BACKGROUND OF THE INVENTION
Field of the Invention
This invention relates to a heating device, and more specifically to a heating module with one or more heating elements configured to be used in cooperation with a cooling system.
Background
An evaporative air cooler is a type of cooling system that cools a stream of ambient air by using a fan to circulate the ambient air through a wet, cooling media, where evaporation converts water to water vapor, to produce a stream of cooled air. Various solutions have been proposed that function to utilize an evaporative air cooler to provide a stream of heated air. For example, U.S. Pat. No. 8,490,422 to Al Waban discloses an evaporative air cooler with one or more heaters. U.S. patent application No. 20030131985 to Patterson et al. discloses an evaporative air cooler with a heater that heats a stream of air. U.S. Pat. No. 5,482,657 to Wright discloses a heater coupled to an evaporative air cooler.
SUMMARY
The embodiments described herein relate to a heating module configured to be removably securable to a cooling system to form a heating system. The cooling system provides a stream of air that is heated by the heating module before being exhausted therethrough. The heating module includes a securement flange having an annular sidewall configured to be removably securable around an exhaust opening of an outlet duct of the cooling system. The annular sidewall includes a lip for positioning the heating module relative to the cooling system. A frame is coupled to the securement flange and formed with an opening through which the stream of air flows. One or more heating elements configured for heating the stream of air are securable to at least one heater support coupled to the frame for adjustably positioning the one or more heating elements in parallel spaced apart relationship across the opening of the frame to heat the stream of air exhausted from the outlet duct of the cooling system. In an embodiment, the one or more heating elements comprise a plurality of positive-temperature-coefficient heating elements adjustably positionable to heat the stream of air. The stream of air is heated by flowing through one or more spaces formed between the plurality of heating elements. A front cover includes a grate secured in alignment with the opening in the frame, and the stream of air is exhausted therethrough.
The heating module is removably securable to the cooling system and operable for heating the stream of air and exhausting the stream of air heated by the one or more heating elements through the opening of the frame. The heating module is removed from the cooling system when the cooling system is usable for cooling the stream of air. In a heating mode, a pump that supplies water to the cooling system is disabled, and the stream of air provided by the cooling system flows through a rear opening of the heating module, through the heating module and between the plurality of heating elements, and exhausts from a front face of the heating module.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention are described in detail below with reference to the attached drawing figures, wherein:
FIG. 1 shows a front, elevation view of an embodiment of a heating module, with a rotary switch assembly;
FIG. 2 shows a front, perspective view of an embodiment of the heating module in FIG. 1, with a rocker switch assembly;
FIG. 3 shows a perspective view of the heating module in FIG. 2, coupled to an evaporative air cooler;
FIG. 4 shows a rear, elevation view of the heating module in FIG. 1 or 2;
FIG. 5 shows an exploded schematic of the heating module in FIG. 1 or 2; and
FIG. 6 shows a cross-sectional view of the heating module in FIG. 1 or 2, the cross section taken along line 6-6 in FIG. 1.
The drawing figures do not limit the invention to the specific embodiments disclosed and described herein. The drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following detailed description references the accompanying drawings that illustrate specific embodiments in which the invention can be practiced. The embodiments are intended to describe aspects of the invention in sufficient detail to enable those skilled in the art to practice the invention. Other embodiments can be utilized, and changes can be made without departing from the scope of the invention. The following detailed description is, therefore, not to be taken in a limiting sense. The scope of the invention is defined only by the appended claims, along with the full scope of the equivalents to which such claims are entitled.
In this description, references to “one embodiment,” “an embodiment,” or “embodiments” mean that the feature or features being referred to are included in at least one embodiment of the technology. Separate references to “one embodiment,” “an embodiment,” or “embodiments” in this description do not necessarily refer to the same embodiment and are also not mutually exclusive unless so stated and/or except as will be readily apparent to those skilled in the art from the description. For example, a feature, structure, act, etc. described in one embodiment may also be included in other embodiments but is not necessarily included. Thus, the technology can include a variety of combinations and/or integrations of the embodiments described herein.
In this description, references to “forward”, “rearward”, “above”, and “below”, and derivatives thereof, generally connote a direction relative to the embodiment shown in FIG. 1. That is, “forward” generally refers to a direction toward a front face 136 of the heating module 100 from which a stream of heated air is exhausted, and “rearward” generally refers to the direction opposite the “forward” direction or toward a rear opening 138 of the module 100, shown in FIG. 4. “Above” and “below” generally refer to the sides of the heating module 100 or the sides of the exhaust grate 190 that extend toward the top and the bottom of the page, respectively, in FIG. 1. The term “lateral sides” general refers to the left and right sides of the heating module 100 or the left and right sides of the exhaust grate 190 of the heating module 100 shown in FIG. 1.
An embodiment of a heating module 100 for use with a cooling system that is an air ventilation or circulation system having a fan to provide a stream of air is described herein. The heating modules 100 shown in FIGS. 1 and 2 are configured to be coupled to an outlet duct 120 that forms an exhaust opening 125 of a cooling system that is an evaporative air cooler 130 for conversion of the evaporative air cooler 130 into a heating system 132 that provides at least one heating mode. The heating system 132, including the heating module 100 removable secured to the outlet duct 120 of the evaporative air cooler 130, is shown in FIG. 3. The heating module 100 may be removed from the evaporative air cooler 130 when the cooler 130 is to be used for cooling a space or a room. The heating module 100 described herein is not intended to be limited to use with the evaporative air cooler 130 and may be modified to be used with any of a variety of air ventilation or circulation systems that have an exhaust opening for exhausting air therethrough.
The heating module 100 includes a front face 136, shown in FIGS. 1 and 2, and a rear opening 138, shown in FIG. 4, which is configured to be positioned across the exhaust opening 125 of the evaporative air cooler 130. An exhaust grill or register (not shown) that is normally secured to the outlet duct 120 of the evaporative air cooler 130, when the evaporative air cooler 130 is in a cooling mode, is removed, and the heating module 100 is secured to the outlet duct 120 of the evaporative air cooler 130 over and across the exhaust opening 125 such that the evaporative air cooler 130 is selectively convertible to the heating system 132 by a user. Preferably, in the heating mode a water distribution or circulation system of the evaporative air cooler 130, including a pump, is not operated to prevent humidifying and cooling a stream of air. An exhaust fan (not shown) within the evaporative air cooler 130 produces the stream of air that flows through the exhaust opening 125 of the outlet duct 120 of the evaporative air cooler 130 and the rear opening 138 of the heating module 100, flows past and contacts one or more heating elements 144 of the heating module 100 to heat the stream of air, and is exhausted from the front face 136 of the heating module 100.
FIG. 5 shows an expanded view of the heating module 100 that includes a securement flange 150 for securing the heating module 100 to the evaporative air cooler 130, a frame or heater support 160 that includes means for mounting the one or more heating elements 144 thereto, and a front cover 185 that is supported on the frame 160 and is integral with or coupled to an exhaust grate or mesh 190.
The securement flange 150, which may also be referred to as a flanged collar or flanged duct, includes an annular sidewall or collar 200 that is removably securable to the outlet duct 120, or an outer surface of a sidewall forming the exhaust opening 125 of the evaporative air cooler 130, by clamps, screws, or other foreseeable fastening devices that are securable to the outlet duct 120, such as, for example, by pressure and/or friction within or against the outlet duct 120, and a flange 202 projecting radially outward from the annular sidewall 200.
As best shown in an embodiment in FIG. 6, the annular sidewall 200 includes an outer wall 210 and an inner wall 220. The outer wall 210 extends from the rear opening 138 toward the frame 160. The inner wall 220 is connected to the outer wall 210 along the rear opening 138 and generally tapers radially inward from the rear opening 138 to a lip 225 that extends radially inward from the inner wall 220 with a gap 227 formed between the inner wall 220 and outer wall 210. The inner wall 220 functions to form a tight fit between the securement flange 150 and the outlet duct 120. Between the rear opening 138 and the lip 225, the inner wall 220 forms an annular shoulder 230 that protrudes radially inward for securing the securement flange 150 to the evaporative air cooler 130. Fasteners extend through bosses 240 formed in the annular sidewall 200 to secure the securement flange 150 to the evaporative air cooler 130. The inner wall 220 includes notches 250 through which the fasteners may extend and which may be aligned with the bosses 240. In an embodiment, the notches 250 and/or the gap 227 provide a degree of adjustability of the securement flange 150 when installing or removing the heating module 100 from the evaporative air cooler 130. The lip 225 functions as a stop to position the heating module 100 relative to the outlet duct 120 of the evaporative air cooler 130 for alignment of the fasteners extending through the bosses 240 with preexisting holes that are used for securing an exhaust grill or register to the outlet duct 120 when used in the cooling mode. Pocket holes 270 are formed in the outer wall 210 of the securement flange 150, as shown in FIG. 4, extending forward (in a direction toward the front face 136) therefrom and corresponding to screw bosses 280, shown in FIG. 6, that extend rearward from the frame 160 to secure the securement flange 150 to the frame 160. The outer wall 210 of the annular sidewall 200 of the securement flange 150 and a sidewall 285 of the frame 160 are in engagement and each include a surface 295 and 300, respectively, that is formed to create an interlocking junction that prevents movement of the securement flange 150 relative to the frame 160. The interlocking junction may be formed with any of a variety of joints or splices known in the art to immovably secure the securement flange 150 to the frame 160, including, for example, a scarf or splice joint that creates a fit that prevents movement at the joint. It is foreseeable that the securement flange 150 may be formed integrally with the frame 160.
As shown in FIGS. 3 and 4, the frame 160 includes a main wall 305 that may include recessed portions or openings 308 that are configured to contain junction boxes 310 extending rearwardly therefrom and with an opening 315 that may include reinforcing ribs 318 extending across the opening 315. In an embodiment, the junction boxes 310 are formed integrally with the frame 160. The sidewall 285 of the frame 160 extends rearward from an outer edge of the main wall 305 toward the outer wall 210 of the annular sidewall 200 of the securement flange 150.
Heater supports 320, that may include a plurality of bosses or other means for mounting the one or more heating elements 144 to the frame 160, extend rearward from a rear face of the main wall 305 and engage mounts 325 coupled to the one or more heating elements 144. The plurality of bosses 320 are spaced apart to enable adjustably mounting the one or more heating elements 144 relative to the opening 315 and the exhaust grate 190 such that the one or more heating elements 144 are positionable in a parallel spaced apart relationship to heat the stream of air or airflow that is circulated through the evaporative air cooler 130 and exhausted through the opening 315 and the exhaust grate 190. As shown in FIG. 4, the heater supports 320 are positioned above and below the opening 315 formed in the frame 160 and the opening 315 is in alignment with the exhaust grate 190. The heater supports 320 are positioned such that various configurations of the one or more heating elements 144 can be employed and the one or more heating elements 144 can be adjustably positioned across and/or rearward of the opening 315. The heater supports 320 shown are horizontally positioned in alignment above and below the opening 315 such that the one or more heating elements 144 are vertically positionable, but it is foreseeable that the heater supports 320 may also or alternatively be vertically positioned in alignment along the lateral sides of the opening 315 such that the one or more heating elements 144 are horizontally positionable. The one or more heating elements 144 in the embodiments shown are positioned to maximize heating of the stream of air and minimize any unheated airflow therethrough. Specifically, the one or more heating elements 144 are positioned proximate each of the lateral sides of the opening 315 to force at least most of the stream of air to flow between the one or more heating elements 144. Other types of means of coupling the one or more heating elements 144 are also contemplated that may allow for fixedly and/or adjustably positioning of the one or more heating elements 144.
The exhaust grate 190 provides a passage or egress to exhaust the heated airflow, and, in an embodiment, the exhaust grate 190/is approximately the same size as the opening 315. The exhaust grate 190 may include one or more of a variety of sizes and shapes of apertures extending therethrough. The exhaust grate 190 limits or restricts the insertion of objects into the heating module 100 and may prevent particles of a selected size from being exhausted from the heating module 100. The exhaust grate 190 is positioned forward of the one or more heating elements 144 and prevents a user or an object from contacting the one or more heating elements 144.
As shown in the embodiment described herein, the one or more heating elements 144 include four positive-temperature-coefficient (PTC) heater elements or self-regulating heaters that are formed from ceramic materials to provide efficient heat production and transfer. The one or more heating elements 144 convert electricity into heat, and produce a heat output that heats the stream of air that flows past and through the one or more heating elements 144. The one or more heating elements 144 have a positive temperature coefficient of resistance such that a resistance of the element increases with an increase in temperature. In effect, the element produces a large amount of heat when there is a low temperature, and as the temperature increases, the element produces less heat. The self-regulating characteristics of the one or more heating elements 144 prevents damage to the heating module 100 or to the evaporative air cooler 130 due to overheating. Other types of heating elements may be used in the heating module 100 to provide a heated stream of air, including, for example, tubular heating elements, heater coils, and other means for heating air known in the art, and the components of the heating elements may comprise one or more elements having a variety of compositions depending on an application and/or requirements of the heating system 132.
The junction boxes 310 house electrical components of the heating module 100 and enclose electrical connections between a power supply or power supply cord 328 (see FIG. 5) and the electrical components to protect against short circuits. In the embodiment shown in FIG. 4, the junction boxes 310 are positioned on a left side and a right side of the opening 315, and the securement flange 150, the frame 160, and the front cover 185 are configured to integrate the junction boxes 310, along with the associated electrical components, into the heating module 100. The junction boxes 310 each include one or more openings or cable connections 330 (see FIG. 6) through which electrical and/or communicative conduits, such as, for example, the power supply 328, extend. It is foreseeable that the junction boxes 310 may be positioned above and/or below the opening 315. It is foreseeable that one or more junction boxes 310 may be positioned on one side of the opening 315.
In an embodiment, one of the junction boxes 310 includes a switch assembly 350 that is electrically connected to the power supply 328 and automatically activates, via thermostat (not shown), the one or more heating elements 144 of the heating module 100 and/or is selectively actuatable by a user to activate the one or more heating elements 144 of the heating module 100, to regulate a temperature. The switch assembly 350 may include one or more of a variety of switches, including a push button switch, a micro switch, a rotary switch, a rocker switch, or another switch known in the art. In an embodiment shown in FIG. 1, a handle or knob or actuator 351 of the rotary switch assembly 350 extends through an opening in the front cover 185 of the heating module 100. The rotary switch assembly 350 includes at least one heating mode, and preferably at least two heating modes, a warm mode and a hot mode, and an alternative option for turning the heating module 100 off. The warm mode electrically connects less than all of a plurality of heating elements 144, and the hot mode electrically connects all of a plurality of heating elements 144. In the embodiment shown that includes four heating elements 144, the warm mode electrically connects two of the heating elements 144 and the hot mode electrically connects four of the heating elements 144. In an embodiment shown in FIG. 2, the switch assembly 350 is a rocker switch with three positions that function similarly to that described with reference to the rotary switch assembly 350.
In the embodiments shown in FIGS. 1 and 2, one of the junction boxes 310 includes an electrical receptacle assembly 360 that is electrically connectable to the power supply 328 and is provided to power the evaporative air cooler 130 and/or another device such that outlet usage is minimized. The electrical receptacle assembly 360 may include a face plate 362 that is mounted on the front cover 185. In the embodiment shown, the electrical receptacle assembly 360 includes two outlets or sockets 364 for plugging electrical devices into the electrical receptacle assembly 360. A plug, such as a three-pronged plug, for an electrical supply cord (not shown) for the evaporative air cooler 130, may be plugged into one of the electrical sockets 364 of the heating module 100 and another electrically powered device can be plugged into the other socket 364. Because the evaporative air cooler 130 may be plugged into the heating module, only a single wall outlet or extension cord is needed to provide power for both the fan of the evaporative air cooler 130 and the heating module 100 through the power supply 328 of the heater 100.
The evaporative air cooler 130 may be of a type having one or more switches or controls for selectively operating a pump when the fan of the cooler 130 is operating to selectively direct water from a tank in the cooler 130 through nozzles which then direct fine droplets of water into the stream of air created by the fan to produce the desired evaporative cooling effect. Instructions and labeling may be included with the heating module 100 to not operate or switch off the power to the pump when operating the heating elements 144
The front cover 185 is coupled to and supported on a front face 385 of the main wall 305 of the frame 160. As best shown in FIG. 6, an annular rim 390 integrally formed with and projecting forward from the periphery of the front face 385 of the main wall 305 of the frame 160 has an inner perimeter dimension that is the same or slightly larger than an outer perimeter dimension of the front cover 185. The front cover 185 is secured to a front face of the main wall 305 of the frame 160, and ribs or spacers 395 extend therebetween to support and/or position the front cover 185 relative to the frame 160. The exhaust grate 190, having apertures extending therethrough, is coupled to or formed integrally with the front cover 185 to exhaust the heated stream of air from the heating module 100. The heated stream of air exits the heating module 100 through the port or exhaust grate 190.
Many different arrangements of the various components depicted, as well as components not shown, are possible without departing from the spirit and scope of the present disclosure. Embodiments of the present disclosure have been described with the intent to be illustrative rather than restrictive. Alternative embodiments will become apparent to those skilled in the art that do not depart from its scope. A skilled artisan may develop alternative means of implementing the aforementioned improvements without departing from the scope of the present disclosure. It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations and are contemplated within the scope of the claims.
Patent Application
20250129969
