This application claims priority to AU Provisional Patent Application No. 2016903166, filed Aug. 11, 2016, the entire contents of which are incorporated herein by reference.
The invention relates to heaters, and more particularly, but not exclusively, to outdoor gas fired radiant heaters, which are often referred to as Patio Heaters. The invention also relates to a control system for a heater.
Existing gas fired radiant heaters include upright heaters with a chamber to store a gas bottle at the bottom and a heater module at the top. The chamber and the heater module are connected by a pole or similar structure. The assembled heater can have a height of about 2100 mm. Generally there is provided an umbrella-like reflector covering the upper heater module.
There are shorter variations of this type of heater.
Almost all of these types of heaters have a burner at the top with a flat or pancake type burner burning inside a mesh walled cylindrical combustion chamber. This chamber generally has a solid top and a perforated bottom to allow ingress of secondary combustion air.
Generally beneath the combustion chamber is a nacelle housing the requisite gas valves and flame management hardware.
A prior art heater is described with reference to
The combustion chamber has perforated mesh walls (5) which allow hot flue gases to escape in a controlled manner. The flue gases are generated by the combustion of gas at a burner (6) which provides primary air and gas to the flames adjacent to each port (7) of the burner. The burner (6) is made up of a burner body (12) and a mixing tube/injector assembly (13). The mixing tube (13) mixes gas and air for the burner (6).
In operation, the burner (6) is provided, via the mixing tube (13), with gas from the gas bottle or other gas supply at the bottom of the unit. The burner controls and control hardware (14) present a correct mixture of gas and air for primary combustion to the burner ports (7).
The burner (6) is ignited by ignition hardware of the burner controls (14). Once alight and the flame is verified, secondary air for completion of the combustion process is urged by the action of the gas hardware and thermal forces, into the lower part of the combustion chamber via air inlets (8) so that a continuous clean combustion process is sustained within the cylindrical and basically vacant combustion chamber interior.
The hot flue gases are distributed over the inside of the mesh walls (5) by the restrictive nature of the mesh to the escaping hot gas, the hole to solid ratio (open area) being selected for that function.
The mesh walls (5), heated by the hot gas generally glow cherry red when in use, especially on high gas settings. The mesh walls (5) generally glow more at the top than the bottom, driven by the fact that the mesh is generally all one whole size and convection forces pool the hot gases more at the top.
A reflective cover (9) is normally provided to reflect ‘lost’ radiation that would otherwise radiate upwards and away from the intended target which is normally seated people.
It has been found that the unit depicted in
The unit has a 360 angular degree radiation zone. In a lot of cases, the user may not wish to have radiation from say the back half of the burner, or may wish to have a lower setting for that hemisphere. For example, in that hemisphere, there may be no persons, or a wall or other object that does not need, or cannot withstand, heating (e.g. a pot plant, shrub, hose wall etc.). In addition, the use of gas for heating an unwanted target area is costly and environmentally not responsible.
It has also been found that the burner/combustion chamber design is inefficient in that being an open chamber inside, there is not directional control over the hot flue gases, so they tend to escape wherever restriction is the least, like on the downwind side of the mesh (3, 5). The lack of control over the hot gases indicates that the process may be inefficient as in most gas appliances control of the gases and secondary air is important. This lack of control also wastes gas.
It has also been found that the top surface of the combustion chamber, generally a non-perforated metal flat dish shape, gets very hot due to the uncontrolled flue gases as described above. This high surface area of hot metal radiates heat substantially vertically, relying on the umbrella reflector (9). This is substantially lost heat, again adding to the running cost/task efficiency of the unit.
The present invention seeks to overcome at least some of the shortcomings identified above and/or to at least provide the public with a useful choice.
In one aspect, the present invention provides a heater comprising:
heating means for heating gas in at least one heating chamber;
wherein the at least one heating chamber comprises a plurality of heating compartments each being operable in a heating operation to provide heat in a respective heating direction, wherein the heating direction of each heating compartment is different from the heating direction of the at least one other heating compartment, and wherein the heating means comprises a respective heating element for each heating compartment, the heating operation of at least one of the heating elements being independently controllable of the heating operation of at least one other of the heating elements.
The heater preferably includes a control system for controlling the heating operation of the heating elements.
Preferably the control system includes a separate control for each heating element of the heating means. This enables the operation of at least one of the heating elements to be independently controllable from at least one other of the heating elements.
In one preferred embodiment, the at least one heating chamber is provided in a housing having one or more internal partitions which divide the housing into the plurality of heating compartments.
In a preferred embodiment, the heating elements are gas burners.
In an alternative embodiment, the heating elements could conceivably be electric heating elements for heating air in each heating compartment. In this case, the control system may include separate electric controls, e.g. in the form of switches, for independently controlling the operation of each heating element.
The heating elements of the heating means preferably include at least one gas burner for each heating compartment.
In one preferred embodiment, a single burner assembly is provided which includes at least one gas burner for each heating compartment.
The burner assembly may include a plurality of mixing tubes, and a separate mixing tube is preferably provided for the burner in each heating compartment.
The heater preferably includes gas supply, with the control system controlling the flow of gas to the gas burners from the gas supply.
The control system preferably includes at least one valve for controlling the flow of gas from the gas supply to the gas burners.
The single assembly may comprise a burner plate having a plurality of flame outlets, a first combustion compartment connected to a first set of said plurality of flame outlets to form a first burner, and a second combustion chamber connected to a second set of combustion outlets to form a second burner, a first mixing tube connected to the first combustion chamber for supplying combustion gas to the first combustion chamber, and a second mixing tube connected to the second combustion chamber for supplying a combustion gas to the second combustion chamber.
According to a second aspect of the invention, there is provided a gas burner assembly for a heater comprising a burner plate having a plurality of flame outlets, a first combustion compartment connected to a first set of said plurality of flame outlets to form a first burner, and a second combustion chamber connected to a second set of combustion outlets to form a second burner, a first mixing tube connected to the first combustion chamber for supplying combustion gas to the first combustion chamber, and a second mixing tube connected to the second combustion chamber for supplying a combustion gas to the second combustion chamber.
Preferably, the flame outlets are of tubular form and arranged around the periphery of the burner plate.
The assembled burner may include a top burner plate and a bottom burner plate, connected together, each having a plurality of part tubular sections around its periphery.
In one embodiment, the top burner plate has two semi-circular raised walls on either side of a diameter of the burner plate and the bottom burner plate has two semi-circular recessed walls on either side of said diameter, wherein in the assembled burner, the semi-circular raised walls and the semi-circular recessed walls together form the first and second combustion chambers of the burner assembly.
The control system may include a plurality of valves, each valve controlling the flow of gas to a respective gas burner.
The control system preferably includes at least one ignition for igniting the gas supplied to at least one of the gas burners.
In one embodiment, the control system includes a plurality of ignitions, each ignition being independently controllable to ignite the gas supplied to a respective gas burner.
In an alternative, preferred embodiment, the control system comprises a master-slave control system which has a separate control for controlling each valve of the plurality of valves, and a single ignition for igniting the gas supplied to a first gas burner via a first valve, wherein gas supplied to the other gas burners via other valves of the plurality of valves is ignited by a cross-lighting effect from the flames of the first burner.
The heating chamber is preferably at least partly defined by at least one mesh wall and includes at least one baffle or reflector inside the heating chamber to guide the heated gases towards the at least one mesh wall of the heating chamber.
In one embodiment, the at least one baffle or reflector may be parallel to the at least one mesh wall of the heater.
In a more preferred embodiment, the at least one baffle or reflector approaches the at least one mesh wall at an angle. Preferably, the at least one baffle or reflector extends from a lower end positioned inwardly of the at least one mesh wall to an upper end positioned adjacent to the at least one mesh wall.
The at least one baffle or reflector preferably includes a high insulation material. The at least one baffle may be formed from the high insulation material, or alternatively, the high insulation material may be provided on a surface of the at least one baffle or reflector.
According to another aspect of the invention, there is provided a control system for a heater the heater comprising at least one heating chamber having a plurality of heating compartments, and a plurality of heating elements which includes a respective heating element for each heating compartment, wherein the control system controls a heating operation of each heating element, the control system including:
a main control for controlling the operation of at least one of the heating elements;
at least one secondary control for selectively controlling the operation of at least one other of the heating elements.
Preferably, the heating elements are gas burners. The main control may control the supply of gas to a first gas burner for heating gas in one of the heating compartments, with the control system including an ignition for igniting the gas supplied to the first gas burner.
Preferably, the secondary control independently controls the supply of gas to at least one secondary gas burner for heating gas in another of the heating compartments.
In one embodiment, the secondary control may include at least one other ignition for igniting the at least one secondary gas burner for heating gas in said other heating compartments.
In an alternative embodiment, the at least one other ignition may be omitted and the arrangement is preferably such that when the gas supplied to the first gas burner is ignited, the secondary control(s) is selectively operable to supply gas to the at least one secondary gas burner, the gas supplied to said at least one secondary gas burner being ignited from the ignited gas from the first gas burner. In this case, the secondary control may include a gas cock.
The present invention will now be described, by way of non-limiting example, with reference to the accompanying drawings in which:
Referring to
As well, in the preferred embodiments, there is provided a novel control mechanism. In one embodiment, there may be provided two or more independently controllable complete gas controls (34), with respective ignition hardware for each gas burner element or segment (21), and this arrangement is shown in
In this embodiment, the main gas control (44) ignites the first gas burner element or segment of the divided burner assembly (11). When the flame of the first burner element or segment is present and verified by the controller, only the first burner element or segment will be alight. The second (and any subsequent) burner element or segment can then be supplied with gas via the secondary slave gas control or gas cock (45). The second (and any subsequent) burner element or segment can be ignited by a cross lighting effect from the ignited gas from the first burner element or segment and the dividing wall (10) is preferably detailed to allow/enhance this cross lighting. The slave gas cock (45) is only supplied from the main gas control (44) so that the gas cock and second burner element or segment is indirectly controlled by the flame management system of the master control (44). This makes it more economically viable to have to or more separate heating elements or segments in the burner assembly (11) and combustion chamber (22).
It is also preferable to include control of hot flue gas within the compartments (23) of the heating combustion chamber (22) for efficiency and lower running costs.
In
The baffle (17) may further be enhanced by including a high temperature insulation material. The high temperature insulation material may be provided on the outer or inner surface of the baffle (17) to prevent heat loss from anywhere but the mesh walls. It has been found that the angled baffle (17) works better than a parallel baffle due to the squeezing effect on the flue gases as they rise and escape. The mesh walls (25) may also have a graded open area to balance out the flue gas heat exchange and escape of the flue gases to further enhance the efficiency of the unit.
The mixing tubes (133a, 133b) are arranged to be mounted to the lower annular side wall (118) of the lower wall member (112) by a mounting plate (114). In the assembled heater, the lower ends of the mixing tubes (133a, 133b) are connected to a gas supply (not shown). The upper ends of the mixing tubes (133a, 133b) are connected to the second, lower burner plate (122b).
The heater (100) includes a gas burner (122) having a first, upper burner plate (122a) and a second, lower burner plate (122b), which are engageable with each other to form an assembled gas burner plate (described in further detail with reference to
The gas burner (122) has a plurality of tubular flame outlets (124) formed by part tubular sections (124a) of the first burner plate (122a), which mate with part tubular sections (124b) of the second burner plate (122b) in the assembled gas burner (122). The tubular flame outlets (124) on one half of the gas burner (122) are connected to one of the combustion compartments (123a), and the tubular flame outlets (124) on the half of the gas burner (122) are connected to the other one of the combustion compartments (123b).
The part tubular sections (124a, 124b) are distributed along the circumference of the first and second burner plates (122a, 122b) respectively. The part tubular sections (124a, 124b) of each burner plate (122a, 122b) have a thickness of about 2 mm to 5 mm, preferably about 3 mm. The part tubular sections (124a, 124b) preferably have a length of about 30 mm to 60 mm, preferably between about 40 mm to 50 mm, and even more preferably about 45 mm.
Referring now to
Referring now to
When the first burner plate (122a) is assembled with the second burner plate (122b), the semi-circular raised and recessed walls (126, 128) of the first and second burner plates form top and bottom walls of the respective heating compartments (123a, 123b) of the heating combustion chamber, where combustion gas is selectively communicated into each combustion compartment via the mixing tubes (134). The tapered neighboring walls (126a, 128a) in the first and second burner plates (122a, 122b) assist in directing the gas towards the flame outlets formed by the part tubular sections (124a, 124b) of the first and second burner plates (122a, 122b).
Various features of the different embodiments described with reference to the drawings may be combined into further embodiments. For example, the Master/Slave gas control arrangement (44, 45) of the embodiment of
It will also be appreciated that various modifications could be made to the preferred embodiments without departing from the scope or spirit of the invention. For instance, the present invention is equally applicable to other shapes of combustion chamber (e.g. square/triangular/rectangular) and other layouts.
Number | Date | Country | Kind |
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2016903166 | Aug 2016 | AU | national |