Heating system for a machine with a light heat source

A heating system for a machine includes a tungsten halogen light bulb, a socket, a heat sink, and a reflector. The tungsten halogen light bulb is configured to emit light when connected to an electric power source. The socket is selectively electrically connected to the electric power source. The tungsten halogen light bulb is removeably connected to the socket. The reflector includes a reflecting surface, and is fixedly mounted in relation to the heat sink, such that the reflecting surface reflects at least a portion of the light onto the heat sink.

TECHNICAL FIELD

The present invention generally relates to heating systems for machines and more particularly to heating systems for machines with a light heat source.

BACKGROUND OF THE INVENTION

Prices for natural gas and electricity have risen over the years, and many consumers desire machines with more energy efficient heat sources. In addition to lowering prices paid for energy, the demand for more energy efficient heat sources is driven by consumers who are worried about conserving finite fossil resources, and lowering carbon emissions.

The EPA and Energy Star have issued new guidelines in June 2014 for a clothes dryer Energy Star certification. Few clothes dryers have achieved this certification. A dryer purchased in 1960 may use the same amount of energy as a current 2014 model, regardless of the make or model. For a dryer to achieve an Energy Star rating, the dryer may be required to reduce current energy use by twenty percent (20%) and the cycle to dry clothes must be no more than 80 minutes on a cycle to dry clothes.

Most current style electric dryers use resistance style/type heating elements with 5000 to 6000 watts at 220 volts. These heating elements may burn bright cherry red at the element itself and heat to a temperature in excess of 2200 degrees F. Most gas dryer work on the same principal by supplying a massive amount of heat (roughly 25000 BTU) to the dryer drum. Both electric and gas dryers may use thermostats to control the temperature inside the drum of the dryer. Many current dryers maintain a drum temperature of around 140 degrees F. The heating element is continually cycled on and off to maintain that optimum temperature inside the drum containing the clothes. The backs of most current dryers have little heat insulation material and a significant amount of heat energy, not utilized in the drying process, is exhausted out. Heated air is not recirculated. Approximately 80% of all dryers manufactured in the United States are electric.

As can be seen, there may be an ongoing need to raise the efficiency of heating sources for machines in general, and electric clothes dryers in specific.

SUMMARY OF THE INVENTION

This summary is provided to introduce a selection of concepts in a simplified form that are further described in the detailed description of the invention. This summary is not intended to identify key or essential inventive concepts of the claimed subject matter, nor is it intended for determining the scope of the claimed subject matter.

In one aspect of the present invention, a heating system for a machine includes a tungsten halogen light bulb, a socket, a heat sink, and a reflector. The tungsten halogen light bulb is configured to emit light when connected to an electric power source. The socket is selectively electrically connected to the electric power source. The tungsten halogen light bulb is removeably connected to the socket. The reflector includes a reflecting surface. The reflector is fixedly mounted in relation to the heat sink, such that the reflecting surface reflects at least a portion of the light onto the heat sink.

In another aspect of the present invention, a clothes dryer includes a drum, an air conduit, an electric power source, at least one heating unit, a heat sink, and a controller. The drum is for placing clothing in to be dried and is configured to rotate. The air conduit is fluidly connected to the drum at a drum end for providing warm air to the drum for drying the clothing. The air conduit includes an interior. The at least one heating unit are fixedly positioned in the interior of the air conduit, and each heating unit includes a reflector including a reflecting surface, a light bulb configured to emit light onto the reflecting surface when connected to the electric power source, and a socket selectively electrically connected to the electric power source. The light bulb is removeably connected to the socket. The heat sink is fixedly mounted in the interior of the air conduit and is positioned such that the reflecting surface reflects at least a portion of the light onto it. The controller is configured to selectively connect the socket to the electric power source.

DETAILED DESCRIPTION OF THE INVENTION

Various inventive features are described using relational terms such as front, back, side, top, and bottom. These terms are used to impart an understanding of spatial relationships between components and elements, views, or other objects, in various embodiments, and are not meant to be limiting.

The heating system illustrated in various exemplary embodiments below, uses light bulbs, and more specifically, in some embodiments, tungsten halogen light bulbs to heat a heat sink. The heat sink may be formed of copper, aluminum, ceramic, metal or gemstone alloys, or other suitable materials. The heating system may be used as a heat source for various household appliances, devices, and/or tools, which currently use natural gas or electrical resistance heat in items such as laundry dryers, hot water heaters, residential furnaces and/or any appliance or device that uses heat energy to heat a media. The heating system uses a new method of focused light energy. Focused light energy is the process of reflecting and/or refracting the energy from the light bulb onto a target heat sink and provides a focal point on that heat sink surface to achieve temperatures that are necessary to accomplish the end design in a much more energy efficient process. By reflecting and/or refracting all the energy from the light and hitting a target on a heat sink, effective temperatures of from 800 to 2000 degrees F. have been achieved in proto-types. The temperatures achieved may be dependent on the distances between the reflectors and/or refractors, the lights bulb, and the heat sink.

The light bulb may be placed into a socket and mounted onto a cuplike reflector that has a reflective material such as polished Aluminum or Aluminum oxide on a reflective surface. The bulb's energy is reflected back onto a target or heat sink material, such as copper, and the heat is transferred into the air or other media for the purpose of heating an object, i.e. air, water or other medium. Other reflective surfaces can be used such as highly polished stainless steel or a brilliant white porcelain coated onto a steel cup. The desired temperatures for the particular application may dictate in part the specific materials used for the heat sink and/or reflector and reflective surface. A copper heat sink may safely can see temperatures of 1800 maybe 1900 degrees safely, as copper's melting point is 1994 degrees F.

The air gap or distance between the reflector and/or refractor and the light bulb, and the distance between the reflector and/or refractor and the heat sink may be designed to achieve the heat output desired within a few degrees. For example, if a temperature of 450 degrees is desired at an x/y location this may be achieved with the heating unit at that precise location, +/−a few degrees, if the environment is stable, with no air currents or outside ambient air infiltration.

Referring now toFIG. 1, an exemplary embodiment of a heating unit102is illustrated in a perspective view. The heating unit102may include a light bulb106configured to emit light when connected to an electric power source208(shown in relation toFIG. 11), a socket108selectively electrically connected to the electric power source208, the light bulb106removeably connected to the socket108, and a reflector104including a reflecting surface105.

Although the reflector104may take a variety of shapes and sizes, the illustrated embodiment is cup shaped with an exterior surface107, an interior surface109, a first end120, a second end122, a first side111, and a second side113. The first side111may be a mirror image of the second side113in relation to a longitudinal axis B. The interior surface109may be the reflecting surface105. The reflector104may include a body portion116, and a first end portion118. The body portion116may be a half cylinder shape. The first end potion118may be a hollow quarter sphere shape.

The light bulb106may be any type light bulb which is capable of emitting sufficient energy for an acceptable life time. Sufficient energy and an acceptable life time may be determined in relation to the particular application the heating unit102will be used in. The light bulb106, may be a tungsten halogen light bulb124, and include a housing128enclosing at least one filament130, and gas132. The gas132may include a small amount of a halogen such as iodine or bromine. The filament130may be a tungsten filament. The combination of the halogen gas132and the tungsten filament130may produce a halogen cycle chemical reaction which redeposits evaporated tungsten back onto the filament130, increasing its life and maintaining the clarity of the housing128and gas130. The tungsten halogen light bulb124may be operated at a higher temperature than a standard gas-filled light bulb of similar power and operating life, producing light of a higher luminous efficacy and color temperature. Tungsten halogen light bulbs124may be commercially available at a reasonable price. Although other light bulbs106, may be used, a light bulb106with high temperature and long life characteristics may provide a better heat source with a longer life.

The light bulb106may include a socket end127for insertion in the socket108. The socket end127may include helical protrusions for meshing with helical grooves in the socket108allowing the light bulb to be removeably connected to the socket108. When the socket end127of the light bulb106is fully inserted into the socket108, the filament130may be electrically connected to a positive terminal and a negative terminal within the socket108as is known in the art.

The socket108may include a positive electric circuit terminal or wire110for connecting with the power source208, and a negative electric circuit terminal or wire112for connecting with a ground242(shown in relation toFIG. 14). The socket108may include a cavity136(shown in relation toFIG. 2) with helical grooves for receiving the socket end127. The socket108may include any receptor device for the light bulb106which allows an electrical circuit to be completed when the socket end127is fully inserted into the cavity136, and the positive terminal110and the negative terminal112are connected to a power source208and the ground242. Although socket ends127and sockets108with helical protrusions and grooves respectively, as described, are well known and common, other types of connectors are contemplated. The term socket108, should therefore be interpreted broadly as a connector device which fixedly and removeably connects the light bulb106to an electrical circuit; and fixedly and removeably places the light bulb106in a desired position relative the reflector104and the heat sink150(shown in relation toFIGS. 6-10).

The mounting bracket114may be fixedly connected to the exterior surface107of the reflector104, for mounting the heating unit102in relation to the heat sink150. The mounting bracket114may be welded, riveted, fastened with bolts, or otherwise fixedly connected to the exterior surface107in any way known ion the art. In some embodiments the mounting bracket114may be an integral portion of the reflector104. In the illustrated embodiment, the mounting bracket114includes apertures126for mounting the heating unit102with bolts. However, in other embodiments the mounting bracket may be fixedly connected to another surface in any way known in the art to mount the heating unit102.

Referring now toFIG. 2, a top expanded view of the heating unit102is illustrated. In the embodiment illustrated, the reflector104includes a reflector mounting flange138, and the socket108includes a socket mounting flange140for fixedly mounting the reflector104to the socket108. In other embodiments, other forms of connecting the reflector104, the socket108, and the light bulb106in desired relational positions may be used. The reflector mounting flange138and the socket mounting flange140may be fastened together with bolts142and nuts144, or other connection means known in the art.

Referring now toFIG. 3, a cross sectional view of the heating unit102, along line A inFIG. 1, is illustrated. The reflector104may be made of aluminum, another metal, a metal alloy, or a ceramic. If the reflector104is made of a metal or metal alloy, the reflecting surface105may be the same metal, but polished, and in some cases highly polished. In some embodiments however, the reflector104may include a reflector base146which may be made of aluminum, copper, another metal, a metal alloy, a ceramic, or any other solid material which has the heat and solidity characteristics needed for the heat unit102in the particular application. The reflector104may also include a reflector coating148which may be a white overlay such as porcelain or aluminum oxide which may have the reflection properties, or be polished to have the reflective properties needed for the particular application the heating unit102will be used in. Other coatings, as known in the art, may also be used.

Referring now toFIG. 4andFIG. 5, a first end120view of the heating unit102, and a second end122view of the heating unit102are illustrated respectively.

Referring now toFIGS. 6-10, several different embodiments of a heating system100are illustrated. The heating system100includes the heating unit102and a heat sink150. The reflector104is fixedly mounted in relation to the heat sink102, such that the reflecting surface105reflects at least a portion of the light emitted by the light bulb106onto the heat sink150. Several exemplary embodiments of heat sinks150are illustrated inFIGS. 6-10, but they should be considered non-limiting. In general, the heat sink150may include any device which may absorb and dissipate into a media heat radiated from the light bulb106. The heat sink150may include devices of various shapes and materials and may be designed to dissipate the desired heat of a particular application the heating system100is being utilized in.

FIG. 6illustrates an exemplary embodiment of the heating system100, with a plate heat sink152. The plate heat sink152may be fixedly attached to the mounting bracket114with bolts142and nuts144, or in another way as known in the art. Light energy from the light bulb106may be reflected by the reflective surface105onto the plate heat sink152. The plate heat sink may absorb the light energy, and dissipate it in a media, such as air, which the plate heat sink152is in thermal contact with.

FIGS. 7 and 8illustrates an exemplary embodiment of the heating system100, with a porous heat sink162. Illustrated inFIG. 7is a side perspective view of an air conduit154. The air conduit154may, for example, be an air conduit154in a clothes dryer200(shown in relation toFIG. 11). The air conduit154may include a drum end158, with a vent156, and an interior surface160. At least one heating unit102may be fixedly mounted to the interior surface160. The porous heat sink162may be mounted at the drum end158, in such a manner that the reflective surface105reflects light energy from the light bulb onto the porous heat sink162. Air flow, illustrated as arrows176, may flow through the air conduit154, past the at least one heating unit102, through the porous heat sink162, out the vent156and into a drum202(shown in relation toFIGS. 11 and 13) of the clothes dryer200. As the air passes through and/or comes in thermal contact with the porous heat sink162, heat is transferred from the porous heat sink162to the air.

As illustrated in a front perspective view of a porous heat sink162inFIG. 8, one embodiment of the porous heat sink162may include a housing164with a porous member166. The porous member166may include a metal mesh168. The metal mesh168may include channels170through which the air flows. The channels170may be formed by cross members172, with fins174between the cross members172. The channels170allow the air to come into thermal contact with a larger surface area of the heat sink150. Other embodiments of the metal mesh168may include, for example, a steel wool type structure, or any other mesh which allows for an increased surface area of the heat sink150to come into contact with the air.

FIG. 9illustrates a top perspective view of a heating system100with a housing heat sink178. The housing heat sink178may be a hollow member formed from sheet metal or another material with two open ends184, an interior surface186, an exterior surface188, and an interior190. At least one heating unit102may be mounted on the interior surface186. The interior surface186, or a portion of the interior surface186may also be an additional reflective surface105. The housing heat sink178may include apertures180, which may be of a variety of sizes and shapes. The apertures180may increase flow of a media (air or another media) through and around the housing heat sink178, and increase heat transfer to the media. The heating system100with the housing heat sink178may be mounted such that a media, to which it is desired to transfer heat, flows around and through the heating system100.

FIG. 10illustrates a front perspective view of a heating system100with a housing heat sink178and at least one rod heat sinks182. The housing heat sink178is similar to and functions similar to the one illustrated inFIG. 9, with the addition of rod heat sinks182mounted in the interior of the housing heat sink178. The additional rod heat sinks182may increase heat retention and transfer.

The heat sink150may be formed of a variety of materials depending on the application specifications, commercial pricing at the time of manufacture, and other factors known in the art. Non-limiting examples of materials which may be suitable for some or all applications include gold, silver, copper, aluminum, diamonds, composite materials, aluminum alloys, and silica or sand held in a matrix or alloy. The cost and low melting point of gold may limit its' usefulness. The cost of silver may be a limiting factor, but silver does have excellent heat sink and reflective properties. However silver also tarnishes quickly making its reflectiveness hard to achieve without continual polishing. Copper is an excellent heat sink, and has excellent conductivity, however high cost may be a limiting factor. Aluminum has good heat sink properties, good conductivity, low cost, is easily cast and molded into a variety of shapes, and is easily alloyed with other metals such as copper. Diamonds have thermal conductivity which is five times that of copper, however at this time they are very expensive so cost may be a limiting factor. Man-made diamonds in alloyed metal such as dymalloy are a possible material for lower cost. Composite materials include are copper-tungsten pseudoalloy, silicon carbide in aluminum, dymalloy, silicon alloy mixture, and beryllium oxide. Aluminum alloys include the 1000 through 7000 series and any variant thereof.

Referring now toFIG. 11, a perspective and schematic view of an exemplary clothes dryer200with the heating system100is illustrated. The clothes dryer200may include the drum202, the air conduit154including an air conduit interior232fluidly connected to the drum202at the drum end158, the electric power source208, at least one heating unit102fixedly positioned in the air conduit interior232, the heat sink150fixedly mounted in the air conduit interior and positioned such that the reflecting surface105reflects at least a portion of the light onto the heat sink150, and a controller212configured to selectively connect the socket108to the electric power source208. The drum202is configured to rotate, and for placing clothing to be dried. The air conduit154may provide warm air to the drum202for drying the clothing.

The drum202may rotate while heated air is pumped through it as is known in the art. A fan204, or other air flow device, may cause air flow through the air conduit154, which may be heated by the heating system100, and flow into the drum202through the vent156in the drum end158. At least one heating unit102may be mounted on the interior surface160, and the porous heat sink162may be mounted between the heating unit102and the vent156. In some embodiments, it may be necessary to slow the flow of air through the air conduit154so that the air is heated to a desired temperature before entering the drum.

For example, the heating system100may be part of a retro-fit kit which is installed in the clothes dryer200after manufacture and/or sale, and replaces a more traditional system—such as a gas heater or an electric resistive element heater. The clothes dryer200may include at least one interference member206(two interference members206are illustrated) to slow the air flow through the air conduit. The interference members206may include a housing164and a porous member166similar to the porous heat sink162illustrated inFIG. 8. In other embodiments the interference member(s)206may be any device known in the art which slows the flow of air through the air conduit154.

The clothes dryer200may include a user interface214through which a user can enter desired commands such as on/off commands, cycle commands, timer commands, and/or heat commands as is known in the art. The controller212may be communicatively connected to the user interface214to receive signals indicative of the desired commands, as is known in the art. The controller212may be communicatively connected to a switch210to actuate the switch210to selectively connect the at least one heating unit102to the power source208as needed to fulfill the commands entered by the user. The controller212may be software based and include one or more processors and one or more memory units. In other embodiments, the controller212may be a hardware control, or the controller212may be a combination of software and hardware. Although shown as separate units, the controller212, switch210, and/or power source208may be combined into one or more units. Referring now toFIG. 12, a partial side perspective and schematic view of an exemplary embodiment of the air conduit154ofFIG. 11is illustrated. Schematic representations of heat units102are used which are not necessarily to scale. The air conduit154may have an interior back wall234, an interior first side wall236, and interior second side wall238, and an air conduit front240. A first heating unit216may be mounted on the first side wall236, a second heating unit may be mounted on the second side wall238, and a third heating unit220and a fourth heating unit222may be mounted on the back wall234. All the heating units102may be selectively electrically connected to the power source208through electrical connectors224.

Referring now toFIG. 13, a perspective and schematic view of another embodiment of the clothes dryer200is illustrated. In this embodiment, the heat sink150is a housing heat sink178, and a housing heating unit assembly226is mounted in the air conduit interior232. Other elements other than the heating system100embodiment are similar to the clothes dryer200ofFIG. 11and will not be further described.

Referring now toFIG. 14, a partial side perspective and schematic view of an exemplary embodiment of the air conduit154ofFIG. 13is illustrated. Schematic representations of heat system100is used which is not necessarily to scale. The housing heating unit assembly226includes the housing heat sink178. A fifth heating unit228and a sixth heating unit230may be mounted on the interior surface of the housing heat sink178. All the heating units102may be selectively electrically connected to the power source208and grounds242through electrical connectors224.

Referring now toFIG. 15, a chart of experimental data comparing an exemplary embodiment of the clothes dryer200to competitive clothes dryers is illustrated. Wattage was calculated by taking incoming voltage times the amperage load—Ex: 122V×16.7 A=2037. The washer used to conduct all testing with the prototype dryer added four pounds to the water weight of the test load. The washers used when testing the commercially available dryers added only three pounds of water weight to the test load. The prototype dryer may dry the same test load in forty-five minutes if a washer adding only three pounds of water weight were used. Washer1, with the washer adding only three pounds of water weight, was the most energy efficient of all the comparison tests, combining the lesser water weight and a modulating dryer. On the maximum dryer setting it will dried the test load in forty minutes but used the maximum wattage of 4758. Washer1was not consistent at removing the same water weight every fifteen minute check, which may have been due to its higher modulating rate (it turns the heating unit off for a longer period of time). At the thirty minute check interval it removed five tenths of a pound of water weight in a fifteen minute period, compared to its initial one and three tenths pounds in a fifteen minute period at start-up. The prototype dryer consistently removed one pound of water weight at every fifteen minute weigh check.

In another test, a prototype dryer dried clothes in the same time period as a gas dryer. The same test set of laundry was used and took fifty to sixty minutes to dry in a gas dryer and the same set of clothes took forty-seven to fifty-five minutes to dry in the prototype consistently. The prototype dryer ran with a consistent temperature during the entire drying process and did not cycle on and off. The gas dryer did cycle on at a temperature of 120 degrees and cycled off at about 150 degrees by design. The fact that the prototype never cycled may be the reason it could achieve a few minutes better time. This new process achieves a far greater energy reduction than the EPA and Energy Star has set forth in their goals, as well as exceeding the time limit of 80 minutes or less. Each heating unit in the new process can be designed specifically for the individual appliance being retrofit with little to no manufacturer retooling or redesign of the basic appliance.

The heat gun has been available for home owners to scrape paint off the wall, and has also been available in the industrial area for various purposes from heat shrinking protective wire wraps for electrical use to curing glues in a timely manner. There are many styles and types of heat guns on the market today. They range in price from thirty dollars all the way into the thousands of dollars depending on the application. They may the range in temperatures from 0 to 1000 degrees. The one thing in common they all have is that they need a lot of energy to perform these tasks because of the method of heating employed. Some guns are 230 volts and some are 115 but they all draw quite a bit of power in order to perform at a peak level The embodiments of heat gun with the heating system100described below may not require as much power power and may use substantially less electricity to perform the same tasks and more.

In addition to being more cost effective, the heat guns with the heating system100described below may perform additional tasks the standard industrial heat gun does not. For example, many serious home mechanics/hobbyists have a collection of tools in their home and/or shop that allow them to fix everything from repairing that bent blade on the lawnmower to replacing the hot water heater. The heat guns with the heating system100described below may switch from stripping paint, to sweating a new fitting, to heat shrinking plastic over the windows for those in colder climates, to welding that plastic fitting on abs pipe assuring there are no leaks.

After sweating fittings together, there can sometimes still be a leak in the fitting. The reason for the leak may be incorrect or uneven heat distribution around all 360 degrees of the fitting. The heat gun with the heating system100described below may provide more even heat all the way around eliminating the danger of catching anything on fire, while sweating the joints together. The process may be performed as quickly, or faster, than a torch without the danger that an open flame can cause.

The heat gun may comprise a main body and three (or more in the future) detachable heads that perform different operations. One head may be for sweating common household sizes of copper piping which are ¼ inch and ¾ inch pipe, although larger sizes are contemplated as part of the invention. Another head may function as a heat gun. Another head may be utilized as a heavy duty-soldering gun. These heads may be mounted to the body in a quick disconnect fashion, perhaps like Black and Decker's Firestorm® system. A prototype of this is already in existence and is proven to work.

Referring now toFIG. 16, a side view of a heat gun300, according to an exemplary embodiment of the invention is illustrated. The heat gun300may include a body318rotably connected to a head320with a heavy-duty hinge316. The body318can be made from molded plastic and the head320can be made from cast aluminum with a coating of aluminum oxide on the inside of the head providing the reflective quality. Other suitable materials as known ion the art may also be used. A simple pistol-grip design with a pull trigger on-off power switch308, and a rheostat switch302mounted to the side of the body318casing may be used. The rheostat switch302may be pre-marked at certain settings for particular temperatures. For example setting one may be equivalent to 500 degrees. The heat gun300may also include a fan switch306for controlling the fan344(shown in relation toFIG. 18A), electrical contacts314for transferring electric power from the body318to the head320, and a latch312for fixedly connecting the head320to the body318. An electric cord310may provide power to the heat gun300.

Each head320may require a different configuration because each head320may do a separate task. For example, the heat gun head320may be different from the head320that sweats copper piping. Each head320may incorporate a quick disconnect style system so that the operator can quickly disconnect one head320from the body318and quickly replace it with another head320to the body318to perform a completely separate task.

Referring toFIG. 2, each individual head will perform different tasks. The first head design will sweat copper pipe joints together The standard method for doing copper plumbing work and sweating joints together is to use mapp gas or propane in a handheld torch configuration The problems with this method include annoying possibility of running out of gas before you have completed the job without any spare cylinders handy. Even with plenty of gas, after heating the joint a half dozen times, when you finally think you have the solder all around the joint, you shut the torch off, turn the water back on, and may then discover that on the backside of that joint has a leak because you the flame had not heated the joint evenly around. The proposed device will solve both problems. The illustrated head is designed to clamp around the pipe and heat both the top and bottom of the joint at the same time. When the operator pulls the trigger, 1300 degrees of heat hits the piping. The process includes clamping the gun onto the coupling, pulling the trigger, in a few seconds applying the solder, and removing the gun

The head may be made from cast aluminum with the inside surface being coated multiple times with aluminum oxide, thus giving the inside of the unit a reflective quality. The head may be divided into two halves—an upper half and a lower half. This will enable the head to clamshell together and lock onto the pipe. A set of dies may be used that attach to the head at the clamshell that will fit ½ inch and ¾ inch pipe also a 1-inch die should be available. Two bulbs will be used that stay with the head, one on top, and one on the lower jaw.

Referring now toFIG. 17, a side view of a heat gun300wherein the head320is a sweating head322is illustrated. The sweating head322is cylindrical in shape and the lower portion326of the jaw324is rotably connected with a jaw hinge330to drop down out of the way so it may the attach to the pipe that is to be sweat together. Once the jaw324is opened, the head322may be inserted onto the pipe and the pipe set into dies332which also may split in half. One half of the die332is mounted onto an upper portion328of the jaw324and the other half mounted onto the lower portion326. The dies332may be mounted to the jaw324sections with two screws, each screw spaced evenly between each die332.

The sweating head322may come with several sets of dies332, each set made for different size pipe couplings.

Two light bulbs106may be mounted inside each jaw portion326,328, with each on the centerline. On the inside of where each bulb106is located, the jaw324may have a concave surface334with a coating of aluminum oxide. The aluminum oxide may be mixed into a paste and applied to the concave surface334. When it cures, it may be a hard white coating that will reflect the light from the light bulb106back onto the pipe. At the backend of each light bulb106there may be a highly polished stainless steel reflector336, set on an angle, to reflect the light forward towards the pipe.

Since the sweating head322may comprise a good percentage of the physical weight of the entire gun300, a heavy duty cam style hinge316may be utilized to rotably connect the head320with the body318. When the head320swings up into place it may slip into a heavy catch/release312located on top of the body320. When the head320is secured to the body318, a body contact wall338may make a connection to a head contact wall340. These walls338,340may have the electrical contacts314permanently mounted to each wall338,340to align up to the respective opposite wall and provide the electrical contact to power the accessories mounted in the head320such as the light bulbs106, or anything else that would be mounted to the head320.

The head320may be completely sealed by the use of a removable end cap342which may slip snugly over the entire end of the head320, giving the operator greater safety while using this tool. The end cap342may also be tethered to the head320in some fashion. The head320may be made, especially around the bulbs106in layers. Going from the light bulbs106outward, the first layer may be the aluminum oxide, the second layer may be the cast aluminum and, the third layer may be heat repelling insulation, and the final layer may be a composite or like material such as sheet metal. This would give the operator extra protection against injury.

Referring now toFIG. 18A, a side view of the heat gun300with a standard head372is illustrated. The standard head372includes two light bulbs106buried inside the head320, in similar to the sweating head322. The addition of a fan344located behind the light bulbs106pushes heated air to the front of the head320. A reflective baffle wall346is fixedly positioned to diffuse most of the light coming from the light bulbs106. There will be several nozzle styles (shown in relation toFIGS. 18B-18F) that an operator may attach to the tip of the head320that will simply and snuggly fit over the very tip such as a wide area nozzle356(shown in relation toFIG. 18D) and a small area nozzle352(shown in relation toFIG. 18B). One of these tips may be a plastic welding nozzle354(shown in relation toFIG. 18C) that will concentrate the hot air in a very small area being heated, and will be able to perform the task of plastic welding.

Because of the new heating method used, the heat gun300is immediately heated as soon as it is powered on. It may reach, for example, up to 1500 degrees F., or more depending on the focal point. The new heat gun300may perform the same task as any standard or industrial style heat gun on the market today. However, the new heat gun300may be much more versatile and may perform many other tasks utilizing the different nozzles352-360that may come with that head320attachment and it may be more economical to run than the old style, and may also be faster.

Standard Industrial heat guns put out about 650 to 700 degrees F. whereas the proposed heat gun300may more than double that output, and use less electricity in doing so, therefore costing less in the process. Also as an added feature a kit may come with the plastic welding nozzle354allowing more versatility with the product. Plastic welders range in price from 300 dollars on up to 1000 dollars, and have a heat range of 800 degrees on up to 1200 degrees. The proposed heat gun300may be capable of the same performance. There may be a variety of nozzles352-360that fit over the end of the heat gun300, and provide the user with a choice for a variety of tasks.

Referring now toFIGS. 18B-18F, a variety of nozzles are illustrated in side perspective views.FIG. 18Billustrates an exemplary small area nozzle352for the heat gun300.FIG. 18Cillustrates an exemplary plastic welding nozzle354for the heat gun300.FIG. 18Dillustrates an exemplary wide area nozzle356for the heat gun300.FIG. 18Eillustrates an exemplary paint scraping nozzle358for the heat gun300.FIG. 18Fillustrates an exemplary straight nozzle360for the heat gun300.

Another nozzle (not shown) may be for plastic welding only, and include a flexible hollow shaft, perhaps a foot in length, with a plastic welding nozzle mounted at the tip of this shaft. This nozzle may allow the operator a lighter more controllable device to hold while welding, rather than the entire gun itself.

Referring back toFIG. 18A, adjacent to where the standard head372attaches to the body318, may be a fan344which provides the air for the heat gun300in all modes. The fan344may have a high velocity blade to provide a maximum air flow to the nozzle352-360. A reflective baffle wall346may be positioned immediately adjacent the fan344and angled back towards the tip of the of the heat gun300. The reflective baffle wall346may be a partial wall and may be in alignment with both the upper and lower light bulbs106. The reflective baffle wall346may be open to the sides so that airflow can pass all around the light bulbs106. An insulated wall348may protect the operator and allow maximum heat to move towards the tip. An inner cone shaped heat sink wall350may be located in the middle in-between the upper and lower light bulbs106. The heat sink wall350may be made of a material that soaks in the heat rather than reflecting the heat. On the inside of heat sink wall350may be a location for another light bulb if additional heat is necessary. A prototype with only two light bulbs reflecting inward towards the middle was capable of temperatures in excess of 1300 degrees. The additional light bulb may have a separate control or may be segregated by a temperature scale. The temperature may be set on the rheostat switch302in increments of, for example 100 degrees. The rheostat switch304and/or the fan switch306may be rotary switches304. At 100 degrees only one bulb may be powered at 25%. At 200 degrees one bulb may be powered at 35%, etc. Finally, at 1300 degrees, all three bulbs may be powered at 100%. This is exemplary only. The fan344may also be controlled with a rheostat style switch306, allowing more control for the different tasks this gun can perform.

Referring now toFIG. 19, a side view of a heat gun300with an exemplary soldering head374is illustrated. With the two light bulb106configuration described in relation to the sweating head322and a better reflector than the aluminum oxide, having for example, more of a mirrored surface, and concentrating the light to the center of the cylinder shaped head320, with a ruby rod364and in the center mounted with a high mirror polish on an inner end368and a dull polish on an outer tip366, a lasing action hot enough for welding purposes may be achieved. If the light bulbs106can generate enough light to excite the atoms into a high energy state, then those atoms will release the energy as photons and shoot down the ruby rod364, causing the lasing action to occur. A proximity sensor (not shown) may be incorporated into the tip of the head320, along with a sensor that may sense human tissue (not shown). The proximity sensor would sense if an object is too far away to cut or weld. In response to sensing such a condition, the heat gun300may not fire. In response to the other sensor sensing human tissue in close proximity the heat gun300would not fire.

The ruby rod364may be located in the center of the soldering head374such that it can be bombarded by the light bulbs106which may be above and below the ruby rod364to focus the light being emitted to the center of the ruby rod364. By bombarding the ruby rod364in this fashion, the atoms may become super excited and release photons into the ruby rod364. Once photons have been released into the ruby rod364it may produce a lasing action, creating a laser beam being projected out the outer tip366of the ruby rod364. The outer tip366of the ruby rod364is only partially polished at the end, while the opposite inner end368has a high polish, creating a mirror like surface, so the photons will bounce off that end368and be released at the outer tip366. The entire inside surface of the head374has highly polished walls370designed to bounce the light emitting from the light bulbs360towards the ruby rod364. The ruby rod364may be secured in place so that it stays centered and non-moving.

Another use of the heating system100includes heated floors. Heated floors are nothing new, however they are becoming a popular option in the high-end housing market. One deterrent to installing a heated floor is a complicated installation process. Some systems use hot water and others use electrical resistance, however both may require several levels of installation. A level sub floor, a cement board over the sub floor, heated floor tubing and or grids over the cement board, and then tile may all be required. A lightweight panel with many cross sectional channels running at ninety degree angles to each other can be made with today's composite and plastics technology that would withstand a high traffic area such as a kitchen or main hallway. This panel would have a porous top and/or thousands of tiny holes in the top only. The cross sectional channels would add strength and allow air to be dispersed throughout the panel evenly. They could be custom made to order to allow customers to choose coloring and styling from a hard wood floor to ceramic tile. These panels could seal to each other and be locked into the adjoining panels. In some embodiment, small ducts may be installed along the edge of the floor to vent air, such as along the edge under cabinets in place of molding.

Another use for the heating system is in tank heaters. Tank heaters are used in various applications in various industrial venues, but their purpose, no matter where the application, is the same—they heat large volumes of a liquid substance. These heaters come in all shapes and sizes for a variety of installations, and going into a variety of environments. Many are in extreme conditions such as acid baths, or caustic baths or washes. The simplest form of tank heaters are classified as over the side heaters, and, as the name implies, they simply are placed over the side of the tank, and lowered into the liquid. It takes roughly 1000 watts of energy from one of these tank heaters, using the current standard, to heat 250 gallons of water to ten degrees above the ambient temperature.

This new system requires only a fraction of that energy and if the operator so desires, he/she may literally boil the water in the immediate area of the heater. The device may be extremely simple to manufacture. It may include a solid cylindrical piece of copper about two inches in diameter, at various lengths, depending on the depth of the tank it will be used in. The copper cylinder is then bored hollow to place the bulbs inside. The copper cylinder would be sleeved in stainless steel or other more exotic alloys, depending on the nature of the environment the heater will be exposed to. The bulbs may be set in place and secured in the position that would allow the most reflective angle against the copper core.

Another use for the heating system100includes water heaters. A new heating unit would be made to retrofit existing water heaters with old style heating units, including electrical or natural gas units. If a completely new unit is being installed, this heating system allows the consumer to install it in any location they so desire, as since no fossil fuels are being used, no need to vent to the outside is necessary. This allows more installation flexibility. The new heating unit may be sealed completely, thus eliminating explosions and other hazards that sometimes occur to natural gas hot water heaters. The new heating unit will be able to do the same job at approximately half the cost of an electrical heater, and approximately 70 to 85% of natural gas.

Another use for the heating system100includes residential furnaces. A new heating unit would be made to retrofit existing furnaces with old style heating units, including electrical or natural gas units. Since no fossil fuels are being consumed, a chimney or flu to vent to the outside is unnecessary. Therefore, 100% of the heat remains inside the house. The new heating unit will be able to do the same job at approximately half the cost of pure electricity, and approximately 70 to 85% or more of natural gas. A big advantage to the new unit would be no replacement costs of the old burner unit. In natural gas fired furnaces, the burner unit often needs replacing periodically. This may be expensive as the task is usually done by a service technician and is not a job that the average homeowner would take on. As with all the new style heating units, the heat is supplied by the tungsten light bulb. If one burns out, you simply replace that bulb. This may be no more difficult than replacing a bulb in your table lamp. An add on to the furnace would be an individual register unit: This device could be put at individual registers to boost the hot air coming into a particular room By putting a single bulb heater with a booster fan behind the unit you could boost the hot air coming in from that one duct register, thus giving the home owner more control over his/her furnace, and providing a greater comfort level to each individual room. By hooking up these individual units to a central brain and having mass air flow sensors on each unit, the furnace could run with greater efficiency then before. Using this central brain would allow the homeowner to control each room in his/her home at an individual level. If a room is essentially unused, it can be cut off, allowing more of the heat being produced to go where it is desired.

In some embodiments, rather than replacing the entire heating system, the old heating unit may be replaced with the new one, and the existing duct work and blower motor unit may remain in place.