Flow-through heater

Abstract

A flow-through heater includes a tubular housing and a heating element. The tubular housing defines a passageway. The heating element is provided in the passageway and attached to the tubular housing. The heating element includes a resistive wire and an electrically insulating coating on the resistive wire. The heating element includes a coiled wire portion coiled along a longitudinal axis of the tubular housing. The coiled wire portion defines a channel extending in a direction along the longitudinal axis to enable a fluid to flow therethrough. The coiled wire portion contacts the fluid when the fluid flows through the channel.

1 . A flow-through heater comprising:
 a tubular housing defining a passageway; and   a heating element provided in the passageway and attached to the tubular housing, the heating element including a resistive wire housed within an electrically insulating coating on the resistive wire,   wherein the heating element further includes a coiled portion defining a channel extending in a direction along the longitudinal axis to enable a fluid to flow therethrough and contacting the fluid when the fluid flows through the channel.   
     
     
         2 . The flow-through heater of  claim 1  wherein the passageway and the channel are coaxially aligned. 
     
     
         3 . The flow-through heater of  claim 1  wherein the tubular housing comprises a cylindrical wall and a support member extending inwardly from the cylindrical wall and wherein the heating element is attached to the support element. 
     
     
         4 . The flow-through heater of  claim 3  wherein the support member includes a plurality of fin elements extending radially inwardly from an inner surface of the cylindrical wall and extending a predetermined length along the longitudinal axis of the tubular housing. 
     
     
         5 . The flow-through heater of  claim 3 , further comprising a pair of terminal assemblies provided at the cylindrical wall. 
     
     
         6 . The flow-through heater of  claim 5 , wherein the terminal assemblies each include an insulating terminal housing inserted into an opening of the cylindrical wall. 
     
     
         7 . The flow-through heater of  claim 6 , wherein the cylindrical member is made of aluminum. 
     
     
         8 . The flow-through heater of  claim 5 , wherein the terminal assemblies each include a terminal housing integrally formed with the cylindrical wall. 
     
     
         9 . The flow-through heater of  claim 8 , wherein the terminal housing and the cylindrical wall are made of a plastic material. 
     
     
         10 . The flow-through heater of  claim 1 , wherein the fluid flows inside and outside the coiled portion of the heating element. 
     
     
         11 . The flow-through heater of  claim 1 , further comprising a support member for removably mounting the heating element to the tubular housing. 
     
     
         12 . The flow-through heater of  claim 11 , wherein the support member includes an elongated rail that is slidingly inserted in a slot of the cylindrical wall, the slot being formed on an inner peripheral surface of the cylindrical wall. 
     
     
         13 . The flow-through heater of  claim 12 , wherein the slot extends in a direction along the longitudinal axis of the tubular housing. 
     
     
         14 . The flow-through heater of  claim 12 , wherein the elongated rail comprises an elongated body and a pair of fingers extending laterally from the elongated body, the fingers securing the heating element therebetween. 
     
     
         15 . The flow-through heater of  claim 1 , wherein the tubular housing includes a cylindrical wall and a pair of hollow portions extending outwardly from the cylindrical wall for receiving at least one of a temperature sensor assembly and a fuse assembly. 
     
     
         16 . The flow-through heater of  claim 15 , wherein the hollow portions are integrally formed with the cylindrical wall. 
     
     
         17 . The flow-through heater of  claim 15 , wherein the cylindrical wall defines a pair of holes to enable a pair of terminal assemblies to pass through, the terminal assemblies including fasteners passing through the holes and the heating elements including connecting portions engaging a corresponding fastener. 
     
     
         18 . The flow-through heater of  claim 1 , wherein the cylindrical wall is a single-piece component. 
     
     
         19 . The flow-through heater of  claim 1 , wherein the cylindrical wall is a two-piece component. 
     
     
         20 . The flow-through heater of  claim 1 , further comprising an insulator provided between the cylindrical wall and the heating element to electrically insulate the heating element from the cylindrical wall. 
     
     
         21 . The flow-through heater of  claim 20 , wherein the insulator comprises a base portion extending in a direction along the longitudinal axis of the tubular housing and a pair of clamping legs extending from the base portion in a first direction toward the support member, the base portion engaging the heating element, the pair of clamping legs defining a slot for receiving the support member. 
     
     
         22 . The flow-through heater of  claim 21 , wherein the clamping legs extend an entire length of the base portion. 
     
     
         23 . The flow-through heater of  claim 21 , wherein each of the insulators further includes a pair of fingers extending from the base portion in a second direction and wherein the second direction is opposite to the first direction. 
     
     
         24 . The flow-through heater of  claim 1 , wherein the heating element contacts a peripheral inner surface of the tubular housing and is mounted to the tubular housing in an interference-fit manner. 
     
     
         25 . The flow-through heater of  claim 1 , wherein the tubular housing further comprises a cylindrical wall and a pair of hollow portions extending outwardly from an outer peripheral surface of the cylindrical wall, wherein the hollow portions are integrally formed with the cylindrical wall. 
     
     
         26 . The flow-through heater of  claim 25 , wherein the heating element further comprises a pair of connecting portions extending from the coiled portion, wherein the connecting portions extend through the hollow portions. 
     
     
         27 . The flow-through heater of  claim 26 , further comprising a potting material that fills cavities of the hollow portions and that electrically insulates a part of the connecting portions. 
     
     
         28 . The flow-through heater of  claim 27 , further comprising a pair of terminal pins extending through the hollow portions, wherein the heating element is connected to a power source through the terminal pins. 
     
     
         29 . A flow-through heater comprising:
 a cylindrical wall extending along a longitudinal axis and defining a passageway to allow a fluid to flow therethrough;   a fin element extending inwardly from an inner surface of the cylindrical wall and in the passageway;   a heating element provided in the passageway and attached to the fin element, the heating element including a resistive wire housed within an electrically insulating coating, the heating element including a coiled wire portion that defines a channel coaxially aligned with the passageway, the fluid flowing inside and outside the coiled wire portion;   a pair of terminal assemblies that connect the heating element to a power source, the terminal assemblies each including a terminal housing at the cylindrical wall and a terminal pin inserted through the terminal housing, the terminal pin connecting the heating element to the power source; and   a potting material provided in the terminal assemblies to embed a portion of the terminal pin therein.   
     
     
         30 . A flow-through heater comprising:
 an outer wall including an inner peripheral surface, the inner peripheral surface defining a passageway along a longitudinal axis of the outer wall;   a plurality of fin elements located in the passageway and extending inwardly from the inner peripheral surface; and   a heating element provided on an outer peripheral surface of the outer wall.   
     
     
         31 . The flow-through heater of  claim 30 , wherein the heating element includes a resistive wire coiled around the outer wall and an electrically insulating coating on the resistive wire. 
     
     
         32 . The flow-through heater of  claim 30 , wherein the outer wall is cylindrical in shape and made from a metal material and includes an outer peripheral surface and an insulating coating on the outer peripheral surface, the heating element being wrapped around the outer peripheral surface.