Self-Regulating Water Boiler

Description

FIELD OF THE DISCLOSED TECHNOLOGY

The present technology relates to water boilers, and, more specifically, to water boilers which conserves energy by reducing thermal output of a heating element when flow rates of water are below a certain threshold.

BACKGROUND

Due to the high heat capacity of water, appliances such as boilers and heaters demand high inputs of energy in order to heat water for utilization. These appliances are used in residential, commercial, and industrial settings, thereby significantly contributing to the energy costs of those locales. Reduction of the energy required to heat water can thereby lower energy costs and can in turn dramatically reduce financial expenditures and hardships on tenants and businesses. Furthermore, environmental effects of electricity generation and fuel combustion can be mitigated.

Traditional boiler systems keep their respective heating mechanisms activated at all times unless manually turned off. This results in energetic consumption which is often wasteful, as hot water is not always needed in an immediate time frame. For example, a restaurant does not require hot water for dishwashers whilst the restaurant is closed.

SUMMARY

It is an object of the present technology to maximize energetic efficiency by detecting when hot water is needed by measuring hot water output rates of hot-water-producing utilities, and reduce the temperature of the stored water when heating thereof is not required.

A self-regulating water boiler has a boiler water tank, which fluidly connects to an exterior water source via an input pipe and which fluidly connects to an external usage site via an output pipe. A flow sensing mechanism having an input detects the rate of flow of water through the output pipe. The flow sensing mechanism is fixedly connected to either the input or the output pipe. “Fixedly connected” is defined as “two devices or parts thereof which are designed to remain stationary relative to one another at a point of connection, during ordinary and intended use of the devices/parts of devices”). A heating element within the boiler water tank heats water within when the heating element is in an active state. The activation and deactivation, either partial or full, is initiated by a contactor. The contactor functions as a communication hub by which data and instructional commands between interfacing components of the self-regulating water boiler are exchanged. Two components are said to be/defined to be “interfacing” when they are arranged in a manner such that at least some data, sent via wireless or wired data connection, exchanged therebetween is interpretable by the respective devices to change functionality of one of the devices, either directly or via intermediary components.

For example, when the flow sensing mechanism detects a flow rate of water below a pre-defined threshold, the contactor switches the heating element to a non-active state, causing the self-regulating water boiler to conserve energy. The pre-defined threshold of water flow, may be, but is not limited to, being volumetric or velocity-dependent. The advent of such a mechanism dependent on the pre-defined threshold is that the water boiler identifies periods of relatively little hot water usage and demand, and thus conserves resources and reduces waste by limiting the amount of energy expended on maintaining high temperatures of the water housed within the tank. It is by this nature that the water boiler is said to be “self-regulating”.

The contactor may instead, under the circumstances of a detection of a flow of water below the pre-defined threshold, only partially deactivate the heating element, by, for example, reducing, but not entirely shutting, the flow of electricity or fuel to the heating element. The heat of the water in the tank may thus be somewhat sustained whilst energy consumption is reduced, so that should the self-regulating water boiler need to output hot water, the time necessary for the boiler to heat up the water within the tank is significantly shorter than if the heating element were entirely deactivated. “Activation” and “deactivation” thus refer to and are defined as changes in thermal output, and excludes irreversible breakage or damage to components. “Activation” and “deactivation” may be relative to a starting thermal output strength and/or may be a full reversibly disabling of functionality/heating of a device being deactivated. For instance, an increase in thermal output from 100 kW to 150 kW may be referred to as an “activation.” A “full activation” refers to an increase in thermal output to the maximum thermal output capability/capacity of a heating element or substantially as such. A “full deactivation” is a case of deactivation where thermal output is decreased/set to okW as a result of electrical current, fuel combustion, or other source of thermal energy of the heating element being disabled and/or modified to be such by the contractor.

The self-regulating water boiler may have a manual override mechanism, which has three configurations. In a first configuration, activation and deactivation of the heating element are determined by the predefined threshold of the flow of water through the self-regulating boiler, as detected by the flow sensing mechanism. In a second configuration of the manual override mechanism, the contactor activates the heating element, whereafter the heating element remains activated regardless of flow rates of water. In yet a third configuration of the manual override mechanism, the contactor inactivates the heating element, which remains activated independent of the predefined threshold of the flow of water. The manual override mechanism is repeatedly switchable between the three configurations.

Turning to the flow sensing mechanism, a first embodiment may constitute a paddle located within the output pipe, a spring fixedly connected to the paddle, and a switch. The paddle is pushed by a flow of water from a first resting position to a second activated position, such that the spring compresses and activates the switch. The activation of the switch indicates the presence of the water flow. Upon a cessation of the water flow, the paddle resiliently reassumes the first resting position. The paddle may be calibrated such that it is resistant to flows of water that are volumetrically or kinetically below the pre-defined threshold of water necessary to activate the heating element. Thus, the movement of the paddle may be correlated to the presence of a flow of water that meets or surpasses the pre-defined threshold, thereby enabling the self-regulating water boiler to rely on the motion of the paddle and the resultant orientation of the switch to regulate the heating element.

The flow sensing mechanism may alternatively comprise a transmitter, which sends ultrasonic waves into a pipe of the self-regulating water boiler. The ultrasonic waves are modified by a flow of water. The modifications are then detected and read by a receiver. The specific modifications to the ultrasonic waves are indicative of a quantifiable flow-rate of water, which is compared to the required threshold of water flow rate in order to determine the activation or deactivation of the heating element. A display connected to the contactor may display the flow-rate of water through said self-regulating water boiler and the pre-defined flow rate threshold.

The self-regulating water boiler may integrate time intervals into the process of activating and deactivating the heating element. The contactor, for instance, may wait for the elapsing of a first pre-set time interval before at least partially deactivating the heating element, should the flow rate of water be detected to be below the flow threshold. The contactor may then wait for the elapsing of a second time interval before fully deactivating the heating element in a scenario where it had not been fully deactivated after the elapsing of the first time interval. The first and second pre-set time intervals may be programmable and modifiable by inputting data into a manual input device, “programmable” being defined as “able to be given a default value or course of action to be executed in response to specific conditions.”

The self-regulating water boiler may have a thermometer, which measures water temperature within the boiler water tank. When the thermometer detects a water temperature lower than a first pre-set temperature, the contactor reactivates the heating element for a duration of time until the thermometer detects that the water temperature has surpassed the first pre-set temperature. The first pre-set temperature may be programmable and modifiable via a manual input device.

When the heating element is activated and the thermometer detects a water temperature above a second pre-set temperature, the contactor may deactivate the heating element in part or in full, such that the water temperature is maintained to be within five degrees Fahrenheit of the second pre-set temperature. The second pre-set temperature may be programmable and modifiable via a manual input device.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic of the constituent components of a self-regulating water boiler in an embodiment of the disclosed technology.

FIG. 2 is a high-level block diagram of a method of self-regulation according to determined flow rates of a self-regulating water boiler in an embodiment of the disclosed technology.

FIG. 3 is a high-level block diagram of a method of maintaining desired water temperature in a self-regulating water boiler in an embodiment of the disclosed technology.

FIG. 4 is a high-level block diagram of a boiler processor in an embodiment of the disclosed technology.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE DISCLOSED TECHNOLOGY

A self-regulating water boiler comprises an input pipe fluidly connecting a water source to a boiler tank storing and heating water, a heating element inside the boiler tank, an output pipe leading to an external usage site, and a flow sensor measuring rate of water flow into the self-regulating boiler. When the flow rate is measured to be less than the threshold, the heating element at least partially deactivates, thereby conserving energy whilst demand for hot water is insufficient to necessitate maximum thermal output of the heating element. The deactivation of the heating element may occur in stages, in which specific time intervals must elapse before partial or full deactivation of the heating element. When the flow rate is measured to be greater than or equal to the threshold, the heating element is reactivated.

Embodiments of the disclosed technology will become more clear in view of the following description of the figures.

FIG. 1 is a schematic of the constituent components of a self-regulating water boiler in an embodiment of the disclosed technology. A boiler tank 32 fluidly connects to an exterior water source 45 via an input pipe 44, such that the upon demand, the boiler tank 32 draws water therefrom for subsequent storage, heating, and dispensing to other elements such as a dishwasher. Dispensing of water from the boiler tank 32 is carried out via an output pipe 60, the output pipe fluidly connecting the boiler tank 32 to an external usage site 46. The usage site 46 is “external” in housed exterior to the components of the self-regulating water boiler through which water flows-namely the input pipe 44, the boiler tank 32, and the output pipe 60. Any location to which water exits from the output pipe 60 may constitute an external usage site 46.

A dishwasher is an example of such an external usage site 46. Sanitation regulations as well as chemical properties of germs and bacteria stipulate minimum temperature thresholds which water that is flushed through dishwashers must meet or surpass in order to effectively sanitize food utensils. Thus, a user of a self regulating water boiler, in embodiments of the disclosed technology, connects the input pipe 44 to a piping system that draws water from a municipal reservoir, and subsequently connects the output pipe 60 to a commercial or industrial dishwasher in a food production facility. In doing so, the self-regulating water boiler regulates water temperature accordingly in a manner that minimizes energy expenditures leading to increased efficiency and reduced costs. The mechanisms by which the self-regulating boiler does so will become clear with further description of the drawings.

A self-regulating water boiler also constitutes a heating element 30 within the boiler tank 32, the boiler tank 32 being the component of water storage whilst the water is heating. The heating element 30 may be a metallic coil, for example, or another mechanism, through which thermal energy is transferred to water within the tank 32. The heating element 30 may be fixedly connected to the interior of the water tank 32. The heating element 30 may supplementally or comprise/consist of a subsection of an interior surface of the water tank 32, whose backside exterior to the water boiler tank 32 is exposed to a fire or pilot. In addition to an active state in which the heating element 32 heats water within the boiler tank 32, the heating element 30 may be operable in a plurality of states of varying power levels. Described differently, the amount of thermal energy supplied to the heating element 30 may be variable, such that the strength of the heating element 30 and temperature to which it raises water within the boiler tank 32 varies accordingly. This feature of variability is, in some embodiments, integral to the self regulation of a self-regulating water boiler, as will be further described.

The activation condition and strength of the heating element 30 is, either directly or via intermediate components, regulated by a contactor 36. The contactor 36 functions as a communication hub by which data and instructional commands between interfacing components, wired or wirelessly, of the self-regulating water boiler are exchanged. The contactor 36 may comprise a microchip or processor. An example of regulation of the heating element 30 may constitute a microchip acting as a contactor 36 directing, via wired connection, a flame pilot to lower methane output rates, thereby reducing the size and thermal output of fires resulting from combustion. The contactor 36 is said to selectably regulate the activation of the heating element, “selectably regulate” being defined as “choosing, upon the meeting or lack of meeting of criteria, between a plurality of states.”

The contactor 36 may further comprise a separate processing unit, referred to as a “smart card” 40. For purposes of this disclosure, embodiments comprising a “smart card” 40 are described as having a contactor 36, which should be viewed as inclusive of the smart card 40. Thus, components of a self-regulating water boiler connected to the contactor 36 via the smart card 40 are described simply as being connected to the contactor 36.

A temperature sensor/thermometer 34 affixed to the boiler tank 32 may interface with the contactor 36, whereby the thermometer 34 measures the water temperature inside the boiler tank 32 before subsequently relaying temperature data to the contactor 36. The contactor 36 may further interface with a display 42, the display 42 displaying data related to the functioning of the self-regulating water boiler. Such data may include or relate to: volume of water inside boiler tank 32, intake rate of water via input pipe 44, output rate of water via output pipe 60, temperature of water inside boiler tank 32 (as measured by temperature sensor 34), and pre-set temperature and flow thresholds, as will be described further in this disclosure. The display 42 may constitute an input mechanism, whereby temperature and flow thresholds can be set and modified, the purpose of which will be further described throughout this disclosure.

FIG. 4 is a high level block diagram of a boiler processor used in an embodiment of the disclosed technology. The boiler processor 70, defined as a physical hardware device and node where data are received and transmitted to another device via electronic or wireless transmission, has a sub-processor 78 directing the interactions and executions of processes of the constituent components of the self-regulating water boiler. The boiler processor further comprises memory 74 (volatile and/or non-volatile) for temporary storage of data, storage 72 for permanent storage of data, and input/output 76 which receives and returns data, and an interface 80 for connecting via electrical connection to other boiler components. The boiler processor 70 of FIG. 4 may be a detailed view of the contactor 36, the smart card 40, the display 42, or a combination thereof.

Turning back to FIG. 3, the display 42 may further constitute a manual override input, though the manual override input may be located elsewhere within the disclosed technology in the form of a physically moveable switch. The manual override input mechanism may comprise three configurations, between which the manual override input mechanism is repeatedly switchable, “repeatedly” switchable being defined as “at least one thousand times without loss of functionality”. In a first configuration, activation and deactivation of the heating element 30 are determined by a predefined threshold of flow of water through the self-regulating boiler, as detected by said flow sensing mechanism, as will be described further in this disclosure. In a second configuration, the manual override mechanism, via the contactor 36, activates the heating element 30, the activation being independent of a threshold of a flow of water. In a third configuration, the manual override mechanism, via the contactor 36, inactivates the heating element 30, the inactivation being independent of a threshold of a flow of water.

Flow rates of water are determined by a flow sensing mechanism 38. The flow sensing mechanism 38 depicted in FIG. 1 is an ultrasonic flow sensor affixed to the input pipe 44.

The flow sensing mechanism 38, however, may be affixed to either the input pipe 44 or the output 60. Shown in greater detail is the ultrasonic flow sensor 38 affixed to a pipe 54, which may be either the input pipe 44 or the output pipe 60, the ultrasonic flow sensor 38 comprising a transducer 50 and a receiver 52. The transducer sends electromagnetic waves into the pipe 54, whereupon a presence of water in the pipe 54 modifies the electromagnetic waves in a manner detectable by the receiver 52, which receives waves from the pipe 54. The modification of the electromagnetic waves of the transducer 50 may affect the frequency, amplitude, or other quantifiable characteristics of the waves. The modifications, as they are quantifiable, correlate to specific volumes of water, which in turn is indicative of flow rate of water through the pipe 54. Described differently, the modifications undergone by electromagnetic waves in water are directly correlated to the amount of water present, such that in observing a modification to a transmitted wave, the amount of water present can be determined. The substantially immobile transducer 50 and receiver 52 are advantageous in being resistant to functional degradation due to the buildup of limescale typically affecting mobile flow sensing mechanisms.

Another embodiment of the disclosed technology comprises a flow sensing mechanism 38 having a paddle 39 located within either said input pipe 44 or said output pipe 60, a spring fixedly connected to the paddle, and a switch. When water flows through the pipe in which the paddle 39 is located, the flow of water pushes the paddle in the direction of the flow of water from a first resting position into a second activated position, which in turn compresses the spring, activating the switch. The activation of the switch alerts the contactor of a detection of water flow. Upon the cessation of water flow, the paddle 39 resiliently reassumes the first resting position, “resiliently” being defined as “returning to a resting state after forces changing the device out of the resting state are removed or cease to act upon the device.” The resistance of the paddle 39 can, in some embodiments, be calibrated to withstand directional kinetic forces below a certain threshold, thereby ensuring that the switch is activated only when the flow of water exerts force greater than that of the threshold minimum. In another embodiment, the switch is activated only upon a pre-defined minimum movement of the paddle which can be a minimum movement over a minimum period of time. This is in order to avoid turning on and off of the boiler based on momentary or small changes in flow which are less than that which are indicative of a change in use/non-use of the hot water via an output pipe 60.

In all embodiments, the flow sensing mechanism 38 interfaces with the contactor 36, either directly or via an intermediate mechanism, such that data pertaining to detected flow rates of water are relayed to the contactor. Flow of water is induced by the self-regulating water boiler drawing in water to be heated in the boiler tank 32 and to be subsequently used at an external usage site 46.

FIG. 2 is a high-level block diagram of a method of self-regulation according to determined flow rates of a self-regulating water boiler in an embodiment of the disclosed technology. The first step of self-regulation is determining whether or not a pre-set flow threshold of water is met 4a. The flow threshold is a quantitative measure, which may be, but is not limited to being, volumetric or velocity dependent. The flow threshold may be set or modified via an input device, such as the display 42. The flow sensor 38 continuously measures flow rate of water through a pipe 54 and sends data pertaining thereto to the contactor 36.

If the flow threshold is met, meaning that the flow of water is quantitatively equivalent or greater than the minimum set by the flow threshold, the heating element 30 is activated by the contactor 36. This activation may be a full activation—an activation in which the heating element 30 outputs maximum thermal output—or the activation may be a partial activation—an activation in which the heating element 30 outputs less than maximum thermal output.

If the flow threshold is not met and the heating element 30 is not activated 5, the self-regulating boiler is in a dormant state, in which no thermal energy is released for purposes of water heating. This dormant state maximizes efficiency and energy savings, as the self-regulating water boiler identifies when the demand for hot water is not above the threshold that warrants activation of the heating element 30. The self-regulating water boiler remains in the dormant state until the flow threshold is met, whereupon the heating element 30 is at least partially activated by the contactor 36.

If the flow threshold is not met but the heating element 30 is activated, the self-regulating water boiler initiates a sequence of steps to reduce energetic consumption and to allow the water in the boiler tank 32 to cool. In some embodiments, a first pre-set time interval must elapse 6a before the heat/thermal output of the heating element 30 is reduced in step 6b, while in other embodiments the heat/thermal output reduction in step 6b occurs immediately after the determination that the flow threshold is not met. Subsequently, a second pre-set time interval elapses in step 6c, after which, if the flow threshold is not met, the contactor 36 entirely deactivates the heating element 30 in step 6d, such that no thermal energy is directed thereto for release into the boiler tank 32 until the flow threshold is once again met.

In some embodiments, the first and second pre-set time intervals are programmable and modifiable via an input device that may be the display 42. Embodiments of the disclosed technology may not wait for the elapsing of two time intervals before fully deactivating the heating element 32. Embodiments of the technology may deactivate the heating element 32 according to only a subset of the aforementioned steps 6a-6d. Whilst the deactivation steps 6a-6d are executed, the flow sensing mechanism 38 continuously and contemporaneously checks to see if the flow threshold is met. (The activation of an appliance, such as a dishwasher or a heater at the external usage site 46, may draw water from the boiler tank 32, thereby cycling new water into the self-regulating boiler at a rate detectable by the flow sensing mechanism 38 that is above the flow threshold, while the self-regulating water boiler is deactivating the heating element 30 in a deactivation sequence 6a-6d.) If the flow threshold is indeed met during deactivation 6a-6d of the heating element, the deactivation sequence 6a-6d is ceased and bypassed, whereupon the contactor 36 activates the heat 12 to the boiler tank 32 via the heating element 30. If the flow threshold is not met, the deactivation sequence 6a-6d progresses until the heating element 30 is partially (in some embodiments) or entirely (in alternative embodiments) deactivated. The heating element 30 then remains deactivated until the flow threshold is once again met.

FIG. 3 is a high-level block diagram of a method of maintaining desired water temperature in a self-regulating water boiler in an embodiment of the disclosed technology. Two parameters-a first pre-set temperature and a second pre-set temperature-define an acceptable temperature range, inclusive of the pre-set temperatures, in which the water temperature must lie. Described using set notation:

Water Temperature E [First Pre-set Temperature, Second Pre-set Temperature]. These two pre-set temperatures are programmable and modifiable via an input device, such as display 42, in some embodiments of the disclosed technology.

In order to maintain the water temperature of the water in the boiler tank 32, the contactor 36 compares the temperature reading of the water as recorded by the temperature sensor 34 to the second pre-set temperature whilst the heating element 30 is activated. If the water temperature is greater than the second pre-set temperature whilst the heating element 30 is activated, the heating element 30 is deactivated 22 in order to allow the water to cool to an acceptable temperature between the first and second pre-set temperatures. Thus, the second pre-set temperature is the upper limit of acceptable water temperatures. Conversely, the first pre-set temperature is the lower limit thereof.

Further, the contactor 36 compares the temperature reading of the water in the boiler tank 32 as recorded by the temperature sensor 34 to the first pre-set temperature, whilst the heating element 30 is inactive 24. If the water temperature is indeed below the first pre-set temperature, the contactor 36 activates the heating element 32 in order to heat the water to a temperature between the two pre-set temperatures 26. If the water temperature is found to be neither above nor below the acceptable temperature range (as previously described), the contactor 36 maintains the activation condition of the heating element 30, i.e fuel/power supply rates to the heating element are kept constant 28.

In some embodiments, the activation and deactivation of the heating element 32 is executed such that the water temperature is maintained to be within five degrees Fahrenheit, inclusive, of the first or second pre-set temperature.

The contactor continuously, some embodiments, compares the water temperature to the two pre-set temperatures and adjusts or maintains power/fuel supply rates to the heating element 30 continuously. This regulation of water temperature may be executed even during the deactivation sequence 6a-6d of the heating element 30, as the decrease in heat 6b after the elapsing of the first time interval 6a whilst the flow threshold is not met may be intended to decrease the water temperature to a specific temperature.

FIG. 4 is a high-level block diagram of a boiler processor in an embodiment of the disclosed technology. Computing device 400 comprises a processor 450 that controls the overall operation of the device by executing the device's program instructions which define such operation. The device's program instructions may be stored in a storage device 420 (e.g., magnetic disk, database) and loaded into memory 430 when execution of the console's program instructions is desired. Thus, the device's operation will be defined by the device's program instructions stored in memory 430 and/or storage 420, and the console will be controlled by processor 450 executing the console's program instructions.

The device 400 also includes one or a plurality of input network interfaces for communicating with other devices via a network (e.g., packet-switched data network). The device 400 further includes an electrical input interface for receiving power and data from a power source. A device 400 also includes one or more output network interfaces 410 for communicating with other devices. Device 400 also includes input/output 440, representing devices which allow for user interaction with a computing device (e.g., touch display, keyboard, fingerprint reader etc.).

One skilled in the art will recognize that an implementation of an actual device will contain other components as well, and that FIG. 4 is a high level representation of some of the components of such a device for illustrative purposes. It should also be understood by one skilled in the art that the methods, systems and/or devices depicted in FIGS. 1 through 3 may be implemented on a device such as is shown in FIG. 4.

Any device or aspect of the technology can “comprise” or “consist of” the item it modifies, whether explicitly written as such or otherwise.

When the term “or” is used, it creates a group which has within either term being connected by the conjunction as well as both terms being connected by the conjunction.

The term “and/or” is inclusive of the items which it joins linguistically, and each item by itself.

“Substantially” is defined as “between 95% and 100%, inclusive, of the term which is being modified with ‘substantially”. Any device or method described herein above can be modified as being “substantially” as described.