RADIANT HEATING ASSEMBLY AND METHOD OF OPERATING THE RADIANT HEATING ASSEMBLY

Abstract

A radiant heating assembly includes a fuel valve, a blower, a controller configured to control the fuel valve and the blower, and a heat exchanger or burner tube having integrated baffle elements. Baffle elements can be integrated externally into the walls of a heat exchanger or burner tube to baffle internally of the heat exchanger.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent application 61/925,953, filed Jan. 10, 2014, the advantages are hereby incorporated by reference in entirety.

BACKGROUND

1. Field of the Invention

The subject invention generally relates to a radiant heating assembly as well as a method of operating the radiant heating assembly and method of manufacturing a radiant heating assembly utilizing an integrated baffle technology in the heating tubes of the assembly.

2. Description of the Related Art

Radiant heaters are widely utilized for a variety of heating purposes. One common type of radiant heater is a radiant tube heater including a burner and a heat tube extending from the burner. In the radiant tube heater, a gas valve provides gas into the burner while a blower motor provides air to the burner. The gas and the air are typically mixed and ignited in the burner. A flame and/or heated exhaust may pass from the burner to the heat tube such that the radiant tube heater emits radiant heat.

Attempts have been made in developing tubes for radiant tube heaters to improve control over the flow characteristics in the heater tube. Baffles have been inserted in some instances to perform such regulation. Although such systems allow variations to the rates of the air characteristics through the tube, such systems involve adding elements in the construction process.

The radiant tube heater may be installed at various different heights above a floor or subjected to a wide variety of environmental conditions. Additionally, users of the radiant tube heater may desire a balanced distribution of heat across a length of the heat tube by selectively increasing blower speed to force the air quickly across the length of the heat tube. Alternatively, users may desire to operate the radiant tube heater in a more thermally efficient manner by selectively reducing input of air and gas into the burner.

Accordingly, there remains an opportunity to provide a radiant tube heater that beneficially addresses the deficiencies set forth above. In other words, there remains an opportunity to provide a radiant tube heater which affords selective control over variable rates of the air in the heater tube without additional baffles to be added during installation. Specifically, there remains an opportunity to provide a radiant heater tube which affords selective control over baffles to maintain control of rates and flow characteristics of the air in the heater tube. Furthermore, there remains an opportunity to provide a radiant tube heater which exhibits increased operational efficiency over conventional modulating systems.

SUMMARY

The present invention includes a method of operating a radiant heating assembly. The radiant heating assembly includes a fuel valve and a blower. The radiant heating assembly may include a controller configured to control at least one of the fuel valve and the blower according to one of a plurality of algorithms corresponding to one of a plurality of selectable modulation modes. The radiant heating assembly includes an interface in communication with the controller which may include the step of selecting one of the plurality of selectable modulation modes from the interface, and the step of modulating at least one of the fuel valve and the blower by the controller according to the one of the plurality of algorithms corresponding to the one of the plurality of selectable modulation modes selected from the interface.

An improved radiant heating assembly tube baffle and system is described here. The radiant heating assembly includes the burner for receiving the air and the fuel for combustion. The radiant heating assembly includes the elongated heat exchanger in communication with the burner. The radiant heating assembly includes the fuel valve for providing the fuel to the burner. The radiant heating assembly includes the blower for providing the air to the burner. The radiant heating assembly includes the controller configured to control the amount of the air and the fuel provided to the burner by modulating at least one of the fuel valve and the blower according to one of the plurality of algorithms corresponding to one of the plurality of selectable modulation modes. The radiant heating assembly includes the interface in communication with the controller. The one of the plurality of selectable modulation modes may be selectable from the interface.

The radiant heating assembly advantageously provides heating tubes having dimples or depressions in the burner tubes, replacing the separate baffles of the prior art that were inserted into the burner tube. The dimples or depressions are coordinated along the burner tube to provide the same or improved flow characteristics over the prior art baffles. In addition, the dimples or depressions in the burner tubes can be selectively placed for selective control of flow characteristics which, in turn, can be used to control other characteristics of the burner tube and the heater in general.

BRIEF DESCRIPTION OF THE DRAWINGS

Other advantages of the present invention will be readily appreciated, as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

FIG. 1 is a perspective view of a prior art radiant heating assembly including an elongated heat exchanger and a housing;

FIG. 2 is a perspective view, partially in phantom, of the radiant heating assembly of FIG. 1 including a burner, a fuel valve for providing fuel to the burner, a blower for providing air to the burner, and a controller configured to control the air and the fuel provided to the burner;

FIG. 3 is a perspective view an alternative prior art embodiment of a radiant heating assembly including an elongated heat exchanger and a housing, with the prior art baffles inserted into the heating tube, as shown in cross-section;

FIG. 4 is a cross-sectional view along line 4-4 of FIG. 3;

FIG. 5 is an elevated view of a prior art baffle separate from the radiant heating assembly;

FIG. 6 is a perspective view of a radiant heating assembly of the present invention including a housing and an elongated heat exchanger or burner tube with the integrated baffle tube of the present invention useable with the assembly of FIG. 2;

FIGS. 7A, 7B, and 7C are various perspective views demonstrating the heat exchanger or burner tube of the present invention having integrated baffles as indicated;

FIGS. 8A and 8B are detailed drawings of a heat exchanger or burner tube having the integrated baffles of the present invention;

FIG. 8C is an end view of a burner tube demonstrating some baffles of the present invention in the burner tube;

FIGS. 9, 10 and 11 are perspective views of an alternative embodiment of a radiant heating assembly including a housing and an elongated heat exchanger or burner tube;

FIG. 12A, 12B, and 12C are various perspective views demonstrating the heat exchanger or burner tube having dimples or depressions as indicated in the device of FIGS. 9-11; and

FIG. 13 is a detailed drawing of a heat exchanger or burner tube having the integrated baffles of the present invention used with the device of FIGS. 9-11.

DETAILED DESCRIPTION

Referring to the Figures, wherein like numerals indicate like parts throughout the several views, a radiant heating assembly is generally shown at 10. As shown in FIG. 1, the radiant heating assembly 10 is typically suspended above an area to heat the area. The radiant heating assembly 10 may be installed in the interior or the exterior of any type of building or structure, such as a restaurant, factory, warehouse, arena, etc. Alternatively, the radiant heating assembly 10 may be independently suspended above any area such as a patio, and the like.

The radiant heating assembly 10 may include a housing 12 for accommodating various components of the radiant heating assembly 10. The housing 12 is typically formed of sheet metal but may be formed of any type of material without departing from the nature of the present invention. Furthermore, the housing 12 may have any suitable configuration for accommodating various components of the radiant heating assembly 10.

With reference to FIG. 2, the radiant heating assembly 10 includes a burner 14 for receiving air and fuel for combustion. The burner 14 typically has an inlet 16 for receiving the air and fuel. The air and fuel are typically mixed and ignited in the burner 14. However, it is to be appreciated that the air and fuel may be mixed before being received by the burner 14 according to any suitable method. The burner 14 typically combusts the air and fuel into exhaust. The burner 14 may include an outlet 18 for emitting exhaust generated by combustion of the air and fuel. Optionally, the radiant heating assembly 10 may include a plurality of burners 14. The burner 14 may have a venturi configuration but alternatively may have other configurations without departing from the nature of the present invention. The burner 14 is typically disposed at least partially within the housing 12.

The radiant heating assembly 10 includes an elongated heat exchanger or burner tube 20 in communication with the burner 14. The elongated heat exchanger 20 typically has an inlet 22 for receiving the exhaust emitted by the outlet 18 of the burner 14. The burner 14 may be positioned adjacent the inlet 22 of the elongated heat exchanger 20. The exhaust emitted by the outlet 18 of the burner 14 passes through and heats the elongated heat exchanger 20 such that the elongated heat exchanger 20 emits radiant heat. The elongated heat exchanger or burner tube 20 may be coupled to the housing 12 at one end. The elongated heat exchanger 20 may include a vent cap at another end to vent the exhaust passing through the elongated heat exchanger 20. Generally, the elongated heat exchanger 20 is mounted below a reflector 24 covering a significant portion of a length of the elongated heat exchanger 20. The reflector 24 directs radiant heat in a directional path towards the area to be heated to optimize the pattern of radiant heat emitted by the elongated heat exchanger 20.

The elongated heat exchanger or burner tube 20 may have various lengths and shapes. Typically, the elongated heat exchanger 20 has a circular cross-section. However, the elongated heat exchanger 20 may have other cross-sections such as a rectangular cross-section, and the like. The elongated heat exchanger 20 may extend in any suitable path, such as a straight path, an L-shaped path, a U-shaped path, and the like. Additionally, the radiant heating assembly 10 may include a plurality of elongated heat exchangers 20 for receiving exhaust emitted by one or a plurality of burners 14.

The radiant heating assembly 10 includes a fuel valve 26 for providing the fuel to the burner 16. The fuel valve 26 may provide fuel directly to the inlet 16 of the burner 14. Alternatively, the fuel valve 26 may provide the fuel indirectly to the burner 14. For example, the fuel valve 26 may pass the fuel through a pre-mixing chamber before entering the burner 14. As illustrated at step 28 of FIG. 6, the fuel is provided to the fuel valve 26. Typically, the fuel valve 26 is coupled to a fuel source 30 which provides the fuel to the fuel valve 26. The fuel may be natural gas, although any suitable fuel, such as propane, may be received by the fuel valve 26. The fuel valve 26 may be disposed within the housing 12.

The fuel valve 26 may be configured to provide the fuel according to a modulating operation, but may also be supplied without modulating operation. With respect to the fuel valve 26, the term “modulating,” is meant generally to describe operating the fuel valve 26 according to any given one of a plurality of fuel input rates defined within a predetermined range of fuel input rates. In the modulating operation, the fuel valve 26 may provide the fuel to the burner 14 according to one of the plurality of fuel input rates. It is to be appreciated that the fuel input rate may correspond to any suitable unit of measurement. The fuel valve 26 is generally capable of allowing from 0% to 100% of the fuel provided to the fuel valve 26 to pass to the burner 14. Said differently, the fuel valve 26 is capable of opening between 0% and 100% to provide various amounts of the fuel to the burner 14.

The radiant heating assembly 10 includes a blower 32 for providing the air to the burner 14. The blower 32 may receive the air and provide the air directly to the inlet 16 of the burner 14. Alternatively, the blower 32 may provide the air indirectly to the burner 14. For example, the blower 32 may pass the air through a pre-mixing chamber before entering the burner 14. As illustrated at a step 34, the air is provided to the blower 32. Typically, the blower 32 receives the air from an air source 36 such as ambient air. In particular, the blower 32 may draw the air through an aperture 38 defined in the housing 12 before providing the air to the burner 14. The blower 32 may be disposed within the housing 12 and in fluid communication with the elongated heat exchanger 20 for forcing the exhaust through the elongated heat exchanger 20.

In one embodiment, the blower 32 may force the air through the burner 14 and the exhaust through the elongated heat exchanger 20 by expelling the air away from the blower 32. Alternatively, the blower 32 may force the air through the burner 14 and the exhaust through the elongated heat exchanger 20 by pulling the air towards the blower 32.

As with the fuel valve 26, the blower 32 is may be configured to provide the air according to a modulating operation, or may supplied with no modulation whatsoever. With respect to the blower 32, the term “modulating,” is meant generally to describe operating the blower 32 according to any given one of a plurality of blower input rates defined within a predetermined range of blower input rates. The blower 32 typically includes a variable speed motor capable of providing the air at various rates. More specifically, the variable speed motor may be an electrically commutated motor or a permanent split capacitor motor. The blower 32 is generally capable of operating between 0 and 10,000 RPM. However, it is to be appreciated that the blower 32 may operate in any other suitable range. In the modulating operation, the blower 32 may provide the air to the burner 14 according to one of the plurality of blower input rates, as will be described below. The blower input rate may correspond to any suitable unit of measurement. For example, the blower input rate may correspond to a pressure differential measured at one or more locations within the blower 32, the burner 14, and the elongated heat exchanger 20, and the like. Specifically, the radiant heating assembly 10 may include a pressure sensor 39 for measuring the pressure differential and for providing a signal corresponding to the pressure differential measured.

As shown in FIGS. 2 and 4, the radiant heating assembly 10 includes a controller 40 configured to control the amount of the air and the fuel provided to the burner 14 by modulating at least one of the fuel valve 26 and the blower 32. The controller 40 may include a processing unit, such as a microcontroller for receiving inputs and processing and executing commands. Furthermore, the controller 40 may include logic, such as PID logic, and memory for monitoring information on past on/off heating cycles and optimizing on/off heating cycles based on the monitored information for increasing efficiency of the radiant heating assembly 10. The controller 40 may be disposed within the housing 12 and electrically connected to the fuel valve 26 and the blower 32. However, electrical connections between the controller 40, the fuel valve 26, and the blower 32 are generally not shown in the figures for simplicity in illustration.

The radiant heating assembly 10 may include an ignition controller 42. Typically, the ignition controller 42 is operatively connected between the burner 14 and the controller 40. Furthermore, an ignitor 44 may be disposed within or adjacent to the burner 14 for providing a flame for igniting the air and the fuel within the burner 14. The ignitor 44 may be controlled by the ignition controller 42. In addition, a flame sensor may be disposed adjacent the burner 14 for monitoring the flame within the burner 14. The ignition controller 42 regulates the flame provided by the ignitor 44 according to signals provided by the flame sensor. The ignition controller 42 is typically mounted in the housing 12. The ignition controller 42 may be configured to provide ignition sequencing and safety lock-out operations for the radiant heating assembly 10.

The controller 40 modulates the fuel valve 26 generally by providing a fuel control signal to the fuel valve 26 and varying the fuel control signal. More specifically, a waveform of the fuel control signal is varied as the fuel control signal is provided to the fuel valve 26. The fuel valve 26 varies fuel provided to the burner 14 according to variations of the waveform of the fuel control signal. The controller 40 may be configured to modulate the fuel valve 26 according to one of the plurality of fuel input rates. As such, in the modulation operation, the controller 40 electrically commands the fuel valve 26 to provide the fuel to the burner 14 according to one of the plurality of fuel input rates.

The controller 40 modulates the blower 32 generally by providing a blower control signal to the blower 32 and varying the blower control signal. In particular, a waveform of the blower control signal is varied as the blower control signal is provided to the blower 32. The blower 32 varies the air provided to the burner 14 according to variations of the waveform of the blower control signal. The controller 40 may be configured to modulate the blower 32 according to one of the plurality of blower input rates. Thus, in the modulation operation, the controller 40 electrically commands the blower 32 to provide the air to the burner 14 according to one of the plurality of blower input rates.

In some instances, the controller 40 may modulate the fuel valve 26 independent of the blower 32. That is, the controller 40 may provide the fuel control signal to the fuel valve 26 before or after providing the blower control signal to the blower 32. Similarly, the controller 40 may vary the fuel control signal before or after varying the blower control signal.

Alternatively, the controller 40 may simultaneously modulate the fuel valve 26 and the blower 32. Specifically, the controller 40 may provide the fuel control signal to the fuel valve 26 simultaneously while providing the blower control signal to the blower 32. Moreover, the controller 40 may vary the fuel control signal simultaneously while varying the blower control signal.

In such an environment, baffle tubes 62 as shown in FIG. 5 have been used and inserted in the heat exchanger or burner tube 100, as shown in section in FIG. 3. Similar baffle tubes can be inserted in the burner tube 20 or FIG. 1 in a similar manner. Like any separate part, there is concern as to the manufacture of the part, the assembly of the part (and the accuracy thereof), the function of the part and control of any changes to the part. What is shown as a baffle 62 in FIGS. 3 and 5 is a 33 inch by 4 inch standard interlocking baffle, Detroit Radiant part number 60366767.

Those concerns have been found here to be managed by providing the functionality of a baffle integrated into the surface metal of the heat exchanger or burner tube 20, 100, 200 forming the tubular structure. The invention may be used with anything from the most basic burner tube or heat exchange connected an on/off radiant heater to the most complex functionality of burner heat exchange unit with multiple or varied modulation, and have advantages in whatever configuration it is used. It may also be customized for specific applications.

Referring to FIG. 6, a perspective view of a radiant heating assembly of the present invention including a housing 12 and an elongated heat exchanger or burner tube 100 with the integrated depression 82, 84 forming baffles 80 is shown useable with the assembly 10 of FIGS. 1 and 2. A radiant reflector 24 can be placed along the length of the heat exchanger or burner tube 100 throughout the length of the tube 100, such as in FIG. 1, but is shown covering only a portion thereof in FIG. 6. FIG. 7A demonstrates the cross-sectional configuration where the baffles 80 mate or pair depressions 82, 84 to be spaced along the length of a three inch wide tube 120 inches in length for the heat exchanger or burner tube 100. Alternately, the depressions 82, 84 forming the baffles 80 can be staggered with spacing from one another or otherwise staggered to overlap or not overlap, as desired for specific applications. FIGS. 7A, 7B, 7C, and 7D are various perspective views demonstrating the burner tube 100 of the present invention having integrated depressions 82, 84 to form baffles 80 as indicated. FIGS. 8A and 8B are detailed drawings of a heat exchanger or burner tube 100 having the integrated depressions 82, 84 to form baffles 80 of the present invention at spaced intervals as shown. FIG. 8C is an end view of a burner tube 100 demonstrating some depressions 82, 84 forming baffles 80 as implemented into the heat exchanger or burner tube 100.

FIGS. 9, 10 and 11 are perspective views of an alternative embodiment of a radiant heating assembly 10 including a housing 12 and an elongated heat exchanger or burner tube 200 in what is commonly called a brooder. FIGS. 12A, 12B, and 12C are various perspective views demonstrating the heat exchanger or burner tube 200 having integrated depressions 82, 84 forming baffles 80 as focused and shown. FIG. 13 is a detailed drawing of a heat exchanger or burner tube 200 having the integrated depressions 82, 84 forming baffles 80 for a device as shown in FIGS. 9, 10 and 11.

The invention has been described in an illustrative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the present invention are possible in light of the above teachings, and the invention may be practiced otherwise than as specifically described.

Claims

1. A radiant heater having an elongated heat exchanger in communication with a burner including baffle elements integrated into the heat exchanger externally of the heat exchanger to provide baffling internal to the heat exchanger.

2. A system to radiantly heat an area comprising a burner and a burner tube in communication with said burner, further comprising depressions in the wall of said burner tube to form baffles.

3. A radiant heating assembly comprising:

a burner for receiving air and fuel for combustion;

an elongated heat exchanger in communication with said burner including baffle elements integrated into the heat exchanger;

a fuel valve for providing the fuel to said burner;

a blower for providing the air to said burner; and

a controller configured to control the amount of the air and the fuel provided to said burner;

4. An assembly in accordance with claim 3, wherein the heat exchanger comprises a U-shaped tube.

5. An assembly in accordance with claim 3, wherein the heat exchanger comprises a single straight tube.

6. A demand radiant heating system comprising:

an elongated radiant heating tube having an inlet end and an exhaust end, further comprising depressions in the wall of the heating tube to form baffles internally within the heating tube;

a burner tube connected to said inlet end of said radiant heating tube;

a housing defining an air tight compartment connected to said burner tube,

a blower for continually forcing air into said air tight compartment;

a burner at least partially disposed in said burner tube, said burner having an inlet end to receive air and fuel, means for mixing air and fuel, and an exit end for emitting the air/fuel mixture for combustion closely adjacent thereto; and

single fuel means disposed in said air tight compartment and operatively connected to said inlet end of said burner for providing regulation of fuel to said burner at a plurality of predetermined pressures for demand heating, whereby fuel and air is mixed and burned by said burner to heat said radiant heating tube and exhaust gases exit said exhaust end; and

temperature means connected to said fuel means for triggering said predetermined pressures at a plurality of temperature settings.

7. A heater comprising: a burner housing having a front panel and an inlet for supplying air into said burner housing; a plurality of burners spaced from each other in said burner housing for combusting a fuel and air mixture into heated gas; a plurality of heater tubes each extending from and returning to said front panel of said burner housing for radiating heat, said heater tubes each having an inlet end and an outlet end with said inlet ends in communication with said burners for receiving the heated gas from said burners and having depressions in the wall of each of said heater tubes to form internal baffles, a collector box disposed in said burner housing in communication with said outlet ends of said heater tubes for receiving the heated gas from said heater tubes; and a fan in communication with said collector box to move the heated gas from said burners to said collector box; said outlet ends of said heater tubes being adjacent each other at said burner housing and each of said inlet ends of said heater tubes being spaced in different directions from said outlet ends at said front panel of said burner housing.