The invention relates to a heater, and in particular a heating assembly having a fan positioned directly behind the heating elements of the heating assembly to direct airflow across and through the heating elements.
Space heaters for heating air are well known in the art, and are usually sold as portable, free-standing units. Space heaters may include many types of heating elements, such as heating coils, ceramic heaters, and/or PCT heaters, to name a few. Space heaters often use blowers or fans to push or pull air, once heated, out of a heating chamber. Most personal space heaters, and in particular fan heaters, having open grills on both the front and back of the heater, place heating elements in the back of the space heater and use a fan to draw air in from the back of the heater, across the heating elements, and then push the hot air out the front of the grill with the fan positioned in the front of the heating element(s) relative to the direction of the air flow.
Portable electric space heaters continue to have problems with distributing heat over large areas. Accordingly, a need still exists for a compact, portable electric space heater that is capable of both increased air velocity and increased temperature outputs over those in the prior art.
A portable space heater is provided having a heating assembly that includes at least one heating element positioned in front of a fan (defined by the direction of the air flow with the air blowing toward the front) such that the heating element is in linear alignment with the fan along the axis of rotation of the fan. The fan and the at least one heating element may be further positioned within a duct assembly that narrows as it approaches a front grill of the portable space heater.
In one example, a space heater is provided that includes a heater housing having a front grill and rear grill; a fan positioned near the rear grill of the heater housing; at least one heating element positioned in front of the fan behind the front grill of the heater housing where the heating element and the fan are linearly aligned; and a duct assembly positioned within the heater housing surrounding both the fan and the heating element where the duct assembly gradually decreases in circumference as it approaches the front grill of the heater housing.
In another example, the space heater may include a heater housing having a front grill and rear grill and a heating assembly. The heater assembly includes a fan having at least two fan blades having fronts and tips and at least one circular heating element positioned in front of the fan where the center of the circular heating element is on the axis of rotation of the fan and where the diameter of the circular heating element extends across the fronts of the fan blades not beyond the tips of the fan blades. The heating assembly is further positioned within the heater housing such that the heating element is behind the front grill of the heater housing and the fan is near the rear grill of the heater housing.
In yet another example, the space heater may include a heater housing having a front grill and rear grill and a heating assembly. Here, the heater assembly may include a fan having a fan hub and fan blades, where the fan blades have fronts and tips and at least one ring shaped heating element positioned in front of the fan where the center of the ring shaped heating element is on the axis of rotation of the fan and where the ring shaped heating element is in linear alignment with the fan such that the at least one ring shaped heating element is positioned between the hub of the fan and the tip of the fan blades. Again, the heating assembly is positioned within the heater housing such that the heating element is behind the front grill of the heater housing and the fan is near the rear grill of the heater housing.
In all the examples above, the heating elements may include one or more ring shaped heating elements, and fan may include a fan hub and two or more fan blades each having fronts and tips. The one or more ring shaped heating element may be positioned in front of the fan where the center of the one or more ring shaped heating elements is on the axis of rotation of the fan and is in linear axial alignment with the fan such that the one or more ring shaped heating elements are aligned between a hub of the fan and the tips of the fan blades. In certain examples, at least two ring shaped heating elements are included. The ring shaped heating elements may take the form of a heating ribbon, which heating ribbon may include ceramic heating elements, coil heating elements or wire heating elements. The ring shaped heating element may further be wire coil or other heating elements generally known in the art.
In all examples, the fan and the at least one heating element may be in communication with a controller that is programed to operate the fan either with, or independent of, the at least one heating element.
In all examples that include a heating assembly, the heater housing may further include a duct assembly positioned within the heater housing enclosing the heating assembly where the duct assembly gradually decreases in circumference as it approaches the front grill of the heater housing.
In all examples, the space heater may further include a motor having a shaft positioned between the at least one heating element and the fan, where the fan is affixed to the shaft of the motor and where the at least one heating element is mounted to the motor on the side of the motor opposing the shaft. The at least one heating element may further be affixed to a barrel mount, where the barrel mount is mounted to the motor.
In the above examples, with the fan positioned behind one or more heating elements, the fan pushes air across the one or more heating elements and out the front of the space heater. This configuration allows the heat produced by the coils to move faster and travel farther than other known prior art personal heaters. In this arrangement, the fan can also be operated separate from the one or more heating elements to enable a fan only option. When more than one heating element is used, the heating elements can be operated together or independently to vary heat production and/or may be operated at different levels.
As described in further detail below, the fan blades may further be designed, as illustrated in
Other devices, apparatus, systems, methods, features and advantages of the invention are or will become apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description, be within the scope of the invention, and be protected by the accompanying claims.
The invention may be better understood by referring to the following figures. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention.
As illustrated in the attached
In the context of this application, when the fan 310 is described as being “directly” behind the heating elements 302, 304 or the heating elements 302, 304 “directly” in front of the fan 310, it means that while there can be intermediary parts positioned between the fan 301 and the heating elements 302, 304, there should be nothing between the fan 310 and the heating elements 302, 304 to substantially obstruct or redirect the air flow from the fan 310 to the heating elements 302, 304. In other words, the fan 310 should be permitted to blow air directly on to the heating elements 302, 304. The positioning of mounting brackets or other mechanisms of attachment between the elements does not change one being deemed directly in front of the another.
The front housing 102 further includes a front grill (or vent) 108 and a control panel 110. The rear housing 202 further includes a rear grill (or vent) 200. The portable space heater 100 is supported at its base 114 by supports 112, which includes a pressure switch 204 that triggers an anti-tilt switch 322 that automatically shut off the portable space heater 100 in the event the portable space heater 100 is tipped over.
The internals of the portable space heater 100 are best shown in
The portable space heater 100 further includes a printed circuit board (“PCB”) 314 having integrated circuit(s), a processor and/or controller is provided that is in communication with a power source (not shown). The first PCB 314 is also in communication with the motor 312 and first and second heating elements 302, 304 to control the operation of the motor 312 and first and second heating elements 302, 304. A second PCB 316 having an integrated circuit(s), controller and/or processor is also provided for the control panel 110, which includes, in addition to the second PCB 314, an LCD display, circuit board cover 318 with user controls and a protective cover 320.
Next we turn to a discussion of the heating assembly 400 contained within the front duct 300 and rear duct 301 of the front and rear housing 102, 202 of the portable space heater 100.
For purposes of reference and description, the heating assembly 400 is considered to have an assembly axis, which is represented by line A-A of (
Terms such as “axial” and “axially” are assumed to refer to the assembly axis or any direction or axis parallel to the assembly axis, unless indicated otherwise or the context dictates otherwise. In this disclosure, the plane orthogonal to the assembly axis is referred to as the transverse plane. For convenience, movement relative to the assembly axis may alternatively encompass movement relative to an axis that is parallel to the assembly axis that is specifically illustrated in
In one example, the assembly axis may be oriented at an angle perpendicular to, or at an obtuse (more than 90 degree) angle relative to, a ground surface on which portable space heater is disposed or is intended to be disposed (e.g., a tabletop, desktop, shelf, floor, etc.). From the perspective of
The heating assembly 400 includes one or more heating elements, which in this example are heating elements 302, 304, and which are positioned directly behind the front grill 108 of the portable space heater 100. The heating elements 302, 304 are mounted on the exterior of a circular barrel mount 306, the center of which is aligned about the assembly axis. The barrel mount 306 has a terminal box 313 for electrically connecting the heating elements 302, 304 to a power supply (not shown) through the first PCB 314. The motor 312 is interposed between one side of the barrel mount 306 and the fan 310. The barrel mount 306 is mounted on a first side of the motor 312. Directly opposing its first side of the motor 600 is a shaft 602 upon which the fan 310 mounted. Operation of the motor 312 rotates the shaft 602, which rotates the fan 310.
The motor 312, having both the barrel mount 306 and fan 310 affixed thereto, is secured to the mounting bracket 308, which is mounted on its ends through holes 402 on the first duct 300 (
The motor 312 and heating elements 302, 304 are electrically connected and in communication with the first PCB 314 to control and provide power to the heating elements 302, 304, motor 312, and conversely the fan 310.
As best illustrated in
As illustrated in
The axis of rotation of the fan 310 runs through the center point of each heating element 302 and 304 defined by the center of the concentric rings of the heating element 302, 304. The diameter across the concentric rings of the heating element 302 and 304, along with the height of the U-shaped wire heating elements 504 is design to position the U-shaped wire heating elements 504 in linear alignment with the front face of the fan blades 404 across the assembly axis.
Further, in the illustrated example, the U-shaped wire heating elements 504 do not extend past the tips 800 of the fan blades 404, but rather extend only to the point just prior to where the fan blades 404 start to bend forward. Accordingly, the heating elements 302, 304 are in linear alignment with the fan blades 404 across the rotational axis of the fan 310, such that the heating elements 302, 304 are positioned directly in front of the fan blades between the hub 802 of the fan 310 and the bend 406 of the distal end of the fan blade 404. In other words, the heating elements 302, 304 are linearly aligned with the fan blades 404 between the hub 802 of the fan 310 and the tip of the fan blade 800 or, more particularly, between the hub 802 of the fan 310 or the bend 406 on the fan blade 800 at its distal end. As designed, air flow produced by the fan is directed through and across the heating elements 302, 304.
Alternatively, the diameter of the heating elements 300, 302 may be equal to or lesser than the fan 310 diameter, such that the heating elements 300, 302 are positioned at or just inside the circumference of fan 310 as defined by the fan blades 404 when rotating. Further, the heating elements 302, 304 are not required to be ring shaped, but could be linear, block or circular in shape and may be positioned in the front of the hub 802 of the fan 310 such that all or at least part of the heating elements are in alignment with the hub 802 of the fan 310 and extend to the bend of the distal end 406 of the fan blade 404, to the tip 800 of the fan blades 404, or beyond.
The wing-tip formation of the fan blades 404 is best illustrated in
As illustrated in
In
By gradually reducing the circumference, the air flowing through the duct assembly 1000, as it moves from back to front, is compressed and thus increases in velocity as it exists the duct assembly 1000. The front duct 300 and back duct 301 are held together by fasteners 1002, and the entire duct assembly 1000 is secured to the housing by mounting members 1004. The mounting bracket 308 is positioned between the front and rear ducts 300, 301 and is fastened to at least one of the front or rear ducts 300, 301. As shown in
While one or more heating elements 302, 304 can be used in the heating assembly 400 described above, the use of more than one heating element provides for the capability of producing heat at various settings, for example, at least two settings. In any event, at least one heating element is required. The at least one heating element is not limited to the heating element described in this application. Those skilled in the art will recognize that other heating elements, such as heating coils, ceramic heaters, heating ribbons, PTC heaters or other heaters generally known in the art may be used without departing from the scope of the invention.
In operation, the fan 310 can also be operated separate from the heating elements 302, 304 coils, to enable a fan only option. Further, the heating coils 302, 304 can be operated together or independently to vary heat production and/or may be operated at different levels. For example, a low heat setting may be 750 Watts and a high heat setting may be 1500 Watts.
Further, when used with the duct assembly 1000, it is not required that the heating elements 302, 304 be equal to or lesser than the fan 310 diameter. In some implementations, the heating elements 302, 304 could extend past the end of the fan blades 404.
As set forth above, the heating assembly 400 and duct assembly 1000 can be contained in housings of varying designs, and may include a cool-touch casing, auto shut-off feature, tip-over protection and/or controls for adjusting the heat settings and controlling the fan operation separate from the heating elements.
Optionally, the fan 310 can operate at a single speed, or at various speeds. The heating elements may be a single heating element or may include one or more heating elements to provide further heat settings. Temperature controls may also be provided, along with a temperature sensor to shut off and activate the heater depending upon the room temperature (i.e., to provide an auto climate feature). The heater may also include a timer, a light, a LED display, manual controls, bedtime light dimming features, and/or cord storage. Standard electrical components are also provided, although not shown, to provide electricity to the fan motor and heating elements and to the control the operation of the same.
It will be understood that terms such as “communicate” and “in . . . communication with” (for example, a first component “communicates with” or “is in communication with” a second component) are used herein to indicate a structural, functional, mechanical, electrical, signal, optical, magnetic, electromagnetic, ionic or fluidic relationship between two or more components or elements. As such, the fact that one component is said to communicate with a second component is not intended to exclude the possibility that additional components may be present between, and/or operatively associated or engaged with, the first and second components.
It will be understood that various aspects or details of the invention may be changed without departing from the scope of the invention. Furthermore, the foregoing description is for the purpose of illustration only, and not for the purpose of limitation—the invention being defined by the claims.
This application claims priority to U.S. Provisional Patent Application Ser. No. 63/245,195, having a filing date of Sep. 16, 2021 and titled Heater Assembly, which application is incorporated into this application in its entirety.
Number | Date | Country | |
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63245195 | Sep 2021 | US |