U.S. patent application number 14/745166 was filed with the patent office on 2016-06-09 for heater having heating core and conductive fin.
The applicant listed for this patent is Homeeasy Industrial Co., LTD. Invention is credited to Ji Yong Zhang, Kai Zhou.
Application Number | 20160161145 14/745166 |
Document ID | / |
Family ID | 56094002 |
Filed Date | 2016-06-09 |
United States Patent
Application |
20160161145 |
Kind Code |
A1 |
Zhang; Ji Yong ; et
al. |
June 9, 2016 |
Heater Having Heating Core and Conductive Fin
Abstract
Heater having an enclosure surrounding a heating core. The
heating core includes heating elements and a self-supporting
corrugated heat conductive fin positioned between first and second
end panels, with at least one heating element positioned between
the end panels. The fin provides air flow channels between the
corrugations as well as multiple heat reflective surfaces, and the
fin is self-supporting between the corrugations.
Inventors: |
Zhang; Ji Yong; (Foshan,
CN) ; Zhou; Kai; (Foshan, CN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Homeeasy Industrial Co., LTD |
Foshan |
|
CN |
|
|
Family ID: |
56094002 |
Appl. No.: |
14/745166 |
Filed: |
June 19, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13229806 |
Sep 12, 2011 |
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14745166 |
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Current U.S.
Class: |
392/355 |
Current CPC
Class: |
F24H 3/002 20130101;
F24C 7/062 20130101; H05B 3/06 20130101 |
International
Class: |
F24H 3/00 20060101
F24H003/00; F24C 7/04 20060101 F24C007/04 |
Claims
1. A heating core for a heater, said heating core comprising: a
corrugated heat conductive fin; a first side panel attached to a
first end of said fin; a second side panel attached to a second end
of said fin; and at least one heating element mounted to and
extending between said first and second side panels; wherein said
fin is self-supporting between said first and second side
panels.
2. The heating core of claim 1, further comprising an additional
third panel attached to said first and second side panels, with a
space between said additional third panel and said fin.
3. The heating core of claim 1, having a plurality of air channels
between corrugations of said fin.
4. The heating core of claim 3, further comprising means for
providing structural stability, including integrity and
self-support, to said heating core.
5. The heating core of claim 4, wherein: said means for providing
structural stability comprises straps joining said side panels;
said heating core having no additional structural supports.
6. The heating core of claim 1, further comprising a plurality of
heating elements.
7. The heating core of claim 6, wherein at least some of said
heating elements extend through holes in said fin.
8. The heating core of claim 6, wherein at least some of said
heating elements do not extend through holes in said fin.
9. A convection heater for use on a substantially horizontal
surface, said convection heater comprising: a ventilated enclosure
surrounding on six sides a heating core, the heating core mounted
within said enclosure and comprising; a corrugated heat conductive
fin, said fin self-supporting; a first side panel attached to a
first end of said fin; a second side panel attached to a second end
of said fin; at least one heating element mounted to and extending
between said first and second side panels and extending through
holes therein; and means for providing structural stability to said
heating core inside said enclosure.
10. The convection heater of claim 9, said heating core element
further comprising: an additional third panel attached to said
first and second side panels, with a space between said additional
third panel and said fin aiding definition of air channels between
said corrugations, reflection of heat, and prevention of the
possibility of accordion-style compression motion of said fin;
thereby aiding structural stability, structural integrity and
rigidity.
11. The heating core of claim 9, wherein said means for providing
structural stability comprises straps joining said side panels
within said enclosure.
12. The convection heater of claim 9, further comprising a
plurality of heating elements.
13. The convection heater of claim 12, wherein at least some of
said heating elements extend through holes in said fin.
14. The convection heater of claim 12, wherein at least some of
said heating elements do not extend through holes in said fin.
15. The convection heater of claim 9, for use on a substantially
horizontal surface, said enclosure further comprising: means for
supporting said heater on such substantially horizontal
surface.
16. The convection heater of claim 15, wherein said means for
supporting comprises devices selected from castors, legs, and
combinations thereof.
17. The convection heater of claim 15, further comprising means for
controlling said heating element.
18. The convection heater of claim 17, wherein said means for
controlling comprises devices selected from temperature
controllers, power controllers, and combinations thereof.
19. The convection heater of claim 15, further comprising
handles.
20. A convection heater for use on a substantially horizontal
surface, said convection heater comprising: a ventilated enclosure
having top, bottom, left, right, front and rear sides, each side
having a cover, the enclosure surrounding a heating core, at least
one cover comprising at least one grill, the bottom side cover
comprising an air inlet board, the enclosure having supports
dimensioned and configured for supporting said heater on such
substantially horizontal surface, the enclosure having at least one
handle on at least one side; the heating core mounted within said
enclosure and comprising; a corrugated heat conductive fin, said
fin self-supporting, said corrugations defining a plurality of
vertical air channels; a first side panel attached to a first end
of said fin, the first side panel being rectangular in shape and
having at least one hole therethrough, the first side panel having
a front side, a rear side, an outer face distal said fin, and upper
and lower corners of the outer face; a second side panel attached
to a second end of said fin, the second side panel being
rectangular in shape and having at least one hole therethrough, the
second side panel having a front side, a rear side, an outer face
distal said fin, and upper and lower corners of the outer face at
both front side and rear side; a third rear panel attached to and
supporting said first and second side panels at their respective
rear sides, the third panel separated from said fin by a space; the
first side panel and the second side panel supported by a first
strap passing from the front upper corner of the outer face of the
first side panel to the front upper corner of the outer face of the
second side panel and by a second strap passing from the front
lower corner of the outer face of the first side panel to the front
lower corner of the outer face of the second side panel; at least
one heating element mounted to said first and second side panels
and extending through the respective holes therein, the heating
element further passing through a plurality of circular holes in
said fin; means for controlling said heating element selected from
the group consisting of: temperature controllers, power
controllers, and combinations thereof, the means for controlling
said heating element being mounted upon at least one side of the
enclosure.
Description
FIELD OF THE INVENTION
[0001] The present invention relates generally to a space heater,
and more particularly to a portable convection and radiation space
heater.
BACKGROUND OF THE INVENTION
[0002] Convection space heaters have been developed, such as the
heater described in U.S. Pat. No. 6,901,213 B2, issued to Bing Bai
on May 31, 2005. That device has many parts, making it expensive
and time-consuming to construct. For example, the '213 device
teaches that multiple independent fins must be held in place by a
series of transverse support rods having threaded ends and retainer
nuts, guiding slots in end panels, a separate reflector and so on.
It would be preferable to reduce this degree of complexity.
[0003] US Patent Application Pub. No. 2002/0076213 published Jun.
20, 2002 in the name Pelonis suffers from such complexity to an
even greater degree: the fins are themselves of comprised of
multiple layers attached at the edges and they are possibly
supported by a fairly complex tubular shape built up of numerous
small cylindrical projections or truncated cones which in turn hold
heating elements. The complexity continues in that the item teaches
an electric heating unit which heats a diathermal fluid, which then
circulates in internal spaces, while a forced air fan is taught as
well. No explanation is provided for how the covers are held in
place, nor how the radiator fins are joined, if they are joined,
nor how the tubular shapes are supported: any structure, real or
imaginary, could be used the attachment mechanisms since Pelonis
teaches nothing. Pelonis is remarkably free of teaching as to how
it is held together, leading to the supposition that major parts
are welded or molded together. Wheels are held to the header
elements by U-shaped fasteners rather than by straps.
[0004] The Pelonis reference also fails to teach an enclosure,
being open on both sides. It further fails to teach a reflective
rear panel within the actual core of the heater, again due to being
open on both sides. The reference further does not show a front
cover attached to any tubular radiator unit, heating elements
mounted to and extending between front and rear covers, and
self-supporting corrugated fins.
[0005] U.S. Pat. No. 5,377,298 to Yang on Dec. 27, 1994 teaches a
PTC semiconductor heating apparatus which relies upon a
sandwich-panel-composite structure including heating elements not
passing through but rather held in contact with coplanar (side to
side linear) square corrugated fin plates: a minimum of two plates
per heating element is apparently required and the corrugated fin
plates lack self-supporting structural ability, stability and
integrity. The apparatus requires forced air and a base structure
having slots to receive slotted ends of each composite panel.
Obviously the making of each composite panel is expensive and
inefficient.
[0006] PTC heating elements of Yang (Passive Temperature
Coefficient) have a positive feedback cycle in which the higher the
temperature, the greater the resistance until the unit ceases
working at all, and thus use of a circulation fan is mandatory. In
addition, unlike the heater of the present invention, the PTC
heating elements cannot be heated hot enough to efficiently use the
same thermodynamic principles as the present invention.
[0007] Yang further lacks legs, side panels attached to the ends of
the corrugated structures, circular holes in the corrugations
through which the heating elements may pass, a ventilated enclosure
separate from the heating core which surrounds the core, and so on.
Obviously, given the fact that the heating elements in Yang are
planar, they cannot pass through small circular holes and teach
away therefrom. Yang even further lacks attachment of half shells
to corrugated fin plates, heating elements which extend all the way
from one side panel to another, a space between conduction plates
and fin plates, means of support on a horizontal surface and
more.
[0008] U.S. Pat. No. 4,931,626 to Shikama et al on Jun. 5, 1990
teaches a PIC thermistor device using forced air relying upon
numerous short fins set between horizontal plates, again requiring
a rather large investment in manufacturing.
[0009] Thus, there is a need for a convection heater that can be
produced inexpensively and efficiently.
[0010] It would be preferable to provide less expensive structures
for heaters.
SUMMARY OF THE INVENTION
[0011] To achieve the foregoing and other objects and in accordance
with the purpose of the present invention broadly described herein,
one embodiment of this invention comprises a heating core for a
heater. The core comprises a corrugated heat conductive fin having,
a first end panel attached to a first end of the fin, a second end
panel attached to a second end of the fin; and at least one heating
element mounted to and extending between the first and second end
panels. The fin is self-supporting between the first and second end
panels.
[0012] The heating core may further comprise an additional panel
attached to the first and second end panels, with a space between
the additional panel and the fin. There may be a plurality of air
channels between corrugations of the fin. The heating core may
further comprise means for providing structural stability to the
heating core, such as straps joining the side panels. The heating
core may further comprise a plurality of heating elements. At least
some of the heating elements may extend through holes in the fin
and/or at least some of the heating elements may not extend through
holes in the fin.
[0013] Another embodiment of the invention comprises a convection
heater. The heater comprises a ventilated enclosure and a heating
core mounted within the enclosure. The heating core comprises a
corrugated heat conductive fin, a first end panel attached to a
first end of the fin, a second end panel attached to a second end
of the fin, at least one heating element mounted to and extending
between the first and second end panels, and means for providing
structural stability to the heating core.
[0014] The heater may further comprise an additional panel attached
to the first and second end panels, with a space between the
additional panel and the fin. The means for providing structural
stability, structural integrity and rigidity may comprise straps
joining the side panels. There may be a plurality of heating
elements. At least some of the heating elements may extend through
holes in the fin, and/or at least some of the heating elements may
not extend through holes in the fin. The convection heater may
further comprise means for supporting the heater on a substantially
horizontal surface, and the means for supporting may be selected
from castors, legs, and combinations thereof. There may be means
for controlling the heating element, selected from temperature
controllers, power controllers, and combinations thereof. The
convection heater may further comprise handles.
[0015] By passing heating elements through small circular holes in
a self-supporting, stable, rigid, integral corrugated fin the
invention achieves an enormous advantage in cost of materials and
manufacture over the references cited above, such as Bai, Yang, and
Pelonis. The construction methods of the device lead to lower costs
and easier construction.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] These and other features, aspects, and advantages of the
present invention will become better understood with reference to
the following description, appended claims, and accompanying
drawings, where:
[0017] FIG. 1 is a front perspective view of a convection heater of
the present invention;
[0018] FIG. 2 is a front perspective exploded view of the
convection heater of FIG. 1;
[0019] FIG. 3 is a front perspective view of the heating core of
the convection heater of FIG. 1;
[0020] FIG. 4 is a front view of the heating core of FIG. 3;
[0021] FIG. 5 is a top view of the heating core of FIG. 3;
[0022] FIG. 6 is a front perspective view of a conductive fin of
the heating core of FIG. 3;
[0023] FIG. 7 is a right side view of a portion of the heating core
of a second embodiment of a heating core in accordance with the
present invention;
[0024] FIG. 8 is a top view of a third embodiment of a heating core
in accordance with the present invention;
[0025] FIG. 9 is a top view of a fourth embodiment of a heating
core in accordance with the present invention;
[0026] FIGS. 10-13 are perspective views showing steps for
assembling the heating core of FIG. 3;
[0027] FIGS. 14-17 are perspective views showing steps for
assembling an enclosure for the heating core of FIG. 3;
[0028] FIG. 18 is a front perspective view showing the steps for
positioning the heating core in the enclosure; and
[0029] FIGS. 19-21 are front perspective views showing additional
steps for assembling the heater enclosure.
INDEX TO THE REFERENCE NUMERALS
[0030] heater 100 [0031] enclosure 110 [0032] rear cover 112 [0033]
left side cover 114 [0034] front cover 116 [0035] right side cover
118 [0036] top cover 120 [0037] air inlet board 122 [0038]
reflector 124 [0039] castors 126 [0040] control panel 128 [0041]
temperature control 130 [0042] heating power control 132 [0043]
handles 134 [0044] front top grill 136 [0045] front grill 138
[0046] front bottom grill 140 [0047] heating core 150 [0048]
corrugated heat-conductive fin 152 [0049] right side panel/end
panel 154 [0050] left side panel/end panel 156 [0051]
rear/additional panel 158 [0052] straps 160 [0053] example of
plurality of heat conductive channels/air channels 162 [0054] heat
reflective surfaces 164 [0055] heating elements 166 [0056] heating
element holders 168 [0057] power cord 170 [0058] hole for power
cord 172 [0059] small circular holes for heating elements 174
[0060] right side panel 176 [0061] holes 178 [0062] conductive fin
180 [0063] heating elements not passing through fins/holes 182
[0064] fin 184 [0065] heating elements 186 [0066] end of fin 200
[0067] end of fin 202 [0068] space between fin and rear panel 204
[0069] example holes in side panels 205
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0070] In reference to the claims and diagrams, the following
detailed description is provided.
[0071] It is thus one aspect, embodiment, objective and advantage
of the present invention to provide a heating core for a heater,
said heating core comprising: a corrugated heat conductive fin; a
first side panel attached to a first end of said fin; a second side
panel attached to a second end of said fin; and at least one
heating element mounted to and extending between said first and
second side panels; wherein said fin is self-supporting between
said first and second side panels.
[0072] It is thus another aspect, embodiment, objective and
advantage of the present invention to provide a heating core for a
heater, further comprising an additional third panel attached to
said first and second side panels, with a space between said
additional third panel and said fin.
[0073] It is thus another aspect, embodiment, objective and
advantage of the present invention to provide a heating core for a
heater, having a plurality of air channels between corrugations of
said fin.
[0074] It is thus another aspect, embodiment, objective and
advantage of the present invention to provide a heating core for a
heater, further comprising means for providing structural
stability, including integrity and self-support, to said heating
core.
[0075] It is thus another aspect, embodiment, objective and
advantage of the present invention to provide a heating core for a
heater, wherein: said means for providing structural stability
comprises straps joining said side panels; said heating core having
no additional structural supports.
[0076] It is thus another aspect, embodiment, objective and
advantage of the present invention to provide a heating core for a
heater, further comprising a plurality of heating elements.
[0077] It is thus another aspect, embodiment, objective and
advantage of the present invention to provide a heating core for a
heater, wherein at least some of said heating elements extend
through holes in said fin.
[0078] It is thus another aspect, embodiment, objective and
advantage of the present invention to provide a heating core for a
heater, wherein at least some of said heating elements do not
extend through holes in said fin.
[0079] Additionally, it is yet another embodiment, advantage,
aspect and objective of the present invention to provide a
convection heater for use on a substantially horizontal surface,
said convection heater comprising: a ventilated enclosure
surrounding on six sides a heating core, the heating core mounted
within said enclosure and comprising; a corrugated heat conductive
fin, said fin self-supporting; a first side panel attached to a
first end of said fin; a second side panel attached to a second end
of said fin; at least one heating element mounted to and extending
between said first and second side panels and extending through
holes therein; and means for providing structural stability to said
heating core inside said enclosure.
[0080] Additionally, it is yet another embodiment, advantage,
aspect and objective of the present invention to provide a
convection heater said heating core element further comprising: an
additional third panel attached to said first and second side
panels, with a space between said additional third panel and said
fin aiding definition of air channels between said corrugations,
reflection of heat, and prevention of the possibility of
accordion-style compression motion of said fin; thereby aiding
structural stability, structural integrity and rigidity.
[0081] Additionally, it is yet another embodiment, advantage,
aspect and objective of the present invention to provide a
convection heater wherein said means for providing structural
stability comprises straps joining said side panels within said
enclosure.
[0082] Additionally, it is yet another embodiment, advantage,
aspect and objective of the present invention to provide a
convection heater further comprising a plurality of heating
elements.
[0083] Additionally, it is yet another embodiment, advantage,
aspect and objective of the present invention to provide a
convection heater wherein at least some of said heating elements
extend through holes in said fin.
[0084] Additionally, it is yet another embodiment, advantage,
aspect and objective of the present invention to provide a
convection heater wherein at least some of said heating elements do
not extend through holes in said fin.
[0085] Additionally, it is yet another embodiment, advantage,
aspect and objective of the present invention to provide a
convection heater for use on a substantially horizontal surface,
said enclosure further comprising:
[0086] means for supporting said heater on such substantially
horizontal surface.
[0087] Additionally, it is yet another embodiment, advantage,
aspect and objective of the present invention to provide a
convection heater wherein said means for supporting comprises
devices selected from castors, legs, and combinations thereof.
[0088] Additionally, it is yet another embodiment, advantage,
aspect and objective of the present invention to provide a
convection heater further comprising means for controlling said
heating element.
[0089] Additionally, it is yet another embodiment, advantage,
aspect and objective of the present invention to provide a
convection heater wherein said means for controlling comprises
devices selected from temperature controllers, power controllers,
and combinations thereof.
[0090] Additionally, it is yet another embodiment, advantage,
aspect and objective of the present invention to provide a
convection heater further comprising handles.
[0091] And it is another embodiment, objective, aspect and
advantage of the present invention, to provide, in a best mode now
contemplated and a presently preferred embodiment, a convection
heater for use on a substantially horizontal surface, said
convection heater comprising: a ventilated enclosure having top,
bottom, left, right, front and rear sides, each side having a
cover, the enclosure surrounding a heating core, at least one cover
comprising at least one grill, the bottom side cover comprising an
air inlet board, the enclosure having supports dimensioned and
configured for supporting said heater on such substantially
horizontal surface, the enclosure having at least one handle on at
least one side; the heating core mounted within said enclosure and
comprising; a corrugated heat conductive fin, said fin
self-supporting, said corrugations defining a plurality of vertical
air channels; a first side panel attached to a first end of said
fin, the first side panel being rectangular in shape and having at
least one hole therethrough, the first side panel having a front
side, a rear side, an outer face distal said fin, and upper and
lower corners of the outer face; a second side panel attached to a
second end of said fin, the second side panel being rectangular in
shape and having at least one hole therethrough, the second side
panel having a front side, a rear side, an outer face distal said
fin, and upper and lower corners of the outer face at both front
side and rear side; a third rear panel attached to and supporting
said first and second side panels at their respective rear sides,
the third panel separated from said fin by a space; the first side
panel and the second side panel supported by a first strap passing
from the front upper corner of the outer face of the first side
panel to the front upper corner of the outer face of the second
side panel and by a second strap passing from the front lower
corner of the outer face of the first side panel to the front lower
corner of the outer face of the second side panel; at least one
heating element mounted to said first and second side panels and
extending through the respective holes therein, the heating element
further passing through a plurality of circular holes in said fin;
means for controlling said heating element selected from the group
consisting of: temperature controllers, power controllers, and
combinations thereof, the means for controlling said heating
element being mounted upon at least one side of the enclosure.
[0092] In reference to the claims and diagrams the following
detailed description is further provided. The present invention
comprises a space heater 100 which is preferably portable and
easily moved from one room or space to another. Because it is a
convection heater, it may operate quietly without a fan. The heater
may include a fan to accelerate convection in alternative
embodiments.
[0093] In the following discussion, terms of orientation, such as
"top," "bottom," "left," "right," "upper," "lower," "front," and
"rear," refer to components as the heater as viewed in FIGS. 1 and
2 and are not meant to limit the orientation of the heater. Similar
features in different embodiments of the heater are identified with
the same callout numbers.
[0094] Referring to FIGS. 1 and 2, heater 100 comprises a heating
core 150 mounted into an enclosure 110. Note that the panels of the
heating core 150 should not be confused with parts of the enclosure
110: they are distinct and different structures. As an example,
rear panel 158 is not rear cover 112, and so on. The enclosure 110
comprises six sides, top, bottom, left, right, front and rear,
which in turn comprise (not in the same order) a rear cover 112, a
left side cover 114, a front cover 116, a right side cover 118, a
top cover 120, and an air inlet board 122--none of which are the
panels described later in reference to FIGS. 3-6 (see below). Air
inlet board 122 supports covers 112, 114, 116, 118, and 120. A
reflector 124 is mounted onto the upper surface of air inlet board
122 and within the enclosure formed between the rear cover 112,
left side cover 114, right side cover 118, front cover 116, and top
cover 120. The enclosure also has supports allowing it to sit on
any substantially horizontal surface such as a floor, the ground,
or the like. The supports may be castors 126 which may be mounted
onto the lower surface of air inlet board 122. Although castors are
preferred for ease of moving heater 100 from one room or space to
another, they could be replaced with legs, feet, or any other
desired support (not shown). As shown, a control panel 128 is
mounted onto the exterior surface of right side cover 118 and
includes a temperature control 130 and a heating power control 132.
Alternatively, the controls 130 and 132 could be mounted onto left
side cover 114 or elsewhere on the heater. Preferably, handles 134
may be provided in right and left side covers 114 and 118 to aid in
moving the heater 100. Handles 134 may be formed from a
heat-insulating material, such as ABS plastic, allowing heater 100
to be moved while the heater is operating, may be apertures,
combinations or may be of other types.
[0095] As shown, rear cover 112, front cover 116, top cover 120,
and air inlet board 122 all include perforations that allow free
air flow through the covers and into and out of heater 100.
Preferably, front cover 116 comprises three portions, a front top
grill 136, a front grill 138, and a front bottom grill 140. Rear
cover 112, front cover 116, top cover 120, air outlet grill, air
inlet board 122, and bottom reflector 124 are preferably formed
from a material that provides sufficient heat tolerance, rigidity,
strength, and durability for long-term use of heater 100. Such
materials include metals and metal alloys. A preferred material is
aluminum, which may be provided in sheets that are cut and bent as
needed. Control panel 128 may be formed from an electrically
insulating material, such as ABS plastic. Rear cover 112, left side
cover 114, front cover 116, right side cover 118, top cover 120,
air inlet board 122, and reflector 124 may be formed from sheet
metal by stamping, cutting, and/or bending the sheet. Plastic
components may be molded, such as by injection molding.
[0096] The covers discussed above form parts of the enclosure, not
of the heating core. On the other hand the panels which form part
of the core (discussed below), are not part of the enclosure.
[0097] Heating core 150 can be understood with reference to FIGS.
3-6. A conductive fin 152 is mounted between a first right side/end
panel 154 and a second, left side/end panel 156. These panels, as
previously noted, are not parts of the enclosure 110. It will be
understood that the terms side and end and rear, when referring to
these panels, are dependent upon orientation. The fin has ends 200
and 202 to which the first and second panels are respectively
attached/mounted. The panels have therethrough holes such as holes
205, through which heating elements may pass.
[0098] Separated from the fin by a space 204 an additional
third/rear panel 158 is mounted onto side panels 154 and 156, and
has different functions. While panels 154 and 156 provide the
heating element mounts, the panel 158 helps define the air channels
between corrugations, helps reflect heat toward the front of the
unit, and prevents the possibility of accordion-style compression
motion of the fin, thus aiding structural stability, structural
integrity and rigidity. Fastening straps 160 (shown in FIGS. 12 and
13) are mounted onto the front portions of the side panels 154 and
156. Alternatively, other means could be used instead of straps 160
to provide structural stability, structural integrity and rigidity
to the heating core 150 and to aid in assembling the heater 100 as
described below. Conductive fin 152 may comprise a corrugated,
waved, or folded sheet of heat conductive material with sufficient
rigidity to be self-supporting between side panels 154 and 156. The
corrugation, waving, or folding provides the rigidity and the wide
footprint for the fin to be self-supporting without the need for
additional support bars, support rods, other supports, and allowing
manufacture without requiring the use of a sandwiched material
having multiple layers. The corrugated structure provides multiple
heat conductive channels/air flow channels 162 with multiple heat
reflective surfaces 164 to enhance convection efficiency and
provide heat via radiation. Heating elements 166 extend through
and/or in front of conductive fin 152, and are retained by holders
168. As shown in FIGS. 3-5, heating elements 166 extend through
holes in conductive fin 152 as well as through the end/side panels
154/156. As shown in FIG. 8, heating elements 166 may alternatively
be positioned between side panels 154 and 156 and in front of fin
152 and thus not pass through holes in the fins. Alternatively, as
shown in FIG. 9, the corrugations or folds of heat conductive fin
152 may have different dimensions, with heating elements 166
passing through some of the corrugations and in front of others.
Conductive fin 152, side panels 154 and 156, and rear panel 158 may
be formed from any material with sufficient rigidity, heat
conductivity, and durability. A preferred material is aluminum,
which may be provided in sheets and then cut and bent as desired.
Heating elements 166 may be formed as known in the art from any
suitable resistive material, such as copper wire.
[0099] The heater 100 also includes electrical circuitry and
components, not shown, for controlling heating elements.
Preferably, a temperature controller is positioned immediately
behind temperature control 130, and a power controller is
positioned immediately behind power control 132. As shown in FIGS.
14-19, a power cord 170, with a plug suitable for insertion into a
wall receptacle, passes through a hole in rear cover 112.
Alternatively, the power cord 170 could pass through a different
part of the enclosure 110, such as through right side cover 118,
left side cover 114, or air inlet board 122. Bottom reflector 124
protects wires and other components from exposure to high
temperatures generated by the heating elements.
[0100] Heater 100 may be assembled as shown in FIGS. 10-19. Heating
core 150 may be assembled by mounting right side panel 154 and left
side panel 156 onto the respective right and left ends of
conductive fin 152, (the terms first and second panels and ends may
be used for this description) shown in FIG. 10. Rear panel 158 is
secured to side panels 154 and 156, with a space 204 between the
rear panel 158 and the conductive fin 152, shown in FIG. 11, and
straps 160 are secured to side panels 154 and 156, shown in FIG.
12. These may be secured at the outer surfaces thereof, as shown,
at the corners as shown or elsewhere. Heating elements 166 are
placed through openings in side panels 154 and 156 and through or
in front of conductive fin 152, shown in FIG. 13.
[0101] The enclosure 110 that surrounds heating core 150 may be
assembled by inserting cord 170 through an opening 172 in rear
cover 112, shown in FIG. 14, and joining the left side cover 114
and right side cover 118 to rear cover 112, shown in FIG. 15. Front
top grill 136 is fixed to the upper portions of right side cover
118 and left side cover 114, shown in FIG. 16. Referring to FIG.
17, control panel 128 is mounted onto right side cover 118.
[0102] The enclosure assembly formed with left side cover 114,
right side cover 118, rear cover 112, and front top grill 156 may
be slid over the assembled heating core 150, shown in FIG. 18.
Referring to FIG. 19, bottom reflector 124 is mounted onto the air
inlet board 122, and then air inlet board 122, with the reflector
124 attached, is mounted to the lower portions of the left side
cover 114, right side cover 118, and rear cover 112. Top cover 120
is secured onto the left, right, and rear covers and front top
grill, and front bottom grill 140 is secured onto the side covers
114 and 118, shown in FIG. 20. Front grill 138 is attached to the
side covers 114 and 118, and castors 126 are mounted onto the
bottom of air inlet board 122, shown in FIG. 21.
[0103] Any suitable devices and methods may be used to join the
various components to each other. For example, fasteners, such as
screws and nuts, may be used.
[0104] As shown in FIGS. 3 and 6, conductive fin 152 has holes 174
placed at varying distances from the front and back corrugations.
Other arrangements of the heating elements and the conductive fin
are possible and within the scope of the invention. It may be
desirable to place the heating elements in an arrangement other
than the array shown in FIGS. 2, 3, and 6. For example, as shown in
FIG. 7, right side panel 176 and the left side panel and conductive
fin (not shown) and the conductive fin (not shown) may have
vertically aligned holes 178 to accommodate the heating elements
166 that pass through the conductive fin. Alternatively, conductive
fin 180 may be positioned entirely behind heating elements 182,
shown in FIG. 8. The corrugations of the conductive fin need not
all have the same depth from front to back. For example, shown in
FIG. 9, fin 184 has corrugations with alternating depths, and
heating elements 186 pass through the front portions of the deeper
corrugations and do not intersect the shallower corrugations.
[0105] Because the corrugated fin of the heater may be formed from
a single sheet of metal, it allows inexpensive and efficient
manufacturing of the heater by decreasing the number of parts and
simplifying assembly of the heater, relative to previous heaters.
The corrugated fin surface and channels provide heating by both
convection and radiation. The corrugated fin and straps and panels
combine to form a self-supporting, stable, integral core.
[0106] The foregoing description is considered as illustrative only
of the principles of the invention. Further, since numerous
modifications and changes will readily occur to those skilled in
the art, it is not desired to limit the invention to the exact
construction and process shown and described above. Accordingly,
all suitable modifications and equivalents may be resorted to
falling within the scope of the invention.
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