Patent Publication Number: US-2019170349-A1

Title: Portable thermostatic infrared heater and support assembly thereof

Description:
TECHNICAL FIELD 
     The technical field generally relates to a portable heater used for providing heat to the surrounding environment, and relates more specifically to a portable gas-fired infrared heater. 
     BACKGROUND 
     Portable heaters, such as gas-fired heaters, are well known in the art and are used for a plurality of activities such as camping or fishing on a lake, among many other possibilities. Generally speaking, known heaters comprise a housing containing a combustion chamber where air and gas can mix so as to combust and thus generate heat. Said heat is distributed over a surface disposed on the front of the housing so as to have a radiant surface exchange heat with the environment surrounding the heater. 
     Over the years, several improvements have been made to the portable heaters, in order to make them more versatile and safer for use in smaller enclosures. An example of such an improvement is an oxygen depletion system (ODS) which would cut off the supply of gas to the combustion chamber when the oxygen levels of the surrounding air would drop below a certain threshold. Such a system is described in U.S. Pat. No. 7,300,278 issued Nov. 27, 2007. Similarly, U.S. Pat. No. 8,863,736 issued Oct. 21, 2014 discloses a portable heater with an automatic shutoff system adapted to shut off the fuel valve in response to a detection of a predetermined level of carbon dioxide. 
     Applicant is also aware of another emergency shutoff device being implemented into portable heaters: a tilt switch. For example, U.S. Pat. No. 5,245,691 issued Sep. 14, 1993, describes a tilt sensitive switch for deactivating the heater in response to tilting movement of said heater beyond a predetermined amount relative to a normal upright position. 
     However, many drawbacks still exist in the field of gas-fired portable heaters, such as miniaturisation, heat regulation and more. As such, these types of heaters can still be improved upon. 
     SUMMARY 
     According to an aspect, a portable heater is provided. The portable heater comprises a housing provided with a front opening, at least one pilot burner, at least one main burner provided within the housing and comprising a front portion facing the front opening of the housing, said at least one main burner unit being supported by at least a portion of the housing. The portable heater further comprises a gas pressure regulation system connectable to a portable supply of gas, a first means adapted to form a first flow of an air/gas mixture, feed the at least one pilot burner with said first flow of the air/gas mixture and allow said first flow of the air/gas mixture to exit from the at least one pilot burner, and a second means adapted to form a second flow of an air/gas mixture, feed the at least one main burner with said second flow of the air/gas mixture and allow said first flow of the air/gas mixture to exit from the at least one main burner. The portable heater also comprises a gas valve assembly mounted to the housing and comprising a gas valve adapted to selectively: 
     prevent the first flow of the air/gas mixture to exit from the at least one pilot burner and prevent the second flow of the air/gas mixture to exit from the at least one main burner; 
     allow the first flow of the air/gas mixture to exit from the at least one pilot burner and prevent the second flow of the air/gas mixture to exit from the at least one main burner; or 
     allow the first flow of the air/gas mixture to exit from the at least one pilot burner and allow the second flow of the air/gas mixture to exit from at least one main burner. 
     The gas valve assembly cooperates with at least one knob movable along and around an axis for selectively operating the gas valve, controls the flow of the second flow of the air/gas mixture, and operates a means to ignite the gas/air mixture exiting from the at least one pilot burner. The portable heater still further comprises a gas piping connecting the gas pressure regulation system to the gas valve, a gas piping connecting the gas valve to the first means adapted to form the first flow of an air/gas mixture, and a gas piping connecting the gas valve to the second means adapted to for the second flow of an air/gas mixture. The gas valve is a thermostatic valve, said thermostatic valve being provided with means cooperating with a temperature sensor and adapted to open and close the gas valve for the control of the flow of the second flow of the air/gas mixture exiting from the at least one main burner. 
     According to a possible embodiment, the portable heater further comprises a support assembly comprising at least one first member provided with a first portion and a second portion, the first portion being adapted to be connected to the housing and the second portion defining a stop positioned close to a portion of the thermostatic gas valve opposite to the knob; and wherein the portion of the thermostatic gas valve opposite to the knob is adapted to engage the stop when a pressure is applied to the knob by a user to move said knob along the axis. 
     According to another possible embodiment, the support assembly further comprises a cover surrounding at least in part a top portion, side portions and/or a rear portion of the at least one burner, said cover being further provided with means adapted to be connected to the housing and/or the at least one main burner unit. 
     According to yet another possible embodiment, the support assembly further comprises at least one second member having at least one end connected to the second portion of the at least first member and at least another end connected to the cover. 
     According to yet another possible embodiment, the cover comprises a top portion, side portions and a rear portion; and the top portion and side portions of the cover angularly extend from the rear portion of the cover, and wherein the side portions of the cover are adapted to be connected to the housing of the portable heater. 
     According to another possible embodiment, the first portion of the at least one first member is a substantially flat platform provided with an opening adapted to receive the gas pressure regulation system therein, and the first portion further comprises an outer edge extending therefrom, the outer edge being adapted to be connected to the housing of the portable heater. 
     According to another possible embodiment, the first portion further comprises a “shield” extending downwardly therefrom. 
     According to still another possible embodiment, the second portion of the at least one first member is an elongated bracket provided with opposed first and second ends, the first end being connected to the first portion of the at least first member, and the second end of the second portion comprises the stop. 
     According to yet another possible embodiment, the stop comprises at least one prong extending from the second end of the second portion, the at least one prong having an extremity being substantially perpendicular to the second portion, the extremity of the at least one prong being adapted to be engaged the thermostatic gas valve opposite to the knob. 
     According to another possible embodiment, the second portion of the at least first member includes an elevated side edge along the second portion adapted to avoid buckling of said second portion. 
     According to yet another possible embodiment, the portable heater is a portable thermostatic infrared heater. 
     According to another aspect, there is provided a support assembly for a portable heater as defined hereinabove, wherein said support assembly comprises at least one first member provided with a first portion and a second portion, the first portion being adapted to be connected to the housing and the second portion defining a stop positioned close to a portion of the thermostatic gas valve opposite to the knob; and wherein the portion of the thermostatic gas valve opposite to the knob is adapted to engage the stop when a pressure is applied to the knob by a user to move said knob along the axis. 
     According to another possible embodiment, the support assembly further comprises a cover surrounding at least in part a top portion, side portions and/or a rear portion of the at least one burner, said cover being further provided with means adapted to be connected to the housing and/or the at least one main burner unit. 
     According to another possible embodiment, the support assembly further comprises at least one second member having at least one end connected to the second portion of the at least first member and at least another end connected to the cover. 
     According to another possible embodiment, the cover comprises a top portion, side portions and a rear portion; the top portion and side portions of the cover angularly extend from the rear portion of the cover, and the side portions of the cover are adapted to be connected to the housing of the portable heater. 
     According to another possible embodiment, the first portion of the at least one first member is a substantially flat platform provided with an opening adapted to receive the gas pressure regulation system therein, and the first portion further comprises an outer edge extending therefrom, the outer edge being adapted to be connected to the housing of the portable heater. 
     According to another possible embodiment, the first portion further comprises a “shield” extending downwardly therefrom. 
     According to another possible embodiment, the second portion of the at least one first member is an elongated bracket provided with opposed first and second ends, the first end being connected to the first portion of the at least first member, and the second end of the second portion comprises the stop. 
     According to another possible embodiment, the stop comprises at least one prong extending from the second end of the second portion, the at least one prong having an extremity being substantially perpendicular to the second portion, the extremity of the at least one prong being adapted to be engaged the thermostatic gas valve opposite to the knob. 
     According to another embodiment, the second portion of the at least first member includes an elevated side edge along the second portion adapted to avoid buckling of said second portion. 
     According to a final aspect, there is provided a use of a portable heater as described hereinabove for providing heat to a surrounding environment of said portable heater. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a front perspective view of a portable thermostatic infrared heater, according to an embodiment, showing a control knob; 
         FIG. 2  is a front perspective view of the portable thermostatic infrared heater of  FIG. 1 , showing a compartment for a supply of gas; 
         FIG. 3  is a rear view of the portable thermostatic infrared heater of  FIG. 1 , where a housing of the heater is removed to show a support assembly for internal components, in accordance with an embodiment; 
         FIG. 4  is a perspective view of a support assembly for a thermostatic infrared heater, in accordance with an embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     As will be explained below in relation to various embodiments, a portable heater for providing heat to the surrounding environment of said heater is provided. The heater includes a housing provided with a front opening and at least one main burner unit provided within said housing. Among other components that will be described hereinbelow, the portable heater further comprises a gas valve and a support assembly provided within the housing. The gas valve is a thermostatic gas valve and is operated by a knob movable along and around an axis. The support assembly is adapted to prevent movement of a plurality of components of the portable heater, as will also be explained below. 
     Moreover, components of the portable heater, associated accessory(ies)/component(s)/part(s) thereof and/or steps of the method(s) described herein could be modified, simplified, altered, omitted and/or interchanged, without departing from the scope of the present invention, depending on particular applications which the present invention is intended for, and the desired end results, as briefly exemplified herein and as also apparent to a person skilled in the art. 
     Referring to  FIG. 1 , a portable heater  10  (hereinafter simply “heater”) for providing heat to the surrounding environment of said heater is shown. In this embodiment, the heater  10  is illustratively provided with a housing  12  adapted to contain and/or support other components of the heater  10 . The housing  12  has a front surface  14 , a rear surface  16 , and two sides (left side  18 , right side  20 ) joining said front and rear surfaces. In some embodiments, the heater  10  can be provided with a top handle  21  to facilitate transportation of the heater  10  and/or to allow hanging from a hook or other supporting means, for example. The housing  12  further comprises a recess  22  provided on one of the sides for receiving a controller knob  24  therein. In this embodiment, the controller knob  24  is configured for controlling the temperature at which the heater  10  operates by turning said knob  24  in different positions. The controller knob  24  can have at least 4 predetermined positions (not shown): Off, Pilot, Minimum and Maximum, and allows for personalized temperature control by positioning the controller knob  24  anywhere between the Minimum and Maximum positions. Additionally, the controller knob  24  can also be used as an igniter button for activating the heater  10 . More specifically, turning the controller knob  24  from the Off position to the Pilot position provides the initial spark needed to activate the heater. To do so, a user must first press down on the controller knob  24 , moving it along an axis, before turning it around said axis, this security feature prevents the involuntary production of sparks by accidentally turning the knob  24 .  FIG. 2  is an illustration of the left side  18  of the housing  12 , said housing comprising a pivotable door  25  for accessing a compartment  26  adapted to at least partially house a supply of gas  28 . Said supply of gas can be connected to a gas pressure regulation system in a manner that will be explained further below. The supply of gas  28  can be a one-pound portable propane cylinder, a ten-pound propane tank, or any other suitable type and/or size of gas containers. It is appreciated that gas containers larger than the aforementioned one-pound cylinder may not fit within the compartment  26  of the heater  10 . As such, the heater  10  can be provided with an extension hose (not shown) for connecting large gas containers with the gas pressure regulation system. 
     In this embodiment, the front surface  14  of the heater  10  is provided with a front opening  32  adapted to communicate with at least one main burner unit  34  provided within the housing  12 . Additionally, said front surface  14  is illustratively provided with protective means  46  adapted to effectively protect the other components of the heater  10  and prevent the user and/or other objects from contacting the heated portions of the front surface  14 . In the present embodiment, the protective means  46  is a metallic cage or grid mounted to the front surface  14  of the housing  10 , but can alternatively be any other suitable means for protecting the heater  10  and/or preventing contact therewith, such as a screen for example. 
     In addition to  FIGS. 1 and 2 ,  FIG. 3  illustrates the heater  10  without the rear and side surfaces of the housing  12  in order to illustrate the inner components of the heater. In the present embodiment, the at least one main burner unit  34  can be supported by at least a portion of the housing  12  and comprise a front portion facing the front opening  32  so as to effectively provide heat to the surrounding environment. More specifically, the main burner unit  34  comprises a plenum (not shown) adapted to receive an air/gas mixture for combustion, and a radiant surface  38  adapted to be heated by said combustion of the air/gas mixture. The heated radiant surface  38  then exchanges heat with the surrounding environment, in a method that is well known in the art of heaters. Furthermore, the heater  10  is provided with at least one pilot assembly  40  comprising a pilot burner  42  and an igniter  44  adapted for providing the initial spark needed to operate the heater  10  and thus allow combustion of the air/gas mixture, within the plenum. Said at least one pilot assembly being at least partially supported by the housing  12 , near a lower portion of the front surface  14  and being activated by the controller knob  24 , as described above. It should be understood from the above characteristics that the heater  10  can be an infrared heater, according to a possible embodiment. 
     Still referring to  FIG. 3 , the heater  10  can be provided with a first means  48  adapted to form a first flow of air/gas mixture and feed said first flow to the pilot burner  42  of the at least one pilot assembly  40 . The first flow of air/gas mixture then exits the pilot burner  42  so as to be ignited by the igniter  44  (shown in  FIG. 1 ) by operating the controller knob  24 . In this embodiment, the first means is a pilot tube  49  but can alternatively be any other suitable means for supplying fluid (i.e. the air/gas mixture) to the pilot burner  42 . Additionally, the heater  10  can further comprise a second means  50  adapted to form a second flow of air/gas mixture and feed said second flow to the at least one main burner unit  34  for combustion, as described above. In this embodiment, the second means is a venturi burner  52  located within the housing  12  of the heater  10  and being in fluid communication with the plenum of the at least one main burner unit  34 . In the illustrated embodiment, the venturi burner  52  has a generally cylindrical and hollow body, and is open to the outside air so as to allow said air to mix with the gas from the supply of gas  28  within the plenum of the main burner unit  34 . 
     The heater  10  further comprises a gas valve assembly  54  mounted to the housing  12  and is effectively provided with a gas valve  56  adapted for selectively controlling the first and second flows of air/gas mixture. More specifically, the gas valve assembly  54  cooperates with the controller knob  24  which is adapted to selectively control the first and second flows of air/gas mixture by turning said controller knob  24  in the various positions described above. In this embodiment, when the controller knob is in the Off position, the gas valve  56  is adapted to prevent the first flow of the air/gas mixture from exiting the pilot burner  42  and simultaneously prevent the second flow of the air/gas mixture from exiting the at least one main burner unit  34 . In the Pilot position, the gas valve  56  allows the first flow of the air/gas mixture from exiting the pilot burner  42 , while still preventing the second flow of the air/gas mixture from exiting the at least one main burner unit  34 . Finally, anywhere from the Min position to the Max position, the gas valve  56  allows the first flow and the second flow of the air/gas mixture to exit the pilot burner  42  and the at least one main burner unit  34  respectively. 
     Still referring to  FIG. 3 , in the present embodiment, the gas pressure regulation system  30  is a regulator  31  adapted to regulate and/or control the flow of gas being fed to the gas valve  56  from the supply of gas  28 . Said regulator  31  is illustratively connected to the gas valve assembly  54  via a top gas piping  58  adapted to allow gas to be fed to the gas valve  56 . In the present embodiment, the gas valve  56  is further connected to the pilot tube  49  via a pilot gas piping  60 , and to the burner venturi  52  of the at least one main burner unit  34  via a burner gas piping  62 . In this embodiment, the gas valve  56  is a thermostatic gas valve. As such, it should be understood that the thermostatic gas valve  56  is provided with means for cooperating with a temperature sensor  64  so as to control and adjust the flow of air/gas mixture exiting the gas valve  56  via the burner gas piping  62  towards the at least one main burner unit  34 . For example, when the temperature sensor  64  reads a surrounding temperature above a predetermined temperature, via the positioning of the controller knob, the flow of air/gas mixture being provided to the at least one main burner unit will be reduced and/or completely shut off so as to lower the heat distribution of the heater to effectively lower said surrounding temperature. In this embodiment, the gas valve  56  can be attached to the housing  12  via any suitable fastening means, such as screws extending through the recess  22  containing the controller knob  24  for example. 
       FIG. 4  illustrates an embodiment of a support assembly  100  adapted to effectively support and protect a plurality of components located within the housing  12  of the heater  10 . Referring to said  FIG. 4 , in addition to  FIGS. 1 to 3 , the support assembly  100  can be adapted to support the regulator  31  and protect the thermostatic gas valve  56 , among others, in a manner that will be explained hereinbelow. In the present embodiment, the support assembly  100  comprises a first member  110  which is attached to the housing  12 , a cover piece  120  attached to an inner side of the front surface  15  of the housing, and a second member, or connecting member  160 , effectively connecting the first member  110  to the cover piece  120 . More specifically, the first member  110  comprises an end defining a stop  112  positioned opposite a portion of the thermostatic gas valve  56  which is connected to the controller knob  24 . The stop  112  is adapted to prevent unwanted movement of the thermostatic gas valve when activating the heater  10 . More specifically, when the controller knob  24  is pressed to activate the heater, the thermostatic gas valve  56  is simultaneously pushed towards the center of the housing and thus engages the stop  112 , therefore preventing damage to the components of the heater. As such, the stop  112  prevents movement of the valve  56  and facilitates operation of the controller knob  24  when activating the heater. 
     In this embodiment, the first member  110  of the support assembly  100  comprises a first portion  114  and a second portion  130 . The first portion  114  can be a substantially flat platform  115  for supporting the regulator  31 . In some embodiments, the platform  115  has an opening  116  generally centered thereon for receiving the regulator  31  and to allow the supply of gas to be connected thereto from below the platform  115 . Furthermore, said platform can be adapted to receive and secure a restraint  118  (shown in  FIG. 3 ) thereon for effectively securing the regulator  31  and the top gas piping  58  within the housing. Additionally, the first portion  114  comprises an outer edge  120  extending from the flat platform  115  and being adapted to be connected to the housing  12 . As such, the support assembly  100  is at least partially secured within the housing  12 . In this embodiment, the first portion  114  further comprises a shield  122  downwardly extending from the platform  115  and being adapted to protect the interior of the housing  12  when opening the pivotable door to access the compartment  26  in order to connect the supply of gas to the regulator  31 . Moreover, a lower portion of the shield  122  can also be connected to the housing to further secure the first portion  114  thereto. 
     Still referring to  FIG. 4 , in this embodiment, the second portion  130  of the first member  110  is a substantially elongated bracket  131  having opposed first and second ends. The first end  132  of the bracket  131  being connected to the first member  110  and the second end  133  of the bracket comprising the stop  112  as described above. In this embodiment, the stop  112  comprises at least one prong  113  extending from the second end of the elongated bracket  131  for engaging the thermostatic gas valve  56 . More particularly, the at least one prong  113  has an extremity being substantially perpendicular to the elongated bracket  131  so as to abut against the portion of the thermostatic gas valve  56  opposite the controller knob  24 . In the illustrated embodiment, the stop comprises two prongs  113 , but can alternatively comprise a single prong, three prongs or any other suitable number of prongs. Moreover, the elongated bracket  131  can comprise a side-edge  134  extending vertically from the bracket along a length thereof. Said side-edge  134  being adapted to provide additional sturdiness to the bracket and to avoid buckling thereof resulting from the pressure of the thermostatic gas valve  56  against the stop  112 . 
     In the present embodiment, the cover piece  140  of the support assembly  100  is adapted to at least partially cover the main burner unit  34  thus reflecting heat generated from the combustion taking place within the plenum towards the front of the heater  10 . As illustrated in  FIG. 4 , the cover piece  140  has a top portion  142 , side portions  144  and rear portion  146  to effectively cover corresponding top, sides and rear portions of the main burner unit. In this embodiment, the side portions  144  of the cover piece  140  each include an upper section  148  extending above and engaging the top portion  142 . Each upper section  148  being adapted to be fixedly attached to said top portion. Furthermore, each side portion  144  includes a lateral section  150  extending from corresponding side portions and being adapted to abut against the inner side of the front surface  15  of the housing  12 . Each side portion of the cover piece  140  can be fixedly attached to the housing using any suitable means such as screws, bolts and/or rivets, among others. Moreover, one of the side portions  144  can be provided with a side opening  152  adapted to allow the venturi burner  52  to connect with the plenum of the main burner unit  34 . In this embodiment, the cover piece  140  can be made from a single piece of material, such as a pattern cut from a sheet of said material, bent and/or assembled into the above-described shape. 
     In the illustrated embodiment, the connecting member  160  connects the first member  110  to the cover piece  140  and is configured for improving structural stability of the support assembly  100  within the housing  12 . Therefore, the connecting member  160  has a first end attached to one of the first member and the cover piece, and a second end attached to the other one of the first member and the cover piece. In this embodiment, the connecting member is a pair of braces  162  provided at opposed ends of the second portion  130  of the first member  110 . Alternatively, the second member can be a single brace having any suitable width and/or length, or any other suitable means for connecting the first member to the cover piece. 
     In a preferred embodiment, the components of the support assembly  100  are made from the same material, preferably a metallic material because of the frequent changes in temperature occurring from activating/deactivating the heater  10 . In alternate embodiments, the support assembly  100  can be made from more than one material, for example the cover piece can be made from a ceramic and the first and second members can be metallic. It will be appreciated that in conjunction with the above-described embodiments, the various components of the heater  10  and/or the support assembly  100  can be connected to one another using any suitable fastening means. For example, the fastening means can be any suitable type of welding technique and/or mechanical fasteners such as screws, bolts, rivets, etc. or a combination thereof. 
     It should be understood that the elements of the accompanying drawings are not necessarily depicted to scale, since emphasis is placed upon clearly illustrating the elements and structures of the present embodiments. In the following description, the same numerical references refer to similar elements. Furthermore, for the sake of simplicity and clarity, namely so as to not unduly burden the figures with several reference numbers, not all figures contain references to all the components and features, and references to some components and features may be found in only one figure, and components and features of the present disclosure which are illustrated in other figures can be easily inferred therefrom. The embodiments, geometrical configurations, materials mentioned and/or dimensions shown in the figures are optional, and are given for exemplification purposes only.