Abstrict
A portable electric heater producing a vertically oriented, heated
exhaust air stream at an elevation above a support surface is provided.
A base contacting the support surface and supporting an elongate
housing in a substantially vertical position from the support surface.
An inlet opening allows air to enter the interior of the housing
and a vertically oriented outlet opening allows a heated exhaust
air stream to exit the housing. An air blower assembly and elongate
electric heating element are disposed within the housing. The air
blower assembly has a substantially vertically oriented axis of
rotation and the electric heating element is substantially vertically
oriented proximate the outlet opening. The flow of the exhaust air
stream from the air impeller assembly toward the vertically oriented
elongate electric heating element is a substantially direct and
straight vector and substantially all of the exhaust air stream
passes through the electric heating element.
Claims
What is claimed:
1. A portable electric heater for providing a heated exhaust air
stream at an elevation above a support surface, said portable electric
heater comprising: an elongate housing having at least one sidewall,
a top end, a bottom end, and a longitudinal length extending substantially
upward from said bottom end to said top end, and a horizontal cross
sectional area; a base for supporting said elongate housing in a
vertical and upright position on said support surface, said base
contacting said support surface; at least one interior space within
said elongate housing; at least one inlet opening in said elongate
housing allowing inlet air to enter said at least one interior space;
an air blower assembly disposed within said at least one interior
space for receiving said inlet air, said air blower assembly comprising:
i) at least one non-axial air impeller having a substantially vertical
axis of rotation; and ii) at least one motor for rotating said non-axial
air impeller about said substantially vertical axis of rotation
to generate an exhaust air stream; at least one vertically oriented
elongate outlet opening in said elongate housing allowing said exhaust
air stream to exit said at least one interior space; and at least
one vertically oriented elongate electric heating element disposed
within said at least one interior space between said air blower
assembly and said at least one outlet opening; wherein the flow
of said exhaust air stream from said non-axial air impeller toward
said at least one vertically oriented elongate outlet opening is
a substantially direct and straight vector; wherein substantially
all of said exhaust air stream is heated by said at least one vertically
oriented elongate electric heating element forming said heated exhaust
air stream; wherein said heated exhaust air stream exits said elongate
housing at an elevation above said support surface, said elevation
being defined by a distance from where said base contacts said support
surface to a highest vertical exit point of said heated exhaust
air stream from said at least one interior space; and wherein said
elevation of said heated exhaust air stream is about 20 inches or
greater.
2. The portable electric heater of claim 1, wherein an overall
length is defined by the distance from where said base contacts
said support surface to said top end of said elongate housing.
3. The portable electric heater of claim 2, wherein said overall
length is about 25 inches or greater.
4. The portable electric heater of claim 3, having a vertical aspect
ratio defined by said overall length to a maximum width dimension
of said horizontal cross sectional area of said elongate housing,
wherein said vertical aspect ratio is greater than about 2 to 1.
5. The portable electric heater of claim 3, wherein said base comprises
a maximum width dimension of a horizontal cross section through
said base, and said maximum width dimension of said horizontal cross
section through said base is less than about 60% of said overall
length.
6. The portable electric heater of claim 1, wherein a first comparative
ratio is defined by said elevation of said heated exhaust air stream
to a maximum width dimension of said horizontal cross sectional
area of said elongate housing, said first comparative ratio being
greater than about 2 to 1.
7. The portable electric heater of claim 1, wherein said air blower
assembly further comprises a transverse blower assembly.
8. The portable electric heater of claim 1, wherein said air blower
assembly is a pre-assembled cartridge, and said pre-assembled cartridge
is pre-tested and installed in said elongate housing during assembly
of said portable electric heater.
9. The portable electric heater of claim 1, wherein said air blower
assembly further comprises a centrifugal blower assembly.
10. The portable electric heater of claim 1, wherein said non-axial
air impeller further comprises; a diameter of said non-axial air
impeller; a length of said non-axial air impeller; and a ratio of
said length of said non-axial air impeller to said diameter of said
non-axial air impeller being greater than about 2:1.
11. The portable electric heater of claim 1, further comprising
a controller for controlling at least one function of said portable
electric heater.
12. The portable electric heater of claim 11, wherein said controller
is mounted to one of said elongate housing and said base.
13. The portable electric heater of claim 11, wherein said controller
is a remote control device.
14. The portable electric heater of claim 11, wherein said motor
further comprises a variable speed motor having one or more rotational
speeds, and said controller controls said rotational speeds.
15. The portable electric heater of claim 1, wherein said elongate
housing rotates or oscillates relative to said support surface,
wherein said rotation or oscillation is about an axis of rotation,
said axis of rotation being substantially aligned with a vertical
longitudinal axis of said elongate housing.
16. The portable electric heater of claim 15, wherein said axis
of rotation of said elongate housing is substantially parallel to
said substantially vertical axis of rotation of said at least one
non-axial air impeller of said air blower assembly.
17. The portable electric heater of claim 15, further comprising
a mechanism for rotating or oscillating said elongate housing relative
to said support surface.
18. The portable electric heater of claim 17, wherein said mechanism
is disposed between said bottom end of said elongate housing and
said base.
19. The portable electric heater of claim 17, further comprising
a controller for controlling a function of said mechanism for rotating
or oscillating said elongate housing with respect to said support
surface.
20. The portable electric heater of claim 1, wherein said at least
one outlet opening further comprises a single elongate outlet opening
in said at least one sidewall and oriented substantially along said
longitudinal length of said elongate housing, wherein said elongate
outlet opening allows said heated exhaust air stream to exit said
interior space as a substantially contiguous elongate heated exhaust
air stream.
21. The portable electric heater of claim 1, further comprising
a grill covering said at least one outlet opening.
22. The portable electric heater of claim 21, wherein a highest
elevation of an extent of said grill above said support surface
is about 21 inches or greater.
23. The portable electric heater of claim 21, wherein said grill
further comprises air directing vanes that can be positioned to
direct said heated exhaust air stream exiting said elongate housing
to a desired location.
24. The portable electric heater of claim 21, wherein said grill
is an integral part of said elongate housing.
25. The portable electric heater of claim 21, further comprising
an air containment frame disposed between said at least one vertically
oriented elongate electric heating element and said grill, wherein
said air containment frame is a distinct and separate part from
said grill.
26. The portable electric heater of claim 25, further comprising
air alignment elements disposed between said at least one vertically
oriented elongate electric heating element and said grill, wherein
said alignment elements are distinct and separate parts from said
grill.
27. The portable electric heater of claim 26, wherein said air
containment frame and said air alignment elements are integral to
each other as a single part.
28. The portable electric heater of claim 26, wherein at least
one of said air containment frame or said air alignment elements
are integral to at least one of said housing or said at least one
vertically oriented elongate electric heating element.
29. The portable electric heater of claim 1, wherein heated exhaust
air stream exiting said elongate housing comprises a substantially
contiguous elongated column of heated exhaust air.
30. The portable electric heater of claim 1, wherein said at least
one vertically oriented elongate electric heating element is a positive
temperature coefficient (PTC) heating element capable of producing
about 1500 watts of energy, said vertically oriented elongate electric
heating element having a vertical aspect ratio defined by a length
of said vertically oriented elongate electric heating element being
greater than a width of said vertically oriented elongate electric
heating element.
31. The portable electric heater of claim 30, wherein said at least
one vertically oriented elongate electric heating element comprises
a single elongate electric heating element disposed proximate said
outlet opening and oriented substantially along said longitudinal
length of said elongate housing.
32. The portable electric heater of claim 30, wherein said vertical
aspect ratio of said vertically oriented elongate electric heating
element is greater than about 7.5:1.
33. The portable electric heater of claim 30, wherein said length
of said vertically oriented elongate electric heating element is
about 13 inches or greater.
34. The portable electric heater of claim 30, wherein said width
of said vertically oriented elongate electric heating element is
about 1.5 inches or less.
35. The portable electric heater of claim 30, wherein said vertically
oriented elongate electric heating element comprises a row of PTC
ceramic stones flanked on at least one side by heat dissipation
fins.
36. The portable electric heater of claim 35, wherein said row
of PTC ceramic stones is a single row aligned substantially linearly
in a substantially vertical orientation.
37. The portable electric heater of claim 30, further comprising
a second comparative ratio defined by said elevation of said heated
exhaust air stream to said width of said vertically oriented elongate
electric heating element, said second comparative ratio being greater
than about 12 to 1.
38. The portable electric heater of claim 1, wherein said base
is a unitary part of said elongate housing.
39. The portable electric heater of claim 1, wherein said base
is detachably coupled to said elongate housing having i) an operating
configuration when said base is coupled to said elongate housing
and ii) a non-operating configuration when base is detached from
said elongate housing.
40. The portable electric heater of claim 39, wherein said non-operating
configuration is disposed in a package for shipment.
41. The portable electric heater of claim 39, wherein said base
further comprises a split base having at least a first portion and
a second portion that can be separated.
42. The portable electric heater of claim 1, wherein said support
surface is a substantially vertical surface and further comprising
at least one mounting means for mounting said portable electric
heater to said substantially vertical surface.
43. The portable electric heater of claim 42, wherein said at least
one mounting means and said base comprise a unitary component.
44. The portable electric heater of claim 42, wherein said at least
one mounting means and said elongate housing comprise a unitary
component.
45. The portable electric heater of claim 42, wherein said at least
one mounting means is a bracket.
46. A portable electric heater for providing a heated exhaust air
stream at an elevation above a support surface, said portable electric
heater comprising: an elongate housing having at least one sidewall,
a top end, a bottom end, and a longitudinal length extending substantially
upward from said bottom end to said top end, and a horizontal cross
sectional area; a base for supporting said elongate housing in a
vertical and upright position on said support surface, said base
contacting said support surface; at least one interior space within
said elongate housing; at least one vertically oriented elongate
electric heating element disposed within said at least one interior
space and oriented substantially along said longitudinal length
of said elongate housing, a length of said at least one vertically
oriented elongate electric heating element being about 13 inches
or greater; at least one inlet opening in said elongate housing
allowing inlet air to enter said at least one interior space; an
air blower assembly disposed within said at least one interior space
between said at least one inlet opening and said at least one vertically
oriented elongate electric heating element, said air blower assembly
comprising: i) at least one non-axial air impeller; ii) at least
one motor for rotating said non-axial air impeller about a substantially
vertical axis of rotation to receive said inlet air and generate
an exhaust air stream; and at least one vertically oriented elongate
outlet opening in said elongate housing allowing said heated exhaust
air stream to exit said at least one interior space; wherein substantially
all of said exhaust air stream passes through said at least one
vertically oriented elongate electric heating element and thermal
energy is transferred from said at least one vertically oriented
elongate electric heating element to said exhaust air stream as
said exhaust air stream flows through said at least one vertically
oriented elongate electric heating element to form said heated exhaust
air stream.
47. The portable electric heater of claim 46, wherein said heated
exhaust air stream exits said elongate housing at an elevation above
said support surface, said elevation being defined by a distance
from where said base contacts said support surface to the highest
vertical exit point of said heated exhaust air stream from said
at least one interior space.
48. The portable electric heater of claim 47, comprising a comparative
ratio defined by said elevation of said heated exhaust air stream
to a width of said vertically oriented elongate electric heating
element, said comparative ratio being at greater than about 12 to
1.
49. The portable electric heater of claim 47, wherein said elevation
of said heated exhaust air stream is about 20 inches or greater.
50. The portable electric heater of claim 46, wherein said at least
one vertically oriented elongate electric heating element is a positive
temperature coefficient (PTC) heating element.
51. The portable electric heater of claim 50, wherein a width of
said at least one vertically oriented elongate electric heating
element is about 1.5 inches or less.
52. The portable electric heater of claim 50, further comprising
a row of PTC ceramic stones flanked on at least one side by heat
dissipation fins, wherein said row of PTC ceramic stones is a single
row aligned substantially linearly in a substantially vertical orientation.
53. The portable electric heater of claim 50, wherein said at least
one vertically oriented elongate electric heating element further
comprises a vertical aspect ratio greater than about 7.5:1, defined
by said length of said at least one vertically oriented elongate
electric heating element being greater than a width of said at least
one vertically oriented elongate electric heating element.
54. The portable electric heater of claim 46, wherein said heated
exhaust air stream exiting said elongate housing comprises a single
substantially contiguous elongated column of heated exhaust air.
55. The portable electric heater of claim 46, further comprising
a grill covering said at least one outlet opening.
56. The portable electric heater of claim 55, wherein a highest
elevation of an extent of said grill above said support surface
is about 21 inches or greater.
57. A portable electric heater for providing a heated exhaust air
stream at an elevation above a support surface, said portable electric
heater comprising: an elongate housing having at least one sidewall,
a top end, a bottom end, and a longitudinal length extending substantially
upward from said bottom end to said top end, and a horizontal cross
sectional area; a base for supporting said elongate housing in a
vertical and upright position on said support surface, said base
contacting said support surface; an overall length defined by the
distance from where said base contacts said support surface to said
top end of said elongate housing, wherein said overall length being
about 25 inches or greater; said elongate housing further comprising
a maximum width dimension of said horizontal cross sectional area,
a vertical aspect ratio defined by said overall length to said maximum
width dimension and being greater than about 2 to 1; at least one
interior space within said elongate housing; at least one inlet
opening in said elongate housing allowing inlet air to enter said
at least one interior space; at least one vertically oriented elongate
outlet opening in said elongate housing allowing a heated exhaust
air stream to exit said at least one interior space; at least one
vertically oriented elongate electric heating element disposed within
said at least one interior space proximate said at least one vertically
oriented elongate outlet opening; and an air blower assembly disposed
within said at least one interior space proximate said at least
one vertically oriented elongate electric heating element, said
air blower assembly receiving said inlet air from said at least
one inlet opening and discharging an exhaust air stream toward said
at least one vertically oriented elongate electric heating element,
said air blower assembly comprising: at least one non-axial air
impeller and at least one motor for rotating said non-axial air
impeller about a substantially vertical axis of rotation to generate
said exhaust air stream; wherein a longitudinal length of said non-axial
air impeller, said elongated electric heating element, and said
outlet opening are each substantially vertically aligned and substantially
horizontally aligned and the flow of said exhaust air stream from
said non-axial air impeller toward said elongate electric heating
element is a substantially direct and straight vector; wherein substantially
all of said exhaust air stream is heated by said at least one vertically
oriented elongate electric heating element forming said heated exhaust
air stream; wherein the flow of said heated exhaust air stream from
said at least one vertically oriented elongate electric heating
element toward said at least one vertically oriented elongate outlet
opening is a substantially direct and straight vector.
58. The portable electric heater of claim 57, wherein said base
is a unitary part of said elongate housing.
59. The portable electric heater of claim 57, wherein said base
is decoupled from said elongate housing in a non-operating configuration.
60. The portable electric heater of claim 59, wherein said base
further comprises a split base having at least a first portion and
a second portion that can be separated.
61. The portable electric heater of claim 59, wherein said non-operating
configuration is disposed in a package for shipment from a place
of manufacturing to a place of sale.
62. The portable electric heater of claim 57, wherein said base
further comprising a maximum width dimension of a horizontal cross
section through said base and said maximum width dimension of a
horizontal cross section through said base is less than about 60%
of said overall length.
63. The portable electric heater of claim 57, wherein said heated
exhaust air stream exits said elongate housing at an elevation above
said support surface, said elevation being defined by a distance
from where said base contacts said support surface to the highest
vertical exit point of said heated exhaust air stream from said
at least one interior space.
64. The portable electric heater of claim 63, wherein said elevation
of said heated exhaust air stream is about 20 inches or greater.
65. A portable electric heater for providing a heated exhaust air
stream, said portable electric heater comprising: a housing having
at least one sidewall, a top end, a bottom end, and a length extending
substantially upward from said bottom end to said top end, and a
horizontal cross sectional area; a base for supporting said housing
in a upright position on a support surface, said base contacting
said support surface; at least one interior space within said housing;
at least one inlet opening in said housing allowing inlet air to
enter said at least one interior space; an air blower assembly disposed
within said at least one interior space having an inlet port for
receiving said inlet air and an exhaust port for discharging an
exhaust air stream, said air blower assembly comprising: i) at least
one non-axial air impeller; and ii) at least one motor for rotating
said non-axial air impeller about a substantially vertical axis
of rotation to generate said exhaust air stream; at least one outlet
opening in said housing allowing said exhaust air stream to exit
said at least one interior space; at least one vertically oriented
elongate electric heating element disposed within said at least
one interior space between said air blower assembly and said at
least one outlet opening; a grill covering said at least one outlet
opening; and an air containment frame disposed between said vertically
oriented elongate electric heating element and said grill, wherein
said air containment frame is a distinct and separate part from
said grill; wherein said exhaust port of said air blower assembly,
said elongate heating element, and said elongate outlet opening
have substantially the same orientation and are aligned; wherein
substantially all of said exhaust air stream exiting said exhaust
port of said air blower assembly is heated by said at least one
vertically oriented elongate electric heating element forming said
heated exhaust air stream; and wherein said containment frame prevents
said heated exhaust air stream from expanding into an area between
said vertically oriented elongate electric heating element and said
grill.
66. The portable electric heater of claim 65, further comprising
air alignment elements disposed between said vertically oriented
elongate electric heating element and said grill, wherein said alignment
elements are distinct and separate parts from said grill.
67. The portable electric heater of claim 66, wherein said air
containment frame and said air alignment elements are integral to
each other as a single part.
68. The portable electric heater of claim 66, wherein at least
one of said air containment frame or said air alignment elements
are integral to at least one of said housing or said at least one
vertically oriented elongate electric heating element.
69. The portable electric heater of claim 65, wherein an overall
length is defined by the distance from where said base contacts
said support surface to said top end of said housing.
70. The portable electric heater of claim 69, further comprising
a vertical aspect ratio defined by said overall length to a maximum
width dimension of said horizontal cross sectional area of said
elongate housing, wherein said vertical aspect ratio is greater
than about 2 to 1.
71. The portable electric heater of claim 70, wherein a highest
elevation of an extent of said grill above said support surface
is about 21 inches or greater.
72. The portable electric heater of claim 65, wherein said grill
is an integral part of said housing.
73. The portable electric heater of claim 65, wherein said at least
one vertically oriented elongate electric heating element further
comprises a vertical aspect ratio defined by a length of said vertically
oriented elongate electric heating element being greater than a
width of said vertically oriented elongate electric heating element.
74. The portable electric heater of claim 73, wherein said at least
one vertically oriented elongate electric heating element is a positive
temperature coefficient (PTC) heating element.
75. The portable electric heater of claim 74, wherein said length
of said at least one vertically oriented elongate electric heating
element is about 13 inches or greater.
76. The portable electric heater of claim 74, wherein said vertical
aspect ratio of said at least one vertically oriented elongate electric
heating element is greater than about 7.5:1.
77. The portable electric heater of claim 74, wherein said width
of said at least one vertically oriented elongate electric heating
element is about 1.5 inches or less.
78. The portable electric heater of claim 74, further comprising
a row of PTC ceramic stones flanked on at least one side by heat
dissipation fins, wherein said row of PTC ceramic stones is a single
row aligned substantially linear in a substantially vertical orientation.
Description FIELD OF THE INVENTION
This invention relates generally to heaters. More specifically,
the present invention relates to an elongated electric heater in
which thermal energy is imparted to exhaust air as it passes through
an elongated heating element.
BACKGROUND OF THE INVENTION
Portable heating devices have been utilized to elevate 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 goal of a portable heating device is to pass a sufficient quantity
and velocity of air over or through the heating element to allow
the user to experience the produced heat quickly and to achieve
the desired temperature levels in a given space. Another goal is
the ability to achieve the heating of the air in an efficient manner.
This implies the efficient distribution of the airflow over the
maximum amount of heating element surface. In addition, it is desirable
to increase the volume and velocity of air that is heated during
a given time period. This allows the desired ambient temperatures
to be reached more quickly. Further, it is advantageous to project
heated air from the heater to allow the user to experience an immediate
heating effect. One manner to achieve this aspect is to raise the
elevation of the heated air stream, this allows the heated air to
effect the users upper body. The upper body is more exposed and
therefore will experience the effects of the heating device quickly.
Moreover, it is desirable to manufacture the device at a cost and
with features (such as a space saving design and consistent heat
output) that are appealing to consumers.
One type of conventional portable heater has a low 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's body efficiently.
Another type of conventional portable heater elevates the heated
exhaust air stream somewhat. The aspect ratio of the heating element
used in such a design, however, limits the height to which the heated
air stream can be elevated. The conventional aspect ratios of the
heating element do not allow for greater length of the element because
of the need to maintain the proper watt density within the electric
heating element to efficiently heat the air steam. The inability
to increase the length of the heating element limits the elevation
of the heating element.
An additional problem with conventional portable heaters is that
many utilize a "hot wire" or "glow wire" heating
element. These elements can have surface temperatures that reach
and exceed 1250 degrees Fahrenheit (676 degree Celsius). This elevated
element temperature is inherently more susceptible to problems if
the device malfunctions.
SUMMARY OF THE INVENTION
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 desirably have a vertical aspect ratio.
The vertical aspect ratio would also provide the portable heater
with a space saving design. Another need is for the heating device
to have the ability to move a sufficient volume and velocity of
air over or through the heating element, thus efficiently achieving
the desired ambient temperature level. Another need is for the electric
heating element to have a vertical aspect ratio that would allow
the device to achieve the desired height. Yet another need for the
heating device is to have the ability to utilize a heating element
with a lower surface temperature while achieving the desired air
stream heating characteristics. There is also a need for the heating
device to utilize an air generator design that will have the desired
characteristics for a portable heating device with a vertical aspect
ratio.
In short what is needed is a heater that combines one or more of
these characteristics at a desirable retail cost for the consumer.
According to one aspect of the present invention a portable electric
heater for providing a heated exhaust air stream at an elevation
above a support surface 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 a horizontal cross sectional area. A base supports
the elongate housing in a vertical and upright position on the support
surface with the base contacting the support surface. The elongate
housing has at least one interior space with at least one inlet
opening in the elongate housing allowing 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.
The air blower assembly comprises at least one air impeller, and
at least one motor for rotating the air impeller to generate an
exhaust air stream. At least one outlet opening is in the elongate
housing allowing the exhaust air stream to exit the at least one
interior space, and at least one electric heating element disposed
within the at least one interior space between the air blower assembly
and the at least one outlet opening. A substantial portion of the
exhaust air stream passes through the at least one electric heating
element and thermal energy is transferred from the at least one
electric heating element to the exhaust air stream as the exhaust
air stream flows through the at least one electric heating element
forming the heated exhaust air stream, the heated exhaust air stream
exits the elongate housing at an elevation above the support surface,
the elevation being defined by a distance from where the base contacts
the support surface to a highest vertical exit point of the heated
exhaust air stream from the at least one interior space; and the
elevation of the heated exhaust air stream being about 20 inches
or greater.
According to another aspect of the present invention, a first comparative
ratio is defined by the elevation of the heated exhaust air stream
to a maximum width dimension of the horizontal cross sectional area
of the elongate housing, the first comparative ratio being greater
than about 2 to 1.
According to a further aspect of the present invention, the air
blower assembly further comprises a transverse blower assembly.
According to a still another aspect of the present invention, the
air blower assembly further comprises a centrifugal blower assembly.
According to a yet further aspect of the present invention, the
air blower assembly is a pre-assembled cartridge, and the pre-assembled
cartridge is pre-tested and installed in the elongate housing during
assembly of the portable electric heater.
These and other aspects and objects will become evident in light
of the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
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 drawing
are not to scale. On the contrary, the dimensions of various features
are arbitrarily expanded or reduced for clarity. Included in the
drawing are the following Figures:
FIG. 1 is a perspective view of a first exemplary embodiment of
the present invention;
FIG. 2 is an exploded view of the exemplary embodiment of FIG.
1;
FIGS. 3A and 3B illustrate the dimensional aspects of exemplary
heating elements;
FIG. 4 illustrates dimensional aspects of the external structure
of an exemplary electric heater in accordance with the present invention;
FIGS. 5A, 5B, 5C and 5D illustrate various exemplary configurations
for protective grills;
FIGS. 6A and 6B show horizontal cross sections through the present
invention illustrating typical air flow patterns through the protective
grill;
FIGS. 7A and 7B illustrate the elevated heated exhaust air stream
of an electric heater according to the present invention compared
to a conventional heater;
FIG. 8 illustrates another exemplary embodiment of the electric
heater which includes a bracket for mounting to a surface; and
FIG. 9 shows a non-operating configuration where the base is uncoupled
from the housing for shipment.
DETAILED DESCRIPTION OF THE INVENTION
This application is a Continuation-in-Part of U.S. patent application
Ser. No. 10/322,169, filed Dec. 18, 2002, the contents of which
is incorporated by reference as if set forth in full.
The following description is of an electric heater that is portable
and has a vertical aspect ratio which allows the generated heat
to effect the users upper body. The vertical aspect ratio also provides
a space saving design. The electric heating element of the described
electric heater has the proper vertical aspect ratio to allow the
generated heat to effect the user's upper body. The electric heater
so described achieves the desired air volume and air velocity over
or through a low surface temperature heating element. The air generator
within the unit is designed so as to be have the desired performance
characteristics for a portable heater that has a vertical aspect
ratio.
FIG. 1 shows a perspective view of an exemplary electric heater
100. As shown in FIG. 1, electric heater 100 includes housing 102,
air blower assembly 110, and elongated heating element 116. Housing
102 includes one or more sidewalls 105 extending between a bottom
107b and a top 107t thereby defining an interior space 103. Housing
102 includes an elongated construction, preferably extending vertically
upward from the bottom 107b to the top 107t. Housing 102 also includes
one or more air inlet openings 108 and at least one air exit which
may be for example, elongated air outlet 104. Protective grill 106
is preferably disposed over elongated air outlet 104 for preventing
foreign objects from entering the interior space 103 of housing
102. Disposed within interior space 103 is air blower assembly 110
and at least one heating element which may be for example elongated
heating element 116. Electric heater 100 also includes power cord
140 and control assembly 126. Control assembly 126 controls one
or more operations of electric heater 100.
FIG. 2 shows an exploded perspective view of electric heater 100.
As shown in FIG. 2, housing 102 may be constructed of more than
one component, such as, for example, two halves 102a, 102b that
are assembled together. Housing 102 has at least one air inlet opening
108 and an elongated air outlet 104.
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 structure 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 electric heater 100 to be less costly
when compared to assembling motor 114, air impeller 112 and blower
housing structure 113 into electric heater 100 as separate components.
In one embodiment, air blower assembly 110 is a transverse type
blower. It is contemplated that other types of blowers may be used,
such as for example a centrifugal type blower.
Also disposed within interior space 103, proximate elongated air
outlet 104 is elongated heating element 116. Preferably, elongated
heating element 116 extends substantially along the length of the
elongated air outlet 104 and a substantial portion of all the air
being discharged from air blower assembly 110 flows through elongated
heating element 116.
In one embodiment, elongated 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 elongated heating element 116,
and exits housing 102 through elongated air outlet 104. As the air
flow passes through elongated heating element 116, thermal energy
(i.e. heat) is imparted to the air flow.
Preferably, protective grill 106 is located proximate elongated
air outlet 104. Protective grill 106 is preferably designed to minimize
its impedance of the air flow as it exits electric heater 100, while
at the same time protecting electric heater 100 from the internal
penetration of foreign objects. Protective grill 106 may include
air directing vanes, such as louvers for example, that can be used
to control the direction of the heated exhaust air stream as it
exits housing 102. Protective grill 106 may be a separate piece
or formed as an integral part of another component of electric heater
100, for example housing 102.
In one embodiment, base 128 can be uncoupled from housing 102.
Base 128 can then be stored in package 900 along with housing 102
and all other components of electric heater 100 to economize space,
as shown in FIG. 9. The space economization for storing electric
heater 100 can be used for shipping purposes, thus allowing more
units in a given transport container (i.e. truck) and thereby reducing
the overall cost per unit for transportation.
Base 128 may be comprised of one or multiple pieces attached to
one another. Base 128 may be made of materials such as metals or
polymers or a combination of various materials. Base 128 sits on
a support surface thus allowing the entire structure of electric
heater 100 to be positioned in a substantially vertical, upright
and elongate position.
Although the exemplary embodiment shown in FIG. 2 illustrates base
128 and housing 102 as separate pieces, the invention is not so
limited. It is contemplated that the support of housing 102 may
be accomplished in a variety of ways, such as forming base 128 as
a unitary member having a variety of predetermined shapes.
In one embodiment, base 128 can be uncoupled from housing 102.
Base 128 can then be stored along with housing 102 and all other
components of electric heater 100 to economize space. The space
economization for storing electric heater 100 can be used for shipping
purposes, thus allowing more units in a given transport container
(i.e. truck) and thereby reducing the overall cost per unit for
transportation.
In another exemplary embodiment, housing 102 rotates with respect
a support surface. 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 of 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 base 128.
FIG. 2 shows oscillating mechanism 118. Oscillating mechanism 118
moves housing 102 of electric heater 100 through oscillation movement.
Oscillation movement allows the heated exhaust air stream to be
dispersed over a larger coverage area. As shown in FIG. 2, oscillating
mechanism 118 includes a motor 124, gear 123, oscillation plate
120. It is contemplated that other rotating mechanisms, such as
a link and pivot design, may be used to achieve rotation/oscillation
movement.
Electric heater 100 may also include a controller, such as control
assembly 126 mounted, for example, on 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, etc. Alternatively, control assembly 126
may be mounted in base 128 or lower portion of housing 102. Alternatively,
control of electric heater 100 may be accomplished by a remote control
unit 126a 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 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 manual adjustment of the
controller.
FIGS. 3A and 3B show exemplary embodiments of elongated heating
element 300a and 300b. The heat generation method can be, for example,
Positive Temperature Coefficient (PTC) heat generation technology.
The use of a PTC heating element assures a self-regulating low surface
temperature, approximately 450 degrees Fahrenheit (232 degrees Celsius).
Elongated heating element 300a and 300b is shown having a predetermined
length "L", in a vertical orientation, a predetermined
width "W" and a predetermined depth "D". The
ratio of length "L" to width "W" is preferably
greater than about 7.5:1. In one embodiment, the predetermined length
"L" of heating element 300a and 300b is greater than about
13 inches. In one embodiment, the predetermined width "W"
of heating element 300a and 300b is about 1.50 inches or less. The
use of a single elongated heating element minimizes the number of
connections and simplifies the design and assembly of the heating
element.
FIG. 3B shows another exemplary embodiment of elongated heating
element 300b. As shown in FIG. 3B, elongated heating element 300b
may be constructed of one or more segments 304a, 304b, 304c. As
shown, segments 302a, 302b and 302c are preferably arranged substantially
contiguous and aligned end to end. The use of multiple segments
304a, 304b, 304c may require additional connections 305a and 305b
between segments.
The use of a PTC elongated 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. For example, the use of a 1500 watt PTC elongated
heating element limits length "L" of elongated heating
element 300a or 300b, in that the watt density within the heating
element will not heat the surfaces of heating element 300a or 300b
sufficiently if length "L" is too long and width "W"
is too wide. This insufficient heating of the elongated heating
element will in turn create insufficient heating of the exhaust
air stream. The ratios and dimensions as described allow the elongated
heating element to have the desired vertical aspect ratio while
creating the desired watt density within the elongated heating element.
In one embodiment, elongate electric heating element 300a or 300b
utilizes a single vertical row of PTC ceramic stones 306. Ceramic
stones 306 can be flanked on at least one side by heat dissipation
fins 308. Heat is generated in ceramic stones 306. Heat dissipation
fins 308 serve to transfer heat from ceramic stones 306 into the
air flow passing through electric heating element 300a or 300b.
The single row of ceramic stones 306, as shown, has an advantage
over a conventional heating element having two or more parallel
rows of ceramic stones and two or more rows of heat dissipation
fins. The single row design does not require that one of the rows
of heat dissipation fins be in contact with a parallel row of heat
dissipation fins. This prevents the migration of heat from one row
of heat dissipation fins to the parallel row of heat dissipation
fins. This in turn allows the available heat dissipation capability
of the heat dissipation fins to be used by the row of ceramic stones
to which it corresponds.
The elongated heating element so designed in combination with a
blower assembly allows electric heater 100 to have an elongated
vertical aspect ratio (best shown in FIG. 4). The elongated vertical
aspect ratio of electric heater 100 allows the heated air flow to
effect the upper body portion of the user. Thus, increasing the
immediate heating effect experienced by the user. The vertical design
and small diameter of the blower along with the elongated heating
element also allow electric heater 100 to have space saving characteristics.
FIG. 4 is a perspective view of electric heater 100. As shown,
electric heater 100 has an overall height "H", an overall
housing diameter "E" and a heat elevation "HE".
Overall height "H" is defined as the vertical distance
from support surface 409 to the top of housing 102. The overall
housing diameter dimension "E" is equal to the largest
horizontal cross section dimension through housing 102. All of the
components of and within housing 102, (not including base 128 and
power cord, not shown in this figure) of electric heater 100 reside
within overall housing diameter "E". Dimension "HE"
is defined as the highest point above support surface 409 at which
heated air stream 402 exits housing 102. In one embodiment, dimension
"H" is greater than about 25 inches. In another embodiment,
dimension "HE" is about 20 inches or greater.
To achieve the desired vertical aspect ratio of electric heater
100, the relationship between these dimensions are described below:
i) A vertical aspect ratio of overall height "H" to overall
housing diameter dimension "E" being greater than about
2:1
ii) A first comparative ratio of heat elevation "HE"
to overall housing diameter dimension "E" being greater
than about 2:1.
iii) A second comparative ratio of heat elevation "HE"
to width "W" of elongated heating element 116 being greater
than about 12:1.
The vertical design of electric heater 100 with the aspect ratios
described allows the heated air flow to effect the upper body portion
of the user. Thus, increasing the immediate heating effect experienced
by the user. The vertical aspect ratio of heater 100 in conjunction
with the vertical aspect ratio of elongated heating element 116
allows the heated air stream 402 to also exit close to support surface
409. This allows heated air stream 402 to increase a heating effect
on a lower portion of the user. The vertical design also allows
electric heater 100 to have space saving characteristics.
Also shown in FIG. 4 is protective grill 106. The elevation of
a highest extent of protective grill 106 above support surface 409
may, as in this example, conform substantially to elevation "HE"
of heated air stream 402. It is contemplated that the elevation
of a highest extent of protective grill 106 above support surface
409 may be greater than elevation "HE" of heated air stream
402. In this case protective grill 106 may be used not only for
the functional purpose of allowing heated air stream 402 to exit
housing 102 but also for ornamental purposes, for example to accentuate
the vertical aspect ratio of electric heater 100. In one embodiment
the elevation of the highest extent of protective grill 106 above
support surface 409 is about 21 inches or greater.
FIG. 4 also illustrates that the rotational axis of oscillation
of housing 102 is preferably substantially co-linear with central
axis "A" of electric heater 100. The vertical aspect ratio
of housing 102 allows oscillation movement to be distributed along
central axis "A". Oscillation movement is defined as the
movement of housing 102 about the rotational axis of oscillation.
The axis of rotation of air impeller 112 of air blower assembly
110 within interior space 103 of housing 102 is preferably oriented
vertically and substantially co-linear with central axis "A"
of electric heater 400. This reduces the effects of gyroscopic precession
during the oscillation of housing 102 and increases the stability
of electric heater 100. 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 air blower assembly 110 to fit within the elongated housing
102 of electric heater 100.
In one embodiment air impeller 112 is a limited volume impeller.
The velocity of air stream 402 is fixed in that it must be able
to effectively reach the user. The desired temperature of air stream
402 is also fixed in that it must deliver an adequate temperature
differential between ambient air and heated air stream 402. Elongate
heating element 116 may be a PTC heating element with a fixed maximum
wattage of 1500 W for example. This fixed wattage requirement along
with the fixed temperature and velocity requirements of air stream
402 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 length "L" and width
"W" of elongate heating element 116. Thus, the area of
elongate heating element 116 is fixed in that it must have the required
watt density to sufficiently heat air stream 402 to the desired
temperature. Air flow through the heating element may be stated:
Where: Q is the volume (cubic feet per minute) of air flowing through
elongate heating element 116, A is the area of elongate heating
element 116 and V is the desired velocity of heated air stream 402.
The volume of air Q must be limited for the desired velocity V to
be achieved while not exceeding the 1500 watt output requirement
of elongate heating element 116.
An effective way to limit volume Q of impeller 112 is to reduce
its diameter. The limited diameter of impeller 112 more easily allows
air blower assembly 110 to fit within the elongated housing 102
of electric heater 100, thus maintaining the desired vertical aspect
ratio.
The vertical aspect ratio of housing 102, and air impeller 112
of blower assembly 110 allow the oscillating components of electric
heater 100 to be substantially on center with central axis "A"
thus increasing the stability of electric heater 100.
The substantially vertical, upright and elongate structure of electric
heater 100, (which includes the vertical aspect ratio of housing
102 and may include an elongated heating element 116 and elongated
impeller 112) helps to minimizes the vertical distance above the
support surface, (floor) to the center of gravity of electric heater
100. This structure, along with substantially centering the oscillating
components along central axis "A", coupled with the reduced
effects of gyroscopic precession during oscillation, increase the
stability of electric heater 100. This increased stability allows
dimension "BB" of base 128 to be minimized. Dimension
"BB" is equal to the largest horizontal cross section
dimension through base 128. The minimized dimension "BB"
of base 128 allows 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.
In one embodiment Dimension "BB" of base 128 is less than
about 60% of overall height "H" of electric heater 100.
FIGS. 5A, 5B, 5C and 5D show several exemplary configurations of
protective grill 506. Protective grill 506 is located proximate
elongated air outlet 104 of electric heater 100. Protective grill
506 is preferably designed to minimize its impedance of the air
flow as the air flow exits electric heater 100 while at the same
time protecting electric heater 100 from the internal penetration
of foreign objects. Protective grill 506 could be fabricated from
various materials such as metal or polymer. FIG. 5A illustrates
protective grill 506a having a series of vertical elements 508.
Although protective grill 506a shows vertical elements 508 it is
contemplated that the elements may be horizontal or on an angle
between vertical and horizontal. Although protective grill 506a
shows elements 508 as being straight it is also contemplated that
elements 508 may be of various shapes, such as curved for example.
FIG. 5B shows protective grill 506b having a hole pattern. FIG.
5C shows protective grill 506c having a slot pattern. FIG. 5D shows
protective grill 506d using a mesh pattern. It is contemplated that
other patterns and configurations can be used for protective grill
506.
Protective grill 506 may have a vertical aspect ratio wherein its
length is greater than its width. The vertical aspect ration of
protective grill 506 may be substantially similar to the ratios
for elongated heating element 116 or elongated air outlet 104. Protective
grill 106 may be, for example aligned with the longitudinal length
of housing 102 of electric heater 100.
FIGS. 6A and 6B are horizontal cross sections through housing 102
of electric heater 100 showing the typical air flow pattern through
protective grill 506. Protective grill 506 may have various hole,
slot or mesh patterns. The ability to minimize the impedance of
protective grill 506 on air flow 602 may require additional components
or elements.
FIG. 6A illustrates the impedance that protective grill 506 places
on air flow 602. As shown in FIG. 6A, air flow 602 is induced to
enter interior space 103 of housing 102 through air inlet openings
108 by the rotation of impeller 112. Air flow 602 exits impeller
112 and moves through elongated heating element 116 and toward protective
grill 506. Thermal energy (i.e. heat) is imparted to air flow 602
as it passes through elongated heating element 116. Air flow 602
expands into the area between elongate heating element 116 and protective
grill 506 allowing the velocity of air flow 602 to decrease. The
expansion of air flow 602 into the area between elongate heating
element 116 and protective grill 506 also allows air flow 602 to
approach protective grill 506 from various angles after passing
through elongated heating element 116. Protective grill 506 may
not allow air flow 602 to efficiently pass. This impedance is increased
if the flow through area of protective grill 506 is a structure
of various holes, slots or mesh patterns.
FIG. 6B illustrates the use of air containment frame 604. Air containment
frame 604 is located between elongated heating element 116 and protective
grill 506. Air containment frame 604 is located proximate protective
grill 506. In one embodiment air containment frame 604 is constructed
with four portions, (walls) creating a substantially enclosed channel
604a from elongate heating element 116 to protective grill 506.
The form of channel 604a enclosed by air containment frame 604 may
conform substantially to the form of elongated heating element 116.
Air containment frame 604 extends from elongate heating element
116 to substantially proximate the interior side 506a of protective
grill 506. Air containment frame 604 prevents the air flow 602 from
expanding into the area between elongate heating element 116 and
protective grill 506, thus maintaining the velocity of air flow
602 as it passes through protective grill 506. Maintaining the velocity
of air flow 602 allows air flow 602 to more efficiently pass through
protective grill 506. This is especially true when protective grill
506 has a structure that includes various hole, slot and mesh patterns.
Also shown in FIG. 6B are air alignment elements 606. Air alignment
elements 606 may be used in conjunction with air containment frame
604 to enhance the alignment of air flow 602. Air alignment elements
606 align air flow 602 substantially perpendicular to protective
grill 506. Aligning air flow 602 substantially perpendicular to
protective grill 506 allows air flow 602 to more efficiently pass
through protective grill 506. This is especially true when protective
grill 506 has a structure that includes various hole, slot and mesh
patterns. Although the example shown illustrates air alignment elements
606 as straight it is contemplated that air alignment elements 606
may be for example curved, or have an "air foil" design
that varies in thickness and/or other design shapes to effectively
align air flow 602 as desired. Air alignment elements 606 may also
be used to support protective grill 506.
Air containment frame 604 and air alignment elements 606 may be
separate components or formed together as an integral part. It is
also contemplated that air containment frame 604 and air alignment
elements 606 may be an integral part of another component of electric
heater 100 such as for example, heating element 116 or housing 102.
The ability to efficiently pass air flow 602 through protective
grill 506 allows air flow 602 to project away from electric heater
100 and into the surrounding area. The thermal energy carried by
air stream 602 will more quickly reach the user, thus allowing the
user to experience an immediate heating effect.
FIGS. 7A and 7B illustrate the advantages of the electric heater
of FIG. 1 when compared to a standard electric heater design. FIG.
7A shows an exemplary embodiment of electric heater 100. FIG. 7B
illustrates standard electric heater 700. As shown in FIG. 7B, heated
exhaust air stream 704 exits standard electric heater 700 at a low
elevation. This low elevation increases the distance that the heat
must traverse to reach an upper portion of user 701. In contrast,
FIG. 7A illustrates the improved performance characteristics of
electric heater 100 in accordance with the present invention. Heated
exhaust air stream 702 exits electric heater 100 at an elevation
"HE" that shortens the distance that must be traversed
by heated exhaust air stream 702 in order to effect an upper potion
of user 701. The upper portion of user 701 is normally more exposed
and therefore will experience the effects of heated exhaust air
stream 702 more readily, contributing to the more immediate relief
of user 701.
The substantially vertical, upright and elongate structure of electric
heater 100 also benefits user 701 in that the shape of heated exhaust
air stream 702 may be elongate and vertical as it exits housing
102. An elongate and vertical shape of heated exhaust air stream
702 generally conforms to the human body.
FIG. 8. shows another exemplary embodiment of the electric heater
of the present invention. It is contemplated that electric heater
100 may be so designed as to be mounted via mounting feature 871
to a mounting surface, such as wall 873. As shown, mounting feature
871 would be connected to wall 873 using screws, adhesive or other
forms of assembly. Alternatively, electric heater 100 could be inverted
so that mounting feature 871 was located above the electric heater
100 which could hang extending downward from mounting feature 871.
Mounting feature 871 may be a separate component or integral with
another part of electric heater 100, for example; base 128 or housing
102. In one preferred embodiment mounting feature 871 is a bracket.
While preferred embodiments of the invention have been shown and
described herein, it will be understood that such embodiments are
provided by way of example only. Numerous variations, changes and
substitutions will occur to those skilled in the art without departing
from the spirit of the invention. Accordingly, it is intended that
the appended claims cover all such variations as fall within the
spirit and scope of the invention. |