Electric Baseboard Radiator Heater Cover

INTRODUCTION

Electric baseboard radiator heaters are widely used in the United States and many other countries. Like other forms of electric resistance heating, electric baseboard heaters offer very high energy efficiency. That is, a very high fraction of the electricity consumed by electric baseboard heaters is used to produce heat making them significantly more efficient than hydronic baseboard heating systems. Consequently, electric baseboard heaters are considered by some to be more environmentally friendly, reducing one's impact on the environment. This is particular true for regions where electricity comes primarily from renewable energy sources. However, in regions where electricity comes primarily from coal or gas, the process of transforming these fossil fuels into electricity and transporting this electricity to the home can be relatively efficient making electric baseboard heaters much less environmentally desirable.

In addition, electric baseboard radiators are relatively inexpensive compared with hydronic baseboard radiators and are much easier and less expensive to install and maintain. Also, electric baseboard radiators are more easily zoned than hydronic baseboard radiators allowing them to provide more flexible heating options to the user, which usually translates into more comfort to the user at a lower energy cost. This combination of features offered by electric baseboard radiators makes them ideal for many types of new and remodeled constructions, especially in temperate climate regions that have hot summers and cool winters where heat is only required for winter months. However, depending on the cost of electric power in the region, electric baseboard radiators can even be cost effective in colder regions that require heat for most of the year.

BRIEF DESCRIPTION OF THE DRAWINGS

The present teaching, in accordance with preferred and exemplary embodiments, together with further advantages thereof, is more particularly described in the following detailed description, taken in conjunction with the accompanying drawings. The skilled person in the art will understand that the drawings, described below, are for illustration purposes only. The drawings are not necessarily to scale; emphasis instead generally being placed upon illustrating principles of the teaching. The drawings are not intended to limit the scope of the Applicants' teaching in any way.

FIG. 1 illustrates a cutaway-view of a prior art hydronic baseboard

radiator heater.

FIG. 2A illustrates a cutaway-view of a prior art electric baseboard radiator heater that is manufactured with a metal cover.

FIG. 2B illustrates one embodiment of a multi-section radiator heater cover according to the present teaching that includes a plurality of sections that can be fabricated with different material and/or different manufacturing processes.

FIG. 2C illustrates another embodiment of a multi-section radiator heater cover according to the present teaching that includes a plurality of sections that can be fabricated with different material and/or different manufacturing processes that is configured to reduce temperatures at the edge of the top surface electric radiator heater with a vented panel.

FIG. 2D illustrates another embodiment of a multi-section radiator heater cover according to the present teaching that includes a plurality of sections that can be fabricated with different material and/or different manufacturing processes that is configured to reduce temperatures at the edge of the top surface electric radiator heater with a solid panel.

FIG. 2E illustrates a multi-section radiator heater cover according to the present teaching positioned over a manufactured electric baseboard radiator heater.

FIG. 3A illustrates a perspective view of a radiator heater cover for an electric radiator heater according to the present teaching that includes a plurality of heat channels which provide a plurality of heat transfer paths for heat to flow from the radiator directly into the room, thereby reducing the temperature at the surface of the radiator cover.

FIG. 3B illustrates a back view of the radiator heater cover for an electric radiator heater described in connection with FIG. 3A that show the standoff ribs and open areas that define the plurality of heat channels which provide the plurality of heat transfer paths for heat to flow from the radiator directly into the room, thereby reducing the temperature at the surface of the radiator cover.

DESCRIPTION OF VARIOUS EMBODIMENTS

Reference in the specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the teaching. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment.

It should be understood that the individual steps of the methods of the present teachings may be performed in any order and/or simultaneously as long as the teaching remains operable. Furthermore, it should be understood that the apparatus and methods of the present teachings can include any number or all of the described embodiments as long as the teaching remains operable.

The present teaching will now be described in more detail with reference to exemplary embodiments thereof as shown in the accompanying drawings. While the present teaching is described in conjunction with various embodiments and examples, it is not intended that the present teaching be limited to such embodiments. On the contrary, the present teaching encompasses various alternatives, modifications and equivalents, as will be appreciated by those of skill in the art. Those of ordinary skill in the art having access to the teaching herein will recognize additional implementations, modifications, and embodiments, as well as other fields of use, which are within the scope of the present disclosure as described herein.

The present teaching relates to covers for baseboard heaters and in particular covers for baseboard heaters that operate at relatively high temperatures including electric baseboard heaters. The first baseboard heaters were hydronic baseboard radiator heater. FIG. 1 illustrates a cutaway-view of a prior art hydronic baseboard radiator heater 100. The hydronic baseboard radiator heater 100 includes a frame 102 that is typically attached to the baseboard molding in a room. A hydronic filled heating element 104 is positioned inside the frame 102 that includes conduits 106 for passing heated liquid and a heat exchanger 108 for radiating the heat from the conduits 106 into the room. The basic operating principle of radiating heat from a liquid into a room was invented by Franz San Galli in 1855 and embodied in free standing hydronic radiators. Cast iron versions of these free standing hydronic radiators have been widely used for more than a 150 years. Many are still in use today worldwide. Such free standing radiators are not attached to wall or other vertical structure in the room, but are sometimes attached to the floor.

The present teaching is particularly relevant to covers for electric baseboard heaters because electric baseboard heaters operate at relatively high temperatures. However, the present teachings are not limited to electric baseboard heaters in that covers according to the present teaching can be used for hydronic baseboard radiator and can provide certain advantages over known covers as well. Electric baseboard heaters were invented around 1925. U.S. Pat. No. 1,664,171 was issued to William Wesley Hicks for an electric heater that he referred to as a “baseboard heater” because the heater was also used as the baseboard trim in a room. The term “baseboard heater” was then used more generally going forward to refer also to heaters that were attached to baseboard trim.

It should be understood that the covers for electric heaters according to the present teaching can be applied to any type of electric heater regardless of its physical shape. That is, although many aspects of the present teaching are described in connection with covers for electric baseboard radiator heaters, it should be understood that the covers according to the present teaching can be used for any type of electric heater including free standing electric heaters that are not attached to baseboard molding. Covers according to the present teaching can be used for hydronic radiator heaters as well.

It should also be understood that some embodiments of the covers for electric radiator heaters according to the present teaching are specifically designed to fit over existing manufactured electric radiator heaters that can include a factory installed cover, which is typically formed of a metal. In other words, some embodiments of the covers for electric radiator heaters according to the present teaching are so called “aftermarket” covers that are a type of accessory which is added on to an original manufactured electric radiator heater to, for example, provide an improvement and/or additional features over the originally manufactured electric radiator heater. In many cases, these so called aftermarket covers are manufactured to have specific advantages, such as being more aesthetically pleasing to the consumer and more durable. However, in some other embodiments, the covers for electric radiator heaters according to the present teaching are specifically designed to be the only cover for the radiator heater. These covers can be installed during manufacturing and/or provided to the consumer at the time of sale of the unit that includes a radiator.

FIG. 2A illustrates a cutaway-view of a prior art electric baseboard radiator heater 200 that is manufactured with a metal cover 201. The electric baseboard radiator heater 200 is similar to the hydronic baseboard radiator heater 100 of FIG. 1. The heater 200 includes a frame 202 that is typically attached to the baseboard molding in a room. However, the electric baseboard radiator heater 200 includes an electrical filament 204 heating element instead of the hydronic filled heating element 104 shown in FIG. 1. The electric baseboard radiator heater 200 has a top surface 206. The electric filament 204 converts electrical energy from an electrical power source, such as an electric wall plug, into heat through a process known as Joule heating. Joule heating is resistive heating, which is also referred to as Ohmic heating and is very well known in the art. Electric current passing through the heating element encounters resistance that results in heating of the element. In other words, Joule heating is the process by which the passage of an electric current through a conductor produces heat.

Many modern electric heater filament heating elements 204 are formed of nichrome wire because nichrome does not oxidize and burn easily at high temperature and because nichrome has a higher melting and boiling point than many other metals. The nichrome wire is supported by ceramic insulators that electrically isolate the heating element so that the heating element can be safely powered. Bushings are sometimes used to reduce noise caused by thermal expansion. Nichrome wire also has a relatively high operating temperature range that is typically in the range of 2,100 degrees Fahrenheit.

Electric radiator heater covers of the present teaching are spaced away from nichrome wire with an air gap that can be, for example, in the range of a few millimeters to a few centimeters wide. The temperature experienced by electric radiator heater covers, which are spaced away from the nichrome wire with such air gaps is typically in the range of 300 degrees Fahrenheit, which is significantly lower than the filament temperature, but still very much higher than the temperatures experienced by covers used for hydronic heating systems. For example, hydronic baseboard heater elements typically don't exceed 140 degrees Fahrenheit. Temperatures experienced by hydronic radiator heater covers spaced apart from the hydronic baseboard heater elements are typically below 100 degrees Fahrenheit.

A serious problem with known electric baseboard radiator heater covers is that temperatures experienced by some regions of electric radiator heater covers far exceed the deformation temperature of many non-metal materials, such as plastic and composite materials. Consequently, known electric radiator heater covers are formed of high temperature resistant materials that are typically metals. Metals are also used because it is conventional wisdom that radiator heater covers formed of conductive material are advantageous in that they radiate more heat into a room, making the overall heating process more efficient.

One problem with metal baseboard radiator heater covers is that they tend to discolor and rust over time. Metal baseboard radiator heaters located near toilets and sinks are notorious for showing discoloration, which is caused by oxidation and rusting from direct exposure to splashing fluids including water and urine. Urine, in particular, rapidly rusts and corrodes known metal baseboard radiators.

A few manufactures have produced plastic radiator heater covers for hydronic radiators formed of plastic materials that are both resistant to rust and corrosion over time and also designed to be aesthetically pleasing. However, no such radiator heater covers exist for electric baseboard radiators as it believed that such covers would experience temperatures that cause deformation or even combustion resulting in complete failure of the cover. Different types of plastic materials have different deformation and melting temperature points. Some plastic materials can melt at temperatures as low as 165 degrees Fahrenheit. There are some heat resistant plastic materials currently on the market with higher deformation/melting temperatures but, these materials are expensive and can be difficult to manufacture into finished products.

Nevertheless, a plastic cover is desirable for consumers because electric baseboard radiator heaters are commonly used in bathrooms and kitchens where they are often exposed to moisture and sometimes directly exposed to water, urine, and other liquids that cause oxidation on the surface of the radiator heater cover. One aspect of the electric radiator heater covers of the present teaching is the realization that a properly designed electric baseboard cover can be formed of a plastic material that is resistant to moisture, urine, and other environmental conditions that cause discoloration of the finish and rust and that such plastic covers can be configured so that they do not deform or melt when positioned near the electric filament 204 of an electric baseboard radiator heater 200.

Currently, commercial plastic baseboard radiator heater covers that are used for hydronic heaters are typically manufactured using extrusion molding. Extrusion molding is a process where molten plastic is pushed through a two-dimensional die opening. Most extrusion molding uses resin plastic formed in small solid beads, which is desirable because it allows for simple loading and quick melting plastic times. A common plastic material used in extrusion molding is acrylonitrile butadiene styrene (ABS), which is commonly known as thermoplastic polymer. ABS is desirable for manufacturing because it has a relatively low melting point, which enables its easy use in the injection molding process. ABS also has high tensile strength and is very resistant to physical impacts and chemical corrosion, which allow the finished plastic to withstand heavy use and adverse environmental conditions making it a good choice for a commercial product. Other plastic materials used for extrusion molding are high impact polystyrene (HIPS), PVC, polyethylene, and polypropylene.

Known plastic baseboard radiator heater covers include a vented grid, comprising perforations that are physically punched out in a secondary manufacturing process. See, for example, U.S. Patent Publication No. 20120055651 A1, entitled “Baseboard Heater Radiator Cover”, which is assigned to the current assignee. See also U.S. Pat. No. 5,884,690, which describes a heater cover formed of thermoplastic material having a series of laterally space apertures or slots. In these known plastic baseboard radiator heater covers, the area of the punched out perforations typically does not exceed 40% of the entire vent area, which corresponds to a ratio of perforation area to unperforated area (solid area) of about two thirds. A baseboard radiator heater cover with such a ratio of perforated area to unperforated area retains the necessary rigidity that provides enough structural integrity to maintain the cover's shape during the lifetime of the radiator heater.

The secondary manufacturing process of “punching” has demonstrated a limitation on the grid area dimensions being punched. This limitation has been shown to be governed by the tensile strength of the material being punched. The force associated with “punching” will damage the grid area if there is not adequate tensile strength present to absorb the associated forces associated with the punching. Materials with inadequate tensile strength for the necessary “punching” will have tearing and/or breaking of the grid during the “punching” process.

The tensile strength increases as the grid line area increases. That is, as the area of the grid lines increases, the tensile strength of the grid lines also increases. Conversely, as the area of grid lines reduces, the tensile strength also reduces in a generally proportionately manner. It has been experimentally determined that when the grid lines are reduced to provide open space of greater than or equal to about 40% of the overall vent area, the strength of the grid lines are reduced to an extent that damage to the grid lines occur due to the “punching” process.

However, it has been determined experimentally that conventional plastic radiator heater covers with a two-thirds ratio of perforation area to solid area does not work with electric radiator heaters as the ventilation through the perforated area is not sufficient to maintain a temperature at the surface of the plastic cover that prevents deformation and melting. The resulting high temperature at the surface of the cover also creates a potential consumer safety hazard. Additional, experiments have shown that when the perforated area to unperforated area of a plastic electric radiator heater cover is less than one half, the electric radiator heater cover will experience temperatures high enough to cause deformation and melting of thermoplastic materials as well as a potential safety hazard to the consumer.

In fact, temperatures at the surface of the electric radiator heater cover have been measured experimentally to be in the range of 320 degrees Fahrenheit for electric radiator heater covers with perforated-to-solid area ratios that are less than one half. Such temperatures are unacceptably high for many common plastic materials used in extrusion molding processes. For example, most plastic radiator heater covers are formed of PVC material, which softens when the temperature increases to about 180 degrees Fahrenheit. For example, ABS plastic, which is commonly used to form plastic radiator heater covers by extrusion molding, has an acceptable operating range that extends to only 176 degrees Fahrenheit and a melting temperature that is only 221 degrees Fahrenheit. Temperatures that have been experimentally measured at the surface of the cover of various electric radiator heaters are significantly higher than the 221 degrees Fahrenheit melting temperature when the perforated-to-solid area ratios are less than one half.

One aspect of the electric radiator heater baseboard covers according to the present invention is the understanding that the ratio of perforated vent area to solid area of an aftermarket cover can be chosen so as to not significantly increase the temperature at the surface of the baseboard radiator heater cover. That is, adding a plastic cover according to one aspect of the present teaching to a commercial electric radiator heater manufactured with a metal cover will not significantly change the temperature at the plastic radiator cover if the plastic cover is configured according to the present teaching. More specifically, it has been determined experimentally that when the ratio of perforated vent area to solid area in the vent area is equal to or greater than 50%, the temperature at the inner surface of a plastic radiator cover according to the present teaching placed over an originally manufactured metal cover of an electric heater is not significantly increased over the temperature at the outer surface of the originally manufactured metal cover under the plastic radiator cover. For example, such a plastic radiator cover, according to the present teaching with a perforated vent area to solid area that is equal to or greater than 50% within the vent area will not see a surface temperature increase that is greater than about 10-20% (depending on the particular configuration) of the temperature of the surface of the originally manufactured metal cover. In contrast, known plastic covers experience temperature increases on order of 30-40%. Such temperature increases of these known plastic covers will cause deformation of the plastic material.

In various embodiments, the ratio of perforated vent area to solid area of the entire vent area is chosen to be equal to or greater than 65%. In yet other embodiments, the ratio of perforated vent area to solid area of the vent area is chosen to be equal to or greater than 75%. The resulting increase in perforated vent area of the vent area in covers configured according to the present teaching compared with the known plastic baseboard radiator heater covers for hydronic baseboard radiators, where the perforated vent area does not exceed 40% of the entire vent area, is that the temperature at the plastic cover is not significantly changed by the addition of the plastic radiator heater cover to a temperature that is dangerous or destructive.

Still, the air passing through the perforated vent area is at a higher temperature than what is acceptable for many plastic materials. The air temperature passing through perforated vent areas has been measured to be approximately 250 degrees Fahrenheit, which is higher than the melting point of ABS plastic material. Known plastic radiator heater covers formed of thermoplastic materials are a one-piece design that is constructed from one type plastics or a blend of various types of plastic materials. So these known one piece designs would fail during normal use when covering an electric radiator heater.

Another aspect of the present teaching is to form plastic or composite material radiator heater covers in a two or multi-piece configuration where higher deformation and melting point materials are used in certain areas exposed to higher temperatures. Areas of the cover that are exposed to low enough temperatures to allow use of inexpensive thermoplastic materials such as ABS or PVC can be formed of these materials in order to reduce the overall cost of the cover. Numerous types of plastic materials can be used. For example, radiator heater covers according to the present teaching can be formed of thermoplastic material including at least one of liquid crystalline polymer, polyethylene, polyamide, polycarbonate, polypropylene, polyphenylene sulfide, thermoplastic elastomer, copolyester elastomer, polystyrene, polyvinyl chloride, polytetraflouroethylene, poly (methyl methacrylate), Nylon 6,6 and PBT. One skilled in the art will appreciate that numerous types of plastic materials having the desired mechanical and thermal properties can also be used. These plastic materials can be embedded with a colorant to change the color of the baseboard radiator heater cover to any color desired by the consumer.

Higher deformation/melting point plastic materials are typically much more expensive than commonly used plastics, such as ABS or PVC. In addition, injection molding is often used for higher deformation/melting point plastic materials. Injection molding is a manufacturing technique that is well known in the art that injects molten material into a mold. Thermoplastic injection molding is a manufacturing process that forms parts by injecting plastic resin into a pre-made mold. The injection molded parts are then oven cured to produce a thermoset polymer that typically has a higher deformation and melting temperature. However, the injection molding process is typically much more expensive than extrusion molding. Consequently, making commercial radiator heater covers from materials with high enough deformation/melting temperatures is currently prohibitively expensive.

FIG. 2B illustrates one embodiment of a multi-section radiator heater cover 220 according to the present teaching that includes a plurality of sections that can be fabricated with different materials and/or different manufacturing processes. In the embodiment shown in FIG. 2B, the cover 220 includes a top panel 222, front panel 224, and a vent panel 226. The vent panel 226 defines a vent area where hot air escapes during use. The top panel includes a tab 228 that positions the multi-section radiator heater cover 220 over a baseboard radiator heater as shown in FIG. 2E. The top panel 222 and the vent panel 226 form a right angle in some embodiments, but can also form an obtuse or acute angle. Also, the top panel 222 and the vent panel 226, that can be a vertical vent panel, are dimensioned to form an air void between the front edge of the top panel 222 and the outer surface of a manufactured electric baseboard radiator heater, such as the one described in connection with FIG. 2E.

These panels 222, 224, 226 can be manufactured separately with different manufacturing processes and then assembled later. For example, the top panel 222 and the front panel 224 can be formed of ABS or PVC with an inexpensive extrusion process.

The vent panel 226, which is positioned where hot air from the electric radiator heater escapes and which experiences a flow of hot air through the vents, can be formed of a relatively high deformation/melting temperature plastic material that is formed by a costlier and time consuming injection molding process. The hot air can have a temperature that is in the range of 250 degrees Fahrenheit. The top panel 222, front panel 224, and vent panel 226 can then be assembled with fixed or movable joints 230, 232 to form the complete radiator cover.

Constructing each of the top panel 222, front panel 224, and vent panel 226 from a high deformation/melting temperature plastic material by injection molding would be prohibitively expensive for a commercial product. However, constructing only the vent panel 226 from a higher deformation/melt point raw plastic material with injection molding allows for a much more cost effective product. In various embodiments, a thermoplastic material can be used to form the top panel 222 and front panel 224 of the radiator cover 220 and can be chosen to have a thermal conductivity that is similar to the thermal conductivity of the vent panel 226. The vent panel 226 can be made of a different material than either or both of the top panel 222 and front panel 224. Also, in various embodiments, a thermoplastic material used to form the top panel 222 and front panel 224 of the radiator cover 220 can be chosen to have a thermal expansion coefficient that is similar to the thermal expansion coefficient of the vent panel 226.

The multi-section radiator heater cover 220 described in connection with FIG. 2B works well for many current commercially available baseboard electric radiator heaters. In some configurations, the cover 220 described in FIG. 2B has limitations. Referring to both FIG. 2A and 2B, when the multi-section radiator heater cover 220 described in connection with FIG. 2B is positioned over some current commercially available baseboard electric radiator heaters, the top panel 222 of the cover 220 will extend beyond the edge of the top surface 206 of the electric baseboard heater 200. In this configuration where the top panel 222 extends beyond the edge of the top surface 206 of the electric baseboard heater 200, the electric baseboard heater 200 will heat the air in a gap between the edge of the top surface 206 of the electric baseboard heater 200 and the corresponding area of the inside of the plastic cover 220 to a temperature that is above the deformation temperature of the thermoplastic material forming the top panel 222.

FIG. 2C illustrates another embodiment of a multi-section radiator heater cover 240 according to the present teaching that includes a plurality of sections that can be fabricated with different material and/or different manufacturing processes that is configured to reduce temperatures at the edge of the top surface electric radiator heater with a vented panel. One feature of this embodiment is that it overcomes the problem of undesirable heating in a gap between the cover and the heater described above in connection with the description of FIG. 2B. The multi-section radiator heater cover 240 is similar to the multi-section radiator heater cover 220 described in connection with FIG. 2B in that it includes a top panel 242, a front panel 244, a vent panel 246 that can be a vertical vent panel, movable joints 252, 254 and the tab 250. In addition, the top panel 242 includes a horizontal vent panel 248. Both the vent panel 246, that can be a vertical vent panel, and the horizontal vent panel 248 define respective vent areas.

These panels 242, 244, 246, 248 can be manufactured separately sometimes with different manufacturing processes and then assembled later as described herein. That is, the top panel 242 and the front panel 244 can be formed of ABS or PVC with an inexpensive extrusion process, while the vent panel 246, that can be a vertical vent panel and the horizontal vent panel 248 can be formed of a higher deformation/melt point raw plastic material with a more expensive and time consuming injection molding process. This allows the vent panel 246 and the horizontal vent panel 248 to experience air at significantly higher temperatures where hot air from the electric radiator heater escapes, which can be in the range of 250 degrees Fahrenheit. The panels 242, 244, 246, 248 can be assembled with fixed or movable joints 252, 254 to form the complete radiator cover.

In various embodiments, the thermoplastic materials used to form the top panel 242 and front panel 244 of the radiator cover 240 can be chosen to have a thermal conductivity that is similar to the thermal conductivity of one or both of the vent panel 246 and the horizontal vent panel 248. Also, in various embodiments, the thermoplastic material used to form the top panel 242 and front panel 244 of the radiator cover 240 can be chosen to have a thermal expansion coefficient that is similar to the thermal expansion coefficient of one or both of the vent panel 246 and the horizontal vent panel 248. In particular, it is sometimes desirable to select thermoplastic materials where the thermal expansion coefficient of the top panel 242 and the horizontal vent panel 248 are similar to avoid gaps at the interface.

Also, in various embodiments, the baseboard radiator heater cover and/or any or all of the various panels described herein can be formed of a conductive polymer material that provides significant heat transfer through conduction in addition to heat transfer through convection. Numerous types of conductive polymer materials can be used. For example, the conductive polymer can be formed of a thermoplastic material that is embedded with carbon steel. The thermoplastic material can also be embedded with numerous other materials, such as boron nitride, and/or ceramic materials. Known thermally conductive plastics will conduct thermal energy in a range from about 0.01 W/mK to 100 W/mK. One such thermally conductive plastic is currently commercially available from Cool Polymers, Inc., of Warwick RI, and sold under the trade name CoolPoly.

The thermal conductivity of conductive plastics can be on order of 500 times greater than the thermal conductivity of conventional plastics. The optimal level of thermal conductivity for baseboard radiator heater covers depends on the thermal energy applied to the cover, size of the radiator, and the particular convection conditions. It is sometimes desirable to use conductive polymers with the highest possible thermal conductivity. However, there are many applications where a particular thermal conductivity is desired to provide a desired heat transfer that minimizes radiation heat losses in the hydronic system.

Conductive polymers are well suited for baseboard radiator heater covers because they provide conductive heat transfer and they will not rust, dent, or flake. In addition, conductive polymers can also be embedded with colorant to change the color of the baseboard radiator heater cover to any color desired by the consumer. Such radiator heater covers are relatively inexpensive, easy to manufacture, and have good visual aesthetics.

In various embodiments of the present teaching, the radiator heater cover 100 can be formed of numerous types of material including various metals and insulating materials, such as polymers and plastics, and any combination thereof. That is, the radiator heater cover can be formed of a plurality of different materials that provide the desired mechanical properties, thermal conductivity properties, and visual aesthetics. In some embodiments, the radiator heater covers according to the present teachings are formed of at least some conductive materials, which provide conductive heat transfer. In other embodiments, the radiator heater covers according to the present teachings are formed of at least some insulating materials that do not provide significant conductive heat transfer, but that reduce radiation heat loss in the hydronic system. In yet other embodiments, the radiator heater covers according to the present teachings are formed of a combination of conductive materials that provide conductive heat transfer in some areas and insulating materials that reduce radiation losses in other areas.

FIG. 2D illustrates another embodiment of a multi-section radiator heater cover 260 according to the present teaching that includes a plurality of sections that can be fabricated with different material and/or different manufacturing processes that is configured to reduce temperatures at the edge of the top surface electric radiator heater with a solid panel. The multi-section radiator heater cover 260 is similar to the multi-section radiator heater cover 220 described in connection with FIG. 2B and the multi-section radiator heater cover 240 described in connection with FIG. 2C in that it includes a top panel 262, a front panel 264, and a vent panel 266, that can be a vertical vent panel, movable joints 252, 254, and tab 270. In addition, the top panel 262 includes a horizontal solid panel 268 that is positioned under the top panel 262. The horizontal solid panel 268 is formed of a higher deformation/melt point raw plastic material that is fabricated with a more expensive and time consuming injection molding process. This allows the vertical solid panel 266 and the horizontal solid panel 268 to experience air at significantly higher temperatures where hot air from the electric radiator heater escapes, which can be in the range of 250 degrees Fahrenheit. Forming the horizontal solid panel 268 out of an insulating material will prevent significant heat transfer from the horizontal solid panel 268 to the lower deformation temperature top panel 262, thereby preventing the horizontal solid panel 268 from failing. The panels 262, 264, 266, 268 can be assembled with fixed or movable joints 272, 274 to form the complete radiator cover.

As described in connection with the multi-section radiator heater cover 240 of FIG. 2C, in various embodiments the thermoplastic materials used to form the top panel 262 and front panel 264 of the radiator cover 260 can be chosen to have a thermal conductivity that is similar to the thermal conductivity of one or both of the vertical solid panel 266 and the horizontal solid panel 268. Also, in various embodiments, the thermoplastic material used to form the top panel 262 and front panel 264 of the radiator cover 260 can be chosen to have a thermal expansion coefficient that is similar to the thermal expansion coefficient of one or both of the vertical vent panel 266 and the horizontal solid panel 268.

FIG. 2E illustrates a multi-section radiator heater cover 260 according to the present teaching positioned over a manufactured electric baseboard radiator heater 280. FIG. 2E is provided to show how the radiator heater cover according to the present teaching fits over an existing manufactured radiator heater. The electrical filament 204 heating element described in connection with FIG. 2A is shown in hidden lines. The radiator heater cover 260 is the same cover described in connection with FIG. 2D for illustrative purposes. However, it should be understood that radiator heater covers described in connection with FIGS. 2B and 2D fit over the manufactured electric baseboard radiator heater 280 in a similar way. The tab 270 keeps the radiator heater cover 260 positioned properly on the top of the radiator heater 280.

The multi-section radiator heater cover 260 will fit over a variety of existing manufactured radiator heater. Referring to FIG. 2B, when the top panel 222 is longer than the top of the existing manufactured radiator heater, which is typically the case, an air gap will be present at the intersection between the top panel 222 and the vent panel 226.

Another aspect of the present teaching is that the radiator cover can include a plurality of apertures and standoff ribs that form a plurality of heat flow channels that provide a path for heat to escape through openings in the back of the radiator cover into the room. The heat flowing through the heat flow channels improves heat transfer from the electric radiator and also reduces the temperature of the electric radiator cover. The plurality of standoff ribs is position in the top of the cover a predetermined distance away from the electric radiator in order to reduce the temperatures that the radiator heater covers are exposed to during operation.

FIG. 3A illustrates a perspective view of a radiator heater cover 300 for an electric radiator heater according to the present teaching that includes a plurality of heat channels which provide a plurality of heat transfer paths for heat to flow from the radiator directly into the room, thereby reducing the temperature at the surface of the radiator cover. This cover configuration allows electric radiator heater covers to be formed of various types of non-metallic materials, such as composite materials. In some embodiments, the radiator heater cover 300 is an electric baseboard radiator heater cover.

The radiator heater cover 300 includes a back surface 302 and a top surface 304 where the top surface 304 is connected to the back surface 302 with a plurality of solid areas 306. The top surface 304 includes a plurality of apertures or open areas 308 proximate to the back surface 302 between the plurality of solid areas 306. The top surface 304 also includes a plurality of apertures 310 that allow cold air from the room to enter into the space between the radiator heater cover 300 and the radiator.

In one embodiment according to the present teaching, the ratio of the area of the open areas 308 to the area of the solid areas 306 of the radiator cover 300 is equal to or greater than one. In other embodiments, the ratio of the area of the open areas 308 to the area of the solid areas 306 of the radiator cover 300 is less than one.

A plurality of standoff ribs 320 (shown as hidden lines) are position on the bottom surface 305 of the cover 300 a predetermined distance away from the electric radiator when installed and extending from the solid areas 306 of the top surface 304 to a front surface 314 of the cover 300 so as to form a plurality of heat flow channels 312.

The electric radiator cover 300 also includes the front surface 314 that includes a first plurality of apertures 316 proximate to the top surface 304 and a second plurality of apertures 318 proximate to the bottom 322 of the radiator cover 300. The first 316 and second plurality of aperture 318 on the front surface 314 allows cold air from the room into the space between the radiator cover 300 and the radiator. In some embodiments, the front surface 314 of radiator cover 300 does not extend down to the bottom of the radiator closest to the floor. This feature further reduces the temperature of the radiator cover during operation. In some embodiments, a length of the front surface 314 can be less than a length of the radiator.

In one embodiment, the entire radiator cover 300 including the back surface 302, top surface 304, bottom surface 305, and the front surface 314, is formed of a polycarbonate material. Polycarbonate is desirable because it is a relatively high temperature tolerant material that begins to deform at a relatively high temperature that is in the range of 428 to 599 degrees Fahrenheit. Because polycarbonate is an amorphous thermoplastic polymer, it doesn't have a single melting point, but rather a range of temperatures at which it softens, known as the glass transition temperature. In addition to superior thermal properties compared with PVC and similar materials, polycarbonate is relatively inexpensive and has good manufacturability.

FIG. 3B illustrates a back view of the radiator heater cover 300 for an electric radiator heater described in connection with FIG. 3A that shows the standoff ribs 320 and open areas 308 that define the plurality of heat channels 312 shown in FIG. 3A. The plurality of heat channels 312 provide a plurality of heat transfer paths for heat to flow from the radiator directly into the room. The heat transfer paths reduce the temperature at the surface of the radiator cover 300. The position of the plurality of standoff ribs 320 can be chosen to form heat flow channels 312 that efficiently remove heat from the back surface of the radiator heater cover 300. It has been experimentally determined that heat flow channels 312 formed by the combination of the plurality of standoff ribs 320 and the plurality of open areas 308 reduces the temperature at the radiator cover 300 by about 50 degrees Fahrenheit.

EQUIVALENTS

While the Applicants' teaching is described in conjunction with various embodiments, it is not intended that the Applicants' teaching be limited to such embodiments. On the contrary, the Applicants' teaching encompass various alternatives, modifications, and equivalents, as will be appreciated by those of skill in the art, which may be made therein without departing from the spirit and scope of the teaching.

	Number	Date	Country
Parent	17327595	May 2021	US
Child	18983838		US

Electric Baseboard Radiator Heater Cover

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