Portable oscillating space heater

Abstract

A portable oscillating space heater is provided, which comprises at least one opening therein, at least one heating assembly including an electric heating element disposed within the housing for producing radiant heat energy, at least one fan mounted within the housing and adapted to produce a directed air flow introducing from the opening in the rear portion of the housing and passing through the electric heating element and thereby producing a heated air flow, and an oscillation mechanism for providing oscillatory movement at least to the heating assembly thereby to continuously change the direction of the heated air flow produced by the fan.

Description

RELATED PRIOR APPLICATIONS

[0001] This application claims priority from Provisional Patent Application Serial Nos. 60/296,382 and 60/318,429, respectively filed on Jun. 6, 2001 and Sep. 10, 2001, the entire contents of which are incorporated herein by reference.

BACKGROUND

[0002] 1. Technical Field

[0003] The present disclosure relates generally to portable space heaters, and more specifically to a portable oscillating space heater having at least one heating assembly for distributing heated air in a continuously changing direction.

[0004] 2. Background of the Related Art

[0005] Portable space heaters for heating air are well known in the art and are available in many different forms, and may incorporate various types of heating elements, including electric resistance-wire heaters and positive temperature coefficient (PTC) heaters. Typically, electric resistance-wire space heaters include a heating element which may reach temperatures exceeding 1600 degrees Fahrenheit. As such, electric resistance-wire space heaters may present a fire hazard and usually require some fire prevention structure. In contrast, electric space heaters incorporating PTC heating elements include a conductive grid supported on a ceramic material body, or heat conductive plastic body. Electric current supplied through the conductive grid heats the ceramic material and the heat is distributed from the ceramic material by an air flow generated by an electric fan. When a PTC heating element rises to a temperature of approximately 340 degrees Fahrenheit, the resistance in the ceramic material prevents further flow of current through the ceramic material to prevent further temperature rise of the ceramic material, thereby minimizing the risk of overheating and the potential for fire.

[0006] One problem associated with space heaters employing PTC heating elements is that the heat generated is directed over a small area. U.S. Pat. No. 5,513,296 to Goldstein (“Goldstein”) attempts to correct this problem by providing space heater having a PTC heating element which distributes the heat over a larger area. Goldstein discloses a space heater including a pair of PTC heater assemblies disposed in side-by-side relationship. Each heating assembly is positioned at an angle of approximately 7.5 degrees from normal so as to produce a diverging column of heated air.

[0007] However, continuing need still exists for a space heater which is compact and portable, does not present a fire hazard and can distribute heat over a large area.

SUMMARY OF THE INVENTION

[0008] In accordance with the present disclosure, a portable oscillating space heater for distributing heated air in a changing direction is provided.

[0009] Generally, the present invention discloses an oscillating space heater which includes a housing having a front portion and a rear portion, each having at least one opening therein, at least one heating assembly including an electric heating element disposed within the housing for producing radiant heat energy, at least one fan mounted within the housing and adapted to produce a directed air flow introducing from the opening in the rear portion of the housing and passing through the electric heating element and thereby producing a heated air flow, and an oscillation mechanism for providing oscillatory movement at least to the heating assembly thereby to continuously change the direction of the heated air flow produced by the fan. A positive temperature coefficient (PTC) heater element is preferably utilized as the electric heating element of the heating assembly. The oscillation mechanism is adapted to provide oscillatory movement at least to the heating assembly over an arc of between about 15 and about 360 degrees.

[0010] In one preferred embodiment, the electric heater of the invention includes a single heating assembly disposed adjacent the front portion of the housing, wherein the single heating assembly is adapted to be subject to oscillatory movement for changing the direction of the heated air flow produced by the fan.

[0011] In another preferred embodiment, the electric heater of the invention includes two heating assemblies, one located adjacent to the other in substantial vertical alignment, wherein the two heating assemblies is adapted to be subject to oscillatory movement in simultaneous opposite directions.

[0012] The present invention further discloses a positive temperature coefficient (PTC) heater which includes a housing, a first and a second heater assemblies, one located above the other, each including a positive temperature coefficient (PTC) heater element for producing heat energy when connected to an electric source, at least one fan disposed within the housing and adapted to produce a directional air flow toward the PTC heater elements and thereby to generate a heated air flow, an air flow guide mechanism disposed within the housing for guiding the direction of the air flow toward the PTC heater elements, and an oscillation mechanism for providing oscillatory movement of the first and the second heater assemblies, each continuously moveable in opposite directions with respect to each other.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Preferred embodiments of the present disclosure are described herein with reference to the drawings, wherein:

[0014] FIG. 1 is a side view in partial cutaway of an oscillating heater constructed in accordance with the present invention;

[0015] FIG. 2 is an exploded perspective view of the oscillating heater of FIG. 1;

[0016] FIG. 3 is a perspective view illustrating another embodiment of the oscillating heater;

[0017] FIG. 3A is a perspective view of the oscillating heater of FIG. 3 illustrating oscillation movement of the first and the second heater assemblies in opposite directions;

[0018] FIG. 4 is a side sectional view of the oscillating heater of FIG. 3;

[0019] FIG. 5 is a top sectional view of the oscillating heater of FIG. 3;

[0020] FIGS. 6 and 7 are perspective views illustrating the oscillation mechanism of the oscillating heater of FIG. 3; and

[0021] FIG. 8 is a schematic view illustrating mounting of the oscillation mechanism of FIGS. 6 and 7 to the oscillating heater of FIG. 3.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0022] Preferred embodiments of the presently disclosed oscillating heater will now be described in detail with reference to the drawings in which like reference numerals designate identical or corresponding elements in each of the several views.

[0023] Referring to FIGS. 1-2, oscillating heater 10 includes a housing having a front housing portion 12, a rear housing portion 14, a lower housing portion 16, an upper housing portion 18, and a housing cover 20. Front housing portion 12 and rear housing portion 14 define a first housing cavity, lower housing portion 16 and rear housing portion 14 define a second housing cavity and upper housing portion 18 and housing cover 20 define a third housing cavity. Each of the housing cavities encloses internal components of oscillating heater 10 as will be described in further detail below. Each of the housing portions is connected to the others in a known manner, preferably with screws. Alternately, other known fastening techniques may be used to fasten the housing portions together including adhesives, welding, snap-fit connectors, etc. The housing portions are preferably molded from a polymeric material but may be formed from a variety of materials including metals, etc.

[0024] The housing of heater 10 is supported on a base member including a base top portion 22 and a base bottom portion 24. Base portions 22 and 24 define a fourth housing cavity which is dimensioned to receive a foot activated switch or oscillation activator 26. Switch 26 includes a foot pedal 28 and switch components 30. Switch 26 is actuable to effect oscillation of a heating assembly 32 as will be described in further detail below.

[0025] Heating assembly 32 includes an outlet screen 34 which is preferably formed of steel mesh but may be formed of other materials including plastics having a plurality of openings or gratings disposed therein. Heating assembly 32 also includes a plurality of vertically oriented PTC heating elements 36, an element holder 38, a body 40, a top portion 42, and a bottom portion 44. PTC elements 36 are supported on element holder 38 and the assembly is secured to body member 40 using screws or the like.

[0026] Body 40 is substantially c-shaped and is configured to be slidably received on front housing portion 12. Front housing portion 12 includes a pair of vertically spaced elongated transverse openings 46 and body 40 includes a pair of vertically spaced openings 48. When body 40 is slidably positioned on front housing portion 12, each opening 48 communicates with a respective elongated opening 46, which is preferably wider than opening 48. Openings 46 and 48 permit air from inside the first housing cavity to flow across the PTC elements 36 and exit heater 10 through outlet screen 34. Accordingly, openings 46 and 48 constitute an air flow guide or baffle mechanism. Other guide structure are also contemplated.

[0027] A blower assembly 50 is supported within the first housing cavity and includes a motor 52 and a pair of fans 54 and 56. Each fan 54 and 56 is configured to direct air through a respective opening 46. While a single motor is shown, separate motors for each fan may be provided. Likewise, a single fan/motor assembly may be provided, with ducts to direct air flow to each opening 46. Rear housing portion 14 includes a grating 58 which allows air to be drawn into the first housing cavity. An inlet grille 60 is removably supported over grating 58 of rear housing portion 14 to act like a filter and to prevent debris from entering the first housing cavity.

[0028] Heating assembly 32 is slidably positioned on base portion 22. Base portion 22 is crescent shaped and includes a curved guide slot 62 formed in an upper surface thereof. Slot 62 is configured to receive a protrusion (not shown) formed on heating assembly 32 to confine heating assembly 32 to a predetermined path of oscillatory motion.

[0029] An oscillatory drive motor 70 is supported within the second housing cavity defined between lower housing portion 16 and rear housing portion 14. Lower housing portion 16 includes an elongated slot 72. A drive arm 74 extends through slot 72 and interconnects drive motor 70 to heating assembly 32. Upon actuation of motor 70 via foot pedal 28, motor 70 drives heating assembly 32 in oscillation about front housing portion 12. Alternately, it is envisioned that heating assembly 32 may be driven in continuous rotation about the heater or in oscillation over any desired arc.

[0030] A thermostat 80 and a control switch 82 are supported in the third housing cavity. Switch 82 is electrically connected to the fan motor 52 and PTC elements 36 to control operation of heater 10 in a known manner. Thermostat 80 may be included to provide variable heat settings.

[0031] In use, when switch 82 is actuated, power is supplied to PTC elements 36 and fan motor 52. As PTC elements 36 heat up, fans 54 and 56 draw air into the first housing cavity through rear housing portion 14 and force the air through openings 46 and 48 into contact with PTC elements 36. As the air flows across PTC elements 36, the air is heated and is forced to flow from heating assembly 32 through outlet screen 34. When switch 30 is actuated via foot pedal 28, motor 70 via link 74 effects oscillation of heating assembly 32 to distribute heated air over a predetermined arc.

[0032] It will be understood that various modifications may be made to the embodiments disclosed herein. For example, the heater assembly may be pivoted about a horizontal axis rather than a vertical axis. Moreover, the PTC heating elements may be replaced by other heating elements known in the art. It is also envisioned that the heater assembly may be rotated 360 degrees continually about a central axis of the heater.

[0033] Referring now to FIGS. 3-5, an alternate embodiment of the present invention is described hereafter in detail. Oscillating heater 100 includes a housing 112, first and second heater assemblies 114 and 116, a heater actuator 118 supported on an upper end of housing 112, and an oscillation actuator 120 supported on a lower end of housing 112. Housing 112 is preferably formed from molded plastic sections. Alternately, other materials may be used to form housing 112 including metals.

[0034] Housing 112 includes a backside 112a including an opening dimensioned to allow airflow into housing 112. A frontside 112b of housing 112 also includes an opening which communicates with an opening formed in the backside of first and second heater assemblies 114 and 116. Each of the openings formed in backside 112a and frontside 112b of housing 112 maybe covered by a grating, which may or may not be integrally formed with housing 112.

[0035] A motor 122 is supported within housing 112 between first and second fans 124 and 126. First and second fans 124 and 126 are positioned to draw air through the opening formed in backside 112a of housing 112 and force it through the opening formed in front side 112b of housing 112. First fan 124 is positioned to force air into first heater assembly 114 and second fan 126 is positioned to force air into second heater assembly 116.

[0036] Each heater assembly 114 and 116 includes a PTC heating element 130 supported within a casing 132 in general vertical orientation. Each casing 132 is movably supported on housing 112. Preferably, each casing 132 is configured to be slidably supported with respect to housing 112, with heater assembly 114 positioned above heater assembly 116, and both heater assemblies 114 and 116 being rotatable with respect to a vertical axis. Alternately, other assembly configurations are envisioned. The use of other known heating elements is also envisioned.

[0037] Referring now to FIGS. 6-8, a rack 140 is secured to each heater assembly 114 and 116. In one preferred embodiment, racks 140 are formed integrally with the housing 1 14a and 116a of each of the heater assemblies 114 and 116. Alternately, racks 140 can be formed separately from housing 114a and 116a and attached thereto using known fastening techniques, e.g., screws, adhesives, welding, etc. A drive shaft 142 driven by motor 143 includes a pinion 144. Pinion 144 is positioned between teeth 146 of each rack 140 such that rotation of pinion 144 affects movement of heater assemblies 114 and 116 in opposite directions. Oscillation actuator 120 (FIG. 3) operates an electric switch to control operation of motor 143 and thus control oscillation of heater assemblies 114 and 116.

[0038] In operation, when heater 110 is connected to a power source, e.g., an electrical outlet, and heater actuator 118 is turned on, current is supplied to PTC elements 130 to generate heat. Motor 122 is actuated to concurrently drive fans 124 and 126 to draw air into the backside 112a of housing 112 and force it over PTC elements 130. Preferably, heater actuator 118 includes multiple settings to control the current supplied to PTC elements 130 to control the heater temperature. Moreover, baffles or air flow guiding mechanisms may be provided to direct air from fans 124 and 126 to flow over PTC elements 130. Heated air flowing from PTC elements 130 flows through a perforated cover or screen 150 supported on each heater assembly 114 and 116 and is directed outwardly therefrom. When oscillation actuator 120 is manually pressed to supply electrical current to motor 143, heater assemblies 114 and 116 are oscillated in opposite directions (as indicated by arrows “a” and “b” in FIG. 3A) over an arc, preferably between about 15 and about 360 degrees. Preferably, each heater assembly is moved over an arc of between about 30 degrees to about 90 degrees, and most preferably, heater assemblies 114 and 116 are oscillated over an arc of about 60 degrees. Preferably, each heater assembly 114 and 116 includes a slot or groove which cooperates with a slot or groove formed in housing 112 to guide the heater assemblies over the arc of oscillation.

[0039] It will be understood that various modifications may be made to the embodiments disclosed herein. For example, the heater assemblies may be pivoted about a horizontal axis rather than a vertical axis. Moreover, the PTC heater elements may be replaced by other heating elements known in the art. It is also envisioned that the heater assemblies may be rotated 360 degrees continually about a central axis of the heater.

[0040] Therefore, the above description should not be construed as limiting, but merely as an exemplification of preferred embodiments. Those skilled in the art will envision other modifications within the scope and spirit of this disclosure as defined by the claims appended hereto.

Claims

1. An electric heater comprising:

a housing including a front portion and a rear portion, each having at least one opening therein;

at least one heating assembly including an electric heating element disposed within the housing for producing radiant heat energy;

at least one fan mounted within the housing and adapted to produce a directed air flow introducing from the opening in the rear portion of the housing and passing through the electric heating element and thereby producing a heated air flow; and

an oscillation mechanism for providing oscillatory movement at least to the heating assembly thereby to continuously change the direction of the heated air flow produced by the fan.

2. The electric heater of claim 1, wherein the electric heating element is a positive temperature coefficient (PTC) heater element.

3. The electric heater of claim 1, wherein the oscillation mechanism is adapted to provide oscillatory movement over an arc of between about 15 and about 360 degrees.

4. The electric heater of claim 1 further including a heater actuator for controlling operating conditions of the electric heating element.

5. The electric heater of claim 4 further including an oscillation actuator for controlling operation of the oscillation mechanism.

6. The electric heater of claim 1, wherein the at least one heating assembly is a single heating assembly disposed adjacent the front portion of the housing.

7. The electric heater of claim 6, wherein the oscillation mechanism includes a drive a motor.

8. The electric heater of claim 7, wherein the oscillation mechanism further includes a drive arm operatively connected to the drive motor for the oscillatory movement of the heating assembly.

9. The electric heater of claim 6 further including an air guide mechanism for guiding air flow toward the electric heating element.

10. The electric heater of claim 1, wherein the at least one heating assembly includes two heating assemblies, one located adjacent to the other.

11. The electric heater of claim 10, wherein one of the two heating assemblies is located above the other heating assembly in substantial vertical alignment with respect to each other.

12. The electric heater of claim 11, wherein the oscillation mechanism includes a drive motor.

13. The electric heater of claim 12, wherein the oscillation mechanism further includes a pinion operatively connected to the drive motor and a pair of racks connected to the two heating assemblies for providing oscillatory movement of the two heating assemblies in simultaneous opposite directions.

14. The electric heater of claim 10 further including an air guide mechanism for guiding air flow toward the electric heating assemblies.

15. A positive temperature coefficient (PTC) heater comprising:

a housing;

a first and a second heater assembly, one located above the other, each including a positive temperature coefficient (PTC) heater element for producing heat energy when connected to an electric source;

at least one fan disposed within the housing and adapted to produce a directional air flow toward the PTC heater elements and thereby to generate a heated air flow;

an air flow guide mechanism disposed within the housing for guiding the direction of the air flow toward the PTC heater elements; and

an oscillation mechanism for providing oscillatory movement of the first and the second heater assemblies, each continuously moveable in opposite directions with respect to each other.

16. The positive temperature coefficient (PTC) heater of claim 15, wherein the oscillation mechanism includes a drive motor, a pinion operatively connected to the drive motor, and a pair of racks connected to the first and the second heater assemblies.

17. A positive temperature coefficient (PTC) heater comprising:

a housing;

a PTC heater element for producing heat energy when connected to an electric source;

a holding member for holding the PTC heater element within the housing;

at least one fan disposed within the housing and adapted to produce a directional air flow toward the PTC heater element and thereby to generate a heated air flow;

an air flow guide mechanism disposed within the housing for guiding the direction of the air flow toward the PTC heater element; and

an oscillation member for providing oscillating movement of the holding member.

18. The positive temperature coefficient (PTC) heater of claim 17, wherein the oscillation member includes a drive motor and a drive arm adapted for providing the oscillating movement of the holding member.