Deicing system and method

Certain embodiments of the present invention provide a deicing system configured to prevent ice from forming in a water containment vessel. The system includes a heating element configured to heat the water within the containment vessel, a first temperature sensor and a second temperature sensor. The first temperature sensor is electrically connected to the heating element through an electrical path and may be configured to monitor water temperature. The second temperature sensor is electrically connected to the heating element through the electrical path and may be configured to monitor heating element temperature. At least one of the temperature sensors may include a reset button.

FIELD OF THE INVENTION

Embodiments of the present invention generally relate to a deicing system and method, and more particularly to a deicing system and method that includes a resettable thermostat.

BACKGROUND OF THE INVENTION

Conventional electric water deicers are used to keep areas of livestock water tanks and ponds free from ice during winter months. Similarly, birdbath deicers and heated birdbaths or pet bowls are used for smaller animals. One type of deicer is a floating deicer in which a buoyant member such as a buoyant ring is attached to a heating element so that the deicer may float on the surface of the water. Another type of deicer is a sinking deicer that is configured to lay at the bottom of a tank or pond, or on a metal guard submerged in the tank. A drain plug deicer is yet another type of deicer that is mounted through a drain hole of a tank and operates similar to a sinking deicer.

Deicers typically include a temperature sensor (e.g., a thermostat) that detects when the water temperature rises above a freezing point. A typical deicer then deactivates a heating element when water is not susceptible to freezing in order to conserve energy. When the temperature sensor detects that the water temperature is at or close to the freezing point, the deicer re-activates the heating element in order to heat the water.

Typically, a deicer includes a single thermostat that is operable to deactivate the heater when water reaches a predetermined temperature. In some configurations, an additional path from the heater to the thermostat is employed to route heat to the thermostat if the deicer is removed from the water or if the containment vessel runs dry. In this case, cooler ambient air causes the deicer to activate and begin heating. Because there is no water to absorb the heat, however, the deicer and/or the containment vessel (such as a livestock water tank or birdbath) begin to heat. The heat reaches the thermostat quicker than normal because water mass is not present to absorb the energy. When the thermostat detects the predetermined deactivation temperature, it trips and the heater is deactivated. The ambient air then cools the deicer until the thermostat detects the predetermined activation temperature and the cycle repeats. The deicer continually cycles on and off even though the containment vessel is substantially or completely devoid of water. Consequently, energy is wasted and the heating element of the deicer typically reaches a much higher temperature in the absence of water, and may pose a fire hazard.

Typically, deicers are designed to trip and reset continually during normal operation in order to regulate the water temperature within a containment vessel between predetermined low and high temperatures. The thermostat closes to energize the heater when the water temperature drops to a point where freezing is possible and remains closed as the water is heated until it reaches the predetermined high temperature point when it opens (trips) and the heater deactivates. The thermostat typically remains open as the water cools until it once again closes and the cycle repeats.

SUMMARY OF THE INVENTION

Certain embodiments of the present invention provide a deicing system configured to prevent ice from forming in a water containment vessel. The system includes a heating element configured to heat the water within the containment vessel, a first temperature sensor and a second temperature sensor. The first temperature sensor is electrically connected to the heating element through an electrical path and is configured to monitor water temperature. The second temperature sensor is electrically connected to the heating element through the electrical path and is configured to monitor heating element temperature (i.e., the temperature of the heating element itself). Each temperature sensor may include a thermostat.

The first temperature sensor may close the electrical path when the water temperature is at or below a predetermined low point. The first temperature sensor may open the electrical path when the water temperature is at or above a predetermined high point.

The second temperature sensor may open the electrical path when the heating element is at or above an overheated point that exceeds the high point. Additionally, the second temperature sensor may include a reset button that is configured to be manually engaged to close the electrical path after the second temperature sensor opens the electrical path.

The deicing system may include an additional temperature sensor that is configured to monitor the water temperature. It may also include another temperature sensor that monitors the heating element temperature.

Certain embodiments of the present invention provide a deicing system that includes a heating element configured to heat the water within the containment vessel, a first temperature sensor and a reset button. The first temperature sensor is electrically connected to the heating element through an electrical path. The first temperature sensor opens the electrical path based on a detected temperature. The reset button operatively connects to the first temperature sensor and is configured to be manually engaged to close the electrical path after the first temperature sensor opens the electrical path based on the detected temperature. The first temperature sensor may be configured to monitor heating element temperature.

Certain embodiments of the present invention provide a method of preventing ice from forming within a water containment vessel. The method includes detecting a temperature of the water within the water containment vessel through a first thermostat, activating a heating element when the temperature of the water is below a predetermined low point, deactivating the heating element when the temperature of the water is at or above a predetermined high point, detecting a heating element temperature with a second thermostat, and preventing the heating element from activating when the heating element temperature is at or above an overheated point that exceeds the predetermined high point.

The method may also include manually resetting the second thermostat after the preventing in order to reactivate the heating element. Further, the overheated point is below a damaging temperature that can cause damage to the heating element and/or the water containment vessel.

The foregoing summary, as well as the following detailed description of certain embodiments of the present invention, will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there are shown in the drawings, certain embodiments. It should be understood, however, that the present invention is not limited to the arrangements and instrumentalities shown in the attached drawings.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1illustrates a simplified view of a sinking deicing system10according to an embodiment of the present invention. The sinking deicing system10includes a main body12that supports a heating element14and temperature sensors/sensing devices, such as thermostats16and17. Instead of thermostats, the system10may employ other such temperature sensors, such as thermometers or the like. The heating element14may be a coil heater contained within a cylindrical sheath. A fluid pump18may be secured on, to and/or within the main body12. For example, the fluid pump18may be disposed on top of the main body12above the heating element14and the temperature sensor16. The heating element14, the thermostats16,17, and the fluid pump18are electrically connected to an insulated power cord20that connects the deicing system10to a source of power, such as a standard wall outlet. Optionally, the deicing system10may be powered by batteries. Alternatively, the deicing system10may not include the fluid pump18.

Each of the heating element14, the thermostats16,17, and the fluid pump18may also be electrically connected to a processing unit (not shown) located within, or remotely from, the deicing system10. The processing unit may be used to control operation of the deicing system10, such as shown and described in U.S. application Ser. No. 11/733,637, entitled “Fluid Heating System and Method,” filed Apr. 10, 2007, which is hereby incorporated by reference in is entirety.

The sinking deicing system10is configured to sink to the bottom of an open-ended water receptacle22, such as a livestock water trough, water tank, bucket or birdbath that retains water24. As shown inFIG. 1, the water receptacle22includes a base integrally formed with upright outer walls. A water retention cavity is defined between the base and outer walls. The thermostat16detects the temperature of the water24proximate the deicing system10. When the thermostat17detects a temperature in which the water surface26is susceptible to freezing, the heating element14is activated in order to warm the water24. After the water24is heated to a temperature in which the water surface26will not freeze, as detected by the thermostat17, the heating element14is deactivated.

The fluid pump18significantly reduces the temperature gradient between the bottom of the water24proximate the deicing system10and the water surface26. Thus, the deicing system10is able to detect the warmed water sooner in order to deactivate the heating element14before the water surface26is excessively heated.

The fluid pump18may be a small pump that circulates 40-150 gallons per hour and consumes a relatively small amount of power (e.g., less than 10 watts per hour). The fluid pump18operates to circulate the water24within the water receptacle22in the direction of arrows A. As such, warmer water near the bottom of the water receptacle22is circulated to the water surface26, thereby warming the water surface26, while cooler water at the water surface26is circulated down toward the deicing system10, where it is warmed. The fluid pump18draws water in through a water inlet or intake28, and ejects water out through a water outlet30in order to provide the circulating water flow within the fluid receptacle22. The water outlet30may be pointed upward in order to establish a circulating fluid current in the fluid receptacle22. The fluid pump18may be continually activated even when the heating element14is deactivated. Thus, the water24within the fluid receptacle22may be continually circulated, thereby warming water at the water surface26, and circulating cooler water to the bottom of the fluid receptacle where it is warmed through heat exchange with the warmer water at the bottom. Heat retained by the water24is spread throughout the fluid receptacle22via convection. As such, the fluid pump18significantly reduces or eliminates potential temperature gradients within the water24.

Because the fluid pump18circulates the water24, thereby reducing or eliminating temperature gradients, the temperature detected by the thermostat16at the bottom of the fluid receptacle22will be the same, or substantially the same, as the temperature at the water surface26. Thus, the heating element14may be configured to activate at a point that is close to the freezing point of the water24at the surface26. That is, the deicing system10does not need to take into account temperature gradients in order to set an activating trigger point for the heating element14. Therefore, the water surface26is not excessively heated, and energy is saved due to the heating element14being operated more efficiently.

Alternatively, embodiments of the present invention may be used with a floating deicing system, although such a floating deicing system is susceptible to being contacted by animals. For example, the main body12, the heating element14, the thermostats16,17, and the fluid pump18may be mounted to, or secured with respect to, a floating member, such as an air filled tube, Styrofoam pontoon or ring structures, or the like. In this embodiment, the heating element14and the thermostats16,17are disposed within the water24(e.g., secured to an underside of the main body12). The fluid pump18is also disposed within the water24such that the water outlet30would be downwardly oriented toward the base of the fluid receptacle22to promote water circulation. The water circulation provides a uniform temperature throughout the water24, thereby reducing or eliminating temperature gradients.

FIG. 2illustrates a simplified view of a drain plug deicing system40according to an embodiment of the present invention. The drain plug deicing system40includes a main body42including a drain plug44that supports thermostats16,17, a heating element14, and a fluid pump18. The drain plug44is sealingly secured within a drain opening of a fluid receptacle22that is configured to retain a fluid, such as water24. The deicing system40operates similarly to the deicing system10, except that the deicing system40is suspended out of a drain, instead of lying submerged at the bottom of the fluid receptacle22.

FIG. 3illustrates a schematic diagram of a deicing circuit50according to an embodiment of the present invention.FIG. 4illustrates a simplified block diagram of the deicing circuit50.

Referring toFIGS. 3-4, the thermostats16and17are disposed within an electrical path52(which may include electrical wires) between a power source54and the heating element14. As noted above, the heating element14may include a coil56disposed within a protective sheath58. The heating element14is, in turn, connected to ground60. Additional components of the deicing systems discussed above, such as a fluid pump, may be also be disposed within the electrical path52.

The thermostat16operates as a water monitor and may include a switch that selectively closes and opens the electrical path52to the heating element14. Thus, when the thermostat16detects a predetermined warm temperature, the thermostat16“trips” and acts to open the switch and deactivate the heating element14. Conversely, when the thermostat16detects a predetermined cold temperature, the thermostat16operates to close the switch and activate the heating element14. A pump may be disposed in the electrical path52upstream from the thermostats16,17. As such, any switch within the thermostats16and17would not affect the pump18. Alternatively, the pump may be activated and deactivated along with the heating element14.

As noted above, the thermostat16is used to monitor the water temperature. The thermostat17is used, however, to monitor over-temperature conditions. The thermostat17may be used to directly monitor the temperature of the heating element14for temperatures that are only reached if water is not present. As discussed above, in the absence of water, the heating element14is susceptible to reaching temperatures that exceed those when the heating element14is immersed in water. The thermostat17is used to monitor such over-temperature conditions. For example, the thermostat17may deactivate the heating element14when it reaches a pre-determined overheated temperature, which exceeds the point at which the thermostat16deactivates the heating element14.

As shown inFIG. 4, in particular, the thermostat17may include a reset button62, which may be electrically connected to the switch within the electrical path52. Thus, when the thermostat17deactivates the heating element14after detecting the overheated temperature, the heating element14is prevented from re-activating until an operator manually engages the reset62(in a manner similar to a circuit breaker) which may be a button or separate switch. As such, the heating element14is prevented from entering a continuous on/off loop and reaching dangerous over-temperature conditions that may pose a fire hazard. In this manner, the dual thermostats16and17provide a level of safety that conventional deicing systems do not match.

The deicing systems may employ additional temperature sensors, such as the thermostats16and17. For example, another water thermostat may be used as a backup to the thermostat16, while another thermostat may be used as a backup to the thermostat17. Thus, the backup thermostats provide reassuring safety backups in case the thermostats16or17malfunction. Further, the backup thermostats may be used as an accuracy check with respect to the thermostats. Each of the water thermostats may be electrically connected to alert devices, such as light emitting diodes (LEDs), when they do not open/close in synchronization with one another. That is, if the thermostat16trips, but the backup does not, the LEDs are activated, thereby signaling to the operator a malfunction in at least one of the thermostats. The resettable over-temperature thermostat17and its backup may be similarly configured.

Embodiments of the present invention provide a deicing system having a plurality of temperature control devices, in which at least one of the devices monitors water temperature, while at least one other of the devices monitors an over-temperature condition of a heating element. At least one of the temperature control devices includes a reset feature. When the temperature control device detects a predetermined tripping temperature, whether in the water or in the heating element, the device opens the electrical path to the heating element to prevent the flow of electricity thereto. The electrical path remains open until an operator manually engages the reset feature, such as a button or switch, to return the temperature control device to its closed position.

Because the resettable temperature sensing device, such as the thermostat17, is configured to deactivate the heating element14only at a temperature that far exceeds the tripping temperature of the water monitoring temperature sensing device, such as the thermostat16, the thermostats ensure that the deicing system operates to continually warm the water, but deactivate the system once water is substantially absent from the containment vessel. For example, the thermostat16may be configured to open the electrical path52when it detects a water temperature of 40° F. (for example) and closes the electrical path52when it detects a water temperature of 33° F. (for example). However, the thermostat17may be configured to open the electrical path52when it detects a heating element temperature of 90° F. (for example). Then, the deicing system may be reactivated when an operator resets the thermostat17to a closed position. In this manner, the thermostat17may be configured to trip at a temperature that the heating element14may only experience when it is not surrounded by water. That is, when immersed in water, the heating element14is incapable of reaching a particular overheat temperature. The thermostat17trips only at the overheat temperature, which it cannot reach when immersed in water. Thus, the deicing system continually operates to ensure that water within a containment vessel remains within a predetermined temperature range, and only deactivates and remains deactivated when a sensed temperature of the heating element approaches, but does not reach, a dangerous level. The temperature sensing devices may be configured to open and close the electrical path based on various temperatures, depending on particular applications.

FIG. 5illustrates a flow chart of a method of operating a deicing system, according to an embodiment of the present invention. At70, water temperature within a containment vessel, such as a livestock water trough or birdbath, is detected with a first temperature sensor, such as a thermostat, thermometer or the like. If, at72, the water temperature is below a predetermined low temperature, the electrical path to the heating element of the deicing system is closed at74in order to activate the heating element to heat the water. The process then returns to70.

If the water is not below the low temperature, but has not reached a predetermined high temperature76, the process returns to70. If, however, the water temperature is at or above the predetermined high temperature, the electrical path is opened at78in order to deactivate the heating element at78.

Next, at80, the temperature of the heating element itself is detected with a second temperature sensor, such as a thermostat, thermometer or the like. If, at82, the temperature of the heating element is detected to be below an overheated temperature, the process returns to70. The overheated temperature exceeds the high temperature. Indeed, the overheated temperature may greatly exceed the high temperature. For example, the high temperature may be between 40-60° F., while the overheated temperature may be between 90-120° F.

If the temperature of the heating element is not below the overheated temperature, but is instead at or above the overheated temperature at84, the electrical path to the heating element is opened, thereby deactivating the heating element at86. The electrical path is then kept open at88, until the second thermostat is manually reset.

While various spatial terms, such as upper, bottom, lower, mid, lateral, horizontal, vertical, and the like may used to describe embodiments of the present invention, it is understood that such terms are merely used with respect to the orientations shown in the drawings. The orientations may be inverted, rotated, or otherwise changed, such that an upper portion is a lower portion, and vice versa, horizontal becomes vertical, and the like.