Patent Publication Number: US-2009223512-A1

Title: Outdoor patio heater

Description:
BACKGROUND 
     1. Technical Field 
     The present disclosure is related to heating devices, for example, outdoor heaters such as outdoor patio heaters. 
     2. Description of the Related Art 
     A variety of devices are available to provide heat in outdoor environments. One of the most common devices is the outdoor patio heater. Outdoor patio heaters typically include a metal base, a metal pole extending from the base, a heat source positioned at the top of the pole, and a metal heat reflector positioned above the burner to direct heat downward. The heat source may take the form of a burner that burns fuel from a fuel source, for example, propane stored in a pressurized canister. Alternatively, the heat source may take the form of an infrared light, which is supplied electrical current from an electrical power source such as a wall socket. 
     Patio heaters have been available for many years. Patio heaters allow people to enjoy an outdoor environment, even in relatively cold temperatures. Patio heaters allow businesses to extend the use of outdoor spaces such as decks, court yards, bars, restaurants, gardens or other outdoor areas, into the winter months. 
     Conventional patio heaters have been aesthetically unappealing, typically having a metallic finish. Thus, conventional outdoor patio heaters have an industrial, sterile appearance. To date, outdoor patio heaters typically have been employed in commercial environments, for example, restaurants, bars or pubs. Such outdoor heaters may be purchased and/or delivered by trained personnel. Thus, packaging and ease of assembly have not been constraints. 
     There is currently a strong movement towards the use of outdoor residential spaces as homeowners and renters maximize the value of their living spaces. As consumers start employing outdoor spaces, for example patios, as living environments, demand for outdoor patio heaters in residential use will increase. 
     Fulfilling such demand requires that outdoor heaters be conveniently packaged. For example, outdoor heaters should be packaged in sufficiently small enough volumes that consumers may purchase patio heaters at retail stores such as outdoor and patio stores or large box stores (e.g., COSTCO, SAM&#39;S CLUBS, EAGLE, HOME DEPOT) and transport the packages to their residences without assistance. Such also requires that patio heaters be simple to assemble. Experience has shown that rate of return is strongly related to the complexity of assembly. Consumers will often return a product which is difficult to assembly even though there is no manufacturing defect in the product. Such is expensive and time consuming for the retailer, distributor and/or manufacturer, as well as frustrating and disappointing for the consumer. Where a device is simple for the consumer to set up or assemble, the rate of return can be decreased. The selling price of such devices may consequently be decreased since less returns need to be accounted for in the selling price. Further, it is important that the various components of the outdoor heater be securely fastened together to provide a stable and safe device. Consequently, improvements in outdoor heaters and methods associated with assembly of such are highly desirable. 
     BRIEF SUMMARY 
     At least one embodiment may be summarized as an outdoor heater, including a base; an elongated support member having a first end and a second end opposed to the first end, the elongated support member selectively coupleable proximate the first end thereof to the base for support thereby; a heat source selectively coupleable to the elongated support member proximate the second end of the elongated support member; and a canopy selectively coupleable to at least one of the heat source or the elongated support member positioned relatively above the heat source with respect to the base, the canopy comprising a number N of panels and an equal number N of elongated ribs, the panels each having a pair of opposed side edges, the elongated ribs each having a pair of longitudinally extending channels, each of the channels sized to receive a respective one of the side edges of a respective one of the panels, each of the channels having a retention structure to physically engage at least a portion of the received one of the side edges to secure two of the panels to each of the elongated ribs. The channels may be formed in opposed edges of the elongated ribs. An opening of the channels at the edges of the elongated ribs may be smaller than a thickness of the side edges of the panels to be received in the channel and the channels are open at an end of the elongated rib to allow the side edges of the panels to slide into the channels. The retention structure may be a lip formed in the channel. The channels may have a substantially L-shaped cross-section when viewed along a longitudinal axis. The elongated ribs may have a substantially annular cross-section. The side edges of each of the panels may be thicker than an interior portion of the panels. The side edges each may include a roll portion of the panel. 
     The outdoor heater may further include a top cap structure fastenable relatively above the canopy. The top cap structure may include an upper plate and a lower plate, the upper and the lower plates fastenable together to securely sandwich a top edge of each of the panels therebetween. The top cap structure may further include a sloped cover selectively coupleable to the upper plate positioned above the upper plate with respect to the lower plate. The top cap structure may include a set of fasteners to couple the lower plate to a portion of the heat source. The canopy may further include a number N of end pieces, each of the end pieces having a recess sized to accommodate an end of a respective one of the elongated ribs. The side edges of the panels may taper from a bottom edge to a top edge such that the bottom edge of the panel is wider than the top edge of the panel. A portion of the panels proximate the top edge may be non-planar with respect to a remainder of the panel. 
     The heat source may be a burner. The base may form a cavity sized to receive a fuel source. The base may have a hatch that is selectively openable, the hatch sized to receive a standard size refillable fuel tank of between approximately 1 gallon and approximately 12 gallons of fuel capacity. The base may include a shell of fiber reinforced plastic. 
     The outdoor heater may further include a table top supported by the base. The table top may include a throughhole and a recess about the throughhole and the elongated support member has a threaded portion, and further include an upper washer having an outer diameter and an inner diameter, the outer diameter sized to be received in the recess of the table top and the inner diameter sized to receive at least a portion of the elongated support member therethrough; a collar having a threaded throughhole sized and dimensioned to matingly couple with the threaded portion of the elongated support member. The collar may include a least one opening sized to receive a portion of a tool for use in securing the collar. The outdoor heater may further include a lower washer having an inner diameter sized to receive at least a portion of the elongated support member therethrough, the lower threaded washer positionable between the collar and the table top in use. The outdoor heater may further include a ferrule having an outer diameter and an inner diameter, the outer diameter larger than a diameter of the recess of the table top and the inner diameter sized to closely receive a portion of the elongated support member. The outdoor heater may further include at least one gasket having an inner diameter sized to receive at least a portion of the elongated support member, the gasket positionable between the ferrule and the table top. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
       In the drawings, identical reference numbers identify similar elements or acts. The sizes and relative positions of elements in the drawings are not necessarily drawn to scale. For example, the shapes of various elements and angles are not drawn to scale, and some of these elements are arbitrarily enlarged and positioned to improve drawing legibility. Further, the particular shapes of the elements as drawn, are not intended to convey any information regarding the actual shape of the particular elements, and have been solely selected for ease of recognition in the drawings. 
         FIG. 1  is an isometric view of an outdoor heater, according to one illustrated embodiment. 
         FIGS. 2A-2D  are partial isometric views showing the assembly of a canopy for an outdoor heater, according to one illustrated embodiment. 
         FIG. 3  is a partial isometric view of a rib of a canopy, according to one illustrated embodiment. 
         FIG. 4  is a top plan view of an end piece of a canopy according to one illustrated embodiment. 
         FIG. 5A  is a partial isometric view showing an assembly of a canopy to a burner, according to one illustrated embodiment. 
         FIG. 5B  is an isometric view showing an assembly of a cap to the canopy according to one illustrated embodiment. 
         FIG. 6  is an exploded partial view of an elongated support member and coupling structure used to couple the elongated support member to a table and/or base, according to one illustrated embodiment. 
         FIG. 7A  is a cross-sectional view showing an elongated support member coupled to a table and base via the coupling structure, according to one illustrated embodiment. 
         FIG. 7B  is a bottom plan view of a portion of the coupling structure and a tool used in applying torque to the coupling structure, according to one illustrated embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     In the following description, certain specific details are set forth in order to provide a thorough understanding of various disclosed embodiments. However, one skilled in the relevant art will recognize that embodiments may be practiced without one or more of these specific details, or with other methods, components, materials, etc. In other instances, well-known structures associated with outdoor heaters such as fuel supply systems for example valves, conduits, and/or couplings have not been shown or described in detail to avoid unnecessarily obscuring descriptions of the embodiments. 
     Unless the context requires otherwise, throughout the specification and claims which follow, the word “comprise” and variations thereof, such as, “comprises” and “comprising” are to be construed in an open, inclusive sense, that is as “including, but not limited to.” 
     Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, the appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment. Further more, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. 
     As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the content clearly dictates otherwise. It should also be noted that the term “or” is generally employed in its sense including “and/or” unless the content clearly dictates otherwise. 
     The headings and Abstract of the Disclosure provided herein are for convenience only and do not interpret the scope or meaning of the embodiments. 
       FIG. 1  shows an outdoor heater  10  which includes a base  12  which may have a separate or integral pedestal  14  that supports a tabletop  16 . The outdoor heater  10  also includes an elongated support member  18 , for example, a pole, a heat source  20 , for example, a burner or infrared light bulb, and a canopy  22  positioned above the heat source  20 . 
     The base  12  and/or pedestal  14  may be formed from any of a variety of materials. For example, the base  12  and pedestal  14  may be formed from fiber-reinforced plastic (FRP). Such allows the base  12  and pedestal  14  to have a variety of aesthetic treatments, for example, different textures, surface finishes and/or colors. For instance, the base  12  and pedestal  14  may be finished to look like aged stones, slate, bricks, and/or terra cotta. The pedestal includes an opening  24  and a selectively removable hatch  26  to provide access to an interior  28  ( FIG. 7A ). The opening  24  and hatch  26  may be sized to receive a standard size canister  30  (e.g., 7-10 gallons) of fuel such as propane. The hatch  26  may optionally include one or more handles  32  to allow removal and replacement of the hatch  26  from the opening  24 . The hatch  26  and pedestal  14  may include one or more complimentary retainment mechanisms, for example, a tongue-in-groove or detent, and may optionally include one or more gaskets (not shown) to seal the interior  28  from an exterior. The base  12  may be weighted, or the weight of the canister  30  may provide sufficient stability. 
     The tabletop  16  may be formed of a variety of materials, for example, FRP. Such may allow the tabletop  16  to have a variety of aesthetic treatments including different textures, surface finishes and/or colors. The tabletop  16  includes a top surface  32  and a bottom surface  34 . The tabletop  16  may be physically coupled to the pedestal  14  and/or elongated support member  18 . The tabletop  16  provides a convenient place for placing various material such as glasses and dishes. 
     The elongated support member  18  may take the form of a hollow pole with a central passage. While illustrated with a circular cross-section, the pole  18  may take a variety of forms, for example an oval cross-section or a hexagonal or octagonal cross-section. The pole  18  may be formed of a variety of materials, for example, metals such as stainless steel or aluminum. Alternatively, the pole  18  may be formed of a plastic, such as FRP. The pole  18  may have a passage (not shown) that provides a conduit for coupling a power source (e.g., canister  30  and/or a batteries, fuel cells, and/or ultracapacitors) to the heat source  20 , for example, via one or more tubes, pipes, valves, or wires. 
     The heat source  20  may take a variety of forms. The heat source  20 , for example, may take the form of a burner with one or more jets to deliver a pressurized flow of fuel for burning. The heat source  20  may include one or more electrical ignition elements such as piezo-electric elements to light the pressurized fuel. In an alternative embodiment, the heat source  20  may take the form or one or more lights, for example, halogen lights or other lights that emit substantially in the infrared portion of the electromagnetic spectrum. One or more screens  36  my surround or partially surround the heat source  20 . The screen  36  may protect users from directly touching the heat source  20  and/or may diffuse heat and/or light. The outdoor heater  10  may include one or more controls  38  which may be activated by a user to cause the heat source  20  to produce heat and/or to adjust an amount of heat produced by the heat source  20 . 
     The canopy  22  is positioned relatively above the heat source  20  and may deflect or reflect heat produced by the heat source  20  downward. The canopy  22  may additionally or alternatively provide environmental protection, for example protecting the heat source  20  and/or users from precipitation (e.g., rain, snow). The canopy  22  may be formed from a variety of materials, although typically will be formed from a metal such as stainless steel or aluminum. The canopy  22  can have a variety of shapes, including shapes having straight edged perimeters and/or arcuate edged perimeters. The canopy  22  may include a number of panels  38   a ,  38   b  (only two shown in  FIG. 1 ) and a number of ribs  40   a ,  40   b  (only two shown in  FIG. 1 ). The ribs  40  couple the panels  38  to one another. The canopy  22  may also include a top cap structure  42  which is described in more detail below. 
       FIGS. 2A-2D  show the canopy  22  assembled according to one illustrated embodiment. 
     In the illustrated embodiment, the canopy  22  includes four panels  38   a - 38   d  (collectively  38 ) and four ribs  40   a - 40   d  (collectively  40 ). As illustrated, the panels  38  are substantially triangular in shape, although other shapes may be employed. Each panel  38   a - 38   d  has a pair of opposed side edges  42   a ,  42   b  (collectively  42 , only called out in  FIG. 2A ), a top edge  44  (only called out in  FIG. 2A ) and a bottom edge  46  (only called out in  FIG. 2A ). The side edges  42  taper inwardly from the bottom edge  46  to the top edge  44  such that the panel is wider proximate the bottom edge  46  than the top edge  44  ( FIG. 2A ). A portion of the panel  38  proximate the top edge  44  is bent or angled to form a lip or ledge  48  (only called out in  FIG. 2A ), such that the ledge  48  is non-planar with the remainder of the panel  38 . 
     As best seen in  FIGS. 2C and 2D , the bottom edge of the panel  38  may include a roll or bead  50  (only one called out in  FIGS. 2C-2D ). As best seen in  FIGS. 2B and 2C , the side edges  42  may include a roll or bead  52 . While shown as being generally trapezoidal, the panels  38  may have a variety of other shapes. For example, the bottom edge  46  may be arcuate instead of straight. The panels  38  may include a number of through holes  54 , for example, to receive fasteners  56  ( FIG. 2D ). The fasteners  56  may take a variety of forms including screws, nuts and bolts, rivets, or other conventional fasteners. 
     The ribs  40  secure the panels  38  to one another. As best seen in  FIGS. 2C and 2D , the ribs  40  are elongated members having a first end  60   a  (only called out in  FIG. 2C ) and a second end  60   b  (only called out in  FIG. 2C ) opposed to the first end  60   a . As best seen in  FIG. 3 , the ribs  40  have a pair of channels  62   a ,  62   b  (collectively  62 ) sized to receive the side edges  42  of the panels  38 , including the roll or bead  50 . The channels  62  may be formed in opposed edges  64   a ,  64   b  of the rib  40 . An opening  66   a ,  66   b  of each channel  62   a ,  62   b  has a width or a thickness that is smaller than a width or thickness of the roll or bead  50  of the side edges  42  of the panels  38 . The opening  66   a ,  66   b  may have a width or thickness sized to closely receive the thickness of the unrolled portion of the panel  38 . An interior portion  68  of the channels  62   a ,  62   b  is sufficiently wide or thick to accommodate the roll or bead  50 . Thus, the channels  62   a ,  62   b  include a retainment structure such as a lip  70   a ,  70   b  to retain the side edges  42  of the panels  38  in the channels  62   a ,  62   b . The channels  62   a ,  62   b  may, for example, be generally L-shaped. The channels  62   a ,  62   b  are open at the first end  60   a  and second end  60   b  of the rib  40  to allow the side edges  42  along with the roll or bead  50  to be slid into the respective channels  62   a ,  62   b . The ribs  40  should be formed of a strong material capable of providing sufficient structural rigidity to the canopy  22 . For example, the ribs  40  may be formed of a metal, for example, stainless steel or aluminum. 
     As best seen in  FIG. 3 , the ribs  40  may have an annular cross-section as viewed along a longitudinal access of the rib  40 . Thus, an upper surface  72   a  and a lower surface  72   b  may have arcuate profiles. Such may provide a smooth transition between adjacent panels  38  enhancing appearance and decreasing the number of exposed sharp edges. Such may also provide structural rigidity to the rib  40 , allowing a smaller cross-sectional area and, hence, a reduction in material and cost. 
     With continuing reference to  FIGS. 2A-2D , the acts of assembling the canopy are illustrated. For example, the side edges  42  of a first panel  38   a  may be slid into a respective channel  62  of a first and a second rib  40   a ,  40   d , respectively. A second panel  38   b  may be slid into the respective channels  62  of the first rib  40   a . A third panel  38   c  may be slid into a respective channel  62  of the second rib  40   d . A third rib  40   c  may be positioned to locate the remaining side edge of the third panel  38   c  into one channel and slid upwardly. The remaining side edge of the second panel  38   b  may be positioned in a respective channel of a fourth rib  40   b  and the fourth rib slid upwardly. The side edges of a fourth panel  38   d  may be positioned in respective channels of the third and fourth ribs  40   c ,  40   b  and slid upwardly. 
     As illustrated in  FIG. 2D , the canopy  22  may include a number of end pieces  80  which mate with adjacent panels  38  and the corresponding ribs  40 . As best seen in  FIG. 4 , the end piece  80  includes a recess  82  sized and dimensioned to accommodate the first end  60   a  of the rib  40 . The recess  82  is typically hidden in use so does not have to be finished or have any special surface treatment. The remainder of the end piece is typically visible when in use so may a special surface treatment such as a texture or color. The end piece may include one or more through holes  84  to receive fasteners  56 . The end piece  80  and fasteners  56  may assist in retaining the panels  38  in the channels  62  of the ribs  40 . The end pieces  80  may have rounded surfaces and corners to reduce exposure to any potentially sharp edges. 
       FIG. 5A  shows a portion of a top cap structure  42 , canopy  22 , and heat source  20 , according to one illustrated embodiment. 
     The top cap structure  42  may include an upper plate  81   a  and a lower plate  81   b  (collectively  81 ) each with a plurality of through holes  83 . The top and bottom plate structures  81  sandwich the lip or ledge portion  48  of the panels  38  therebetween. Fasteners  84  may be received through the through holes  83  to securely fasten the lips or ledges  48  of the panels  38  together. Such provides a highly rigid structure. 
     The heater  20  may include one or more threaded members  86  extending generally upwardly to be received through some of the through holes  83  in the upper and lower plates  81  as well as through the through holes  54  ( FIGS. 2B and 2D ) of the panels  38 . Fasteners such as nuts and washers  88  secure the canopy  22  to the heat source  20  via threaded members  86 . The washers may be locking washers. 
       FIG. 5B  shows a cover  90  that is fastenable to the top plate  81   a  over the canopy  22 . The cover  90  may be sloped or pyramidal. The cover  90  provides an aesthetically pleasing effect, hides the fastening hardware, and may allow water or moisture to drain off the canopy  22 . The over  90  may be fastened to the cover plate  81   a  using a standoff coupler  92  and a cap nut  94 . 
       FIGS. 6 ,  7 A and  7 B show portions of the elongated support member  18  and a coupling structure  100  to couple the support member  18  to the tabletop  16 , pedestal  14  and/or base  12 , according to one illustrated embodiment. 
     As best seen in  FIG. 7A , the tabletop  16  may include a throughhole  102  and a recess  104  sized to receive a portion of the support member  18 . As best illustrated in  FIG. 6 , a portion of the support member  18  may include a thread  106 . The thread  106  may be proximate an end of the elongated support member  18  or spaced between the ends. 
     The coupling structure  100  may include a coupler  110  according to one illustrated embodiment. The coupler  110  may include a relatively thick-walled threaded nut section  112  and a relatively thin-walled body section  114 . The threaded nut section  112  has a threaded central passage  116  sized to matingly coupled with the thread  106  of the elongated support member  18 . The threaded nut section  112  is sufficiently thick and wide to securely fasten the elongated support member  18  along with the heat source  20  and canopy  22  to the tabletop  16 , pedestal  14  and/or base  12 . The thin-walled body section  114  may provide a surface for exerting torque on the threaded nut section  112 . For example, the relatively thin-walled body section  114  may be sized to be comfortably grasped by a user. Additionally, or alternatively, the thin-walled body section  114  may include one or more holes, apertures or notches  118  which may allow the use of a tool  120  ( FIG. 7B ) to apply torque to the coupler  110 . 
     The coupling assembly  100  may include an inner washer  122 , that is received between an upper face of the threaded nut section  112  and the bottom surface  34  ( FIG. 1 ) of the tabletop  16  or pedestal  14 . The inner washer  122  may have an outer diameter greater than an outer diameter of the threaded nut section  112  to distribute a load against a larger surface area of the tabletop  16  or pedestal  14 . The inner washer  122  may have a central passage with an inner diameter sufficiently large to receive a portion of the elongated support member  18 . 
     The coupling assembly  100  may also include an outer washer  130 . The outer washer  130  may have an outer diameter and thickness sized to be received within the recess  104  of the tabletop  16 . The outer washer  130  may have a central passage sized to receive a portion of the elongated support member  18 . The outer washer  130  may be received between a bottom portion or flange  132  of the elongated support member  18  and the tabletop  16  or pedestal  14 . The outer washer  130  may be sized to distribute the load of the elongated support member  18 , heater  20  and canopy  22  over a larger surface area of the tabletop  16  or pedestal  14  than would otherwise occur without the outer washer  130 . 
     The coupling assembly  110  may include a ferrule  140  with a central passage  142  sized to closely receive a portion of the elongated support member  18 . The ferrule  140  cosmetically hides a connection between the elongated support member  18  and the tabletop  16  or pedestal  14 . The connection assembly  100  may also include a gasket  150  which may provide a seal between the ferrule  140  and the tabletop  16 . The ferrule  140  and gasket  150  may provide environmental protection, preventing liquid or moisture from seeping into the interior  28  ( FIG. 7A ) of the pedestal  14 . Such may advantageously prevent corrosion of the canister  30  and/or valves or couplers from the canister  30  to the heat source  20 . In some embodiments, the connector assembly  100  may secure the tabletop  16  to the pedestal  14  in addition to securing the elongated support member  18  to the tabletop  16 , pedestal  14  and/or base  12 . 
     The above description of illustrated embodiments, including what is described in the Abstract, is not intended to be exhaustive or to limit the embodiments to the precise forms disclosed. Although specific embodiments of and examples are described herein for illustrative purposes, various equivalent modifications can be made without departing from the spirit and scope of the disclosure, as will be recognized by those skilled in the relevant art. The teachings provided herein of the various embodiments can be applied to other outdoor heaters, not necessarily the exemplary outdoor patio heater generally described above. 
     For instance, the foregoing detailed description has set forth various embodiments of the devices and/or processes via the use of block diagrams, schematics, and examples. Insofar as such block diagrams, schematics, and examples contain one or more functions and/or operations, it will be understood by those skilled in the art that each function and/or operation within such block diagrams, flowcharts, or examples can be implemented, individually and/or collectively, by a wide range of hardware, software, firmware, or virtually any combination thereof. In one embodiment, the present subject matter may be implemented via Application Specific Integrated Circuits (ASICs). However, those skilled in the art will recognize that the embodiments disclosed herein, in whole or in part, can be equivalently implemented in standard integrated circuits, as one or more computer programs running on one or more computers (e.g., as one or more programs running on one or more computer systems), as one or more programs running on one or more controllers (e.g., microcontrollers) as one or more programs running on one or more processors (e.g., microprocessors), as firmware, or as virtually any combination thereof, and that designing the circuitry and/or writing the code for the software and or firmware would be well within the skill of one of ordinary skill in the art in light of this disclosure. 
     In addition, those skilled in the art will appreciate that the mechanisms of taught herein are capable of being distributed as a program product in a variety of forms, and that an illustrative embodiment applies equally regardless of the particular type of signal bearing media used to actually carry out the distribution. Examples of signal bearing media include, but are not limited to, the following: recordable type media such as floppy disks, hard disk drives, CD ROMs, digital tape, and computer memory; and transmission type media such as digital and analog communication links using TDM or IP based communication links (e.g., packet links). 
     The various embodiments described above can be combined to provide further embodiments. To the extent that they are not inconsistent with the specific teachings and definitions herein, all of the U.S. patents, U.S. patent application publications, U.S. patent applications, foreign patents, foreign patent applications and non-patent publications referred to in this specification and/or listed in the Application Data Sheet are incorporated herein by reference, in their entirety. Aspects of the embodiments can be modified, if necessary, to employ systems, circuits and concepts of the various patents, applications and publications to provide yet further embodiments. 
     These and other changes can be made to the embodiments in light of the above-detailed description. In general, in the following claims, the terms used should not be construed to limit the claims to the specific embodiments disclosed in the specification and the claims, but should be construed to include all possible embodiments along with the full scope of equivalents to which such claims are entitled. Accordingly, the claims are not limited by the disclosure.