A COMPONENT FOR A FLOW HEATER

Abstract

 A component for a flow heater, the component (10) comprising: a body (12) that defines a first fluid conduit (18) with a first aperture (20a; 20b; 20c; 20e), a cover (14) that defines a second aperture (38a; 38b), and at least one cap (32a, 32b) that is couplable to a flow heater inset (76, 80). The body (12), the cover (14) and the cap (32a, 32b) are connectable to form an assembled state. In the assembled state, the cover (14) is fluid tightly connected to the body (12) by a material connection and the cap (32a; 32b) is fluid tightly connected to the cover (14) in such a way that the first aperture (20a; 20b; 20c; 20e) and the second aperture (38a; 38b) are in at least partial registration with one another, and the cap (32a; 32b) and the body (12) define a second fluid conduit that comprises at least the first conduit (18), and, if the flow heater inset (76, 80) is coupled to the cap (32a; 32b), the flow heater inset (76, 80) is arrangeable at least in part in the first conduit (18).

Description

Field

[0001] The present invention relates to flow heaters, and in particular to a component for accommodating insets such as heating elements or coils, and to a method of manufacturing such a component.

Background

[0002] One existing flow heater has a main body in which inset components-such as heating elements-are mounted. During manufacture, the inset components are mounted inside the main body, then a cover is welded to the main body.

[0003] However, the welding process may cause movement or vibration that can damage the inset components. In addition, typically this approach undesirably constrains the manufacturer to locate the mounting station near the welding machine on a line serial production line.

[0004] In one alternative approach, the main body and cover are screwed rather than welded together, but screwing is more expensive and can become uneconomical.

[0005] In another alternative, the inset components are designed to be more robust, so that they are sufficiently strong to withstand the welding process without sustaining the aforementioned damage. However, this consumes more material and adds expense, and in many cases makes the inset components uneconomical.

Summary

[0006] It is an object of the present invention to provide an arrangement that addresses at least some of these problems.

[0007] In a first aspect, the invention provides a component for a flow heater, the component comprising: a body that defines a first fluid conduit with a first aperture, a cover that defines a second aperture, and at least one cap that is couplable to a flow heater inset (comprising, for example, one or more heating coils), wherein

[0008] the body, the cover and the cap are connectable to form an assembled state, and wherein in the assembled state, the cover is fluid tightly connected to the body by a material connection (such as welding or screws) and the cap is fluid tightly connected to the cover in such a way that the first aperture and the second aperture are in at least partial registration with one another, and the cap and the body (together with, in some example, the cover) define a second fluid conduit that comprises at least the first conduit, and, if the flow heater inset is coupled to the cap, the flow heater inset is arrangeable at least in part in the first conduit.

[0009] Thus, one or more flow heater insets may be located in the body after the connection (such as by welding) of the cover to the body. In addition, the cap may be configured to be disengagably connectable to the cover, in which case the flow heater inset may readily be exchanged when desired, by removing the cap.

[0010] In an embodiment, the cover comprises a plurality of openings for receiving respective flow heater insets and the component comprises a plurality of caps configured to be fluid tightly connectable to the cover when locates at the respective openings. In one example, at least one of the caps is a blind cap (that is, configured to entirely close a respective opening on the cover), not connectable to a flow heater insets. This enables the subsequent modification of heating power level: the blind cap can be removed, a further flow heater insets in the form of a heating coil inserted and coupled to a 'normal' cap, and the normal cap connected to the cover in place of the blind cap.

[0011] There are many suitable material from which the cap may be formed, but in certain embodiments, the cap is made of a first material that comprises polypropylene. In some embodiments, the cover and/or the body are made of a second material that comprises glass fibers. In an embodiment, the cap is made of the first material, and the cover and/or the body are made of the second material.

[0012] The body and cover are desirably of a reinforced material (e.g. with a high glass fibre portion). The caps may be of an unreinforced material because of the lower loads (lower pressure-surface) is will typically be subjected to, such as with a lower glass fibre portion for a better movement of, for example, a snap-fasteners.

[0013] The cap, however, may be made of a material with a low Young's Modulus, such as polypropylene. Polypropylene may be particularly suitable for the cap depending on the type of connection to be formed with the cover. For example, polypropylene would facilitate the resilient displacement of a snap-fit fastener, and is relatively inexpensive.

[0014] In an embodiment, the assembled state the cover and the cap are releasably connected to one another.

[0015] In an embodiment, in the assembled state the cover and the cap are connected to one another by snap-fit fastening, and/or with a bayonet connection.

[0016] Snap-fit fastening and bayonet connections have the advantage that they can be effected quickly (when compared with screwing, welding or bonding): they are essentially tool-less coupling mechanisms.

[0017] In an embodiment, in the assembled state the cover and the cap are connected to one another with a clamp connection (in which case the component may include a clamping element, such as a brace, band, or clasp), desirably of metal.

[0018] All these kinds of connection are removable, though some (e.g. fixation by snap-fastening) may require a suitable tool to disassemble the cap from the cover.

[0019] In an embodiment, the cap is provided with a seal (such as one or more O-rings) for facilitating a fluid tight seal between the cap and the cover, wherein the seal is located axially about the cap such that the seal radially contacts an internal face of a peripheral wall of the cover.

[0020] This arrangement has the advantage that pressure in the cover will urge the cap and hence the seal more firmly against the internal face of a peripheral wall of the cover. This reduces the likelihood of leakage, even if-with use-the cap becomes warped or otherwise distorted. In contrast, a seal located under the cap for sealing against an end face of the cover would be vulnerable to failure if the cap, with use, shrinks.

[0021] This can be a particular problem with certain plastics materials form which the cap may be manufactured. Polypropylene, for example, is a material that creeps under pressure and temperature load, resulting in deformation over the lifetime of the article-in this example the cap. Such deformation can affect the cap, including portions of the cap that connect the cap to the cover (e.g. snap-fasteners). To reduce creep, it is useful to expose the article to a compression load instead of a tensile load, so in one embodiment the cap comprises distally, axially extending arms for engaging the cover distal from the body. The arms can be provided with projections or hooks for engaging apertures in the cover (thereby constituting so-called 'sky-hooks').

[0022] In certain embodiments, the cap closes an opening in the cover for a single flow heater inset, while in other embodiments the cap closes an opening in the cover for plural flow heater insets. In the latter case, the cap may have a generally cylindrical geometry (with a generally circular cross-section), but in the former case the cap may have a more elongate cross-section (e.g. oblong) to correspond to the shape of the opening in the cover through which the flow heater insets will be installed. In the former case, a bayonet connection between the cap and cover may be readily effected, reflecting the cylindrical geometry of the cap.

[0023] In an embodiment, the component further comprises the flow heater inset, wherein, in the assembled state, the flow heater inset is coupled to the cap and arranged at least in part in the first conduit. The flow heater inset may be, for example, one or more heating coils.

[0024] In an embodiment, the cap comprises a third aperture, wherein the cap is fluid tightly connectable to the cover and the flow heater inset is arrangeable at least in part in the third aperture and fluid-tightly connectable to the cap in such a way that in the assembled state the second fluid conduit comprises the third aperture, and wherein, if the flow heater inset is coupled to the cap, in the assembled state the flow heater inset is arrangeable at least in part outside the second fluid conduit and at least in part in the third aperture.

[0025] In an embodiment, the cover comprises a first connecting element and the cap comprises a cap portion and a second connecting element complementary to the first connecting element, wherein, in the assembled state, the first connecting element and the second connecting element are engaged such that the cover and the cap are fluid-tightly connected and the cap portion defines the second fluid conduit, and wherein,

[0026] in the assembled state, the second connecting element and the cap portion are arranged in such a way that, when a first force, which is directed outwardly of the second conduit, is exerted on the cap portion, the first connecting element exerts a second force on the second connecting element such that a compressive load is exerted on the cap. In one example, in the assembled state the third opening is sealed, such as by the inset inserted therein.

[0027] In one example, the first connecting element may comprise one or more recesses in a wall of the cover, and the second connecting element one or more complementary tabs or projections configured to be received by the respective recesses. For example, the tabs or projections may be laterally directed with the cap configured to be received within a wall of the cover, the wall being provided with recesses (e.g. apertures) for receiving the tabs or projections. The tabs or projections may be located on respective outwardly projecting arms of a resilient plastics material so that the tabs or projections can engage the recesses in a snap-lock manner.

[0028] In one embodiment, the cover is connected to the body by a material connection such that the first aperture and the second aperture are in at least partial registration with one another, such as by the cover and the body being welded together.

[0029] The advantage of welding the cover and body is that the use of screws is avoided. It also more readily allows a variety of connection geometries, which would be more difficult to achieve with screwing.

[0030] In an embodiment, the body, the cover, and the cap are connected and in the assembled state.

[0031] In an embodiment, the cap comprises at least one sensor, such as a temperature, stress and/or pressure sensor. This allows conditions within the cover (and in some cases the main body) to be monitored. Also, in embodiments in which the cap is decouplable from the cover, failure of the sensor can be remedied by replacement of only the cap.

[0032] In some embodiments, the cap and the cover are permanently or semi-permanently coupled (a coupling that is distinct from the connection between the cover and the cap when in the assembled state), such as with one or more hinges (e.g. film hinges), straps or lanyards. This arrangement reduces the likelihood of losing or misplacing the cap, or of employing an incorrect (such as in size, material or performance characteristics) cap. It may be desirable, also, if it is desired to manufacture the cap and cover integrally, such as by injection molding.

[0033] In a second aspect, the invention provides a flow heater comprising the component of the first aspect.

[0034] In a third aspect, the invention provides a method for producing the component of the first aspect. The method comprises: fluid tightly connecting the body and the cover with a material connection in such a way that the first aperture and the second aperture are in at least partial registration with one another; and fluid tightly connecting the cap and the cover such that the body and the cap define a second fluid conduit that comprises at least the first conduit and such that the inset, if coupled to the cap, is arrangeable at least in in part in the first conduit.

[0035] In an embodiment, the component comprises the inset and the method further comprises: arranging at least a portion of the inset in the first conduit portion, and connecting the inset to the first cap element. In an example, the arranging is performed after the body/cover connection is formed, and/or the connecting and arranging are performed before the cover/cap connection is formed.

[0036] In an embodiment, the step of connecting the cover and the body comprises welding (e.g. friction welding) the cover and the body together.

[0037] It should be noted that any of the various individual features of each of the above aspects of the invention, and any of the various individual features of the embodiments described herein including in the claims, can be combined as suitable and desired.

Brief Description of the Drawing

[0038] In order that the invention may be more clearly ascertained, embodiments will now be described, by way of example, with reference to the accompanying drawing, in which:

Figure 1 is a perspective view of a flow heater component according to an embodiment of the present invention;

Figure 2 is a partially exploded perspective view of the flow heater component of figure 1;

Figure 3A is a perspective view of the first end cover and plug-in caps of the flow heater component of figure 1, prior to engagement;

Figure 3B is a perspective view of the plug-in caps of the flow heater component of figure 1, once the plug-in caps have been located within and engaged with the first end cover;

Figure 3C is a cross-sectional view of the first end cover and plug-in caps of the flow heater component of figure 1, illustrating their snap-fit fastening engagement;

Figures 4A and 4B are perspective views of the first end cover and plug-in caps of a flow heater component according to a variant of the embodiment of figure 1, prior to engagement;

Figure 4C is a perspective view of the plug-in caps and first end cover of the variant flow heater component of figures 4A and 4B, once the plug-in caps have been located within and engaged with the first end cover;

Figure 5 illustrates schematically a method of manufacturing or assembling the component of figure 1 according to an embodiment of the present invention; and

Figure 6 is a flow diagram that summarizes the method of manufacturing or assembling the component of figure according to an embodiment of the present invention.

Detailed Description

[0039] Figure 1 is a perspective view of a flow heater component 10 of a flow heater according to an embodiment of the present invention. Component 10 is essentially the heating block of a fluid heater (such as a continuous flow water heater); such a heater would additionally typically include an external housing, a power supply, etc.

[0040] Component 10 includes a main body 12 through which a fluid (such as water) may flow, and first and second end covers 14, 16 provided with respectively an entry port (not shown) and an exit port (not shown) for admitting the fluid to and emitting the fluid from main body 12. Component 10 is shown in its assembled state, in which first and second end covers 14, 16 are connected to main body 12, in this example by friction welding.

[0041] Main body 12 and first and second end covers 14,16 are generally of fiberglass.

[0042] Main body 12 comprises a plurality of fluid or flow conduits 18 (of which conduits 18a, 18b, 18c and 18d are visible in this figure) that conduct the fluid flow from the entry port to the exit port. Two of conduits 18 (as is discussed below) are configured to accommodate respective inset components in the form of, in this embodiment, pairs of heating elements (each of which includes at least one heating coil).

[0043] Fluid conduits 18, as will be appreciated by those in the art, are coupled by connecting channels: these are defined by and between the inner face (not visible in this view) of first end cover 14 and the first end (not visible in this view) of main body 12, and by and between the inner face (not visible in this view) of second end cover 16 and the second end (not visible in this view) of main body 12. The connecting channels direct fluid entering the entry port to pass along all of conduits 18 before exiting from the exit port, including passing the aforementioned heating coils.

[0044] Figure 2 is a partially exploded perspective view of component 10, illustrating in particular the first end 30 of main body 18, and the first end cover 14. Conduits 18a to 18i are also depicted, as are the apertures 20a, 20b, 20c and 20e proximate first end cover 14 of conduits 18a, 18b, 18c and 18e, respectively. Component 10 also includes first and second plug-in caps 32a, 32b (in this example of polypropylene), configured to be located in first end cover 14. It may be noted that, in this embodiment, first and second plug-in caps 32a, 32b are essentially identical but are reverse mirrors of one another.

[0045] Referring to figure 2, first end 30 is provided with gaskets 34a, 34b for facilitating a fluid tight seal between first end 30 and first end cover 14. First end cover 14 includes the entry port 36, located so as to be in registration with conduit 18i-and thereby forming a continuous conduit for the fluid. First end cover 14 also includes inset apertures in the form of first and second generally oblong inset ports 38a, 38b, defined by respective walls 40a, 40b. First inset port 38a is aligned with conduits 18a and 18e, and second inset port 38b is aligned with conduits 18b and 18c, such that heating coils can be located in conduits 18a, 18e, 18b and 18c via first and second inset ports 38a, 38b respectively, after first end cover 14 has been connected to main body 12.

[0046] Thus, first end cover 14 (and indeed second end cover 16) can be connected to main body 12, such as by welding, without first locating the heating elements within conduits 18a, 18e, 18b and 18c. This avoids the risk of damage to the heating elements during the welding process.

[0047] Plug-in caps 32a, 32b are configured to be accommodated by first and second inset ports 38a, 38b respectively. In this view, plug-in caps 32a, 32b are shown unengaged with first end cover 14, such as would obtain during manufacture before heater component 10 is in its assembled form.

[0048] Plug-in caps 32a, 32b are configured to be received by, and form fluid tight connections with, first and second inset ports 38a, 38b, after heating insets have been located in conduits 18a, 18e, 18b and 18c. However, plug-in caps 32a, 32b include respective apertures 42a, 42b (in this example arranged axially) for engaging or accommodating a portion of the insets (in this example, heating coil pins).

[0049] In some applications, a plug-in 'blind' cap may be substituted for a plug-in cap 32a, 32b. Such a blind cap would be essentially identical to a plug-in cap 32a, 32b, but omit the aperture, and would be employed if a reduced number of insets (e.g. heating coils) were to be used. The blind cap could, however, be removed should it be desired to insert a further inset, after which a standard plug-in cap (32a, 32b) would be employed.

[0050] Each of plug-in caps 32a, 32b has a smaller cross-section than does first end cover 14, so plug-in caps 32a, 32b are subjected to a lower force arising from the inner fluid pressure. Consequently, plug-in caps 32a, 32b do not require as strong a form of connection with first end cover 14 as the connection between main body 12 and first end cover 14 (by welding), and plug-in caps 32a, 32b are-in this embodiment-connected to first end cover 14 by snap-fit fastening.

[0051] Figure 3A is a perspective view of first end cover 14 (connected to main body 12) and plug-in caps 32a, 32b, illustrating the manner in which this snap-fit fastening is effected. Plug-in caps 32a, 32b are each provided with respective O-rings 50a, 50b for forming fluid tight seals with walls 40a, 40b.

[0052] Plug-in caps 32a, 32b also have respective pluralities (in this example, six) of upwardly (in this view) extending arms 52a, 52b, provided with outwardly directed projections 54a, 54b. Walls 40a, 40b, which define inset ports 38a, 38b respectively, are provided with complementary recesses, in this example in the form of respective apertures 56a, 56b. First and second plug-in caps 32a, 32b are configured to be received by inset ports 38a, 38b respectively, with snap-fit fastening being effected between projections 54a, 54b and apertures 56a, 56b.

[0053] The polypropylene from which plug-in caps 32a, 32b (and hence arms 52a, 52b) are made has sufficient flexibility that arms 52a, 52b are displaced inwardly by the force of walls 40a, 40b on projections 54a, 54b, and sufficient resilience that arms 52a, 52b urge projections 54a, 54b into apertures 56a, 56b once projections 54a, 54b are aligned with apertures 56a, 56b. This is facilitated by providing a lower surface of projections 54a, 54b with inclined faces; the retention of projections 54a, 54b in apertures 56a, 56b is facilitated by providing an upper surface of projections 54a, 54b with flat lands for bearing against upper faces of apertures 56a, 56b (under the fluid pressure inside main body 12 and first end cover 14 and against the lower surfaces of plug-in caps 32a, 32b).

[0054] Figure 3B is a perspective view of plug-in caps 32a, 32b once located within and engaged with first end cover 14, with projections 54a, 54b received by and engaged with apertures 56a, 56b. Figure 3C is a cross-sectional view of first end cover 14 (connected to main body 12) and plug-in caps 32a, 32b. In this view, plug-in caps 32a, 32b are shown in the configuration of the assembled form of flow heater component 10, with plug-in caps 32a, 32b located in inset ports 38a, 38b respectively. As is apparent from figure 3B, in the assembled state of component 10, apertures 38a, 38b of first end cover 14 are in at least partial registration with the respective apertures constituting the entries to conduits 18a, 18b respectively, so that insets to be inserted into conduits 18a, 18b can be inserted via apertures 38a, 38b. (Although not visible in this view, apertures 38a, 38b of first end cover 14 are also in at least partial registration with the respective apertures constituting the entries to conduits 18e, 18c, respectively.)

[0055] In the assembled state, arms 52a, 52b are adjacent walls 40 a, 40b, respectively, with projections 54a, 54b projecting into apertures 56a, 56b-thereby resisting the expelling of plug-in caps 32a, 32b from inset ports 38a, 38b when the interior of component 10 contains fluid above ambient pressure. However, as is apparent for this figure, arms 52a, 52b are accessible from outside first end cover 14, and can be bent inwardly to release projections 54a, 54b from apertures 56a, 56b, so that plug-in caps 32a, 32b can be removed from inset ports 38a, 38b respectively.

[0056] It will also be noted that O-rings 50a, 50b are located in peripheral grooves 58a, 58b that run around plug-in caps 32a, 32b respectively. In the assembled state, O-rings 50a, 50b as a consequence form a fluid tight radial seal between plug-in caps 32a, 32b and the internal surface of walls 40a, 40b. Raised internal pressure in first end cover 14 and caps 32a, 32b serves to urge plug-in caps 32a, 32b (and hence O-rings 50a, 50b) against the internal surface of walls 40a, 40b, thereby creating a stronger radial seal.

[0057] In some applications, it may be desirable to couple a variant of the flow heater component 10 o embodiment og embodiments, the cap and the cover are permanently or semi-permanently coupled, such as with one or more hinges (e.g. film hinges), straps or lanyards. This arrangement reduces the likelihood of losing or misplacing the cap, or of employing an incorrect (such as in size, material or performance characteristics) cap.

[0058] Figures 4A, 4B and 4C are perspective views of the first end cover 14' and first plug-in cap 32a' of a flow heater component 10' according to a variant of the embodiment of figure 1, though the lower portion of main body 12 and second end cover 16 have been omitted for clarity. Figures 4A and 4BB show first end cover 14' and first plug-in cap 32a' prior to being connected, while figure 4C shows first end cover 14' and first plug-in cap 32a' once connected.

[0059] Component 10' is essentially identical with flow heater component 10 of figure 1. However, first end cover 14' and first plug-in cap 32a' are permanently coupled to one another by one or more straps (in this example, two) 60, as would further straps (not shown) for permanently coupling first end cover 14' and the second plug-in cap (not shown).

[0060] Straps 60 are formed integrally with first end cover 14' and first plug-in cap 32a' and are generally of the same plastics material. Straps 60 may extend-as illustrated in figure 4A-from the distal end of two of arms 52a' to wall 40a' of first end cover 14'.

[0061] Straps 60 are thin and flexible, so allow first plug-in cap 32a' to be rotated from a first decoupled orientation shown in figure 4A, to the second decoupled orientation shown in figure 4B, then to the arrangement shown in figure 4C in which first end cover 14' and first plug-in cap 32a' are coupled together. It will be noted that straps 60 extend from those two of arms 52a' that are outermost once first end cover 14' and first plug-in cap 32a' are coupled, such that straps 60 do not interfere with the connecting of first end cover 14' and a second plug-in cap.

[0062] In a further variation, the first end cover and the plug-in cap or caps are coupled or couplable semi-permanently. The semi-permanent coupling is effected by releasably attaching the straps to the first end cover and/or to the plug-in cap or caps. This may be done, for example, by providing the first end cover with keyed apertures and the straps with complementary heads that are receivable by the keyed apertures, such that-in normal use-the first end cover and the plug-in cap or caps should not become decoupled. However, by suitable manipulation, the heads of the straps can be disengaged from the keyed apertures, such that the cap or caps can be decoupled from the first end cover.

[0063] Figure 5 illustrates schematically a method of manufacturing or assembling component 10 according to an embodiment of the present invention. At register 70, body 12 has been welded to first end cover 14 and second end cover 16. At register 72, first plug-in cap 32a is ready for engagement with an assembly comprising a pair of heating coils 76, a pair of heating coils leads 78 and a threaded heating coil pin 80 and, initially, first plug-in cap 32a is located on pin 80 with pin 80 received within aperture 42a. At register 82, leads 78 and heating coils 76 are threaded (in this view) via first end cover 14 into body 12, until leads 78 protrude from second end cover 16 and heating coil pin 80 is located (e.g. from below in this view) in aperture 42a of first plug-in cap 32a. At register 84, assembly is essentially complete: leads 78 protrude from second end cover 16 and have been secured by any suitable conventional technique, and plug-in cap 32a has been located in first end cover 14 with pin 80 extending out of plus-in cap 32a (for securing in place, such as with a nut). At register 84, second plug-in cap 32b is also depicted as assembled, located in first end cover 14 with another, like pin 80' extending from second plug-in cap 32b. Another like pair of leads 78' (coupled to another pair of hearing elements, not shown) is shown protruding from second end cover 16.

[0064] In one variation of this assembly procedure, of particular but not exclusive relevance to those embodiments in which the plug-in caps are permanently or semi-permanently coupled to first end cover, leads 78, heating coils 76 and pin 80 are located in their final positions and only then is plug-in cap 32a positioned over pin 80 and located within aperture 42a, such that plug-in cap 32a is connected to first end cover 14.

[0065] The assembly procedure is summarized in flow diagram 90 of figure 6. At step 92, first and second end covers 14, 16 are connected to main body 12 (separated by gaskets) by welding. At step 94, the heating elements (including heating coils 76 and leads 78, 78') are assembled (if not provided in assembled form).

[0066] At step 96, heating coil pins 80, 80' are attached to plug-in caps 32a, 32b, and at step 98, the insets-in this example, the heating elements-are mounted within main body 12, by inserting them through first end cover 14. (In other embodiments it may be possible to insert one or more insets through second end cover 16, before attaching heating coil pins 80, 80' to plug-in caps 32a, 32b.)

[0067] At step 100, leads 78, 78' are fed through second end cover 16 and secured thereto and, at step 102, plug-in caps 32a, 32b are connected by snap-fasting to first end cover 14 within respective apertures 38a, 38b, thereby forming a connection.

[0068] At step 104, the heating coil pins 80, 80' are secured, such as with respective nuts.

[0069] In the assembly variation described above as of particular relevance to those embodiments in which the plug-in caps are permanently or semi-permanently coupled to first end cover, step 96 would instead follow step 100.

[0070] Modifications within the scope of the invention may be readily effected by those skilled in the art. It is to be understood, therefore, that this invention is not limited to the particular embodiments described by way of example hereinabove.

[0071] In the claims that follow and in the preceding description of the invention, except where the context requires otherwise owing to express language or necessary implication, the word "comprise" or variations such as "comprises" or "comprising" is used in an inclusive sense, that is, to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention. Furthermore, any reference herein to prior or background art is not intended to imply that such prior art forms a part of the common general knowledge.

Claims

1. A component for a flow heater, the component comprising:

a body that defines a first fluid conduit with a first aperture, a cover that defines a second aperture, and at least one cap that is couplable to a flow heater inset, wherein

the body, the cover and the cap are connectable to form an assembled state, and wherein

in the assembled state, the cover is fluid tightly connected to the body by a material connection and the cap is fluid tightly connected to the cover in such a way that

the first aperture and the second aperture are in at least partial registration with one another, and the cap and the body define a second fluid conduit that comprises at least the first conduit, and, if the flow heater inset is coupled to the cap, the flow heater inset is arrangeable at least in part in the first conduit.

2. A component according to claim 1, wherein

(i) the cap is made of a first material that comprises polypropylene; and/or

(ii) the cover and/or the body are made of a second material that comprises glass fibers.

3. A component according to either claim 1 or 2, wherein, in the assembled state, the cover and the cap are releasably connected to one another.

4. A component according to any one of the preceding claims, wherein, in the assembled state, the cover and the cap are connected to one another by snap-fit fastening, with a clamp connection, and/or with a bayonet connection.

5. A component according to any one of the preceding claims, further comprising the flow heater inset, wherein, in the assembled state, the flow heater inset is coupled to the cap and arranged at least in part in the first conduit

6. A component according to anyone of the preceding claims, wherein the cap comprises a third aperture, wherein
the cap is fluid tightly connectable to the cover and the flow heater inset is arrangeable at least in part in the third aperture and fluid-tightly connectable to the cap in such a way that
in the assembled state the second fluid conduit comprises the third aperture, and wherein,

if the flow heater inset is coupled to the cap, in the assembled state the flow heater inset is arrangeable at least in part outside the second fluid conduit and at least in part in the third aperture.

7. A component according to any one of the preceding claims, wherein the cover comprises a first connecting element and the cap comprises a cap portion and a second connecting element complementary to the first connecting element, wherein,
in the assembled state, the first connecting element and the second connecting element are engaged such that the cover and the cap are fluid-tightly connected and the cap portion defines the second fluid conduit, and wherein,
in the assembled state, the second connecting element and the cap portion are arranged in such a way that, when a first force, which is directed outwardly of the second conduit, is exerted on the cap portion, the first connecting element exerts a second force on the second connecting element such that a compressive load is exerted on the cap.

8. A component according to any one of the preceding claims, wherein the cover is connected to the body by a material connection.

9. A component according to any one of the preceding claims, wherein the cover and the body are welded together.

10. A component according to any one of the preceding claims, wherein the body, the cover, and the cap are connected in the assembled state.

11. A component according to any one of the preceding claims, wherein (i) the cap comprises at least one sensor, and/or (ii) the cap and the cover are permanently or semi-permanently coupled.

12. A flow heater comprising a component according to any one of the preceding claims.

13. A method for producing a component according to any one of the preceding claims, the component comprising a body that defines a first fluid conduit with a first aperture, a cover that defines a second aperture, and a cap that is couplable to a flow heater inset, wherein
the method comprises at least the steps of:

(i) fluid tightly connecting the body and the cover with a material connection in such a way that the first aperture and the second aperture are in at least partial registration with one another; and

(ii) fluid tightly connecting the cap and the cover such that the body and the cap define a second fluid conduit that comprises at least the first conduit and such that the inset, if coupled to the cap, is arrangeable at least in in part in the first conduit.

14. A method according to claim 13, wherein the component comprises the inset and the method further comprises the steps of:

(i) arranging at least a portion of the inset in the first conduit portion, and

(ii) connecting the inset to the first cap element.

15. A method according to either claim 13 or 14, wherein the step of connecting the cover and the body comprises welding the cover and the body together.

Drawing