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.

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, &agr;, (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 &agr; is preferably between about 10° and about 20°.

[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, &agr;. 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.

Claims

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.