CENTRIFICAL BLOWER AND HEATING ELEMENT APPARATUS

Abstract

A centrifugal blower and heating element apparatus includes a base, a scroll housing having primary and secondary inlet ports, and an integrated heating element, motor and impeller. The apparatus may be provided as a portable appliance used for heating a room. The apparatus may have an elongated aspect ratio and a space efficient design.

Description

RELATED APPLICATION DATA

This application claims priority to U.S. provisional patent application Ser. No. 62/208,855 filed Aug. 24, 2015, which patent application is hereby incorporated by reference in its entirety.

TECHNOLOGY FIELD

The present disclosure relates to portable space heaters. More specifically, the disclosure relates to a simplified portable electric space heater having a reduced physical size while maintaining the same heating capability of larger sized space heaters.

BACKGROUND

Portable electric heaters have been used for many years as an efficient manner to directly heat an area or individual. Permanent heating, ventilating and air conditioning systems (HVAC) use duct work and other permanent structures that may be expensive to construct. The physical structures of HVAC systems may also absorb heat. The heat absorption of duct work etc. contributes to system inefficiencies of permanent structures. Portable heaters may reduce the energy usage normally required to heat an entire room or building.

Conventional portable electric heaters may use approximately 1500 watts of power. Safety is a concern for both the manufacturer and the consumer. Portable electric heaters have used many types of heating elements, such as for example, nickel chromium (NiCr) resistance wire, quartz tubes, Positive Temperature Coefficient (PTC) heating elements and the like. Some of these heating elements have excessive surface temperatures and may present a safety compromise if the portable electric heater is not constructed properly. For example, the surface temperatures of NiCr resistance wire used in a heater may be in excess of 1000° F. [525° C.]. The combustion temperatures of many household materials are well below the surface temperature of the NiCr resistance wire.

These heating elements also require the delivery of high amperage current. The conductors and electrical connections need to be thermally protected from the heat generated by the element to avoid physical deterioration. Air generators used to move air through the heating system of a conventional portable electric heater also need to be protected from the heat generated by the heating element.

Manufacturers desire to make an aesthetically pleasing product for the consumer market. The thermal and electrical safety requirements of a conventional portable heater have limited manufacturers when attempting to reduce the size of portable heaters. The size of portable electric heaters is important since the user may place devices in close proximity in an effort to acquire the needed thermal relief. The size of the devices can limit the proximity of the heater relative to the user. The size of the device can also limit the ability of the user to place a conventional portable heater on or below a desk or table top. The ability to reduce the size of the device also amplifies the portability of the device.

Size reduction can also have the effect of lowering transportation costs for the device. As the size is reduced, the quantity of units in a given shipping space will increase as well therefore lowering the cost of transportation.

SUMMARY

Described herein are embodiments a centrifugal blower and heating element apparatus that improve upon conventional heaters.

Embodiments of the centrifugal blower and heating element apparatus as described use a unique structure that engenders several advantages when compared to conventional portable electric heaters. In some embodiments, the size of the device permits the device to be located proximate the user. In certain embodiments, the reduced size of the device further allows the user to place the device on a desktop or below a desk without interfering with the normal functionality of the workspace.

In some embodiments, a unique structural use in conjunction with a Positive Temperature Coefficient (PTC) type heat electric heating element assures a self-regulating low surface temperature of approximately 450 degrees Fahrenheit (232 degrees Celsius) on the heating element surface. The self-regulating low surface temperature of the PTC heating element may be below the combustion temperatures of many household materials, allowing the low wattage space heater to be utilized in a manner not possible with conventional heaters using nickel chromium (NiCr) resistance wire or quartz tubes.

In certain embodiments, a heating element is incorporated into the structure of a blower scroll to reduce the size and costs of the device compared to conventional portable heaters as additional housings and materials are not needed. Multi-functional components within the structure may serve to enhance the dynamic performance of the air generator while simultaneously isolating the electrical connections from physical and thermal damage.

According to an embodiment of the present disclosure, at least a portion of a secondary wall further comprising an additional non-unitary component relative to a primary wall. The additional component may serve to create a passageway for electrical and/or control wires and impedes the electrical and/or control wires from contacting an impeller. According to another embodiment of the present disclosure, the additional component serves as a high temperature mounting structure for the heating element.

According to yet another embodiment of the present disclosure, the primary wall further comprises a first half and a second half and a portion of a secondary wall is unitary to one or both of the first and/or said second halves. In an embodiment of the present disclosure the primary inlet port is located in one of the first or second halves of the primary wall and the one exit port is located in the other of the first or second halves of the primary wall.

According to another embodiment of the present disclosure further includes a base attached to a scroll housing wherein the base supports the centrifugal blower with heating element relative to a support surface and the axis of rotation of the impeller is orthogonal to the support surface.

Another advantageous aspect of the centrifugal blower and heating element apparatus results in a reduced shipping cube. This has cost and value advantages to both the manufacturer and consumer.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure is best understood from the following detailed description when read in connection with the accompanying drawing. It is emphasized that, according to common practice, the various features of the drawing are not to scale. The dimensions of the various features may be arbitrarily expanded or reduced for clarity. Included in the drawing are the following Figures:

FIG. 1 is a front and a side view of an exemplary embodiment centrifugal blower and heating element apparatus;

FIG. 2 is a perspective exploded view of the centrifugal blower and heating element apparatus of FIG. 1;

FIG. 3 is a perspective exploded view of another embodiment of the centrifugal blower and heating element apparatus;

FIG. 4 is a side cross sectional view of the centrifugal blower and heating element apparatus of FIG. 1 along plane “4-4”;

FIG. 5 is a horizontal cross sectional view of the centrifugal blower and heating element apparatus of FIG. 1 along plane “5-5”; and

FIG. 6 is a perspective view of another exemplary embodiment centrifugal blower and heating element apparatus.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

FIG. 1 is a front and a side view of an exemplary embodiment centrifugal blower and heating element apparatus 100, according to an embodiment of the disclosure. Centrifugal blower and heating element apparatus 100 includes scroll housing 110, base 150. Scroll housing 110 is comprised of primary rear wall 110a and primary wall 110b. Primary inlet ports 120 are located in primary wall rear 110a and primary outlet port 130 is located in primary wall front 100b. Outlet grill 140 is located proximate primary outlet port 130. Base 150 is utilized to maintain the vertical upright position of scroll housing 110.

Also shown are overall dimensions W, D and H, wherein W is the maximum dimension left to right width of centrifugal blower and heating element apparatus 100 and D is the maximum dimension front to back depth of centrifugal blower and heating element apparatus 100 and H is the maximum dimension height of centrifugal blower and heating element apparatus 100. As can be seen centrifugal blower and heating element apparatus 100 has a vertical aspect ratio defined by dimension H being greater than dimension W and dimension D.

Also shown are sectional planes 4-4 and 5-5 which correspond to FIG. 4 and FIG. 5 respectively.

FIG. 2 is a perspective exploded view of the centrifugal blower and heating element apparatus 100 of FIG. 1, according to an embodiment of the disclosure. As shown, scroll housing 110 may also include secondary walls 110c, 110d, 110e and 110f. As shown, secondary walls 110e and 110f are unitary with primary rear wall 110a while secondary walls 110c and 110d are assembled to primary wall 110b as separate components. Secondary inlet ports 114 are located in secondary walls 110c, 110d, 110e and 110f and are comprised of portions 114a, 114b, 114c and 114d. When assembled, primary walls 110a and 110b of scroll housing 110 define a first interior space and secondary walls 110c, 110d, 110e and 110f define a second interior space.

Located within secondary interior space is impeller 162 which is connected to motor 160. Also located within said first interior space is heating element 166 located proximate primary outlet port 130 of scroll housing 110. Air cut off 164 is shown as part of a unitary structure that includes secondary walls 110c and 110d. Also shown is control 170, control wires 174 and safety device 172.

Scroll housing 110 is connected to oscillation plate 186. Oscillation plate 186 is rotatable with reference to base 150. Oscillator motor 180, drive pin 182 and bearing segments 184 are used to move scroll housing 110 relative to base 150. When assembled drive pin 182 engages oscillation plate via slot 187 and a rotation on drive pin 182 by oscillator motor 180 causes scroll housing to rotate in an oscillating fashion relative to base 150. Base 150 is comprised of base top 152, base bottom 154 and feet 156. As shown in the present embodiment oscillation motor 180 is located inside base top 152 when fully assembled.

FIG. 3 is a perspective exploded view of centrifugal blower and heating element apparatus 300, according to an embodiment of the disclosure. Centrifugal blower and heating element apparatus 300 is similar to centrifugal blower and heating element apparatus 100 of FIG. 2. Unlike centrifugal blower and heating element apparatus 100 heat bower centrifugal blower and heating element apparatus 300 incorporates element holder 367 as s part of a unitary structure that includes secondary walls 110c and 110d and air cut off 164. Heating element 166 is assembled to element holder 367 through passage 368 and held in position by retainers 369. As such only the unitary structure that includes element holder 367 may need to be composed of heat resistant materials. This is unlike centrifugal blower and heating element apparatus 100 where all of front housing 110b may need to be composed of heat resistant material. This generates material cost savings for the manufacturer of centrifugal blower and heating element apparatus 300.

FIG. 4 is a side cross sectional view of the air generator along plane “4-4” of FIG. 1, according to an embodiment of the disclosure. As shown, when impeller 162 is rotated by motor 160, air enters inlet ports 120 along first flow path 400 and subsequently air passes through secondary inlet ports 114 along second flow path 402. The air then passes through heating element 160 and primary outlet port 130 along third flow path 404 as a heated exhaust air. In this embodiment second flow path 402 is substantially orthogonal to first flow path 400 and third flow path 404.

FIG. 5 is a horizontal cross sectional view of the centrifugal blower and heating element apparatus of FIG, according to an embodiment of the disclosure. 1 along plane “5-5”. As can be seen the shape rear scroll housing 110a and front scroll housing 110b define the needed profile and form in conjunction with air cut off 164 to facilitate air movement generation when impeller 162 is rotated. Rear scroll housing 110a and front scroll housing 110b also present a compact and aesthetically pleasing design. The structure including primary and secondary inlet ports 120 and 114 respectively allows both the functional and aesthetically pleasing design of centrifugal blower and heating element apparatus 100 without the use of additional housings normally required on conventional portable electric heaters. This reduces the size and cost of the device and increases the portability of the device, these improving the deficiencies of conventional portable electric heaters.

Air cut off 164 in conjunction with front scroll housing 110a defines passageway 500. Passageway 500 prevents control wires 174 from contacting impeller 162 and creates a thermal shield protecting control wires 174 from the heat generated by heating element 166.

FIG. 6 is a perspective view of another exemplary embodiment centrifugal blower and heating element apparatus 600, according to an embodiment of the disclosure. Centrifugal blower and heating element apparatus 600 includes scroll housing 610 and base 650. Also shown is control 670 located on base 650. Primary outlet port 630 is located on scroll housing 610 and outlet grill 640 is located proximate primary outlet port 630. Scroll housing 610 rotates along axis 680 relative to base 650. Outlet port 630 can be moved through motion

Claims

1. A centrifugal blower and heating element combination comprising:

a scroll housing comprising: a primary wall defining a first interior space; at least one primary inlet port in said primary wall; at least one secondary wall located in said first interior space and defining a second interior space; at least one secondary inlet port in said secondary wall; and at least one exit port in said primary wall;

an air impeller located at least partially within said second interior space;

a motor connected to said impeller and rotating said impeller;

an air stream generated by a rotation of said impeller;

a first flow path of said air stream entering said first interior space through said at least one primary inlet port;

a second flow path of said air stream passing through said secondary inlet port and entering said second interior space;

a third flow path of said air stream exiting said first interior space through said at least one exit port; and

at least one heating element located between said impeller and said at least one exit port and within said first interior space and/or said second interior space,

wherein said air stream exiting said at least one exit port along said third flow path comprises a heated air stream.

2. The combination of claim 1 wherein said primary wall further comprises a first half and a second half.

3. The combination of claim 2 wherein said at least one primary inlet port is located in one of said first or second halves of said primary wall and said at least one exit port is located in the other of said first or second halves of said primary wall.

4. The combination of claim 2 wherein said at least one secondary wall is unitary to one or both of said first and/or said second halves.

5. The combination of claim 1 wherein said first flow path and said third flow path are substantially orthogonal to said second flow path.

6. The combination of claim 1 wherein at least a portion of said primary wall defines a profile required to facilitate said generation of said air stream when said impeller is rotated and absent said profile of said primary wall said generation of said air stream would not ensue.

7. The combination of claim 1 further comprising a base wherein said base supports said scroll housing, said air impeller and said motor relative to a support surface.

8. The combination of claim 7 further comprising an axis of rotation of said impeller, wherein said axis of rotation in substantially orthogonal to said support surface.

9. The combination of claim 8 wherein said axis of rotation in substantially parallel to said support surface.

10. The combination of claim 7 wherein said base further comprises attachment features to attach said base to a mounting surface.

11. The combination of claim 1 wherein at least a portion of said at least one secondary wall further comprising an additional non-unitary component relative to said primary wall.

12. The combination of claim 11 wherein said additional non-unitary component serves to create a passageway for electrical and/or control wires and impedes said electrical and/or control wires from contacting said impeller.

14. The combination of claim 11 wherein said additional non-unitary component serves as a high temperature mounting structure for said heating element.

15. The combination of claim 1 further comprising an overall height dimension H as measured from said support surface to a top of said scroll housing and an overall width dimension W as measured left to right wherein said overall height dimension H is at least 3 times (300% of) said overall width dimension W.