Abstract:
A combustion system for a portable forced air heater having two frusta-conical sections attached to a circular burner tube, wherein each frusta-conical section has pre-determined vent hole patterns that allow the gas heater to have a variable burn rate.

Description:
FIELD OF THE INVENTION  
         [0001]    The present invention relates generally to heaters and, in particular, a new combustion system for use in a forced-air type heater.  
         BACKGROUND OF THE INVENTION  
         [0002]    Portable heaters are well known. One type of portable heater for commercial use draws air into the heater and forces the air through a flame. As the air passes through the flame, it is heated and output into a room or other structure which is intended to be heated. This type of portable heater is referred to as a forced-air and/or direct-fired heater. In a direct-fired heater, part of the product of the combustion is output into the room or the structure to be heated.  
           [0003]    Direct-fired heaters are fairly distinctive in their appearance since they utilize an elongated cylindrical housing. Within the housing is mounted a means for moving the air (usually at a high velocity) and a combustion system.  
           [0004]    The means for moving the air consists of a fan (or a propeller) attached to an electric motor. The motor and fan turn at a constant speed and blow air over the combustion system. The combustion system is designed to burn gas (vapor propane or natural gas). A control circuit releases a pre-determined amount of gas and mixes it with air. The air/gas mixture is ignited at the combustion system and, as long as gas is supplied, the fire stays lit.  
           [0005]    Mounted on the outside of the housing are valve(s). The valve(s) are connected between an external gas source and the combustion system by tubing. Normally, the valves are completely closed (i.e., “off”) or completely open (i.e., “on”) and ensure a steady flow of gas to the combustion system. A modulating secondary valve is sometimes utilized.  
           [0006]    Air is drawn in by the fan at the inlet or first end of the housing, heated as it passes and mixes with the combustion system and exits through the outlet or second end of the housing.  
           [0007]    Although the housing, fan and the electric motor that drives the fan are all fairly typical in such forced-air commercial heaters, the shape and efficiency of the combustion system may be quite different. However, one thing previous burner assemblies in other heaters have in common is that they are not capable of having their input gas flow rate adjusted without affecting safe and efficient combustion. Because of this drawback, most portable direct-fired heaters run at maximum output and are usually designed to produce constant heat while on (e.g., 500,000 British thermal units [Btus] or higher).  
         SUMMARY OF THE INVENTION  
         [0008]    In contrast with prior portable commercial heaters, the present invention is an improved heater having a novel combustion system that burns gas more efficiently—even at reduced gas flow rates. Therefore, the present invention allows the heat output of the heater to be variably controlled. This may be done by replacing the valves with modulating regulators, and connecting the regulators to a new control circuit (e.g., one having a thermostat). Although the present invention is described in connection with a portable heater, it may be utilized by any type of direct-fired heater. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0009]    The accompanying drawings, which are incorporated in and form a part of the specification, illustrate the embodiments of the present invention and, together with the description, serve to explain the principles of the invention.  
         [0010]    In the drawings:  
         [0011]    [0011]FIG. 1 is a perspective view of a heater utilizing a combustion system in accordance with the present invention;  
         [0012]    [0012]FIG. 2 is an exploded perspective view of the heater illustrated in FIG. 1;  
         [0013]    [0013]FIG. 3 is an opposite side perspective view of the heater illustrated in FIG. 1;  
         [0014]    [0014]FIG. 4 is a partial cut-away view of the heater illustrated in FIG. 1 showing the location of the combustion system;  
         [0015]    [0015]FIG. 5 is a back view of the heater illustrated in FIG. 1 showing the inlet;  
         [0016]    [0016]FIG. 6 is a partial cut-away view of the left side of the heater illustrated in FIG. 1; and  
         [0017]    [0017]FIG. 7 is a perspective view of the combustion system in accordance with the present invention;  
         [0018]    [0018]FIG. 8A is a front plan view of the combustion system shown in FIG. 7;  
         [0019]    [0019]FIG. 8B is a partial cross-sectional side view of the combustion system illustrated in FIG. 8A taken across line  8 - 8 ;  
         [0020]    [0020]FIG. 9A is an enlarged front plan view of a section of the combustion system illustrated in FIG. 8A showing the details of the flanges;  
         [0021]    [0021]FIG. 9B is a cross-sectional view of the combustion system section illustrated in FIG. 9A taken across line  9 - 9 ; and  
         [0022]    [0022]FIG. 10A is an enlarged right side plan view of the control box in accordance with the present invention;  
         [0023]    [0023]FIG. 10B is an enlarged front plan view of the control box illustrated in FIG. 10A illustrating the switch cut-out; and  
         [0024]    [0024]FIG. 10C is an enlarged top plan view of the internal mounting plate used to secure at least part of the control circuitry within the control box. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0025]    In describing preferred embodiments of the invention, specific terminology will be selected for the sake of clarity. However, the invention is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes all technical equivalents that operate in a similar manner to accomplish a similar purpose.  
         [0026]    The terms “right,” “left,” “top,” and “bottom” designate relative directions in the drawings to which reference is made. The terms “inner” and “outer” will be used to refer to a general area inside or outside of the heater.  
         [0027]    The preferred embodiments of the present invention will now be described in detail with reference to the accompanying drawings in which a forced-air or direct-fired heater in accordance with the present invention is generally indicated at  10 .  
         [0028]    Referring to FIG. 1, the forced-air heater  10  includes an elongated, substantially cylindrical housing  12 . Although the cylindrical housing  12  may be formed from a plurality of pieces of sheet metal, in the preferred embodiment, one piece of sheet metal is manipulated to form the housing  12 . Also, in the preferred embodiment, the housing  12  is made of steel.  
         [0029]    Referring now to FIGS. 2, 3 and  4 , the housing  12  has an inlet  16 , an outlet  18 , a top  96  and a bottom  98 . A pair of wheels  28  depend from the bottom  98  of the housing  12 , and are positioned closer to the inlet  16 , to ease moving the heater  10 . The wheels  28  are typically made of hard rubber and resist deterioration caused by exposure to the weather or accidental contact with chemicals that may be found at construction sites. A rest  30 , mounted on the bottom of the housing  12 —at the end opposite to which the wheels  28  are found (i.e., closer to the outlet  18 —is used to support the heater  10 . A unique handle  32  is mounted to the rest  30  to allow a person to raise the outlet end of the heater and move the heater  10  to a desired position.  
         [0030]    The wheels  28 , rest  30 , and handle  32  are dimensioned and positioned to assist in moving or wheeling the heater  10  from one place to another. Specifically, the wheels  28 , rest  30 , and handle  32  are designed so that the heater  10  may be pulled or pushed around like a cart.  
         [0031]    A liner  14 , also substantially cylindrical in shape, may be placed in spaced-apart relation immediately inside of the housing (see FIG. 2). The spaced-apart relationship forms an air gap between the housing  12  and the liner  14  which insulates the housing from the heat-generating and heat-conducting parts of the heater  10 . The air gap keeps the housing  12  cool to the touch.  
         [0032]    The spaced-apart relation may be achieved by bolting the liner  14  to the inside of the housing  12  and using a plurality of large washers or metallic spacers (not shown) at specific points to maintain the spaced-apart relationship.  
         [0033]    The relative position of the liner  14  with respect to the housing  12  is important; if a portion of the liner  14  is too close to the housing  12 , a hot spot will appear on the housing  12 . Referring now to the partial cutaway view of FIG. 4, in the preferred embodiment, the housing  12  and the liner  14  are substantially concentrically located along their longitudinal axis. However, in order to reduce manufacturing costs, and because it is not necessary to line the entire length of the housing  12 , the liner  14  is only slightly longer than one-half the length of the housing  12 , when measured from the outlet  18 .  
         [0034]    Referring again to FIGS. 1 and 2, a grill  93  is fastened to the inlet  16  of the heater  10 . The grill  93  prevents large articles from entering and damaging the interior of the heater  10 .  
         [0035]    A motor  20  is mounted within the housing  12 , usually closer to the inlet  16  side of the housing  12 . As illustrated in FIGS. 2 and 4, propeller  22  is mounted on the shaft  24  of the motor  20 . The shaft of the motor  20  and the propeller  22  are also concentrically located with the axis of the housing  12  and liner  14  as illustrated in FIG. 4.  
         [0036]    In the present design, the propeller is positioned closer to the inlet  16  than the motor  20 . This design allows for a more efficient flow of air through the housing  12  and liner  14 .  
         [0037]    In the preferred embodiment, the motor  20  is typically electric and its power is supplied by a wire (not shown) connected to the heater&#39;s control circuitry. The control circuitry is located in a control box  64  which is mounted on the outside of the housing  12 . As illustrated in FIGS.  1 - 4 , the control box  64  is shown on the top side  96  of the housing  12 . The control circuitry will be described more fully hereafter.  
         [0038]    Referring now to FIGS. 6 and 7, the combustion system  50  is an important feature of the present invention. A combustion system  50  is mounted within the liner  14 . In a preferred embodiment, the combustion system  50  is positioned approximately at the longitudinal midpoint of the housing  12 .  
         [0039]    The ideal location of the combustion system is calculated based on the maximum output of the heater, the diameter (or volume) of the interior heater body, the air volume moved across the combustion system  50  measured in cubic feet per minute (CFM), and the velocity of the air moved across the combustion system measured in feet per minute (FPM). Generally speaking, the diameter measurement of the combustion system increases in relation to the Btu output of the heater  10 .  
         [0040]    Referring now to FIGS. 2 and 3, pipe  52  is connected between the combustion system  50  and a pair of solenoid valves  54 ,  56  in the pipe-train assembly that controls the pre-regulated gas to the combustion system  50 . The first solenoid valve  54  controls the flow of gas to the combustion system  50 . The second solenoid valve  56  is a redundant system used to meet certification requirements for safety if the first solenoid valve  54  were to fail.  
         [0041]    Pipe  58  connects the solenoid valves  54 ,  56 , to a regulator  60  which in turn is connected to an external gas source via pipe  62 .  
         [0042]    Referring now to FIG. 7, the combustion system  50  is mounted within the liner  14  via a plurality of ears  111  (in a preferred embodiment three equally-spaced ears are used). The combustion system  50  has a gas inlet tube  70  that connects to pipe  52 .  
         [0043]    The combustion system  50  comprises a circularly-shaped burner tube  72  having a plurality of gas exit holes  74  on one side (i.e., the side facing the outlet of the housing  18 ). The burner tube  72  has a pre-determined diameter that depends on the Btu output of the heater  10  and the volume of air forced over the combustion system  50 .  
         [0044]    Gas enters the combustion system  50  through tube  70  and eventually is relatively evenly distributed throughout ring-shaped burner tube  72 . As gas leaves via gas exit holes  74  it is ignited by ignitor  76 . After the gas is ignited, the control circuit ensures that a stream of gas exits gas holes  74 , thereby ensuring that a flame is continuously lit at the combustion system  50 .  
         [0045]    The sensor can have dual functions, initially it can act as the ignition source and light or ignite the air/gas mixture to initiate proper combustion, and secondly it provides flame rectification thus signaling to the control circuit that there is proper combustion to the control circuit to maintain the gas valves open  54 ,  56  and discontinue the ignition source.  
         [0046]    Referring now to FIGS. 8A, 8B,  9 A and  9 B, the combustion system  50  has a first frusta conical section  82  (sometimes referred to as the first flange) having a pre-determined first pattern of orifice ports  101 ,  103 . The first frusta conical section  82  has a basal end  86  having a diameter proximate the diameter of the burner tube  72  and a smaller diameter secondary end  88 . The basal end  86  being attached to the burner tube at a position radially inward from said gas exit holes  74 .  
         [0047]    The combustion system  50  also has a second frusta conical section  80  (sometimes referred to as the second flange) having a predetermined second pattern of vent holes  105 ,  107 . The second frusta conical section  80  has a basal end  84 ; the basal end  84  of the second frusta conica having a diameter proximate the diameter of the burner tube  72 . The basal end  84  is attached to the burner tube at a position radially outward from said gas exit holes  74 .  
         [0048]    The lengths of the air/gas mixing frusta conical sections or flanges are determined by the desired heat output of the combustion system.  
         [0049]    The dimension of this assembly is a relative to the following:  
         [0050]    The diameter or area of the interior heater body.  
         [0051]    the air volume moved across the combustion system measured in cubic feet per minute (CFM)  
         [0052]    The velocity of the air moved across the combustion system measured in feet per minute (FMP).  
         [0053]    Generally speaking, the length of this conical frusta system or flange increases proportionately in relation to the Btu output of the heater.  
         [0054]    The size and the placement of the orifice ports  101  and  105  closest to the basal ends of the flanges are smaller in diameter than the orifice ports  103 ,  107  on the perimeter. In the preferred embodiment, there are five rows of smaller diameter orifice ports  101 ,  105  in each flange and two rows of large diameter orifice ports  103 ,  107 . However, there may be more or less smaller diameter and/or large diameter orifices depending on the Btu output of the heater.  
         [0055]    Each row of orifice ports is staggered from the adjacent rows. As illustrated in FIGS. 7 and 9A, the ports are positioned such that a diagonal line may be drawn through a set of seven orifice ports (five smaller diameter and two larger diameter ports). This actually gives the ports a spiral-like appearance. Moreover, the first row of ports  101 ,  105  of each flange  82 ,  80  are aligned with the gas exit holes  74  of the burner tube  72 . The pattern of the ports  101 ,  103 ,  105 , and  107  with respect to the gas exit holes  74  allow the heater  10  to be variably controlled. That is, to the combustion system  50  uniquely mixes the air with the gas so that the air/gas mixture is efficiently burned so that the heat output of the heater may be adjusted from about 20% to 100% of the rated output and the heater does not have to be continuously operated at its maximum output.  
         [0056]    Referring now to FIGS. 4 and 7, a mounting box  77  is secured to the first frusta conical member. The ignitor  90  is positioned inside the mounting box  77 . The mounting box  77  provides a pocket for gas to accumulate upon initial ignition or start-up. This pocket of gas surrounds the ignitor ensuring that the gas comes in direct contact with the igniter and promoting a quick and complete ignition.  
         [0057]    An electronic control circuitry is preferably protected within control box  64 . The control box  64  is mounted on the top of housing  12 . The electronic control circuitry includes an ignitor circuit; switches/relays (for controlling the operation of the motor  20 , the operation of the regulator  60  and the opening and closing of solenoid valves  54 ,  56 ), a thermostat  66  and an on/off switch  67 . An AC power cord (not shown) provides electrical power to the control circuitry.  
         [0058]    The control circuitry is similar to the control circuitry in other direct-fired heaters and is a key element in the safe operation of the combustion system. An important difference, though, is that the subject control circuitry includes circuits to allow the variable or gradual adjustment of the heater&#39;s output. The control circuit, when signaled by the operator to start the combustion process, activates the ignition circuit. The ignition circuit and the solenoid valves  54 ,  56  are activated beginning the flow of gas into the combustion system  50  and over the ignition source.  
         [0059]    A flame sensor  37 , positioned proximate to the mounting box  77 , extends beyond the physical dimensions of the mounting box and into the path of the flame after combustion has been established. The sensor  37  is connected to the control circuitry and provides feedback as to the amount of heat, quality of combustion and/or type of flame at the frusta conical members. The flame sensor  37 , in combination with the mounting box  77 , allows the control circuitry to accurately detect the flame, thereby allowing a wide range of turn down (i.e., adjustability) in the volume of incoming gas. In this manner, the heater  10  can vary its output over a relatively wide range, for example from 100% to about 20% of capacity, while maintaining clean combustion and to make flame rectification as needed.  
         [0060]    Referring now to FIGS. 10A and 10B, the control box  64  has a lid  65 , a base  69 , and a mounting bracket  83 . The control box  64  is preferably constructed of stainless steel to prevent corrosion and to extend the life of the control circuitry secured inside. As shown in FIGS. 10A and  10 B, the control box has an integrated piano hinge  45  which allows easy access for maintenance. A tool-less latch (not shown) keeps the lid securely closed and an integrated gasket resists the entry of water and moisture, thereby reducing the possibility that the control circuitry will corrode.  
         [0061]    The control box  64  is mounted on the housing  12  with the bracket  68 . Referring now to FIG. 10C, bracket  83  fits inside of control box  64  and the control circuit is mounted to it. The bracket improves production flow, hides all attachment bolts, and creates an integrated or streamlined look to the heater  10 .  
         [0062]    If the combustion system  50  is positioned approximately midway along the axial length of the housing  12 , then the liner  14  extends from the outlet  18  to a point slightly past the axial midpoint. Since the air is heated as it passes the flame at the combustion system  50 , the liner  14  does not have to extend all the way from the outlet  18  to the inlet  16 .  
         [0063]    The interior portion of the liner  14  from the combustion system  50  to the outlet  18  serves as a combustion chamber. An ignitor  90  is mounted on the interior of inner flange  82 . The ignitor  90  produces a spark to light the gas exiting the combustion system  50 . The ignitor  90  is connected to the electronic control circuit.  
         [0064]    Upon initial start-up, the on/off switch  67  sends line voltage to the fan motor  20 . When the motor turns, propeller (fan)  22  begins to spin. Air is drawn into inlet  16 . As the propeler (fan)  22  picks up rotational speed, air is forced through the combustion system  50  and around the flanges  80 ,  82 . Substantially contemporaneously, the control circuitry sends a signal to the solenoids  54 ,  56  and the regulator to open, thereby allowing gas to flow from external gas source to the combustion system  50 . Simultaneously, the control circuitry also sends a signal to the ignitor  90  which produces a controlled spark thereby igniting the gas exiting from gas holes  74 . A flame appears between the flanges  82 ,  80 . As air passes over and around the flanges  81 ,  80 , it is heated and eventually exits from outlet  18 . This heated air then raises the temperature of the ambient air in the room or structure to be heated.  
         [0065]    Although this invention has been described and illustrated by reference to specific embodiments, it will be apparent to those skilled in the art that various changes and modifications may be made which clearly fall within the scope of this invention. The present invention is intended to be protected broadly within the spirit and scope of the appended claims.