WO2007010538A1

WO2007010538A1 - Method and means for producing hot water from a hot water boiler system

Info

Publication number: WO2007010538A1
Application number: PCT/IL2006/000841
Authority: WO
Inventors: Zvi Shtilerman
Original assignee: ACTIVEHOME Ltd
Current assignee: ACTIVEHOME Ltd
Priority date: 2005-07-20
Filing date: 2006-07-20
Publication date: 2007-01-25
Anticipated expiration: 2008-01-20
Also published as: WO2007010538B1

Abstract

The invention provides a method for producing hot water from a hot water boiler system 10 comprising the steps of: (a) supplying water through an inlet line 26 from an upper portion of a hot water boiler 12 to a heating element sleeve 24 having a heating element 14, wherein the water is supplied to the heating element 14 after flowing across a thermostat 16 located in an inlet sleeve 26 leading to the heating element sleeve 24; (b) providing a further hot water line 28 which connects a hot water line outlet 22 of the heating element sleeve 24 to an upper portion of the hot water boiler wherein the height difference between the lower of either of the upper ends 27 of the inlet sleeve 26 or an outlet 29 of the further hot water line 28 in the upper portion of the hot water boiler and the top of the hot water boiler define a hot water volume V maintained hot by the heating element 14 and available for substantially immediate use or consumption; and (c) providing a hot water consumption line 22 with an inlet 21 positioned higher than the heating element 14 within the boiler 12 for extracting the hot water from the hot water boiler 12 for hot water use or consumption.

Description

METHOD AND MEANS FOR PRODUCING HOTWATER FROM A HOTWATER

BOILER SYSTEM Field of the Invention

The present invention relates to the field of producing hot water. More particularly, the invention relates to a method of and means for producing hot water from a hot water boiler system. Background of the Invention

Over the last few years, the effective and efficient production of hot water has become increasingly important. This is particularly the case as the cost of energy sources such as liquid and gaseous fuels has been escalating lately.

Solar water heaters with electrical back-up capacity are designed to store quite a large quantity of water due to the virtually "free energy" coming directly from the sun for most of the year.

In case of shortage of hot water due to weather conditions or malfunction of the system, there is a need to use electrical energy in order to supply sufficient hot water for household use. The main problem with such an electrical back-up system is the large quantity of water, often all of the water present in the hot water tank, to be heated which means that a huge amount of electrical energy will be spent for long periods of time. Another difficulty is related to the inconvenience in determining the quantity of hot water and its temperature in the tank and in controlling the activity of switching on to have hot water available on time and switching off later on.

There are many solutions to these problems, some of them very simple such as: using an additional small volume tank for electrically heating the water; and using an instantaneous gas water heater in series with a hot water line from the solar system tank.

Some solutions are covered by patents such as: Israeli patents Nos. 59569 dated 09/85; 16824 dated 02/64 and 78015 dated 12/89, that consist of a sleeve around the heating element which transfers the heated water toward the upper zone of the tank while throttling the flow by an orifice or external valve; 121064 dated 07/01 and 104768 dated 04/94 that consist of inter-layers or inter-dividers meant to avoid the mixing of hot and cold water; 63300 dated 06/85, 63003 dated 06/85, 53083 dated 01/85 and 105097 dated 08/96 that consist of an apparatus for forcing the hot water from the upper part of the tank through the heating element chamber; 59575 dated 12/83 and 119984 dated 05/00 that consist of an apparatus preheating the water coming to the heating element sleeve from the area above the sleeve; 53971 dated 12/80 that consists of two heating elements - one at the bottom and one at the upper zone of the tank; and US patents 4282421 dated 08/81 that consists of a heating element sleeve and a combination of heat exchangers for preheating the water; 4551613 dated 11/85 that consists of a heating element surrounding the pipe all along its length up to the discharge outlet; 4403137 dated 09/83 that consists of a sleeve perforated all along its length; 4514617 dated 4/85 and 6321036 dated 11/01 that consist of an apparatus for producing hot water for consumption flowing through the sleeve.

While the above mentioned patents describe inventions relating to providing hot water for immediate consumption, none of them are concerned with limiting the amount of hot water available for instantaneous use. In addition, only little consideration is given in these patents to reducing the rate at which power is consumed to provide the required hot water.

There is therefore a need to provide a new and improved method of and apparatus for producing hot water wherein the disadvantages as outlined are reduced or substantially overcome.

It is therefore an object of the present invention to provide method of and means for producing hot water from a hot water boiler system, which increases efficiency of hot water production when compared to other methods or systems.

Other objects and advantages of the invention will become apparent as the description proceeds. Summary of the Invention

Thus according to the present invention there is now provided a method for producing hot water from a hot water boiler system comprising the steps of:

(a) supplying water through an inlet line from an upper portion of a hot water boiler to a heating element sleeve having a heating element, wherein the water is supplied to the heating element after flowing across a thermostat located in an inlet sleeve leading to said heating element sleeve;

(b) providing a further hot water line which connects a hot water line outlet of the said heating element sleeve to an upper portion of the hot water boiler wherein the height difference between the lower of either of the upper ends of said inlet sleeve or an outlet of said further hot water line in the upper portion of said hot water boiler and the top of said hot water boiler define a hot water volume maintained hot by said heating element and available for substantially immediate use or consumption; and

(c) providing a hot water consumption line with an inlet positioned higher than said heating element within the boiler for extracting the hot water from the hot water boiler for hot water use or consumption. In addition, the present invention provides an apparatus for producing hot water from a hot water boiler system comprising:

(a) an inlet line for supplying water from an upper portion of a hot water boiler to a heating element sleeve having a heating element wherein the water is supplied to the heating element after flowing across a thermostat located in an inlet sleeve leading to said heating element sleeve;

(b) a further hot water line which connects a hot water line outlet of the heating element sleeve to the upper portion of the hot water boiler wherein the height difference between the lower of either of the upper ends of said inlet sleeve or an outlet of said further hot water line in the upper portion of said hot water boiler and the top of said hot water boiler define a hot water volume maintained hot by said heating element and available for substantially immediate use or consumption; and

(c) a hot water consumption line with an inlet positioned higher than said heating element within said boiler for extracting the hot water from the hot water boiler for hot water use or consumption.

By use of the present invention, hot water from the upper portion of the hot water boiler is used for providing substantially immediately hot water for consumption. This permits the heating process to be more efficient since the water used for providing hot water is hot water located in the upper portion of the hot water boiler. This contributes to shortening the time of operation of the heating element thus reducing the amount of carbonate build-up and consequently maintaining the efficient operation of the heating element and prolonging the life of the heating element.

Furthermore, by positioning, in accordance with the present invention, the thermostat in an inlet sleeve leading to said heating element sleeve which supplies - A -

the water to said heating element, accurate measurement of the temperature of the heated water and the water to be heated is achieved.

Thus, according to one embodiment of the present invention, an apparatus is provided for producing hot water from a hot water boiler system comprising: an inlet line for supplying water from the upper portion of a hot water boiler to a heating element sleeve having a heating element, wherein the water is supplied to the heating element after flowing across a thermostat located in an inlet sleeve of said heating element sleeve; a further hot water line which connects a hot water line outlet of the heating element sleeve to an upper portion of the hot water boiler wherein the height difference between the lower of either of the upper ends of said inlet sleeve or said further hot water line in the upper portion of said hot water boiler and the top of said hot water boiler define a hot water volume maintained hot by said heating element and available for substantially immediate use or consumption; and a hot water consumption line having an inlet in the upper portion of said hot water boiler for extracting the hot water from the hot water boiler during hot water use or consumption.

Furthermore, according to another embodiment of the present invention, an apparatus is provided for producing hot water from a hot water boiler system comprising: an inlet line for supplying water from the upper portion of a hot water boiler to a heating element sleeve having a heating element, wherein the water is supplied to the heating element after flowing across a thermostat located in an inlet sleeve of said heating element sleeve; a further hot water line which connects a hot water line outlet of the heating element sleeve to an upper portion of the hot water boiler wherein the height difference between the lower of either of the upper ends of said inlet sleeve or said further hot water line in the upper portion of said hot water boiler and the top of said hot water boiler define a hot water volume maintained hot by said heating element and available for substantially immediate use or consumption; and a hot water consumption line is constructed and arranged such that it is located in said heating element sleeve and so that the inlet of said hot water consumption line is located close to and above the heating element. Brief Description of the Drawings

A description of the present inventive subject matter including embodiments thereof is presented and with reference to the accompanying drawings, the description is not meant to be considered limiting in any manner, wherein:

Fig. 1 is a schematic arrangement of an apparatus for producing hot water from a hot water boiler system in accordance with one embodiment of the invention;

Fig. 2 is a schematic arrangement of an apparatus for producing hot water from a hot water boiler system in accordance with another embodiment of the invention;

Fig. 3 is a schematic arrangement of an apparatus for producing hot water from a hot water boiler system in accordance with a further embodiment of the invention; and

Fig. 4 is a schematic arrangement of an apparatus for producing hot water from a hot water boiler system in accordance with an additional embodiment of the invention.

Similar reference numerals and symbols refer to similar components. Detailed Description of Preferred Embodiments

The present invention comprises an apparatus for producing hot water from a hot water boiler system. Fig. 1 shows a hot water boiler system in accordance with an embodiment of the present invention, designated by numeral 10 having hot water boiler 12 shown as a horizontal hot water boiler, heating element 14 and thermostat 16. Usually, such hot water boilers can contain about 80-300 liters of water. In addition, hot water boiler system 10 includes external thermostat 18 and flow switch 20 positioned on hot water outlet or discharge line 22 used for increasing or boosting the temperature of the hot water extracted during hot water consumption while maintaining a substantially low average temperature in hot water boiler 12. Hot water boiler system 10 furthermore includes heating element sleeve 24 containing heating element 14 and thermostat 16 and water is supplied to heating element 14 after flowing across thermostat 16 located in inlet sleeve 26 leading to heating element sleeve 24. Also provided is a further hot water line 28 containing check valve 30, such as a floating ball check valve, etc., located preferably in the lowest portion of further hot water line 28 substantially adjacent heating element sleeve 24, for preventing water other than the water flowing across heating element 14 from being extracted via hot water outlet or discharge line 22 during hot water consumption. Preferably, check valve 30 including its body and ball are constructed of smooth plastic polymer material in order to diminish build up of carbonate sediments. In addition, the sizes of inlet sleeve 26 and further hot water line 28 as well as the size of check valve 30 are preferably chosen to be large enough, e.g. inlet sleeve 26 and further hot water line 28 having a diameter of about 25 mm or a cross-sectional area of about 500 mm2, in order to permit a substantially high thermo-syphon water flow rate at a limited pressure difference so that the temperature of water flowing through inlet sleeve 26 and further hot water line 28 is substantially low to minimize the build up of scale and carbonate sediments. In the present invention, preferably no constrictions are included in the inlet sleeve 26 and further hot water line 28. Fig. 1 shows a height difference between inlet 27 of inlet sleeve 26 and outlet 29 of further hot water line 28. The height difference between the lower of either of the upper end 27 of inlet sleeve 26 or the outlet 29 of the further hot water line 28 in the upper portion of the hot water boiler and the top of the hot water boiler is used for defining a certain volume, V, of water, e.g. between about 25-50 liters, to be maintained at a hot water temperature for substantially immediate use by the consumer during hot water consumption and thus permits a smaller volume of water located in the upper portion of the hot water boiler 12 than the whole hot water boiler 12 to be maintained at the hot water temperature suitable for immediate use. In addition, in the present embodiment, inlet 21 of hot water consumption line or discharge 22 is preferably positioned at a position higher than heating element 14 in order to ensure effective heating of the volume of water traversing heating element 14 from thermostat 16 to inlet 21 of hot water outlet or discharge 22 even during hot water consumption.

In operation, thermostat 16 controls the operation of heating element 14 in order to produce a volume of hot water in hot water boiler 12 between outlet 29 of further hot water line 28 and the top of hot water boiler 12 to be maintained and available for substantially immediate use or consumption. Thus, when hot water is not consumed or extracted from hot water boiler 12, water flows into inlet sleeve 26 via inlet 27 and thereafter into heating element sleeve 24 at its lowest portion across thermostat 16 positioned in the inlet sleeve 26 leading to heating element sleeve 24. The portion of inlet sleeve 26 which is part of heating element sleeve 24 is constructed and arranged such that the water flowing out of inlet sleeve 26 flows across the length of heating element sleeve 24 and the volume of heating element 14 itself where it is heated by the heating element and the hot water thereafter exits the heating element sleeve via further hot water line 28 and check valve 30 through its outlet 29. In such a manner, a thermo-syphon flow pattern or cycle is produced across heating element sleeve 24 and within the upper portion of hot water boiler 12. When hot water is required by the consumer, flow switch 20 is activated, check valve 30 shuts and hot water commences to exit hot water boiler 12 via heating element sleeve 24 through hot water outlet or discharge line 22 and cold water enters through pipe 31. Due to the fact that the inlet 21 of hot water discharge line 22 is positioned at a height higher than heating element 14, the water exiting hot water boiler 12 will be drawn across heating element 14 prior to exiting hot water boiler 12 and heating element sleeve 24, thus ensuring that such water is heated by heating element 14. If necessary, during hot water consumption, external thermostat 18 serves to operate the heating element 14 such that there is boosting of hot water heating and the water is thus heated to the required temperature.

Turning to the embodiment of the invention designated 10A as shown in Fig.2, a hot water boiler system is shown having hot water boiler 12A shown as a vertical hot water boiler, heating element 14A and thermostat 16A. Usually, such hot water boilers can contain about 80-300 liters of water. In addition, hot water boiler system 10A includes external thermostat 18A and flow switch 2OA positioned on hot water outlet or discharge line 22A used for increasing or boosting the temperature of the hot water extracted during hot water consumption while maintaining a substantially low average temperature in hot water boiler 12A. Hot water boiler system 10A furthermore includes heating element sleeve 24A containing heating element 14A and thermostat 16A and water is supplied to heating element 14A after flowing across thermostat 16A located in inlet sleeve 26A leading to heating element 24A. Also provided is a further hot water line 28A containing check valve 3OA, such as a floating ball check valve, etc., located preferably in the lowest portion of further hot water line 28A substantially adjacent heating element sleeve 24A, for preventing water other than the water flowing across heating element 14A from being extracted via hot water outlet or discharge line 22A during hot water consumption. Preferably, check valve 3OA including its body and ball are constructed of smooth plastic polymer material in order to diminish build up of carbonate sediments. In addition, the sizes of inlet sleeve 26A and further hot water line 28A as well as the size of check valve 3OA are preferably chosen to be large enough, e.g. inlet sleeve 26A and further hot water line 28A having a diameter of about 25 mm or a cross-sectional area of about 500 mm^, in order to permit a substantially high thermo-syphon water flow rate at a limited pressure difference so that the temperature of water flowing through inlet sleeve 26A and further hot water line 28A is substantially low to minimize the build up of scale and carbonate sediments. In the present invention, preferably no constrictions are included in the inlet sleeve 26A and further hot water line 28A.

Fig. 2 shows a height difference between inlet 27A of inlet sleeve 26A and outlet 29A of further hot water line 28A. The height difference between the lower of either of the upper end 27A of inlet sleeve 26A or the outlet 29A of the further hot water line 28A in the upper portion of the hot water boiler and the top of the hot water boiler is used for defining a certain volume, V, of water e.g. between about 25- 50 liters, to be maintained at a hot water temperature for substantially immediate use by the consumer during hot water consumption and thus permits a smaller volume of water located in the upper portion of the hot water boiler 12A than the whole hot water boiler 12A to be maintained at the hot water temperature suitable for immediate use. In addition, in the present embodiment, inlet 21A of hot water consumption line or discharge 22A is preferably positioned at a position higher than heating element 14A in order to ensure effective heating of the volume of water traversing heating element 14A from thermostat 16A positioned in the inlet line of heating element sleeve 24A to inlet 21A of hot water outlet or discharge 22A even during hot water consumption.

In operation, thermostat 16A controls the operation of heating element 14A in order to produce a volume of hot water in hot water boiler 12A between outlet 29A of further hot water line 28A and the top of hot water boiler 12A to be maintained and available for substantially immediate use or consumption. Basically, the operation of this embodiment is similar to the operation of the embodiment described with reference to Fig. 1. Thus, when hot water is not consumed or extracted from hot water boiler 12A, water flows into inlet sleeve 26A via inlet 27A and thereafter into heating element sleeve 24A at its lowest portion across thermostat 16A positioned in the inlet sleeve 26A leading to heating element sleeve 24A. Simultaneously cold water enters through pipe 31 A. The portion of inlet sleeve 26A which is part of heating element sleeve 24A is constructed and arranged such that the water flowing out of inlet sleeve 26A flow across the length of heating element sleeve 24A and the volume of heating element 14A itself where it is heated by the heating element and the hot water thereafter exits the heating element sleeve via further hot water line 28A and check valve 3OA through its outlet 29A. Thus, the water flows across the volume of heating element sleeve 24A where it is heated by heating element 14A and the hot water exits the heating element sleeve via further hot water line 28A and check valve 3OA through its outlet 29A. In such a manner, a thermo-syphon flow pattern or cycle is produced across heating element sleeve 24A and within the upper portion of hot water boiler 12A. When hot water is consumed or required by the consumer, flow switch 2OA is activated, check valve 3OA shuts and hot water commences to exit hot water boiler 12A via heating element sleeve 24 through hot water outlet or discharge line 22A. Due to the fact that the inlet 21 A of hot water discharge line 22A is positioned at a height higher than heating element 14A, the water exiting hot water boiler 12A will be drawn across heating element 14A prior to exiting hot water boiler 12A and heating element sleeve 24A thus ensuring that such water is heated by heating element 14A. If necessary, during hot water consumption, external thermostat 18A serves to operate heating element such that there is boosting of hot water heating and the water is thus heated to the required temperature.

As far as the embodiment of the invention shown as a vertical hot water boiler and designated 10B as shown in Fig.3, hot water boiler 12B includes heating element 14B and thermostat 16B. Usually, such hot water boilers can contain about 80-300 liters of water. Hot water boiler system 10B furthermore includes heating element sleeve 24B containing heating element 14B and thermostat 16B. Water is supplied to heating element 14B after flowing across thermostat 16B located in inlet sleeve 26B leading to heating element sleeve 24B. In addition, the sizes of inlet sleeve 26B and further hot water line 28B are preferably chosen to be large enough, e.g. inlet sleeve 26B and further hot water line 28B having a diameter of about 25 mm or a cross-sectional area of about 500 mm2, in order to permit a substantially high thermo-syphon water flow rate at a limited pressure difference so that the temperature of water flowing through inlet sleeve 26B and further hot water line 28B is substantially low to minimize the build up of scale and carbonate sediments. In the present invention, preferably no constrictions are included in the inlet sleeve 26B and further hot water line 28B. Fig. 3 shows a height difference between inlet 27B of inlet sleeve 26B and outlet 29B of further hot water line 28B. Preferably, the height, H, between the outlet 29B of further hot water line 28B and the top of hot water boiler 12B can be e.g. at least 7 cm. The height difference between the lower of either of the upper end 27B of inlet sleeve 26B or the outlet 29B of the further hot water line 28B in the upper portion of the hot water boiler and the top of the hot water boiler is used for defining the volume, V, of water e.g. between about 25-50 liters, to be maintained at a hot temperature for substantially immediate use by the consumer during hot water consumption. In addition, in the present embodiment, inlet 21 B of hot water consumption line or discharge 22B is preferably positioned at a position in the upper portion of hot water boiler 12B in order to extract hot water from the hot portion of hot water boiler 12B (during hot water consumption).

In operation, thermostat 16B controls the operation of heating element 14B in order to produce a volume of hot water in hot water boiler 12B between inlet 27B of inlet sleeve 26B and the top of hot water boiler 12B to be maintained and available for substantially immediate use or consumption. Thus, when hot water is not consumed or extracted from hot water boiler 12B, water flows into inlet sleeve 26B via inlet 27B and thereafter into heating element sleeve 24B at its lowest portion across thermostat 16B positioned in the inlet sleeve 26B leading to heating element sleeve 24B. The portion of inlet sleeve 26B which is part of heating element sleeve 24B is constructed and arranged such that the water flowing out of inlet sleeve 26B flow across the length of heating element sleeve 24B and the volume of heating element 14B itself where it is heated by the heating element and the hot water thereafter exits the heating element sleeve via further hot water line 28B through its outlet 29B. Replacement cold water is drawn in through the pipe 31 B. Thus the water flows across the volume of heating element sleeve 24B where it is heated by heating element 14B and the hot water exits the heating element sleeve via further hot water line 28B through its outlet 29B. In such a manner, a thermo-syphon flow pattern or cycle is produced across heating element sleeve 24B and within the upper portion of hot water boiler 12B. When hot water is required by the consumer, hot water exits hot water boiler 12B via hot water consumption line or discharge line 22B.

Turning to the embodiment of the invention shown as a horizontal axis hot water boiler and designated 1OC as shown in Fig.4, hot water boiler 12C includes heating element 14C and thermostat 16C. Usually, such hot water boilers can contain about 80-300 liters of water. Hot water boiler system 10C furthermore includes heating element sleeve 24C containing heating element 14C and thermostat 16C. Water is supplied to heating element 14C after flowing across thermostat 16C located in inlet sleeve 26C leading to heating element sleeve 24C. Also provided is a further hot water line 28C. In addition, the sizes of inlet sleeve 26C and further hot water line 28C are preferably chosen to be large enough, e.g. inlet sleeve 26C and further hot water line 28C having a diameter of about 25 mm or a cross-sectional area of about 500 mm^, in order to permit a substantially high thermo-syphon water flow rate at a limited pressure difference so that the temperature of water flowing through inlet sleeve 26C and further hot water line 28C is substantially low to minimize the build up of scale and carbonate sediments. . In the present invention, preferably no constrictions are included in the inlet sleeve 26C and further hot water line 28C. Fig. 4 shows a height difference between inlet 27C of inlet sleeve 26C and outlet 29C of further hot water line 28C. Preferably, the height, H, between the outlet 29C of further hot water line 28C and the top of hot water boiler 12C can be e.g. at least 7 cm. The height difference between the lower of either of the upper end 27C of inlet sleeve 26C or the outlet 29C of the further hot water line 28C in the upper portion of the hot water boiler and the top of the hot water boiler is used for defining the volume, V, of water e.g. between about 25-50 liters, to be maintained at a hot temperature for substantially immediate use by the consumer during hot water consumption. In addition, in the present embodiment, inlet 21 C of hot water consumption line or discharge 22C is preferably positioned at a position in the upper portion of hot water boiler 12C in order to extract hot water from the hot portion of hot water boiler 12C (during hot water consumption).

In operation, thermostat 16C controls the operation of heating element 14C in order to produce a volume of hot water in hot water boiler 12C between inlet 27C of inlet sleeve 26C and the top of hot water boiler 12C to be maintained and available for substantially immediate use or consumption. Basically, the operation of this embodiment is similar to the operation of the embodiment described with reference to Fig. 3. Thus, when hot water is not consumed or extracted from hot water boiler 12C, water flows into inlet sleeve 26C via inlet 27C and thereafter into heating element sleeve 24C at its lowest portion across thermostat 16C positioned in the inlet sleeve 26C leading to heating element sleeve 24C. The portion of inlet sleeve 26C which is part of heating element sleeve 24C is constructed and arranged such that the water flowing out of inlet sleeve 26C flow across the length of heating element sleeve 24C and the volume of heating element 14C itself where it is heated by the heating element and the hot water thereafter exits the heating element sleeve via further hot water line 28C through its outlet 29C. Thus, the water flows across the volume of heating element sleeve 24C where it is heated by heating element 14C and the hot water exits the heating element sleeve via further hot water line 28C through its outlet 29C. In such a manner, a thermo-syphon flow pattern or cycle is produced across heating element sleeve 24C and within the upper portion of hot water boiler 12C. When hot water is required by the consumer, hot water exits hot water boiler 12C via hot water consumption line or discharge line 22C , while cold water enters at 31 C.

While outlets 29 and 29A of further hot water lines 28 and 28A respectively are shown in Figs. 1 and 2 are straight-edged, if preferred a deflector can be added to this outlet in each of the embodiments described with reference to Figs. 1 and 2 so that hot water exiting these outlets will mix effectively with other water present in hot water boilers 12 and 12A respectively. Such a deflector designated 32 and 32A respectively are shown in Figs. 1 and 2.

Furthermore, optionally, if preferred, a heating element comprising two sections can be used instead of heating elements 14 and 14A respectively. One section operates and is controlled by internal thermostat 16 and 16A respectively, while both of the sections operate during water consumption.

Thus, in accordance with the present invention, the height difference between the end or outlet 29 or 29A of further hot water line 28 or 28A and the top of the hot water boiler, respectively shown in Figs. 1 and 2, or the height difference between the lower end or inlet 27B of hot water inlet sleeve 26B and the top of the hot water boiler shown in Fig. 3 defines a predetermined volume of hot water, substantially less than the total volume of hot water boilers 12, 12A, 12B and 12C, that is available for substantially immediate use or consumption. Thus, by designing these ends or outlet 29 or 29A of further hot water line 28 or 28A or inlet 27B, 27C of hot water inlet sleeve 26B, 26C to produce a height difference between each of these ends and the top of the hot water boiler, a hot water volume suitable for substantially immediate use or consumption can be provided for e.g. one person, two persons, three persons, four persons, a family, etc.

In addition, it should be pointed out that while inlet 21 or 21A of hot water outlet or discharge line 22 or 22A is preferably positioned in the close vicinity of further hot water line 28, 28A near check valve 30 or 3OA respectively, and above or at a height higher than heating element 14 or 14A respectively, inlet 21 or 21A, can be positioned at a location anywhere along the length of heating element 14 or 14A respectively. By using the preferred location in the close vicinity of further hot water line 28, 28A near check valve 30 or 3OA respectively, a higher level of thermal efficiency for heating the water with heating element 14 or 14A respectively is achieved as well as permitting simplifying its manufacture. Furthermore, this permits the substantially sole use of water heated by heating element 14 or 14A₁ respectively, as the hot water supplied via hot water outlet or discharge line 22 or 22A for consumption.

Furthermore, inlet 27, 27A of inlet sleeve 26 or 26A are located near the top of hot water boiler 12 or 12A respectively in order to facilitate extraction of air from the hot water boiler system.

In addition, heating element sleeves, 24, 24A, 24B and 24C are constructed preferably from plastic which can operate up to 95°C.

Moreover, the present invention will permit lowering the temperature set by thermostat 16, 16A, 16B and 16C. In accordance with the prior art, usually the temperature would be set at 6O⁰C.

It is to be emphasized that the size of the inlet hot water lines and further hot water lines are preferably chosen to be substantially large in order to reduce the formation and deposition of carbonate in the apparatus described herein and in particular in the further hot water line.

In addition, by using the method and apparatus of the present invention, the amount of time needed for the heating element to reach the desired temperature is small compared to the amount of time apparatuses of the prior art need, thus also ensuring that the carbonate production and deposition when using the methods and apparatus of the present invention will be substantially reduced.

Furthermore, by use of the present invention, hot water from the upper portion of the hot water boiler is used for providing substantially immediately hot water for consumption.

Moreover, by locating, in accordance with the present invention, thermostat 16, 16A, 16B and 16C in the inlet sleeves 26, 26A, 26B and 26C respectively leading to the heating element sleeves which supply the water to the heating element, accurate measurement of the temperature of the water to be heated is achieved. Preferably, the portion of line or inlet sleeve 26, 26A, 26B and 26C where thermostat 16, 16A, 16B and 16C is located is spaced from heating element 14, 14A, 14B and 14C in heating element sleeve 24, 24A, 24B and 24C in order to reduce loss of heat to incoming water supplied to heating element sleeve 24, 24A, 24B and 24C via thermostat 16, 16A, 16B and 16C located in hot water line 26, 26A, 26B and 26C respectively.

These measures contribute to shortening the time of operation of the heating element thus reducing the amount of carbonate build-up and consequently maintaining the efficient operation of the heating element and prolonging its operating life. Thus, the operation of a hot water boiler system in accordance with the present invention will also bring about a savings in energy consumed.

While the above description refers to a horizontal and a vertical hot water tank and a suitable apparatus, the apparatus used for the horizontal hot water tank can, if preferred, be used in a vertical hot water tank.

Furthermore, while the above description refers to a hot water boiler system and embodiments thereof, specifically, the hot water boiler system can be a solar hot water boiler system wherein solar energy or radiation can be used to provide hot water in addition to the heating elements 14, 14A, 14B and 14C described above using e.g. a solar hot water collector.

Furthermore, the present invention can be used as a retrofit kit to retrofit an existing boiler. In other words, the flange containing the heating element sleeve together with the thermostat, heating element and hot water discharge can be used to replace the existing flange of an existing boiler. Auxiliary equipment (e.g. values, controls, etc.) are not shown in the figures for the sake of simplicity.

While some embodiments of the invention have been described by way of illustration, it will be apparent that the invention can be carried into practice with many modifications, variations and adaptations, and with the use of numerous equivalents or alternative solutions that are within the scope of persons skilled in the art, without departing from the spirit of the invention or exceeding the scope of the claims.

Claims

CLAlMS

1. A method for producing hot water from a hot water boiler system comprising the steps of:

(a) supplying water through an inlet line from an upper portion of a hot water boiler to a heating element sleeve having a heating element , wherein the water is supplied to the heating element after flowing across a thermostat located in an inlet sleeve leading to the heating element sleeve;

(b) providing a further hot water line which connects a hot water line outlet of said heating element sleeve to an upper portion of the hot water boiler wherein the height difference between the lower of either of the upper ends of said inlet sleeve or an outlet of the said further hot water line in the upper portion of said hot water boiler and the top of said hot water boiler define a hot water volume maintained hot by said heating element and available for substantially immediate use or consumption; and

(c) providing a hot water consumption line with an inlet positioned higher than said heating element within said boiler for extracting the hot water from the hot water boiler for hot water use or consumption.

2. The method according to claim 1 further comprising the step of using a flow switch and an external thermostat external to the hot water boiler located on the hot water consumption line for increasing the temperature of the hot water extracted during hot water consumption while maintaining a substantially low average temperature in the hot water boiler.

3. The method according to claim 1 further comprising the step of providing a check valve located in the further hot water line for preventing water other than the water flowing across the heating element from being extracted via hot water discharge or consumption line during hot water consumption.

4. The method according to claim 1 further comprising positioning said hot water consumption line within said heating element sleeve with the inlet of said hot water consumption line located close to and above the heating element.

5. The method according to claim 3 further comprising positioning said hot water consumption line within said heating element sleeve with the inlet of said hot water consumption line located close to and above the heating element and also adjacent said check valve.

6. The method according to claim 1 further comprising positioning said hot water consumption line in the upper portion of said hot water boiler.

7. The method according to claim 1 wherein the upper end of said inlet sleeve located in the upper portion of said hot water boiler is higher than the outlet of said further hot water line.

8. The method for producing hot water according to claim 3 wherein said check valve comprises a floating ball check valve.

9. The method for producing hot water according to claim 1 wherein said hot water system comprises a solar hot water system.

10. The method for producing hot water according to claim 3 wherein said check valve is located in the close vicinity to said heating element sleeve.

11. The method according to claim 1 wherein the upper end of said inlet sleeve located in the upper portion of said hot water boiler is lower than the outlet of said further hot water line.

12. The method according to claim 1 wherein the step of providing a further hot water consumption line for extracting the hot water from the hot water boiler is carried out by providing a hot water consumption line for extracting the hot water from the hot water boiler, the outlet of which is located in the upper portion of said hot water boiler external to said heating element sleeve.

13. The method for producing hot water according to claim 1 wherein the diameters of said inlet sleeve and of said further hot water consumption line are selected so that a flow rate of water is permitted which minimizes the build up of scale and carbonate sediments.

14. The method for producing hot water according to claim 1 wherein the size of the check valve is selected so that a flow rate of water is permitted which minimizes the build up of scale and carbonate sediments.

15. The method for producing hot water according to claim 1 wherein said thermostat is positioned so that the water supplied from the top of the hot water boiler is supplied first to the thermostat and thereafter to the heating element.

16. Apparatus for producing hot water from a hot water boiler system comprising: (a) an inlet line for supplying water from an upper portion of a hot water boiler to a heating element sleeve having a heating element wherein the water is supplied to the heating element after flowing across a thermostat located in an inlet sleeve leading to said heating element sleeve;

(b) a further hot water line which connects a hot water line outlet of the heating element sleeve to an upper portion of the hot water boiler wherein the height difference between the lower of either of the upper ends of said inlet sleeve or an outlet of said further hot water line in the upper portion of said hot water boiler and the top of said hot water boiler define a hot water volume maintained hot by said heating element and available for substantially immediate use or consumption; and

17. Apparatus according to claim 16 further comprising a flow switch and an external thermostat external to the hot water boiler located on the hot water consumption line for increasing the temperature of the hot water extracted during hot water consumption while maintaining a substantially low average temperature in the hot water boiler.

18. Apparatus according to claim 16 further comprising a check valve located in the further hot water line for preventing water other than the water flowing across the heating element from being extracted via hot water discharge or consumption line during hot water consumption.

19. Apparatus according to claim 16 wherein said hot water consumption line is constructed and arranged such that it is located in said heating element sleeve with the inlet of said hot water consumption line located close to and above the heating element.

20. Apparatus according to claim 18 wherein said hot water consumption line is constructed and arranged such that it is located in said heating element sleeve with the inlet of said hot water consumption line located close to and above the heating element and also adjacent said check valve.

21. Apparatus according to claim 16 wherein said hot water consumption line is constructed and arranged such that it is located in the upper portion of said hot water boiler.

22. Apparatus for producing hot water according to claim 18 wherein said check valve comprises a floating ball check valve.

23. Apparatus for producing hot water according to claim 18 wherein said floating ball check valve is constructed and arranged to diminish build up of scale and carbonate sediments.

24. Apparatus for producing hot water according to claim 18 wherein said floating ball check valve is constructed from smooth plastic polymer which diminishes build up of scale and carbonate sediments.

25. Apparatus for producing hot water according to claim 16 wherein said hot water system comprises a solar hot water system.

26. Apparatus for producing hot water according to claim 18 wherein said check valve is located in close proximity to said heating element sleeve.

27. Apparatus for producing hot water according to claim 16 wherein the diameters of said inlet sleeve and of said further hot water consumption line are selected so that a flow rate of water is permitted which minimizes the build up of scale and carbonate sediments.

28. Apparatus for producing hot water according to claim 16 wherein the size of the check valve is selected so that a flow rate of water is permitted which minimizes the build up of scale and carbonate sediments.

29. Apparatus for producing hot water according to claim 16 wherein said thermostat is positioned so that the water supplied from the top of the hot water boiler is supplied first to the thermostat and thereafter to the heating element.

30. Apparatus according to claim 29 wherein the portion of said line or inlet sleeve in which the thermostat is located is spaced from the heating element in said heating element sleeve in order to reduce loss of heat to incoming water supplied to the heating element sleeve and flowing across the thermostat located in said hot water line.

31. Apparatus according to claim 16 further comprising a deflector connected to said further hot water line near its outlet so that water exiting said further hot water line will mix with water present in the upper portion of said hot water boiler.

32. Apparatus for producing hot water from a hot water boiler system comprising: (a) an inlet line for supplying water from the upper portion of a hot water boiler to a heating element sleeve having a heating element, wherein the water is supplied to the heating element after flowing across a thermostat located in an inlet sleeve of said heating element sleeve;

(b) a further hot water line which connects a hot water line outlet of the heating element sleeve to an upper portion of the hot water boiler wherein the height difference between the lower of either of the upper ends of said inlet sleeve or said further hot water line in the upper portion of said hot water boiler and the top of said hot water boiler define a hot water volume maintained hot by said heating element and available for substantially immediate use or consumption; and

(c) a hot water consumption line having an inlet in the upper portion of said hot water boiler for extracting the hot water from the hot water boiler during hot water use or consumption.

33. Apparatus for producing hot water from a hot water boiler system comprising:

(a) an inlet line for supplying water from the upper portion of a hot water boiler to a heating element sleeve having a heating element, wherein the water is supplied to the heating element after flowing across a thermostat located in an inlet sleeve of said heating element sleeve;

(c) a hot water consumption line is constructed and arranged such that it is located in said heating element sleeve and so that the inlet of said hot water consumption line is located close to and above the heating element.

34. A method for producing hot water from a hot water boiler system according to claim 1 substantially as hereinbefore described and with reference to the accompanying drawings.

35. Apparatus for producing hot water from a hot water boiler system according to claim 16 substantially as hereinbefore described and with reference to the accompanying drawings.

36. Apparatus for producing hot water from a hot water boiler system according to claim 32 substantially as hereinbefore described and with reference to the accompanying drawings.

37. Apparatus for producing hot water from a hot water boiler system according to claim 33 substantially as hereinbefore described and with reference to the accompanying drawings.