Patent Publication Number: US-2022228755-A1

Title: Heater directional reflectors

Description:
This patent application claims priority to U.S. Provisional Patent Application 63/199,738 filed on Jan. 21, 2021, which is incorporated by reference herein in its entirety. 
    
    
     BACKGROUND OF THE SYSTEM 
     The present apparatus relates to space heaters and, more particularly, a heater directional reflector for improving space heaters such as column flame patio heaters. 
     Column flame or vortex patio and/or table-top heaters come in a variety of shapes, styles and sizes. Some are made with four corners and resemble a pyramid shape with a wide base and a narrowing profile toward the top, others have three sides and also narrow toward the top. There are also column heaters that are round, cylinder like structures. Some are very large and tall while others are small enough to fit on top of patio table. These patio heaters are typically identifiable by a flame column, which adds ambiance to an outdoor setting while also helping to warm the space for added comfort. While these heaters are generally pleasing to look at, they all suffer from a critical design flaw. The fail to radiate a useful level of heat to any distance beyond their immediate surroundings. 
     Column flame designs are most effective when placed in the middle of the environment to be heated. The designs emit heat in a circle with the device at the center. However, there are some situations where the heater must be placed at an edge of an environment, or only on one side of where people will be located. In those conditions, the heaters are not efficient because much of the heat is emitted into unoccupied space. One solution to that problem is to use a more powerful heater so that enough heat is provided to the occupied spaces. The alternative is to have inadequate heating in the occupied area. 
     SUMMARY 
     The present apparatus improves on the existing designs for pyramid, vortex or column flame type patio heaters because it allows a user to modify the shape and direction of the heat output by the heater. Thus, when desired, the heater output may be left at 360 degrees or selectively modified and focused down to a pattern that is narrower. A wider pattern closer to 360 degrees will result in a shorter range of maximum heat while a narrower pattern such as 180 degrees will result in higher temperatures in the pattern range and more efficient heater operation. 
     The present apparatus is a heat focusing reflector that can either be built in by the manufacturer of the heater or an add-on attachment that can be installed by an end user to allow these types of heaters to project more heat to further distances. The heat focusing reflector will block heat from traveling all around these types of heater and will instead focus and/or reflect all of the heat to travel toward one side of the heater. By redirecting heat from these heaters and focusing the heat to travel longer distances away from the heater, these heaters can become more efficient and functional as an outdoor space heater. In addition to directing heat, the reflective surfaces will also reflect the light from the flames that are emitted by the outdoor heater thereby increasing the ambiance and visual output of the heater which would make it more pleasing to look at as well. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an embodiment of the apparatus with hinged panels. 
         FIG. 2  is a detailed view of the panel of  FIG. 1 . 
         FIG. 3  illustrates an embodiment of the apparatus in a closed configuration. 
         FIG. 4  illustrates the embodiment of  FIG. 3  in an open configuration. 
         FIG. 5  illustrates the embodiment of  FIG. 4  with side panels deployed. 
         FIG. 6  is a front view of the embodiment of  FIG. 5 . 
         FIG. 7  illustrates a rear view of an embodiment of the apparatus. 
         FIG. 8  illustrates the embodiment of  FIG. 7  in an open configuration from a rear view. 
         FIG. 9  illustrates the embodiment of  FIG. 8  in a front view. 
         FIG. 10  illustrates an embodiment of the apparatus coupled to a cap of a heater. 
         FIG. 11  is a rear view of the embodiment of  FIG. 10 . 
         FIG. 12  is a view of the fastener  1003  of the embodiment of  FIG. 10 . 
         FIG. 13  is a bottom perspective view of the fastener  1003  of  FIG. 12 . 
         FIG. 14  illustrates a mechanism to hold the bottom of the reflector panels in place on a heater. 
         FIG. 15  illustrates the top and bottom fastening mechanisms in use. 
         FIG. 16  illustrates a bottom perspective front view of the lower fastener in an embodiment. 
         FIG. 17  illustrates a bottom perspective rear view of the lower fastener in an embodiment. 
         FIG. 18  illustrates an alternate upper fastener. 
         FIG. 19  illustrates a clip fastener for use in an embodiment. 
         FIG. 20  illustrates the clip fastener in operation as a bottom fastener. 
         FIG. 21  illustrates the clip fastener in operation as a top fastener. 
         FIG. 22  illustrates a cotter pin fastener in an embodiment of the apparatus. 
         FIG. 23  is an embodiment of a four-panel assembly. 
         FIG. 24  is a multi-panel embodiment. 
         FIG. 25  illustrates the joining of two multi-panel configurations. 
         FIG. 26  illustrates an embodiment of a hinge fastener. 
         FIG. 27  illustrates the hinge fastener in operation. 
         FIG. 28  illustrates the hinge fastener in a folded position. 
         FIG. 29  illustrates an alternative hinge fastener. 
         FIG. 30  illustrates the alternative hinge fastener in operation. 
         FIG. 31  illustrates a fastener to join reflector panels in an embodiment. 
         FIG. 32  illustrates an alternative version of the fastener of  FIG. 26 . 
         FIG. 33  illustrates an alternative version of the fastener of  FIG. 26 . 
     
    
    
     DETAILED DESCRIPTION OF THE SYSTEM 
     The present device provides a way for a pyramid type heater to direct and reflect radiant and/or convective heat in a desired direction, and to reduce or prevent the flow of heat in another direction. This allows the same amount of heat to be provided with less fuel, or to provide more heat with the same fuel, as well as various other combinations. 
       FIG. 1  illustrates a directional heat shield for use with a vortex or pyramid style heater. A vortex or pyramid flame style heater  100  comprises a base  101 , control unit  102 , pyramid structure  103 , and reflector cap  104 . The fuel source (e.g., propane) is kept in the base  101  and is activated and ignited via control unit  102 . The fuel is emitted into a clear tube (e.g., glass, not shown) that extends through the middle of the pyramid structure  103 . The heater  100  is topped by a reflector cap  104 . In operation, a flame extends through some or all of the length of the glass tube when lit, providing heat that is radiated away from the heater in all directions. 
     Vortex or pyramid type heaters are known for poor performance when compared to round heaters because much of the heat radiance is traded for the aesthetic appeal of the open and visible flame. In one embodiment, a one, two, or three panel directional heat shield  105  is provided that matches the dimensions of the side walls of the pyramid structure  103 . In one embodiment, the heat shield  105  includes open slits  107  and fasteners  106 . The heat shield  105  may be attached to the edge of the cap  104  in one embodiment. In one embodiment, the heat shield  105  may be coupled to the heater  100  directly overlaying the sides of the pyramid structure  103 . The use of the heat shield  105  can improve the heating performance of the vortex heater  100  such that it can approximate the ability of a round heater. 
       FIG. 2  illustrates the directional heat shield  105  of  FIG. 1 . The heat shield  105  may be flat or it may have open slits  107 . It may be individual panels shaped like each side of the pyramid structure or it may be a pair of panels joined by hinge  108 . The panels may be metal or heat resistant fabric as desired. The panels may be soft or rigid. 
     The open slits  107  may be provided along the surface of each reflective plate to allow wind to pass through the reflective plates  105  to reduce any risk of having the heater tip over due to increase wind drag of the reflective plates. In one embodiment, instead of open slits, the elements could be convex ribs that help focus the heat back toward the open area of the heater. 
       FIGS. 3, 4, and 5  illustrate an embodiment of the system where the reflector is comprised of telescoping shingle like members that unfold on one, two, or three sides of the heater to provide customizable directional heating.  FIG. 3  illustrates a heater with a cap  104  and a telescoping mechanism  305  in housing  301  that allows multiple reflector plates  302  to be stored easily on the heater when not in use. 
     As seen in  FIG. 4 , the plates  302  telescope upwardly from optional housing  301  using the telescoping mechanism  305  which may be similar to nested sliding doors, for example. The top plate  302  can have a mechanism to engage fastener  304  on the top of cap  104 . The fastener may be mechanical, magnetic, or the like. The fastener may include an angle adjustment mechanism to allow the reflectors to swing and let wind pass through. 
     As shown in  FIG. 5 , each plate  302  may comprise additional plates coupled by hinges such as hinge  303 . This allows the telescoping plates to cover one, two, or three sides of the heater, to focus the direction of the heat as desired in a multiple of customizable configurations. The panels may be soft or rigid and can be single shingle like units or can be sets of two or more folding reflective surfaces as shown. The panels may include small open slits formed in such a way to permit heat reflection while still allowing wind to pass through. 
       FIG. 6  illustrates a view of the plates  302  from the front. The hinged plates may be used to provide a wider reflecting surface as shown in  FIG. 6 , or they may be folded against the sides of the heater to further concentrate the heat reflection in one direction. 
     One embodiment of the present apparatus includes two or three reflective panels that are hinged together and hung from one side of a column flame patio heater. When the hinged plates are expanded, the reflective surface on one side of the heater is greatly increased. A large amount of heat that is being outputted by the heater is then deflected and redirected toward only one half of the heater. The concentrated heat output results in more heat and a longer range of heat which is all directed toward the side of the heater that is opposite to the reflector. 
     One variant of this reflector apparatus may be produced using aluminium or steel sheet metal. Softer, heat resistant, reflective fabrics may also be used to achieve the same result. The heat reflective heat shield may be produced in a number of ways. Rigid reflective surfaces may be hinged or fastened together and propped up, hung from or fastened to an outdoor column flame type patio heater to direct and focus the heat being produced by the heater. The hinges, fasteners, panel angle adjustment, scratch prevention, wind pass, and housing mechanism are optional. 
       FIGS. 7, 8, and 9  illustrate an embodiment of the apparatus.  FIG. 7  illustrates a heater  100  with a panel attached to one of the four sides. As shown in a rear view in  FIG. 8 , the panel may have two additional panels  105  hingedly coupled to the first panel  105 . These panels may fold down on the back of the center panel and then be swung out to change the reflective effect of the apparatus.  FIG. 9  illustrates a front view of the panel with these side panels helping direct additional heat to one side of the heater  100 . The user can have more heat directed to one area using the same amount of fuel. Alternatively, the user can use less fuel to provide the same amount of heat due to the directing of formerly wasted heat in a directional manner. 
     Additionally, the present apparatus can be used at different applications where directing heat or light is desired. For example, the user can place this apparatus next to a gas fire pit to redirect the heat from that fire pit toward one side of the fire pit. 
       FIG. 10  illustrates an alternate embodiment of the apparatus. Here the panels  1001  and  1002  are affixed to the heater cap  104  via fastener  1003 . The panels are wider than the sides of the heater and allow for greater reflection of light and heat by the reflector panels. The panels  1001  and  1002  can slide together in openings on the edge to reduce their size for storage and transportation. As seen in rear view  FIG. 11 , the panels have short “wings”  1004  on either side that are turned in slightly to direct heat in the desired direction. 
     The fastener  1003  is shown in more detail in  FIG. 12 . The fastener  1003  has an upper member  1006  that extends onto the heater cap  104 . A rear protruding member  1008  extends through a hole  1007  in panel  1001  to retain the panel in place. Referring now to  FIG. 13 , a bottom perspective view of fastener  1003  is shown. The fastener  1003  is a C or D clamp shape  1009  with a set screw  1010  that can be tightened onto the cap  104  to hold the fastener in place. The panel  1001  can then be placed on the member  1008  to direct heat as desired. The versatility of the fastener  1003  allows it to be placed nearly anywhere on the cap  104 . 
       FIG. 14  illustrates a bottom fastener  1400  to provide stability and a three-point connection to the reflector panels  1001  and  1002 . The bottom fastener  1400  comprises two notched members  1402  slidably mounted in slot  1401 . This permits customized lateral positioning of the bottom fastener.  FIG. 15  illustrates the top and bottom fasteners in operation. The top fastener  1003  in one embodiment provides a single point of connection between the top of the panels and the heater. The bottom fastener  1400  provides two points of connection between the bottom of the panels and the heater. 
     As seen in  FIG. 16 , the notched members  1402  can be engaged with the ribs of the heater housing and thereby hold the bottom of the panels in place. The three-point connection is more stable than a one or two point connection. The plurality of notches allows the panels to be placed closer to, or further from, the heater.  FIG. 17  shows a rear view of the bottom fastener in operation. 
       FIG. 18  illustrates an alternative fastener  1800  for use with the apparatus. The fastener includes a C or D shaped member for extending over a heater cover or other point of attachment. A thumb screw  1802  extends through a hole in the end of one of the legs of member  1801  to secure the fastener to the heater. A rounded cap  1803  is optionally provided to prevent damage to the heater. The cap may be pliant to provide additional friction to help hold the fastener in place. A rear thumbscrew  1804  is used to couple the fastener to a reflective panel. 
       FIG. 19  illustrates an alternative fastener  1900  that may be used in an embodiment of the apparatus. Fastener  1900  is comprised of rear spring clip  1901  and front alligator clip  1902 . The rear spring clip  1901  is used to attach clip  1900  to a reflector panel. The spring clip  1901  engages a bottom section  1904  of alligator clip  1902 . The alligator clip includes a pivoting and spring biased upper member  1903  that can be compressed to widen the gripping section of the alligator clip  1902  to engage a surface, protrusion, rib, wire, or other area of a heater to hold the panel in place.  FIG. 20  shows clips  1900  in use holding the bottom of panels  1001  to wires on a heater. The clips  1900  can move freely to attach at multiple points on a heater.  FIG. 21  shows the clips  1900  holding the tops of reflector panels to the cap of a heater. 
       FIG. 22  illustrates the user of a cotter pin  2200  to secure a hinge region of two reflector panels. One panel has upper and lower open tubes  2201  and the other panel has at least one open tube  2202  to dispose between tubes  2201 . The cotter pin  2200  has a straight member that is inserted into the hinge tubes, and a biased curved member holds the pin  2200  in place during use. 
       FIG. 23  shows a four-panel embodiment of a reflector configuration, with clamps  1800  at the top of the panels, cotter pins  2200  to hold the panels hingedly together, and clips  1900  to attach the bottom of the panel configuration to a heater. 
     In one embodiment as shown in  FIG. 24 , the reflector assembly  2400  is comprised of multiple smaller reflector panels  2401 , each hingedly joined to the next panel  2401 , with the top and bottom panel including one or more fasteners (e.g., clips  1900 ) to attach the assembly  2400  to a heater to reflect heat in a directional manner. 
     Two or more reflector assemblies  2400  can be joined together to form a larger assembly  2500  as shown in  FIG. 25 . Each assembly  2400  can be coupled to another assembly at one or more locations, such as locations  2402  shown in  FIG. 25 . There may be openings pre-formed some of the panels  2401  so that a fastener can be used to couple the assemblies together. 
     A fastener  2600  for joining two panels together is illustrated in  FIG. 26 . The fastener  2600  comprises a base  2601  and two or more protruding members  2602 . Each protruding member  2602  is comprised of a conical style cap  2603  disposed on a lower shaft  2604  that has a diameter smaller than that of the cap  2603 . The fastener is made of a compressible material such as silicon, rubber, and the like. The members  2602  are inserted into an opening that has a smaller diameter than the largest portion of the cap  2603 . The cap  2603  compresses as it is inserted into the opening and re-expands as it exits, holding the fastener securely in place. This is shown in  FIG. 27  where the caps  2603  extend through openings in first and second panels. Once inserted, the flexible nature of base  2601  allows the fastener  2600  to act as a hinge, allowing full movement of the panels toward each other as shown in  FIG. 28 . 
       FIG. 29  illustrates an alternative fastener  2900  that can be used in an embodiment. The fastener  2900  has a base  2901  and two openings  2902  formed therein. The openings  2902  have a raised ring that extends above the surface of base  2901 . The fastener  2900  can also include two regions  2903  that extend beyond the lower surface of base  2901 . These regions  2903  can be used to position the fastener  2900  in a desired location on a panel to provide optimized operation of the fastener  2900 . This is shown in  FIG. 30  where regions  2903  abut the edge of two panels, registering the positioning of the fastener  2900 . A bolt  3001  can be inserted through the opening  2902  in fastener  2900  and an opening in a panel, and then secured with a nut  3001  to hold the fastener in place. The fastener  2900  is made of flexible material that allows it to bend and act as a hinge, in a manner similar to that of fastener  2600 . 
       FIG. 31  illustrates an alternative fastener  3100  for use in an embodiment of the apparatus to connect two panels together. The fastener  3100  comprises a thumb screw  3101  and thumb nut  3102  that allows panels to be connected by hand, without the need for tools. In one embodiment, this fastener  3100  is used with the configuration of  FIG. 23 , but can be used with any embodiment. 
       FIG. 32  illustrates an alternative configuration of the fastener of  FIG. 26 . Here the fastener  3200  has a triangular base  3201  on which there are three protruding members  2602 , each comprising a conical member  2603  on a shorter shaft  2604 . The shaft  2604  has a smaller diameter than the diameter of the base of the conical member  2603 . The triangular shape provides more stability when joining panels and prevents or reduces relative motion between the panels. 
       FIG. 33  illustrates an alternative configuration of the fastener of  FIG. 26 . Here the fastener  3300  has a rectangular base  3201  on which there are four protruding members  2602 , each comprising a conical member  2603  on a shorter shaft  2604 . The shaft  2604  has a smaller diameter than the diameter of the base of the conical member  2603 . The rectangular shape provides more stability when joining panels and prevents or reduces relative motion between the panels. 
     It should be understood, of course, that the foregoing relates to exemplary embodiments of the apparatus and that modifications may be made without departing from the spirit and scope of the present apparatus. The present apparatus can be used on non-fire column patio heaters, such as electric heaters and the like.