WO2025193195A1

WO2025193195A1 - A dry resistor hybrid heating module with limescale formation prevention

Info

Publication number: WO2025193195A1
Application number: PCT/TR2024/051309
Authority: WO
Inventors: Mehmet Sahin
Original assignee: Salmex Isi Sanayi Ve Ticaret AS
Current assignee: Salmex Isi Sanayi Ve Ticaret AS
Priority date: 2024-03-12
Filing date: 2024-11-08
Publication date: 2025-09-18
Anticipated expiration: 2026-09-12

Abstract

The invention relates to a heating module (1) for the use of electrical energy in fluid heating, comprising at least one flow pipe (10) through which the fluid is passed, at least one resistor (50) for providing heat, and at least one body (20) for positioning said resistor (50) and the flow pipe (10) in. The novelty of the invention is characterized in that the resistor (50) is located adjacent to the flow pipe (10) without contacting the fluid in order to prevent the formation of limescale.

Description

A DRY RESISTOR HYBRID HEATING MODULE WITH LIMESCALE FORMATION PREVENTION

TECHNICAL FIELD

The invention relates to a heating module for the use of electrical energy in fluid heating, comprising at least one flow pipe through which the fluid is passed, at least one resistor for providing heat, and at least one body for positioning said resistor and the flow pipe in.

PRIOR ART

Water heaters with electric resistor are devices that heat water using electrical energy. The basic operation of these devices is based on the conversion of electric current into heat energy by passing it through a metal resistor. The resistor shows resistance during the passage of electric current and this resistance allows the energy to be converted into heat. The heated resistor allows the water to heat up. These heaters are used for different needs in houses and workplaces. For example, small electric kettles in kitchens are ideal for quickly heating and boiling water. Larger storage type water heaters are used to meet the need for continuous hot water in bathrooms and kitchens. These heaters store a certain amount of water, providing the user with hot water immediately when needed. Electric kettles have a wide range of uses due to their efficiency and ease of use.

The application No. 2018/04931 known in the literature is related to a high-efficiency electric combi boiler construction. The object of the invention is to obtain an electric combi boiler that is equivalent to natural gas systems in terms of fuel cost, where the risks and maintenance costs encountered in natural gas systems are eliminated. The invention consists of a radiator heating unit, resistor, domestic water heating unit, heat exchanger, photon absorbing coating, circulation pump, expansion tank, flow switch, and pressure switch. There are two resistors in the radiator heating unit and one in the domestic water heating unit. The resistor producing heat with electrical energy simultaneously absorbs the infrared rays emitted by the photon absorbing coating, converts them into heat, and transfers them to the copper heat exchanger to generate heat energy.

Malfunctions in water heaters with electric resistors can vary. The limescale production malfunction in electric resistor water heaters is the process by which mineral salts in the water, especially calcium and magnesium, accumulate and solidify on the resistor during the heating process. This accumulation is caused by a decrease in the solubility of these minerals with the heating of water, which over time forms layers on the heating elements. These layers reduce the efficiency of the heater since the heat has to pass through the limescale layer before it can be delivered directly to the water, resulting in greater energy consumption and a longer heating time. In addition, the limescale production can shorten the life of the heater and increase maintenance costs.

As a result, all the above-mentioned problems have made it imperative to make an innovation in the relevant technical field.

SUMMARY OF THE INVENTION

The present invention relates to a heating module for eliminating the above-mentioned disadvantages and bringing new advantages to the relevant technical field.

An object of the invention is to introduce a heating module with an extended range of uses, in which limescale formation is prevented.

To achieve all the objects mentioned above and that will emerge from the following detailed description, the present invention is a heating module for the use of electrical energy in fluid heating, comprising at least one flow pipe through which the fluid is passed, at least one resistor for providing heat, and at least one body for positioning said resistor and the flow pipe in. Accordingly, its novelty is that the resistor is located adjacent to the flow pipe without contacting the fluid in order to prevent the formation of limescale.

A possible embodiment of the invention is characterized in that it comprises at least one service hatch enabling access to the inside of the body and repair of malfunctions. Thus, users and technicians can easily access the internal components of the heating module and perform the necessary maintenance or repairs quickly and efficiently. Another possible embodiment of the invention is characterized in that the body comprises at least a body first part and a body second part. Thus, the module provides ease of installation and maintenance, and the two-piece structure facilitates access to the internal components of the module while also offering a strong and durable outer structure.

Another possible embodiment of the invention is characterized in that it comprises at least one sensor for detecting the temperature of the fluid inside the flow pipe. Thus, the efficiency of the system is increased, the heating process is optimized, and energy use is made more efficient.

Another possible embodiment of the invention is characterized in that the flow pipe has a zigzag or layered structure, and the resistor is located between at least one of these layers. Thus, heat distribution is optimized, the efficiency of the resistor is increased, and problems such as limescale production are minimized.

Another possible embodiment of the invention is characterized in that it comprises at least one inlet-outlet part to allow fluid entry and exit on one side and at least one collector on the opposite side of the flow pipe for ensuring that the flow pipe has a zigzag or layered structure. Thus, effective distribution of fluid within the module is ensured and heat transfer is maximized.

Another possible embodiment of the invention is characterized in that the resistor is manufactured from aluminum material. Thus, the heat transfer efficiency is increased and the module can provide heat more quickly.

Another possible embodiment of the invention is characterized in that the flow pipe is manufactured from stainless steel material. Thus, the durability and service life of the module increases, offering a more corrosion-resistant structure.

Another possible embodiment of the invention is characterized in that it comprises at least one transition part for the passage of an electric cable between the inside of the body and the outside. This ensures that electrical connections are managed safely and regularly, preventing unwanted heat loss and electrical interference. Another possible embodiment of the invention is characterized in that the body is manufactured from a plastic-based material and covered with insulating material to retain heat on inward-facing surfaces. This increases heat efficiency, saves energy, and keeps the outer surface of the module at a safe temperature when touched.

BRIEF DESCRIPTION OF THE DRAWING

Fig. 1 shows a representative perspective view of the heating module of the invention.

Fig. 2 shows a representative exploded view of the heating module of the invention.

DETAILED DESCRIPTION OF THE INVENTION

In this detailed description, the subject of the invention is explained by way of example only for a better understanding of the subject, which shall not create any limiting effect.

Fig. 1 shows a representative perspective view of the heating module (1 ) of the invention. Accordingly, the heating module (1 ) of the invention is essentially a system that converts electrical energy into thermal energy. The heating module (1 ) works by means of the resistor (50) inside. When the electric current is applied to this resistor (50), heat is generated due to the resistance of the resistor (50). This generated heat is transferred to the water inside the heating module (1 ). Thus, the temperature of the water increases. The heating module (1 ) heats the water through this process, providing the required hot water. This heating module (1 ) can be used to heat domestic water in areas such as houses and offices in a possible embodiment of the invention, or it can be integrated into existing combi boilers in alternative embodiments of the invention to provide sudden heat loading and capacity increase in space heating.

Fig. 2 shows a representative exploded view of the heating module (1 ) of the invention. Accordingly, the heating module (1 ) of the invention is essentially configured to comprise at least one flow pipe (10) through which fluid can pass; at least one resistor (50) positioned adjacent to said flow pipe (10) and capable of heating; at least a body first part (21 ) and at least a body second part (22) in which the flow pipe (10) and the resistor (50) are positioned; at least one service hatch (40) allowing access to the inside of the body (20) and repairing malfunctions; at least one sensor (51 ) for detecting the temperature of the fluid inside the flow pipe (10); at least one transition part (41 ) allowing cable connections from inside the body (20).

Said flow pipe (10) is the main path in which the fluid inside the heating module (1 ) moves. The structure of the flow pipe (10) is optimized to ensure that the fluid circulates effectively around the resistor (50) which is the heating element, and maximum heat exchange. The geometry of the flow pipe (10) influences the transition time of the fluid through the heating module (1 ) and thus the heat uptake. For this, the flow pipe (10) is essentially formed on top of each other to form layered zigzags. The flow pipe (10) is manufactured from stainless steel material in a possible embodiment of the invention. The resistor (50) can also be manufactured from stainless steel-based material. However, the invention is not limited to these and it is possible to use different combinations of materials. Making the resistor (30) out of aluminum material improves heat transfer, while making the flow pipe (10) out of stainless steel improves lifetime. The flow pipe (10) comprises at least one inlet-outlet part (30) on one side and at least one collector (31 ) on the other side. Said inlet-outlet part: (30) is the part that allows the entry and exit of the fluid into the heating module (1 ). This inlet-outlet part (30) ensures the continuous and controlled movement of the fluid, increasing the efficiency and effectiveness of the heating process. The inlet-outlet part (30) is configured to allow fluid to enter and exit the flow pipe (10) as well as to maintain the flow integrity between the layers of the flow pipe (10). Said collector (31 ) is located on the opposite side of the inletoutlet part (30) to ensure that the flow pipe (10) is positioned in a stacked, layered arrangement. Thanks to the collector (31 ), the fluid inside the heating module (1 ) is spread over a larger area and thus absorbs heat more efficiently. (1 )

The resistor (50) belonging to the heating module (1 ) is a heat source. As the electric current passes through the resistor (50), the resistor (50) heats up and this heat is transferred to the fluid circulating in the flow pipe (10). The resistor (50) does not come into contact with the fluid in the flow pipe (10). The resistor (50) is located on at least one of the layers of the flow pipe (10). In the preferred embodiment of the invention, the resistor (50) is configured to be located between each layer of the flow pipe (10). Thus, the capacity of the heating module (1 ) can be regulated depending on the number of resistors (50). In this way, direct contact of the resistor (50) with the fluid in the flow pipe (10) is prevented and limescale production problems are eliminated. In the heating module (1 ), the flow pipe (10) and the resistor (50) are located in the body. The body (20) consists essentially of a body first part (21 ) and a body second part (22). This two part body (1 ) forming the outer casing of the heating module (20) protects and supports the internal components. The junction of the two parts is crucial for maintenance and repair operations, as it provides access to the inside of the heating module (1 ). The body (20) is essentially manufactured from plastic-based material. However, the inwardfacing side of the body (20) may be covered with insulating material to retain heat. Said service hatch (40) is located on one side of the body (20). Said service hatch (40) provides access to the components in the body (20) and especially to the electrical connections of the resistor (50). The service hatch (40) is in an easily opening and closing form. In this way, it is possible to perform malfunction detection and repair operations quickly and effectively. The transition part (41 ) located on the body (20) is a component that provides the entry and exit of electrical cables into the heating module (1 ). With the presence of the transition part (41 ), unwanted heat losses are also prevented. The sensor (51 ) of the heating module (1 ) detects the temperature of the fluid and transfers it to a control unit (not shown in the figures). In this way, the energization of the resistors (50) is managed.

The heating module (1 ) structure described above contains many features that minimize the problem of limescale production. The flow pipe (10) used in the design of the heating module (1 ) is optimized to ensure maximum heat exchange by effectively circulating the fluid around the resistor (50). The zigzag or layered structure of the flow pipe (10) allows the water to make longer and indirect contact with the heating element. This, in turn, increases heat transfer and reduces limescale formation. Distributing the resistor (50) to the different layers of the heating module (1 ) evens out the heat distribution and prevents overheating and thus rapid limescale formation of each resistor (50).

The scope of protection of the invention is specified in the appended claims and cannot be limited to what is described for illustrative purposes in this detailed description. It is clear that a person skilled in the art can produce similar embodiments in the light of what is explained above, without deviating from the main theme of the invention. REFERENCE NUMERALS GIVEN IN THE DRAWING

1 Heating Module 10 Flow Pipe

20 Body

21 Body First Part

22 Body Second Part

30 Inlet-Outlet Part

31 Collector

40 Service Hatch 41 Transition Part

50 Resistor

51 Sensor

Claims

1 . A heating module (1 ) for the use of electrical energy in fluid heating, comprising at least one flow pipe (10) through which the fluid is passed, at least one resistor (50) for providing heat, and at least one body (20) for positioning said resistor (50) and the flow pipe (10) in, characterized in that the resistor (50) is located adjacent to the flow pipe (10) without contacting the fluid in order to prevent the formation of limescale.

2. A heating module (1 ) according to claim 1 , characterized in that it comprises at least one service hatch (40) enabling access to the inside of the body (20) and repair of malfunctions.

3. A heating module (1 ) according to claim 1 , characterized in that the body (20) comprises at least a body first part (21 ) and a body second part (22).

4. A heating module (1 ) according to claim 1 , characterized in that it comprises at least one sensor (51 ) for detecting the temperature of the fluid inside the flow pipe (10).

5. A heating module (1 ) according to claim 1 , characterized in that the flow pipe (10) has a zigzag or layered structure, and the resistor (50) is located between at least one of these layers.

6. A heating module (1 ) according to claim 5, characterized in that it comprises at least one inlet-outlet part (30) to allow fluid entry and exit on one side and at least one collector (31 ) on the opposite side of the flow pipe (10) for ensuring that the flow pipe (10) has a zigzag or layered structure.

7. A heating module (1 ) according to claim 1 , characterized in thatthe resistor (50) is manufactured from aluminum material.

8. A heating module (1 ) according to claim 1 , characterized in that the flow pipe (10) is manufactured from stainless steel material.

9. A heating module (1 ) according to claim 1 , characterized in that it comprises at least one transition part (41) for the passage of an electric cable between the inside of the body (20) and the outside.

10. A heating module (1 ) according to claim 1 , characterized in that the body (20) is manufactured from a plastic-based material and covered with insulating material to retain heat on inward-facing surfaces.