The invention may be more completely understood in consideration of the following detailed description of various embodiments of the invention in connection with the accompanying drawings, in which:
The present invention pertains to a thermoelectric fan, specifically, a shrouded circulating air moving member, such as a fan blade, powered solely by the conversion of heat from a separate heater into electricity via an integrated thermoelectric module. The present invention also pertains to a self-powered fan that can safely perform in hazardous atmospheres. The thermoelectric fan of the present invention enables the air within a given space to be more effectively distributed and ensures that the temperature gradients are minimized. The thermoelectric fan is suitable for use with various types of radiation-based heaters, particularly catalytic heaters.
The term “hazardous atmospheres”, as used herein, refers to atmospheres containing concentrations of explosive and/or flammable gases.
It is to be understood that the singular forms of “a”, “an”, and “the”, as used herein and in the appended claims, include plural reference unless the context clearly dictates otherwise.
The thermoelectric fan of the present invention is configured and designed for improved efficiency and greater safety. Whereas thermoelectric fans in the prior art are designed to operate based on conductive heat transfer through direct physical contact with a heated surface on the heater, the thermoelectric fan of the present invention is designed for efficient operation with radiant-based heaters, particularly, catalytic heaters. The present invention comprises features useful for securing the fan to a radiant-based heater. In a preferred embodiment, the thermoelectric fan is used with a catalytic type radiant heater. The present invention comprises the features to efficiently transfer radiant heat from the catalytic heater into a component of the fan while maintaining high heater efficiency. The present invention also comprises energy limiting components that eliminate the potential for an ignition or an explosion when operating in a hazardous atmosphere. The thermoelectric fan of the present invention involves the movement of a single airflow stream across a heat exchanger surface and then across the heated surface of the heater.
The thermoelectric fan 100 of the present invention, as illustrated in
The thermal plate sub-assembly 102, shown in detail in
The thermal plate 301 is insulated on the side opposite the heater with an insulation sheet 302 comprising a shape and size consistent with that of the thermal plate 301. The insulation sheet 302 prevents the airstream exiting from the housing sub-assembly 102 from cooling the thermal plate 301. If the airstream directly impacts the thermal plate 301, then the thermal plate 301 temperature is reduced due to the heat transfer from the thermal plate 301 to the airstream. The reduction of thermal plate 301 temperature results in a loss of the required thermal gradient between the thermal plate 301 and the thermoelectric module 202, and a resulting loss in performance of the thermoelectric fan 100. The insulation sheet 302 has a thickness in the range of from about 0.0625 in. to about 1.0 in. In a preferred embodiment of the present invention, the insulation sheet 302 comprises a hole in the center to facilitate the attachment of and thermal communication between the thermal plate 301 and the heat exchanger disk 204. In an alternate embodiment, the insulation sheet 302 comprises a thermally conductive section, rather than a hole, to facilitate the thermal communication between the thermal plate 301 and heat exchanger disk 204. The insulation sheet 302 improves the efficiency of the thermoelectric fan of the present invention by minimizing loss of heat due to the cooling effect of the airflow as it exits the fan housing 201 and blows against the thermal plate 301. In a preferred embodiment, the insulation sheet 302 is secured against the thermal plate 301 and protected from damage via an insulation shield 303. The insulation shield 303 can comprise any suitable rigid or stiff material, such as a metallic material or a plastic material. In a preferred embodiment, the insulation shield 303 is thin and comprises a metallic material. The insulation shield 303 has a thickness in the range of from about 0.01 in. to about 0.125 in. In a preferred embodiment, the insulation shield 303 comprises a hole in the center to facilitate the attachment of the thermal plate 301 to the heat exchanger disk 204. The insulation shield 303 holds the insulation sheet 302 firmly against the thermal plate 301, thus improving the insulation effectiveness and providing protection to the insulation sheet 302 when the thermoelectric fan 100 is handled and is in operation. In one embodiment of the present invention, the insulation sheet 302 is attached to the thermal plate 301 via an adhesive, and in another embodiment, the insulation sheet 302 is a sprayed-on insulation resulting in the insulation sheet 302 and the thermal plate 301 forming one component rather than the insulation sheet 302 being separate and distinct from the thermal plate 301; the configuration of these two embodiments obviates the need for an insulation shield 303.
The thermal plate sub-assembly 102 is assembled with at least one fastening means 304. The fastening means includes, but is not limited to, a bolt, a clip, an adhesive, and a weld. The thermal plate sub-assembly 102 may be fastened in any appropriate location, preferably in the corners of thermal plate 301 and the insulation shield 303. In a preferred embodiment, the at least one fastening means 304 also serves the function of an extension member to ensure that the proper spacing is maintained between the heated surface of the thermal plate 301 and the heater surface upon installation. In another embodiment, the thermal plate sub-assembly 102 comprises an extension member and at least one fastening means 304 which are separate and distinct from each other. In alternate embodiments, extension member may be integrated into an element of the housing sub-assembly or into an element of the thermal plate sub-assembly, for example, the extension member may be integrated with the thermal plate 301, or the fastening means 304, or the fan housing 201. The spacing between the heater surface and the thermal plate 301 is in the range from about 0.125 in. to about 1.0 in. The extension member is constructed of certain length to facilitate said spacing, as the spacing is critical to the efficient functioning of the thermoelectric fan 100 with catalytic heaters. Catalytic heaters require sufficient airflow to maintain efficient operation. If the thermal plate 301 is spaced too close to the heated surface, the airflow is significantly reduced and the heater surface temperature drops, resulting in poor performance of the thermoelectric fan 100. If the thermal plate 301 is spaced too far from the heated surface, the radiant heat transfer mechanism is reduced, thus the heat transferred to the thermoelectric module 202 and the corresponding electricity generated are reduced, resulting in poor performance of the thermoelectric fan 100. The spacing is important to ensure that there is no physical contact between the thermal plate 301 and the heated surface of the heater upon installation. The stated spacing range for the invention has been determined through great experimentation so as to provide optimal heat transfer between the thermoelectric fan 100 and the catalytic heater. The particular spacing for use herein, within the stated spacing range, is determined in combination with the specific type of a catalytic heater, the thermal plate 301 material, the thermal plate 301 color, the insulation sheet 302 material, the thermoelectric module 202 temperature and power specifications, the motor 203 inertia and power specifications, the air moving member shape and inertia, and the housing 201 shape, design and thermal performance to yield optimal heat transfer. As these components are coupled together, they consequently impact the proper selection of spacing to ensure optimal heater surface temperature, heater performance and thermoelectric fan 100 performance.
In one embodiment of the present invention, the thermal plate sub-assembly 102 is in thermal communication with the heat exchanger disk 204 of the housing sub-assembly 101. In a preferred embodiment, as illustrated in
In one embodiment of the present invention, a circuit board assembly 401 is mounted to the inside wall of the fan housing 201. In another embodiment, as shown in
In one embodiment of the present invention, the thermoelectric fan 100 comprises a light source, such as a light emitting diode (“LED”), in electrical communication with the thermoelectric module 202. The light source is affixed to the thermoelectric fan 100 in such a manner as to direct light into and thus illuminate the space where the fan is operating. In one embodiment of the present invention, thermoelectric fan 100 comprises a light source in electrical communication with a circuit board assembly 401. In this embodiment, the light source voltage and power specifications are selected to allow for safe operation with the circuit board assembly 401 and thus support operation of the thermoelectric fan 100 within a hazardous atmosphere.
In one embodiment of the present invention, the thermoelectric fan 100 comprises an electrical connection for a rechargeable battery to be in electrical communication with the thermoelectric module 202. In an alternate embodiment, the thermoelectric fan 100 is operated in a hazardous environment and the electrical connection for a rechargeable battery is in electrical communication with the circuit board assembly 401. Suitable connection means include, but not limited to, electrical wires, an integrated power connector, and an electrical receptacle. In another embodiment, a portion of the power generated by the thermoelectric module 202 and electrically transferred to the circuit board assembly 401 is used to provide a voltage to maintain the electrical charge within the battery, or to completely recharge the battery.
The thermoelectric fan of the present invention is secured to a radiant heater, particularly a catalytic heater; the fan may be secured via any suitable means, including but not limited to fastener(s) and bracket(s). The thermoelectric fan 100 may also be placed in close proximity to such a heater rather than being secured thereto.
In one embodiment of the present invention, the thermoelectric fan 100 comprises fasteners 304 and accommodations for fasteners in the thermal plate sub-assembly 102 which provide for the assembly of the thermal plate 301 to the insulation sheet 302 and the insulation shield 303. The heat exchanger disk 204 of the housing sub-assembly 101 comprises a means for affixing it to the thermal plate 301. The thermoelectric fan 100 comprises electrical connections for inserting the one to four diodes, one to four resistors and at least one fuse in an electrical path between the thermoelectric module 202 and motor 203.
Methods for assembling the thermoelectric fan 100 comprise fastening the thermal plate sub-assembly 102 via at least one fastening means 304, the affixing of the thermal plate to the heat exchanger disk via another fastening means. In embodiments in which a circuit board 401 is included, assembling the thermoelectric fan 100 also comprises inserting one to four diodes, one to four resistors and at least one fuse in an electrical path between the thermoelectric module 202 and the motor 203.
The thermoelectric fan 100 is designed to allow for transportation of the housing sub-assembly 101 and the thermal plate sub-assembly 102 unattached. This design reduces the risk of potential shock loads impacting the thermal plate sub-assembly 102 during shipping and transferring high loads into the thermoelectric module 202. The design of the thermoelectric fan of the present invention supports a simple method of installation for affixing the thermal plate sub-assembly 102 to the housing sub-assembly 101 at the location of operation. However, the housing sub-assembly 101 and the thermal plate sub-assembly 102 may be coupled prior to transportation. The present invention also comprises features to allow for simple installation of the thermoelectric fan 100 to the catalytic heater while maintaining proper spacing of the thermal plate sub-assembly 102 from the heater surface.
Methods for installing the thermoelectric fan 100 comprise placing the insulation sheet 302 against the thermal plate 301, in embodiments where the insulation sheet is distinct from the thermal plate, to minimize the heat transfer from the thermal plate to the airflow emanating from the housing 201, and affixing the thermal plate 301 to the heat exchanger disk 204 via a fastening means. The thermoelectric fan is then secured to a radiant heater, particularly a catalytic heater, via a securing means, preferably via brackets 103. Installing the thermoelectric fan also comprises positioning the thermoelectric fan 100 in thermal communication with the heated surface of the heater. The positioning of the thermoelectric fan is made in such a manner as to maximize radiation heat transfer from the heater to the thermal plate 301 and to ensure directed airflow from the thermoelectric fan 100 across the heated surface of the heater. The installation of the thermoelectric fan comprises positioning an extension member in communication with the heated surface of a catalytic heater in such a manner as to create an essential space, in the range of from about 0.125 in. to about 1.0 in., between the thermal plate 301 and the heater surface.
In one embodiment of the present invention, heat is extracted from a radiant heater, preferably a catalytic heater, and converted, at least in part, into an alternative form of energy; the resulting alternative form of energy is utilized to propel an air moving member, such as a fan blade, to power to an illumination device, such as an LED, to charge or recharge charge a battery, or any combination of thereof. The thermoelectric fan of the present invention is utilized to accomplish said extraction and conversion of heat into an alternative form of energy, and said fan is further utilized to communicate the alternative form of energy to achieve the desired useful result.
In one embodiment of the present invention, the thermoelectric fan 100 is operated in a safe manner by limiting the amount of electrical energy supplied by the thermoelectric module 202 to the motor 203. The amount of electrical energy is limited through the use of a circuit board assembly 401, which comprises one to four Zener diodes, one to four resistors and at least one fuse. In a preferred embodiment, the voltage is limited with four 4.7 Volt, 5 Watt Zener diodes positioned electrically in parallel. This preferred embodiment also comprises two 0.25 Ohm, 5 Watt resistors positioned electrically in series, and one 2.0 ampere, 250 Volt fast-acting fuse, electrically in series with the resistors, to limit the current. The circuit board assembly 401 limits the amount of energy which can be transferred to the motor 203 and potentially released in the event of a fault condition. The potential level of energy which can thus be released is of low enough value to prevent the ignition of gases in the environment surrounding the thermoelectric fan 100.
As noted above, the present invention pertains to a thermoelectric fan for radiation-based heaters, particularly catalytic heaters, and methods related thereto. The present invention should not be considered limited to the particular embodiments described above, but rather should be understood to cover all aspects of the invention as fairly set out in the appended claims. Various modifications as well as numerous structures to which the present invention may be applicable will be readily apparent to those skilled in the art to which the present invention is directed upon review of the present specification. The claims are intended to cover such modifications.
This is a non-provisional application claiming the benefit of and priority to provisional patent application having serial number 60/829,372 and filed on Oct. 13, 2006, which is incorporated herein by reference.
Number | Date | Country | |
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60829372 | Oct 2006 | US |