deposits, and particle erosion. This composite design maintains both heating efficiency and long-term reliability in water contact applications.
Solution Approach 2:
The protective coating acts as an intermediary barrier between the electrical heating layer and the water medium. This intermediary layer prevents direct contact between the heating elements and corrosive or deposit-prone water, thereby protecting the heating layer while allowing heat to transfer through to the water. The coating material is selected to be chemically inert and resistant to fouling.
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 system achieves efficient and reliable heating with reduced flow pressure losses and enhanced thermal stability, suitable for various applications without limiting water quality, while maintaining high temperature control and resistance to calcification.
Implementation Method 1
The heating unit is formed from an electric coating material... the medium to be heated is heated by the joulese effect
Implementation Method 2
The layer according to the invention is a thermally conductive and electrically insulating layer
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
An electric water heating system is provided. The hot water treatment system includes a film heat transfer element having a substrate and a heating unit made of an electrical coating material. The electrical coating material is disposed on the substrate. The layered heat transfer element is configured as a double-walled heat transfer element and has an inner flow channel, an outer flow channel, a thermally sprayed electrically conductive layer, a thermally sprayed electrically insulating layer, a substrate and an insulating unit.