ADVANCED HEAT REFLECTOR

Description

BACKGROUND OF THE SYSTEM

Heat focusing reflectors have grown popular in recent years in the patio heater market as a useful aid in managing the heat output and efficiency of outdoor space heaters or patio heaters. Heat focusing reflectors usually consist of a reflective surface that is used to block a portion of the lateral flow of heat produced by a patio heater and redirect that heat to travel toward a different lateral direction. This is typically useful when a user finds themselves needing heat only on one half of the patio heater as opposed to all around the heater. It may also be useful in situations where the heater is located close to one or more objects that would not benefit from receiving the heat produced by the heater. While their use is highly beneficial and typically a substantial improvement in the heater's versatility, performance and efficiency, heat focusing reflectors are not free from drawbacks.

While clamp-on or clip-on reflectors have grown popular in the aftermarket accessory industry, patio heater manufacturers have been unable to implement such a reflector as part of the original manufactured design of their patio heaters. This is due to a number of reasons.

One reason is due to certain industry safety specifications to which patio heater manufacturers must abide to legally sell in their largest global markets. While directional heat reflectors themselves are generally not disallowed by such safety standards, it is often the indirect impact of adding the reflector that causes the heater to fall out of compliance with such specifications. One such indirect impact of adding a heat focusing reflector is the change in the heaters center of mass/gravity (CG). Heaters are usually required to pass certain safety checks including a tilt test which measures the tendency of a heater to return to a standing position after being tilted to a certain degree. Thus, when a supplementary heat reflector is added at the top of a heater near the hot components, its weight increases the tip hazard of a patio heater to the point where most heaters would fall out of compliance with current safety requirements. Heaters are also required to maintain a minimum specified height under which temperatures of components must remain below specified limits. Adding a reflector can result in a part of the heater having hot parts that fall below the height limit.

Another reason why heater manufacturers have trouble adding reflectors is the increased tipping hazard due to wind. Directional reflectors for patio heaters often consist of large, nearly flat surfaces found near the very top of a heater. Such a surface would effectively act like a large wind sail in the worst possible location in regards to tipping. Most people do not use their heaters in such windy conditions because they are typically not sitting outside in windy weather. However, if the heater is left outside and the heat focusing reflector is still on the heater, the reflector can add a significant amount of wind drag to the heater top. This can contribute to a hazardous situation in addition to the heater being damaged as a result of it tipping over. Manufacturers are unable to take on such liability.

One prior art attempt to dissipate wind energy involves a mechanism that allows the reflective surface to swing in wind relative to the heater itself. This is often accomplished by having the reflective surface be hinged, allowing the surface to move towards or away from the center of the heater when the wind is acting on the reflective surface. This is a single axis of rotation.

One disadvantage of a single axis of rotation for a hinging reflector is that it significantly moves the center of mass of the reflector each time the reflector swings on the hinge. Thus, the center of mass of the reflector may move further away from the center of mass of the heater. This further increases the risk of tipping and in most cases is the reason the heater will fall out of compliance with safety standards. This is particularly risky if a swinging reflector remains in this configuration while stowed. While one may argue that a pre-existing design may instead swing such that the CG of the reflector moves closer to the heater, this doesn't work practically in a real-world design. To elaborate, even if swinging toward the CG of the heater, the axis that the reflector would be swinging would need to be close enough to the CG of the heater such that the CG of the reflector is still tolerable even while the reflector is hanging straight down. Thus, the reflector should be hinged close to the center of the heater and consequently close to the burner of the heater. Being that close, the reflective surface would need to be impractically small to fit between the swinging axis and the burner when swinging inward toward the burner. It should be noted that most prior concepts considered hinging merely as a method to change the angle at which heat is reflected, or as a means to stow the reflector when not in use. Prior concepts have not factored for the effects of real world conditions such as wind or the changes in the heaters CG as in their designs.

Fixed reflectors, in contrast, don't have the problem of moving weight away from the CG of the heater. Nor do fixed reflectors have issues with being too close to the burner. They can be fixed closer to the center of mass of the heater. However, fixed reflectors have their own disadvantage. Existing fixed reflector designs do not dissipate wind energy. Fixed reflectors allow the force of wind to transfer to the heater. By doing so, the risk of tipping increases to levels that are unacceptable. Most existing hinged concepts also aimed to constrain the swinging movement of reflective surfaces when fully deployed or at certain angles. Fixing the reflector dissolves the benefit of a swinging design in terms of dissipating wind energy. Thus, dissipating wind energy was likely not even a design consideration in most prior designs. There exists a need for reflector designs that can perform their intended function without compromising the standard heaters center of gravity or balance, and tolerance to wind energy.

Another disadvantage of existing reflector designs have failed to account for is the position at which a heat focusing reflector may be installed on a heater. It is important to limit the direction that a heat focusing reflector may be able to direct heat on a heater. This applies to both add-on or built-in existing designs. This is because lateral heat focusing reflectors should not direct heat back to the control knobs of a heater. Doing so could create a potentially hazardous situation where the temperature of the knobs may increase to unsafe handling temperatures. When being assembled, existing heaters do not have means of controlling the clocking at which symmetric parts like the heater base, shaft or top are installed. Thus, users are free to rotate and assemble most symmetric parts in any fashion irrespective of the clocking of these components with respect to one another.

SUMMARY

The system integrates a heat reflector with a heater in such a way that the disadvantages of prior art reflectors are resolved. In one embodiment, the system utilizes an unfixed, movable axis of rotation, allowing the reflector to float freely and unconstrained, which helps dissipates wind energy.

One such concept presented herein is a reflector with an unfixed, variable axis of rotation. The solution allows for reflector designs that can both dissipate wind energy, and relocate their axis of rotation, which in turn changes the CG of the reflector as well. The result could adequately resolve both CG and wind concerns and help heaters continue to comply with tip safety standards.

In one embodiment, the deployed reflector is positioned adequately close to the center of the heater as to not have a detrimental impact on the CG of the heater. When stowing, the reflector swings outward, however the reflector's axis of rotation changes and the reflector simultaneously moves closer toward the center of the heater. Moving the reflector toward the center when stowed adequately reduces the impact that its weight would have on the balance of the heater. In one embodiment, the reflector tucks deep under the heaters existing primary overhead reflector.

An added benefit of the reflector tucking in under the heaters existing primary overhead reflector is that the patio heater returns closer to its original near-net shape. Thus, a user may utilize almost any existing outdoor heater cover to protect their patio heater against the elements when not in use. If the reflector does not stow in such a way, most existing heater covers would probably not fit the heater. The heat focusing reflector would obstruct the fit. Thus, the user would be forced to either remove the reflector or seek a cover that is specially designed to fit heaters with heat focusing reflectors.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a hinge assembly of an embodiment of the system.

FIG. 2 illustrates the hinge assembly in an extended position.

FIG. 3 illustrates the reflective surface in a vertical position.

FIG. 4 illustrates the reflective surface in a horizontal position.

FIG. 5 illustrates the CG location of the reflective surface in an embodiment.

FIG. 6 illustrates an embodiment of a reflective surface coincident with the upper cap of a heater.

FIG. 7 illustrates the reflective surface of FIG. 6 in a down position.

FIG. 8 illustrates an embodiment of the reflective surface of FIG. 6.

FIG. 9 illustrates an embodiment of the system with pivot arms.

FIG. 10 illustrates the embodiment of FIG. 9 in a stowed position.

FIG. 11 illustrates an embodiment of the system attached to a cap of a heater.

DETAILED DESCRIPTION OF THE SYSTEM

The system provides a reflective surface utilizing an unfixed, moveable axis of rotation. This allows the reflective surface to freely move in a windy condition while at the same time maintaining the CG of the heater. This is accomplished by a unique hinge design used to attach the reflector to the heater. FIG. 1 illustrates an embodiment of the hinge.

The hinge assembly 100 is comprised of a channels 101 comprised of a pair of triangular formed wires, pin 102, and rail 106 (which attaches the assembly to reflective surface 107). The channels 101 allow the assembly to pivot around, and move relative to, pin 102. Channels 101 have a generally triangular shape with a curved narrow end point 104, an upright section 103, and upper section 105. An optional notched region 108 of the upper section 105 may be employed to define a midpoint resting place for the reflective surface 107. Corner 109 also defines a location that may engage pin 102.

The pin 102 is part of support 110, that may be fastened to the top 111 of the heating element of the heater. The support 110 remains fixed in place while the rail and hinge assembly can freely pivot about pin 102. It should be noted that the pin can be on the rail, while the channel is attached to the support 110. In that embodiment, the channel orientation may be reversed so that gravity allows the pin to remain in the desired notches and curved sections during use.

FIG. 2 illustrates the system when the reflective surface 107 is essentially horizontal, after being manually moved to that position. The hinge assembly is free to slide on pin 102 and so the angle of the channel 101 causes the reflective surface 107 to slide forward so that corner 109 rests on pin 102, which brings the reflective surface 107 closer to the center of the heater. The channel 101 allows freedom of movement of the hinge assembly during manual movement of the reflective surface 107.

FIG. 3 illustrates the reflective surface 107 in a vertical position during use on a heater. Figure illustrates the reflective surface 107 in a horizontal position during use on a heater. As seen in FIG. 4, the surface 107 is somewhat curved to operate more efficiently to focus the reflected heat back from the surface 107. The heater 200 includes a cap 201, heating element 202, controls 203, and shaft 204.

The channels 101 rest on the pin 102 at curved area 104, allowing the surface 107 to hang at a desired close distance to the heating element 202. When the surface 107 is horizontal as shown in FIG. 4, by being manually moved, the shape of channels 101 allows the surface 107 to move forward so that curved region 109 rests on pin 102.

FIG. 5 illustrates the CG location of the reflective surface 107 in two positions. On the left, the surface 107 is pushed all the way in so that the channel 101 is resting on the pin 102 at curved area 109. On the right, the surface is pulled out so that the channel 101 is resting on the pin 102 at curve area 104. The CG of the reflector is at location 501 on the left, and 502 on the right. The CG of the surface 107 is still relatively close to the center of the heater 200 and does not significantly affect the CG of heater 200.

The use of a wire to implement channel 101 allows the device to tolerate potential warpage during and after thermal cycling, and continue to work as designed. The channel 101 is designed to continue working even after components become rusted. The wire of the channel can continue to function effectively even if bent, and the channel 101 can continue working in spite of debris such as pine needles, dirt and leaves. This is due to the fact that there are fewer confined spaces for foreign objects to get lodged. It should be noted that other embodiments can carry out a similar mechanical function and may even be more tolerant to such conditions. For example, the mechanism may be made from sheet metal that might be either flat, L shaped or U shaped, with specially shaped slots cut into it to allow a pin to travel though and achieve a similar function. Alternatively, the mechanism may be a solid bar or hollow tube with channels formed therein.

FIG. 6 illustrates an embodiment of the reflective surface that is substantially coincident with the circumference of the cap of the heater. The heater 600 has a cap 601 that includes a hinged section 602 that has substantially the same curvature as the remainder of the cap 601. As seen in FIG. 7, the section 602 can be moved downward to act as a reflective surface to reflect more heat in a particular direction. In one embodiment, the reflector 602 is hinged at a location closer to the center and beneath the cap 601. As shown in FIG. 8, the reflector 602 may be hinged on the edge of the cutout at point 801.

An advantage of this embodiment is that the CG of the device is not impacted during use of the reflector 602. In addition, the heater 600 can use a standard heater cover because the reflector version presents the same profile and silhouette as a standard heater cap.

FIG. 9 illustrates an embodiment of the system with pivot arms. The heater 900 has a reflector 901 that utilizes one or more swing arms, slides or telescoping arms 902 that may rotate about a point 903 at their base at point 905 on the heater 900. The arms or slides 902, couped to the reflector 901 at pivot point 904, help to rotate and/or locate a lateral heat focusing reflector 901 in deployed and stowed positions while not significantly compromising the CG. The point at which the arms of slides 902 may rotate or originate may be found above or below the burner of the heater 900. The reflector 901 may also attach to the arms or slides 902 at one or more points that may also rotate to allow the reflector to swing freely in windy conditions.

The arms 902 move reflector 901 to predetermined deployed and stowed locations (FIG. 10) without compromising the CG of the heater 900 and its compliance with tilt test requirements.

FIG. 11 illustrates a heater 1100 that includes a reflector 1102 coupled to the cap 1101 at attachment points 1103. The attachment points 1103 may includes hinges or pivots so that the reflector 1102 can swing freely in the wind. The location of the reflector 1102 is such that there is substantially no impact on the CG of the heater during operation. In addition, this embodiment maintains the profile and silhouette of the heater 1100 so that a standard heater cover may be used.

Deliberately clocking (i.e. registering) various relevant heater components with respect to one another can make the difference between an acceptable design and a design concept that is too dangerous to produce. Deliberate clocking may be achieved via means of asymmetric bolt patterns, alignment fits, visual markers, including warning labels, instructions and numbers or clocking pins in mating interfaces throughout the assembly of the patio heater and between the patio heaters overhead reflector components. As an example, for lateral heat reflector embodiments that interface directly to a heaters existing overhead reflector (heater top), the heater top may need to be installed in a specific orientation with respect to the heater controls, while including features to disallow installation of the top in any other way. Additionally, the lateral reflector itself should be limited in the way it can interface with the top. This ensures the safest operational clocking position of the lateral reflector with respect to the controls on the heater. While safety instructions and warning signs are recognized by the inventors as a possible embodiment of the concept to achieve a similar outcome, the inventors believe that physical means to achieve deliberate clocking is critical for safety if one is considering scaling such a design for mass production.

Deliberate clocking of various heater components can have other important benefits as well. For example, components with asymmetric mass may be deliberately clocked with respect to where a heat focusing reflector would be installed. This may be used to help offset the center of gravity change in a heater with a heat focusing reflector. There are other ways to utilize deliberate clocking of heater components as well. For instance, many portable patio heaters include a set of wheels to help roll the heater around as needed. Those wheels stick out beyond the base of the heater, effectively increasing the balance of the heater if tipped in the same direction as those wheels. With deliberate clocking, the location of the wheels when installed can be limited to the space directly under the supplemental heat focusing reflector. This would supplement the balance of the heater when tilt tested in the direction where the added weight of the reflector would be most detrimental. While one may argue that the wheels on an existing heater can be installed under a heat focusing reflector anyway, that doesn't necessarily mean that they will be installed that way. Additionally, safety tilt testing, which is necessary for legal sale of portable heaters in many markets, may be performed at all possible installed configurations.

Thus, an advanced heat reflector has been described.