ELECTRIC HEATING ELEMENTS AND WATER HEATERS INCLUDING SAME

Abstract

A stamped bare wire metal heating element for heating fluid in a tankless electric fluid heating device may include a first electrically conductive portion extending linearly; a second electrically conductive portion extending linearly; and a third electrically conductive portion connecting the first electrically conductive portion to the second electrically conductive portion at a first end of the stamped bare wire metal heating element, wherein the stamped bare wire metal heating element is open between the first electrically conductive portion and the second electrically conductive portion at a second end of the stamped bare wire metal heating element.

Description

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application claims the benefit of U.S. Provisional Application No. 63/365,045, filed on May 20, 2022, the disclosure of which is incorporated herein by reference in its entirety.

FIELD OF THE DISCLOSURE

The presently disclosed subject matter relates generally to electric heating elements and, more particularly, to electric heating elements for heating water or other fluids such as in a fluid heating device.

BACKGROUND

Some fluid heating devices, such as tankless water heaters, include a heating chamber in which a heating element is located and through which water can flow. As water flows through the heating chamber, the heating element increases the temperature of the passing water. The manufacturing process for some heating elements is expensive and difficult. In addition, some heating elements can incur stress during the manufacturing process, which can weaken the heating elements, and some heating elements can operate at undesirably high temperatures. More specifically, during operation, some heating elements can experience high wall temperatures in which the outer surfaces of the heating elements can run at temperatures high enough to cause deformation and/or eventual failure. Any deformations or failures experienced by a heating element can reduce the product lifetime and/or can result in unwanted maintenance or repair fees for the owner of the fluid heating device and/or the manufacturer of the fluid heating device. In some instances, the heating element can become so hot that it causes damage or failure of other nearby components of the fluid heating device, resulting in additional negative impact to the product lifetime of the fluid heating device and/or the overall cost of the fluid heating device.

Accordingly, it is beneficial to provide improved heating element designs that can sufficiently heat water without incurring unnecessary stresses, deformations, and/or failures. It is additionally beneficial to provide fluid heating devices including such improved heating element designs.

SUMMARY

These and other problems can be addressed by embodiments of the technology disclosed herein. The disclosed technology relates to heating elements for a fluid heating device and to fluid heating devices including such heating elements.

The disclosed technology includes an electric heating element for a fluid heating device. The electric heating element can comprise an open end, a closed end, a first portion extending between the open end and the closed end, and a second portion extending between the open end and the closed end. An internal volume of the electric heating element can be generally defined by the first portion, the second portion, and the closed end. The first portion can comprise a plurality of first fins extending outwardly from the first portion and a plurality of first openings extending through the first portion. The second portion can comprise a plurality of second fins extending outwardly from the second portion and a plurality of second openings extending through the second portion.

The plurality of first fins can extend generally toward the open end. The plurality of second fins can extend generally toward the open end. Alternatively, the plurality of second fins can extend generally toward the closed end.

At least some of the plurality of first fins or at least some of the plurality of second fins can have a generally rectangular shape. Alternatively or in addition, at least some of the plurality of first fins or at least some of the plurality of second fins can have a semispherical shape.

One of the plurality of first fins can have a first dimension, and another of the plurality of first fins can have a second dimension different from the first dimension. Alternatively or in addition, one of the plurality of second fins can have a third dimension, and another of the plurality of second fins has a fourth dimension different from the third dimension.

The first portion and the second portion can be parallel. Alternatively, the first portion and the second portion can diverge at the open end.

The disclosed technology includes a fluid heating device comprising a heating chamber and a heating element. The heating element can comprise an open end, a closed end, a first portion extending between the open end and the closed end, and a second portion extending between the open end and the closed end. An internal volume of the heating element can be generally defined by the first portion, the second portion, and the closed end. The first portion can comprise a plurality of first fins extending outwardly from the first portion and a plurality of first openings extending through the first portion. The second portion can comprise a plurality of second fins extending outwardly from the second portion and a plurality of second openings extending through the second portion. The heating chamber can comprise an inlet, an outlet, a first partition, and a second partition. The first partition can at least partially define a first section that is configured to receive a fluid from the inlet, and the first partition can direct a flow of the fluid in a first direction. The heating chamber can include a second section at least partially defined by the first partition and the first portion of the heating element, and the second section can be configured to direct the flow of the fluid in a second direction generally opposite the first direction. The heating chamber can include a third section at least partially defined by the second portion of the heating element and the second partition, and the third section can be configured to direct the flow of the fluid in the first direction. The heating chamber can include a third section at least partially defined by the second portion of the heating element and the second partition, and the third section being configured to direct the flow of the fluid in the second direction to the outlet.

The fluid heating device can comprise a mount configured to secure the heating element within the heating chamber. The mount can comprise plastic. The fluid heating device can include a gap between an exterior surface of the mount and an interior surface of the heating element such that fluid can flow along both the interior surface of the heating element and an exterior surface of the heating element.

These and other aspects of the present disclosure are described in the Detailed Description below and the accompanying figures. Other aspects and features of the present disclosure will become apparent to those of ordinary skill in the art upon reviewing the following description of specific examples of the present disclosure in concert with the figures. While features of the present disclosure may be discussed relative to certain examples and figures, all examples of the present disclosure can include one or more of the features discussed herein. Further, while one or more examples may be discussed as having certain advantageous features, one or more of such features may also be used with the various other examples of the disclosure discussed herein. In similar fashion, while examples may be discussed below as devices, systems, or methods, it is to be understood that such examples can be implemented in various devices, systems, and methods of the present disclosure.

BRIEF DESCRIPTION OF THE FIGURES

Reference will now be made to the accompanying figures, which are not necessarily drawn to scale, and wherein:

FIG. 1A illustrates a perspective view of an example heating element, in accordance with the disclosed technology;

FIG. 1B illustrates a side view of an example heating element, in accordance with the disclosed technology;

FIG. 2 illustrates a cross-sectional view of a heating chamber of an example fluid heating device, in accordance with the disclosed technology;

FIG. 3 illustrates a visualization of a fluid simulation conducted using an example heating element in accordance with the disclosed technology;

FIG. 4 illustrates an example heating element, in accordance with the disclosed technology; and

FIG. 5 illustrates an example heating element, in accordance with the disclosed technology.

DETAILED DESCRIPTION

The disclosed technology relates to electric heating elements. For example, the disclosed technology includes various designs for electric heating elements that are less susceptible to incurring stresses during manufacturing (e.g., as compared to existing designs) and/or experience decreased wall temperatures during operation (e.g., as compared to existing designs), which can decrease the likelihood the disclosed heating elements will experience deformation or failure, thereby increasing the product lifetime and/or decreasing the overall cost of the corresponding fluid heating device for the owner of the fluid heating device and/or the manufacturer of the fluid heating device. Moreover, the disclosed technology relates to fluid heating devices including a heating chamber that includes one or more of the heating devices disclosed herein.

Examples of the disclosed technology are discussed herein with reference to heating “fluid” or “water.” It is to be appreciated that the disclosed technology can be used with a variety of fluids, including water. Thus, while some examples may be described in relation to heating water specifically, all examples of the disclosed technology can be used with fluids other than water unless otherwise specified.

The disclosed technology is referenced herein in relation to a “heating chamber,” which can reference an area or portion of a fluid heating device in which heat is provided and/or transferred to a fluid.

The disclosed technology will be described more fully hereinafter with reference to the accompanying drawings. This disclosed technology can, however, be embodied in many different forms and should not be construed as limited to the examples set forth herein. The components described hereinafter as making up various elements of the disclosed technology are intended to be illustrative and not restrictive. Many suitable components that would perform the same or similar functions as components described herein are intended to be embraced within the scope of the disclosed electronic devices and methods. Such other components not described herein can include, but are not limited to, for example, components developed after development of the disclosed technology.

In the following description, numerous specific details are set forth. But it is to be understood that examples of the disclosed technology can be practiced without these specific details. In other instances, well-known methods, structures, and techniques have not been shown in detail in order not to obscure an understanding of this description. References to “one embodiment,” “an embodiment,” “example embodiment,” “some embodiments,” “certain embodiments,” “various embodiments,” etc., indicate that the embodiment(s) of the disclosed technology so described can include a particular feature, structure, or characteristic, but not every embodiment necessarily includes the particular feature, structure, or characteristic. Further, repeated use of the phrase “in one embodiment” does not necessarily refer to the same embodiment, although it can.

Throughout the specification and the claims, the following terms take at least the meanings explicitly associated herein, unless the context clearly dictates otherwise. The term “or” is intended to mean an inclusive “or.” Further, the terms “a,” “an,” and “the” are intended to mean one or more unless specified otherwise or clear from the context to be directed to a singular form.

Unless otherwise specified, the use of the ordinal adjectives “first,” “second,” “third,” etc., to describe a common object, merely indicate that different instances of like objects are being referenced and are not intended to imply that the objects so described should be in a given sequence, either temporally, spatially, in ranking, or in any other manner.

Some heating elements in fluid heaters, such as tankless electric water heaters, use bare wire elements to heat the water. Other water heaters may use sheathed wire for the heating elements. Bare wire may be coiled to maximize the surface area of the heating element (e.g., reduce watt density). However, some of the coiled bare wire heating elements may experience high wall temperatures, resulting in failures and hot pockets. In addition, winding the bare wire heating elements on a lathe can be difficult in the manufacturing process.

Stamping of bare wire may allow for the increased surface area of the heating element to reduce the watt density, and may allow for more simple manufacturing process. Metal stamping refers to converting flat metal into specific shapes. The stamped heating elements herein may use, for example, an 80-20% nickel-chromium metal, may be flat-bodied, and may have variations in shape, dimensions, and features. For example, the heating elements may provide a variable watt density (wattage output relative to the size—area—of the heating element) and an even heat distribution. The nickel-chromium metal may lower the wall temperature, increase durability, reduce hot pockets, and allow for the various shapes and features described herein. Instead of applying nickel-chromium strips to already manufactured heating elements, for example, the heating elements herein may be manufactured using a nickel-chromium metal.

The present disclosure provides enhanced heating elements for fluid heaters. In particular, the heating elements disclosed herein may reduce wall temperature, reduce or eliminate hot pockets, improve heat transfer, simplify manufacturing, improve durability, and reduce fluid heater cost and maintenance.

In one or more embodiments, the heating elements herein may use stamped elements and may be sized according to Ohm's Law: V=IR (voltage=current×resistance). Stamping (e.g., pressing) may allow for forming metal wire into a specific shape using techniques like punching, bending, blanking, embossing, flanging, etc. To form the heating elements herein, metal wire may be stamped to generate fins, holes, flat, and/or twisted portions. For example, stamping may include rolling or flattening wire, annealing the wire, shaping the wire by pulling or pushing the wire, and using techniques like bending the wire into U- or V-shapes, bending the fins, punching holes, and/or twisting the wire. While metal wire may be stamped to form the features of the heating elements shown and described herein, other techniques may be used to create the heating elements.

FIGS. 1A and 1B illustrate an example heating element 100. The heating element 100 can include a first portion 110 and a second portion 120. The first portion 110 can include a plurality of first fins 112 and a plurality of first openings 114. Similarly, the second portion 120 can include a plurality of second fins 122 and a plurality of second openings 124. The heating element 100 can include a closed end 130 and an open end 140. As will be described more fully herein, the open end 140 can be configured to attach to a mount to secure the heating element within a heating chamber and/or electrically connect the heating element 100 to a power source.

The first portion 110 and the second portion 120 can be parallel or substantially parallel. Alternatively, the first portion 110 and the second portion 120 can diverge at the open end 140 such that the heating element 100 forms a generally V shape (e.g., with a sharply angled closed end 130 or an arced and/or curved closed end 130). Although the first portion 110 and the second portion 120 are illustrated as being substantially linear, the disclosed technology is not so limited. Instead, one or both of the first and second portions 110, 120 can have at least one curved section. That is to say, some or all of the first portion 110 can be curved, and/or some or all of the second portion 120 can be curved. The first portion 110, second portion 120, and/or closed end 130 can have the same, or substantially the same, width and/or the same, or substantially the same, thickness. The heating element 100 can be made from and/or comprise e.g., nichrome or any other material having an electric resistance sufficient to heat passing water when the heating element 100 is exposed to electricity.

As illustrated, the first and second portions 110, 120 can be generally flat (other than the fins 112, 122). The disclosed technology is not so limited, however. Alternatively, some or all of the first portion 110, the closed end 130, and/or the second portion 120 can be twisted or otherwise bent. For example, some or all of the first portion 110, the closed end 130, and/or the second portion 120 can include torsional and/or helical features.

The heating element 100 can be formed from a single piece of material. That is to say, the first portion 110, first fins 112, closed end 130, second portion 120, and/or second fins 122 can together form a unitary piece. To form the heating element 100, a flat ribbon of material can be stamped to form the fins 112, 122 and the openings 114, 124. The fins 112, 122 can be stamped (e.g., three sides of a generally rectangular shape can be cut from an internal portion of the ribbon) from the ribbon of material and bent outwardly (e.g., along the fourth, uncut side of the generally rectangular shape). Once the fins 112, 122 have been stamped and/or bent, the resulting negative space in the ribbon can provide the openings 114, 124.

As illustrated, the first fins 112 and the second fins 122 can have the same, or substantially the same, shape. Alternatively, one, some, or all of the first fins 112 and/or the second fins 122 can have a different shape, such as a generally triangular shape, a generally semispherical shape, a generally semicircular shape, any generally polygonal shape, or any other shape. Alternatively or in addition, one, some, or all of the first fins 112 and/or the second fins 122 can have a different size. More specifically, some or all of the first fins 112 can have a first width and/or a first length. Alternatively or in addition, some of the first fins 112 can have a second width different from the first width and/or a second length different from the first length. Alternatively or in addition, some or all of the second fins 122 can have a third width and/or a third length. The third width can be the same as the first width, and/or the third length can be the same as the first length. Alternatively or in addition, some of the second fins 122 can have a fourth width different from the first width and/or the third width and/or a fourth length different from the first length and/or the third length.

Likewise, the first openings 114 and the second openings 124 can have the same, or substantially the same, shape. Alternatively, one, some, or all of the first openings 114 and/or the second openings 124 can have a different shape, such as a generally triangular shape, a generally semispherical shape, a generally semicircular shape, any generally polygonal shape, or any other shape. Alternatively or in addition, one, some, or all of the first openings 114 and/or the second openings 124 can have a different size. More specifically, some or all of the first openings 114 can have a first width and/or a first length. Alternatively or in addition, some of the first openings 114 can have a second width different from the first width and/or a second length different from the first length. Alternatively or in addition, some or all of the second openings 124 can have a third width and/or a third length. The third width can be the same as the first width, and/or the third length can be the same as the first length. Alternatively or in addition, some of the second openings 124 can have a fourth width different from the first width and/or the third width and/or a fourth length different from the first length and/or the third length.

The sizes of the fins 112, 122 and/or openings 114, 124 can gradually change (e.g., increase, decrease) along the length of the first portion 110 and/or second portion 120. For example, the fins 112, 122 and/or openings 114, 124 proximate the open end 140 can have a longer length and/or width than the fins 112, 122 and/or openings 114, 124 proximate the closed end 130, and vice versa, depending on the particular configuration. Alternatively, or in addition, the size of the fins 112, 122 and/or openings 114, 124 can alternate between longer and shorter lengths and/or widths along the length of the first portion 110 and second portion 120.

As will be appreciated, differences in the size and/or shape of some or all of the first fins 112, first openings 114, second fins 122, and/or second openings 124 can help optimize fluid flow through the heating element 100 and the heating chamber (e.g., heating chamber 200 described herein). Accordingly, fluid flow velocity can be adjusted to prevent discrepancies in flow rate between different areas of the heating element and/or heating chamber 200.

The first fins 112 and the second fins 122 can extend in the same general direction. For example, the first fins 112 and the second fins 122 can extend generally in the direction of the open end 140. Alternatively, the first fins 112 and the second fins 122 can extend generally in the direction of the closed end 130. Alternatively or in addition, the first fins 112 can extend generally in the direction of the open end 140, and the second fins 122 can extend generally in the direction of the closed end 130 and vice-versa.

Some or all of the first fins 112 can have the same or approximately the same angle relative to the first portion 110. For example the angle of the first fins 112 can be in a range between approximately 20 degrees and approximately 30 degrees, in a range between approximately 30 degrees and approximately 40 degrees, in a range between approximately 40 degrees and approximately 50 degrees, in a range between approximately 50 degrees and approximately 60 degrees, in a range between approximately 60 degrees and approximately 70 degrees, in a range between approximately 70 degrees and approximately 80 degrees, or in a range between approximately 80 degrees and approximately 90 degrees, as non-limiting examples. Similarly, some or all of the second fins 122 can have the same or approximately the same angle relative to the second portion 120. For example the angle of the second fins 122 can be in a range between approximately 20 degrees and approximately 30 degrees, in a range between approximately 30 degrees and approximately 40 degrees, in a range between approximately 40 degrees and approximately 50 degrees, in a range between approximately 50 degrees and approximately 60 degrees, in a range between approximately 60 degrees and approximately 70 degrees, in a range between approximately 70 degrees and approximately 80 degrees, or in a range between approximately 80 degrees and approximately 90 degrees, as non-limiting examples. All of the first and second fins 112, 122 can have the same or approximately the same angle. Alternatively, the angle of the first fins 112 can gradually change (e.g., increase, decrease) along the length of the first portion 110, and/or the angle of the second fins 122 can gradually change (e.g., increase, decrease) along the length of the second portion 120.

Referring to FIG. 2, a heating chamber 200 of a fluid heating device is illustrated. The heating chamber 200 can have an inlet 202 configured to receive fluid (e.g., water) from an inlet of the fluid heating device and an outlet 204 configured to output fluid to an outlet of the fluid heating device. The heating chamber 200 can include one or more partitions 206. The heating chamber 200 can include a mount 210 configured to mechanically attach the heating element 100 within the heating chamber 200. The mount 210 can include one or more electrical contacts configured to contact the heating element 100 and transmit electricity to the heating element 100 from a power source (e.g., the heating element 100 may be conductive). The mount 210 can be made from or comprise plastic, metal, ceramic, or any other useful material. As illustrated, a gap can exist between the exterior surface of the mount and some or all of an interior surface of the first portion 110, some or all of an interior surface of the closed end 130, and/or some or all of an interior surface of the second portion 120. As such, fluid can be permitted to flow on either side (i.e., exterior, interior) of the first portion 110, closed end 130, and/or second portion 120. This can increase the surface area of the heating element 100 in contact with water at any given time.

As illustrated, the heating chamber 200 can include two partitions 206A, 206B. As fluid enters the heating chamber 200, it can flow in a first direction through a first section of the heating chamber 200 that is generally defined by an outer wall of the heating chamber 200 and a first side of a first partition 206A. At the end of the first partition 206A, the fluid can change direction to flow in a second direction that is generally opposite the first direction. The fluid can flow in the second direction in a second section generally defined between a second side of the first partition 206A and the first portion 110 of the heating element 100. The fluid can again change direction back to the first direction upon reaching the closed end 130 of the heating element, flowing through a third section generally defined between the second portion 120 and a first side of a second partition 206B. At the end of the second partition 206B, the fluid can again change direction back to the second direction, flowing through a fourth section generally defined between the second side of the second partition 206B and an outer wall of the heating chamber 200.

Referring to FIG. 3, a visualization of a fluid simulation conducted using the heating element 100 is shown. The fluid simulation was conducted using a heating chamber 200 substantially similar to the heating chamber illustrated in FIG. 2. The incoming fluid had a temperature of approximately 72° F. and was heated to approximately 120° F. The maximum temperature of the heating element 100 was approximately 152° F. In contrast, existing spiral-wound heating elements commonly reach temperatures of approximately 450° F. when providing the same amount of heating. Thus, the heating element 100 can have a greater surface area as compared to existing designs and can thus provide the same or substantially the same heating effect with a comparatively lower watt density, which can prolong the working life of the heating element, among other benefits.

As illustrated in FIG. 3, the fluid can be heated from an inlet temperature to an exit temperature that is greater than the inlet temperature as the fluid is passed through the heating chamber 200. The fluid can be heated as it is passed through the heating chamber 200 from the inlet 202 and to the outlet 204 by passing over the heating element 100. As explained previously, the heating chamber 200 can include a first partition 206A and a second partition 206B to help direct the fluid from the inlet 202, across the first portion 110 of the heating element 100, across the second portion 120 of the heating element, and then out the outlet 204.

As illustrated in FIG. 4, the heating element 100 can omit the fins 112, 122 and the openings 114, 124. Stated otherwise, the heating element 100 can be a flat ribbon having a bend to form the closed end 130, with the bend separating the first portion 110 and the second portion 120. As discussed herein, some or all of the first portion 110 can be linear, and/or some or all of the second portion 120 can be linear. Alternatively or in addition, some or all of the first portion 110 can be curved, and/or some or all of the second portion 120 can be curved. The first portion 110, second portion 120, and/or closed end 130 can have the same, or substantially the same, width and/or the same, or substantially the same, thickness. Some or all of the first portion 110 can be generally flat, and/or some or all of the second portion 120 can be generally flat. Alternatively or in addition, some or all of the first portion 110, the closed end 130, and/or the second portion 120 can be twisted or otherwise bent. For example, some or all of the first portion 110, the closed end 130, and/or the second portion 120 can include torsional and/or helical features.

As shown in FIG. 5, the heating element 100 can have a torsional and/or helical feature. The heating element, as illustrated in FIG. 5, can be formed via a process different from the process described herein utilizing a ribbon of material. For example, the heating element 100 can be casted. The thickness of the heating element 100 can be approximately equal to the width of the heating element 100, as a non-liming example.

While the present disclosure has been described in connection with a plurality of exemplary aspects, as illustrated in the various figures and discussed above, it is understood that other similar aspects can be used, or modifications and additions can be made to the described subject matter for performing the same function of the present disclosure without deviating therefrom. In this disclosure, methods and compositions were described according to aspects of the presently disclosed subject matter. But other equivalent methods or compositions to these described aspects are also contemplated by the teachings herein. Therefore, the present disclosure should not be limited to any single aspect, but rather construed in breadth and scope in accordance with the appended claims.

Moreover, the various diagrams and figures presented herein are for illustrative purposes and are not to be considered exhaustive. That is, the systems described herein can include one or more additional components, such as various valves, expansions tanks, and the like, as will be appreciated by one having ordinary skill in the art.

Claims

1. A stamped bare wire metal heating element for heating fluid in a tankless electric fluid heating device, the stamped bare wire metal heating element comprising:

a first electrically conductive portion extending linearly;

a second electrically conductive portion extending linearly; and

a third electrically conductive portion connecting the first electrically conductive portion to the second electrically conductive portion at a first end of the stamped bare wire metal heating element,

wherein the stamped bare wire metal heating element is open between the first electrically conductive portion and the second electrically conductive portion at a second end of the stamped bare wire metal heating element.

2. The stamped bare wire metal heating element of claim 1, further comprising a plurality of first fins extending outwardly from the first electrically conductive portion and a plurality of second fins extending outwardly from the second electrically conductive portion.

3. The stamped bare wire metal heating element of claim 2, wherein the plurality of the first fins and the plurality of the second fins are of a same size.

4. The stamped bare wire metal heating element of claim 2, wherein a first fin of the plurality of the first fins is a different size than a second fin of the plurality of the first fins.

5. The stamped bare wire metal heating element of claim 2, wherein the plurality of the first fins and the plurality of the second fins are of a same shape.

6. The stamped bare wire metal heating element of claim 2, wherein a first fin of the plurality of the first fins is a different shape than a second fin of the plurality of the first fins.

7. The stamped bare wire metal heating element of claim 2, further comprising first openings extending through the first electrically conductive portion and second openings extending through the second electrically conductive portion.

8. The stamped bare wire metal heating element of claim 1, wherein the first electrically conductive portion and the second electrically conductive portion are parallel to one another.

9. The stamped bare wire metal heating element of claim 1, wherein the third electrically conductive portion is curved.

10. The stamped bare wire metal heating element of claim 1, wherein a thickness of the first electrically conductive portion is not uniform.

11. The stamped bare wire metal heating element of claim 1, wherein the first electrically conductive portion, the second electrically conductive portion, and the third electrically conductive portion are flat.

12. The stamped bare wire metal heating element of claim 1, wherein the first electrically conductive portion and the second electrically conductive portion are twisted.

13. A tankless electric fluid heating device comprising:

a heating chamber; and

a stamped bare wire metal heating element at least partially arranged within the heating chamber and configured to heat fluid within the heating chamber, the stamped bare wire metal heating element comprising: a first electrically conductive portion extending linearly; a second electrically conductive portion extending linearly; and a third electrically conductive portion connecting the first electrically conductive portion to the second electrically conductive portion at a first end of the stamped bare wire metal heating element, and wherein the stamped bare wire metal heating element is open between the first electrically conductive portion and the second electrically conductive portion at a second end of the stamped bare wire metal heating element.

14. The tankless electric fluid heating device of claim 13, further comprising a plurality of first fins extending outwardly from the first electrically conductive portion and a plurality of second fins extending outwardly from the second electrically conductive portion.

15. The tankless electric fluid heating device of claim 14, further comprising first openings extending through the first electrically conductive portion and second openings extending through the second electrically conductive portion.

16. The tankless electric fluid heating device of claim 13, wherein the first electrically conductive portion and the second electrically conductive portion are parallel to one another.

17. The tankless electric fluid heating device of claim 13, wherein the third electrically conductive portion is curved.

18. The tankless electric fluid heating device of claim 13, wherein the first electrically conductive portion, the second electrically conductive portion, and the third electrically conductive portion are flat.

19. The tankless electric fluid heating device of claim 13, wherein the first electrically conductive portion and the second electrically conductive portion are twisted.

20. A method of heating fluid in a tankless fluid heating device, the method comprising:

arranging a stamped bare wire metal heating element within a heating chamber, the stamped bare metal wire heating element comprising: a first electrically conductive portion extending linearly; a second electrically conductive portion extending linearly; a third electrically conductive portion connecting the first electrically conductive portion to the second electrically conductive portion at a first end of the stamped bare wire metal heating element, and wherein the stamped bare wire metal heating element is open between the first electrically conductive portion and the second electrically conductive portion at a second end of the stamped bare wire metal heating element; and

transmitting electricity to the stamped bare wire metal heating element.