Flow-Through Heating Element for Water Heater Calcification Control
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Solution Overview
Problem
Existing water heaters in commercial aircraft suffer from calcification and impurity deposits on heating elements, leading to reduced thermal conductivity and increased power requirements over time, necessitating frequent replacements.
Innovation Solution
A water heater design featuring a flow-through heating element located in the lower portion of the water tank, which recirculates water to promote thermal mixing and efficient heating, reducing the need for high surface heating areas and minimizing deposits, while using a recirculation line and control logic to manage temperature and circulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a tank water heater with immersed heating elements is used, then water can be heated to high temperatures, but calcification and impurity deposits form on the heating elements over time
Solution Approach 1:
Instead of heating water from the bottom upward with immersed elements, this invention heats water from the top downward using a flow-through heating element. Water enters the heating element at the top, is heated as it flows through, and exits at the bottom. This inversion prevents water from continuously contacting the heating element surface, thereby preventing calcification and deposit formation while still achieving high temperature heating.
2Use of energy by moving object
If heating elements are immersed in water, then efficient heating can be achieved, but thermal mixing is insufficient leading to temperature stratification
Solution Approach 1:
This invention uses hydraulic principles by creating a forced circulation system where water flows through the heating element and is redistributed throughout the tank. The flow-through design combined with strategic outlet positioning creates natural convection currents and thermal mixing, ensuring uniform temperature distribution throughout the water volume while maintaining continuous heating efficiency.
3Productivity
If high power is used for heating, then water heating speed increases, but power consumption increases and weight increases
Solution Approach 1:
This invention implements continuous heating through forced circulation, where water is constantly pumped through the heating element and redistributed in the tank. This continuous flow ensures that heating action is maintained throughout the entire water volume without interruption, achieving fast heating speeds with lower power consumption by eliminating idle heating periods and temperature stratification.
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 effectively maintains efficient water heating with reduced power consumption, minimizes calcification, and extends the lifespan of the heating elements by ensuring uniform temperature and reducing bacterial growth, thus providing a more reliable and cost-effective heating solution.
Implementation Method 1
the flow-through heating element heats water as volumes of water are passed through an interior of the heating element
Implementation Method 2
a recirculation line that transports water from the water tank to the input end of the heating element
Data Source
Figure 1A
Figure 1B
Figure 2
AI summary
A water heater includes a water tank and a flow-through heating element. The water tank contains heated water. The flow-through heating element is located in the lower portion of the water tank and heats water as water is passed through an interior channel of the heating element. In another configuration, the water heater further includes a recirculation line and the heating element further includes an input end external of the water tank to receive water to be heated and an output end to output heated water into the water tank. The recirculation line transports water from the water tank to the input end of the heating element that is external of the water tank.