Patent Publication Number: US-9429330-B2

Title: Closed loop heating system

Description:
This application is a continuation-in-part of U.S. application Ser. No. 12/457,397, filed on Jun. 10, 2009. 
    
    
     This invention relates generally to a heating system, and more particularly to an improved closed loop heating system which is durable and reliable, that possesses easily removable or replaceable heating elements, and which can be easily installed in a home. 
     DESCRIPTION OF THE PRIOR ART 
     It is well known that furnaces are used to heat homes. Traditionally, such furnaces were oil furnaces. However, as the demand for oil has risen sharply in the last decade, the price has correspondingly risen sharply, reducing the ability of such furnaces to be economical to the home or business owner. Recently, gas-fired furnaces, using natural gas, have been much in demand for homeowners in economically heating their home. However, much as has occurred with oil, natural gas has also seen large price increases in the last couple of years, which has also reduced the economical viability of gas-fired furnaces. 
     It is also well known to heat homes using, for example, electrical baseboards, but, as hydro rates have risen quite sharply recently, and can be expected to continue upwardly in the future, these types of devices are not necessarily economical also. What is required is a heating system which is very economical, and which can generate substantial amounts of heat to heat larger spaces, such as in a home or business. Thus, there is a further need for an improved environmentally friendly heating system for heating a space which has a generally uncomplicated and simple design, which may be installed easily, and is durable and reliable, and which possesses easily removable or replaceable heating elements. 
     There is also a need for an improved closed loop heating system which utilizes environmentally friendly heating elements which have a generally uncomplicated and simple design, which may be installed or removed easily, and which, by virtue of its design, are more durable and reliable to withstand the constant flow of coolant or fluid flowing around it over time. There is also a further need for an improved closed loop heating system using heating elements having a greater surface area so as to contact the coolant or fluid flowing past and around it, therefore heating the coolant or fluid in a faster and more efficient manner. In this regard, the present invention substantially fulfills this need. 
     SUMMARY OF THE INVENTION 
     It is an object and advantage of the present invention to provide an improved heating system which is environmentally friendly and extremely economical, and which has a generally uncomplicated and simple design, and which may be installed easily. 
     It is another object and advantage of the present invention to provide an improved heating system which is durable and reliable, and which possesses easily removable or replaceable heating elements. 
     It is another object and advantage of the present invention to provide an improved heating system which can be run with a minimum of electrical power, and yet which can generate substantial amounts of heat to heat larger spaces. 
     It is another object and advantage of the present invention to provide an improved heating system which utilizes environmentally friendly heating elements which have a generally uncomplicated and simple design, which may be installed or removed easily, and which, by virtue of its design, are more durable and reliable. 
     It is another object of the present invention to provide an improved heating system which utilizes heating elements having a greater surface area so as to contact the coolant or fluid flowing past and around it, and therefore heating the coolant or fluid in a faster and more efficient manner. 
     According to one aspect of the present invention, there is provided a closed loop heating system for heating a space comprising a first flow pipe and a second flow pipe, the first flow pipe and the second flow pipe being interconnected at ends thereof to form a closed loop fluid flow circuit; a housing interconnected with the closed loop fluid flow circuit, and having a passage extending therethrough for passage of a heatable transfer fluid through the housing, the housing having at least one opening defined within the housing which is separate from the passage; at least one electric heating element inserted into the at least one opening, the at least one electric heating element being removable from the housing without disassembly of the housing and without disconnection of the housing from the closed loop fluid flow circuit, and wherein the at least one electric heating element has a substantially vertical upper stem body and an elongated lower end being connected thereto in a substantially perpendicular relationship to the upper stem body, the lower end being constructed and arranged for insertion into the at least one opening and projecting into the passage whereby the lower end is in direct contact with the heatable transfer fluid; a pump in communication with the heating system for continuously circulating the heatable transfer fluid through the closed loop fluid flow circuit; and heat transfer means connected to at least a portion of the closed loop fluid flow circuit, the heat transfer means being constructed and arranged for transferring the heat from the heatable transfer fluid flowing in the closed loop fluid flow circuit to the space heated by the heating system. 
     According to yet another aspect of the present invention, there is provided a heating system for heating a space comprising a first flow pipe and a second flow pipe, the first flow pipe and the second flow pipe being interconnected at ends thereof to form a closed loop fluid flow circuit; a housing interconnected with the closed loop fluid flow circuit, and having a passage extending therethrough for passage of a heatable transfer fluid through the housing, the housing having at least one opening defined within the housing and separate from the passage; at least one electric heating element inserted into the at least one opening, the at least one electric heating element being removable from the housing without disassembly of the housing and without disconnection of the housing from the closed loop fluid flow circuit, and wherein the at least one electric heating element has a substantially vertical upper stem body and an elongated lower end being connected thereto in a substantially perpendicular relationship to the upper stem body, the lower end being constructed and arranged for insertion into the at least one opening and projecting into the passage whereby the lower end is in direct contact with the heatable transfer fluid; at least one electric heating element inserted into the at least one opening, the at least one electric heating element being removable from the housing without disassembly of the housing and without disconnection of the housing from the closed loop fluid flow circuit, and wherein the at least one electric heating element has a substantially vertical upper stem body and an elongated lower end being connected thereto in a substantially perpendicular relationship to the upper stem body, the lower end being constructed and arranged for insertion into the at least one opening and projecting into the passage whereby the lower end is in direct contact with the heatable transfer fluid; a pump in communication with the closed loop fluid flow circuit for continuously circulating the heatable transfer fluid through the closed loop fluid flow circuit; a power source in communication with the heating system, for supplying the at least one glow plug and the pump with power, and enabling the at least one glow plug to heat the heatable transfer fluid and the pump to circulate the heatable transfer fluid; heat transfer means connected to at least a portion of the closed loop fluid flow circuit, the heat transfer means being constructed and arranged for transferring the heat from the heatable transfer fluid flowing in the closed loop fluid flow circuit to the space heated by the heating system; and a remote device to remotely selectively activate or de-activate heating of the at least one electric heating element from a distance. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       A preferred embodiment of the present invention is described below with reference to the accompanying drawings, in which: 
         FIG. 1  is a perspective view of an embodiment of the closed loop heating system of the present invention; 
         FIG. 2  is a perspective view of an embodiment of the heating element for use in the closed loop system of the present invention; 
         FIG. 3  is a perspective view of a further embodiment of an embodiment of a heating element that can be inserted into the housing of the closed loop system of the present invention; 
         FIG. 4  is a perspective view of radiator panels connected to the first flow pipe and the second flow pipe of the fluid flow circuit; and 
         FIG. 5  is a perspective view of an embodiment of the closed loop heating system of the present invention utilized for radiant floor heating. 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     In the preferred embodiment, and with reference to  FIG. 1 , a heating system  1  comprises a housing  3  having a passage  5  extending therethrough for passage of a heat transfer fluid  7  through the housing  3 . Preferably, the heat transfer fluid  7  will be water, though it is conceivable that other fluids could be utilized, as would be apparent to one skilled in the art. 
     As can be seen in  FIG. 1 , the passage  5  of the housing  3  extends substantially horizontally throughout a length of the housing. The housing  3  further comprises at least one opening  9  on an upper surface of the housing, but more preferably, a plurality of openings defined thereon, each of which are separate from the passage  5 , and each of which define an internally defined chamber  11  within the body of the housing  3 . As can be seen in  FIG. 1 , the housing is adapted to be mounted generally horizontally. As can also be readily seen in  FIG. 1 , the housing  3  possesses an inlet  15  at one end of the housing, and an outlet  13  at the opposite end of the housing  3 . Preferably, the housing  3  is made of metal, though it is conceivable that other materials could also be utilized, as would be apparent to one skilled in the art. 
     The housing  3  is interconnected with a first flow pipe  19  and a second flow pipe  21  which are interconnected at ends  23  thereof to form a closed loop fluid flow circuit, wherein the heat transfer fluid  7 , or water, may flow. The closed loop fluid flow circuit will preferably be in a vacuum environment. A pump  6  is also utilized to continuously circulate the heat transfer fluid  7 , or water, through the fluid flow circuit. 
     As can also be readily seen in  FIG. 1 , heating elements  17  are inserted through the opening  9  on the upper surface of the housing  3 , so as to reside within the internally defined chambers  11  within the body of the housing  3 . Preferably, the heating elements are DC electrical heating elements, though it is conceivable that other devices could be utilized. These can be easily removable and replaceable if required. The heating elements  17  projects into the passage  5  of the housing  3  whereby the electric heating elements  17  are in direct contact with the heat transfer fluid  7 , or water flowing in the fluid flow circuit. In a preferred embodiment, each of the chambers  11  will have an associated heating element inserted therein.  FIG. 1  illustrates three such removable electric heating elements  17  being utilized, though it will, of course, be understood that numerous variations to this number are possible, such as six or eight. 
     When positioned within the internally defined chambers  11  within the body of the housing  3  the heating element  17  comprises, as shown in  FIG. 2 , an elongated stem  34  that is inserted into chambers  11  of the housing  3 . An upper end of the stem  34  comprises an electrical connection  31 , which is connected to, and supplied with, electrical power from a power source  25  shown in  FIG. 1 , such as a battery for enabling the heating element  17  to heat the heat transfer fluid  7  being circulated by the pump  6 . The electrical connection portion  31  will, preferably, be made of Inconel™, it being understood that this refers to a family of austenitic nickel chromium-based super-alloys, which are typically used in high temperature applications. Common trade names for Inconel™ include: Inconel 625™, Chronin 625™, Altemp 625™, Haynes 625™, Nickelvac 625™ and Nicrofer 6020™, for example. The stem  34 , and the heating element  17 , are electrically insulated by way of an insulating sheath  32  that surrounds the stem  34 , so as to provide negative grounding to the device. Surrounding a substantially middle portion of the stem  34  and the insulating sheath  32  is a threaded portion  33 , by which the heating element  17  can be threadably fixed and inserted into chambers  11  of the housing  3 . 
     The heating elements  17  in the housing  3  are supplied with electrical power from a power source  25  for enabling the heating elements  17  to heat the heat transfer fluid  7 , or water, within the fluid flow circuit. For example, some electrical heating elements can be heated to 3500 degrees, or temperatures in varying other degrees, and this, in combination with the temperatures generated by other elements in the housing, amounts to a considerable temperature which can be generated to heat the fluid flowing in the fluid flow circuit. In one embodiment, the power source  25  is an electrical type power source, or a DC power pack that can be plugged in by means of a power cord (not shown), though it is conceivable that, alternatively, other types of power sources could be utilized, such as solar power cells, A/C power, DC power pack, wind generated power sources or the like, as would be apparent to one skilled in the art. Of course, it would be readily apparent that such a power cell could also be re-energized or re-charged also, as is also known in the art. The power from the power source  25  is connected to the heating elements  17  by means of data board  27  and wiring  29 . In a preferred embodiment, the power source  25  is a DC power pack and can be easily unplugged and replaced from the system if necessary, whereby a new power pack can be inserted. 
     A lower end  35  of the stem  34  will, preferably, be L-shaped, the lower end  35  thus being substantially perpendicular in relationship to the stem  34 . The outermost end  36  of the lower end  35  will preferably be tapered, at least slightly. In this manner, when the heating element  17  is inserted into chambers  11  of the housing  3 , so as to project downwardly into the passage  5  of the housing  3  to be direct contact with the heat transfer fluid  7 , the tapered outermost end  36  of the lower end  35  will act as a breakwater to the onrushing coolant flowing past it in the passage  5 , (the directional passage flow of the fluid being shown as “A” in  FIG. 2 ) separating the heat transfer fluid  7  and forcing the heat transfer fluid  7  to flow past both sides of the lower end  35 . Such a construction is advantageous when contrasted to that of a conventional electric heating element having a straight, vertically depending lower end, as when such element is vertically positioned to extend downwardly within the passage, the straight vertical lower end thereof is thus subjected to the stress of encountering fully the heat transfer fluid  7  or coolant flowing past within the passage  5 . Over time, such a construction means such an electric heating element is subjected to greater structural stresses than that of the heating element  17  of the present invention, and likely will require more frequent replacement and potential for breakage. 
     Moreover, by virtue of the lower end  35  of the stem  23  being L-shaped, the lower end  35  possesses a greater surface area with which to contact, and thus heat the heat transfer fluid  7 . This effectively means that heat transfer fluid  7  can be heated at a faster rate than a conventional electric heating element, since the heat transfer fluid  7  is separated and heated by both sides of the lower end  35 , rather than just encountering, and being heated by, the immediate, and only, surface of a straight conventional electric heating element projecting downwardly in passage  5  to contact the flow of the heat transfer fluid  7 . And, by virtue of the tapered outermost end  36  of the lower end  35  forcing the heat transfer fluid  7  to flow past both side of the lower end  35 , the lower end  35  is thus enabled to heat the heat transfer fluid  7  in smaller quantities, since the heat transfer fluid  7  is effectively being split in half by the breakwater qualities of tapered outermost end  36 . 
     As can be seen in  FIG. 3 , there is shown an alternative embodiment of a heating element  52  that is inserted through the opening  9  on the upper surface of the housing  3 , so as to reside within the internally defined chambers  11  within the body of the housing  3 , as noted previously. Preferably, any of the heating elements  52  are easily removable and replaceable if required. When positioned within the internally defined chambers  11  within the body of the housing  3  shown in  FIG. 1 , the heating element  52  comprises an elongated stem  59  that is inserted into chambers  11  of the housing  3 . An upper end of the stem  59  comprises an electrical connection portion  53 , which is connected to, and supplied with, electrical power from a power source (not shown) such as a battery for enabling the heating element  52  to heat the coolant (not shown), the coolant of course being circulated by pump (not shown). The electrical connection portion  53  will, preferably, be made of Inconel™, it being understood that this refers to a family of austenitic nickel chromium-based super-alloys, which are typically used in high temperature applications. Common trade names for Inconel™include: Inconel 625™, Chronin 625™, Altemp 625™, Haynes 625™, Nickelvac 625™ and Nicrofer 6020™, for example. 
     Surrounding a substantially middle portion of the stem  59  and the insulating sheath  55  is a threaded portion  57 , by which the electric heating element  52  can be threadably fixed and inserted into chambers  11  of the housing  3 . A lower end  61  of the stem  59  is substantially angled at a 45 degree angle and projects into the passage  5  of the housing  3  whereby the heating element  52  is in direct contact with the heat transfer fluid  7 , the lower end thus being substantially perpendicular in relationship to the stem  59  and the remainder of the heating element  52 , giving the lower end  61  of the heating element  52  a greater surface area with which to contact, and thus heat the heat transfer fluid  7 . 
     The outermost point  63  of the lower end  61  will preferably be tapered, at least slightly. In this manner, when the electric heating element  52  is inserted into chambers  11  of the housing  3 , so as to project downwardly into the passage  5  of the housing  3  to be in direct contact with the heat transfer fluid  7 , the tapered outermost point  63  of the lower end  61  will act as a breakwater to the onrushing heat transfer fluid  7  flowing past it in the passage  5 , (the directional passage flow of the heat transfer fluid  7  being shown as “A” in  FIG. 3 ) separating the heat transfer fluid  7  and forcing the heat transfer fluid  7  to flow past both sides of the lower end  61 . Such a construction is advantageous, when contrasted to that of a conventional heating element that merely extends downwardly into the passage, as when such an element is vertically positioned to extend downwardly within the passage, the vertical lower end is thus subjected to the stress of encountering fully the coolant flowing past within the passage  5 . Over time, such a construction means that such a heating element is subjected to greater structural stresses than that of this embodiment of the heating element  52  of the present invention, and likely will require more frequent replacement and potential for breakage. 
     Moreover, by virtue of the lower end  61  of the stem  59  being substantially angled at a 45 degree angle, the lower end  61  possesses a greater surface area with which to contact, and thus heat the heat transfer fluid  7 . This effectively means that heat transfer fluid  7  can be heated at a faster rate than that accomplished by a conventional heating element, since heat transfer fluid  7  is separated and heated by both sides of the lower end  61 , rather than just encountering, and being heated by, the immediate, and only, surface of a conventional heating element projecting downwardly in passage  5  to contact the flow of heat transfer fluid  7 . And, by virtue of the tapered outermost point  63  of the lower end  61  forcing the heat transfer fluid  7  to flow past both sides of the lower end  61 , the lower end  61  is thus able to heat the heat transfer fluid  7  flowing past it in smaller quantities, since the heat transfer fluid  7  is effectively being split in half by the breakwater qualities of tapered outermost point  63 , and the lower end  61  is effectively in contact with both halves of the heat transfer fluid  7  flowing past it. It will of course be understood that the lower end  61  of the stem  59  of the electric heating element  52  can be substantially angled at from between a 45 degree angle to a 90 degree angle when it is inserted into the housing  3  to project into the passage  5 . 
     In a preferred embodiment, and as shown in  FIG. 4 , radiator panels  41  are connected to the first flow pipe  19  and the second flow pipe  21  of the fluid flow circuit, to radiate the heat from the heat transfer fluid  7  flowing in the fluid flow circuit to a space (not shown) to be heated by the heating system. Such a space could be, for example, a home, a room, an office or a building. In one embodiment, the radiator panels  41  could be interconnected, with each of the radiator panels  41  having the heat transfer fluid  7 , derived from the fluid flow circuit, flowing therethrough, the radiator panels  41  being in fluid flow communication therewith. 
     In a further embodiment, the heating system  1  includes a thermostatic safety control  18  in association with the heating elements  17 , which could be installed within or on the housing  3  so as to be in association with the heating elements  17  and the other components therein, in a conventionally known manner. In a preferred embodiment, each of the heating elements  17  will have a corresponding thermostatic safety control  18  associated therewith. Each thermostatic safety control  18  is adapted to turn the heating element  17  off when a temperature of the heat transfer fluid  7  within the fluid flow circuit and the housing  3  exceeds a pre-determined level, or when it is detected that a component has failed. For example, if the pump  6  malfunctions and is no longer circulating the heat transfer fluid  7  in the housing  3 , each thermostatic safety control  18  activates to shut down each of the heating elements  17 . Moreover, in the event of a power surge to the system, or in the event the system is too hot or too cold, each thermostatic safety control  18  activates to shut down each of the heating elements  17  to prevent damage to the system. 
     In an alternative embodiment, as shown in  FIG. 1 , the heating system of the present invention can be selectively activated (or deactivated) by a remote device  42  by a user, whereby the power source  25 , activates the heating elements  17  from a distance, it being understood that the remote device used could be of a conventionally known variety. Of course, the housing  3  can also contain thereon a conventional on/off switch (not shown), as would be apparent to one skilled in the art. It is conceivable that the present invention could be utilized, but not limited to, such applications as heating a greenhouse, radiant flooring, heating an office or the like, or a home or building. In addition, it is also conceivable that a water source could also be interconnected with the closed loop fluid flow circuit of the present invention. Such a water source could be, as an example only, a water heater, which could be deactivated from operation, but which would provide sufficient quantities of water for the system. Other variations to this are possible also, as would be apparent to one skilled in the art. 
     In a further embodiment, the heating system of the present invention, for example, could be utilized as a radiant floor heating system. With reference to  FIG. 5 , in this embodiment, a heating system  70  comprises a housing  91  having a passage  85  extending therethrough for passage of a heat transfer fluid (not shown) through the housing  91 . Preferably, the heat transfer fluid will be water, though it is conceivable that other fluids could be utilized, as would be apparent to one skilled in the art. 
     The housing  91  is interconnected with a first flow pipe  81  and a second flow pipe  84  which are interconnected at ends  83  thereof to form a closed loop fluid flow circuit, wherein the heat transfer fluid may flow. The closed loop fluid flow circuit will preferably be in a vacuum environment. A pump  93 , which can of a conventional sort, is also utilized to continuously circulate the heat transfer fluid through the fluid flow circuit. 
     As can also be readily seen in  FIG. 5 , heating elements  87  are inserted through the openings  90  on the upper surface of the housing  91 , so as to reside within the internally defined chambers  92  within the body of the housing  91 . Preferably, the heating elements are DC electrical heating elements, though it is conceivable that other devices could be utilized. These can be easily removable and replaceable if required. The heating elements  87  projects into the passage  85  of the housing  91  whereby the electric heating elements  87  are in direct contact with the heat transfer fluid flowing in the fluid flow circuit. In a preferred embodiment, each of the chambers  92  will have an associated heating element inserted therein.  FIG. 5  illustrates fifteen such removable electric heating elements  87  being utilized, though it will, of course, be understood that numerous variations to this number are possible. 
     The heating elements  87  in the housing  91  are supplied with electrical power from a power source  71  for enabling the heating elements  87  to heat the heat transfer fluid within the fluid flow circuit. For example, some electrical heating elements can be heated to 3500 degrees, or temperatures in varying other degrees, and this, in combination with the temperatures generated by other elements in the housing, amounts to a considerable temperature which can be generated to heat the fluid flowing in the fluid flow circuit. In one embodiment, the power source  71  is an electrical type power source, or a DC power pack that can be plugged in by means of a power cord (not shown), though it is conceivable that, alternatively, other types of power sources could be utilized, such as solar power cells, A/C power, DC power pack, wind generated power sources or the like, as would be apparent to one skilled in the art. Of course, it would be readily apparent that such a power cell could also be re-energized or re-charged also, as is also known in the art. The power from the power source  71  is connected to the heating elements  87  by means of circuit board  89  and wiring  78 . In a preferred embodiment, the power source  71  is a DC power pack and can be easily unplugged and replaced from the system if necessary, whereby a new power pack can be inserted. 
     The embodiment of the heating system  70  includes a thermostatic safety control  79  in association with the heating elements  87 , which could be installed within or on the housing  91  so as to be in association with the heating elements  87  and the other components therein, in a conventionally known manner. In one embodiment, each of the heating elements  87  will have a corresponding thermostatic safety control  79  associated therewith. Each thermostatic safety control  79  is adapted to turn the heating element  87  off when a temperature of the fluid within the fluid flow circuit and the housing  91  exceeds a pre-determined level, or when it is detected that a component has failed. For example, if the pump  93  malfunctions and is no longer circulating the fluid in the housing, thermostatic safety controls  79  activates to shut down each of the heating elements  87 . Moreover, in the event of a power surge to the system, or in the event the system is too hot or too cold, thermostatic safety controls  79  activates to shut down each of the heating elements  87  to prevent damage to the system. 
     With further reference to  FIG. 5 , it can be seen that the system has a ground  77  integrated with the circuit board  89  and the system. Power from power source  71  is conveyed, by means of circuit board  89 , to heating line  75 , which relays this power to the heating elements  87 . Cold water flowing in to the system, shown at  95 , from a radiator (not shown), is conveyed through first flow pipe  81  and second flow pipe  84 , by means of pump  93 , into the passage  85  of the housing  91  whereby the electric heating elements  87  directly contact and heat the fluid. The heat transfer fluid is then circulated out through an outlet  97  of the system, and the heat generated from the system being radiated out from conventional type components, such as radiator panels (now shown), integrated with the radiant flooring system. 
     The present invention has been described herein with regard to preferred embodiments. However, it will be obvious to persons skilled in the art that a number of variations and modifications can be made without departing from the scope of the invention as described herein.