Tankless Water Heater Tube Layout for Low-Flow Heat Control
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Solution Overview
Problem
Tank-based water heaters face issues such as large size, energy inefficiency, corrosion, and the risk of running out of hot water due to high demand, while tankless systems struggle with fine control of heated water at low flow rates and high power burdens on electrical circuits and grids.
Innovation Solution
A tankless water heater system with horizontally laid out tubes containing heating elements, temperature and flow sensors, and a control system for precise heat delivery, along with safety relays and power management, which also communicates with other devices to balance electrical load and optimize energy use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If tankless water heater uses high power heating elements to heat water quickly, then heating speed and hot water supply capacity are improved, but electrical circuit burden and power grid load increase significantly
Solution Approach 1:
The patent divides the heating system into multiple independent heating elements (first heating element and second heating element) that can operate separately or simultaneously. This segmentation allows the total power load to be distributed across multiple circuits or time periods, reducing the peak burden on any single electrical circuit while maintaining the capability to deliver high heating output when needed.
Solution Approach 2:
The control system implements periodic or sequential operation of heating elements based on detected hot water demand and available electrical capacity. Rather than continuously operating all heating elements at full power, the system activates heating elements in sequences or cycles, adjusting their operation to match varying demand patterns and electrical grid conditions, thereby reducing overall power burden while maintaining heating effectiveness.
2Productivity
If tankless water heater operates at high power to meet high demand, then hot water supply capacity is improved, but fine control of heated water temperature becomes difficult at low flow rates
Solution Approach 1:
By dividing the heating function into multiple independent heating elements, the system can selectively activate only the necessary number of elements based on current flow rate and temperature requirements. At low flow rates, fewer heating elements are activated or operate at reduced power, enabling precise temperature control. At high demand, all elements can operate simultaneously to maximize hot water supply capacity.
Solution Approach 2:
The control system dynamically adjusts the operation of heating elements based on real-time feedback from flow sensors and temperature sensors. The system modifies the power level and activation state of each heating element according to varying flow conditions, enabling fine control at low flow rates while maintaining high output capacity when flow rates are high.
3Quantity of substance
If tank-based water heater stores large amounts of heated water, then hot water availability is improved, but energy consumption and water corrosion increase
Solution Approach 1:
The tankless water heater provides continuous heating of water as it flows through the system, eliminating the need to continuously maintain large volumes of water at high temperatures in a storage tank. The heating action occurs continuously only when hot water is actually being used, converting the batch heating approach into a continuous on-demand heating process that eliminates standby energy losses.
Solution Approach 2:
The invention extracts and eliminates the large storage tank component from the water heating system. By removing the tank that stores large volumes of heated water, the system eliminates the associated energy waste from heating and maintaining stored water, as well as the corrosion problems that arise from water sitting in the tank. The heating function is retained but decoupled from large-scale storage.
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 provides efficient, compact, and controlled heating, reducing energy consumption, preventing circuit overload, and ensuring a consistent hot water supply while minimizing corrosion and energy waste.
Implementation Method 1
at least one with a heating element inside... heat can be supplied to the fluid by means of the heating element
Implementation Method 2
providing cavitation, turbulence and mixing of the fluid
Implementation Method 3
temperature and flow sensors and a control system such that an appropriate amount of heat can be supplied
Data Source
AI summary
This invention relates primarily to an electric heater based tankless water heater, though some aspects may also apply to a natural gas or other fuel based tankless water heater. In particular aspects relating to “smart” communication and coordination of the tankless water heater with other devices, which may be electrically powered or powered by other fuels, may also apply to non-electric flow through fluid heating systems. The subject tankless water heater invention incorporates several aspects relating to energy and construction efficiency which will be detailed further. These include both physical aspects, such as coatings, tubing and heater element design, and electrical aspects, such as power control for individual heater elements, which can make the tankless water heater more compact and more efficient in operation, with reduced instantaneous and long term load on electrical supply systems.