Emitter apparatus

Abstract

A gas fired infrared radiation emitter that contains a frame, a screen assembly attached to the frame, and a device for locking the screen assembly to the frame. The screen assembly contains a support rod structure and at least four attachment rings attached to a screen. Each of the attachment rings is contiguous with a portion of the screen and, at the point at which each such attachment ring is contiguous with the screen, forms a screen contact point. The distance between any one screen contact point and the closest adjacent screen contact point does not exceed 75 millimeters.

Description

CROSS-REFERENCE TO RELATED PATENT APPLICATION

This patent application claims priority based upon applicants' provisional patent application 60/719,481, filed on Sep. 22, 2005.

FIELD OF THE INVENTION

A gas fired infrared radiation emitter with improved screen life, improved energy efficiency and improved, and improved durability.

BACKGROUND OF THE INVENTION

U.S. Pat. No. 6,007,329, the entire disclosure of which is hereby incorporated by reference into this specification, described and claimed a novel gas fired infrared radiation emitter. U.S. Pat. No. 6,514,071 improved upon the emitter with design aspects aimed at improving durability. U.S. Pat. No. 6,514,071, the entire disclosure of which is hereby incorporated by reference into this specification, describes and claims: “A gas-fired infrared radiation emitter, comprising a frame, a screen removably attached to said frame, and means for releasably locking said screen to said frame, wherein said frame is comprised of a first side, a second side, a first end, and a second end, and wherein: (a) said first side of said frame is integrally connected to a first receptacle, a second receptacle, and a third receptacle; (b) said second side of said frame is integrally connected to a fourth receptacle, a fifth receptacle, and a sixth receptacle; (c) said first end of said frame is integrally connected to a first support, and said second end of said frame is integrally connected to a second support, wherein said screen is contiguous with said first support and said second support; (d) said means for releasably locking said screen to said frame is comprised of a first bar removably disposed within said first receptacle and said fourth receptacle, a second bar removably disposed within said second receptacle and said fifth receptacle, and a third bar removably disposed within said third receptacle and said sixth receptacle, wherein each of said first bar, said second bar, and said third bar is disposed less than about 0.2 inches from said screen; (e) said emitter further comprises means for allowing movement of said first bar, said second bar, and said third bar towards one of said first side and said second side for at least about 0.15 inches; (f) said emitter further comprises means for limiting the movement of said first bar, said second bar, and said third bar towards one of said first side and said second side; and (g) said emitter further comprises a fourth bar extending between said first end and said second end, wherein said fourth bar is removably connected to said first bar, said second bar, and said third bar . . . wherein each of said first receptacle, said second receptacle, said third receptacle, said fourth receptacle, said fifth receptacle, and said sixth receptacle extend through said screen . . . . wherein each of said first receptacle, said second receptacle, said third receptacle, said fourth receptacle, said fifth receptacle, and said sixth receptacle is comprised of an orifice . . . further comprising a third support integrally connected to said first end of said frame . . . further comprising a fourth support integrally connected to said second end of said frame . . . wherein said screen is contiguous with said third support and said fourth support . . . further comprising a seventh receptacle integrally connected to said first end of said emitter . . . further comprising an eighth receptacle integrally connected to said second end of said emitter . . . wherein said fourth bar is removably disposed within said seventh receptacle and said eighth receptacle . . . further comprising means for allowing movement of said fourth bar for at least about 0.15 inches . . . comprising first means for limiting the movement of said fourth bar . . . comprising second means for limiting the movement of said fourth bar . . . further comprising a back body . . . further comprising a distributor . . . wherein each of said first support, said second support, said third support, and said fourth support has a height of from about 0.2 to about 0.6 inches . . . wherein said orifice is a slotted orifice . . . wherein said emitter further comprises a multiplicity of end stops connected to said first bar, said second bar, said third bar, and said fourth bar . . . wherein each of said first bar, said second bar, said third bar, and said fourth bar is comprised of an orifice.”

The gas fired radiation emitter of U.S. Pat. No. 6,514,071 has met with a reasonable degree of commercial success. However, during prolonged high-temperature usage of such emitter, the screens often sag and ultimately split, thereby causing damage to the substrates being dried as well as adversely affecting the energy efficiency and operation of the emitter. Additionally, an improved screen design provides an improved screen replacement process reducing some of the cumbersome steps in the screen replacement process of U.S. Pat. No. 6,514,071.

It is an object of this invention to provide an improved gas fired infrared radiation emitter that is more durable than the emitters of U.S. Pat. Nos. 6,007,329 and 6,514,071.

It is an object of this invention to provide an improved gas fired infrared radiation emitter that is more energy efficient than the emitters of U.S. Pat. Nos. 6,007,329 and 6,514,071.

It is an object of this invention to provide an improved gas fired infrared radiation emitter with a screen that has a longer screen life than the emitters of U.S. Pat. Nos. 6,007,329 and 6,514,071.

It is an object of this invention to provide an improved gas fired infrared radiation emitter with a screen with increased flatness stability than the emitters of U.S. Pat. Nos. 6,007,329 and 6,514,071.

It is an object of this invention to provide an improved gas fired infrared radiation emitter with a screen with reduced inward sagging toward the emitter surface than the emitters of U.S. Pat. Nos. 6,007,329 and 6,514,071.

It is an object of this invention to provide an improved gas fired infrared radiation emitter with a screen with reduced sagging outward from the emitter surface than the emitters of U.S. Pat. Nos. 6,007,329 and 6,514,071.

It is an object of this invention to provide an improved gas fired infrared radiation emitter with a simplified screen replacement process than the emitters of U.S. Pat. Nos. 6,007,329 and 6,514,071. The reduced time required in replacing the screen reduces the down-time of the drying equipment employing this apparatus.

SUMMARY OF THE INVENTION

In accordance with this invention, there is provided a gas fired infrared radiation emitter that contains a frame, a screen assembly attached to the frame, and a device for locking the screen assembly to the frame. The screen assembly contains a support rod structure and at least four attachment rings attached to a screen. Each of the attachment rings is contiguous with a portion of the screen and, at the point at which each such attachment ring is contiguous with the screen, forms a screen contact point. The distance between any one screen contact point and the closest adjacent screen contact point does not exceed 75 millimeters.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be described by reference to the following drawings, in which like numerals refer to like elements, and in which:

FIG. 1 depicts one preferred emitter of this invention;

FIG. 2 depicts the frame and backbody of the emitter of FIG. 1 with the screen assembly removed;

FIG. 3 depicts one preferred embodiment of a screen assembly of the emitter of FIG. 1;

FIG. 4 is an exploded view of the emitter of FIG. 1 with the screen assembly separated from the backbody;

FIGS. 5A and 5B are partial perspective views of a one embodiment of a vertically extending mounting bracket of the emitter of FIG. 1;

FIG. 6 is a partial perspective view of one embodiment of a screen support of the emitter of FIG. 1;

FIG. 7 is a side view of the emitter of FIG. 1; and

FIG. 8 is a partial schematic view of the device depicted in FIG. 2;

FIG. 9 is a top view of the support rod assembly of the screen assembly of FIG. 3.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

U.S. Pat. No. 6,514,071 describes an emitter where the “frame” does not require the welding of any fixtures. Instead, when the frame is made, the “retaining bar holders” are bent up and thus are an integral part of the assembly. The entire disclosure of this United States patent is hereby incorporated by reference into this specification.

FIG. 1 depicts one preferred emitter of this invention, a gas-fired infrared radiation emitter 10. Emitter 10 is comprised of a back body 12. This back body 12 is provided with a distributor (not shown) for distributing a fuel-oxygen containing gas mixture (not shown); and it is substantially identical to the back body 28 depicted in FIG. 2 of U.S. Pat. No. 6,007,329 and FIG. 1 of U.S. Pat. No. 6,514,071.

Referring again to FIG. 1, the emitter 10 is further comprised of a distributor (not shown) that preferably is substantially identical to the distributor 32 depicted in FIG. 2 of U.S. Pat. No. 6,007,329 and FIG. 1 of U.S. Pat. No. 6,514,071.

The emitter 10 also is comprised of a frame 16. In one embodiment, this frame 16 differs from the frame 12 depicted in U.S. Pat. Nos. 6,007,329 and 6,514,071. In another embodiment, a metal fiber mat (not shown) is the radiating medium in the emitter. Reference may be had, e.g., to element 34 of FIG. 2 of U.S. Pat. No. 6,007,329, which, in one embodiment thereof, is a mat of sintered metal fibers with a thickness of about 3.0 millimeters and a surface area of about 48 square inches.

Referring again to FIG. 1, the emitter 10 is further preferably comprised of a screen assembly 70. This screen assembly, more fully depicted in FIG. 3 and described below, preferably differs from the screen assemblies described in U.S. Pat. Nos. 6,007,329 and 6,514,071.

Screen assembly 70, in one embodiment, is removably attached to frame 16 and comprises a support rod structure, a plurality of attachment rings and a screen.

FIG. 2 depicts the frame and backbody of the emitter of FIG. 1 with the screen assembly removed. Referring to FIG. 2, it will be seen that frame 16 is comprised of a first end 18, a second end 20, a first side 21, and a second side 24, and an upper surface 25/58/46/48.

Referring to FIG. 2, integrally connected to the first end 18 is a first vertically extending mounting bracket 22. Preferably, the vertically extending mounting bracket is bent up from the frame, however, the vertically extending mounting bracket 22 may be operatively connected by welding or other appropriate means of adhesion known to those skilled in the art. This vertically extending mounting bracket 22, as well as vertically extending mounting bracket 28, forms an angle with upper surface 25 of frame 18 of from about 70 to about 90 degrees; and it preferably has a height 26 of from about 8 millimeters to about 20 millimeters and, more preferably, from about 10 millimeters to about 15 millimeters. As will be apparent, the vertically extending mounting bracket 22 is adapted to engage the emitter screen assembly 70 (not shown in FIG. 2, see FIG. 1). The mounting bracket 22 is preferably adapted to prevent the screen assembly 70 from moving longitudinally and transversely.

Similarly, and again referring to FIG. 2, vertically extending mounting brackets 30 and 32 form an angle with upper surface 58 of frame 18 of from about 70 to about 90 degrees; and they preferably have a height 26 of from about 8 millimeters to about 20 millimeters and, more preferably, from about 10 millimeters to about 15 millimeters. As will be apparent, vertically extending mounting brackets 30/32/22/28 are adapted to engage the emitter screen assembly 70 (not shown in FIG. 2, see FIG. 1). These mounting brackets 30/32/22/28 prevent the screen assembly 70 from moving longitudinally and transversely.

In the embodiment depicted in FIG. 2, there are two vertically extending mounting brackets 22, 28 connected to the first end 18, and an additional two such vertically extending mounting brackets 30, 32 oppositely disposed and connected to the second end 20 of the frame 16. In another embodiment, not shown, only one such vertically extending mounting bracket is connected to each of ends 18 and 20. In yet another embodiment (not shown), at least three such vertically extending mounting brackets are connected to each of ends 18 and 20. In general, from about 1 to about 4 such vertically extending mounting brackets are preferably disposed on each of ends 18 and 20. As it will be apparent to those skilled in the art, the number of vertically extending mounting brackets depends upon the length of the side 18,20, where a longer side length requires more supports. Vertically extending mounting brackets 22/28/30/32 are more fully depicted in FIGS. 5A and 5B and described in greater detail below.

In another embodiment (not shown), the vertically extending mounting brackets may be disposed on sides 21 and 24. As will be apparent, the screen supports would correspondingly be disposed on sides 18 and 20.

Referring again to FIG. 2, it will be seen that, in the preferred embodiment depicted, each of sides 21 and 24 has integrally connected to it a multiplicity of screen supports 34 and 36, and 40 and 42, respectively. Screen supports 34/36/40/42 are more fully depicted in FIG. 6 and described in greater detail below.

In one embodiment, depicted in FIG. 2, each of the secondary screen supports 34 and 36 forms an angle with upper surface 46 of side 21 of from about 70 to about 100 degrees. Similarly, in this embodiment, each of secondary screen supports 40 and 42 also forms an angle with upper surface 48 of side 24 of from about 70 to about 100 degrees. Preferably, the screen supports are bent up from the frame, however, they may be operatively connected by welding or other appropriate means of adhesion known to those skilled in the art. Each screen support 34/36/40/42 comprises a top surface 318/320/322/324 and an exterior surface 310/312/314/316 of the screen supports 34/36/40/42. In some embodiments of the screen assembly, where the edges of the screen are downwardly bent, the screen contacts exterior surfaces 310/312/314/316 of the screen supports 34/36/40/42.

Referring again to FIG. 2, the supports 22 and 28 limit the extent to which screen assembly 70 (not shown in FIG. 2, see FIG. 1) can move in one direction, and supports 30 and 32 limit the extent to which the screen assembly 70 can move in another direction.

Referring again to FIG. 2, and in the preferred embodiment depicted therein, it will be seen that each of the vertically extending mounting brackets 22/28/30/32 is comprised of an orifice 52 adapted to receive a locking device 54. In the embodiment depicted, the locking device 54 is a cotter pin. As will be apparent, other locking devices and/or locking assemblies also may be used. In using the present invention, it will be apparent that screen assembly 70 is secured by disposing locking mechanism 54, e.g. a cotter pin, in orifice 52 in the direction of arrow 60.

In one embodiment, when the frame 16 is made, the screen supports 34/36/40/42 are preferably bent up and are integrally attached to the frame 16, thereby obviating the need to weld such holders to the frame. Similarly, vertically extending mounting brackets 22/28/30/32 are preferably bent up and are integrally attached to the frame 16, thereby obviating the need to weld such holders to the frame.

FIG. 3 depicts screen assembly 70. Screen 200 is substantially identical in structure and function to the screen 14 illustrated in FIGS. 1 and 2 of U.S. Pat. No. 6,007,329 and screen 70 in FIG. 3 of U.S. Pat. No. 6,514,071. Referring again to FIG. 3, and in the preferred embodiment depicted therein, the screen 200 preferably has a wire thickness of from about 1 to about 3 millimeters and, more preferably, about 1.5 millimeters. In a preferred embodiment (not depicted) the screen 200 is downwardly along first edge 302, second edge 304, third edge 306 and fourth edge 308. Referring again to FIGS. 2 and 3, when in use, downwardly bent edges 302/304/306/308 are disposed adjacent to the exterior surface 310/312/314/316 of the corresponding screen supports 34/36/40/42. Without wishing to be bound by any particular theory, applicant believes that bending the edges of the screen inward toward the direction of the primary radiating surface further increases the emitter efficiency. Applicant believes that extending the flat dimensions of the screen by about 30 millimeters into the length and the width and then bending the 4 edges of the screen by, for example 90 degrees and to a distance of about 15 millimeters, would increase the total screen surface area by from about 15% to about 35% (subject to the flat screen size). As will be apparent to those skilled in the art, one major benefit of using a screen is to increase efficiency of the emitter apparatus. Applicant believes that the screen becomes a secondary infrared radiator that obtains its energy not only from absorbing infrared radiation emitted from the primary radiator, but also by absorbing energy contained in the flue gases (which energy otherwise would be wasted).

Referring again to FIG. 3, screen 200 as depicted has a length 208 of from about two inches to about twenty inches and a width 210 of from about one inch to about ten inches. In a preferred embodiment, screen 200 has a length 208 of about eight inches and a width 210 of about six inches.

In another embodiment (not shown), the screen size approximately equals the outside dimensions of frame 16. In such embodiment, screen 200 could be notched at each corner to allow for the protrusion of the vertically extending mounting bracket. Put more simply, the screen shape would approximate a rectangle with its four corners missing. In such embodiment, the length of each side of the screen would be proportionately reduced by a distance not exceeding 25% of the length of the side.

Referring again to FIG. 3, screen 200 has an open space area of from about 30 per cent to about 70 per cent of the total surface area of the screen 200, preferably from about 45 to about 55 per cent. As used in this specification, open space area means that portion of the screen 200 that comprises a void between the wire mesh members, or, in the vernacular, “the holes in the screen.”

Referring again to FIG. 3, and to the preferred embodiment depicted therein, screen assembly 70 further comprises support rod structure 212 and attachment rings 202. As will be apparent, the length and width of the support rod structure 212 is appropriately proportioned according to the size of screen 200. In the embodiment depicted, Support rod structure 212 comprises a first outer longitudinal support rod 214, a second outer longitudinal support rod 204, a first inner longitudinal support rod 405, a second inner longitudinal support rod 409, and transverse support rods 411/413/415/417/419. The inner longitudinal support rods 405 and 409 and the transverse support rods 411/413/415/417/419 together form a substantially H-shaped connecting portion 206. Each outer longitudinal support rod has a first securing point 216 and a second securing point 218 that is disposed in a vertically extending mounting bracket, e.g. 22/28/30/32, (not shown in FIG. 3, but see FIG. 2) while in use.

In one preferred embodiment, each of the outer longitudinal support rods 204 and 214 are substantially parallel to each other. In another embodiment, each of the inner longitudinal support rods 405 and 409 are substantially parallel to each other. In one aspect of this embodiment, the transverse support rods 411, and/or 413, and/or 415, and/or 417, and/or 419 are substantially perpendicular to one or more of such longitudinal support rods, forming an angle therebetween of from about 85 to about 95 degrees and, more preferably, from about 88 to about 92 degrees.

As used herein, the term “substantially parallel” refers to structures whose horizontal axes form an angle of from about 0 to about 5 degrees with regard to each other.

More particularly described, the support rod structure may be constructed such that the unsupported distance of the contact points on the screen portion to the closest adjacent contact point is preferably not greater than about 75 millimeters and, more preferably, not greater than about 60 millimeters. In one embodiment, the distance between adjacent support points is from about 15 to about 20 millimeters.

Referring to FIG. 4, and to the preferred embodiment depicted therein, it will be seen that a multiplicity of attachment rings 202 are connected to the screen 200 and are contiguous with a portion of such screen. Where such contiguity exists, it forms contact points 203, 205, 207, 209, 211, 213,215, 217, 219, 221 and 223 Each contact point will be adjacent to two or more contact points. Thus, and referring to FIG. 4, contact point 203 is adjacent to contact point 205 and 207. As used herein, the term “adjacent” refers to contact points that are encountered when one sweeps 360 degrees around a first contact point to determine the closest adjacent contact points. Thus, and referring to FIG. 4, the closest adjacent contact points about the periphery of contact point 203 are contact points 205, 207, 209, and 211. The maximum distance between contact point 203 and such contact points 205, 207, 209, and 211 does not exceed 75 millimeters and, more preferably, 60 millimeters. In one aspect, such maximum distance is between 15 and 20 millimeters.

Put another way, and referring to the surface of the screen 200, there is no attachment ring that is more than 75 millimeters away from an adjacent attachment ring when one looks around the periphery of the reference attachment ring.

Referring to FIG. 9, and in the preferred embodiment depicted therein, the support rod structure may be formed from a first member 204, a second member 409, a third member 419, a fourth member 405, and a fifth member 214 Referring again to FIG. 9, first member 204 and fifth member 214 preferably have a length 970 of from about 25 per cent less than to about 25 per cent greater than the length 208 of screen 200, in one embodiment, about six inches. In one embodiment, length 970 comprises from about 1.9 to about 25 inches. Referring again to FIG. 9, second member 409 and fourth member 405 have a length 971 of from about 5 per cent less than to about 25 per cent greater than the length 208 of screen 200, in one embodiment, about six inches. In one embodiment, length 970 is from about 1.9 to about 25 inches In one embodiment with a screen size of 4 inches by 3 inches, said third member 419 has a length 934 of about one inch. It is to be understood that the measurements of members 204/409/419/405/214 may be proportioned as appropriate for the size of screen 200.

In one preferred embodiment depicted in FIG. 9, fourth member 405 is bent at four points 928/920/918/926. At points 926 and 928 of from about one to about one and one-quarter inches from each end of the fourth member, both points being equidistant from the midpoint 936 of the fourth member, said member is bent to form an angle 902 of from about 70 to about 120 degrees, preferably about 90 degrees. At a point 918 and 920 of from about one-eighth inch to about three-quarters inch from the closest end of said fourth member, both points being equidistant from the midpoint 936 of said fourth member, said fourth member is bent to form an angle 906 of from about 70 to about 120 degrees, preferably about 90 degrees, to form a platforms 910 and 912 that may facilitate attachments 960 and 958 with said fifth member 214. Said third member 419 is integrally attached to the midpoint 936 of said fourth member 405 at point 966 by welding or other appropriate method known to those skilled in the art.

Similarly, again referring to FIG. 9, the second member 409 is attached to the first member 204 and the third member 419 thus forming an “H” configuration. Second member 409 is bent at four points 922/924/932/930. At a point 930 and 932 of from about one to about one and one-quarter inches from the closest ends of the second member, both points being equidistant from the midpoint 938 of the second member, said member is bent to form an angle 904 of from about 70 to about 120 degrees, preferably about 90 degrees.

Optionally, at a point 922 and 924 of from about one-eighth inch to about three-quarters inch from the closest end of said second member, both points being equidistant from the midpoint 938 of said second member, said second member is bent at an angle 908 of from about 70 to about 120 degrees, preferably about 90 degrees, to form a platforms 914 and 916 that may facilitate integral attachment with said first member 204 at points 962 and 964. Said third member 419 is integrally attached to the midpoint 938 of said second member 409 at point 968.

In another embodiment (not shown), members 405 and 409 are not bent at points 922/924/930/932, but rather, cross over members 214 and 204 respectively, extending a distance such that said member does not protrude beyond the outside dimensions of frame 16. Said members may be welded or otherwise integrally connected at such points where they meet. In another embodiment (not shown) said members may be notched and connected according to the teachings of FIG. 4 of U.S. Pat. No. 6,514,071 and the specification generally.

In one embodiment, ends 954, 956 of first member 204 are bent to form a radius of from about 45 degrees to about 330 degrees. The bends form a first and second securing point of the first member. Similarly, ends 950 and 952 of fifth member 214 are bent to form a radius of from about 45 degrees to about 330 degrees. These bends form a third and fourth securing points of the second member. This bent configuration facilitates an operative connection with the vertically extending mounting brackets.

Referring again to FIG. 3, and in the preferred embodiment depicted therein, the support rod structure 212 preferably has a diameter or wire thickness of from about 2 to about 10 millimeters and, more preferably, from about three millimeters to about 5 millimeters. In the embodiment depicted, the support rod structure 212 comprises relatively flat members, however, it should be understood that these may be rounder (e.g. wire-shaped) without affecting functionality as long as securing points 216 and 218 (and their respective equivalents on other longitudinal support rods) are appropriately shaped for insertion in the vertically extending mounting brackets 22/28/30/32.

Referring again to FIG. 3, and in the preferred embodiment depicted therein, substantially H-shaped connecting portion 206 may be formed from 3 members 220/224/222 integrally connected by welding or other adhesion means known to one skilled in the art at points 226 and 228. Substantially H-shaped connecting portion 206 may be integrally connected to outer longitudinal support rods 214 and 204 by welding or other adhesion means known to one skilled in the art at points 230/232/234/236. The substantially H-shaped connecting portion functions to secure screen 200 to emitter frame 16 in a manner that allows for expansion and contraction of the metals of rod structure 212 and screen 200 while in use while preventing inward and outward sagging of screen 200.

Referring again to FIG. 3, and in the preferred embodiment depicted therein, attachment rings 202 secure support rod structure 212 to screen 200. Attachment rings 202 comprise a section of wire formed into a small loop with a diameter of the loop from about one millimeter to about 5 millimeters, preferably from about 1 millimeter to about 3 millimeters. In other embodiments, one may alternatively use any appropriate fastening means known to one skilled in the art. Attachment rings 202 function to secure support rod structure 212 to screen 200 in a manner that allows for expansion and contraction of the metals of rod structure 212 and screen 200 while in use while preventing inward and outward sagging of screen 200. The “play” between the screen 200 and the support rod structure 212 is from about one to about five millimeters, preferably from about one to about three millimeters, and most preferably about one millimeter. As used in the specification, the play means the maximum distance between the exterior surfaces of the screen 200 and the support rod structure 212 when connected by the attachment rings 202. As depicted in FIGS. 1,3,4 and 9, a plurality of said attachment rings 202 are disposed about the support rod structure 212 and are adapted to secure screen 200 to support rod structure 212.

In one embodiment (not depicted), the screen supports 34/36/40/42 protrude through the screen 200. In order for the screen supports 34/36/40/42 to protrude through the screen 200, two methods may be used. In one embodiment, slots are cut into the screen 200. In another embodiment, that portion of the screen 200 is simply cut away.

FIG. 4 is an exploded view of the emitter 10, with the screen assembly separated from the backbody and showing how such parts are fitted together. In one embodiment, screen assembly 70 is lowered in the direction of arrows 404 toward backbody 16, fitted into second slot-type opening 408 in vertically extending mounting brackets 22/28/30/32 and secured by disposing locking mechanism 54 (e.g. a cotter pin) in orifice 52 in the direction of arrow 60. In the embodiment depicted, cotter pins 54 may then be bent downward 402 to secure the screen assembly 70 in place in the vertically extending mounting brackets 22/28/30/32. In a preferred embodiment, cotter pins 54 have a diameter at least as thick as that of the wire mesh of screen 200. In one embodiment, the diameter of cotter pin 54 is from about 1 millimeter to about 3 millimeters.

FIGS. 5A and 5B are partial perspective views of one embodiment of a vertically extending mounting bracket of the emitter of FIG. 1. Referring to FIGS. 5A and 5B, vertically extending mounting brackets, e.g. 22/28/30/32 (not shown in FIGS. 5A or 5B, see FIGS. 2 and 4), have a length 506 of from about 8 millimeters to about 20 millimeters and, more preferably, from about 10 millimeters to about 15 millimeters. Vertically extending mounting brackets, e.g. 22/28/30/32 (not shown in FIGS. 5A or 5B, see FIGS. 2 and 4), have a width 508 of from about 6 millimeters to about 30 millimeters and, more preferably, from about 10 millimeters to about 18 millimeters. In a preferred embodiment, a slot-type opening 408 in vertically extending mounting brackets 22/28/30/32 (not shown in FIGS. 5A or 5B, see FIGS. 2 and 4) is disposed at a distance 502 of about 7 millimeters to about 14 millimeters and, preferably, about 10 millimeters from the surface of frame 16. In some embodiments (not shown) void 512 (see FIG. 5B) does not exist, that is to say that the bracket is a continuous member at this situs. In the embodiment depicted, orifice 52 comprises a hole and has a diameter appropriately sized to receive the locking mechanism 54 (not shown in FIGS. 5A or 5B, see FIGS. 2 and 4), which, in some embodiments is from about one to about three millimeters.

In another embodiment (not shown), the vertically extending mounting brackets have rounded and/or flared out features (as opposed to geometric, angular and perpendicular alignments) forming angles of from about 30 to about 280 degrees with the frame. In some embodiments, orifice 408 has rounded or flared out features (as opposed to geometric, angular and perpendicular alignments) forming angles of from about 30 to about 280 degrees with the vertically extending mounting bracket. In all embodiments, orifice 408 is appropriately sized to receive the rod support structure of the screen assembly.

FIG. 6 is a partial perspective view of one embodiment of a screen support of the emitter of FIG. 1. Each of the screen supports 34, 36, 40, and 42 (34, 36 and 40 are not shown in FIG. 6, see FIGS. 2 and 4) has a height 606 of from about 7 millimeters to about 14 millimeters, preferably about 10 millimeters. Each of the screen supports 34, 36, 40, and 42 (34, 36 and 40 are not shown in FIG. 6, see FIGS. 2 and 4) has a width 604 of from about 8 millimeters to about 25 millimeters, preferably about 15 millimeters, and a depth 602 of from about 3 millimeters to about 15 millimeters, preferably about 9 millimeters. Optionally, sloped surface 608 may be incorporated, or alternatively, there may be a fourth vertical wall (depicted by dashed line 612) forming the screen support. As will be apparent, the top surface 610 of the screen supports should be the same height at the bottom surface 510 (depicted in FIG. 5B) of the slot-type opening of the vertically extending mounting brackets.

Referring again to FIG. 6, each of the screen supports 34, 36, 40, and 42 (34, 36 and 40 are not shown in FIG. 6, see FIGS. 2 and 4) is comprised of the same material as frame 16 and integrally connected thereto. As will be apparent to one skilled in the art, the materials that comprise frame 16, as well as all parts of emitter apparatus 10 (not shown in FIG. 6, see FIG. 1), must be selected for structural integrity at high temperatures such as from about 1900 to about 2300 degrees Fahrenheit. As known to those skilled in the art, loss of structural stability of the frame 16 can lead to leakage of the gas and air mixtures from either the back of the emitter apparatus (where the backbody is joined to the frame) or the front of the emitter apparatus, where the primary radiating material is joined to the frame 16. Such leakage can lead to “flashback” of the flame front from the primary radiating material into the interior of emitter apparatus 10 (not shown in FIG. 6, see FIG. 1) and rapid failure.

FIG. 7 is a side view of the emitter of FIG. 1 and FIG. 8 is a partial schematic view of the screen assembly of FIG. 2. These figures demonstrate how screen assembly 200 is secured in the vertically extending mounting brackets. In using the present invention and referring to FIG. 7, first end 708 of screen assembly 70 is brought toward end 18 of frame 16 and vertically extending mounting bracket 28 in the direction of arrow 704 until securing point 218 is disposed within an orifice, e.g., slot-type opening 408. Then second end 710 of screen assembly 70 is then brought down toward end 20 of frame 16 in the direction of arrow 706, rotating securing point 218 about a pivot about orifice 52 in the direction of arrow 702, until screen assembly 70 rests on the top surface 712 of screen supports 34 and 36 and securing point 216 is disposed within second orifice, e.g., slot-type opening 718 on vertically extending mounting bracket 32 of end 20 of frame 16. Referring to FIG. 8, outer longitudinal support rod 204 is disposed in second orifice, e.g., slot-type opening 408 on vertically extending mounting bracket 28. A locking mechanism, e.g. a cotter pin, (not shown) is optionally and additionally disposed in orifice 52.

Referring again to FIGS. 4, 5A, 5B, and 9, in one embodiment, a first vertically extending mounting bracket 22 comprises a first orifice 408 adapted to receive one of said first member 204 or said fifth member 214, a second vertically extending mounting bracket 28 comprises a second orifice 408 adapted to receive one of said first member 204 or said fifth member 214, a third vertically extending mounting bracket 30 comprises a third orifice 408 adapted to receive one of said first member 204 or said fifth member 214, a fourth vertically extending mounting bracket 32 comprises a fourth orifice 408 adapted to receive one of said first member 204 or said fifth member 214. Thus, the means for releasably locking said screen assembly 70 to said frame 16 comprises a first member 204 removably disposed within said first orifice and said third orifice, a fifth member 214 removably disposed within said second orifice and said fourth orifice, and wherein said first member 204 and said fifth member 214 are disposed from about 0.5 to about 5.0 millimeters from said screen. Similarly, the means for allowing movement of said first member 204 and said fifth member 214 towards one of said first end 18 of said frame or said second end 20 of said frame comprises a first member 204 removably disposed within said first orifice and said third orifice, a fifth member 214 removably disposed within said second orifice and said fourth orifice, and wherein said first member 204 and said fifth member 214 are disposed from about 0.5 to about 5.0 millimeters from said screen. In one embodiment, said means for allowing movement of said first member 204 and said fifth member 214 towards one of said first side 21 of said frame or said second side 24 of said frame comprises said slot-shaped orifice.

Referring again to FIG. 4, in one embodiment, a first vertically extending mounting bracket 22 comprises a fifth orifice 52 adapted to receive a locking device 54, a second vertically extending mounting bracket 28 comprises a sixth orifice 52 adapted to receive a locking device 54, a third vertically extending mounting bracket 30 comprises a seventh orifice 52 adapted to receive a locking device 54, and a fourth vertically extending mounting bracket 32 comprises an eighth orifice 52 adapted to receive a locking device 54.

It will be apparent to those skilled in the art that there are substantial advantages to the instant assembly, when it is compared to the assembly of U.S. Pat. Nos. 6,007,329 and 6,514,071, copies of which are attached. The screen and vertically extending mounting brackets are integrally connected to each other through loops that make that connection a “freely floating” connection. As will be apparent to those skilled in the art, the screen 70 can expand and contract freely with changes in temperature while the vertically extending mounting bracket 22/28/30/32 structure can also expand and contract independently. The expansion range fro the emitter apparatus is from about one to about eight millimeters.

The shape of the screen support structure is designed to offer greater form stability to the screen. The loosely attached attachment rings 202 reduce inward sagging toward the emitter and the oddly shaped rods reduce outward distortion away from the emitter. Sagging, both inward sagging and outward sagging, is a function of screen 200 exposure to temperatures greater than 1900 degrees Fahrenheit and gravity acting upon the heated wire of the screen. For example, when the apparatus is installed facing downward, gravity will want to pull the screen shape away from the apparatus surface, and conversely, when the apparatus is installed facing upward, gravity will want to pull the hot screen wired toward the emitter surface. In either case, when the screen distorts too much into either direction, the life of the screen is shortened and the energy efficiency of the apparatus is reduced. As known to those skilled in the art, there is a clearly established correlation between screen distance from the radiating material underneath and the efficiency.

Screen replacement time is shortened, thereby reducing the down-time of dryers that use this infrared technology. For all existing technologies, the replacement of a screen involves numerous steps: each of the support rods has to be disconnected from two brackets, the screen has to be removed, a new screen must be held in place, new support brackets are installed, and new support brackets are locked into place. The present invention provides a novel design that greatly simplifies this process. In the process of the present invention, or in using the present invention, the screen assembly simplifies replacement wherein a locking mechanism (a bent wire) is removed from each of the vertically extending mounting brackets, the entire screen assembly is removed, a new screen assembly is placed into the brackets, and the brackets are locked.

The emitter of the present invention is unexpectedly substantially superior to prior art emitters and substantially more durable. Tests have demonstrated that the emitter of the instant invention has a screen life that is at least about 35% percent greater than the screen life of the emitter of U.S. Pat. No. 6,514,071, when tested in high temperature drying environments.

It is to be understood that the aforementioned description is illustrative only and that changes can be made in the apparatus, in the ingredients and their proportions, and in the sequence of combinations and process steps, as well as in other aspects of the invention discussed herein, without departing from the scope of the invention

Claims

1. A gas fired infrared radiation emitter comprising a frame, a screen assembly attached to said frame, and a means for locking said screen assembly to said frame, wherein said screen assembly comprises a support rod structure, at least four attachment rings and a screen, wherein said attachment rings are disposed about said support rod structure and are adapted to secure said screen to said support rod structure, wherein:

(a) said support rod structure is comprised of a first outer longitudinal support rod, a second outer longitudinal support rod, a first inner longitudinal support rod, and a second inner longitudinal support rod, wherein: 1. each of said first and second outer longitudinal support rods, and each of said first and second inner longitudinal support rods, are substantially parallel to each other; forming an angle with regard to each other of from about 0 to about 5 degrees; 2. said first outer longitudinal support rod is connected to said first inner longitudinal support rod, and 3. said second outer longitudinal support rod is connected to said second inner longitudinal support rod, 4. said first inner longitudinal support rod is connected to said second inner longitudinal support rod;

(b) each of said attachment rings is contiguous with a portion of said screen and, at the point at which each such attachment ring is contiguous with said screen, forms a screen contact point; and

(c) the distance between any one screen contact point and the next closest screen contact point does not exceed 75 millimeters.

2. The gas fired radiation emitter as recited in claim 1, wherein said screen assembly is removably attached to said frame.

3. The gas fired radiation emitter as recited in claim 2, wherein said radiation emitter is comprised of means for releasably locking said screen assembly to said frame.

4. The gas fired radiation emitter as recited in claim 2, wherein said support rod structure comprises a first member, a second member, a third member, a fourth member and a fifth member, and wherein said second member, said third member and said fourth member form a substantially H shaped connecting portion.

5. The gas fired radiation emitter as recited in claim 4, wherein said radiation emitter is comprised of at least 10 of said attachment rings.

6. The gas fired radiation emitter as recited in claim 4, wherein said radiation emitter is comprised of from about 4 to about 16 of said attachment rings.

7. The gas fired infrared radiation emitter of claim 1, wherein said frame comprises a first side, a second side, a first end, and a second end, wherein said first side of said frame is integrally connected to a first screen support, said second side of said frame is integrally connected to a second screen support, and said screen assembly is contiguous with said first screen support and said second screen support.

8. The gas fired infrared radiation emitter of claim 7, wherein said first end of said frame is integrally connected to a first vertically extending mounting bracket and a second vertically extending mounting bracket, wherein said second end of said frame is integrally connected to a third vertically extending mounting bracket and a fourth vertically extending mounting bracket, and wherein said first vertically extending mounting bracket, said second vertically extending mounting bracket, said third vertically extending mounting bracket and said fourth vertically extending mounting bracket are adapted to engage said screen assembly.

9. The gas fired infrared radiation emitter of claim 8, wherein said first vertically extending mounting bracket comprises a first orifice adapted to receive one of said first member or said fifth member, said second vertically extending mounting bracket comprises a second orifice adapted to receive one of said first member or said fifth member, said third vertically extending mounting bracket comprises a third orifice adapted to receive one of said first member or said fifth member, said fourth vertically extending mounting bracket comprises a fourth orifice adapted to receive one of said first member or said fifth member.

10. The gas fired infrared radiation emitter of claim 9, wherein said emitter further comprises a means for allowing movement of said first member and said fifth member towards one of said first end of said frame or said second end of said frame.

11. The gas fired infrared radiation emitter of claim 10, wherein said emitter further comprises a means for limiting the movement of said first member and said fifth member towards one of said first side of said frame and said second side of said frame.

12. The gas fired infrared radiation emitter of claim 11, wherein said frame further comprises an upper surface, wherein said first vertically extending mounting bracket, said second vertically extending mounting bracket, said third vertically extending mounting bracket and said fourth vertically extending mounting bracket form an angle with said upper surface of said frame of from about 70 to about 90 degrees.

13. The gas fired infrared radiation emitter of claim 12, wherein said first vertically extending mounting bracket, said second vertically extending mounting bracket, said third vertically extending mounting bracket and said fourth vertically extending mounting bracket have a height of from about 8 millimeters to about 20 millimeters.

14. The gas fired infrared radiation emitter of claim 13, wherein said first vertically extending mounting bracket comprises a fifth orifice adapted to receive a locking device, said second vertically extending mounting bracket comprises a sixth orifice adapted to receive a locking device, said third vertically extending mounting bracket comprises a seventh orifice adapted to receive a locking device, and said fourth vertically extending mounting bracket comprises an eighth orifice adapted to receive a locking device.

15. The gas fired infrared radiation emitter of claim 14, wherein said first orifice, said second orifice, said third orifice, and said fourth orifice comprise a slot-type opening disposed at a distance of from about 7 millimeters to about 14 millimeters from said upper surface of said frame.

16. The gas fired infrared radiation emitter of claim 15, wherein said first screen support further comprises a first top surface, said second screen support further comprises a second top surface, said first screen support and said second screen support further comprise a height of from about 7 millimeters to about 14 millimeters, and said first top surface of said first screen support and said second top surface of said second screen support comprise a height that is substantially the same distance as said distance said slot-type opening is disposed from said upper surface of said frame.

17. The gas fired infrared radiation emitter of claim 16, wherein said first member comprises a first securing point and a second securing point, said fifth member comprises a third securing point and a fourth securing point, wherein said first securing point and said second securing point each comprise a bend in opposing ends of said first member where said bends comprise a radius of from about 45 to about 330 degrees and wherein said third securing point and said fourth securing point each comprise a bend in opposing ends of said second member where said bends comprise a radius of from about 45 to about 330 degrees.

18. The gas fired infrared radiation emitter of claim 17, wherein said screen comprises a length of from about 2 to about 20 inches and a width of from about 1 to about 10 inches.

19. The gas fired infrared radiation emitter of claim 18, wherein said screen further comprises an open space area of from about 30 to about 70 percent of the total surface area of said screen.

20. The gas fired infrared radiation emitter of claim 19, wherein the length of said first member and said fifth member comprise from about 1.5 to about 25 inches.