Abstract:
A safe electrical heat energy generator which comprises a heater unit equipped with a set of systematically organized heat radiating metal fins. A feature of the invention is its reenforced compact structure in which a heating element arrangement and the heat radiating metal fin arrangement are manufactured as a single heater unit structure. In such a structure, a heating element is surrounded with an insulating layer and enclosed inside a central heat conductive tubing of the framework for the metal fin arrangement, thereby defining the major components of the heater unit. In this manner, the entire heater unit structure is the source of radiant heat energy, not simply the heating element itself.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    1. Field of the Invention  
           [0002]    This invention relates to the field of electric heaters, and more particularly to an electric heater having improved heating efficiency and safety aspects, and implemented as a reenforced compact structure.  
           [0003]    2. Brief Description of the Prior Art  
           [0004]    A variety of heaters are available on the current market, such as oil burning heaters, electric fan heaters, quartz heaters, convection heaters with round heating elements, PTC (ceramic) heaters, etc. Apart from oil burning heaters, all the others release radiant heat energy directly from infrared heating elements. Such heating elements can provide fast creation of heat, but also increase the danger of fire or electric shock.  
           [0005]    Electric heaters of the prior art generally are constructed with an exposed glow bar or wire which produces all of the radiant heat of the heater, the glow bar or wire being mounted in the heater behind a grating or wire screen through which the radiant heat energy passes into the environment.  
           [0006]    In some such prior art heaters, heat reflecting panels redirect rearwardly directed radiant heat energy back toward the front of the heater. In others, a fan is installed in the heater behind the glow bar or wire to force hot air in the vicinity of the heating element toward the front of the heater through the grating or wire screen.  
           [0007]    In all such prior art heaters, there exists a very hot region in the vicinity of the heating element, increasing the risk of fire if the heater is tipped over or if a combustible material, such as a curtain, is drawn into contact or near contact with the heating element. Such heater construction also increases the risk of being shocked or even electrocuted by accidentally touching the heater element through the grating or wire screen.  
           [0008]    Other characteristics of prior art heaters are problematical, such as having low to medium heat transfer rate, being structurally fragile, having unsafe (infrared) surface conditions, having a short life, having high surface temperatures (some greater than 600° C.), having poor insulation characteristics, and being subject to damage by exposure to water.  
         SUMMARY OF THE INVENTION  
         [0009]    The present invention provides a comprehensive and rational solution to the problems associated with prior art heaters and heater elements, while still retaining a very high level of conductivity of heat energy in a safe manner.  
           [0010]    A heater constructed according to the present invention represents a safe electrical heat energy generator which comprises a heater unit equipped a set of systematically organized heat radiating metal fins. An important feature of the invention is its reenforced compact structure in which a heating element and the heat radiating metal fin arrangement are manufactured as a single heater unit structure.  
           [0011]    In such a structure, a heating element is surrounded with an insulating layer and enclosed inside a central heat conductive tubing of the framework for the metal fin arrangement, thereby defining the major components of the heater unit. In this manner, the entire heater unit structure is the source of radiant heat energy, not simply the heating element itself.  
           [0012]    That is, the heating element, confined within the central heat conductive tubing, transfers heat to the interior surface of the tubing which, in turn transfers heat to the arrangement of spaced heat radiating metal fins, thereby increasing the amount of heat release due to the large surface area of the plurality of spaced metal fins. The gaps between the metal fins enforce movement of air currents and thus heat the surrounding air efficiently and uniformly.  
           [0013]    Because the electrical current of the system is confined to the heating element enclosed in a central heat conductive tube, there is no risk of getting shocked by touching the heater unit, since no current carrying elements are exposed.  
           [0014]    Additionally, due to the combined large area of heat radiating surfaces and the uniform distribution of radiant heat from the heater unit by the arrangement of heat radiating metal fins, there are no hot spots along the entire extent of the heater unit which would cause igniting of objects in the near vicinity of the heater unit or even objects touching the heater unit fin structure.  
           [0015]    Compared with other heater appliances on the market, the heater unit of the present invention effectively reduces the risk of fire and electric shock.  
           [0016]    As to the application of the invention, the heater unit can be used as a direct heat energy generator, or as the heat energy provider for any other kind of appliance requiring a radiant heat energy source.  
           [0017]    In a broad sense, the present invention overcomes the aforementioned negative attributes of prior art heaters by providing a compactly constructed unique heat distribution system to reduce excessive hot spots or regions in the heater, while producing efficient, safe, and uniform heat radiation into the environment, e.g., a room.  
           [0018]    In accordance with one aspect of the invention, there is provided a heater comprising: a housing; a heater unit fixedly mounted in the housing, the heater unit comprising means for radiating heat into the environment about the heater unit; and a heating element arrangement confined within the heater unit.  
           [0019]    In another aspect of the invention, there is provided a heater unit for use in an electric heater, comprising: a heat conductive tube having an interior surface and an exterior surface; an electrical heating element arrangement contained within, and in thermal contact with, the interior surface of the heat conductive tube; and a plurality of heat radiating fins arranged along, and in thermal contact with, the exterior surface of the heat conductive tube.  
           [0020]    Variations of physical construction parameters are possible without departing from the basic concepts of the present invention. For example, instead of providing a single central heat conductive tube, a plurality of such tubes may be provided, and additional metal fins may be provided to interconnect the plurality of tubes for improved heat radiation and distribution.  
           [0021]    Various geometric shapes for the overall configuration of the heater unit are likewise possible, the preferred configuration being an elongated linear central heat conductive tube, or tubes, from which two sets of thin, spaced apart metal fins extend in a V shape as viewed from one end of the heater unit, the fins making an angle of approximately 90degrees.  
           [0022]    It is to be understood that any number of central heat conductive tubes can be employed, any shape for the heat conductive tube(s) including curved and angled shapes, and any number of heat radiating metal fin arrangements can be fitted to associated heat conductive tubes, and any overall geometrical shape and cross section for the heater unit, or units, are possible, consistent with the improved heater and heater unit concepts and aspects according to the present invention.  
           [0023]    Compared with prior art heaters of similar usage, the heater, or heater unit, of the present invention exhibits a number of advantages:  
           [0024]    a. a high heat transfer rate, due to the choice of materials, construction design, and large surface area for heat radiation;  
           [0025]    b. mechanically very robust, due to unitary, single cast construction;  
           [0026]    c. a safe surface condition, due to full confinement of electrical heating element, and uniform heat distribution with the aid of one or more heat radiating metal fin arrangements maintaining surface temperatures to under 400° C.;  
           [0027]    d. a relatively long life, due to protection of a confined heating element from excessive oxidation and inadvertent mechanical damage by the user;  
           [0028]    e. excellent insulation characteristics, due to the use of a heating element arrangement which includes a heater element, insulation surrounding the heating element, and a heat conductive body surrounding the insulation; and  
           [0029]    f. highly water resistant, due to inaccessibility of the heating element through which current flows to produce heat energy. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWING  
       [0030]    Further objects and advantages and a better understanding of the present invention may be had by reference to the following detailed description taken in conjunction with the accompanying drawings in which certain figures are lined for color or texture, and in which:  
         [0031]    [0031]FIG. 1 is a front perspective view of a heater having a cutaway portion exposing a heating unit made in accordance with the present invention;  
         [0032]    [0032]FIG. 2 is a perspective view of a heating unit constructed in accordance with the present invention, the view taken looking into the V-shaped configuration according to a preferred embodiment of the present invention;  
         [0033]    [0033]FIG. 3 is a perspective view of the heating unit shown in FIG. 2, but from a different angle to show the structure of the heater unit on the exterior side of the V-shaped configuration;  
         [0034]    [0034]FIG. 4 is a top plan view of the heating unit shown in FIGS. 2 and 3;  
         [0035]    [0035]FIG. 5 is a side elevational view of the heater unit shown in FIGS. 2 and 3;  
         [0036]    [0036]FIG. 6 is a cross sectional view of the heater unit taken along the line  6 - 6  in FIG. 4; and  
         [0037]    [0037]FIG. 7 is an enlarged view of a portion of FIG. 6, showing, in cross section, the internal construction of one of the heat conductive tubes.  
       DEFINITIONS  
       [0038]    For the purposes of this description, the following definitions are provided.  
         [0039]    “Heater” is used to indicate a complete heat generating system such as would be suitable to warm a room, and includes a housing, at least one heater unit with its associated heating element, and electrical interconnections allowing the heating element to by activated by plugging an associated power cord into a power outlet.  
         [0040]    “Heater unit” is defined as the basic heat radiating apparatus that is mounted in the housing of a heater, and comprises a heating element arrangement confined within a heat conductive tube, and a heat radiating fin arrangement in thermal contact with the heat conductive tube.  
         [0041]    “Heating element” is defined as the electrical heat source, which may be a wire or rod heated by the passage of electrical current therethrough.  
         [0042]    “Heating element arrangement”, as used herein, includes a heater element, insulation surrounding the heating element, and a heat conductive tubular member surrounding the insulation. The heat conductive tube and heat radiating fin arrangement are cast around the preassembled heating element arrangement.  
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0043]    [0043]FIG. 1 is a front perspective view of a heater  1  having a cutaway portion  2  in a housing  4  exposing a heating unit  3  made in accordance with the present invention. The heating unit  3  is fixedly mounted within the housing  4  by any appropriate mounting hardware (not shown). In this embodiment of the invention, the housing  4  has an opening  7  in the top side of housing  4  through which heated air passes upwardly, from a bottom opening  7 A, through one or more installed heater units  3 , and out top side opening  7 .  
         [0044]    It will be understood that, as an optional construction, instead of, or in addition to, a top side opening  7 , the housing  4  may have at least one sidewall opening  8  (optionally shown in FIG. 1 in dashed lines on a front sidewall  4 A, a mirror image of sidewall opening  8  being provided on a rear sidewall  4 B) for horizontal air current flow. The invention is not limited to any overall physical design or to any placement of, or number of, openings through which air currents can flow past an internal heater unit or units  3 .  
         [0045]    The housing  4  is open (opening not visible in FIG. 1) at the bottom  6  which is elevated above the surface upon which the heater  1  is placed, thereby permitting continuous and unobstructed air currents to be drawn into the opening  7 A in housing bottom  6 , through the heater unit  3 , and out the top opening  7  (or, optionally, the sidewall opening, or openings,  8 , or any combination of such openings).  
         [0046]    Operating controls and indicators are provided, as represented by knob  5 , which operating controls and indicators function similarly to those of conventional electric heaters.  
         [0047]    [0047]FIG. 2 is a perspective view of a heating unit  3  constructed in accordance with the present invention, the view taken looking into the V-shaped configuration according to a preferred embodiment of the present invention.  
         [0048]    [0048]FIG. 3 is another perspective view of the heating unit  3  shown in FIG. 2. Each of FIGS. 2 and 3 depicts the heating unit  3  from a different angle to show the structure of the heater unit  3  on the interior and exterior sides of the V-shaped configuration, as well as to show the opposite ends of the heater unit  3 .  
         [0049]    [0049]FIGS. 4 and 5 show, respectively, a top plan view and a side elevational view of the heating unit  3  shown in FIGS.  2  and  
         [0050]    As seen in FIGS.  2 - 5 , the heater unit  3 , according to a preferred embodiment, comprises means  9 - 12 , 13 , 15 , 16 , 18  for radiating heat into the environment about the heater unit  3 , and a heating element arrangement  19  (FIG. 6) confined within each heat conductive tube  9 , 11  of the heater unit  3 .  
         [0051]    Electrical connections to the heating element  22  (see FIG. 7) are made through contact pins  21 , 25  at each end of the heater unit  3 . In the embodiment of the invention shown in the figures, a pair of heating elements  22  are employed, one electrically connected to contact pins  21  and another electrically connected to contact pins  25 . Series or parallel connection of the two sets of contact pins  21 , 25  is left to the discretion of the designer and need not be addressed in this specification.  
         [0052]    The means  9 - 12 , 13 , 15 , 16 , 18  for radiating heat comprises at least one heat conductive tube  9 , 11  and a plurality of heat radiating fins  10 , 12  in thermal contact with respective heat conductive tubes  9 , 11 , a heating element arrangement  19  (FIG. 6) being confined within each heat conductive tube  9 , 11 .  
         [0053]    When a pair of heat conductive tubes  9 , 11  are used, as is the case of the preferred embodiment shown in the figures, additional heat radiating metal fins  15  are provided to interconnect the two heat conductive tubes  9 , 11 , thereby increasing heat transfer throughout the heater unit  3  between the two heat conductive tubes  9 , 11 , as well as providing additional heat transfer to air passing through the space between the two heat conductive tubes  9 , 11 . The number of heat radiating connecting fins  15  can be greater than shown in the figures, and advantageously are the same in number as the number of heat radiating fins  10 , 12 .  
         [0054]    The preferred embodiment of the heater unit  3  shown in the figures is of elongated V-shape, and the heat radiating fins  10 , 12  are constructed as a plurality of relatively thin systematically arranged heat radiating elongated flat metal parallel bars, as best seen in FIG. 6 which is a cross sectional view of the heater unit  3  taken along the line  6 - 6  in FIG. 4.  
         [0055]    For a structurally strong and rigid construction, metal end strips  16 , 18  connect the ends of fins  10 , 12 , respectively, and also serve as yet additional metallic heat radiating surfaces. In a preferred embodiment of the invention, the heat conductive tubes  9 , 11 , the heat radiating fins  10 , 12 , the heat radiating connecting fins  15 , and reinforcement end blocks  13  are of unitary, single die cast construction. These elements of the invention are cast around a central heating element arrangement to be described hereinafter in connection with FIG. 7.  
         [0056]    By die casting these elements of the invention, a very compact structural design results, with ample structural reinforcements, such as end blocks  13 , connecting fins  15 , and the metal end strips  16 ,  18  joining the tips of the set of systematically organized heat radiating metal fins  10 , 12 . Importantly, the casting process eliminates the need for expensive time consuming hand assembly of the component parts of the heater unit  3 .  
         [0057]    The openings  17  formed in reinforcement end blocks  13  may be internally threaded to accept mounting screws (not shown) inserted through aligned holes (not shown) in the framework or panel structure of the housing  4 .  
         [0058]    As shown in the figures, a preferred configuration of the heater unit  3  has first and second pluralities of heat radiating fins  10 , 12  extend away from their respective heat conductive tubes  9 , 11  to form an angle of approximately 90 degrees with respect to one another, thereby defining a generally V-shaped side profile.  
         [0059]    With reference to FIG. 7, which is an enlarged view of a portion of FIG. 6, showing, in cross section, the internal construction of one of the heat conductive tubes  9 , 11 , it will be observed that the heat conductive tube  9  encloses a heat conductive tubular member  24 , preferably made of copper or brass, which encloses insulation  20 , preferably of ceramic material, which surrounds the heating element  22 . The heat conductive tubular member  24 , insulation  20 , and heating element  22  may be referred to herein as a heating element arrangement  19 .  
         [0060]    In a method of producing the heater unit  3 , there is provided a preassembled heating element arrangement  19  which is held in place while the heat radiating elements  9 - 12 , 13 , 15 , 16 , 18  are die cast around the heating element arrangement  19 . After hardening of the cast components, a compact unitary heater unit  3  results having excellent heat transfer characteristics between the heating element arrangement  19  and the heat radiating elements  9 - 12 , 13 , 15 , 16 , 18 .  
         [0061]    The insulation  20  may be of any suitable high temperature insulating material, such as ceramic. Ceramic insulation is preferred, since it is structurally robust and can withstand high temperatures without significant degradation over time. Moreover, ceramic itself can, when heated, sustain a significant amount of infrared heat radiation.  
         [0062]    While only a single embodiment has been set forth herein, alternative embodiments and various modifications will be apparent from the above description to those skilled in the art.  
         [0063]    For example, although the embodiment of the invention shown in the figures provides a linear V-shaped configuration for the heater unit  3 , it will be appreciated that the heater unit  3  may be implemented by employing a virtually limitless number of configurations, shapes, and designs.  
         [0064]    The heat conductive tube or tubes  9 , 11  may be rectangular, oval, or polygonal in cross section; the heat conductive tube or tubes  9 , 11  may be bent into curved, angular, or any shape suitable to fit within a similarly configured housing  4 ; the fins  10 , 12  may be of any shape, thickness, and length, preferably consistent with good heat radiation patterns and air flow parameters; and the number of heat conductive tubes  9 , 11  and associated heat radiating fin arrangements  10 , 12 , 15  may be greater than the number shown and described herein.  
         [0065]    These and other variations, and combinations of shapes and configurations, are possible and presumed to be within the teaching of the present invention.