Patent Grant
7158716
This invention relates generally to heaters. More specifically, the present invention relates to an elongate electric heater elevated above a support surface in which thermal energy is imparted to exhaust air as it passes through a heating element.
Portable heating devices have been utilized to raise the temperature in a living space for many years. Conventional portable forced hot air heaters for consumer use are well-known and are comprised of an electrical heating element and a fan within a housing. Ambient air is forced to pass through or over the heating element thus raising the temperature of the air. As sufficient air passes through the heating element the ambient temperature of the room is raised as desired.
One type of conventional portable heater is normally low in elevation with respect to a support surface, such as the floor. This low profile increases the distance that the heat must travel (i.e., the heat path) to reach the upper trunk of the users body. The added heat path distance does not produce the desired effect of heating the upper trunk and extremities of the user body efficiently.
Another type of conventional heater utilizes a transverse air impeller assembly. This type of heater attempts to raise the exit height of the hot air exhaust stream with respect to the floor. One drawback of this type of air circulator is that transverse air impeller assemblies typically have several sections which must be coupled together by glue or ultrasonic welding. This assembly must then be balanced to insure correct operation. Transverse air impeller assemblies may also necessitate the use of vibration dampers on the motor. In addition, long transverse air impeller assemblies tend to become misaligned, thereby requiring a special bearing mounted in rubber pads to compensate for the misalignment. The above mentioned problems are exacerbated as the length of the transverse air impeller assembly is increased, which limits the elevation that the heated exhaust stream can be raised above the floor with a conventional tower heater design. These features and associated problems also add significant expense to the manufacturing process. The result is translated into a higher retail price and less desirable comfort levels for the consumer.
Conventional heaters that utilize a centrifugal blower assembly encounter similar manufacturing problems when the impeller length is increased. Shaft length of the motor, impeller balancing and the need for a more powerful motor to rotate the longer impeller increase manufacturing costs. These problems all result in higher retail prices for heaters having long centrifugal blower assemblies.
The design of conventional tower heaters therefore limits the vertical height of the heated exhaust air stream. This is caused, in part, because the cost and complexity of the devices increases as the length of the heating element and/or the length of the impeller increases.
In light of the aforementioned problems there is a need for a forced air heater having a heated exhaust air stream at a height sufficient to shorten the heat path to an upper portion of the user's body. This heating device should have a vertical aspect ratio while using an air generator with an impeller design having the desired air flow characteristics that allow ease of manufacturing and a desirable retail cost for the consumer.
In view of the shortcomings of the prior art the present invention is a portable pedestal electric heater apparatus for providing a heated exhaust air stream at an elevation above a support surface.
According to an aspect of the present invention, the apparatus comprises a tower electric heater and a support riser for supporting the tower electric heater at an elevation above a support surface. The tower electric heater comprises an elongate housing having at least one sidewall, a top end, a bottom end, and a longitudinal length extending substantially upward from the bottom end to the top end; and at least one interior space within the elongate housing. At least one inlet opening in the elongate housing allows inlet air to enter the at least one interior space. An air blower assembly is disposed within the at least one interior space for receiving the inlet air. An air outlet opening in the housing allows the exhaust air stream to exit the at least one interior space. An electric heating element is disposed within the at least one interior space between the air blower assembly and the air outlet opening such that substantially all of the exhaust air stream passes through the electric heating element and thermal energy is transferred from the electric heating element to the exhaust air stream as the exhaust air stream flows through the electric heating element forming the heated exhaust air stream. The support riser comprises a base in contact with the support surface; and at least one riser having a first end and a second end, the first end being connected to the base and the riser extending substantially upward from the first end to the second end, the second end being connected to the bottom end of the elongate housing. The support riser has a rise height defined by a distance from where the base contacts the support surface to the second end of the riser. An elevation of the heated exhaust air stream is defined by a distance from where the support riser contacts the support surface to a vertical midpoint of the air outlet opening in the housing of the tower electric heater, such that the elevation of the heated exhaust air stream is about 14 inches or greater.
According to another aspect of the invention, the air blower assembly further comprises either a centrifugal blower assembly, a transverse blower assembly or an axial fan type blower assembly
According to a further aspect of the invention, the at least one air impeller further comprises a length and a diameter, and a ratio of the length to the diameter is greater than about 2:1.
According to yet a further aspect of the invention, the electric heater further comprises a controller for controlling a function of the portable pedestal electric heater.
According to still a further aspect of the invention, the motor further comprises a variable speed motor having one or more rotational speeds, and the controller controls the rotational speeds.
According to another aspect of the invention, the housing rotates or oscillates relative to the support surface, and the rotation or oscillation is about an axis of rotation, the axis of rotation being substantially aligned with a vertical longitudinal axis of the support riser.
According to yet another aspect of the invention, the axis of rotation of the housing is substantially parallel to the axis of rotation of the at least one impeller.
According to still another aspect of the invention, the axis of rotation of the housing is substantially perpendicular to the axis of rotation of the air impeller.
According to a further aspect of the invention, the electric heater further comprising a mechanism for rotating or oscillating the housing relative to the support surface with the mechanism being disposed between one of i) the first end of the riser and the base, and ii) the second end of the riser and the housing.
According to still a further aspect of the invention, the heater further comprises a grill covering the air outlet opening with air directing vanes that can be positioned to direct the exhaust air stream exiting the housing to a desired location.
According to yet a further aspect of the invention, an overall length of the portable pedestal electric heater is defined by the distance between where the support riser contacts the support surface and the top end of the housing, with the elevation of the heated exhaust air stream being greater than about 65% of the overall length.
According to another aspect of the invention, the rise height is greater than about 15% of the overall length.
According to another aspect of the invention, the rise height is greater than about 3.5 inches.
According to yet another aspect of the invention, the longitudinal length of the housing is less than about 85% of the overall length.
According to still another aspect of the invention, the elevation of the heated exhaust air stream is greater than about 70% of the longitudinal length of the housing.
According to a further aspect of the invention, the rise height is greater than about 25% of the elevation of the heated exhaust air stream.
According to yet a further aspect of the invention, the rise height is greater than about 16% of the longitudinal length of the housing.
According to still a further aspect of the invention, the air outlet opening further comprises an elongate air outlet opening in the at least one sidewall and oriented substantially along the longitudinal length of the housing, the elongate air outlet opening allowing the exhaust air to exit the interior space as an elongate exhaust air stream.
According to another aspect of the invention, the electric heating element is an elongate electric heating element, the elongate electric heating element being disposed proximate the elongate air outlet opening and oriented substantially along the longitudinal length of the housing, and wherein the elongate electric heating element further comprises a vertical aspect ratio defined by a length of the elongate electric heating element being greater than a width of the elongate electric heating element.
According to yet another aspect of the invention, the vertical aspect ratio of the elongate electric heating element is greater than about 2:1.
According to still another aspect of the invention, the elongate electric heating element has a length of about 5 inches or greater.
According to a further aspect of the invention, the elongate electric heating element is a positive temperature coefficient (PTC) heating element capable of producing about 1500 watts of energy.
According to yet a further aspect of the invention, the electric heater further emits a column of heated exhaust air having a flow pattern that substantially conforms to the vertical aspect ratio of the elongate electric heating element.
According to still a further aspect of the invention, the electric heater further comprising a power cord, where the power cord is routed through a central portion of the support riser and exits at a lower portion of the support riser.
According to another aspect of the invention, the support riser comprises an extension of the housing toward the support surface, and wherein the support riser remains assembled to the housing for shipment from a place of manufacturing to a place of sale.
According to yet another aspect of the invention, the electric heater further comprises an axis of rotation about which the elongate housing rotates or oscillates and a longitudinal center axis of the support riser, wherein the axis of rotation and the longitudinal center axis are substantially aligned.
According to still another aspect of the invention, a portable pedestal electric heater apparatus comprises an operating position, in which the portable pedestal electric heater is assembled and ready for operation, and a non-operating position, in which the portable pedestal electric heater apparatus is disassembled and packaged for shipment. In the operating position, the portable pedestal electric heater apparatus comprises a support riser, and a space saving tower electric heater mounted on top of the support riser. In the non-operating position the portable pedestal electric heater apparatus comprises the space saving tower electric heater being disconnected from the support riser and stored in a package for shipment.
These an other aspects will become apparent in view of the following description.
The invention is best understood from the following detailed description when read in connection with the accompanying drawing. It is emphasized that, according to common practice, various features of the drawings are not to scale. On the contrary, the dimensions of various features are arbitrarily expanded or reduced for clarity. Included in the drawings are the following Figures
The following description is of a pedestal electric heater 100 that is preferably portable (e.g., free standing and easily movable). Referring now to
The combination of a tower type electric heater 101 mounted on top of a vertical support riser 130 shortens the heat path between the heating element and an upper portion of the user's body. Since the heat source is further elevated above a support surface and is more closely related to an upper portion of the body, the heat effect to the user is more direct and immediate.
The use of a tower electric heater 101 in conjunction with a support riser 130 to further elevate the heated exhaust air stream allows for flexibility in design of the individual components of the portable electric heater 100 while also providing for cost efficiency. For example, the length of the tower electric heater 101 and the length of the support riser 130 can be manipulated as desired for any particular application in order to obtain the desired heating design characteristics while also minimizing manufacturing cost. By using a support riser, the desired heating characteristics can be achieved at an elevation above a support surface while still maintaining cost efficiency in, for example, the air blower assembly design and the electric heating element design.
The pedestal electric heater 100 having a tower electric heater 101 also provides a space saving design over conventional heater and provides for a lower center of gravity thereby improving stability and minimizing the size of the base required to maintain the pedestal electric heater 100 in an upright position and thus avoid tipping of the apparatus.
Additional details of the structure of the elongate housing having a vertical aspect ratio, the elongate heating element, and the blower assembly impeller design can be found in commonly assigned, application Ser. No. 10/322,169, filed Dec. 18, 2002, entitled “Electric Heater”, which is hereby incorporated by reference in its entirety.
Additional details of the structure of the support riser and the blower assembly impeller design can be found in commonly assigned, application Ser. No. 10/720,374, filed Nov. 24, 2003, entitled “home comfort device” and application Ser. No. 10/431,964, filed May 8, 2003 entitled “home comfort appliance” both of which are hereby incorporated by reference in their entirety.
Referring again to
Disposed within interior space 103 of housing 102 is at least one air blower assembly 110. Air blower assembly 110 includes at least one motor 114 and at least one air impeller 112 connected to motor 114. Air blower assembly 110 may also include, as in this example, blower housing 113 and other components (not shown). The use of air blower assembly 110 preferably allows for the pre-assembly and pre-testing of air blower assembly 110 thereby allowing the manufacture and assembly of portable pedestal electric heater 100 to be less costly when compared to assembling motor 114, air impeller 112 and blower housing 113 into portable pedestal electric heater 100 as separate components. In one embodiment, air blower assembly 110 is a centrifugal type blower. It is contemplated that other types of blowers or fans may be used, such as for example, transverse type blowers or axial type fan.
Also disposed within interior space 103, proximate air exit opening 104 is heating element 116. Preferably, substantially all of the air being discharged from air blower assembly 110 flows through heating element 116. It is contemplated that a portion of the air being discharged from air blower assembly 110 may bypass heating element 116. Such a bypass may be used to allow safety devices, such as for example a thermal cut off, (not shown) to function properly.
As shown in
In one embodiment, heating element 116 uses a Positive Temperature Coefficient (PTC) type heat generation technology. The use of a PTC heating element assures a self-regulating low surface temperature of approximately 450 degrees Fahrenheit [232 degrees Celsius].
The rotation of air impeller 112 causes air to be drawn into housing 102 through air inlet opening(s) 108. The air flow passes through blower assembly 110, passes through heating element 116, and exits housing 102 through air outlet opening 104. As the air flow passed through heating element 116, thermal energy (i.e. heat) is imparted to the air flow.
Preferably, protective grill 106 is located proximate air outlet opening 104. Protective grill 106 is preferably designed to minimize it's impedance of the air flow as it exits portable pedestal electric heater 100 while at the same time protecting portable pedestal electric heater 100 from the internal penetration of foreign objects. Protective grill 106 may include air directing vanes that can be used to control the direction of the heated exhaust air stream as it exits housing 102.
Protective grill 106 may be, for example as shown in
In one exemplary embodiment, an intermediate coupler 128 may be used to couple housing 102 to support column 130. Such a coupler 128 may be either fixed or rotatable. Alternatively, housing 102 may be coupled directly to support column 130 such that housing 102 is fixed with respect to support column 130.
In another exemplary embodiment, housing 102 rotates with respect 20 to support column 130. Such rotation may be accomplished either in an oscillatory fashion (over any angular range that may be desired), a stepwise positioning of housing 102 (either manually or under automated control), or in a constant rotation, either in a clockwise or counter-clockwise direction. As shown, the mechanism for rotation may be located within or below housing 102 and coupled between housing 102 and support riser 130. In yet another embodiment the rotation mechanism may be located between base 134 and riser 132 of support riser 130.
As shown, support riser 130 extends from housing 102 and includes riser 132 and base 134. Support riser 130 may be formed of metal, polymer or other materials. Riser 132 maybe comprised of more than one riser member thus allowing for height adjustability (best described with reference to
Base 134 may be comprised of one or multiple pieces attached to one another. Base 134 may be made of materials such as metals or polymers or a combination of various materials. Base 134 sits on a support surface thus allowing the entire structure of portable pedestal electric heater 100 to be positioned in a substantially vertical, upright and elongate position.
Although the exemplary embodiment shown in
Portable pedestal electric heater 100 may also include a controller, such as control assembly 126 mounted, for example, on (or in the vicinity of) top 107t of housing 102 for controlling one or more functions of the device, such as for example, the speed of blower assembly 110, the rotation or oscillation of the device, power on/off, heat level, etc. Alternatively, control assembly 126 may be mounted in oscillation section 122, a lower portion of housing 102, on riser 132 or on base 134. Alternatively, control of portable pedestal electric heater 100 may be accomplished by a remote control unit (not shown) in conjunction with or as a replacement for control assembly 126.
The position of the control assembly 126 on top 107t of housing 102 on the substantially vertical, upright and elongate structure of portable pedestal electric heater 100 also benefits the user in that the height of the controller above a support surface (floor) allows convenient accessibility for visual inspection and manually adjustment of the controller.
Referring again to
The use of a PTC elongate heating element, for example, requires that the length “L” to width “W” aspect ratio be designed to achieve the proper watt density and flow through characteristics. In general, as length “L” increases, the watt-density decreases, and cost increases for the same width heating element. For example, the use of a 1500 watt PTC elongate heating element limits length “L” of elongate heating element 116a or 116b, in that the watt density within the heating element will not heat the surfaces of heating element 116a or 116b efficiently if length “L” is too long. This inefficient heating will in turn create inefficient heating of the exhaust air stream. This design limitation on the length of the elongate heating element limits the elevation height of a conventional tower heater above a support surface (e.g., floor).
The use of a support riser 130 in pedestal electric heater 100 of the present invention is utilized to overcome this heating element design limitation (as well as other design consideration, as discussed below). Support riser 130 allows length “L” of elongate heating element 116a or 116b to be of a length so as to maintain the desired watt density while at the same time achieving the desired elevation of the heated exhaust air stream above a support surface. (see
The use of elongate housing 102 of tower electric heater 101 in conjunction with support riser 130 provides flexibility in the design and selection of different components of the device, such as the characteristics and type of air blower assembly 110 or heating element 116, and also allows the dimensions of elongate housing 102 and support riser 130 to be manipulated to obtain the desired height for optimizing the delivery of the heated exhaust air stream above a support surface. For example, increasing the length or height RH of the support riser 130 allows housing 102 to have a smaller length or height HL, thereby simplifying the design and manufacturing of air blower assembly 110 and heating element 116. This can save both materials and manufacturing complexity which in turn lowers the cost to the end user.
In one embodiment rise height RH is greater than about 25% of dimension CE. In addition, in another embodiment rise height RH is greater than about 15% of overall length OAL of portable pedestal electric heater 100. In yet another embodiment, rise height RH is greater than about 16% of length HL of housing 102. In another embodiment, length HL of housing 102 is less than about 85% of overall length OAL
In one embodiment dimension CE is greater than about 65% of overall length OAL. In yet another embodiment dimension CE is greater than about 70% of length HL.
In one exemplary embodiment dimension CE is preferably about 14 inches or greater. In another exemplary embodiment, rise height RH is at least about 3.5 inches or greater and may be adjustable as desired. Further, length HL of housing 102 may preferably be between about 14 inches and about 50 inches, while the overall length OAL from the floor to the top of portable pedestal electric heater 100 is preferably about 18 inches or greater, and alternatively between about 18 inches to about 60 inches.
The above dimensional relationships of portable pedestal electric heater 100 allow for elevating the heated exhaust air stream, thus shortening the heat path and promoting the desired effect on the user. These proportional relationships also provide that the length of air impeller 112 will be of a dimension allowing cost effective manufacturing, while yet providing portable pedestal electric heater 100 with the desired vertical elongate aspect ratio. The length of air impeller 112 would also require less power to rotate than a longer air impeller, thus allowing motor 114 to use less materials and be more cost effective. These proportional relationships also provide that heating element 116 will have the desired watt density to efficiently heat the exhaust air stream while yet providing the desired vertical elongate aspect ratio and space saving characteristics, best described with respect to
In one exemplary embodiment oscillation envelope 510 is substantially equal to a maximum width of a horizontal cross-sectional area of housing 102. In another exemplary embodiment the maximum width of a horizontal cross-sectional area of housing 102 is about 12 inches or less. In yet another embodiment the ratio of the length dimension HL of housing 102 to a maximum width of a horizontal cross-sectional area of housing 102 is less than about 1.5:1.
In one exemplary embodiment air impeller 112 has a predetermined diameter and a predetermined length to allow air impeller 112 to have an elongated aspect ratio. In one embodiment the predetermined length to the predetermined diameter aspect ratio of impeller 112 is greater than about 2:1. Maintaining the elongated aspect ratio of air impeller 112 allows it to fit within elongate housing 102 of pedestal electric heater 100.
In one embodiment air impeller 112 is a limited volume impeller. For example, the velocity of the heated exhaust air stream is preferably fixed to effectively reach the user. The desired temperature of the heated exhaust air stream is also preferably fixed to deliver an adequate temperature differential between the ambient air temperature and the temperature of the heated exhaust air stream. Elongate heating element 116 may be for example a PTC heating element with a fixed maximum wattage of 1500W. This fixed wattage requirement along with the fixed temperature and velocity requirements of the heated exhaust air stream determines a fixed watt density requirement of elongate heating element 116. The fixed watt density requirement of elongate heating element 116 is achieved by the proper ratio of length “L” to width “W” of elongate heating element 116. Thus the area of elongate heating element 116 is preferably fixed to have the desired watt density to sufficiently heat the heated exhaust air stream to the desired temperature. Air flow through the heating element may be stated:
Q/A=V
An effective way to limit volume Q of impeller 112 is to reduce its diameter. The limited diameter of impeller 112 also more easily fits within elongate housing 102 of pedestal electric heater 100, thus maintaining the desired vertical aspect ratio.
The vertical aspect ratio of housing 102, allows the oscillating components of portable pedestal electric heater 100 to be substantially on center with support riser 530 along central axis “A” thus increasing the stability of portable pedestal electric heater 100.
The substantially vertical, upright and elongate structure of portable pedestal electric heater 100, (which includes the vertical aspect ratio of housing 102 and preferably includes an elongate heating element 116) helps to minimizes the vertical distance above a support surface, (floor) to the center of gravity of portable pedestal electric heater 100. This structure, along with substantially centering the oscillating components on support riser 530 along central axis “A”, coupled with the reduced effects of gyroscopic precession during oscillation, increase the stability of portable pedestal electric heater 100. This increased stability allows dimension BB of base 134 to be minimized. The minimized dimension BB of base 134 allows portable pedestal electric heater 100 to have further space saving characteristics and, to be easily transported from place to place within a living space or between various living spaces as desired. The minimized dimension BB of base 134 also allows an economization of the size of a shipping package for portable pedestal electric heater 100. The economization of the size of a shipping package allows more units to be shipped in a container, (i.e. truck) and thereby reduces the overall cost per unit of transportation, (see
Dimension BB of base 134 is equal to the maximum width of a horizontal cross-sectional area of base 134. In another exemplary embodiment dimension BB of base 134 is about 18 inches or less for a portable pedestal electric heater 100 having housing 102 with a maximum width of a horizontal cross-sectional area of about 12 inches or less. In yet another exemplary embodiment the maximum width of a horizontal cross-sectional area of housing 102 is less than about 70% of dimension BB.
Air 644 is drawn into blower assembly 610 through at least one inlet opening 108 in housing 102. Exhaust air 645 is discharged from blower assembly 610 into interior space 603 of housing 102. Exhaust air 645 then passes through elongate heating element 116 and is discharged from portable pedestal electric heater 600 as heated exhaust air stream 640. Heating element 116 is located proximate air exit opening 104. Also located proximate air exit opening 104 is protective grill 106.
The location of blower assembly 610 in the lower portion of housing 102 lowers the center of gravity of portable pedestal electric heater 600 in that the weight of motor 614, impeller 612 and blower housing 613 are low with respect to the bottom of support riser 130. This increases the stability of portable pedestal electric heater 600 and allows for the desired vertical elongate aspect ratio, increased height of the heated exhaust air stream, and space saving characteristics.
In contrast,
The substantially vertical, upright and elongate structure of portable pedestal electric heater 100 also benefits user 701 in that the shape of heated exhaust air stream 740 may be elongate and vertical as it exits housing 102. An elongate and vertical shape of heated exhaust air stream 740 generally conforms to the human body.
As shown in
Although the invention has been described with reference to exemplary embodiments, it is not limited thereto. Rather, the appended claims should be construed to include other variants and embodiments of the invention, which may be made by those skilled in the art without departing from the true spirit and scope of the present invention.
This application claims priority to provisional application No. 60/523,369, filed Nov. 19, 2003. This application is also a Continuation-in-Part of application Ser. No. 10/720,374, filed Nov. 24, 2003, which is a Continuation-in-Part of application Ser. No. 10/431,964, filed May 8, 2003 now U.S. Pat. No. 6,942,456, which is a Continuation-in-Part of application Ser. No. 10/347,079, filed Jan. 17, 2003, which is a Continuation-in-Part of application Ser. No. 10/322,169, filed Dec. 18, 2002 now U.S. Pat. No. 6,760,543.
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| Number | Date | Country | |
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| Number | Date | Country | |
|---|---|---|---|
| Parent | 10720374 | Nov 2003 | US |
| Child | 10855697 | US | |
| Parent | 10431964 | May 2003 | US |
| Child | 10720374 | US | |
| Parent | 10347079 | Jan 2003 | US |
| Child | 10431964 | US | |
| Parent | 10322169 | Dec 2002 | US |
| Child | 10347079 | US |
