TECHNICAL FIELD
The present disclosure relates generally to the field of outdoor heaters. More particularly, the present disclosure relates to a patio-type outdoor heater that includes a combustion chamber for burning pellets and a pellet hopper for containing pellets.
BACKGROUND
Various devices regulate air temperature to increase comfort and safety both indoors and outdoors. Outdoor heaters provide heat in an outdoor setting when temperatures are cool. Various different kinds of outdoor heaters are of different sizes, use different types of fuel, and provide different functions. One common type of outdoor heater generates heat by flames created from combustible gas, like propane. While propane is a commonly used fuel for outdoor heaters, it presents several disadvantages. Propane can be expensive and difficult to supply. Sourcing propane typically involves refilling a propane tank by a professional service. In addition, propane emits a distinct and strong odor that is often considered unpleasant. Propane is also not a renewable source, leading to potentially adverse effects to the environment. In addition, most floor standing outdoor heaters that use propane as the fuel position the heat source at the top of the heater, making directing the heat downward difficult.
Wood pellet heaters address many of these issues by using a less expensive, renewable fuel, eliminating the odor of propane, and more uniformly directing heat. However, a unique challenge of pellet heaters is ensuring that a pellet hopper storing pellets prior to combustion are kept sufficiently cool to prevent unwanted hopper fires. To overcome this challenge, many wood pellet patio heaters house wood pellets in isolated, separate housings from the combustion chamber and have inconvenient access to the burn chamber. However, housing wood pellets in an isolated chamber prior to combustion may increase manufacturing complexity and cost, negatively affect the structural integrity and strength of the outdoor heater, and decrease aesthetic value for some customers.
SUMMARY
In some example aspects, the present disclosure is directed to a heater. The heater may include a combustion chamber configured to burn pellets, the combustion chamber comprising a first barrier; a pellet hopper configured to contain the pellets, the pellet hopper comprising a second barrier; a ventilated chamber between the combustion chamber and the pellet hopper, the ventilated chamber being enclosed by: the first barrier; the second barrier; and one or more surfaces comprising one or more orifices allowing air to pass through the ventilated chamber; a flue for carrying heat from the combustion chamber; and a heat deflector disposed on the flue to deflect heat in a radial direction.
In some aspects, the pellet hopper is positioned adjacent to the combustion chamber along a horizontal axis. In some aspects, the ventilated chamber is fully enclosed. In some aspects, the first barrier and the second barrier are parallel to one another. In some aspects, the first barrier extends parallel to a vertical axis of the heater. In some aspects, the second barrier extends parallel to a vertical axis of the heater. In some aspects, the heater further comprises a chute extending between the pellet hopper and the combustion chamber. In some aspects, the chute extends through the ventilated chamber. In some aspects, the chute is angled relative to a horizontal axis of the heater. In some aspects, the heater further comprises a movable barrier within the pellet hopper configured to selectively allow one or more of the pellets within the pellet hopper to move along the chute from the pellet hopper to the combustion chamber. In some aspects, the first barrier comprises one or more additional orifices configured to allow air to move from the ventilated chamber to the combustion chamber.
In some example aspects, the present disclosure is directed to a pellet heater. The pellet heater may include a combustion chamber for burning pellets, the combustion chamber comprising a first barrier; a pellet hopper configured to contain the pellets, the pellet hopper comprising a second barrier; a chamber between the combustion chamber and the pellet hopper, the chamber being enclosed by: the first barrier; the second barrier; and one or more surfaces comprising one or more orifices allowing air to pass through the chamber; a fire pot disposed at a lower portion within the combustion chamber, the fire pot comprising a fuel grate configured to: receive the pellets from the pellet hopper; and support the pellets during combustion; a chute extending from a lower portion of second barrier of the pellet hopper to the fire pot by which the pellets within the pellet hopper move to the fire pot; a slidable ash grate disposed beneath the fire pot, the slidable ash grate configured to receive ashes from the fire pot and comprising a first handle configured to facilitate movement along a horizontal axis of the combustion chamber; and a removeable ash pan disposed beneath the slidable ash grate, the grate configured to catch and store ashes from the slidable ash grate and comprising a second handle.
In some aspects, the fuel grate includes a first region and a second region, the first region being angled at a first angle with respect to a horizontal axis of the pellet heater and the second region being angled at a second angle with respect to the horizontal axis.
In some example aspects, the present disclosure is directed to a heater. The heater may include a combustion chamber for burning pellets, the combustion chamber comprising a first barrier and defining a vertical axis and a horizontal axis; a pellet hopper positioned adjacent to the combustion chamber along a horizontal axis and configured to contain the pellets, the pellet hopper comprising a second barrier; and a ventilated chamber between the combustion chamber and the pellet hopper, the chamber being enclosed by: the first barrier; the second barrier; and one or more surfaces comprising one or more orifices allowing air to pass through the chamber.
In some aspects, the pellet hopper is positioned such that a top surface of the pellet hopper is parallel to a top surface of the combustion chamber. In some aspects, the first barrier and the second barrier are parallel to one another. In some aspects, the heater further comprises a chute extending between the pellet hopper and the combustion chamber. In some aspects, the chute is an enclosed chute including a first opening at the pellet hopper and a second opening at the combustion chamber. In some aspects, the chute is angled relative to a horizontal axis of the heater. In some aspects, the first barrier comprises one or more additional orifices configured to allow air to move from the ventilated chamber to the combustion chamber.
It is to be understood that both the foregoing general description and the following drawings and detailed description are exemplary and explanatory in nature and are intended to provide an understanding of the present disclosure without limiting the scope of the present disclosure. In that regard, additional aspects, features, and advantages of the present disclosure will be apparent to one skilled in the art from the following. One or more features of any implementation or aspect may be combinable with one or more features of other implementation or aspect.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings illustrate implementations of the systems, devices, and methods disclosed herein and together with the description, serve to explain the principles of the present disclosure.
FIG. 1 is a perspective view of an outdoor heater, shown as a patio heater, according to aspects of the present disclosure.
FIG. 2 is a cross-sectional side view of a patio heater, according to aspects of the present disclosure.
FIG. 3 is a cross-sectional side view of a base of a patio heater, according to aspects of the present disclosure.
FIG. 4A is a left side view of a base of a patio heater, according to aspects of the present disclosure.
FIG. 4B is a right side view of a base of a patio heater, according to aspects of the present disclosure.
FIG. 4C is a front side view of a base of a patio heater, according to aspects of the present disclosure.
FIG. 4D is a rear side view of a base of a patio heater, according to aspects of the present disclosure.
FIG. 4E is a top cutaway view of a base of a patio heater, according to aspects of the present disclosure.
FIG. 4F is a bottom view of a base of a patio heater, according to aspects of the present disclosure.
FIG. 5 is a cross-sectional side view of a base of a patio heater, according to aspects of the present disclosure.
FIG. 6 is a cross-sectional side view of a base of a patio heater, according to aspects of the present disclosure.
FIG. 7 is a cutaway perspective view of components of a base of a patio heater, according to aspects of the present disclosure.
FIG. 8 is a cross-sectional side view of a patio heater according to aspects of the present disclosure.
These Figures will be better understood by reference to the following Detailed Description.
DETAILED DESCRIPTION
For the purpose of promoting an understanding of the principles of the present disclosure, reference will now be made to the implementations illustrated in the drawings and specific language will be used to describe them. It will nevertheless be understood that no limitation of the scope of the disclosure is intended. Any alterations and further modifications to the described devices, instruments, methods, and any further application of the principles of the present disclosure are fully contemplated as would normally occur to one skilled in the art to which the disclosure relates. In addition, this disclosure describes some elements or features in detail with respect to one or more implementations or Figures, when those same elements or features appear in subsequent Figures, without such a high level of detail. It is fully contemplated that the features, components, and/or steps described with respect to one or more implementations or Figures may be combined with the features, components, and/or steps described with respect to other implementations or Figures of the present disclosure. For simplicity, in some instances the same or similar reference numbers are used throughout the drawings to refer to the same or like parts.
Some aspects of the disclosure teach a pellet burning outdoor heater, such as a patio heater. The patio heater may include a base having a pellet hopper and a combustion chamber separated by an enclosed, yet ventilated chamber. The pellet hopper, combustion chamber, and ventilated chamber may be positioned within the same housing and interior walls within the housing may separate these chambers, creating a uniform appearance and providing stability to the patio heater. The ventilated chamber may include multiple holes in the exterior walls of the ventilated chamber as well as multiple holes in the interior walls of the ventilated chamber allowing air to flow in and out of the ventilated chamber. In this way, pellets in the pellet hopper are insulated from the heat of the combustion chamber and kept below a combustible temperature. A flue is positioned above the combustion chamber of the heater base allowing heat to emanate into the surrounding environment. The flue also has a directed exit for exhaust. A heat deflector affixed to the top of flue also directs heat to a desired surrounding space.
FIG. 1 is a perspective view of a patio heater 100, according to aspects of the present disclosure. The patio heater 100 may include a base 110, a flue 180, and a heat deflector 190. The patio heater 100 may also be referred to as an outdoor heater, a standing heater, a pellet heater, a combustion heater, or any other term. In some aspects, the patio heater 100 may be used to heat an outdoor space. The patio heater may create heat by combustion of various fuels.
In one aspect, the base 110 of the patio heater 100 may house wood pellets. The wood pellets may be both stored prior to combustion and burned within the base 110. The base 110 may include a housing. Chambers withing the housing of the base 110 may serve various purposes. For example, a chamber for pellet storage and a chamber for pellet combustion may be disposed within the same housing of the base 110.
The flue 180 shown in FIG. 1 may include an inner column 185 and an outer shield 187. In some aspects, the inner column 185 may include a lower opening affixed to a combustion chamber of the base 110. In this way, heat from a fire in the base 110 may travel up the inner column 185. The outer shield 187 of the flue 180 may be a grate. For example, the outer shield may include a perforated metal sheet positioned around the inner column 185. In this way, the outer shield 187 may include multiple holes allowing air flow through the outer shield 187. In some aspects, the outer shield may be a grating or a mesh, such as a wire mesh. In some aspects, a purpose of the outer shield 187 may include preventing a user of the patio heater 100 from touching the inner column 185. For example, the material of the inner column may be heated by combustion of pellets within a combustion chamber of the base 110. In that regard, the inner column 185 may be heated to a temperature unsafe for touch. The outer shield 187 may, therefore, protect users of the patio heater 100 from burning.
The heat deflector 190 radiates heat outward and downward from the patio heater 100. In some aspects, the heat deflector 190 may include a circular deflector 194 and a rectangular cap 192. As will be described in more detail with reference to FIG. 2, the circular a lower surface of the circular deflector 194 may radially direct heat emanating from the patio heater 100 in outward and downward directions. In some aspects, the rectangular cap 192 may be of any suitable shape, including a square. The rectangular cap 192 may be positioned above the circular deflector 194. In some aspects, the rectangular cap 192 may be affixed to the circular deflector 194, for example by one or more fasteners.
FIG. 2 is a cross-sectional side view of the patio heater 100, according to aspects of the present disclosure. FIG. 2 illustrates a cross-sectional view along the line 2 shown in FIG. 1. FIG. 2 provides additional details of the base 110, the flue 180, and the heat deflector 190.
As shown in FIG. 2, the base 110 includes a combustion chamber 120, a pellet hopper 140, and an enclosed, ventilated chamber 130. In some aspects, fuel for combustion may be stored in the pellet hopper 140. Wood pellets for use in the patio heater 100 may include compressed saw dust, wood, wood products, various bonders or adhesives, or any other materials. In some aspects, the fuel may include alternative fuels. For example, the pellet hopper 140 may alternatively house charcoal of various shapes, wood of various shapes, or any other combustible fuel.
During a combustion process, pellets housed in the pellet hopper 140 may be moved at various times to the combustion chamber 120. In the combustion chamber 120, the pellets may burn, generating heat. This heat may move to the inner column 185 of the flue 180 and emanate into the surrounding environment.
In some aspects, the enclosed ventilated chamber 130 may separate the pellet hopper 140 from the combustion chamber 120. A chute may deliver wood pellets from the pellet hopper 140 to the combustion chamber 120 as will be described in more detail with reference to FIG. 3. In some aspects, the ventilated chamber 130 may also be referred to as an insulating chamber, a separation, or any other term.
FIG. 2 additionally shows a chamber 145 positioned beneath the pellet hopper 140. In some aspects, the chamber 145 may provide additional ventilation to the patio heater 100 and may prevent inadvertent contact with portions of the heater 100, such as a barrier 141 forming a part of a chute 150 (shown in and described with reference to FIG. 3). In some aspects, the chamber 145 may additionally or alternatively be used for storage by a user of the patio heater. In that regard, a door my provide access to the chamber 145.
As shown in FIG. 2, the flue 180 may be positioned directly above the combustion chamber 120. FIG. 2 includes a vertical axis 195. The vertical axis 195 may define a vertical direction of the patio heater 100. The flue 180 may be co-axially aligned parallel with the vertical axis 195. The flue 180 may additionally be aligned along the vertical axis 195 with a central region of the combustion chamber 120, as shown in FIG. 2. As previously mentioned, the flue 180 may include an inner column 185 and an outer shield 187. A horizontal axis of the patio heater 100 may extend perpendicular to the vertical axis 195.
The inner column 185 may include a column shaped wall that in this implementation has a substantially circular cross-section. Other implementations have cross sections of other shapes, including any of a variety of polygonal and oval shapes. In some aspects, the inner column 185 may be open at a lower end of the inner column. The lower opening of the inner column 185 may be in communication with an upper opening of the combustion chamber 120. In some aspects, heated air and/or exhaust may pass from the combustion chamber 120 into the inner column 185 by this lower opening.
In some aspects, the inner column 185 may have an open top, while in other aspects, the inner column 185 may include a cap at an upper end of the inner column 185.
As shown in FIG. 2, the inner column 185 may include one or more vents 182. The inner column 185 may include any suitable number of vents 182. In addition, the vents 182 may be positioned at any position along the inner column 185. In some aspects, the vents 182 may allow heated air to exit the inner column 185. In this way, the vents 182 may direct heat to a side of the patio heater 100. In addition, the vents 182 may allow exhaust to exit the inner column 185. In some aspects, any of the vents 182 may be selectively opened or closed to direct heat and/or exhaust in various directions from the patio heater 100. The vents 182 may additionally be of any shape or size. In some aspects, various deflecting components or surfaces may be affixed to, or positioned proximate to, the vents 182 to further direct heat and or exhaust in any suitable direction.
The location and dimensions of the vents 182, as well as dimensions of the combustion chamber 120 and inner column 185 may be selected to create a draft moving upward from the combustion chamber 120 through the inner column 185. For example, as hot air rises from the fire pot 160, it escapes through the vents 182 in the top of the chimney and creates an upwards pull through the combustion area below. As heated air is pulled upward and out the vents 182, it forms a vacuum within the combustion chamber 120. This vacuum in turn pulls air from the outside environment through holes in the combustion chamber 120, most notably through the slotted holes or slotted holes 630 (shown in FIG. 6) and the holes 710 (shown in FIG. 7) in the rear of the combustion chamber behind the chute 150. The placement of the slotted holes 630 and holes 710 may result in the draft created by the chimney pulling fresh air through these openings directly in and through the area where the pellets are burning. In this, oxygen to the fire pot is maximized.
As noted with reference to FIG. 1, the outer shield 187 may surround the inner column 185. In some aspects, the outer shield 187 may be formed of any suitable material including steel, carbon steel, aluminum, or any other material. In some aspects, the outer shield 187 may be constructed of a material which is of a low heat conductivity. While the patio heater 100 is in use, the inner column 185, which is directly exposed to the heated air from the combustion chamber 120 may increase in temperature. In some aspects, during use of the patio heater 100, the temperature of the inner column 185 may increase such that it becomes unsafe to touch. The outer shield 187, therefore, may prevent individuals from touching the inner column 185.
In some aspects, the outer shield 187 may allow heat to pass from the inner column 185, through the outer shield 187, and to the surrounding environment. The path of heat from the inner column 185 to the surrounding environment may be illustrated by the arrows 290 shown in FIG. 2. For example, heat may pass from the inner column 185 through the outer shield 187 and outward and upward into the surrounding environment.
A cross-section of the heat deflector 190 is also shown in FIG. 2. As described with reference to FIG. 1, the heat deflector 190 may include the circular deflector 194 and the rectangular cap 192. In some aspects, a lower surface 193 of the circular deflector 194 may reflect heat downward and outward from the inner column 185. In this way, the heat deflector 190 directs heat in a radial direction out from the patio heater 100. For example, as shown by the arrows 292, heat may travel from the inner column 185 through the outer shield 187 and be deflected by the lower surface 193 of the circular deflector 194. In this way, heat is directed downward and outward from the upper region of the patio heater 100. In some aspects, a height of the patio heater may correspond to an average height of users of the patio heater 100, such as between about five and eight feet tall, although other heights are contemplated. As a result, the space beside the patio heater 100, but typically not above the heater, is desired to be heated. As a result, the heat deflector 190 may serve to concentrate heat in the desired space as opposed to spaces above the patio heater 100.
FIG. 3 is a cross-sectional side view of the base 110 of the patio heater 100 and illustrates additional features of the base 110 of the patio heater 100 in more detail.
As shown in FIG. 3, the pellet hopper 140 may include one or more angled barriers 141. The angled barriers 141 may be angled so as to direct pellets through an upper opening 152 of a chute 150 described in more detail hereafter.
In some aspects, the pellet hopper 140 may include a liftable lid 144. Lid 144 may rotate about a joint securing the lid 144 to an edge of the pellet hopper 140, such as the barrier 142. In some regards, the lid 144 may include a handle 146. The handle 146 may be spaced from the heater 100 by a gap 147. This gap 147 may be created by one or more flanges extending from an outer surface of the lid 144. In this way the handle 146 may be insulated from other components of the heater 100. For example, as the combustion chamber 120 increases in temperature, some heat may be transferred to the hopper 140 or the lid 144 of the hopper 140. In such case, the handle 146 may maintain a lower temperature for a longer period of time decreasing the chances of a user of the heater 100 burning themselves when touching the handle 146. The gap 147 may interrupt or slow the transfer of conductive heat from the lid 144 to the handle 146.
In some aspects, a slidable gate 510 may be affixed to a hopper-facing surface of the barrier 142. As will be described in more detail with reference to FIG. 5 hereafter, the slidable gate 510 may selectively allow pellets to pass from the pellet hopper 140 to the combustion chamber 120. In some aspects, the slidable gate may be referred to as a movable barrier.
The chute 150 may include the upper opening 152 previously mentioned as well as a lower opening 154. The chute 150 may be affixed to the pellet hopper 140 at a lower region of the pellet hopper 140. In some aspects, the heater 100 is a gravity-fed heater, and the angled nature of angled barriers 141 of the pellet hopper 140 directs pellets into the upper opening 152 of the chute 150 as the pellets move downward within the pellet hopper 140 by gravity. Similarly, the chute 150 may be angled as shown in FIG. 3 such that pellets which are allowed to pass through the slidable gate 510 move downward along the chute 150 and through the lower opening 154. Pellets which pass out of the lower opening 154 may move into the combustion chamber 120. The chute 150 may be referred to an enclosed chute.
Various components may be included in relation to the chute 150 to control the movement of wood pellets from the hopper 140 to the fire pot 160 or to insulate the hopper 140 from heat generated within the combustion chamber 120. For example, the slidable gate 510 (described in more detail with reference to FIG. 5), may control the movement of wood pellets from the hopper 140 down the chute 150. In addition, a rotating gate 153 may be positioned within the upper opening 152 of the chute 150. In some aspects, the rotating gate 153 may be hingedly affixed to an upper edge of the opening 152 as shown. In that regard, the rotating gate 153 may rotate about the upper hinge in a direction 155 shown in FIG. 3. In this way, the rotating gate 153 may further control the movement of pellets from the hopper 140 to the fire pot 160. In some aspects, the rotating gate 153 may insulate pellets within the hopper 140 from heat of the combustion chamber 120. For example, when pellets within the hopper 140 reach a level such that they do not completely fill the chute 150, the rotatable gate 153 may assume a closed position preventing heat from traveling through the chute 150 and increasing the temperature of the hopper 140 or other components of the heater 100. In that regard, the rotating gate 153 may be moved between an open and closed position by a motorized element or may swing freely.
The combustion chamber 120 may be defined at least by a lower barrier 121, a front barrier 124, an upper barrier 123, and a rear barrier 122. In some aspects, the combustion chamber 120 may be additionally defined by a left barrier 482 (FIG. 4A) and a right barrier 484 (FIG. 4B).
The combustion chamber 120 may house a fire pot 160 at a lower region of the combustion chamber 120. The fire pot 160 may include a fuel grate 162. In some aspects, pellets which pass from the pellet hopper 140, down the chute 150, and into the combustion chamber 120 may be received on the fuel grate 162. The fuel grate 162 may include multiple angled rails as will be described in more detail with reference to FIG. 7.
The fire pot 160 may include four vertically positioned walls defining a box with an open top. In some aspects, the fire pot 160 may be any suitable shape including any number of walls. The walls of the fire pot 160 may enclose the fuel grate 162 such that pellets which pass from the chute 150 are retained within the fire pot 160. The walls of the fire pot 160 may additionally ensure that burning material or ash is kept substantially within the fire pot 160 and does not pass to other areas within the combustion chamber 120.
As shown in FIG. 3, the fire pot 160 and the angled fuel grate 162 may be disposed within an opening in the lower barrier 121 of the combustion chamber 120. This lower opening may allow waste (e.g., ash) from combustion to move downward through the fuel grate 162 clearing the way for new pellets from the pellet hopper 140.
A slidable ash grate 164 may be positioned beneath the angled fuel grate 162, as shown in FIG. 3. In some aspects, the slidable ash grate 164 may prevent burning pellets or fragments of pellets from passing into a removable ash pan 166. The slidable ash grate 164 may include a handle 165. The handle 165 may extend away from the slidable ash grate 164 and be positioned outside of the base 110. In that regard, the handle 165 may be grasped by a user at the front of the patio heater 100 (FIG. 1). In some aspects, as a user of the patio heater 100 slides the handle 165 outward, the slidable ash grate 164 may be moved in a forward direction 295. In this way, the slidable ash grate 164 may be partially or completely removed from the base 110 of the patio heater 100. In some aspects, as the slidable ash grate 164 is thus removed, contents including ashes from burned pellets or any other residue on a top surface of the slidable ash grate 164 may contact a wall of the fire pot. As the contents on the top surface of the slidable ash grate 164 contact the wall and as the slidable ash grate 164 is removed in the forward direction 295, the wall may prevent movement of the content outside the fire pot 160. In this way, after the slidable ash grate 164 is removed, the content which was on the top surface of the slidable ash grate 164 drops into the removable ash pan 166. In some aspects, an angled wall 163 may be included as a wall of the fire pot as shown in FIG. 3. This angled wall 163 may direct material dropping from the grate 162 toward the slidable ash grate 164. In some aspects, the angled wall 163 may be any of the walls of the fire pot or any of the walls of the fire pot may be angled to direct material from the grate 162 as needed.
The removable ash pan 166 may receive contents caught by the slidable ash grate 164 and/or or any other material from the fire pot 160. The removable ash pan 166 may also include a handle 167. The handle 167 may be positioned forwardly of the removable ash pan 166. Like the handle 165, the handle 167 may be grasped by a user at the front of the patio heater 100 (FIG. 1). The removable ash pan 166 may be removed from the patio heater in the forward direction 295 and emptied of its contents during or after combustion of pellets within the combustion chamber 120.
A functional requirement of any pellet burning device may be to ensure that the pellets stored prior to combustion are kept sufficiently cool so as not to reach a combustion temperature. For many pellet burning devices, if stored pellets reach a combustible temperature, they may ignite starting a hopper fire. Hopper fires may be potentially dangerous to the pellet burning device itself as well as users of the device. In the event of a hopper fire, care must be taken to extinguish the hopper fire and use of the device must typically be stopped. In some cases, hopper fires may permanently disable the pellet burning device or require extensive repair to return to a functioning state.
With reference to FIG. 3, the temperature of pellets housed in the pellet hopper 140 should similarly be kept below a combustion temperature. To ensure that the pellets within the pellet hopper 140 remain sufficiently cool, the ventilated chamber 130 may separate the combustion chamber 120 and the pellet hopper 140.
As shown in FIG. 3, the ventilated chamber 130 may include multiple holes 132. The holes 132, as well as any holes described herein, may additionally be referred to as orifices. In some aspects, the holes 132 of the ventilated chamber 130 may provide ventilation and may be referred to as ventilation holes. In some aspects, the holes 132 may additionally provide oxygen to the burning pellets of the combustion chamber 120 (e.g., through the slotted holes 630 of FIG. 6 and/or the holes 710 of FIG. 7). In that regard, the holes 132 may additionally be referred to as combustion holes or combustion air inlets or may serve dual purposes of providing ventilation and combustion. In some aspects, as will be shown and described with reference to FIGS. 4A-4F, each exterior wall of the ventilated chamber 130, as well as some or all interior walls (e.g., the barrier 142 and/or the barrier 122) may include holes like the holes 132 shown in FIG. 3. This configuration allows air flow in and out of the ventilated chamber 130 at multiple locations permitting air flow within the ventilated chamber 130, while still integrating the pellet hopper 140 and the combustion chamber 120 for an integrated form factor. The air flow through the ventilation chamber 130 may help to insulate the pellet hopper 140 from the heat generated within the combustion chamber 120. For example, heat generated from burning pellets within the combustion chamber 120 may increase the temperature of the walls of the combustion chamber, including, for example, the wall 122. As the wall 122 increases in temperature, the air within the chamber 130 may also be heated. This heated air may increase the temperature of the pellet hopper 140 by convection. In addition, conductive heat may pass through components of the base 110 to the pellet hopper 140. In some aspects, when the pellet hopper 140 and combustion chamber 120 are housed within the same base 110, including within the same housing, various barriers or components may be shared by the pellet hopper 140 and the combustion chamber 120. These share barriers or components may increase conductive heat which may pass from the combustion chamber 120 to the pellet hopper 140. The holes 132 may provide ventilation to control temperature increases. By providing air flow within the ventilated chamber 130, the air heated by the wall 122 may be moved out of the ventilated chamber 130 and into the surrounding environment. In addition, barriers and components which are heated may be cooled by the air flow.
Additional aspects of the base 110, including the pellet hopper 140, ventilated chamber 130, and combustion chamber 120 being formed within an integrated housing will be described in greater detail with reference to FIGS. 4A-4F. It may be possible to form the pellet hopper 140 and combustion chamber 120 within an integrated housing in part due to the placement and ventilation characteristics of the ventilated chamber 130.
In some aspects, the base 110 may include six exterior walls, including an upper and lower wall, a front and rear wall, and a left and right wall. The pellet hopper 140, ventilated chamber 130, and combustion chamber 120 may be formed within this housing by the two interior walls 142 and 122 separating the respective chambers, as shown in FIG. 3.
Including the pellet hopper 140, ventilated chamber 130 and combustion chamber 120 within the same housing as shown and described may increase aesthetic value of the patio heater 100 (FIG. 1). In some aspects, having these structures within the same housing also decreases manufacturing complexity and cost. In addition, having these structures within the same housing may increase the structural strength and integrity of the patio heater 100.
In some aspects, the patio heater 100 may additionally include one or more legs 205 and casters 210. The legs 205 may separate the base 110 of the patio heater from a floor on which the patio heater 100 is placed. This separation may additionally aid in increasing air flow beneath the base 110 of the patio heater 100 further controlling component temperatures as well as increasing airflow within the patio heater 100. The casters 210 may promote ease of transportation of the patio heater. For example, a user of the patio heater 100 may tilt the patio heater 100 toward the casters 210 such that the weight of the patio heater 100 is supported by the casters 210. In this position, the patio heater 100 may be easily rolled to different locations.
FIG. 4A is a left side view of the base 110 of the patio heater 100, according to aspects of the present disclosure. The left side of the base 110 may include a barrier 481 and a barrier 482. As shown, the barrier 481 may correspond to a left exterior barrier of the pellet hopper 140 (FIG. 3) and the ventilated chamber 130. The barrier 482 may correspond to a left exterior barrier of the combustion chamber 120 (FIG. 3). In some aspects, the barriers 481 and 482 may be the same unitary structure. In other aspects, the barriers 481 and 482 may be separate structures which are fixedly coupled to one another.
A left side of the ventilated chamber 130 is shown in FIG. 4A. The left side of the ventilated chamber 130 may include multiple holes 431. As shown in FIG. 4A, the holes 431 may be positioned all along the left side of the ventilated chamber 130. For example, holes 431 may extend from a lower region of the left side of the ventilated chamber 130 to an upper region of the left side of the ventilated chamber 130. These holes 431, like the holes 132 described previously, may allow air to pass in and out of the ventilated chamber 130 providing ventilation to the ventilated chamber 130 and/or oxygen for combustion as described with reference to the holes 132 described previously.
FIG. 4B is a right side view of a base 110 of a patio heater 100, according to aspects of the present disclosure. A right side of the base 110 may include a barrier 483 and a barrier 484. Those could be the same barrier in some aspects. In some aspects they may be separate.
The ventilated chamber 130 may be illustrated in FIG. 4B. A right barrier of the ventilated chamber may include multiple holes 132 previously shown and described with reference to FIG. 3.
FIG. 4B is a right side view of the base 110 of the patio heater 100, according to aspects of the present disclosure. The right side of the base 110 may include a barrier 481 and a barrier 482. As shown, the barrier 483 may correspond to a right exterior barrier of the pellet hopper 140 (FIG. 3) and the ventilated chamber 130. The barrier 484 may correspond to a right exterior barrier of the combustion chamber 120 (FIG. 3). In some aspects, the barriers 483 and 484 may be the same unitary structure. In other aspects, the barriers 483 and 484 may be separate structures which are fixedly coupled to one another.
A right side of the ventilated chamber 130 is shown in FIG. 4B. The right side of the ventilated chamber 130 may include multiple holes 132. As shown in FIG. 4B, the holes 132 may be positioned all along the right side of the ventilated chamber 130. For example, the holes 132 may extend from a lower region of the right side of the ventilated chamber 130 to an upper region of the right side of the ventilated chamber 130, as described with reference to FIG. 3.
FIG. 4C is a front side view of the base 110 of the patio heater 100, according to aspects of the present disclosure. The front side of the base 110 may include the barrier 124. The front barrier 124 may include a door 492. The door 492 may provide access to the interior of the combustion chamber 120 (FIG. 3). For example, a user of the patio heater 100 may use the door 492 to access the combustion chamber for maintenance including cleaning or repair.
The door 492 may include multiple holes 433. The holes 433 may provide oxygen to the combustion chamber 120. In some aspects, the holes 433 may allow air to pass into or out of the combustion chamber 120. In that regard, the holes 433 may provide ventilation to the combustion chamber 120 and may be referred to as ventilation holes and/or may provide oxygen for combustion to the combustion chamber 120 to facilitate burning of the pellets and may be referred to as combustion holes or combustion air inlets. In some aspects, the door 492 may include a handle 496. The handle 496 may be grasped by a user of the patio heater 100 (FIG. 1). In some aspects, a user of the patio heater 100 may access the interior of the combustion chamber 120 (FIG. 2) by grasping the handle 496 of the door 492 and pulling the door to an open configuration.
FIG. 4D is a rear side view of the base 110 of the patio heater 100, according to aspects of the present disclosure. The rear side of the base 110 may include the barrier 486. The rear barrier 486 may correspond to the pellet hopper 140 and/or the chamber 145 (FIG. 3). For example, the pellet hopper 140 may be defined by the rear barrier 486, the left barrier 481 (FIG. 4A), the right barrier 483 (FIG. 4B), the lid 144, and the angled barriers 141 (FIG. 3). The chamber 145 (FIG. 3) may be defined by the rear barrier 486, the left barrier 481 (FIG. 4A), the right barrier 483 (FIG. 4B), the bottom barrier 488 (FIG. 4F), and the angled barriers 141 (FIG. 3).
In some aspects, Rear barrier 486 may include multiple holes 434. The holes 434 may allow air flow into and out of the chamber 145. In some ways, as previously described, air flow within the chamber 145 may help to keep temperatures of pellets within the pellet hopper 140 below a combustion temperature. The holes 434 may be referred to as ventilation holes.
FIG. 4E is a top cutaway view of the base 110 of the patio heater 100, according to aspects of the present disclosure. The top view shown in FIG. 4E may illustrate the top barrier 123. The top barrier 123 may include the opening 128 (described with reference to FIGS. 2 and 3) as well as multiple holes 435. In some aspects, the opening 128 may correspond to the combustion chamber 120. As shown in FIG. 4E, the opening 128 may be positioned vertically above the fire pot 160 and angled grates 162 (FIG. 3).
FIG. 4E also shows multiple holes 435. The holes 435 may correspond to the ventilated chamber 130. For example, the holes 435 may be positioned vertically above the ventilated chamber 130 and within the top barrier 123. The holes 435 may allow air to flow in and out of the ventilated chamber 130 and may extend from a left to a right side of the ventilated chamber 130. As described with reference to the holes 132 and 431 previously, the holes 435 may provide ventilation to the ventilation chamber 130 and/or may provide oxygen for combustion within the combustion chamber 120.
FIG. 4E additionally includes a view of the lid 144. The lid 144 may form an upper barrier of the pellet hopper 140 described previously. The lid 144 may provide selective access to the pellet hopper 140. For example, a user of the patio heater 100 may lift the lid 144 in an upward direction about a rotatable hinge. The user may fill the pellet hopper 140 with wood pellets or any other alternative fuels.
FIG. 4F is a bottom view of the base 110 of the patio heater 100, according to aspects of the present disclosure. The bottom view of the base 110 of the patio heater 100 includes an illustration of a bottom barrier 488 of the base 110 of the patio heater 100. Bottom barrier 488 includes holes 436 as well as holes 437. The holes 436 shown may correspond to the ventilation chamber 130. For example, the holes 436 may be positioned along a bottom region of the ventilation chamber 130. The holes 436 may allow air to flow into and out of the ventilation chamber 130. As described with reference to the holes 132 and 431 previously, the holes 436 may provide ventilation to the ventilation chamber 130 and/or may provide oxygen for combustion within the combustion chamber 120.
The bottom barrier 488 may also include holes 437. The holes 437 may correspond to the chamber 145. For example, the holes 437 may be positioned within a bottom region of the chamber 145. The holes 437 may allow air to flow into and out of the chamber 145.
FIG. 5 is a cross-sectional side view of the base 110 of a patio heater 100, according to aspects of the present disclosure. FIG. 5 illustrates a cross-sectional view along the line 5 shown in FIG. 4E. FIG. 5 may correspond to a cross-sectional view along the pellet hopper 140 of the patio heater 100. As shown, FIG. 5 may illustrate a hopper-facing surface of the barrier 142 separating the pellet hopper 140 from the ventilated chamber 130. FIG. 5 also shows the upper opening 152 of the chute 150 (FIG. 3).
As previously described the angled barriers 141 may direct pellets within the hopper through the opening 152. As some pellets within the pellet hopper 140 move through the opening 152, other pellets within the pellet hopper 140 may move downward toward the opening 152.
FIG. 5 also illustrates the slidable gate 510. The slidable gate 510 may include a vertical handle 512. The slidable gate 510 may be affixed to the hopper-facing surface of the barrier wall 142. The slidable gate 510 may be moved in a vertical direction 590, between a closed and an open position. In some aspects, the slidable gate 510 may be positioned within a track 514. The track 514 may be positioned along the hopper-facing surface of the barrier 142. In that regard, the track 514 may provide a space through which the slidable gate 510 may move. In some aspects, the slidable gate 510 shown in FIG. 5 may be in an open position. An open position may correspond to an upper position along the direction 590. A closed position may correspond to a lower position along the direction 590.
With the slidable gate 510 in an open position, pellets within the pellet hopper 140 may be gravity-fed through opening 152, down the chute 150 and into the combustion chamber 120 (FIG. 3). With the slidable gate 510 in a closed position, pellets within the pellet hopper 140 may not pass through the opening 152.
In some aspects, the slidable gate 510 may be coupled to a motor. The motor may be any suitable type of motor. The motor may move the slidable gate 510 along the vertical direction 590. In some aspects, the motor may selectively allow pellets to move from the pellet hopper 140 to the combustion chamber 120. In some aspects, the slidable gate 510 may be moved according to a temperature measured within the combustion chamber 120 or any other metric associated with a fire within the combustion chamber or the pellets within the pellet hopper 140. In some aspects, the slidable gate 510 may be moved between upper and lower positions according to a proportional-integral-derivative (PID) controller.
FIG. 6 is a cross-sectional side view of the base 110 of the patio heater 100, according to aspects of the present disclosure. FIG. 6 illustrates a cross-sectional view of the barrier 122 along the line 6 shown in FIG. 4E. FIG. 6 may correspond to a cross-section along the ventilated chamber 130 of the patio heater 100. As shown, FIG. 6 may illustrate a surface of the barrier 122 separating the ventilated chamber 130 from the combustion chamber 120.
As shown, the barrier 122 may include an opening 610 and multiple slotted holes 630. The chute 150 (FIG. 3) may be positioned within the opening 610 within the barrier 122. In this way, pellets may be moved through the barrier 122 within the chute 150.
In some aspects, the slotted holes 630 may be positioned below the opening 610 and the chute 150 (FIG. 3). In some aspects, the slotted holes 630 may allow air to pass between the combustion chamber 120 and the ventilated chamber 130. The slotted holes 630 may be positioned proximate to the fire pot 160 and/or chute 150. In this way, air for facilitating combustion of pellets may be provided directly to the fire pot. In that regard, the slotted holes 630 may be referred to as combustion holes or combustion air inlets.
FIG. 7 is a cutaway perspective view of components of the base 110 of the patio heater 100, according to aspects of the present disclosure. FIG. 7 illustrates some components of the base 110 of the patio heater 100. Specifically, FIG. 7 includes a view of the angled barriers 141 of the pellet hopper 140 (FIG. 3), the chute 150 directing pellets from the pellet hopper 140 to the combustion chamber 120 (FIG. 3), the fire pot 160, the slidable ash grate 164, and the removable ash pan 166.
As shown in FIG. 7, the chute 150 may include multiple holes 710. In some aspects, the holes 710 may be positioned within a bottom wall of the chute 150. In other aspects, the holes 710 may be positioned within any of the walls defining the chute 150. The holes 710 may align with the slotted holes 630 described with reference to FIG. 6. For example, the holes 710 may be positioned adjacent to and proximate to the slotted holes 630. In that regard, the holes 710 may allow air to pass through the holes 710. In this way, air which passes through the slotted holes 630 between the ventilated chamber 130 and the combustion chamber 120 may also pass through the holes 710 of the chute 150. In some aspects, air passing through the slotted holes 630 and the holes 710 may increase air flow feeding a fire within the fire pot 160. In some aspects, the slotted holes 630 and holes 710 may provide ventilation, including an escape for exhaust or further ensuring that temperatures of the pellet hopper 140 or other portions of the patio heater 100 are kept below a suitable temperature.
As previously described, the fire pot 160 may include the angled fuel grate 162. As shown in FIG. 7, the angled grate may include multiple angled rails. The angled rails may be of any suitable number. In addition, the angled rails of the angled fuel grate 162 may be spaced from one another such that pellets do not pass between the rails but are supported by the rails. However, ashes from burned pellets may pass between the angled rails and drop below to the slidable ash grate 164 and/or the removable ash pan 166.
As previously described, the slidable ash grate 164 may include a handle 165 and may be moved in the direction 790 in and/or out of the base 110 of the patio heater 100 (FIG. 3). In addition, the removable ash pan 166 may include the handle 167 and may be moved in and out of the base 110 (FIG. 3) in the same direction 790.
FIG. 8 is a cross-sectional side view of a patio heater according to aspects of the present disclosure. The patio heater 800 may include any of the same features of the patio heater 100 shown and described previously.
In the example shown, the patio heater 800 may include a base 810, a flue 880, and a heat deflector 890. The patio heater 800 may also be referred to as a patio heater, a standing heater, a pellet heater, a combustion heater, or any other term. In some aspects, the patio heater 800 may be used to heat an outdoor space. The patio heater 800 may create heat by combustion of various fuels.
In one aspect, the base 810 of the patio heater 800 may house wood pellets. The wood pellets may be both stored prior to combustion and burned within the base 810. The base 810 may include a housing. Chambers withing the housing of the base 810 may serve various purposes. For example, a chamber for pellet storage and a chamber for pellet combustion may be disposed within the same housing of the base 810.
The flue 880 shown in FIG. 8 may include a column 885. In some aspects, the column 885 may include a lower opening affixed to a combustion chamber of the base 810 and aligned along the axis 895. In this way, heat from a fire in the base 810 may travel up the column 885. With reference to FIG. 1, the outdoor heater 800 may differ from the heater 100 in that the outdoor heater 800 does not include an outer shield (see e.g., outer shield 187 of FIG. 1). In some aspects, an outer shield of the outdoor heater 800 may be removable by a user and the view shown in FIG. 8 may correspond to a configuration with the outer shield removed.
In some aspects, the column 885 may have an open top, while in other aspects, the column 885 may include a cap at an upper end of the column 885.
As shown in FIG. 8, the inner column 185 may include one or more vents 882. The vents 882 may be similar to the vents 182 described with reference to FIG. 2. In addition, as shown, heat may emanate from the column 885 in directions shown by the arrows 890.
The heat deflector 890 radiates heat outward and downward from the patio heater 800. In some aspects, the heat deflector 890 may include a circular deflector and a rectangular cap. This cap may radially direct heat emanating from the patio heater 800 in outward and downward directions. For example, the path of heat redirected by the heat deflector 890 may be shown by the arrows 892 of FIG. 8 and aspects of the emanation and redirection of heat by the vents 882, and/or heat deflector 890, as well as aspects of creating a draft pulling air into the combustion chamber and up the column 885, may be similar to those described with reference to FIG. 2 previously.
Persons of ordinary skill in the art will appreciate that the implementations encompassed by the present disclosure are not limited to the particular exemplary implementations described above. In that regard, although illustrative implementations have been shown and described, a wide range of modification, change, combination, and substitution is contemplated in the foregoing disclosure. It is understood that such variations may be made to the foregoing without departing from the scope of the present disclosure. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the present disclosure.
Patent Application
20240053021
