Improved catalytic heater and casing for access and easy replacement of the pads of the catalytic heater

Abstract

A catalyst heater system, apparatus, and method. The catalyst heater system includes a casing, a fuel input system disposed within the casing, a standoff disposed within the casing, at least one heating element disposed within the casing, a dispersion pad, and a catalyst pad, wherein the dispersion pad and the catalyst pad are configured to be removed from and inserted into the casing through an access opening of the casing while the fuel input system, the standoff, and the heating element remain stationary within the casing.

Description

Patent Application DOCKET NO.: CATCO-POOl-PCTIMPROVED CATALYTIC HEATER AND CASING FOR ACCESS AND EASY REPLACEMENT OF THE PADS OF THE CATALYTIC HEATERFIELD OF THE INVENTION

[0001] The disclosure relates to systems, apparatus and methods for replaceable of the pads of a catalytic heater.CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to pending U.S. Provisional Patent Application No.63 / 775,247, entitled “IMPROVED CATALYTIC HEATER AND CASING FOR ACCESS AND EASY REPLACEMENT OF THE PADS OF THE CATALYTIC HEATER,” filed on March 20, 2025, the entirety of which is incorporated by reference.BACKGROUND OF THE INVENTION

[0003] A catalyst and dispersion pads in a catalytic heater are a crucial component that helps evenly distribute fuel vapors across the catalyst surface, ensuring efficient combustion and heat output. Over time, these pads can degrade due to heat exposure, contamination, or clogging from fuel residues, leading to reduced heater performance and potential safety hazards. Replacing them is necessary to maintain the heater’s efficiency and longevity, especially in industrial or field applications where reliable heat is essential. Neglecting to replace a worn-out pads in a catalytic heater can lead to inefficient fuel use, increased emissions, and even damage to other components, resulting in higher long-term costs.

[0004] Replacing the catalyst and dispersion pads tend to be time consuming and labor intensive, which includes disconnecting and reinstalling of the gas connection and explosion proof electrical connection. Additionally, in many circumstances, more expenses are incurred for professional maintenance and downtime. Some models require more intricate disassembly, including removing fuel lines, seals, or other internal components.

[0005] The effort required to change the catalyst and dispersion pad depends on the heater's design. In most cases, the process involves disassembling part of the heater, removing the old pad, cleaning any residue, and installing the new pad securely. Proper installation is essential to ensure even fuel distribution and optimal performance; followingPatent Application DOCKET NO.: CATCO-POOl-PCT the manufacturer’s guidelines or seeking professional assistance is recommended. Owners who are unfamiliar with these systems may struggle with proper installation, risking uneven fuel distribution or even damage to the heater. Additionally, improper replacement could lead to reduced efficiency or safety hazards such as incomplete combustion.Ensuring the new pads are properly seated and secured is critical for maintaining heater efficiency, fuel economy, and safe operation. Therefore, the overall expense of replacement can increase significantly if professional servicing or extended downtime is necessary.

[0006] Thus, there is a need for improved catalytic heater and casing that allow for a simpler and more efficient way for replacing the dispersion pad.SUMMARY OF THE INVENTION

[0007] Embodiments described herein relate to a catalyst heater system, apparatus, and method. The catalyst heater system includes a casing, a fuel input system disposed within the casing, a standoff disposed within the casing, at least one heating element disposed within the casing, a dispersion pad, and a catalyst pad, wherein the dispersion pad and the catalyst pad are configured to be removed from and inserted into the casing through an access opening of the casing while the fuel input system, the standoff, and the heating element remain stationary within the casing.BRIEF DESCRIPTION OF DRAWINGS

[0008] Reference will now be made to the following drawings:

[0009] FIG. 1 is an embodiment illustrating a diagram of a traditional catalytic heater;

[0010] FIG. 2 is an embodiment illustrating a diagram of a catalytic heatersystem for an accessible catalyst and dispersion pads;

[0011] FIG. 3 is an embodiment illustrating a block diagram of an catalyticheater system designed with an accessible catalyst and dispersion pad;

[0012] FIG. 4 is an embodiment illustrating a flow diagram for catalyst and dispersion pads replacement method; and

[0013] FIG. 5 are embodiments of various casings for a catalytic heater casing modified for accessibility dispersion pad.Patent Application DOCKET NO.: CATCO-POOl-PCTDESCRIPTION

[0014] In the descriptions that follow, like parts are marked throughout the specification and drawings with the same numerals, respectively. The drawing figures are not necessarily drawn to scale and certain figures may be shown in exaggerated or generalized form in the interest of clarity and conciseness.

[0015] It will be appreciated by those skilled in the art that aspects of the present disclosure may be illustrated and described herein in any of a number of patentable classes or context including any new and useful process, machine, manufacture, or composition of matter, or any new and useful improvement thereof.

[0016] Aspects of the present disclosure are described herein with reference to flowchart illustrations and / or block diagrams of devices, systems, and methods according to embodiments of the disclosure. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented in various ways. It is also understood that not all the elements listed are required and that the order specified is only by way of example.

[0017] FIG. 1 is an embodiment illustrating a diagram of a traditional catalytic heater 100. The traditional catalytic heater 100 includes a steel case or structure 1, a gas inlet for feeding a distribution system 2, a standoff 3 for creating space for the distribution system and for functioning as an expansion chamber, a dispersion pad 4 for spreading the natural gas evenly, an electric heating element 5 for bringing the catalyst up to reaction temperature (i.e. 250F), a catalyst pad 6 where gas interacts with a hot catalyst and a chemical reaction takes place generating infrared heat and byproducts, a wire mesh screen 7 for holding the catalyst in place while still allowing for adequate oxygen for the reaction, and a structural components 8 for holding the face of the heater on.

[0018] Over time, the interaction between fuel, catalyst, and oxygen gets disrupted due to a chemical contamination with sulfur or some other “catalyst poison,” a physical contamination by impurities or foreign substances in the fuel lines (water, oil, or other liquids; dirt; gunk, etc.), and physical contamination from the environment (high humidity, rain, snow, corrosive salty air).

[0019] To work as effectively and efficiently as possible, the gas must be distributed evenly across the heater face. When gas is not distributed evenly because of physicalPatent Application DOCKET NO.: CATCO-POOl-PCT barriers (like wet or contaminated spots) the result is some areas of high fuel concentration and low fuel concentration. The areas where there’s high concentration there is more fuel than the catalyst can facilitate so there is a higher percentage of the fuel that goes unoxidized and just stays fuel rather than being converted into heat and reaction byproducts. The end result is a less efficient heater and more unoxidized hydrocarbons in the exhaust. This is undesirable for both environmental and performance reasons.

[0020] Eventually, as the problem becomes more severe, the heater is not capable of staying in operation and fails entirely. When the heater becomes defective, it can either be replaced with a new heater or it can be sent to the heater to the manufacturer or a specialist to beremanufactured. Either way, the catalytic heater is deeming it out of service, sometime for 4-6 weeks.

[0021] In the current catalytic heater, the design does not allow for replacement of the dispersion pad because it is behind the heating element. When a heater becomes contaminated by foreign substances, the dispersion pad is also affected, and this disrupts the gas distribution to the catalyst. This results in the heater not meeting original factory standards and operating inefficiently, which causes environmental and performance implications.

[0022] In one embodiment, replacing the dispersion pad requires access to the front of the heater, which is problematic when the face of the heater is inside an enclosure or housing. The result is that many uses would have to uninstall the heater from the housing, which usually results in having to uninstall the electrical and gas connections. In other embodiment, removing the bezel requires hand tools and re-use of hardware like screws and nuts, which is cumbersome and time consuming.

[0023] FIG. 2 is an embodiment illustrating a diagram of a catalytic heater system 200 for an accessible dispersion pad. The catalytic heater system 200 is a novel design on a catalytic heater that allows the replacement of both the catalyst pad and the dispersion pad, herein after referenced together as a cartridge. In one embodiment, the catalyst pad and the dispersion pad are replaceable as a single unit. In another embodiment, these pads are situated in independent slots in the casing and are two separate units and are not a united cartridge. In one embodiment, the cartridge and / or pads are removed and insertable from the side of the catalytic heater 200 where the heat elements remain fixed and are not required to be removed to facilitate the replacement of the pads (separately) or cartridgePatent Application DOCKET NO.: CATCO-POOl-PCT (pads removed as a unit together). As such, even when the catalytic heater 200 is in enclosure, it remains installed and does not require to be uninstalled in order to be replaced. Whereas the pads and / or cartridge containing the catalyst pad and dispersion pads are replaced by sliding away from the electric heating element. In some embodiments, the catalytic heater system 200 contains multiple cartridges. The dispersion pad and catalyst pad may be coupled in a single cartridge or may be in separate cartridges. Further, a catalytic heater system may also be configured where there are multiple catalyst cartridges and multiple dispersion pad cartridges per unit. In yet another embodiment, the catalytic heater system 200 may include multiple catalyst / dispersion pad combo cartridges, multiple catalyst cartridges and a single dispersion cartridge, multiple catalyst cartridges with multiple dispersion pad cartridges, and / or multiple combos.

[0024] FIG. 3 is an embodiment illustrating a block diagram of an catalytic heater system 200 designed with an accessible catalyst and dispersion pad. The catalytic heater system 200 includes a fuel input system 302, standoff 304, dispersion pad 306, one or more heating element 308, and catalyst pad 310. The dispersion pad and the catalyst pad are removable together as a unit from the casing as a cartridge, or separately. In one embodiment, the removal is configured to slide from the side of the catalytic heater 200. The fuel input system 302, standoff 304, and heating element 308 are not removable.

[0025] The fuel input system 302 might be a combination of a fuel distribution block and sometimes includes a manifold, which maybe a tubing that has little holes punched in it where fuel comes out in the expansion chamber. The standoff 304 maybe a perforated material that creates the expansion chamber. It may give space for the fuel to come out of the manifold or distribution block into the back of the catalyst heater system 300 to bleed through the dispersion pad 306. The dispersion pad 306 maybe encased in some kind of a cartridge with the catalyst pad 310 to facilitate easy replacement. The heating element 308 is used for pre-heating the catalyst, which is necessary for starting the reaction. It is located between the dispersion pad 306 and the catalyst pad 310. The catalyst pad 310 contains the actual catalyst for the reaction. It may also be contained within a “cartridge” with the dispersion pad 306 to make it easy to replace.

[0026] In one embodiment, as shown in FIG. 5, the cartridge would consist of a housing that slides in and out of the heater case. FIG. 5 are embodiments of various casings for a catalytic heater casing modified for accessibility dispersion pad. The housing allows for installation and uninstallation by uncoupling and undoing a clamp, clip, latch, fastener,Patent Application DOCKET NO.: CATCO-POOl-PCT screws, or any coupling mechanism. As such, in this embodiment, hand tools are not needed or required. Once the coupling is undone, the cartridge is removed and replaced, and the coupling is reengaged to secure the cartridge in place. This is a very efficient process that is accomplished in minutes rather than hours or days. In some embodiments, the standoff may not be included. The expansion chamber is created via the rails that guide the input of the cartridge. In an embodiment, a space is incorporated to accommodate the fuel input system to allow the gas to spread out via the heater pan. The cartridge may also integrate some perforated metal to facilitate good gas dispersion. Whereas in other embodiments, the gas spreads better without perforated metal or with different material perforation, not metal, that is integrated into the cartridge. Some embodiments utilize a latch while other embodiment may utilize tools as fasteners, where such tools facilitate such fastening. In one embodiment, a specific tool that is custom for the specific is utilized to restrict access to the cartridge to a specific individual or group.

[0027] FIG. 4 is an embodiment illustrating a flow diagram for a dispersion pad replacement method 400. The method 400 illustrates an embodiment of a catalyst and dispersion pada replacement process for a catalytic heater casing with removable components for the pads. The method 400 starts at step 402 and proceeds to step 404. At step 404, the method 400 unlatches a coupler, fastener, screw or the likes to expose the catalyst and dispersion pads of the catalytic heater system 300. At step 406, the method 400 removes pads or cartridge from slot (if a single cartridge) or slots (if pads are separate). At step 408, the pads or cartridge are removed by sliding to the side of the heater. At step 410, new pads or cartridge are secured to replace the old ones. At step 412, the coupler is closed, and all components are secured. At step 416, the catalytic heater system is set to functional setting. The method 400 ends at step 418. In some embodiment, the cartridge slide out from the top or bottom allowing the access port to be located in various locations to accommodate convenience access.

[0028] It will be appreciated by those skilled in the art that changes could be made to the embodiments described above without departing from the broad inventive concept. It is understood, therefore, that this disclosure is not limited to the particular embodiments herein, but it is intended to cover modifications within the spirit and scope of the present disclosure as defined by the appended claims.

Claims

Patent Application DOCKET NO.: CATCO-POOl-PCT What is claimed is:CLAIMS1. A catalytic heater system comprising:a casing;a fuel input system disposed within the casing;a standoff disposed within the casing;at least one heating element disposed within the casing;a dispersion pad; anda catalyst pad, wherein the dispersion pad and the catalyst pad are configured to be removed from and inserted into the casing through an access opening of the casing while the fuel input system, the standoff, and the heating element remain stationary within the casing.

2. The catalytic heater system of claim 1, wherein the dispersion pad and the catalyst pad are contained within a removable cartridge.

3. The catalytic heater system of claim 1, wherein the dispersion pad and the catalyst pad are removable independently.

4. The catalytic heater system of claim 1, wherein the dispersion pad and the catalyst pad are configured to slide into and out of the casing.

5. The catalytic heater system of claim 4, wherein the sliding occurs along rails or guides disposed within the casing.

6. The catalytic heater system of claim 1, further comprising a coupling mechanism configured to secure the dispersion pad and the catalyst pad within the casing.

7. The catalytic heater system of claim 6, wherein the coupling mechanism comprises at least one of a latch, clip, clamp, fastener, and screw.Patent Application DOCKET NO.: CATCO-POOl-PCT8. The catalytic heater system of claim 1, wherein the access opening is located on at least one of a side surface, a top surface, and a bottom surface of the casing.

9. The catalytic heater system of claim 1, wherein the catalytic heater system comprises at least one of multiple dispersion pads, multiple catalyst pads, and multiple removable cartridges.

10. The catalytic heater system of claim 9, wherein the removable cartridges contain at least one of a catalyst pad, a dispersion pad, and a combination of the catalyst pad and the dispersion pad.

11. A removable pad assembly for a catalytic heater comprising:a housing configured to be received within a casing of the catalytic heater;a dispersion pad disposed within the housing; anda catalyst pad disposed within the housing; wherein the housing is configured to be inserted into and removed from the casing while a fuel input system, a standoff, and at least one heating element remain installed within the catalytic heater.

12. The removable pad assembly of claim 11, wherein the housing forms a cartridge configured to contain the dispersion pad and the catalyst pad.

13. The removable pad assembly of claim 11, wherein the housing is configured to slide into and out of the catalytic heater.

14. The removable pad assembly of claim 13, wherein the housing slides along at least one of rails, tracks, and guide structures.

15. The removable pad assembly of claim 11, further comprising a coupling interface configured to secure the housing within the catalytic heater.Patent Application DOCKET NO.: CATCO-POOl-PCT 16. The removable pad assembly of claim 15, wherein the coupling interface comprises at least one of a latch, clip, clamp, fastener, and screw.

17. The removable pad assembly of claim 11, wherein the housing includes at least one perforated structure configured to facilitate fuel dispersion.

18. The removable pad assembly of claim 17, wherein the perforated structure comprises at least one of perforated metal, perforated composite material, and non-metallic perforated material.

19. The removable pad assembly of claim 11, wherein the housing is configured for insertion through an access port located on at least one of a side surface, top surface, and bottom surface of the catalytic heater.

20. The removable pad assembly of claim 11, wherein the assembly comprises at least one of multiple catalyst pads, multiple dispersion pads, and multiple cartridge assemblies.

21. A catalyst and dispersion pads replacement method for replacing pads of a catalytic heater comprising:providing a catalytic heater comprising a casing, a fuel input system, a standoff, a heating element, a dispersion pad, and a catalyst pad;opening an access portion of the casing; removing the dispersion pad and the catalyst pad from the casing while the fuel input system, the standoff, and the heating element remain installed within the casing;inserting at least one replacement pad into the casing; andsecuring the replacement pad within the casing.

22. The catalyst and dispersion pads replacement method of claim 21, wherein removing the pads comprises removing a cartridge containing the dispersion pad and the catalyst pad.Patent Application DOCKET NO.: CATCO-POOl-PCT 23. The catalyst and dispersion pads replacement method of claim 21, wherein removing the pads comprises removing the dispersion pad and the catalyst pad independently.

24. The catalyst and dispersion pads replacement method of claim 21, wherein removing the pads comprises sliding the pads out of the casing.

25. The catalyst and dispersion pads replacement method of claim 24, wherein sliding occurs along at least one of rails, tracks, and guide structures.

26. The catalyst and dispersion pads replacement method of claim 21, further comprising disengaging a coupling mechanism prior to removing the pads.

27. The catalyst and dispersion pads replacement method of claim 26, wherein the coupling mechanism comprises at least one of a latch, clip, clamp, fastener, and screw.

28. The catalyst and dispersion pads replacement method of claim 21, wherein removing the pads occurs without disconnecting at least one of gas connections and electrical connections.

29. The catalyst and dispersion pads replacement method of claim 21, wherein the pads are removed through an access port located on at least one of a side surface, a top surface, and a bottom surface of the casing.

30. The catalyst and dispersion pads replacement method of claim 21, wherein replacing the pads is performed while the catalytic heater remains installed within an enclosure.

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