Patent Document

BACKGROUND 
     1. Field of Invention 
     The present invention relates generally to radiant heating systems and more specifically to a unique furnace for heating liquid that circulates though a conventional radiator type system by transferring the heat generated from friction brake pads pressed against rotating wheels to thermally conductive liquid running through them. 
     2. Prior Art 
     The basic concept of circulating hot liquid through radiators is well known in the art. Gas and coal fired furnaces have been in use for many years as have electrical resistance heaters for heating the liquid. The concepts of running liquid through wheel brake caliper systems to cool the brakes and improve their efficiencies are also well known. The combination of these two divergent concepts, cooling the brake systems and heating liquid in a controlled fashion, however make this a unique approach to providing the heat needed to bring the circulating liquid to the appropriate temperature to heat a given size space with a given size radiator. 
     SUMMARY OF THE INVENTION 
     An object of the Brake Furnace is to provide an efficient heat source and heat transfer mechanism that is capable of raising the temperature of liquid in a closed loop system that circulates through a standard hot water radiator type room heating system. 
     Still further objects and advantages will become apparent from a consideration of the ensuing description and accompanying drawings. In the description, reference is made to the accompanying drawings which form a part thereof, and in which are shown by way of illustration a specific embodiment in which the invention may be practiced. This embodiment will be described in sufficient detail to enable those skilled in the art to practice this invention, and be understood that other embodiments may be utilized and that structural changes may be made without departing from the scope of the invention. In the accompanying drawings, like reference characters designate the same or similar parts throughout the several views. 
    
    
     
       DRAWINGS 
       The invention is described with reference to the following drawings: 
         FIG. 1  is a front view of the Brake Furnace; 
         FIG. 2  is a rear view; 
         FIG. 3  is a right side view; 
         FIG. 4  is a left side view; 
         FIG. 5  is a top view; 
         FIG. 6  is a partial exploded side view showing assembly of the wheels and their connection to the drive shaft; 
         FIG. 7  is an enlarged front view of large wheel; 
         FIG. 7A  is a section view taken along section line A-A; 
         FIG. 8  is an enlarged front view of small wheel; 
         FIG. 8A  is an enlarged side view with a partial section view of small wheel showing milled grooves, through holes and tapped holes for screws; 
         FIG. 9  is a partial perspective view showing large and small wheels, spacer wheel, drive wheel, the drive shaft and the liquid flow pattern through the furnace. 
       
         
           
                 
               
                 
                 
               
             
                 
                     
                 
                 
                   REFERENCE NUMBERS: 
                 
                 
                     
                 
               
               
                 
                     
                 
               
            
             
                 
                   12 
                   Brake Furnace 
                 
                 
                   14 
                   left end plate 
                 
                 
                   16 
                   manifold 
                 
                 
                   18 
                   manifold fitting 
                 
                 
                   20 
                   rotating chuck 
                 
                 
                   22 
                   chuck fitting 
                 
                 
                   24 
                   drive shaft 
                 
                 
                   26 
                   bearing assembly 
                 
                 
                   28 
                   large brake pad 
                 
                 
                   30 
                   chain 
                 
                 
                   32 
                   brake caliper 
                 
                 
                   34 
                   right end plate 
                 
                 
                   36 
                   caliper support plate 
                 
                 
                   38 
                   small L-bracket 
                 
                 
                   40 
                   right manifold support plate 
                 
                 
                   42 
                   large L-bracket 
                 
                 
                   44 
                   cylinder mounting bracket 
                 
                 
                   46 
                   drive means 
                 
                 
                   48 
                   cylinder assembly 
                 
                 
                   50 
                   bearing support 
                 
                 
                   52 
                   base plate 
                 
                 
                   54 
                   left manifold support plate 
                 
                 
                   56 
                   large wheel inner plate 
                 
                 
                   58 
                   large wheel 
                 
                 
                   60 
                   large wheel outer plate 
                 
                 
                   62 
                   small brake pad 
                 
                 
                   64 
                   brake caliper mounting bracket 
                 
                 
                   66 
                   small wheel back plate 
                 
                 
                   68 
                   small wheel front plate 
                 
                 
                   70 
                   small wheel 
                 
                 
                   72 
                   caliper mounting bolts 
                 
                 
                   74 
                   medium L-bracket 
                 
                 
                   76 
                   inlet tube to small wheel 
                 
                 
                   78 
                   drive means key 
                 
                 
                   80 
                   chain mount 
                 
                 
                   82 
                   spacer wheel 
                 
                 
                   84 
                   drive wheel 
                 
                 
                   86 
                   drive wheel key 
                 
                 
                   88 
                   outlet tube from small wheel 
                 
                 
                   90 
                   outlet tube from large wheel 
                 
                 
                   92 
                   outlet for brake furnace 
                 
                 
                   94 
                   inlet for brake furnace 
                 
                 
                   96 
                   cap screws 
                 
                 
                   98 
                   flat head screws 
                 
                 
                   100 
                   bolts 
                 
                 
                   102 
                   nuts 
                 
                 
                   104 
                   drive wheel key slot 
                 
                 
                   106 
                   large wheel outlet port 
                 
                 
                   108 
                   large wheel inlet port 
                 
                 
                   110 
                   drive means keyway 
                 
                 
                   112 
                   milled grooves 
                 
                 
                   114 
                   drive wheel keyway 
                 
                 
                   116 
                   tapped through holes 
                 
                 
                   118 
                   through holes 
                 
                 
                   120 
                   tapped holes 
                 
                 
                   122 
                   running channel 
                 
                 
                     
                 
               
            
           
         
       
     
    
    
     DESCRIPTION 
     In order that the invention is fully understood it will now be described by way of the following examples in which Brake Furnace  12  is shown in  FIGS. 1-9 . Drive motor, water pump, hydraulic pressure pump for brake caliper and tensioning cylinder and controls are not shown or claimed as part of this invention as there are industry standards systems available to the artisan skilled in these trades. 
       FIGS. 1-5  disclose a two stage liquid heating Brake Furnace  12  that uses the heat generated from brake pads held in frictional contact with rotating wheels, transferring that heat to liquid being pumped through Brake Furnace  12 , raising its temperature to a level needed to warm a given space to a controlled temperature using standard radiation techniques. 
     Left end support arrangement for Brake Furnace  12  is assembled on base plate  52  that is preferably constructed of ½ inch thick steel plate, approximately 14 inches long by 12 inches wide. Bearing supports  50  are preferably constructed of rectangular steel tubing approximately 4 inches tall by 2 inches wide and 7 inches long with ¼ inch thick side walls. First bearing support  50  is aligned with the left edge of the top surface of base plate  52  with the 7 inch dimension located centrally along the left end of base plate  52 . Second bearing support  50  is positioned parallel to the first, approximately ⅝ inches inboard of first bearing support  50 . Bearing assemblies  26  are mounted to the top surfaces of bearing supports  50 , carefully aligning bearing assembly  26  centers. Medium L-bracket  74  is mounted on the left or outboard side in the front to back center of bearing support  50  at a height sufficient to allow latter component alignment with bearing assembly  26  centers. Medium L-bracket  74  is preferably a 3/16 inch thick by 1½ inch by 1½ inch angle approximately 4 inches long. Left manifold support plate  54  is mounted on the top surface of medium L-bracket  74  and is a rectangular steel plate, approximately 6½ inches long by 1¾ inches wide by ¼ inch thick. Small L-bracket  38  is attached to the top surface of left manifold support plate  54 , approximately ½ inch from the outboard end of left manifold support plate  54 . Left end plate  14  is attached to the vertical wall of small L-bracket  38  and is formed from a rectangular steel plate approximately ¼ inch thick by 1¾ inches wide and approximately 4 7/16 inches high with a centrally located U-shaped slot approximately ⅞ inch wide and 1 inch deep. 
     Right end support arrangement for Brake Furnace  12  is also assembled on base plate  52 . Large L-bracket  42  is attached to the top surface of base plate  52 , approximately 2½ inches from the right end of base plate  52 . Large L-bracket  42  is preferably constructed from a 2 inch by 2 inch angle approximately 12 inches long and 3/16 inch thick. Caliper support plate  36  is mounted to the vertical face of large L-bracket  42 . Caliper support plate  36  is preferably constructed of a ¼ inch thick steel plate, 12 inches wide by 8 inches high with a clearance notch approximately 2 inches wide by 3 inches deep, in top center to allow drive shaft  24  clearance. Centrally located with the horizontal surface parallel to the top of Large L-bracket  42  is small L-bracket  38 . On the horizontal surface of small L-bracket  38  is mounted right manifold support plate  40 . Right manifold support plate  40  is preferably constructed of a ¼ inch thick rectangular plate, 3¾ inches long by 1½ inches wide. Small L-bracket  38  is located on the top surface of right manifold support plate  40 , 3¼ inches from the outboard wall. Mounted to the vertical surface of small L-bracket  38  is right end plate  34  which is preferably constructed from a rectangular steel plate ¼ inch thick and 1½ inches wide by 4¼ inch high with a centrally located U-shaped slot, having the same dimensions as the U-shaped slot in left end plate  14 . 
     Drive shaft  24  is the base for all the rotating liquid moving assemblies. Drive shaft  24  is a 1½ inch diameter steel rod, approximately 14 inches long. Approximately ½ inch from the left end of drive shat  24  begins drive means keyway  110 . When drive means key  78  is engaged between drive means keyway  110  in drive means  46  and drive shaft  24  and drive means  46  is caused to rotate, drive shaft  24  rotates synchronously. Approximately 2½ inches from the left end of drive shaft  24  starts drive wheel keyway  114 . When drive wheel key  86  is engaged between drive wheel keyway  114  and drive wheel key slot  104  and drive means  46  is caused to rotate, all of the wheel assemblies rotate synchronously. 
     Drive shaft  24  has a liquid carrying lumen drilled and tapped that extends from the left end of drive shaft  24  to approximately 8 inches in depth as to align with cross drilled and tapped holes for fittings for inlet tube to small wheel  76 . Drive shaft  24  also has a liquid carrying lumen drilled and tapped in the right end approximately 1½ inches in depth as to align with cross drilled and tapped holes for fittings for outlet tube from large wheel  90 . 
     Attached to the left and right ends of drive shaft  24  are chuck fittings  22 . Fastened outboard of each of chuck fittings  22  are rotating chucks  20  with manifold fittings  18  attached to their outboard ends. Finally, attached to the outboard end of manifold fittings  18  are 1 inch diameter manifolds  16  with 1/16 inch flats on opposing sides. 
       FIG. 6  shows the wheel assembly onto drive shaft  24  in an exploded view for clarification. Large wheel inner plate  56  is fastened to the inner side of large wheel  58  preferably with 10-24×½ inch flat head screws  98 , in 37 places in drilled and tapped through holes  116 . The flat heads are required to provide a smooth surface for brake pads  62  to slide over as brake pads  62  interface with the outside surface of inner plate  56  when it rotates. Four bolts  100  are inserted through diametrically opposed clearance holes in large wheel inner plate  56 , spacer wheel  82 , drive wheel  84  and small wheel back plate  66  and the assembly completed by placing nuts  102  over bolts  100  and tightening. Small wheel back plate  66  and small wheel front plate  68  are attached to the back and front surfaces of small wheel  70 , preferably with 10-24×½ inch socket head cap screws, 18 places per side in tapped holes  120 . Large wheel outer plate  60  is attached to the outer surface of large wheel  58  preferably with 10-24×½ inch flat head screws  98  in 37 places in drilled and tapped through holes  116 . Since all wheels are fastened together and keyed to drive shaft  24 , all wheels rotate synchronously with drive shaft  24 . Spacer wheel  82  is preferably constructed from an aluminum wheel approximately 5% inches in diameter by ⅞ inch thick with four clearance holes diametrically opposed on a 4 inch diameter bolt circle. Drive wheel  84  is preferably constructed from ⅞ inch thick, 5% inch diameter tool steel with a step down in diameter to allow interface with small wheel back plate  66  inner diameter with attendant mass savings. 
       FIG. 9  shows in a broken perspective view the liquid flow path through Brake Furnace  12 . Beginning with the left end of drive shaft  24 , liquid is pumped into tapped hole in the center of drive shaft  24  and flows down the lumen in the center of drive shaft  24  until it breaks into cross drilled and tapped hole for fittings for inlet tube to small wheel  76 . Liquid travels through tube  76  and enters small wheel  70  through fittings in small wheel front plate  68 , breaking into one of the ¼ inch diameter through holes  118  leading to ¼ inch deep milled groove  112 , descending through the adjacent ¼ inch diameter through hole  118 , traveling across 114 inch deep milled groove  112  on backside, returning to front side through adjacent ¼ inch diameter through hole  118 , progressing thusly around annular ring of small wheel  70 . When the liquid completes its journey around small wheel  70  it exits through fittings in small wheel front plate  66  into outlet tube from small wheel  88 . Outlet tube from small wheel  88  then carries the liquid through clearance holes in drive wheel  84 , spacer wheel  82 , and large wheel inner plate  56 , parallel to drive shaft  24 . When outlet tube from small wheel  88  clears the outer surface of large wheel inner plate  56  it turns upward and enters a fitting in the center of the width of large wheel  58  at large wheel inlet port  108 . Large wheel  58  is preferably constructed of a 10⅞ inch diameter aluminum wheel with running channel  122  approximately ¼ inch wide cut through, starting at large wheel inlet port  108  moving from within  1 / 4  inch from Inner diameter to within ¼ inch of outer diameter of annular ring as shown in  FIGS. 7 and 7A . Running channel  122  continues until it runs into large wheel outlet port  106  and exits through fittings at large wheel outlet port  106  to outlet tube to drive shaft  90 . Liquid then flows through outlet tube to drive shaft  90  back into drive shaft  24  at the cross drilled and tapped hole toward the right end of drive shaft  24  and exits drive shaft  24  through lumen drilled into the right end of drive shaft  24  that intersects with above mentioned cross-drilled hole in the center of drive shaft  24 . 
     Cylinder assembly  48  is pivotally mounted beneath an approximately 3 inch by 3 inch notch centered on the front side of base plate  52  as shown in  FIGS. 1 and 5 . Cylinder assembly  48  is mounted with 2 cylinder mounting brackets  44  attached to the underside of base plate  52 . The top of cylinder assembly  48  protrudes through the above mentioned notch and the distal end of the cylinder piston is connected to the proximal end of chain  30  which has a semi-circular large brake pad  28  attached to its under side. Large brake pad  28  has a matching radius to small wheel  70 &#39;s outer wall and small wheel front plate  66  and small wheel back plate  68  outer walls of approximately 4⅛ inches. Chain  30 , with large brake pad  28  attached, is laid over the top of small wheel  70  and the distal end is connected to base plate  52  with chain mount  80  as shown in  FIG. 2 . 
     Brake caliper mounting bracket  64  is then attached to the upper back of caliper support plate  36 . Attached with caliper mounting bolts  72  to caliper mounting bracket  64  is brake caliper  32  which in C-clamp fashion, positions small brake pads  62  on opposing sides of large wheel inner plate  56  and large wheel outer plate  60  toward their outside perimeters. 
     Operation: 
     A standard liquid pump (not shown or part of this invention) of sufficient size to move a large enough volume of liquid through a radiation based space heating system (not shown or part of this invention) to provide the required temperature stability within a given space is selected. It is connected to Brake Furnace  12  as described above at the fixed end of manifold  16 , attached at the left end of drive shaft  24 . An exit line is attached to manifold  16  at the right end of drive shaft  24 , connecting to the circulation line and radiator system (not shown or part of this invention). A standard electric motor (not shown or part of this invention) is connected through drive means  46  that is keyed to drive shaft  24 , causing rotation of drive shaft  24  in synchronous rotation with the electric motor. This drive means  46  can be a chain and sprocket, a belt and pulley system or a standard reducing gear train arrangement. A sprocket  46  is shown for illustration purposes. This electric motor can also be used to drive the above described liquid pump. The amount of heat generated by the first stage of Brake Furnace  12  is controlled by the force applied to large brake pad  28  by cylinder assembly  48  pulling chain  30 , creating frictional contact between large brake pad  28  and rotating outside wall of small wheel  70 . Industry standard hydraulic pumps and controls (not shown) are readily available to adjust the force generated by cylinder assembly  48 . Small wheel  70  is rigidly connected to drive shaft  24  by its connection to drive wheel  84  which is also keyed to drive shaft  24 . The amount of heat generated by the second stage of Brake Furnace  12  is controlled by the clamping force applied to small brake pads  62  by brake caliper  32 . The force against small brake pads  62  is adjustable with standard brake hydraulics (not shown). That force creates frictional contact between small brake pads  62  and rotating large wheel inner plate  56  and large wheel outer plate  60  toward their perimeters where the large wheel is also rigidly connected to drive wheel  84  and therefore rotates with it. 
     Brake Furnace  12  is described in the above specification by detailing a preferred embodiment with exemplary components. These examples are not intended to limit the size or scope of this invention as material selection, size of components, or choice of drive means are well within the purview of persons skilled in these arts. It is not intended to be limited to this set of materials and dimensions. Rather, the scope of this invention is defined by the following claims.

Technology Category: f