Patent Application
20220333820
This invention relates generally to a cabinet heater system. More particularly, the present invention relates, for example, to an air plenum thermostat controller usable with a suitable cabinet heater system.
Generally, cabinet unit heaters are designed to maintain temperature within a designated area, such as rooms within residential homes, a garage, or other enclosure. While commonly used to heat small or enclosed areas, cabinet unit heaters can be implemented to assist with temperature maintenance, e.g., for cables, computer equipment, and other electronics, within designated areas. Various cabinet unit heater sizes are available to provide a power output appropriate to the desired heating requirements.
Traditional cabinet unit heaters sense the temperature of incoming air in order to determine heating requirements and utilize a temperature sensor within the unit itself. Heater controls are typically located within a separate control compartment, and require a remote temperature sensor, located in the air plenum, to sense the incoming air. Thus, the remote temperature sensor must be physically wired to the main controller in the control compartment.
Installation and preparation of such configurations are labor intensive and often require a technician or other skilled worker to properly configure and wire the thermostat controls in the control panel and run the remote temperature sensors into the plenum (for a thermostat with an integral remote temperature sensor) or separately connect a remote sensor to the thermostat if necessary. Each of the hardware parts—the controller, the wires, and the temperature sensor(s)—must be routinely monitored and maintained, since any issues with these temperature control mechanisms will affect the effectiveness of the cabinet unit heater to properly maintain the temperature of its designated area. Such configurations are found in both electro-mechanical and electronic based cabinet unit heater controls and face the challenges noted above. Accordingly, there is a need to improve the design of cabinet heaters to reduce the necessity of routine hardware maintenance and improve efficiency and effectiveness in performance.
The foregoing needs are met, to a great extent, by the present invention, wherein aspects of a cabinet heater and air plenum thermostat controller, as discussed herein.
An embodiment of the present invention pertains to a cabinet heater comprising: a housing forming a cavity comprising a heating unit and an air moving device, a thermostat mounted within the cavity, the thermostat comprising an internal temperature sensor configured to sense temperature within an air plenum formed in the cavity and configured to adjust at least one of the heating unit and air moving device to maintain a set temperature within the air plenum, a mounting unit securing a position of at least one of the heating unit, the air moving device, and the thermostat, a control compartment, separate from the cavity, housing controls configured to adjust the thermostat.
In various embodiments, the cabinet heater can further comprise a thermostat mount positioned within the cavity further comprising an upper bar secured to the mounting unit and a first plate, a second plate positioned beneath the first plate and attached to the thermostat, a stability bar positioned behind the second plate and securing the housing to prevent movement of the mounting unit. The thermostat mount can further comprise at least one of: a wire protector, a wire pathway, and a strain relieving grommet. In additional embodiments the thermostat can be mounted within the cavity using at least one hook to secure a position of the thermostat within the cavity.
In addition, the heating unit can be secured on an upper face of the mounting unit and the air moving device secured on a bottom face of the mounting unit. In embodiments, an area above the mounting unit containing the heating unit is thermally separated from an area below the mounting unit. Moreover, the areas above and below the mounting unit can be thermally separated using one or more of: an air-blocking baffle, a cover placed on the mounting unit, and insulation panels.
In other embodiments, the housing can comprise a removable outer panel enclosing the cavity. The outer panel can comprise an insulation layer and the outer panel can be removably coupled to the housing with at least one hinge. The housing can also comprise one or more panels removably covering the cavity and the control compartment. In embodiments, the cabinet heater of claim 1, wherein the air-moving device is a cylindrical blower.
The controls, within the control cabinet, can be configured to adjust the thermostat in response to received temperature information. As discussed herein, the controls can be configured to execute a program comprising automatic adjustments to the thermostat. Such adjust can be operated through various means and methods, such as through at least one of: manual, remote, digital, and automatic adjustments. Such controls can be further configured to adjust the heating unit and the air-moving device.
There has thus been outlined, rather broadly, certain embodiments of the invention in order that the detailed description thereof herein may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional embodiments of the invention that will be described below and which will form the subject matter of the claims appended hereto.
In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of embodiments in addition to those described and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting.
As such, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
Various embodiments of the present invention provide for an improved cabinet heater and plenum thermostat controller. Examples include electro-mechanical and electronic-based configurations. In various embodiments, a control thermostat with internal temperature sensor can be mounted in the inlet air plenum to control the unit. The controller can be connected via wire, for example, to the heater and fan relays, and allow for a simpler system architecture. Advantages of the present embodiments allow for use of electronic controls, without the traditional requirement of remote temperature sensors. Embodiments of the present invention allow for use of off-the-shelf, standard components, such as thermostats, which provide increased efficiency with respect to aspects such as heater construction, design, repair, and modification. The present invention provides an improved, customizable assembly configuration, that is readily adaptable to various environments and heating purposes, while reducing maintenance requirements and eliminating needs for designing customized, on-board electronics. The use of a thermostat within the air plenum further overcomes limitations of traditional designs, and heaters having a remote sensor within the air plenum. In addition, since the air plenum is cooler than the control compartment, the electronics are not exposed to as high of a temperature range, which thereby results in a greater lifespan of such electronics.
Turning now to the drawings,
The cabinet heater 100 can comprise at least two sections, which separate a control cabinet 130 from a main cavity 170 containing the thermostat 110, heating elements, and mounting components 115, 160. In embodiments, the control cabinet section 130 can contain one or more controls, as discussed herein, to manage one or more components within the cabinet heater 100 system. For example, the control cabinet 130 can house controls to adjust the thermostat, an air moving element, a heating element, and one or more aspects associated with each device.
In embodiments, the thermostat 110 is located within an air plenum of the cabinet heater 100. The thermostat can comprise an onboard temperature sensor configured to sense air temperature within the main cavity. In embodiments, the thermostat comprises at least one processor configured to execute one or more programs to adjust a temperature within the cavity, through operation of at least one of heating elements and air movement devices. The thermostat can be configured to communicate with at least one of a remote control system and a computing device. The thermostat can, for example, provide updates regarding the sensed temperature, and execute a program to maintain one or more set temperatures for a given period of time. The thermostat can be wired or wireless, and connected to other components and computing devices, including the control devices.
As illustrated in
The positioning of a thermostat within the air plenum allows for more accurate air measurement and, compared to traditional heating systems, reduces the amount of wiring and components necessary needed to connect a temperature sensor to a remote thermostat and remote control system.
As discussed herein, the thermostat can further be in communication with a control system, which can be located within the control cabinet 130. The control system can program the thermostat to execute one or more operations, such as temperature settings, in order to maintain a desired temperature and output of the cabinet heater system 100. In addition, the control system can be configured to adjust the receive temperature information from the thermostat and adjust the one or more settings of the thermostat in response to the received temperature information. Likewise, a program can be set, which comprises automatic adjustments to the thermostat. For example, the programmed set temperature on the thermostat can be changed based on a time of day or year. The set temperature could also be triggered in response to a certain temperature reading, such as the temperature going above or below a certain threshold temperature. In various embodiments, the control system can further be configured to adjust one or more of the heating unit and air-moving device. Such controls can be in addition to the thermostat's control, for example, or in response to a failure or other issue with the thermostat.
In embodiments, the control system can comprise a computing device or be in communication with one or more computing devices. Such communication can be wired or wirelessly connected to one or more computing devices. In addition, the control system can be manually controlled, remotely controlled, automatically controlled, or a combination of any of the above, as discussed herein.
In additional embodiments, the control system can comprise be manual controls, comprising a plurality of physical features, such as one or more buttons, switches, and levers, located within the control cabinet. In other embodiments, the controls can comprise digital controls, for example, and/or at least one screen, such as a touch screen, to adjust one or more operations of the cabinet heater system. It will be appreciated that the design of the control features can take any of a plurality of forms, such as digital, computer-controlled, manually-operated, and remote controls.
In additional embodiments, the control section can be kept open for easier access. In other embodiments, a panel 130 can be placed over the controls for aesthetic purposes, shielding, protection, and the like. The panel 130 can be fully or partially removable. In embodiments the panel can be a door. The panel 130 can be locked, or otherwise secured, for example, to prevent unintentional exposure of the controls, protect the controls from damage, maintain a certain temperature within the cabinet section, among others. The panel can comprise a layer of insulation. As discussed herein, one or more panels can cover the control cabinet and the main cavity. In embodiments, each section can be accessed separately. In other embodiments, each section is accessed upon removal of the panel.
The upper bar 220 is further secured to a first plate 210 formed above which a second plate 240 onto which the thermostat 110 is affixed. In embodiments, the upper bar is a horizontal bar affixed to the mounting unit 160. In other embodiments, at least one of the plates are vertically positioned, and located beneath the upper bar 220. In embodiments, the first plate 210 and second plate 240 can formed as a single fixture, or comprise two or more plates and connected via fasteners. In embodiments one or both of the first plate 210 and the second plate 240 are positioned vertically and different heights. The positioning of the thermostat mounting mechanism can be adjusted, depending on a preferred placement of the thermostat. In examples, the mounting mechanism can be secured along various lengths of the upper bar 220. Such placements can depend on the positioning of air blowing, heater elements, and other components within the main cavity, in addition to other considerations, such as an overall size of the cabinet heater, a size of the main cavity, an ideal position for determining air temperature, and other considerations.
A stability bar 230 positioned behind the second plate 210 can provide additional security and support, to prevent movement of the thermostat mounting mechanism. The stability bar can be mounted to the frame of the housing unit 150, for example, or attached to one or more components within the main cavity. In embodiments, the stability bar can be attached to one or more components within the main cavity using fasteners, adhesives, and the like. In embodiments, the mounting mechanisms discussed herein can be formed of metal, steel, or other durable material that can withstand the temperatures and temperature fluctuations occurring within the cabinet heater during operation. It will be appreciated that any of a plurality of materials, and combination of materials can be used in accordance with embodiments discussed herein.
In addition, the mounting plate 400 can further comprise a grommet 430, which can be a strain relieving grommet, e.g., for a wire pigtail. In some embodiments, as discussed herein, the thermostat can comprise one or more wires, which are functional for any of a variety of purposes, including but not limited to providing power, transferring information, sending signals to a local or remote device, and operation of one or more components within the cabinet heater. The grommet 430 can be provided on the mounting plate 400 to reduce strain on the wire, contact with other components, and generally decrease a risk for damage, pinching, and malfunction, in order to maintain, or even increase a lifespan of components. It will be appreciated that while a grommet is illustrated as an exemplary feature, similar components, such as wire coverings, protectors, dedicated pathway, and the like, can be used for similar purposes and to maintain the integrity and functionality of the wires and other physical components.
As further illustrated in
The attachment of the blowers to the mounting unit 160 can occur using any of a plurality of attachment methods. In an example, a plate 670 formed on or attached to the blower unit 650 can be secured to a mounting area 675 on the mounting unit 160. In embodiments, one or more screws, adhesives, fasteners, and the like can serve to attach the two components together. In embodiments, a similar plate attachment configuration can be used to secure a motor unit 680 to the mounting unit. A plate 685 can be formed on or attached to the motor unit 680 to attach to a bottom side of the mounting unit 160.
In various embodiments, an attachment 610 can be used to affix one or more components of the air moving units 650 to the mounting unit 160. Such attachments can be a removable, U-shaped faster, mounted on a bottom side of the mounting unit.
The back panel 700 can comprise a plurality of side panels 710 that can be fitted and/or formed with insulation 720. The side panels 710 and optional insulation 720 can assist in providing thermally separated areas within the cabinet heater, and within the main cavity, if desired. In addition, the side panels 710 can serve to separate the main cavity with the control unit cabinet section, as discussed herein. In embodiments, the insulation can extend along an entire length of the back panel 700, in order to prevent heat loss and/or heat transfer between sections of the cabinet heater. In addition, an air-blocking baffle can be installed to prevent air transfer between sections of the main cavity, or between areas of the air intake and air output components. Such baffles can be installed to assist in maintaining a set temperature within the main cavity and prevent heat loss.
In embodiments, the panel 1100 can be fully or partially removable. The panel can be a door. The panel 1100 can be locked, in embodiments, or otherwise secured, for example, to prevent unintentional exposure of the controls, protect unintended access, damage, and/or to help maintain a certain temperature within the cabinet section, among others. The panel 1100 can further comprise a layer of insulation. As discussed herein, one or more panels can cover both the control cabinet and the main cavity. In embodiments, each section can be accessed separately. In other embodiments, each section is accessed upon removal of the panel. In various embodiments, the control cabinet can comprise an additional panel beneath the front panel 1100. In other embodiments, the control cabinet can be kept open for easier access. It will be appreciated that each of the designs and implementations discussed herein can be modified, for various purposes such as aesthetics, shielding, protection, and the like, and fall within the scope of the embodiments discussed herein.
The many features and advantages of the invention are apparent from the detailed specification, and thus, it is intended by the appended claims to cover all such features and advantages of the invention which fall within the true spirit and scope of the invention. Further, since numerous modifications and variations will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation illustrated and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.
