BACKGROUND OF THE INVENTION
The present invention relates to a heater, and more specifically, to a portable gas or propane heater.
SUMMARY OF THE INVENTION
In an embodiment, the disclosure provides a heater including a housing, a heater unit, a control interface, and a fan unit. The housing includes a base. The heater unit is supported on the base and includes an ignitor mechanism and a heater element having an external surface configured to emit heat. The control interface is supported on an exterior of the housing and includes an actuator operable by a user. The fan unit is coupled to the base or the heater unit and is positioned to induce an airflow through the heater unit within the heater element to heat the airflow. The fan unit includes a fan shroud having an air outlet to direct the heated airflow radially outward.
In another embodiment, the disclosure provides a heater including a housing, a heater unit, a control interface, and a second grip. The housing includes a base having a first grip extending from the housing to facilitate transport of the heater. The heater unit is supported on the base and includes an ignitor mechanism and a heater element having an external surface configured to emit heat 360 degrees around a longitudinal axis. The control interface is supported on an exterior of the base and includes an actuator operable by a user to control the heater unit. The second grip is positioned on the base adjacent the control interface. The second grip is graspable by a user to facilitate manipulation of the control interface.
In another embodiment, the disclosure provides a heater including a housing, a heater unit, a fan unit, and a control interface. The housing includes a base. The heater unit is supported on the base and includes and ignitor mechanism and a heater element having an external surface configured to emit heat. The fan unit is coupled to the base or the heater unit and is positioned to induce an airflow through the heater unit to heat the airflow. The fan unit includes a fan shroud having a plurality of air outlets positioned to direct the heated airflow radially outward 360 degrees around a longitudinal axis extending through the housing and the heater unit. The control interface is supported on an exterior of the housing and is manipulatable by a user to control the heater unit and the fan unit.
Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a perspective view of an exemplary heater.
FIG. 1B is a perspective view of an exemplary blower.
FIG. 2A is a front perspective view of a heater system including a base, a control interface, a fan unit, and a heater unit according to the present disclosure.
FIG. 2B is a rear perspective view of the heater system of FIG. 2A.
FIG. 2C is an exploded view of the heater system of FIG. 2A.
FIG. 2D is a top view of the heater system of FIG. 2A.
FIG. 3 is a plan view of the heater system of FIG. 2A.
FIG. 4 is a perspective view of a portion of the heater system of FIG. 2A.
FIG. 5 is a cross-sectional view of the heater system of FIG. 2A taken along line 5-5.
FIG. 6 is a cross-sectional view of the heater system of FIG. 2A taken along line 6-6.
FIG. 7 is a perspective view of a fan unit for the heater system of FIG. 2A.
FIG. 8 is a perspective view of a portion of the fan unit of FIG. 2A.
FIG. 9 is a perspective view of a portion of the heater unit of FIG. 2A.
FIG. 10 is a cross-sectional view of the heater system of FIG. 2A taken along the center of the heater system.
FIG. 11 is another cross-sectional view of the heater system of FIG. 2A taken along the center of the heater system.
FIG. 12 is a perspective view of a control interface according to another embodiment of the disclosure for the heater system of FIG. 2A.
FIG. 13A is a side view of a heater system according to the present disclosure.
FIG. 13B is cross-sectional view taken along line B-B of the heater system of FIG. 13A.
FIG. 14A is an enlarged view of a portion of the heater system of FIG. 13A.
FIG. 14B is an enlarged view of a portion of the heater system of FIG. 13B.
FIG. 15A is a perspective view of a portion of the heater system of FIG. 13A.
FIG. 15B is a perspective view of a portion of the heater system of FIG. 13A with components removed for clarity.
FIG. 16 is a schematic view of the enlarged view of FIG. 14B illustrating airflow for the heater system.
FIG. 17A is a side view of a heater system according to another embodiment of the disclosure.
FIG. 17B is a side view of a heater system according to another embodiment of the disclosure.
FIG. 17C is a side view of a heater system according to another embodiment of the disclosure.
FIG. 17D is a side view of a heater system according to another embodiment of the disclosure.
FIG. 18 is a perspective view of a heater system according to another embodiment of the disclosure.
FIG. 19 is a cross-sectional view of the heater system of FIG. 18 taken along line 19-19.
FIG. 20 is a schematic view of the enlarged view of FIG. 19 illustrating airflow for the heater system.
FIG. 21 is a perspective view of a heater system according to another embodiment of the disclosure.
FIG. 22 is a cross-sectional view of the heater system of FIG. 21 taken along line 22-22.
FIG. 23 is a cross-sectional view of a heater system according to another embodiment of the disclosure.
FIG. 24 is a cross-sectional view of a heater system according to another embodiment of the disclosure.
FIG. 25 is a cross-sectional view of a heater system according to another embodiment of the disclosure.
FIG. 26 is a cross-sectional view of a heater system according to another embodiment of the disclosure.
FIG. 27 is a cross-sectional view of a heater system according to another embodiment of the disclosure.
FIG. 28 is a cross-sectional view of a heater system according to another embodiment of the disclosure.
DETAILED DESCRIPTION
Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.
The detailed description uses numerical and letter designations to refer to features in the drawings. Like or similar designations in the drawings and description have been used to refer to like or similar parts of the invention.
The singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise. The terms “coupled,” “fixed,” and the like refer to both direct coupling or fixing, as well as indirect coupling or fixing through one or more intermediate components or features, unless otherwise specified herein. As used herein, the terms “includes,” “including,” “has,” “having” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a process, method, article, or apparatus that comprises a list of features is not necessarily limited only to those features but may include other features not expressly listed or inherent to such process, method, article, or apparatus. Further, unless expressly stated to the contrary, “or” refers to an inclusive-or and not to an exclusive-or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).
Benefits, other advantages, and solutions to problems are described below with regard to specific embodiments. However, the benefits, advantages, solutions to problems, and any feature(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature of any or all the claims.
FIG. 1A shows an embodiment of an exemplary heater system 4 that may be turned on to provide heat 360 degrees around the heater system 4. The heater system 4 includes a heater 6 that has a heater element 10 (e.g., a mesh wire heat structure) that may emit heat in 360 degrees around the heater 6 when a fuel (e.g., gas) is provided from a fuel source 12 of the heater system 4 (e.g., a gas or propane tank, a gas line, etc.). The heater 6 is fluidly coupled to the fuel source 12 to provide fuel to the heater element 10. FIG. 1B illustrates an exemplary embodiment of a blower 8 that may be powered on to blow air 360 degrees around the blower 8. The blower 8 includes a fan 16 that is configured to blow air in 360 degrees around the blower 8.
FIGS. 2A-2D illustrate a heater 20 that may be part of a heater system that also includes a fuel source (e.g., the tank 12). The heater 20 may emit heat 360 degree around the heater 20 and to blow air 360 degrees around the heater 20 (e.g., as illustrated by direction DI in FIG. 2D). The heater 20 may be connected to a fuel line or a fuel tank configured to supply gas to the heater 20. In the illustrated embodiment, the heater system 20 is connectable with a twenty-pound propane tank such as the gas tank 12 illustrated in FIG. 1A. The heater 20 may be connected to a non-portable gas supply. In one example, the heater 20 may be placed and used within a space, such as an outdoor space (e.g., a patio) or an indoor space (e.g., a garage), to heat the space. The heater 20 may emit between 30,000 and 40,000 British Thermal Units (BTUs). It will be appreciated that the heater 20 may be configured to emit higher or lower BTUs.
As illustrated in FIGS. 2A-2C, the heater 20 includes a housing 24 that has a base 28 and that supports a fan unit 32 and a heater unit 36. The base 28 may be placed on a horizontal surface 40 or hung from other structure. With reference to FIGS. 2B, 3, and 5, the base 28 defines a cavity 48 and includes grips or handles 52a, 52b, a battery receptacle 56, a cord storage slot 60, a control interface 64, a valve assembly 68, and a printed circuit board (PCB) 72. In the illustrated embodiment, the base 28 includes two handles 52a, 52b. The handles 52a, 52b are positioned diametrically across from one another on the base 28 and are graspable to facilitate transport of the heater 10. The battery receptacle 56 is positioned between the first handle 52a and the second handle 52b and is configured to removably receive a battery 76 that provides power to the fan unit 32. The hose storage slot 60 includes two retention hooks 80a, 80b, and each of the retention hooks 80a, 80b is positioned below a corresponding one of the handles 52a, 52b (e.g., between the handles 52a, 52b and the surface 40 of FIG. 2A). Hose 84 interconnects the gas supply and a gas inlet 44 (e.g., a nipple) on the base 28, and at least a portion of the hose 84 may be wrapped around the base 28 for storage in the hose storage slot 60 (e.g., when not in use). The hose 84 includes a knob or other control 86 that is actuatable to open and close and selectively provide flow of gas to the heater 10 when the hose is connected to a gas supply.
The control interface 64 is supported on an exterior of the housing 24 As best illustrated in FIGS. 2A, 3, and 4, the control interface 64 is positioned between the handles 52a, 52b and diametrically opposite from the battery receptacle 56. The control interface 64 includes a plurality of actuators (described in detail below) that can be manipulated to control operation of the heater 10. A grip 88 (e.g., including a first grip 88a, and a second grip 88b) is disposed around or adjacent the control interface 64 to facilitate engagement of one or more of the actuators, as described in detail below.
In the illustrated embodiment, the control interface 64 includes a gas supply actuator 92, an ignition actuator 96, a BTU actuator 100, and a fan actuator 104. The illustrated gas supply actuator 92 includes a button that is manipulatable or actuatable (e.g., pressable) to control a supply of gas from the gas supply, through the gas supply line 44, and to the heater unit 36. The illustrated ignition actuator 96 includes a button that is manipulatable or actuatable (e.g., pressable) to ignite the heater unit 36 while gas is supplied to the heater unit 36. The illustrated BTU actuator 100 includes a dial that is manipulatable or actuatable (e.g., rotatable) to adjust the heat output of the heater unit 36 (e.g., to adjust the amount of BTU generated by the heater unit 36). Specifically, the BTU actuator 100 is configured to the adjust the amount of heat emitted from the heater unit 36 (e.g., between 30,000 and 40,000 BTUs, or another range). The fan actuator 104 includes a switch that is manipulatable or actuatable to adjust a rotation speed of a portion of the fan unit 32 to adjust the airflow output from the heater 10 (e.g., between zero and a non-zero speed). In the illustrated embodiment, the fan actuator 104 is configured to turn the fan unit 32 on and off. The fan actuator 104 or another actuator may be actuatable to adjust the rotation speed of the fan unit 32. The fan actuator 104 may be manipulatable to continuously or incrementally adjust the rotational speed of the fan unit 32 and the output of airflow from the heater 10.
With reference to FIGS. 3 and 4, the first grip 88a and the second grip 88b are positioned on lateral sides of the control interface 64. As shown, the grips 88a, 88b at least partially surround the control interface 64. Each grip 88a, 88b is defined by a flange that extends away from the base 28 (e.g., outward and downward) and is offset from a surface 28a of the base 28 so that a user may grasp one or both grips 88a, 88b to manipulate one or more actuators. Each of the grips 88a, 88b overhangs a surface 28a of the base 28 such that a portion of each of a user's hands may be received between the base surface 28a and the corresponding grips 88a, 88b. Stated another way, the first grip 88a and the second grip 88b are cantilevered on the base 28 and extend outward and downward (e.g., when the base 28 is positioned on the horizontal surface 40 (FIG. 2A)). The first grip 88a and the second grip 88b oriented to assist with actuation of the actuators and improve the ergonomics of engaging the control interface 64. It will be appreciated that the control interface 64 may be manipulated without engaging either grip 88a, 88b. That is, the grips 88a, 88b are shaped to support a user's hand and remove strain from trying to engage the actuators without the grips 88a, 88b. In the illustrated embodiment, the gas supply actuator 92 is positioned adjacent to the first grip 88a, and the ignition actuator 96 is positioned adjacent to the second grip 88b. As such, the first grip 88a and the second grip 88b may be simultaneously graspable to actuate the gas supply actuator 92 and the ignition actuator 96 to simultaneously supply gas to heater unit 36 and ignite the gas for heating the surrounding environment.
The valve assembly 68 and the PCB 72 are housed within the cavity 48 and are connected to the control interface 64. The valve assembly 68 includes one or more valves that are controlled by the gas supply actuator 92 and the BTU actuator 100. Actuation of the gas supply actuator 92 opens and closes a corresponding valve (e.g., a gas supply valve) to permit or inhibit flow of gas to the heater unit 36, and actuation (e.g., rotation) of the BTU actuator 100 is coupled to a BTU valve that adjusts the volume of gas that may flow to the heater unit 36 to control the amount of heat that is produced by the heater unit 36. The PCB 72 is electrically coupled to the fan actuator 104 and the fan unit 32, and the fan actuator 104 can be manipulated to send a signal to the PCB 72 to supply power to the fan unit 32 from the battery 76.
The fan unit 32 is positioned between the base 28 and the heater unit 36, and the fan unit 32 is arranged to induce an airflow A1 to flow past, or through, the heater unit 36 before discharge radially outward from the heater 10. As best shown in FIGS. 2A, 2B, and 11, the fan unit 32 may blow the heated airflow A1 in 360 degrees around the heater 10. As illustrated in FIGS. 5 and 6, the fan unit 32 includes a motor assembly 108, a fan shroud 112, and a fan 120. The motor assembly 108 includes a motor mounting plate 128 that is coupled to the top of the base 28, a motor 132 that extends downward from the motor mounting plate 128 into the cavity 48 of the base 28, and a phenolic spacer 136 that spaces the motor 132 from the motor mounting plate 128 to reduce heat flow from the heater unit 36 to the motor 132. The motor 132 includes an output shaft 132a that extends through the motor mounting plate 128 to a motor mounting shaft 140. The motor 132 is configured to drive rotation of the motor mounting shaft 140 via the output shaft 132a.
With reference to FIG. 6, the fan shroud 112 includes a first fan plate 112a, a second fan plate 112b, a plurality of airflow guides 144, and a plurality of vanes 146. The first fan plate 112a (e.g., a bottom fan plate) is spaced a distance from the motor mounting plate 128, and the second fan plate 112b (e.g., a top fan plate) is spaced a distance from the first fan plate 112a. The airflow guides 144 are arranged radially and circumferentially around the motor mounting shaft 140. The airflow guides 144 at least partially define a plurality of outlets 144a for air to flow out of. Each of the vanes 146 is defined by a flat plate extending between adjacent pairs of the airflow guides 144. Each of the airflow guides 144 and each of the vanes 146 is evenly distributed around a circumference of the first fan plate 112a. As such, the outlets 144a are evenly distributed around a circumference of the first fan plate 112a.
The fan 120 is mounted to the motor mounting shaft 140 such that the motor 132 drives rotation of the fan 120. The fan 120 includes a plurality of fan blades 148 that extend between the first fan plate 112a and the second fan plate 112b. As the motor 132 drives rotation of the fan 120, the plurality of fan blades 148 induces airflow A1 (FIG. 11) through the heater unit 36, as will be described in more detail. The airflow guides 144 and the vanes 146 are provided to direct airflow blown outward from the fan 120 to the outlets 144a.
The heater unit 36 extends from the fan unit 32 (above as viewed in FIGS. 2A, 2B) opposite from the base 28. The heater unit 36 is in fluid communication with a gas supply line 44 that may be connected to gas source to supply gas to the heater unit 36. The heater unit 36 is configured to ignite gas supplied from the gas supply line 44 to emit heat (e.g., between 30,000 and 40,000 BTUs). With reference to FIGS. 5, 7, and 8, the heater unit 36 extends along a longitudinal axis L1 and includes a heater base 152, a grate 156, a heater element or ignition wall 160, a cap 164, a first airflow duct 168, a second airflow duct 170, a plurality of gas flow ducts 172, and an ignition mechanism 176. The heater base 152 extends upwardly from the fan unit 32. Specifically, the heater base 152 extends upwardly from the second fan plate 116 of the fan unit 32 and includes a heater plate 180 opposite from the second fan plate 116. The heater base 152 defines a heater base cavity 184 between the second fan plate 112b and the heater plate 180. The grate 156 is supported by and extends upwardly from the heater plate 180. The grate 156 has a substantially cylindrical profile. The illustrated ignition wall 160 is positioned within the grate 156 and has a substantially cylindrical profile that projects heat 360 degrees around the longitudinal axis L1.
The grate 156 may inhibit a user from incidentally or accidentally touching the ignition wall 160. The ignition wall 160 is hollow and defines an ignition cavity 188. In the illustrated embodiment, the cap 164 is positioned within the grate 156 and is mounted to an end of the ignition wall 160. In some embodiments, the cap 164 may be mounted to the grate 156. The cap 164 includes a first portion 164a and a second portion 164b that are each formed of a metal plate. The first portion 164a is mounted to the end of the ignition wall 160. The second portion 164b is mounted to the first portion 164a via mounting posts 192 that offset the second portion 164b from the first portion 164a to define an air inlet 196 therebetween. In other embodiments, the cap 164 may define an air inlet in different locations. For example, the cap 164 may be formed of just a single portion that includes apertures that define the air inlet. The second portion 164b of the cap 164 is substantially frustoconical to improve airflow through the air inlet 196.
The first airflow duct 168 extends linearly through a center of the ignition wall 160 (e.g., through the ignition cavity 188) and is in fluid communication with the air inlet 196. Specifically, the first airflow duct 168 extends linearly along the longitudinal axis L1 from the air inlet 196. The second airflow duct 170 extends from the first airflow duct 168 and is defined by a curved wall 170a to place the first airflow duct 168 in fluid communication with the fan 120, and as a result, place the air inlet 196 in fluid communication with the fan 120. As such, the fan 120 may induce the airflow A1 to enter through the air inlet 196 and flow through the first airflow duct 168 past the heated ignition wall 160. When the ignition wall 160 is ignited, the ignition wall 160 emits heat that warms the airflow A1 as the airflow A1 (FIG. 11) travels past the ignition wall 160. The second airflow duct 170 distributes the heated airflow A1 (FIG. 11) radially outward (e.g., directly prior to the reaching the fan 120). Once the airflow A1 (FIG. 11) reaches the fan 120 (i.e., at an end of the airflow duct 168 opposite from the air inlet 196), the fan 120 is configured to blow the heated airflow A1 radially outward.
In the illustrated embodiment, the plurality of gas flow ducts 172 includes two gas flow ducts 172. Each of the gas flow ducts 172 is relatively smaller than the first airflow duct 168 and extends generally parallel to the gas flow duct 170. Each of the plurality of gas flow ducts 172 has a first end 172a positioned within the heater base cavity 184 and a second end 172b positioned within the ignition cavity 188 between the ignition wall 160 and the airflow duct 168. The first end 172a of each of the plurality of gas flow ducts 172 may be connected to the gas supply line 44 through the valve assembly 68. As such, the gas supply actuator 92 is actuatable to allow gas to flow from the gas supply line 44, through the valve assembly 68, and to the gas flow ducts 172 at the first ends 172a of the of the ducts 172. As gas enters through the first ends 172a of the gas flow ducts 172, the gas then flows to the second ends 172b of the gas flow ducts 172 to exit the gas flow ducts 172 and enter the ignition cavity 188. As such, the airflow duct 168 extends through the ignition cavity 188 between the gas flow ducts 172. Stated another way, each of the gas flow ducts 172 is positioned between the airflow duct 168 and the grate 156.
With reference to FIG. 9, the ignition mechanism 176 is positioned external relative to the ignition wall 160 such that the ignition mechanism 176 is positioned between the grate 156 and the ignition wall 160. In some embodiments, the ignition mechanism 176 may be positioned inside the ignition wall 160 (i.e. within the ignition cavity 188). The ignition mechanism 176 is configured to produce a spark, or another type of high-voltage electrical discharge, that may light, or ignite, a fuel such as gas (e.g., propane). In the illustrated embodiment, the ignition mechanism 176 is a piezo ignitor. In other embodiments, the ignition mechanism 176 may be another type of mechanism capable of producing a spark. The ignition actuator 96 may be actuated to induce the ignition mechanism 176 to produce a spark that ignites gas that has entered the ignition cavity 188 from the gas flow ducts 172. Due to the position of the ignition mechanism 176, the ignition mechanism 176 is configured to ignite an external surface of the ignition wall 160. In other embodiments, the ignition mechanism 176 may be configured to ignite an internal surface of the ignition wall 160.
With reference to FIGS. 2A-2C, in operation of the heater 20, a user may first place the heater 20 on the surface 40 of a space to be heated. A user may then attach the gas supply line 44 to a gas supply to provide a gas source for the heater 20 and attach the battery 76 to the battery receptacle 56 to provide an electricity source for the fan unit 32. With the heater 20 positioned in a desired location and provided with a gas source and an electricity source, the heater unit 36 and the fan unit 32 may be turned on to heat the space. The heater unit 36 and the fan unit 32 may be used together or independently.
With reference to FIGS. 3 and 10, a user may turn on the heater unit 36 by simultaneously actuating the gas supply actuator 92 and the ignition actuator 96. To do so, a user may grasp the grips 88a, 88b to reduce strain felt by the user during actuation of the actuators 92, 96. For example, the actuators 92, 96 are positioned to allow a user to grasp the grips 88a, 88b such that the user's thumbs are easily positioned to simultaneously actuate the gas supply actuator 92 and the ignition actuator 96. As the gas supply actuator 92 is actuated, the gas supply actuator 92 opens a portion of the valve assembly 68 to allow gas to flow along the gas supply line 44, through the valve assembly 68, into the first ends 172a of the gas flow ducts 172, and out of the second ends 172b of the gas flow ducts 172 into the ignition cavity 188. As this gas flow occurs, actuation (e.g., repeated actuation) of the ignition actuator 96 induces the ignition mechanism 176 to ignite the gas, which ignites the external surface of the ignition wall 160 (or the entire wall 160). After ignition, the gas flow actuator 92 may be held for a period of time (e.g., 30 seconds) to ensure the ignited surface of the ignition wall 160 is not extinguished due to, for example, a lack of fuel. Once the ignition wall 160 is ignited, the heater unit 36 will emit heat 360 degrees around the heater 20. A user may adjust the amount of heat emitted from the heater unit 36 between 30,000 and 40,000 BTUs through rotation of the BTU actuator 100.
With reference to FIGS. 3, 6, and 7, a user may turn on the fan unit 32 by actuating the fan actuator 104 to send a signal to the PCB 72 to direct the PCB 72 to supply power from the battery 76 to the fan unit 32. With reference to FIG. 11, when the fan 120 is activated, the fan 120 induces the airflow A1 to enter the air inlet 196 (e.g., from a location external to the heater 10) under the cap 164 and to flow past the ignition wall 160 (e.g., internally or externally) before the airflow is directed through the outlets 144. In one or more embodiment, the cap 164 heats the airflow induced by the fan 120. In one or more embodiment, the ignition wall 160 also heats the airflow induced by the fan 120. In one or more embodiment, the cap 164 receives a significant amount of heat from the ignition wall 160 through radiation and heated air. In one or more embodiment, after the airflow A1 that is induced by the fan 120 is inside the first airflow duct 168, the airflow does not gain any additional heat or may even start to lose heat (e.g., the airflow duct 168 may be constructed as, or to include, a thermal isolator).
The frustoconical shape of the second portion 164b of the cap 164 and the rotation of the fan 120 directs the airflow A1 through the first airflow duct 168 and the second airflow duct 170 before reaching the fan 120. After the airflow A1 reaches the fan 120, the airflow A1 is directed outward to and through the outlets 144. As the airflow A1 is blown radially outward, the airflow guides 144 and the vanes 146 of the fan unit 32 separate the airflow A1 into a plurality of sub-flows to ensure that the heated airflow A1 is blown from the fan unit 32 in an even distribution of air 360 degrees around the heater 20. As such, the fan unit 32 advantageously increases the distance at which the heater 10 is able to emit heat. It will be appreciated that the heater 20 may be used to emit heat without the fan unit 32. For example, a user may turn on the heater unit 36 without actuation the fan unit 32.
FIG. 12 illustrates a portion of a control interface 64′ according to another embodiment of the disclosure. The control interface 64′ includes a plurality of actuators configured to control operation of a heater. As shown, the control interface 64′ includes a gas supply actuator 92′, an ignition actuator 96′, a BTU actuator 100′, and a fan actuator 104′. Each of the gas supply actuator 92′, the ignition actuator 96′, the BTU actuator 100′, and the fan actuator 104′ may be substantially similar to a respective one of the gas supply actuator 92, the ignition actuator 96, the BTU actuator 100, and the fan actuator 104 of FIG. 3, except for the differences described herein. The gas supply actuator 92′ and the ignition actuator 96′ are positioned in a stacked orientation. That is, each of the gas supply actuator 92′ and the ignition actuator 96′ is positioned above or below the other of the gas supply actuator 92′ and the ignition actuator 96′. Each of the BTU actuator 100′ and the fan actuator 104′ is positioned on a respective side of the stacked gas supply actuator 92′ and the ignition actuator 96′ such that the gas supply actuator 92′ and the ignition actuator 96′ are positioned between the BTU actuator 100′ and the fan actuator 104′. Each of the BTU actuator 100′ and the fan actuator 104′ is formed as a dial that is actuatable via rotation. Specifically, the BTU actuator 100′ is rotatable to adjust the heat output of a heater unit. The fan actuator 104′ is electrically connected to a PCB 72′ and is configured to adjust a rotation speed of a fan. Specifically, rotation of the fan actuator 104′ sends a signal to the PCB 72′ which in turn transmits a signal to a fan to increase or decrease the rotation speed of the fan. The control interface 64′ is connected to a valve mechanism 68′. The valve mechanism 68′ may be substantially similar to the valve mechanism 68 of FIG. 5. However, the valve mechanism 68′ of FIG. 12 has a different orientation than the valve mechanism 68 of FIG. 5 due to the layout of the actuators 92′, 96′, 100′, 104′ of FIG. 12.
FIGS. 13A and 13B show another embodiment of a heater system 220 according to the disclosure. The heater system 220 includes a gas tank 224 coupled to a heater unit 228. The gas tank 224 may be a twenty-pound gas tank or another common gas tank that may provide gas to the heater unit 228 or another similar gas-fueled heater. In the illustrated embodiment, the gas tank is a propane tank. The gas tank 224 includes a valve 226 for switching the supply of gas on and off. According to one or more embodiments, the valve 226 may be a gas valve with an integral regulator. According to one or more embodiments, the regulator is attached to the gas tank 224.
The heater unit 228 includes a housing 232, a gas flow duct 236 disposed therein, a heater element or an ignition wall 240 positioned within a cylindrical grate 242, a fan 244 disposed in a fan housing or cap 246, and a shroud 248 partially inserted in the cap 246. A hose adapter 252 extends from the gas flow duct 236 and is threadedly coupled to the gas tank 224. The hose adapter 252 permits fluid communication from the gas tank 224 to the gas flow duct 236 and the ignition wall 240.
The ignition wall 240 is disposed above and is supported by the housing 232 and the gas tank 224. The ignition wall 240 is generally cylindrical and extends between the housing 232 and the shroud 248. The cylindrical grate 242 additionally extends between the housing 232 and the shroud 248. The cylindrical grate 242 may provide a safeguard to prevent a user from touching the ignition wall 240 while the heater system 220 is on. As illustrated in FIGS. 14A-15B, the fan 244, the cap 246, and the shroud 248 are disposed above the ignition wall 240. The cap 246 includes a first portion 246a mounted to the grate 242 via fasteners 254 and a second portion 246b mounted to and offset from the first portion 246a. In the illustrated embodiment, the fasteners 254 are formed as hooked ends of the grate 242. In other embodiments, the fasteners 254 may another type of fastener. The fan 244 is positioned within the second portion 246b of the cap 246, and the shroud 248 is mounted between the first portion 246a and the second portion 246b of the cap 246. The fan 244 is rotatably driven by a motor 256 disposed within the shroud 248. With reference to FIGS. 14B and 16, an air inlet 258 is defined above the fan 244 and an air outlet 259 is defined between the second portion 246b of the cap 246. As such, the fan 244 is configured to induce a first airflow A2 into the air inlet 258 and blow the first airflow A2 in three-hundred-sixty degrees around the heater system 220. The first airflow A2 may mix with a flow of heat A3 emitted from the ignition wall 240 to form a mixed flow A4. Therefore, the fan 244 and the shroud 248 are provided to spread heat emitted by the ignition wall 240 radially around the heater system 220. A battery may be removably coupled to the housing 232 above the tank 224. A sleeve 260 covers wires (not shown) that electrically couple a battery to the motor 256 for driving the fan 244.
FIGS. 17A-17D illustrate additional embodiments of heater systems 320, 420, 520, 620 according to the present invention. The systems 320, 420, 520, 620 of FIGS. 17A-17D may include some or all of the features of the heater system 220 of FIGS. 13A-15B, except for the differences described herein. As shown in FIG. 17A, the heater system 320 includes a clamp 368 that removably couples a heater unit 328 to a gas tank 324. As shown in FIG. 17B, the system 420 has a heater unit 428, which includes a plurality of legs 472 that support the heater unit 428 over a gas tank 424. The heater unit 428 may include a clamp (not shown) that removably couples the heater unit 428 to the gas tank 424. As shown in FIG. 17C, the heater system 520 includes a plurality of legs 574 that surround a gas tank 524 and removably engage a heater unit 528 to support the heater unit 528. The legs 574 may be collapsible or foldable. As shown in FIG. 17D, the heater system 620 includes a heater element 628, dolly 676 that has a frame 680, and a plurality of wheels 684. A gas tank 624 is removably disposed on a base 688 of the dolly 676. A plurality of wheels 684 is rotatably coupled to the dolly 676 and provides wheeled transportation of the dolly 676. A battery (not shown) is removably coupled to the housing 32 on a back side of the dolly 676.
FIGS. 18 and 19 illustrate another embodiment a heater 720 that may be part of a heater system in combination with a fuel source (e.g., the tank 12). The heater 720 may be similar to the heater 20 of FIGS. 2A-11, except for the differences described below. The heater 720 includes a frame stand 724, a gas pipe 728, a heater unit 732, a fan unit 736, and a cap 740. The frame stand 724 supports the heater 720 in an upright position on a surface 744. A battery 748 is mounted to the frame stand 724 and may be used to power the fan unit 736. The gas pipe 728 is connectable to a gas supply such as a gas tank (e.g., a propane tank) or a gas line (e.g., a propane line). As such, the gas pipe 728 is a gas inlet and includes a valve 752 for opening and closing the supply of gas to the heater unit 732. The cap 740 is mounted to an end 732a of the heater unit 732 that is opposite from the frame stand 724 such that the heater unit 732 is positioned between the frame stand 724 and the cap 740.
With reference to FIGS. 19 and 20, the heater unit 732 includes a grate 760 and an ignition wall 764 positioned within the grate 760. In the illustrated embodiment, both the grate 760 and the ignition wall 764 are cylindrical. In the illustrated embodiment, the ignition wall 764 is an infrared ignition wall 764 that is configured to emit, or radiate, a flow of heat A5. The heater unit 732 further includes a gas flow duct 768 and a plurality of airflow ducts 772. The gas flow duct 768 defines a gas flow path, and the plurality of airflow ducts 772 defines an air flow path. The gas flow duct 768 and the plurality of airflow ducts 772 are at least partially disposed within the periphery of the cylindrical ignition wall 764. The gas flow duct 768 is fluidly coupled to the gas pipe 728 and extends through the center of the ignition wall 764. The gas flow duct 768 does not extend through the full length of the ignition wall 764 such that gas flowing through the gas flow duct 768 may escape from the gas flow duct 768 within the periphery of the ignition wall 764 at an end 768a of the gas flow duct 768. The airflow ducts 772 are disposed around the gas flow duct 768 such that the airflow ducts 772 are positioned radially between the gas flow duct 768 and the ignition wall 764. In the illustrated embodiment, the heater unit 732 includes four airflow ducts 772. In other embodiments, the airflow ducts 772 may include fewer or more airflow ducts 772.
The fan unit 736 may be similar to or the same as the fan unit 32. As shown, the fan unit 736 is mounted to the frame stand 724 and is positioned between the stand 724 and the heater unit 732. The fan unit 736 supports the heater unit 732 and the cap 740 such that the fan unit 736 is positioned between the heater unit 732 and the frame stand 724. The fan unit 736 includes a motor 776, a fan 780, and a plurality of fan outlet vanes 784. The fan 780 is in fluid communication with the plurality of airflow ducts 772. The battery 748 provides power to the motor 776 to drive rotation of the fan 780 for inducing airflow A6 through the heater unit 732. That is, the fan 780 may induce ambient air to flow under the cap 740 and through any of the four airflow ducts 772 (e.g., past the ignition wall 764. The fan 780 may then blow the heated airflow A6 through the plurality of fan outlet vanes 784. In the illustrated embodiment, the fan unit 736 is cylindrical such that the fan outlet vanes 784 are disposed uniformly around the fan unit 736. As such, the fan 780 is configured to blow heated airflow A6 in a range of three-hundred-sixty degrees around the heater 720 during operation of the heater 720.
In the illustrated embodiment, the cap 740 includes a first portion 740a and a second portion 740b. The second portion 740b is mounted to and offset from the first portion 740a via mounting posts 788 such that an air inlet 792 is defined therebetween. As such, openings to the plurality of airflow ducts 772 are in fluid communication with a space defined between the first portion 740a and the second portion 740b of the cap 740. The cap 740 is advantageously sized and shaped to direct ambient airflow into the openings of the plurality of airflow ducts 772. In the illustrated embodiment, the cap 740 is substantially dome-shaped. In some embodiments, the cap 740 may include a plurality of breathing holes 796 to improve airflow within the cap 740 and through the heater unit 732.
In some embodiments, the first portion 740a of the cap 740 may function as a heat collection skirt. In such embodiments, the first portion 740a of the cap 740 provides a shroud over at least a portion of the ignition wall 764. As such, the first portion 740a of the cap 740 may improve heat retention for the heater 720. The first portion 740a of the cap 740 may collect heat radiated from the ignition wall 764 to heat the airflow A6 along the air flow path. Additionally, the first portion 740a of the cap 740 may inhibit airflow A6 along the air flow path from extinguishing the ignition wall 764 near openings of the airflow ducts 772.
In operation of the heater 720, a user may attach the gas pipe 728 to a gas supply and actuate the battery 748 to provide power to the motor 776 of the fan unit 736 to begin rotation of the fan 780. As gas flows through the gas pipe 728, the gas flows to and escapes from the end 768a of the gas flow duct 768 to provide fuel for the ignition wall 764. When ignited, the ignition wall 764 radiates heat laterally inward and outward. Rotation of the fan 780 induces ambient airflow to enter the cap 740 and induces air to flow through the plurality of airflow ducts 772 such that heat emitted from the ignition wall 764 warms the flow of air. The fan 780 then blows the warmed flow of air out of the heater 720 in a range of three-hundred-sixty degrees around the heater 720 via the fan outlet vanes 284. In some embodiments, the cap 740 may inhibit heat radiated by the ignition wall 764 from flowing upwardly (i.e. in a direction away from the frame stand 724) such that heat is retained in proximity to the surface 744.
FIGS. 21 and 22 illustrate another embodiment of a heater 820, although only a portion of the heater 820 is illustrated in FIGS. 21 and 22. The heater 820 may be part of a heater system in combination with a fuel source (e.g., the tank 12). The heater 820 may be similar to the heater 20 of FIGS. 2A-11 and to the heater 720 of FIGS. 19 and 10, except for the differences described below. The heater 820 includes a gas pipe 828, a heater unit 832, a fan unit 836, and a cap 840. The heater 820 may further include a frame stand that is the same or similar to the frame stand 724 of FIG. 18, and the fan unit 836 may be mounted to the frame stand. The heater unit 832 is mounted to the fan unit 836, and the cap 840 is mounted to the heater unit 832 at an end 832a of the heater unit 832 opposite from the fan unit 836. The heater unit 832 is connectable with the gas pipe 828.
The heater unit 832 includes an ignition wall 864. In the illustrated embodiment, the ignition wall 864 is cylindrical and includes a plurality of apertures 866. The plurality of apertures 866 may advantageously improve airflow through the heater unit 832. While the apertures 866 are shown to have relatively large diameters, according to one or more embodiments, apertures 866 may have small diameters in greater numbers. According to one or more embodiments, the apertures 866 may be covered with a fine metal mesh. In the illustrated embodiment, the ignition wall 864 is an infrared ignition wall. The heater unit 832 further includes a gas flow duct 868 and an airflow duct 872. The gas flow duct 868 defines a gas flow path A7, and the airflow duct 872 defines an air flow path. The airflow duct 872 extends between the fan unit 836 and the cap 840 and is in fluid communication with the fan unit 836. The airflow duct 872 is provided radially inward of the ignition wall 864. That is, the ignition wall 864 surrounds the airflow duct 872. The gas flow duct 868 extends around the airflow duct 872 such that the gas flow duct 868 is disposed between the airflow duct 872 and the ignition wall 864. As such, the gas flow duct 868 is ring-shaped. The gas flow duct 868 is configured to release gas such that gas flows from the gas flow duct 868 toward the cap 840 between the airflow duct 872 and the ignition wall 864.
In operation of the heater unit 832 of FIGS. 21 and 22, a user may attach the gas pipe 828 to a gas supply and actuate the fan unit 836, for example, by actuating a battery such as the battery 76 of FIG. 2B. Gas flowing through the gas pipe 828 enters the gas flow duct 868 between the airflow duct 872 and the ignition wall 864. Gas may then flow upward between the airflow duct 872 and the ignition wall 864 toward the cap 840. The gas flowing toward the cap 840 provides fuel for the ignition wall 864 to ignite and radiate heat. The fan unit 836 may induce airflow A8 to enter the cap 840 and to flow through the airflow duct 872 such that heat emitted from the ignition wall 864 heats the airflow A8 in the airflow duct 872. As the heated airflow A8 flows through the airflow duct 872 (downward, as shown in FIG. 12), heat from the ignition wall 864 warms the air, which then exits the heater 820 via the fan unit 836. For example, heated airflow A8 may exit the heater 820 via fan vanes (e.g., in a range of three-hundred-sixty degrees around the heater 820 similar to or the same as the fan outlet vanes 784 of FIG. 19). In the illustrated embodiment of FIGS. 21 and 22, heat is radiated inward and outward. Heat that is radiated inward of the ignition wall 864 may flow past the airflow duct 872 and exit from the inner periphery of the ignition wall 864 through the apertures 866.
FIG. 23 illustrate another embodiment of a heater 920, although only a portion of the heater 920 is illustrated in FIG. 23. The heater 920 may be part of a heater system in combination with a fuel source (e.g., the tank 12). Many of the features of the heater 920 are the same as those of the heaters described above. As illustrated, the heater 920 includes a heater unit 924, a cap 928, and a fan unit 932. The heater unit 924 is mounted to a shaft 936 that may be connected to a base that is configured to support the heater 920 on a surface. The shaft 936 may also be configured to provide a flow of gas to the heater unit 924. The heater unit 924 includes an ignition wall 940. The ignition wall 940 is cylindrical and is configured be ignited (e.g., when gas is supplied to the heater unit via the shaft) to emit heat (e.g., a flow of heat A9) in three-hundred-sixty degrees around the heater 920. The cap 928 is mounted to the ignition wall 940 and defines a cavity 944 for air to flow therein. The fan unit 932 is mounted to an external side of the cap 928 (e.g., outside of the cavity 944). The fan unit 932 includes a fan 948 that is configured to induce airflow A10 through the cap 928 and blow the airflow A10 radially outward. Specifically, the fan 948 induces ambient air to flow past the ignition wall 940 on an external side of the ignition wall 940 and into the cavity 944 of the cap 928. As the airflow A10 flows past the ignition wall 940, the heat emitted from the ignition wall 940 warms the airflow A10. The fan 948 then blows the heated airflow A10 outward such that the fan unit 932 increases the distance with which the heater 920 is able to emit heat.
With reference to FIG. 24, in some embodiments of the heater 920 of FIG. 23, the heater 920 may further include a globe 952 that surrounds the heater unit 924. In the illustrated embodiment of FIG. 24, the globe 952 is provided in addition to a grate 956 such that the grate 956 inhibits a user from incidentally or accidentally touching the globe 952. The globe 952 is formed of glass and surrounds the ignition wall 940. As such, the globe 952 may capture heat emitted from the ignition wall 940 to increase the heat in the space adjacent to the ignition wall 940 and still allow for some heat to travel through the globe 952. With the addition of the globe 952, the fan 948 is configured to induce air to flow through the globe 952 before being blown radially outward from the fan 948. Therefore, the globe 952 may increase the level of heat (e.g., in BTUs) of the air being blown from the fan 948.
FIG. 25 illustrates another embodiment of a heater 1020, although only a portion of the heater 1020 is illustrated in FIG. 25. The heater 1020 may be part of a heater system in combination with a fuel source (e.g., the tank 12). The heater 1020 includes a heater unit 1024, a cap 1028, and a fan unit 1032. The heater unit 1024 is mounted to a shaft 1036 that may be connected to a base that is configured to support the heater 1020 on a surface. The shaft 1036 may also be configured to provide a flow of gas to the heater unit 1024. The heater unit 1024 includes an ignition wall 1040 and airflow ducts 1044. The ignition wall 1040 is cylindrical and is configured be ignited (e.g., when gas is supplied to the heater unit 1024 via the shaft 1036) to emit a flow of heat A11 in three-hundred-sixty degrees around the heater 1020. The airflow ducts 1044 extend through an internal side of the ignition wall 1040. The cap 1028 is mounted to the ignition wall 1040 and defines a cavity 1048. The fan unit 1032 is mounted to an external side of the cap 1028 (e.g., outside of the cavity 1048). The fan unit 1032 includes a fan 1052 that is configured to induce airflow A12 to enter the airflow ducts 1044 at a bottom end of the airflow ducts 1044, to flow through the ducts 1044 such that the ignition wall 1040 emits heat to warm the airflow A12, and to exit the ducts 1044 into the cavity 1048 of the cap 1028. The fan 1052 is further configured to blow the heated airflow A12 radially outward from the heater 1020 such that the fan unit 1032 increases the distance with which the heater 1020 is able to emit heat.
FIG. 26 illustrates another embodiment of a heater 1120, although only a portion of the heater 1120 is illustrated in FIG. 25. The heater 1120 may be part of a heater system in combination with a fuel source (e.g., the tank 12). The heater 1120 includes a fan unit 1124, a heater unit 1128, and a cap 1132. The fan unit 1124 is positioned below the heater unit 1128 and the cap 1132 and may be mounted to, for example, a base. The fan unit 1124 includes a fan 1136 is configured to induce airflow A13 upward through the heater unit 1128 and to the cap 1132. The heater unit 1128 includes an ignition wall 1140, an airflow duct 1144, and a gas flow duct 1148. The ignition wall 1140 is cylindrical and at least a portion of both the airflow duct 1144 and the gas flow duct 1148 is positioned internal to the ignition wall 1140. In the illustrated embodiment, the airflow duct 1144 extends through the center of the ignition wall 1140 and allows the airflow A13 blown upward from the fan 1136 to reach the cap 1132. The gas flow duct 1148 surrounds the airflow duct 1144 such that at least a portion of the gas flow duct 1148 is ring-shaped. The gas flow duct 1148 is configured to release gas in an upward direction such that gas flows from the gas flow duct 1148 toward the cap 1132 between the airflow duct 1144 and the ignition wall 1140. The cap 1132 is mounted to the ignition wall 1140 opposite from the fan unit 1124 and includes a first portion 1132a and a second portion 1132b. The second portion 1132b of the cap 1132 is configured to redirect the airflow A13 blown through the airflow duct 1144 radially outward from the heater 1120. Specifically, the second portion 1132b of the cap 1132 is configured to redirect air in three-hundred-sixty degrees around the heater 1120.
FIG. 27 illustrates a hybrid heater 1220. The hybrid heater 1220 is configured to generate and emit heat from an output end 1220a of the heater 1220. The hybrid heater 1220 further includes a redirection mechanism 1224 that is positioned at the output end 1220a of the heater 1220 and is configured to redirect heat emitted from the heater 1220. In the illustrated embodiment, the redirection mechanism 1224 is configured to redirect heat to be blown in a direction parallel to the opening of the output end 1220a of the heater 1220. In other embodiments, the heater 1220 may be configured to blow the heat in other desired directions. In further embodiments, as illustrated in FIG. 28, the heater 1220 may further include a fan 1228 that assists with redirection of the heat blown from the heater 1220.
The configuration of the heaters and heater systems described herein advantageously enables delivery of heated airflow to surrounding areas at a greater distance than prior art heaters. Specifically, the fan unit blows heated airflow farther away from the ignition wall than is possible by radiation of heat from the ignition wall alone. Additionally, the fan unit blows air that has already been heated away from the heater rather than inducing an airflow of cooler ambient air to blow heat away from a heater. Therefore, the heater is advantageously enabled to deliver heat to larger spaces, or areas, than prior art heater systems.
Although the invention has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the scope and spirit of one or more independent aspects of the invention as described. It will be appreciated that features described with regard to components of specific embodiments may be included in similar components described with regard to other embodiments.
Patent Application
20240219069
