The present invention relates to portable heating units in particular to a portable heating unit with pre-start indicator.
In the drawings, like reference characters generally refer to the same parts throughout the different views. Also, the drawings are not necessarily to scale, emphasis instead generally being placed upon illustrating the principles of the invention.
It is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless limited otherwise, the terms “connected,” “coupled,” “in communication with” and “mounted,” and variations thereof herein are used broadly and encompass direct and indirect connections, couplings, and mountings. In addition, the terms “connected” and “coupled” and variations thereof are not restricted to physical or mechanical connections or couplings.
The term “controller” is used herein generally to describe various apparatus relating to the operation of one or more heater components and indicator elements. A controller can be implemented in numerous ways (e.g., such as with dedicated hardware) to perform various functions discussed herein. A “processor” is one example of a controller which employs one or more microprocessors that may be programmed using software (e.g., microcode) to perform various functions discussed herein. A controller may be implemented with or without employing a processor, and also may be implemented as a combination of dedicated hardware to perform some functions and a processor (e.g., one or more programmed microprocessors and associated circuitry) to perform other functions. Examples of controller components that may be employed in various embodiments of the present disclosure include, but are not limited to, conventional microprocessors, application specific integrated circuits (ASICs), and field-programmable gate arrays (FPGAs).
In various implementations, a processor or controller may be associated with one or more storage media (generically referred to herein as “memory,” e.g., volatile and non-volatile computer memory such as RAM, PROM, EPROM, and EEPROM, floppy disks, compact disks, optical disks, magnetic tape, etc.). In some implementations, the storage media may be encoded with one or more programs that, when executed on one or more processors and/or controllers, perform at least some of the functions discussed herein. Various storage media may be fixed within a processor or controller or may be transportable, such that the one or more programs stored thereon can be loaded into a processor or controller so as to implement various aspects of the present invention discussed herein. The terms “program” or “computer program” are used herein in a generic sense to refer to any type of computer code (e.g., software or microcode) that can be employed to program one or more processors or controllers.
The term “user interface” as used herein refers to an interface between a human user or operator and one or more devices that enables communication between the user and the device(s). Examples of user interfaces that may be employed in various implementations of the present disclosure include, but are not limited to, switches, potentiometers, buttons, dials, sliders, a mouse, keyboard, keypad, various types of game controllers (e.g., joysticks), track balls, display screens, various types of graphical user interfaces (GUIs), touch screens, microphones and other types of sensors that may receive some form of human-generated stimulus and generate a signal in response thereto.
Furthermore, and as described in subsequent paragraphs, the specific mechanical or electrical configurations illustrated in the drawings are intended to exemplify embodiments of the invention and that other alternative electrical and mechanical configurations are possible.
The portable forced air heating unit 10 depicted in the figures provides for an alarm, warning, or pre-start indicator element 20 that includes, but is not limited to, an audible and/or visual indicator or alarm, 24 and 22 respectively, occurring for a predetermined time period to give an alert or warning of imminent heater startup or heat production. The indicator element 20 emits an attention identifier sufficient to call attention to the operator and any bystanders while in a variety of heater environments and portable heater modes. The attention identifier may be, but is not limited to, visual, audio, vibratory, combinations thereof, or other sensory emissions. The predetermined time period and/or the pre-start indicator element 20 may allow those in close proximity to the portable heater to reposition themselves relative to the heater, move materials or devices away from the heated airflow, or make changes to the heater operation, such as but not limited to, repositioning the heater, stopping the operation of the heater, changing between modes such as manual or thermostat, or making input adjustments indirectly or directly.
Portable forced air heaters conventionally include a housing, a burner head assembly mounted within the housing, and an air blower system within the housing behind the burner head assembly. Fuel (kerosene, fuel oil, or diesel fuel, etc.) is conveyed to the burner head assembly and combustion chamber. The blower supplies combustion air to the burner head assembly and forces hot combustion gases from the burner head assembly while cooling the exterior of the burner head assembly and combustion chamber. Although a kerosene forced air heater is shown in detail it is understood that the embodiments of the invention may be used in any type of portable forced air heater such as, but not limited to, a gas or multi-fuel forced air heater.
As shown in
Elongated housing 50 is generally cylindrical and may support a combustion chamber assembly 40, best shown in
During operation of heating unit 10, air is drawn from the surrounding environment through inlet end 12 of housing 50, heated, and then forced out of outlet end 14 to heat the surrounding environment. Burner head assembly 80 includes an air line 82 in fluid communication with the motor and pump assembly 90. Motor 91 drives a fan 92 to draw air from the back of the unit or inlet end 12 in order to circulate or push air into and around a combustion chamber assembly. When pushed air circulates around the combustion chamber assembly through the annular spacing 45a, 45b the housing wall 50 is cooled. Air may be circulated through a rear plate 48 when entering combustion chamber assembly 40. A mixture of fuel and air is routed into a nozzle 85 adjacent the combustion chamber 44 through burner head assembly 80 where it is burned in a combustion process via an igniter 84. The fuel may be delivered to the combustion chamber 44 through fuel line 82 in the form of oil droplets formed by an atomizing process. Regardless of the atomizing process, however, incomplete combustion may occur within the combustion chamber 44 due to non-uniformity in size of the fuel droplets or an uneven mixing of the fuel droplets with air. Combustion chamber outlet end 44a provides the discharge end for combustion chamber 44, and the afterburner 46 is positioned adjacent the outlet end 44a of the chamber 44 for burning fuel particles which are not burned within the combustion chamber 44 to reduce the likelihood that unburned fuel particles will be discharged from heater 10 and enter the surrounding environment. The air is heated and provides a stream of clean, hot air out of the exit or outlet end 14 of unit 10. Air circulated between the combustion chamber assembly 40 and housing 50 cools the burner head assembly 80, combustion chamber assembly 40, and housing 50.
As shown in
The pre-start indicator elements 20 will emit the attention identifier to alert the operator and/or bystanders in the vicinity of the heater 10 in each one of the manual mode 32 and thermostat mode 33. It is understood that an embodiment of the portable heater 10 may have one or both of the manual and thermostat modes 32 and 33 and still include one or more pre-start indicator elements 20. While in the manual mode 32, the portable heater's heat production or heated airflow output will be preceded by the output or alert of one or more indicator elements 20. For instance in use, once the heater 10 is turned on and in the manual mode 32, the indicator element 20 will sound and/or display for the predetermined time period before ignition. Further while in thermostat mode 33, the portable heater's heat production or output will be preceded by the one or more indicator elements 20 when the ambient value is less than the user set point input. Alternatively, if the ambient value is greater than the user set point input, the igniter 84 and heater is turned off and the predetermined time period of the indicator element may not occur until the subsequent temperature condition for startup is met. As a result, a portable heater 10 equipped with a thermostat while in the thermostat mode 33 may startup at various times and the one or more indicator elements 20 may advantageously alert or warn bystanders via the attention identifier in each occurrence that there is an imminent or automatic heater startup.
A depicted in
One such sensor element that could comprise sensor element 66, in whole or in part, is a thermostat. The thermostat may have an appropriate location to obtain the data or ambient temperature. The temperature obtained by the thermostat is used by the controller 62, among other things, to compare to the set point temperature to obtain the desired temperature of the surrounding environment of the portable heater.
Another sensor element 66 could be a photo sensor 83 such as a fast photocell, a light sensitive resistor, or a fiber optic cable connected to a phototransistor, photoresistor, or photodiode. An example of such a photo sensor 83 is shown most clearly in
Another sensor element 66 could be a line voltage sensor such as a voltage divider monitored by controller 62. If the voltage monitored by controller 62 is too high or too low, controller 62 may remove power or prevent power from being applied to igniter 84 to prevent damage to the components and a message or a code indicating high voltage may be displayed visually or audibly.
Other sensors that may form part of sensor element 66 may include a carbon monoxide sensor or carbon dioxide sensor incorporated to monitor air quality and programmable timers to turn the heater on or off. Again, the entirety of the sensors described and their placement in the forced air heater 10 are merely exemplary of the multitude of sensors that could be placed in a multitude of places and could form in whole or in part sensor element 66. Additionally, the controller 62 may utilize data from any given sensor or heater component in a plurality of ways to operate the heater unit 10.
Controller 62 could also execute instructions to effectuate a delay lockout period to prevent rapid on and off cycling of heater 10 or a stabilization period during manual mode 32 for temperature adjustments to take effect. After a predetermined amount of ignition failures, the delay lockout period would prevent forced air heater 10 from restarting for a predetermined amount of time to allow any unburned fuel to escape combustion chamber 44 and to allow combustion chamber 44 to cool for a predetermined amount of time.
Each interface in communication with the controller 62 may be the interface that could comprise the user interface 30 in whole or in part. One such interface is an On/Stop button 34 to turn on and off the heater 10. Further another user interface 30 is the Mode/Reset button 35 that can cycle between the thermostat mode 33 and manual mode 32 as well as reset the heater. The actuation of buttons or user interfaces by the user may cause voltage change received at controller 62 (e.g., 0, +5V). Appropriately as shown in
In use to start the portable heater 10 according to one embodiment, the user pushes the On/Stop button 34 to ON after the portable heater 10 has power. While being in manual mode 32, the one or more indicator elements 20 including the audible and visual indicator elements 24 and 22, respectively, will sound and display a start countdown to ignition. However, it is understood that another portable heater embodiment may have only one of the audible or visual indicator elements 20 instead of using both as is shown. Upon the lapse of the predetermined time period, approximately 8 seconds, the portable heater 10 will start and the pump pressure will be displayed for approximately six seconds on display 31. The pump pressure 38a indicator light will also be illuminating during the six second display. With the manual mode LED 32a on, the user may adjust the desired setting on the display 31 by pressing the increase adjustment button 36a to raise the BTU output or press the decrease adjustment button 36b to lower the BTU output. Further upon startup, the heater BTU output can be adjusted, but the adjustments may not take effect for a time period of approximately two minutes in order to allow for heater stabilization. Alternatively when the thermostat mode LED 33a is on, the user may change the thermostat set point temperature on the display 31 higher by pressing the increase adjustment button 36a and lower the set point by pressing the decrease adjustment button 36b. If the thermostat set temperature is higher than the surrounding air temperature, more specifically by three degrees, the heater will ignite after the pre-start indicator elements 20 alert of the imminent start of heat production as described above in the manual mode. However, if the thermostat set point is lower than the surrounding air temperature, the heater will not ignite. Heater output will adjust automatically to maintain the set temperature in the thermostat mode 33. As such, each automatic heater start that occurs over a time period, dependent on the thermostat, may include the pre-start indicator elements 20 to alarm and call attention to the bystanders and/or users before the imminent heat production or ignition. Further, when operating in the thermostat mode 33, the user may press the Mode/Reset button 35 once to change to manual mode 32. Also, when operating in the manual mode 32, the user may press the Mode/Reset button 35 twice within five seconds to change to the thermostat mode 33. Also, the display 31 not only shows the visual indicator element 22 but may show the set temperatures, surrounding temperatures, pressure, and BTU output temperatures when the user is adjusting the inputs of the user interfaces 30 or checking the status of these conditions.
Moving now to the flow chart of
Further, although the one or more indicator elements 20 are described and shown as emitting a attention identifier to alert individuals of the imminent start of heat production from a portable heater, it merely represents one embodiment, and it is to be understood that the indicator elements may alert or produce the attention identifier for a variety of other portable heater conditions. For example, fault or abnormal portable heater conditions may be desired to be communicated to the operator or bystanders. Fault conditions or abnormal heater conditions may be, but are not limited to, events such as when the motor does not start after the heater is plugged in and the on/stop button is on, motor starts and runs but heater does not ignite, heater ignites but control assembly shuts heater off before running out of fuel, high or low voltage, high or low pressure, high or low temperature, improper electrical connection, no ignition, improper or extinguished flame, high or low fuel, user interfaces are stuck, and other general problems that may occur when the heater is running or not running. For example in use while normally the operator could believe a stopped heater may be in a thermostat mode awaiting the automatic start of the heater, an audible attention identifier as described above may alert the operator that the heater has actually shut down for an unexpected problem or abnormal condition, such as no fuel. As a result, the operator may be advantageously alerted of the abnormal condition and remedy the condition. Alternatively, the indicator elements and its attention identifiers may alert or communicate desirable or normal portable heater data or conditions to the operator while the heater is running or not running.
It is understood that while certain embodiments of the invention have been illustrated and described, it is not limited thereto except insofar as such limitations are included in the following claims and allowable functional equivalents thereof.
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