Knock-Down Outdoor Flame Heater for Compact Shipping
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Solution Overview
Problem
Traditional flame heaters are heavy and bulky due to their solid metallic construction, making them costly and inefficient for shipping and distribution, as they do not easily disassemble to reduce volume or weight.
Innovation Solution
A knock-down design for both rectangular and pyramid shape flame heaters, utilizing a structural framework with metallic alloys and innovative support members that can be disassembled and reassembled, allowing for compact storage and transportation while maintaining structural rigidity and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional welded metallic construction is used, then structural rigidity and durability are improved, but weight and volume increase making shipping costly
Solution Approach 1:
The heater is divided into multiple separable components including a frame assembly, burner assembly, reflector assembly, and glass panel assembly that can be disconnected and packaged separately. This segmentation allows each component to be optimized for strength-to-weight ratio while enabling compact packaging for economical shipping.
Solution Approach 2:
The patent employs composite construction combining lightweight aluminum extrusions for the frame, stainless steel for burner components, tempered glass for panels, and high-temperature ceramics for reflectors. This multi-material approach achieves the required structural rigidity and heat resistance while minimizing overall weight compared to traditional solid metallic construction.
2Strength
If traditional welded metallic construction is used, then structural rigidity is improved, but shipping volume and distribution cost increase
Solution Approach 1:
By dividing the heater into modular assemblies that can be nested or stacked during packaging, the patent reduces shipping volume from what would be required for a fully assembled unit. The segmented design allows efficient space utilization in shipping containers while maintaining structural integrity through precision-engineered connection interfaces.
3Volume of moving object
If knock-down design is used, then shipping cost and volume are reduced, but assembly complexity increases
Solution Approach 1:
The heater is segmented into major assemblies (frame, burner, reflector, glass panels) that are further divided into sub-components designed for tool-free assembly using interference fits, snap-connections, and friction-based joints. This hierarchical segmentation balances packaging efficiency with assembly simplicity.
Solution Approach 2:
Critical components such as the burner assembly and reflector sections are pre-assembled at the factory with precision alignment features and self-centering mechanisms. This preliminary action ensures that field assembly requires minimal adjustment while maintaining manufacturing precision, reducing both assembly complexity and installation time.
Data Source
AI summary
The present invention is a knock-down design of an outdoor heater. An outdoor heater without resorting to knock-down designs is heavy and bulky. It is costly to ship due to its sheer size and heavy weight. A knock-down design on the other hand resorts to innovative designs in using light weight components with structural reinforcements to increase load bearing capacities thus achieve the same effect as using heavier traditional materials. A knock-down design also resorts to innovative designs in reducing component size so as to occupy a small footprint for ease of packaging and shipment. Consequently, a knock-down design heater can be packaged in a footprint many times smaller than a full size heater and it weights much less than a traditional outdoor heater. It provides cost advantages in pre-sale shipment and general distribution, post-sale transportation convenience as well as ease of relocation during subsequent years of usage.