Heater module

Abstract

A heating module includes a fixed flange, a center frame, and a front cover. The fixed flange includes an annular sidewall configured to be securable to an outlet duct of a cooling system from which an air stream is provided. The center frame is formed with an opening for the air stream to flow and includes one or more heating elements positioned to heat the air stream and a support for adjustably positioning the one or more heating elements across the opening. The front cover includes a grille aligned with the opening of the center frame through which the air stream is discharged.

Description

Cross-reference to related applications

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 591,996, filed on October 20, 2023, the disclosure of which is incorporated herein by reference in its entirety. Technical Field

[0002] The present invention relates to a heating device, and more particularly to a heating module having one or more heating elements configured for use in conjunction with a cooling system. Background Technology

[0003] An evaporative air cooler is a type of cooling system that uses a fan to circulate ambient air through a humidifying cooling medium to generate a cooled airflow, where evaporation converts water into water vapor. Various solutions have been proposed using evaporative air coolers to provide heated airflow. For example, U.S. Patent No. 8,490,422 to Al Waban discloses an evaporative air cooler with one or more heaters. U.S. Patent Application No. 20030131985 to Patterson et al. discloses an evaporative air cooler with a heater that heats the airflow. U.S. Patent No. 5,482,657 to Wright discloses a heater coupled to an evaporative air cooler. Summary of the Invention

[0004] The embodiments described herein relate to a heating module configured to be removably fixed to a cooling system to form the heating system. The cooling system provides an airflow that is heated thereto before being discharged through the heating module. The heating module includes a mounting flange with an annular sidewall configured to be removably fixed around an exhaust opening of an outlet duct of the cooling system. The annular sidewall includes a lip for positioning the heating module relative to the cooling system. A frame is coupled to the mounting flange and has an opening through which airflow flows. One or more heating elements configured to heat the airflow may be fixed to at least one heater support coupled to the frame for adjustingly positioning the one or more heating elements in a parallel, spaced-apart relationship across the opening in the frame to heat the airflow discharged from the outlet duct of the cooling system. In one embodiment, the one or more heating elements include a plurality of positive temperature coefficient (PTC) heating elements that are adjustably positioned to heat the airflow. The airflow is heated by flowing through one or more gaps formed between the plurality of heating elements. A front cover includes a grille aligned and fixed to the opening in the frame, through which airflow is discharged.

[0005] The heating module is removably attached to the cooling system and is operable to heat an airflow and to discharge the airflow heated by one or more heating elements through openings in the frame. When the cooling system is available to cool the airflow, the heating module is removed from the cooling system. In heating mode, the pump supplying water to the cooling system is deactivated; and the airflow supplied by the cooling system flows through the rear opening of the heating module, through the heating module and between the multiple heating elements, and exits from the front of the heating module. Attached Figure Description

[0006] Embodiments of the present invention are described in detail below with reference to the accompanying drawings, wherein: Figure 1 A front view of an embodiment of a heating module is shown, which has a rotary switch assembly; Figure 2 It shows Figure 1 A front perspective view of an embodiment of a heating module having a rocker switch assembly; Figure 3 It shows Figure 2 A perspective view of the heating module connected to the evaporative air cooler; Figure 4 It shows Figure 1 or Figure 2 Rear front view of the heating module; Figure 5 It shows Figure 1 or Figure 2 An exploded view of the heating module; and Figure 6 It shows Figure 1 or Figure 2 A cross-sectional view of the heating module, the cross-section along... Figure 1 Intercept at the midline 6-6.

[0007] The accompanying drawings do not limit the invention to the specific embodiments disclosed and described herein. The drawings are not necessarily drawn to scale, but are intended to clearly illustrate the principles of the invention. Detailed Implementation

[0008] The following detailed description refers to the accompanying drawings, which illustrate specific embodiments in which the invention can be practiced. The embodiments are intended to describe various aspects of the invention in sufficient detail to enable those skilled in the art to practice it. Other embodiments may be utilized and changes may be made without departing from the scope of this disclosure. Therefore, the following detailed description should not be construed as limiting. The scope of the invention is defined only by the appended claims together with the full scope of their equivalents.

[0009] In this specification, references to "an embodiment," "an embodiment," or "an embodiment" mean that one or more features referenced are included in at least one embodiment of the technical solution. Independent references to "an embodiment," "an embodiment," or "an embodiment" in this specification do not necessarily refer to the same embodiment; and are not mutually exclusive unless so stated and / or unless obvious to those skilled in the art based on this specification. For example, features, structures, actions, etc., described in one embodiment may also be included in other embodiments, but are not necessarily so. Therefore, the technical solution may include various combinations and / or integrations of the embodiments described herein.

[0010] In this specification, references to “forward,” “backward,” “above,” and “below,” and their derivatives, generally indicate relative to… Figure 1 The orientation of the illustrated embodiment. That is, "forward" generally refers to the direction toward the front face 136 of the heating module 100, from which the heated airflow is discharged; and "rearward" generally refers to the direction opposite to the "forward" direction or toward the rear opening 138 of the module 100. Figure 4 As shown. "Above" and "below" typically refer to the sides of the heating module 100 or the exhaust grille 190, which extend towards... Figure 1 The top and bottom of the page. The term "horizontal side" usually refers to... Figure 1 The left and right sides of the heating module 100 or the left and right sides of the exhaust grille 190 of the heating module 100 are shown.

[0011] This document describes an embodiment of a heating module 100 used with a cooling system, which is an air ventilation or circulation system having a fan to provide airflow. Figure 1 and Figure 2 The heating module 100 shown is configured to be connected to an outlet pipe 120, which forms an exhaust opening 125 for a cooling system (evaporative air cooler 130) to convert the evaporative air cooler 130 into a heating system 132 that provides at least one heating mode. Figure 3 A heating system 132 is shown, comprising a heating module 100 removably attached to an outlet duct 120 of an evaporative air cooler 130. The heating module 100 can be removed from the evaporative air cooler 130 when the cooler 130 is to be used to cool a space or room. The heating module 100 described herein is not intended to be limited to use with the evaporative air cooler 130 and can be modified for use with any of a variety of air ventilation or recirculation systems having exhaust openings for discharging air through them.

[0012] Heating module 100 includes Figure 1 and Figure 2 shown on the front 136, and Figure 4 The rear opening 138 shown is configured to position an exhaust opening 125 that traverses the evaporative air cooler 130. When the evaporative air cooler 130 is in cooling mode, an exhaust grille or vent (not shown), which is normally fixed to the outlet duct 120 of the evaporative air cooler 130, is removed; and a heating module 100 is fixed to the outlet duct 120 of the evaporative air cooler 130 above or across the exhaust opening 125, allowing the evaporative air cooler 130 to be selectively converted by the user into a heating system 132. Preferably, in heating mode, the water distribution or circulation system (including a pump) of the evaporative air cooler 130 is not operated to prevent humidification and cooling of the airflow. An exhaust fan (not shown) within the evaporative air cooler 130 generates an airflow that flows through the exhaust opening 125 of the outlet duct 120 of the evaporative air cooler 130 and the rear opening 138 of the heating module 100, flows through and contacts one or more heating elements 144 of the heating module 100 to heat the airflow, and is discharged from the front 136 of the heating module 100.

[0013] Figure 5 An unfolded view of the heating module 100 is shown; the heating module 100 includes a mounting flange 150, a frame or heater support 160, and a front cover 185; the mounting flange 150 is used to secure the heating module 100 to the evaporative air cooler 130; the frame or heater support 160 includes means for mounting one or more heating elements 144 thereto; the front cover 185 is supported on the frame 160 and is integral with or connected to the exhaust grille or mesh cover 190.

[0014] The fixed flange 150 (which may also be referred to as a flange collar or flange pipe) includes an annular sidewall or collar 200 and a flange 202; the annular sidewall or collar 200 is removably fixed to the outer surface of the outlet pipe 120 or the sidewall by clamps, screws or other foreseeable fastening devices (which may be fixed to the outlet pipe 120, such as by pressure and / or friction within or against the outlet pipe 120), the sidewall forming the exhaust opening 125 of the evaporative air cooler 130; the flange 202 protrudes radially outward from the annular sidewall 200.

[0015] like Figure 6As best illustrated in the embodiment, the annular sidewall 200 includes an outer wall 210 and an inner wall 220. The outer wall 210 extends from a rear opening 138 toward the frame 160. The inner wall 220 connects to the outer wall 210 along the rear opening 138 and generally tapers radially inward from the rear opening 138 to a lip 225, which extends radially inward from the inner wall 220 with a gap 227 formed between the inner wall 220 and the outer wall 210. The inner wall 220 acts to form a tight fit between the fixed flange 150 and the outlet pipe 120. Between the rear opening 138 and the lip 225, the inner wall 220 forms an annular shoulder 230 that projects radially inward for securing the fixed flange 150 to the evaporative air cooler 130. Fasteners extend through bosses 240 formed in the annular sidewall 200 to secure the fixed flange 150 to the evaporative air cooler 130. The inner wall 220 includes a recess 250; fasteners can extend through the recess 250, and the recess 250 is alignable with the boss 240. In one embodiment, the recess 250 and / or gap 227 provide a degree of adjustability to the mounting flange 150 when the heating module 100 is installed or removed from the evaporative air cooler 130. A lip 225 serves as a stop to position the heating module 100 relative to the outlet duct 120 of the evaporative air cooler 130 for aligning a fastener extending through the boss 240 with a pre-drilled hole; when used in cooling mode, this pre-drilled hole is used to secure an exhaust grille or vent to the outlet duct 120. A countersunk hole 270 is formed in the outer wall 210 of the mounting flange 150, as shown below. Figure 4 As shown, extending forward from it (in the direction towards front 136) and corresponding to Figure 6 The screw boss 280 shown extends rearward from the frame 160 to secure the fixing flange 150 to the frame 160. The outer wall 210 of the annular sidewall 200 of the fixing flange 150 engages with the sidewall 285 of the frame 160, and each includes surfaces 295 and 300, forming an interlocking engagement that prevents movement of the fixing flange 150 relative to the frame 160. The interlocking engagement can be formed using any of a variety of joints and splices known in the art to securely fix the fixing flange 150 to the frame 160, including, for example, a miter joint or splice joint that forms an fit preventing movement at the joint. It is contemplated that the fixing flange 150 can be integrally formed with the frame 160.

[0016] like Figure 3 and Figure 4As shown, frame 160 includes a main wall 305, which may include a recess or opening 308 and an opening 315; the recess or opening 308 is configured to include a junction box 310 extending rearward therefrom; the opening 315 may include a reinforcing rib 318 extending across the opening 315. In one embodiment, the junction box 310 is integrally formed with frame 160. Sidewall 285 of frame 160 extends rearward from the outer edge of main wall 305 toward the outer wall 210 of an annular sidewall 200 of mounting flange 150.

[0017] A heater support 320 (which may include multiple bosses or other means for mounting one or more heating elements 144 to the frame 160) extends rearward from the rear of the main wall 305 and engages with a mounting member 325 connected to one or more heating elements 144. The multiple bosses 320 are spaced apart to allow adjustable mounting of one or more heating elements 144 relative to the opening 315 and the exhaust grille 190, such that the one or more heating elements 144 are positioned in a parallel, spaced-apart relationship to heat an airflow or airflow that circulates through the evaporative air cooler 130 and is exhausted through the opening 315 and the exhaust grille 190. Figure 4 As shown, heater support 320 is positioned above and below opening 315 formed in frame 160, and opening 315 is aligned with exhaust grille 190. Heater support 320 is positioned such that various configurations of one or more heating elements 144 can be employed, and one or more heating elements 144 are adjustably positioned across and / or behind opening 315. The heater support 320 is horizontally positioned with vertical alignment to opening 315, such that one or more heating elements 144 are vertically locating; however, it is foreseeable that heater support 320 may also be vertically aligned or alternatively positioned along the lateral sides of opening 315, such that one or more heating elements 144 are horizontally locating. In the illustrated embodiment, one or more heating elements 144 are positioned to maximize heating of the airflow and minimize any unheated airflow passing through it. Specifically, one or more heating elements 144 are located near each of the lateral sides of opening 315 to force at least a majority of the airflow between the one or more heating elements 144. Other types of appliances are also envisioned for connecting one or more heating elements 144, which may allow for fixed and / or adjustable positioning of one or more heating elements 144.

[0018] The exhaust grille 190 provides a passage or outlet for discharging heated airflow; and in one embodiment, the exhaust grille 190 is substantially the same size as the opening 315. The exhaust grille 190 may include one or more orifices of various sizes and shapes extending through it. The exhaust grille 190 restricts or prevents objects from being inserted into the heating module 100 and prevents particles of selected size from being discharged from the heating module 100. The exhaust grille 190 is located in front of one or more heating elements 144 and prevents a user or object from contacting one or more heating elements 144.

[0019] As described in the embodiments herein, one or more heating elements 144 comprise four positive temperature coefficient (PTC) heater elements or self-regulating heaters; they are made of ceramic material to provide efficient heat generation and transfer. The one or more heating elements 144 convert electrical energy into heat and produce a heat output that heats the airflow flowing through and passing over the one or more heating elements. The one or more heating elements 144 have a positive temperature coefficient of resistance, such that the resistance of the element increases with increasing temperature. In fact, the element generates a large amount of heat when low temperatures are present; and generates less heat as the temperature increases. The self-regulating characteristics of the one or more heating elements 144 prevent damage to the heating module 100 or the evaporative air cooler 130 due to overheating. Other types of heating elements may be used in the heating module 100 to provide a heated airflow, including, for example, tubular heating elements, heater coils, and other heating appliances known in the art; and the components of the heating elements may include one or more elements having various compositions depending on the application and / or requirements of the heating system 132.

[0020] Junction box 310 houses the electrical components of heating module 100 and encloses the power supply or power cord 328 (see [reference]). Figure 5 Electrical connections between components and electrical parts should be made to avoid short circuits. Figure 4 In the illustrated embodiment, junction boxes 310 are located on the left and right sides of openings 315; and mounting flanges 150, frame 160, and front cover 185 are configured to integrate junction boxes 310, along with associated electrical components, into the heating module 100. Each junction box 310 includes one or more openings or cable connection portions 330 (see...). Figure 6 Electrical and / or communication conduits (such as, for example, power supply 328) extend through one or more openings or cable connections 330. It is anticipated that junction box 310 may be located above and / or below opening 315. It is anticipated that one or more junction boxes 310 may be located on one side of opening 315.

[0021] In one embodiment, one of the junction boxes 310 includes a switch assembly 350 electrically connected to a power supply 328 and automatically activating one or more heating elements 144 of the heating module 100 via a thermostat (not shown), and / or selectively actuable by a user to activate one or more heating elements 144 of the heating module 100 to regulate the temperature. The switch assembly 350 may include one or more of a variety of switches, such as push-button switches, micro switches, rotary switches, rocker switches, or other switches known in the art. Figure 1 In the illustrated embodiment, the handle, knob, or actuator 351 of the rotary switch assembly 350 extends through an opening in the front cover 185 of the heating module 100. The rotary switch assembly 350 includes at least one heating mode, preferably at least two heating modes (warm mode and high heat mode), and an alternative option for turning off the heating module 100. The warm mode electrically connects portions of a plurality of heating elements 144, and the high heat mode electrically connects all of the plurality of heating elements 144. In the illustrated embodiment including four heating elements 144, the warm mode electrically connects two of the heating elements 144, and the high heat mode electrically connects all four of the heating elements 144. Figure 2 In the illustrated embodiment, the switch assembly 350 is a rocker switch with three positions, which functions similarly to that described with reference to the rotary switch assembly 350.

[0022] exist Figure 1 and Figure 2 In the illustrated embodiment, one of the junction boxes 310 includes an electrical socket assembly 360 electrically connectable to a power source 328 and providing power to the evaporative air cooler 130 and / or another device, minimizing socket usage. The electrical socket assembly 360 may include a panel 362 mounted on a front cover 185. In the illustrated embodiment, the electrical socket assembly 360 includes two sockets or outlets 364 for inserting electrical devices into it. A plug (such as a three-prong plug) for the power cord (not shown) of the evaporative air cooler 130 can be inserted into one of the electrical outlets 364 of the heating module 100, and another electrical device can be inserted into the other outlet 364. Because the evaporative air cooler 130 can be inserted into the heating module, only a single wall socket or extension cord is required to power both the fan of the evaporative air cooler 130 and the heating module 100 via the power source 328 of the heater 100.

[0023] The evaporative air cooler 130 may be of the type having one or more switches or controls for selectively operating a pump when the fan of the cooler 130 is operating to direct water from the tank of the cooler 130 through a nozzle, which then directs fine water droplets into the airflow generated by the fan to produce the desired evaporative cooling effect. The heating module 100 may include instructions and markings to indicate that the pump is not operated or its power is not cut off when the heating element 144 is operated.

[0024] The front cover 185 is connected to and supported on the front 385 of the main wall 305 of the frame 160. For example... Figure 6 As best shown, the annular edge 390 (integrated with and projecting forward from the circumference of the front surface 385 of the main wall 305 of the frame 160) has an inner circumference dimension that is the same as or slightly larger than the outer circumference dimension of the front cover 185. The front cover 185 is fixed to the front surface of the main wall 305 of the frame 160, and ribs or spacers 395 extend therebetween to support and / or position the front cover 185 relative to the frame 160. An exhaust grille 190 (having orifices extending through it) is coupled to or integrally formed with the front cover 185 to exhaust heated airflow from the heating module 100. The heated airflow exits the heating module 100 through a port or the exhaust grille 190.

[0025] Many different arrangements of the various components described, and of components not shown, are possible without departing from the spirit and scope of this disclosure. Embodiments of this disclosure have been described for illustrative purposes and not for limitation. Alternative embodiments without departing from the scope of this disclosure will be apparent to those skilled in the art. Those skilled in the art can develop alternative ways to achieve the foregoing improvements without departing from the scope of this disclosure. It should be understood that certain features and sub-combinations are practical and can be employed without reference to other features and sub-combinations, and are within the scope of the claims.

Claims

1. A heating module configured to be fixed to a cooling system to form a heating system, wherein the cooling system provides an airflow, the heating module comprising: A fixed flange, which is removably fixed to the outlet pipe of the cooling system; A frame, which is connected to the fixed flange and has an opening through which the airflow passes; One or more heating elements for heating the airflow, the one or more heating elements being fixed to at least one heater support connected to the frame for positioning the one or more heating elements across the opening to heat the airflow exiting from the outlet duct of the cooling system; wherein: The heating module is operable to heat the airflow and discharge the airflow heated by the one or more heating elements through the opening of the frame, and the heating module is removed from the cooling system when the cooling system is available to cool the airflow.

2. The heating module according to claim 1, wherein, The fixed flange includes an inwardly projecting lip to position the fixed flange of the heating module relative to the outlet pipe of the cooling system.

3. The heating module according to claim 1, wherein, The one or more heating elements include positive temperature coefficient heating elements.

4. The heating module according to claim 1, wherein, The one or more heating elements are a plurality of heating elements that are adjustablely positioned in a parallel and spaced-apart relationship, and the airflow heats the air by flowing between the plurality of heating elements.

5. The heating module of claim 1, further comprising one or more spacers that position the front cover relative to the frame and in front of the one or more heating elements, and the front cover including an exhaust grille aligned with the opening in the frame.

6. The heating module of claim 1, further comprising a switching assembly electrically coupled to the one or more heating elements, the one or more heating elements comprising a plurality of heating elements positioned across the opening, wherein the switching assembly is activatable between more than one heating mode, including a first mode in which portions of the plurality of heating elements are electrically connected to heat the airflow and a second mode in which all of the plurality of heating elements are electrically connected to heat the airflow.

7. The heating module of claim 1 further includes an electrical socket assembly having at least one electrical port accessible through the front of the heating module, the electrical socket assembly being configured to supply power to an electrical device.

8. The heating module according to claim 1, wherein, The cooling system is an evaporative air cooling system.

9. The heating module according to claim 8, wherein, When the heating module is connected to the cooling system and is in heating mode, the pump of the cooling system is deactivated.

10. A heating module configured to be fixed to a cooling system to form a heating system, wherein the cooling system provides an airflow, the heating module comprising: A fixed flange having an annular sidewall configured to be removably fixed to the cooling system around an exhaust opening of the cooling system; A frame having openings for the airflow; A plurality of heating elements, the plurality of heating elements being configured to heat the airflow and positioning openings across the frame in a spaced-out relationship; A front cover having a grille aligned with the opening of the frame, through which the airflow is exhausted; wherein: The cooling system includes an evaporative air cooling system, and In heating mode, the pump supplying water to the evaporative air cooling system is deactivated; and the airflow provided by the evaporative air cooling system flows through the rear opening of the heating module, flows through the heating module, flows between the plurality of heating elements, and is discharged from the front of the heating module.

11. The heating module according to claim 10, wherein, The annular sidewall includes a lip for positioning the heating module relative to the cooling system.

12. The heating module according to claim 10, wherein, The plurality of heating elements includes positive temperature coefficient heating elements.

13. The heating module of claim 10, further comprising at least one heater support extending rearward from the back of the frame to support the plurality of heating elements, the plurality of heating elements being adjustablely positioned in a parallel, spaced-apart relationship behind the opening in the frame.

14. The heating module according to claim 10, wherein, The front cover includes one or more spacers that position the grille relative to the frame.

15. The heating module of claim 10, further comprising a power line electrically connected to a switching assembly, wherein the switching assembly is activatable to electrically connect the plurality of heating elements to heat the airflow, and wherein the switching assembly is operable between one or more modes of supplying power from the power line to one or more of the plurality of heating elements and of an option to turn off the heating module.

16. The heating module of claim 10, further comprising a power cord electrically connected to an electrical socket assembly having at least one electrical socket accessible through the front cover for supplying power to an electrical device, wherein the cooling system is powered thereon.

17. A heating module configured to be fixed to a cooling system to form a heating system, wherein the cooling system provides an airflow, the heating module comprising: A fixed flange having an annular sidewall configured to be removably fixed to an outlet pipe of the cooling system, wherein the annular sidewall includes a lip for positioning the heating module relative to the cooling system; A frame having openings for the airflow; Multiple positive temperature coefficient heating elements, wherein the multiple positive temperature coefficient heating elements are positioned to heat the airflow; At least one heater support member is provided for adjustingly positioning the plurality of positive temperature coefficient heating elements in a parallel, spaced-apart relationship through an opening in the frame, wherein the airflow is heated by flowing between the plurality of positive temperature coefficient heating elements. A grille is aligned and fixed with the opening of the frame, and the airflow is discharged through the grille.

18. The heating module of claim 17, further comprising a switching assembly electrically connected to the plurality of positive temperature coefficient heating elements and configured to be activated to provide power thereto.

19. The heating module of claim 17, further comprising an electrical socket assembly having at least one electrical port accessible from the front of the heating module, the electrical socket assembly being configured to supply power to an electrical device.

20. The heating module according to claim 17, wherein, When the heating module is removably fixed to the cooling system and the heating module is in heating mode, the pump of the cooling system is deactivated.

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