Abstract:
A heater having an evaporating and humidifying apparatus therein, the evaporating and humidifying apparatus comprising a fluid pan with a heating element. In one aspect, the pan is in fluid communication with a condensate trap assembly. In one aspect the apparatus can include a base pan, the heating element, an insulator and an evaporation pan above the heating element. The evaporating and humidifying apparatus can include a fluid level sensor operatively associated with the heater controls. The condensate trap assembly may include a fluid level sensor operatively associated with the heater controls to determine fluid levels in the trap assembly. In one aspect the pan comprises an ultrasonic vaporization element in lieu of a heating element.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of provisional application Ser. No. 61/619,186 filed Apr. 2, 2012, which is incorporated herein by reference. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    High efficiency fireplaces or heaters can produce significant condensate. Various embodiments employ a tray located above the firebox to evaporate the condensed products of combustion and humidify in the area around the appliance. However, if a heater does not include a large, hot firebox, there is not enough heat generated within the heater itself to evaporate all the condensate. 
         [0003]    Also, such heaters are generally used in cold weather to heat a space within a building. Often there is low humidity in the enclosed space as a result of the operation of heaters and furnaces. Low humidity can aggravate inhabitants by drying the skin and mucous membranes of inhabitants of the heated space. 
         [0004]    It would be advantageous, therefore, to have an efficient apparatus within the heater to evaporate condensation and moisture. Moreover, it would be beneficial to use the evaporated condensate to humidify the area around the heater. 
       SUMMARY OF THE INVENTION 
       [0005]    A heater having a condensate trap and an evaporating and humidifying apparatus, the apparatus comprising an evaporation pan with a heating element wherein heat from the heating element evaporates moisture from the evaporating pan to eliminate the moisture and generate humidity. 
         [0006]    In another aspect, the pan comprises an ultrasonic vaporizing element to vaporize moisture collected in the pan. 
         [0007]    The apparatus can include a sensor with a feedback to heater controls. Also the heater can include a water trap that normally feeds condensate to the apparatus. The trap can include a sensor with feedback to the heater controls. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]      FIG. 1  is a front elevational view of a heater employing the apparatus of the present invention, sans cover, to show the internal components of the heater; 
           [0009]      FIG. 2  is an end plan view of the heater; 
           [0010]      FIG. 3  is an enlarged perspective view of one embodiment of a condensate trap; 
           [0011]      FIG. 4  is a perspective view of an assembled evaporation apparatus; and 
           [0012]      FIG. 5  is an exploded view of an evaporation apparatus. 
       
    
    
     DETAILED DESCRIPTION 
       [0013]    In general, the present invention employs an electric element to heat condensate from the products of combustion for the purpose of humidification. 
         [0014]      FIGS. 1 and 2  illustrates a heater, indicated generally by number  10 , which employs a representative embodiment of an evaporating apparatus indicating generally by reference number  12 . Apparatus  12  also can be referred to as a humidifying apparatus, as will be understood from the detailed description, below. 
         [0015]    The salient components of heater  10  include an outer housing  14  which enclose the inner working parts inside chamber  16 . The working parts include an induced draft blower  18  that draws combustion products from a heat exchanger  24 . An exhaust pipe  26  is in fluid communication with the heat exchanger and blower  18  to discharge exhaust gas. A burner housing  27  houses gas burners (not seen). Flames from the gas burner enter heat exchanger  24  tubes adjacent burner housing  27 . A circulating air blower  28  draws in room air from the upper rear area of heater  10  across heat exchanger  24  and discharges heated air out of the lower front of the unit. Chamber  16  generally comprises sheet metal walls that define the inner chamber and shields, such as shield  29  over heat exchanger  24 . 
         [0016]    Heater  10  is operated or controlled in any acceptable way. One preferred aspect of a heater control system is disclosed in the assignee&#39;s patent application Ser. No. 13/770,446, filed Feb. 19, 2013, which is incorporated herein by reference 
         [0017]    During operation, condensation occurs inside the heat exchanger tubes when the products of combustion are cooled below the dew point. This is a consequence of highly efficient gas heating equipment. There is a condensate collection point, indicated generally by number  30  adjacent induced draft blower  18  to collect condensation from combustion chamber  16 . There is a second condensation collection point, indicated generally by number  32 , on exhaust pipe  26 . It will be appreciated that the two condensation collection points described herein are merely illustrative of the broad aspects of the invention. One skilled in the art will appreciate that there can be one or there can be a plurality of collection points, optimally positioned within housing  14  to collect moisture and condensation. The number or location of the collection points is incidental. 
         [0018]    In any event, heater  10  can include an apparatus to trap or collect the condensate from the collection points. One aspect of such an apparatus is trap assembly  34  shown in  FIG. 3 . Trap assembly  34  is a container or canister which can have a top  36 , a closed bottom  38  and circumferential wall  40  that define and inner chamber  41  that has sufficient volume to accommodate a continuous flow of condensate from the condensate collection points without filling up. Conduits or tubes  42  and  44  extend through top  36  and terminate near the bottom of the inner chamber at their first ends and each one is in fluid communication with a condensate collection point at a second end of the tube. 
         [0019]    There is an overflow drain  46  that extends through circumferential wall  40  and is in fluid communication with the inner cavity. Drain  46  is position on wall  40  adjacent top  36 . This allows some level of fluid accumulation within the trap before it flows out of the overflow drain to the evaporating apparatus  12 , as will be explained below. Hence, the position of the overflow drain may vary depending upon the fluid level desired. 
         [0020]    Trap assembly  34  is positioned below blower  28  such that condensate will flow under force of gravity from the collection points into the chamber. The purpose of the condensate trap is to allow condensate to flow from the collection points even though the collection points are each at different pressures. These pressures are different from the pressure at evaporation apparatus  12 . Trap  34  allows condensate to flow without allowing flue gas to escape. Overflow drain  46  is in fluid communication with the upper end  48  of a condensate drain tube  50 . Tube  50  extends downwardly and terminates in with an open end adjacent evaporating apparatus  12 . Although in a preferred aspect of the invention, drain tube  50  terminates adjacent evaporating apparatus  12 , it also may terminate in a discharge to or drain outside housing  14  to dispose of condensate. 
         [0021]    Nevertheless, it will be understood that condensation is collected from the condensation points  30  and  32  and flows into trap assembly  34 . When the fluid level reaches a predetermined level, i.e. at the level of overflow drain  46 , it will flow out, through the upper end  48  of drain tube  50 . In a preferred aspect it drains into evaporating apparatus  12 . The location and configuration of the trap, the tubing and the condensation collection points can vary between heaters. The salient principle is that the heater may include apparatus to collect condensation and transport the condensate to the novel evaporating apparatus  12 . 
         [0022]    Trap assembly  34  can include a sensor, indicated generally by reference number  51 . Sensor  51  can be any type of acceptable sensor, such as a float, electric eye, electrical connection switch. It will be noted that sensor  51  can be located within the canister or outside, depending upon the type. Regardless of the type of sensor employed, sensor  51  is configured to detect an excess accumulation of water in the trap, which could indicate a blocked drain or other impediment to fluid flow. Sensor  51  can be operatively connected to the heater controls so that detection of a critical fluid accumulation would shut down the heater to prevent overflow of condensate. Also, it can be operatively connected to the evaporating apparatus to shut down the evaporating heating element, as will be explained. 
         [0023]    Evaporating apparatus  12  is shown in detail in  FIGS. 4 and 5 . In the exemplary embodiment, apparatus  12  includes a bottom pan  52  which, in the illustrated embodiment, has a generally rectangular shape. It will be understood that apparatus  12  can have any useful configuration that works well in the intended environment. Pan  52  includes a bottom wall  54 , a first end wall  56  with holes  58  and  60 , a second end wall  62  and first side wall  64  and a second side wall  66 . The recited walls define an inner cavity  68 . In one aspect, an insulative sheet  70  may be positioned in the cavity on bottom wall  54 . Insulative sheet  70  can be constructed from any acceptable insulative material. Furthermore, top surface  72  of the insulative sheet can be heat reflective. 
         [0024]    Apparatus  12  includes a vaporization element. In one aspect, the vaporization element is an electric heating element  74  is positioned in cavity  64 . If the apparatus includes an insulative sheet, heating element  74  is positioned above the insulative sheet. Heating element  74  can be any conventional heating element with electrical connections  76  and  78  that protrude through holes  58  and  60  and are connected to electricity. In one aspect, an evaporating pan  80  is positioned on top of heating element  74  and under the open end of tube  50 . Pan  80  has a bottom wall  82 , a first end wall  84 , a second end wall  85 , a first side wall  86  and an opposed second side wall  88 . The recited walls and bottom define an inner cavity  90 . It will be noted that the configuration of pan  80  is complementary to that of bottom pan  52  and sized so as to nest in the bottom pan. In other aspects or embodiments of the invention, there can be a layer of metal (not shown) between insulative sheet  70  and heating element  74 . The size and configuration of the various components of the evaporating apparatus may vary without departing from the scope of the invention. 
         [0025]    Also, it will be recognized by one skilled in the art that the evaporation apparatus can comprise only one pan, with a heating element operatively associated with the pan. By way of example, heating element  74  can be positioned inside an evaporation pan or outside, for example, under the pan. Moreover, the heating element can be integrated into the pan itself, for example, with heating wires within the pan material. In the appropriate circumstances, the heating element could be a gas flame, rather than an electric heating element. Hence, the term heating element can encompass any apparatus that heats moisture to evaporate or vaporize the moisture. 
         [0026]    Furthermore, although the exemplary embodiments refer to pans for simplicity and convenience, it will be understood that any type of fluid reservoir that can collect and hold fluid such as condensate is within the scope of the invention. 
         [0027]    In operation, there can be a sensor  92  associated with evaporating pan  80  to sense an accumulation of liquid in the pan. A feedback loop can actuate a switch to turn on heating element  74 . In other aspects, a temperature sensor may be employed to sense when the condensate has boiled and can include a feedback loop to de-energize or shut off the heating element. 
         [0028]    The heat from the heating element causes evaporation of the liquid in pan  80 . Consequently, condensate from the operation of heater  10  is dissipated through evaporation. Sensor  92  (or another sensor) can be used to determine if the fluid level in the patent exceeds a predetermined level and shut down the heater to prevent further fluid accumulation. Sensor  92  can be any appropriate sensor that serves its intended purposes, such as the sensors described above relative to trap assembly  3  and can be located in or on, or associated with any of the evaporation apparatus components. 
         [0029]    As set out above, heating element  74  can be operatively associated with sensor  51  of the trap assembly. If there is an increase in fluid in the trap, it could indicate that fluid is not flowing to the evaporation apparatus and the sensor could shut down the heating element or the entire heater. 
         [0030]    In another aspect or evaporation apparatus  12 , the vaporization element may be an ultrasonic vaporization device  94  in the pan, as shown in  FIG. 5 . An ultrasonic vaporization device uses a metal diaphragm vibrating at an ultrasonic frequency, much like the element in a high-frequency speaker, to create water droplets. An ultrasonic vaporization device is usually silent, and also produces a cool fog. 
         [0031]    It will be appreciated that evaporated or vaporized liquid serves as a source of humidity for the space where the heater is located. As shown, evaporating apparatus  12  is located adjacent the bottom of heater  10 , below heat exchanger  24  and blower  28 . This arrangement permits air forced downward by the blower across the heat exchanger to pick up moisture from apparatus  12  and expel it into a room from the bottom front of the heater. However, other locations of apparatus  12  that accomplish the desired purposes are intended to be included in the broad disclosure. 
         [0032]    Heater  10  can include sensors and switches that allow the heating element or ultrasonic vaporizer to be actuated only when blower  28  is operating so vapor from the condensate is introduced into room air rather than building up in the heater. The heater with the evaporating apparatus  12  serves the dual function of providing heat and humidity. 
         [0033]    The evaporation or vaporization feature of the heater may be employed in any heater that produces moisture in operation and has means for collecting the moisture and diverting it to the evaporation and vaporization elements. 
         [0034]    The foregoing description and accompanying drawings are intended to be illustrative of exemplary embodiments of the heater only and should not be construed in any manner that limits the scope of the appended claims.