US-20260126209-A1 - Modular Electric Boiler and Heat Exchanger

Abstract

The present disclosure describes a modular electric boiler. The modular electronic boiler may include a control panel with a display and one or more modular pressure vessels. Each pressure chamber, of the plurality of pressure chambers, may comprise an inlet to receive water, an outlet to output water, and a cavity configured to receive one or more heating elements. In operation, the control panel may activate the one or more heating elements associated with each pressure chamber. Water may enter the pressure chamber via the inlet, pass over the one or more heating elements, and exit the pressure chamber as heated water via the outlet. Modular pressure vessels may be stacked alongside one another to expand the capabilities of the modular electric boiler. Accordingly, the modular electric boiler described herein can replace existing boilers with an energy efficient solution that can operate in the same, or smaller, footprint as existing boilers.

Inventors

• Jonathan Goldberg
• Peter RIMASSA
• Fernando ENDOZO
• Cornelius PILAAR
• Dean MONTESANO
• James COLES

Assignees

• DIVERSIFIED HEAT TRANSFER, INC.

Dates

Publication Date

20260507

Application Date

20250730

Claims (20)

1. 1 . A modular pressure vessel for an electric boiler, the modular pressure vessel comprising: a water inlet configured to receive water via a return line; a water outlet configured to output hot water via a supply line; a plurality of cylindrical pressure chambers, wherein: a first cylindrical pressure chamber comprises: a first inlet configured to receive water via the water inlet; and a first outlet configured to output water via the water outlet; and a second cylindrical pressure chamber comprising: a second inlet configured to receive water via the water inlet; and a second outlet configured to output water via the water outlet; and one or more heating elements located within each cylindrical pressure chamber of the plurality of cylindrical pressure chambers.
2. 2 . The modular pressure vessel of claim 1 , wherein: the water inlet comprises a first manifold configured to distribute water to each of the plurality of cylindrical chambers; and the water outlet comprises a second manifold configured to receive water from each of the plurality of cylindrical chambers after the water has passed over the one or more heating elements.
3. 3 . The modular pressure vessel of claim 1 , wherein the plurality of cylindrical pressure chambers is connected in parallel.
4. 4 . The modular pressure vessel of claim 1 , wherein: the first cylindrical pressure chamber further comprises a first flow restriction ring configured to control a first flow of water through the first cylindrical pressure chamber; and the second cylindrical pressure chamber further comprises a second flow restriction ring configured to control a second flow of water through the second cylindrical pressure chamber.
5. 5 . The modular pressure vessel of claim 4 , wherein: the first flow restriction ring comprises a first notch configured to allow air to escape via a first opening in a top surface of the first cylindrical pressure chamber; and the second flow restriction ring comprises a second notch configured to allow air to escape via a second opening in a top surface of the second cylindrical pressure chamber.
6. 6 . The modular pressure vessel of claim 5 , wherein: the first opening comprises a first air separator; and the second opening comprises a second air separator.
7. 7 . The modular pressure vessel of claim 1 , wherein the one or more heating elements comprise at least one of a resistance heating coil or an electrode.
8. 8 . A boiler comprising: a return line; a supply line; a control panel; and one or more modular pressure vessels, wherein a first modular pressure vessel, of the one or more modular pressure vessels, comprises: a water inlet configured to receive water via the return line; a water outlet configured to output hot water via the supply line; a plurality of cylindrical pressure chambers, wherein: a first cylindrical pressure chamber comprises: a first inlet configured to receive water via the water inlet; and a first outlet configured to output water via the water outlet; and a second cylindrical pressure chamber comprising: a second inlet configured to receive water via the water inlet; and a second outlet configured to output water via the water outlet; and one or more heating elements located within each cylindrical pressure chamber of the plurality of cylindrical pressure chambers
9. 9 . The boiler of claim 8 , wherein the return and supply lines comprise one or more flow restriction rings in order to maintain even flow throughout the one or more modular pressure vessels.
10. 10 . The boiler of claim 8 , further comprising: one or more flow control switches configured to control a flow of water to each of the modular pressure vessels.
11. 11 . The boiler of claim 8 , further comprising: one or more pumps configured to control a flow of water to each of the modular pressure vessels.
12. 12 . The boiler of claim 8 , further comprising: a first sensor configured to measure a first water temperature of water received via the return line; and a second sensor configured to measure a second water temperature of water outputted via the supply line.
13. 13 . The boiler of claim 12 , wherein the control panel is configured to cycle through a plurality of heating elements based on the second water temperature.
14. 14 . The boiler of claim 13 , wherein the control panel is further configured to select the plurality of heating elements to cycle through based on at least one or more of: a run-time of each of the plurality of heating elements; or a number of cycles of one or more contactors associated with each of the plurality of heating elements.
15. 15 . The boiler of claim 8 , further comprising: a first sensor configured to measure a water pressure of water received via the supply line.
16. 16 . The boiler of claim 15 , wherein the control panel is configured to activate one or more pumps based on the water pressure.
17. 17 . The boiler of claim 8 , wherein the return line and the supply line are provided by a single pipe.
18. 18 . The boiler of claim 8 , further comprising: a display configured to display a user interface for control of the boiler.
19. 19 . The boiler of claim 8 , further comprising: a communication interface configured to exchange signals with an automation system.
20. 20 . The boiler of claim 8 , further comprising: one or more control components configured to fit any application size.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Provisional Application No. 63/676,969, filed on Jul. 30, 2024 and entitled “Modular Electric Boiler and Heat Exchanger,” the entirety of which us hereby incorporated by reference in its entirety. FIELD OF THE INVENTION Aspects of the disclosure generally relate to electric boilers and heat exchangers. BACKGROUND OF THE INVENTION Many boilers today rely on fossil fuels, such as natural gas. As many municipalities create policies and strategies to reduce and/or move away from fossil fuels, there is a need to replace existing boilers with energy efficient solutions that can operate in the same footprint as existing boilers, with better efficiency. SUMMARY OF THE INVENTION The following presents a simplified summary of various features described herein. This summary is not an extensive overview, and is not intended to identify key or critical elements or to delineate the scope of the claims. The following summary merely presents some concepts in a simplified form as an introductory prelude to the more detailed description provided below. Corresponding apparatus, systems, and computer-readable media are also within the scope of the disclosure. Aspects of the disclosure generally relate to electric boilers and heat exchangers. In particular, the present disclosure describes modular electric boilers and heat exchangers that can be expanded to suit residential, commercial, and/or industrial customers' needs. Moreover, the modular electric boilers and heat exchangers described herein may be “smart” products that can easily integrate into building automation systems. Certain aspects of the disclosure describe a modular electric boiler that is configured to add, or remove, pressure vessels to expand, or reduce, the capabilities of the modular electric boiler. The modular electronic boiler described herein may include a control panel and one or more modular pressure vessels. Each of the one or more modular pressure vessels may comprise an inlet to receive water, an outlet to output hot water, and a cavity configured to receive one or more heating elements. The one or more heating elements may attach to each of the one or more modular pressure vessels such that the heating element is located within a cavity of the chamber. The one or more heating elements may be communicatively coupled to the control panel. In operation, the control panel may activate the one or more heating elements associated with each pressure chamber. Water may enter the pressure chamber via the inlet, pass over the one or more heating elements, and exit the pressure chamber as heated water via the outlet. Modular pressure vessels may be added to expand the capabilities of the modular electric boiler. The modular pressure vessels may be stacked upon one another or placed alongside one another for expansion purposes. Moreover, the control panel may be configured to activate (e.g., turn on) each of the one or more heating elements individually. This may allow the control panel to cycle (e.g., rotate) through the one or more heating elements to ensure even heating of the water and/or prolong the life of each of the one or more heating elements by ensuring equal, or near equal, run-time for each of the one or more heating elements. The control panel may also track the cycles on each contactor, thereby prolonging the life of each contactor and preventing a single contactor from failing before the others. Accordingly, the modular electric boiler described herein can replace existing boilers with an energy efficient solution that can operate in the same, or smaller, footprint as existing boilers. These features, along with many others, are discussed in greater detail below. BRIEF DESCRIPTION OF DRAWINGS The present disclosure is described by way of example and not limited in the accompanying figures in which like reference numerals indicate similar elements and in which: FIGS. 1A and 1B show examples of modular electric boilers in accordance with one or more aspects of the disclosure; FIG. 1C shows an example of a plurality of pressure vessels connected to return and supply lines in accordance with one or more aspects of the disclosure; FIG. 1D shows another example of a plurality of pressure vessels connected to return and supply lines in accordance with additional aspects of the disclosure; FIGS. 1E-1H shows an example of a plurality of pressure vessels in a vertical arrangement in accordance with one or more aspects of the disclosure; FIGS. 1I-M show an example of vertically arranged pressure vessels connected to supply/return lines in accordance with one or more aspects of the disclosure; FIG. 1N shows an example of a wall-mounted boiler in accordance with one or more aspects of the disclosure; FIG. 1O shows an example of various configurations of pressure vessels in accordance with one or more aspects of the disclosure; FIG. 2 shows an example of a modular electric boile