# US 9,518,759 B2 · Photovoltaic DC heater systems

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- Number: US 9,518,759 B2
- Document ID: US9518759B2
- Status: Granted
- Kind: B2
- Application number: 14/051,383
- Filed: 2013-10-10
- Published: 2015-04-16
- Granted: 2016-12-13
- Earliest claimed: 2013-10-10
- Applicants: Barry Lynn Butler
- Inventors: Barry Lynn Butler
- Web page: https://patentgrep.com/patent/US9518759B2

## CPC

- F24H 1/201: {using electric energy supply}
- F24D 18/00: Small-scale combined heat and power [CHP] generation systems specially adapted for domestic heating, space heating or domestic hot-water supply
- F24H 1/202: {with resistances}
- F24H 9/0021: {Sleeves surrounding heating elements or heating pipes, e.g. pipes filled with heat transfer fluid, for guiding heated liquid}
- F24H 9/2021: {Storage heaters}
- H05B 3/82: Fixedly-mounted immersion heaters
- F24D 2101/40: Photovoltaic [PV] modules
- F24H 15/174: Supplying heated water with desired temperature or desired range of temperature
- F24H 15/223: in the water storage tank
- F24H 15/335: Control of pumps, e.g. on-off control (control of compressors of heat pumps F24H15/38)
- F24H 15/37: of electric heaters
- F24H 2250/02: Resistances
- F24H: FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL (steam generation F22)
- F24D: DOMESTIC- OR SPACE-HEATING SYSTEMS, e.g. CENTRAL HEATING SYSTEMS; DOMESTIC HOT-WATER SUPPLY SYSTEMS; ELEMENTS OR COMPONENTS THEREFOR (using steam or condensate extracted or exhausted from steam engine plants for heating purposes F01K17/02)
- H05B: ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL

## Abstract

Direct current solar electric heating elements can be powered by an array of photovoltaic panels. The direct current voltage can be low or high with proper electrocution protection. Insertable immersion heating elements can be placed into any existing, gas, propane or electric hot water tank, cooking pot or hot tub. Heating elements in air can also be used for heating ovens, range cook tops and sauna heaters. The output of the photovoltaic panel is interfaced to the electric heater element via either direct connection or using a load-matching controller which maximizes the power delivered to the heater under all sun conditions. The maximum heater temperature is regulated by a thermostat.

## Claims

### Claim 1

A photovoltaic powered electric water heater for use with a pressurized hot water tank or unpressurized water tanks or open containers, comprising:
a double wall isolation immersion heater, the immersion heater comprising:
inner and outer walls having mechanical contact with a space between them;
a threaded plumbing fitting such that the immersion heating element is configured to be threaded to the tank, the outer wall being mounted to the plumbing fitting such that the space is vented outside of the fitting;
an immersion resistance heating element being encased within the inner wall such that the inner and outer walls space the heating element from an interior of the tank; the heating element further comprising:
internal resistance heating wires and lead in wires sealed within said inner wall and insulated by being encased in solid or powdered ceramic materials or by being immersed in mineral oil;
solar photovoltaic panels wired to power the immersion resistance heating element such that the heater resistance is configured to match DC power produced by the panels without the use of impedance matching circuitry;
the power wiring is directly connected through one open end to the immersion resistance heating element through only an independent temperature sensor activated switch.

### Claim 2 (depends on 1)

A heater system according to claim 1, wherein the lead in wires and resistance heater are within the inner wall made of a single metal corrosion-resistant sheath of copper, stainless steel or monel with the power lead in wires exiting the fitting on a single end, the inner sheath assembly being placed into the outer wall made of a second outer sheath assembly placed into a second outer sheath wall of metal or polymer where the conduction of heat between these two walls is by intimate contact or filling the space with non-flammable oil, so perforation of the outermost wall will cause fluid, water or oil, trapped between the walls to be visibly discharged outside of the water storage tank creating a positive indication that the units outer wall has failed while the inner wall keeps the electric elements free of fluid intrusion.

### Claim 3 (depends on 1)

A heater system according to claim 1 where the immersion straight chromalloy wire resistance elements surrounded by said ceramic electrical insulating material and/or said insulating oil, all within the inner wall; the inner wall being a liquid corrosion-resistant metal sheath.

### Claim 4 (depends on 1)

A heater system according to claim 1 where the immersion resistance heating element is immersed in air and uses coiled or straight chromalloy wire resistance elements surrounded by said ceramic electrical insulating material all within the inner wall; the inner wall being a high temperature air corrosion-resistant single metal sheath, where the heat is transmitted to said outer wall by metal to metal conduction and/or air convection.