U.S. patent application number 10/141901 was filed with the patent office on 2003-02-13 for knock-down dome cover for a patio heater.
This patent application is currently assigned to Uniflame Corporation. Invention is credited to Bossler, Martin C..
Application Number | 20030029439 10/141901 |
Document ID | / |
Family ID | 22072195 |
Filed Date | 2003-02-13 |
United States Patent
Application |
20030029439 |
Kind Code |
A1 |
Bossler, Martin C. |
February 13, 2003 |
Knock-down dome cover for a patio heater
Abstract
A dome cover for an outdoor heater is provided that is made up
of a plurality of sides that easily assemble to form the cover.
Each of the sides has at least three edges, at least one of which
is a finished edge. The sides are configured and arranged for being
connected to form a generally raised shape, where the sides are
elevated at an angle above a plane formed by the finished edges of
the assembled dome cover. A cap is configured and arranged to hold
the sides at the angle. All of the sides are held in place by a
locking plate that cooperates with the cap to capture the sides
therebetween. A fastener holds the dome cover together. This
construction makes the dome cover easily assembled by the user
without the need for tools.
Inventors: |
Bossler, Martin C.; (Spring
Grove, IL) |
Correspondence
Address: |
GREER, BURNS & CRAIN
300 S WACKER DR
25TH FLOOR
CHICAGO
IL
60606
US
|
Assignee: |
Uniflame Corporation
|
Family ID: |
22072195 |
Appl. No.: |
10/141901 |
Filed: |
May 8, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10141901 |
May 8, 2002 |
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10066864 |
Aug 10, 2001 |
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Current U.S.
Class: |
126/92B ;
126/92AC; 126/92R |
Current CPC
Class: |
F24C 1/10 20130101 |
Class at
Publication: |
126/92.00B ;
126/92.0AC; 126/92.00R |
International
Class: |
F24C 003/04 |
Claims
What is claimed is:
1. A dome cover for an outdoor heater, comprising: a plurality of
sides, each having at least three edges at least one of which is a
finished edge, configured and arranged for being connected to form
a generally raised shape, said sides being elevated at an angle
above a plane formed by said finished edges of said dome cover; a
cap configured and arranged to hold said sides at said angle; and
at least one locking plate configured and arranged to cooperate
with said cap to capture said sides therebetween.
2. The dome cover of claim 1 wherein said raised shape forms a
pyramid or a dome.
3. The dome cover of claim 2 wherein said raised shape is a dome
having from 3 to 10 sides.
4. The dome cover of claim 1 wherein said three edges comprise a
first finished edge, a second edge having at least a first
complementary fastener portion and a third edge having a second
complementary fastener portion, and wherein said first and second
complementary fastener portions are configured and arranged to
attach adjacent pairs of said sides.
5. The dome cover of claim 1 further comprising a rim lock being
configured and arranged for removably attaching adjacent pairs of
first edges.
6. The dome cover of claim 1 wherein said first complementary
fastener portion is a tongue and said second complementary fastener
portion is a groove.
7. The dome cover of claim 6 further including a fastener, and
wherein said locking plate cooperates with said upper plate to
capture said sides therebetween by use of a fastener.
8. The dome cover of claim 1 wherein each of said sides is
curved.
9. The dome cover of claim 1 wherein three or four of said sides
are provided.
10. The dome cover of claim 1 wherein said side further comprises
at least one rib.
11. The dome cover of claim 10 wherein said cap further comprises
indentations to engage said rib.
12. The dome cover of claim 5, wherein said finished edge has a
rolled shape.
13. The dome cover of claim 12, wherein said rolled shape defines a
channel and said rim lock engages said channel of adjacent
sides.
14. The dome cover of claim 5 wherein said rim lock comprises a
pin.
15. The dome cover of claim 1 further comprising an upper plate
disposed between said cap and said sides.
16. The dome cover of claim 1 wherein said cover is of knockdown
construction allowing assembly without the use of tools.
17. An outdoor heater comprising: a base; a standard mounted to
said base; a burner mounted to said standard; an insulator disposed
on said standard, said insulator being heated by said burner; an
emitter surrounding said insulator and emitting heart; and a dome
cover mounted atop said emitter and having a plurality of sides
each having at least three edges, configured and arranged for being
connected to form a generally raised shape, said sides being
elevated at an angle above a plane formed by a base of said dome
cover; a cap configured and arranged to hold said sides at said
angle; a locking plate configured and arranged to frictionally
engage each of said sides with said cap; and a fastener to hold
said locking plate in position to frictionally engage each of said
sides with said cap.
18. The outdoor heater of claim 17 wherein said three edges
comprise a first finished edge, a second edge having at least a
first complementary fastener portion and a third edge having a
second complementary fastener portion, and wherein said first and
second complementary fastener portions are configured and arranged
to attach adjacent pairs of said sides.
19. The outdoor heater of claim 18 wherein said dome cover further
comprises a rib attached said second edge or said third edge of
each of said sides, said rib comprising an tongue if said rib is
attached to said second edge or said rib comprising a groove if
said rib is attached to said third edge.
20. The outdoor heater of claim 19 wherein said rib is removably
attached to said side.
21. The outdoor heater of claim 19 wherein said generally dome
shape of said dome cover is constructed from 3 or 4 sides.
22. The outdoor heater of claim 19 wherein said dome cover is of
knock-down construction allowing assembly without the use of
tools.
23. The outdoor heater of claim 17 further comprising a rim lock
configured and arranged for removably attaching adjacent pairs of
sides.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of co-pending
application Ser. No. 10/066,864, entitled "Knock-Down Dome Cover
for a Patio Heater," filed Aug. 10, 2001.
BACKGROUND
[0002] Outdoor or patio heaters have become popular for providing
warmth in the out of doors, for example on a cool summer evening or
in the spring or fall. Heat is provided by a burner atop a standard
that burns a fuel, such as propane. Flames from the burner heat an
insulator that becomes red hot and gives off radiant heat through
an emitter, providing the desired warmth. A dome cover generally
covers the burner and emitter from some of the weather, such as
rain, but it also retains hot gasses rising from the burner, and
reflects radiant heat that is directed skyward back down toward the
users.
[0003] On a windy day, if the breeze reaches the burner, it can
change the heat distribution around the insulator. Heat will be
carried by the breeze from the side facing the wind to the side
away from the wind, significantly reducing the warmth on the
windward side of the heater. Such changes in temperature
distribution are visually indicated by the color of the insulator.
When there is no wind, it is a uniform bright red color. However,
introduction of a steady breeze of approximately 10 miles per hour
results in a lack of coloration on approximately one quarter of the
insulator facing the wind and a noticeable drop in temperature on
that side.
[0004] The size of the dome cover is carefully considered to trade
off the amount of surface area available to reflect heat and
protect the burner from weather compared with the shipping cost of
the unit. The dome cover is generally supplied as a one-piece item.
As the size of the dome cover increases to block more wind and
reflect additional heat, a larger shipping box is required to
contain it. As the box for each heater gets larger, fewer numbers
of units are able to fit inside a shipping container, thus
increasing shipping costs. Currently, some manufacturers ship the
dome cover separately from the heating unit to minimize the overall
shipping volume and reduce costs.
[0005] When assembly of a device is required prior to use, the
consumer can be frustrated by construction of an article that is
difficult to put together or requires a large number of tools.
Contributing to this frustration is the unavailability of the
required tools, or by the inconvenience of having to retrieve the
correct tools and assemble them in an appropriate area for assembly
of the new article. The consumer can be further frustrated if the
parts do not fit together well or require two or three people
present to assemble the device.
[0006] Thus there is a need for a dome cover for a patio heater
that provides a large area to block wind, yet does not have
increased shipping costs. The dome cover should be able to be
assembled by the consumer without the need for tools.
SUMMARY OF THE INVENTION
[0007] These and other needs are met or exceeded by the present
dome cover for a patio heater that provides improved wind
protection without high shipping costs. The present dome cover
ships compactly in a number of pieces and is easily assembled
without the need for tools.
[0008] More specifically, a dome cover for an outdoor heater is
provided that is made up of a plurality of sides that easily
assemble to form the cover. Each of the sides has at least three
edges, at least one of which is a finished edge. The sides are
configured and arranged for being connected to form a generally
raised shape, where the sides are elevated at an angle above a
plane formed by the finished edges of the assembled dome cover. A
cap is configured and arranged to hold the sides at the angle. All
of the sides are held in place by a locking plate that cooperates
with the cap to capture the sides therebetween. A fastener holds
the dome cover together. This construction makes the dome cover
easily assembled by the user without the need for tools.
[0009] The knock down construction of the present dome cover allows
it to be made larger for improved heat distribution on a windy day.
Making the dome or pyramid taller by increasing the angle of the
sides with respect to the base of the dome blocks more wind from
interfering with an even heat distribution out of the burner. A
taller dome also blocks the wind for a greater depth. Enlarging the
dome cover also provides a larger zone of calm air so that the area
around the burner is less susceptible to eddys or wind currents
that may penetrate the edge of the dome cover. Further, a larger
surface area around the burner reflects more of the radiant energy
downward toward the users. Adjacent sides of the cover are attached
at the rim to provide stability and less flexing of the lower edge
in the wind, helping to minimize air gusts that reach the
burner.
[0010] Despite the larger size, the present dome cover is no more
costly, and may be less costly, to ship than prior art dome covers.
Shipment of the dome cover in several pieces greatly reduces the
amount of space required to accommodate the larger size. Yet, due
to the handy knock-down construction, assembly of the dome cover is
accomplished without tools to reduce inconvenience to the user. The
present dome cover also allows for the unit to be easily packed
away for winter storage, taking up a reduced amount of storage
space.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a front elevational view of an outdoor heater with
the present dome cover with a portion of the base cut away;
[0012] FIG. 2 is an exploded perspective view of the top of the
heater, showing the burner and insulator behind the emitter;
[0013] FIG. 3 is a top perspective view of the present dome
cover;
[0014] FIG. 4 is a bottom view thereof;
[0015] FIG. 5 is an enlarged fragmentary view of the bottom of the
dome cover, before installation of the locking plate;
[0016] FIG. 6 is an exploded perspective view of the dome cover of
FIG. 3;
[0017] FIG. 7 is a vertical cross-section taken along the line 7-7
of FIG. 6 as viewed from the direction generally indicated;
[0018] FIG. 8 is a side view of the rim support pin;
[0019] FIG. 9 is a fragmentary view of a pin partially installed in
the rim channel; and
[0020] FIG. 10 is a perspective view of a second embodiment of the
dome cover.
DETAILED DESCRIPTION OF THE INVENTION
[0021] Referring now to FIGS. 1 and 2, the present dome cover,
generally designated 10, is designed for an outdoor heater,
generally designated 12. The present dome cover 10 is equally
useful on any size or type of outdoor or patio heater, thus the
heater 12 is depicted for purposes of illustration only and not to
limit the scope of the present dome cover. A base 14 that provides
weight and stability to the heater 12 is constructed so that it is
not easily tipped over when in use. Fuel from a fuel source 16,
such as an LP gas tank, is piped up the inside of a standard 20 to
a burner 22 through fuel line 23. Burning of the fuel heats an
insulator 24 causing it to become red hot and emit copious amounts
of radiant heat. A perforated metal emitter 26 surrounds the
insulator 24 and protects the burner 22 while allowing the
combustion gasses to escape to the atmosphere. The dome cover 10 is
mounted atop the emitter 26. An outdoor heating apparatus is
described in detail in U.S. Pat. No. 6,102,031, herein incorporated
by reference.
[0022] The present dome cover is constructed in pieces that are
assembled by the consumer. Preferably, the cover 10 is made of a
knock-down construction that is easily assembled by the user
without the need for tools. Parts removably attach to each other
preferably using a tongue and groove, tab and slot, friction fit
elements or other types of easily assembled knock-down construction
known in the art. Throughout this specification and claims,
references to direction, up and down, for example, refer to the
outdoor heater and dome cover oriented as in FIG. 1.
[0023] Any lightweight, flexible material is suitable for
construction of the dome cover 10. Since the dome cover 10 is
supported only in the middle and at the rim, the material from
which it is constructed should be strong enough to hold its shape.
During use, the cover 10 is subjected to heat radiated from the
insulator 24 and hot air rising from the burner. To be useful, the
dome cover 10 should not sag or lose its shape under these
conditions. Metals and high temperature plastics are the preferred
construction materials. High temperature polymer resins, such as
polyimides, are suitable. Because of the low cost, malleability,
and ready availability, metals, including aluminum, are most
preferred.
[0024] The dome cover 10 is made up of a plurality of sides 28 each
having at least first, second and third edges 30, 32, 34, seen best
in FIG. 6. These edges may be defined functionally as well as
literally. For example, where the corners of the sides 28 are
rounded or radiused, forming one continuous edge, the first edge
30, the second edge 32 and the third edge 34 are suitably
considered to be portions of one or more larger edges.
[0025] The first edge 30 is a finished edge. This is the edge that
will be exposed to users while the heater 12 is in operation. The
finished edge 30 is merely one that has no sharp, burred or jagged
edges that would tend to injure a person who touched the edge.
Preferably, the finished edge 30 is rolled, smooth coated, folded,
sanded, or treated by any other technique to remove burrs or sharp
portions.
[0026] Referring to FIGS. 8 and 9, a first embodiment has a rim
lock, generally designated 35, that removably attaches the finished
edge 30 of adjacent sides 28. Most preferably, the finished edge 30
is a rolled edge that forms a channel 36. The most preferred rim
lock 35 is a pin that slidably engages the channel 36, maintaining
alignment between the adjacent sides 28 even during heavy winds. It
is contemplated that the pin 35 be removable from both adjacent
sides 28, or that it is affixed to one side and removably engage
the adjacent side. Most preferably, the pin 35 is temporarily
attached to the channel 36 by means of a friction fit, one or more
detents or a fastener that holds the pin in place. Other types of
rim locks 35 are contemplated.
[0027] One embodiment of the pin 35 is seen in FIG. 8. The pin 35
has at least two forks 37, each of which engage with one side 28 of
the dome cover 10. A center ring 38 preferably projects radially
beyond the forks 37, holds the two forks together and acts as a
spacer to hold the two sides 28 an appropriate distance apart. In
the preferred embodiment, at least one protrusion 39 on at least
one of the forks 37 engages with a detent or cavity 40 in the
channel 38 of the finished edge 30, as shown in FIG. 9.
[0028] Referring now to FIGS. 6 and 7, the second edge 32 has at
least a first complementary fastener portion that removably
attaches to a second complementary fastener portion on the third
edge 34 of the adjoining side 28. Preferably, the first
complementary fastener portion is an adjoining part or tongue
formation configured as a tongue, tab, hook or other protrusion
that is removably received into the second complementary fastener
portion such as a groove, slot, opening or indentation. As the
tongue 32 and groove 34 construction is the preferred construction
for removably attaching adjacent sides 28 to each other, it will be
exemplified in the following discussion. It is also contemplated
that the first and second complementary fastener portions include
abutting formations separated by a seal, such as a high temperature
gasket. Other configurations for the first and second complementary
fastener portions are contemplated, and in some circumstances may
be preferred.
[0029] Although both the tongue 32 and the groove 34 are preferably
integral parts of the side 28, it is also contemplated that the
side includes a separate rib 44. The rib 44 has the complementary
fastener portion that engages with and is removably attachable to
either the tongue 32 or the groove 34 of the side 28. For some
users, it may be easier to assemble the dome cover 10 if, for
example, all tongues 32 are located on the side 28 and all grooves
34 are located on the rib 44. The ribs 44 optionally add structural
strength to the dome cover 10. A preferred rib 44 is configured so
that the groove 34 is U-shaped and faces a corresponding portion of
the side 28.
[0030] In one embodiment, each of the ribs 44 provides at least two
grooves 34, while each of the sides 28 has at least two tongues 32.
Attaching one of the tongues 32 into one of the grooves 34,
removably attaches the rib 44 to the side 28. The resulting side 28
has the required tongue 32 and groove 34.
[0031] Preferably the sides 28 are of a configuration that they
nest together to conserve space during shipping. As depicted in
FIGS. 3-7, the first embodiment sides 28 is curved, forming a dome
or umbrella shape when assembled to form the cover 10. In this
embodiment, all of the sides 28 have similar curvature, allowing
them to nest together when the cover 10 has been disassembled. In a
second embodiment 110, shown in FIG. 10, the sides 128 are
generally flat, assembling to form a substantially pyramid shape
that is held in place with a cap 152, a finial 164 and the locking
plate 65. "Generally flat" means that the thickness of the single
side, is less than 25% of the smaller of the first edge 130, the
second edge 132 or the third edge 134. Most preferably, each of the
sides 28 is identical to every other side and designed so that each
of the sides nest inside each other and for ease of assembly.
[0032] Referring now to FIGS. 3 and 4, any number of the sides 28
may be used, but from about three to ten sides is preferred. The
preferred shape for the side 28 is generally a three or four-sided
polygon when projected in two dimensions. It is advantageous to
remove a portion of one or more sides 28 to make room for hardware
to hold all of the sides 28 together. In the preferred embodiment,
a concave scallop 49 in each of the sides 28 defines an opening 50
(FIG. 5) in the center of the dome cover 10 when the sides are all
attached. Each of the sides 28 are preferably elevated at an angle,
.alpha., (FIG. 7) above a plane formed by the finished edges 30 of
the assembled dome cover 10, allowing the finished edges to depend
below the top of the emitter 26 (FIG. 1) to which it is attached.
While other shapes are contemplated, the preferred angle .alpha. is
preferably between about 10.degree. and about 20.degree..
[0033] As shown in FIG. 6, at the apex of the dome cover 10, there
is a cap 52 that is configured and arranged to hold the sides 28 at
the desired angle, .alpha.. Indentations 60 or other shapes are
optionally included on the peripheral edge of the cap 52 to
matingly engage the ribs 44, preventing the cap from turning when a
fastener or finial 64 is applied.
[0034] Referring again to FIG. 6, a locking plate 65 and the cap 52
are configured and arranged to frictionally sandwich each of the
sides 28 therebetween. Many shapes are suitable for the locking
plate 65, as long as the sandwiching relationship of each of the
sides 28 is maintained and secured by the fastener 64, holding all
parts of the dome cover 10 together. The preferred locking plate 65
is a circle, or alternately a polygon with the same number of faces
as there are sides 28. Suitably, the locking plate 65 is optionally
a bowl shape to nestingly engage with the cap 52, however use of a
flat surface for the plate is sufficient and is preferred for its
simplicity, ease of manufacture and low cost.
[0035] Optionally, an upper plate 67 fits under the cap 52 to
assist in holding the sides 28 and the ribs 44 in position.
Together with the rim lock 35, the locking plate 66 and the cap 52,
the upper plate 67 acts to add stability to the dome cover 10 by
providing a surface against which the locking plate 66 sandwiches
the sides 28 to hold them in place.
[0036] The fastener or finial 64 holds the locking plate 65 and
optional upper plate 67 in position to frictionally engage each of
the sides 28 with the cap 52. In keeping with the objective of
requiring no tools for assembly, preferably the finial 64 is easily
installed and tightened by hand, such as a bolt or other threaded
fastener. If the finial 64 is provided as a bolt, the cap 52 has an
opening 72 configured for receiving the bolt. The preferred opening
72 is itself threaded or has a nut (not shown) affixed thereto to
securely hold the bolt 64. Any finial 64 optionally includes a
decorative portion 78 above the cap 52 to make it aesthetically
pleasing. The plate 65 has a preferably threaded opening 66, which
receives the finial 64. Also, if provided, the upper plate 67 also
has an opening 69 in registry with the opening 66.
[0037] The dome cover 10 is preferably assembled by first placing
one of the ribs 44 on each of the sides 28. If not already affixed
to one of the sides 28, the rim lock 35 is attached to one side.
Each of the sides 28 is then properly aligned and removably
attached to each other, for example by engaging tongue 32 on the
second edge of the side 28 into groove 34 in the third edge of the
adjacent side. As the tongue 32 and groove 34 are being fit
together, the rim lock 35 is concurrently aligned with the channel
36 and fit into place. When all of the sides 28 have been fit
together, the finished edges 30 are all adjacent to each other,
forming the outline of the base of a dome or pyramid.
[0038] Next, the upper plate 67 and the cap 52 are placed on the
top of the dome cover 10, aligning the indentations 60 with the
ribs 44, if present. The locking plate 65 is positioned on the
inside of the dome cover 10 and aligned with the cap 52 so that the
sides 28 are sandwiched between the upper plate 67 and the locking
plate. The entire assembly is completed by the fastener 64 when it
is attached through the opening 72, holding the locking plate 65,
the upper plate 67, the sides 28 and the cap 52 in position.
[0039] While a particular embodiment of the present knock-down dome
cover has been shown and described, it will be appreciated by those
skilled in the art that changes and modifications may be made
thereto without departing from the invention in its broader aspects
and as set forth in the following claims.
* * * * *