Note: Descriptions are shown in the official language in which they were submitted.
FLUID STORAGE AND DISPENSING SYSTEM HEATING UNIT
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ACKGROUND
1. Technical Field
[0002] The present invention relates to warming applications. More
specifically,
the invention relates to methods, systems, and devices for warming fluid
storage and
dispensing systems and fluid stored therein or delivered therewith.
2. The Relevant Technology
[0003] In recent years, environmental concerns have been receiving
significantly
more attention, and various governmental agencies have responded by
implementing
stringent regulations to reduce or prevent pollution. Many of these
regulations and
concerns are directed towards vehicle emissions. For example, medium and heavy-
duty
trucks, especially diesel trucks, and large agricultural equipment, such as
tractors,
produce large amounts of pollutants that are believed to be harmful to the
environment.
Thus, some environmental regulations are requiring that such vehicles now be
made to
produce fewer harmful pollutants or, for existing vehicles, be retrofitted
with systems
that reduce the amount of pollutants released into the environment.
[0004] In order to comply with these environmental regulations, most
diesel engine
manufacturers are using Selective Catalytic Reduction (SCR) technology. The
SCR
system uses diesel exhaust fluid to convert nitrogen oxides ("NOx") emissions
into
nitrogen and water vapor, which are two harmless and natural components. NOx
are an
exhaust element that contributes to acid rain, smog and greenhouse gas levels.
This
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environmental pollutant is a byproduct of the high temperature diesel
combustion
process. The hotter the combustion temperature, the more NOx is created.
[0005] The
Selective Catalytic Reduction system is an emissions-reduction
technology using Diesel Exhaust Fluid (DEF) to deliver near-zero emissions of
NOx.
SCR reduces NOx emissions to extremely minute levels, while at the same time
delivering improved fuel economy and reliability. SCR technology does not
change the
design or operation of the basic engine. Rather, SCR is a simple after
treatment system
that converts NOx in the exhaust stream into harmless gases. Modern diesels
already
use exhaust after treatment systems, called diesel particulate filters, to
control emissions
of other pollutants, such as soot (also known as particulate matter or PM).
SCR works
by injecting diesel exhaust fluid into the exhaust stream only as required.
The diesel
exhaust fluid works with the heat of the exhaust and a catalyst to convert NOx
into
nitrogen and water vapor.
[0006] Diesel
exhaust fluid is one of the key elements of the Selective Catalytic
Reduction process used by many vehicle engines to reduce the amount of harmful
pollutants being introduced into the environment. Diesel exhaust fluid is a
nontoxic
solution of about 67.5% purified water and 32.5% ultra pure automotive grade
urea.
Diesel exhaust fluid is not a fuel or fuel additive. Instead, when injected
into the
exhaust stream and passed over a catalyst, Diesel exhaust fluid helps convert
NOx into
nitrogen gas and water vapor, which are harmless to the environment.
[0007] While SCR
technology can be employed to help vehicles meet the
increasingly more stringent environmental regulation, there are some
challenges that are
associated with this technology. Vehicles equipped with SCR systems have a
tank for
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holding the diesel exhaust fluid used in the SCR system. For over the road
vehicles,
such as semi-trucks, these tanks can be filled at a filling station, such as a
gas station,
that provides diesel exhaust fluid. In other situations, such as agricultural
settings, a
diesel exhaust fluid supply may be located on a farm for refilling farm
tractors, for
example. In either case, the diesel exhaust fluid supply typically includes a
fluid tank
for storing the diesel exhaust fluid and a dispensing system for delivering
the fluid from
the storage tank to the vehicle. One challenge arises when temperatures drop.
For
instance, during cold winter months, temperatures may drop far enough that the
diesel
exhaust fluid freezes. In such a circumstance, the diesel exhaust fluid would
not be able
to be transferred from the storage tank to the vehicle tank. As a result, the
vehicle may
be operated without diesel exhaust fluid, which would lead to pollutants being
introduced into the environment as well as decreased engine horsepower.
[0008] Thus, there is a need for systems, methods, and devices that can
prevent the
diesel exhaust fluid from becoming frozen, and thereby ensure that vehicles'
SCR
systems can be supplied with the necessary diesel exhaust fluid even in very
low
temperature situations.
[0009] The subject matter claimed herein is not limited to embodiments that
solve
any disadvantages or that operate only in environments such as those described
above.
Rather, this background is only provided to illustrate one exemplary
technology area
where some embodiments described herein may be practiced.
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BRIEF SUMMARY OF THE INVENTION
10010] The present invention relates to heating applications, and
particularly to
heating units for heating fluid storage and dispensing systems to prevent
freezing of
fluid stored therein and delivered therewith. In one embodiment, the heating
unit
includes a wall module that forms the walls of the heating unit. The wall
module can be
selectively coupled around fluid system, including a fluid storage tank and a
fluid
dispensing system using one or more fasteners. The one or more fasteners can
include
grommets, snaps, straps, clips, cords, rope, or a combination thereof. The
wall module
can be configured to generate heat and evenly spread the heat over a surface
thereof so
that the fluid system can be evenly warmed to prevent freezing of the fluid
within the
fluid system.
[0011] In one exemplary embodiment, a heating unit is provided for use in
warming
a fluid system and fluid disposed therein. The fluid system can include a
fluid storage
tank and a fluid dispensing system mounted to the fluid storage tank. The
heating unit
used to warm the fluid system can include a wall frame, a wall module, and a
lid
module. The wall frame can be configured to be positioned adjacent the fluid
storage
tank whereby the wall frame generally surrounds the fluid dispensing system.
The wall
module can be configured for arrangement to at least partially define an
interior space in
which the fluid storage tank and the wall frame may be disposed.
[0012] The wall module can include a first cover layer and a second cover
layer
coupled to the first cover layer. The wall module can also include a heating
component
positioned between the first and second cover layers, the heating component
having a
heat generating element for generating heat energy and a heat spreading
element for
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substantially uniformly spreading the heat energy over the wall module. The
heat
spreading element can comprise graphite. The wall module can further include
an
insulation layer positioned respectively at one side of the heating component
and
configured to direct heat energy toward the interior space defined by the wall
module.
100131 The lid module can be configured to rest upon the wall module to
cover and
retain heat within the interior space of the heating unit, whereby the fluid
storage tank,
the fluid dispensing system, and the fluid may be warmed. At least a portion
of the lid
module can be configured to be used as a door to access the fluid storage tank
or the
fluid dispensing system disposed within the heating unit. In some instances,
the lid
module comprises first and second panels pivotally coupled to one another by a
hinge to
enable at least one of the first and second panels to pivot between a closed
position and
an open position.
[0014] In some embodiments, the heating component of the wall module
comprises
a receiving power connector electrically connected to the heat generating
element. The
receiving power connector can be configured to couple to an electrical power
source.
Similarly, the heating component can further include an outgoing power
connector
electrically connected to the heat generating element.
[0015] The interior space of the heating unit can be formed when the wall
module is
selectively secured around at least one of the fluid storage tank and the wall
frame.
Additionally, the wall module can generally secure the wall frame in place
relative to
the fluid dispensing system when the wall module is selectively secured around
the
fluid storage tank and the wall frame.
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[0016] An alternative embodiment provides a fluid system for storing and
dispensing fluid. The fluid system can include a fluid tank adapted to have
fluid
disposed therein and a fluid dispensing system associated with the fluid tank
so that the
fluid dispensing system is in fluid communication with fluid disposed in the
fluid tank.
The system can also include a wall frame adapted to substantially surround the
fluid
dispensing system;
10017] In addition, the system further includes wall module configured to
be
arranged to substantially surround the fluid storage tank, the fluid
dispensing system,
and the wall frame. The wall module comprises a heating component comprising a
heat
generating element for generating heat energy and a heat spreading element for
substantially uniformly spreading the heat energy over a surface of the wall
module.
The heat spreading element can be thermally isotropic in one plane. The wall
module
also includes an insulation layer positioned respectively at one side of the
heating
component and configured to direct heat energy toward the fluid storage tank,
the fluid
dispensing system, and the wall frame. Also, a lid module is provided that is
configured
to rest upon the wall module to cover and retain heat the fluid storage tank
and the fluid
dispensing system so that the fluid within the fluid storage tank may be
warmed. The
lid module and the wall module can include one or more fasteners for
selectively
securing the lid module to the wall module and/or selectively securing the
wall module
around the fluid storage tank and fluid dispensing system. In addition, the
lid can
include flaps arranged to prevent or inhibit wind from entering into the
heating unit. In
some embodiments, the wall module can define a window for providing access to
the
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fluid dispensing system. In such embodiments, the lid module can include an
access
panel for selectively covering the window in the wall module.
[0018] In still another embodiment, a method for warming fluid in a
fluid
system is provided. The fluid system can have a fluid tank for storing fluid
and a fluid
dispensing system mounted to the fluid tank for dispensing fluid from the
fluid tank.
The method includes substantially surrounding the sides of the fluid tank and
fluid
dispensing system with a heating component. The heating component can be
configured to convert electrical energy to heat energy and to distribute the
heat energy
over the fluid tank and fluid dispensing system. The heating component can
include a
heat generating element for converting electrical current to heat energy and a
heat
spreading element comprising carbon thermally coupled to the heat generating
element.
The method further includes substantially surrounding the sides of the fluid
tank and
fluid dispensing system with an insulation layer, such as closed cell foam,
that is
adapted to direct the heat energy from the heating component toward the fluid
tank and
fluid dispensing system. The heating component and the insulation layer can be
selectively secured around the fluid tank and fluid dispensing system.
Additionally, the
method can include substantially covering the fluid tank and fluid dispensing
system
with a lid having an insulation layer for retaining the heat energy under the
lid. The
method can also include providing a thermostat configured to regulate an
operating
temperature of the heating component or to maintain the fluid at a desired
temperature.
[0018a] Also provided herein is a heating unit for use in warming a
fluid system
and fluid disposed therein, the fluid system comprising a fluid storage tank
and a fluid
dispensing system mounted to the fluid storage tank, the heating unit
comprising: a wall
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frame configured to be positioned adjacent said fluid storage tank whereby the
wall
frame generally surrounds said fluid dispensing system; a wall module
configured to be
arranged to at least partially define an interior space in which said fluid
storage tank and
the wall frame may be disposed such that the wall module substantially
surrounds the
sides of the fluid storage tank and the fluid dispensing system, the wall
module
comprising: a first cover layer and a second cover layer coupled to the first
cover layer;
a heating component positioned between the first and second cover layers, the
heating
component comprising an electric heat generating element for generating heat
energy
and a heat spreading element comprising carbon, the heat spreading element
being
configured to draw the heat energy out of the electric heat generating element
and
substantially uniformly spread the heat energy over the wall module to
substantially
evenly distribute the heat energy over the fluid tank and the fluid dispending
system;
and an insulation layer positioned respectively at one side of the heating
component and
configured to direct heat energy toward the interior space defined by the wall
module;
and a lid module configured to rest upon the wall module to cover and retain
heat within
the interior space of said heating unit, whereby said fluid storage tank, said
fluid
dispensing system, and said fluid may be warmed.
19018b] Further
provided herein is a fluid system for storing and dispensing fluid,
the fluid system comprising: a fluid tank adapted to have fluid disposed
therein; a fluid
dispensing system associated with the fluid tank, wherein the fluid dispensing
system is
in fluid communication with fluid disposed in the fluid tank; a wall frame
adapted to
substantially surround the fluid dispensing system; a wall module configured
to be
arranged to substantially surround the fluid storage tank, the fluid
dispensing system,
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and the wall frame, the wall module comprising: a heating component comprising
an
electric heat generating element for generating heat energy and a heat
spreading element
comprising carbon, the heat spreading element being configured to draw the
heat energy
out of the electric heat generating element and substantially uniformly spread
the heat
energy over a surface of the wall module to substantially evenly distribute
the heat
energy over the fluid tank and the fluid dispending system; and an insulation
layer
positioned respectively at one side of the heating component and configured to
direct
heat energy toward the fluid storage tank, the fluid dispensing system, and
the wall
frame; and a lid module configured to rest upon the wall module to cover and
retain
heat the fluid storage tank and the fluid dispensing system, whereby the fluid
within the
fluid storage tank may be warmed.
[0018e1
Additionally provided herein is a method for warming fluid in a fluid
system, the fluid system having a fluid tank for storing fluid and a fluid
dispensing
system mounted to the fluid tank for dispensing fluid from the fluid tank, the
method
comprising: substantially surrounding the sides of the fluid tank and fluid
dispensing
system with a heating component, the heating component being configured to
convert
electrical energy to heat energy and to distribute the heat energy over the
fluid tank and
fluid dispensing system, the heating component comprising a heat generating
element
for converting electrical current to heat energy and a heat spreading element
comprising
carbon thermally coupled to the heat generating element, the heat spreading
element
being configured to draw the heat energy out of the heat generating element
and
substantially evenly distributes the heat energy over a substantial surface
area of the
heating component to substantially evenly distribute the heat energy over the
fluid tank
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and fluid dispending system; substantially surrounding the sides of the fluid
tank and
fluid dispensing system with an insulation layer adapted to direct the heat
energy from
the heating component toward the fluid tank and fluid dispensing system; and
substantially covering the fluid tank and fluid dispensing system with a lid
having an
insulation layer for retaining the heat energy under the lid.
[0019] This
Summary is provided to introduce a selection of concepts in a
simplified form that are further described below in the Detailed Description.
This
Summary is not intended to identify key features or essential features of the
claimed
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subject matter, nor is it intended to be used as an aid in determining the
scope of the
claimed subject matter.
[0020] Additional
features and advantages will be set forth in the description which
follows, and in part will be obvious from the description, or may be learned
by the
practice of the teachings herein. Features and advantages of the invention may
be
realized and obtained by means of the instruments and combinations
particularly
pointed out in the appended claims. Features of the present invention will
become more
fully apparent from the following description and appended claims, or may be
learned
by the practice of the invention as set forth hereinafter.
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BRIEF DESCRIPTION OF THE DRAWINGS
[0021] In order to describe the manner in which the above-recited and other
advantages and features can be obtained, a more particular description of the
subject
matter briefly described above will be rendered by reference to specific
embodiments
which are illustrated in the appended drawings. Understanding that these
drawings
depict only typical embodiments and are not therefore to be considered to be
limiting in
scope, embodiments will be described and explained with additional specificity
and
detail through the use of the accompanying drawings in which:
[0022] Figure 1 illustrates a perspective view of a heating unit according
to one
exemplary embodiment of the present invention, the heating unit being
configured as a
fluid storage and dispensing system wanner;
100231 Figure 2 is a perspective view of the heating unit of Figure 1
illustrating the
lid of the heating unit being opened to provide access to the fluid dispensing
system
disposed therein;
[0024] Figure 3 is an exploded perspective view of the heating unit of
Figure 1 and
an associated fluid storage and dispensing system;
[0025] Figure 4 illustrates a partially exploded view of a wall module of
the heating
unit of Figure 1;
[0026] Figure 5 illustrates an exploded view of the wall module of the
heating unit
of Figure 1, showing the construction of various elements of the heating unit;
[0027] Figure 6 illustrates details of a heat spreading element of the
heating unit of
Figure 1;
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[0028] Figures 7A and 7B illustrate comparative alternate temperature
arrangements
for the heating unit of Figure 1:
[0029] Figure 8 illustrates a partially exploded view of a lid module of
the heating
unit of Figure 1; and
[0030] Figure 9 is an exploded view of internal components for use in the
lid
module of the heating unit of Figure 1.
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DETAILED DESCRIPTION
[0031] The embodiments described herein extend to methods, devices,
systems,
assemblies, and apparatuses for providing heat to a fluid storage and
dispensing system,
such as a diesel exhaust fluid storage and dispensing system. Such are
configured to,
for example, reliably, evenly, and efficiently warm the fluid storage and
dispensing
system components and the fluid associated therewith to maintain the fluid
above a
predetermined temperature, such as freezing, and/or prevent to the components
of the
fluid system fluid from freezing.
[0032] In describing and claiming the present invention, the terms "fluid
storage
system," "fluid dispensing system," "fluid storage and dispensing system," and
the like
(individually or collectively referred to hereinafter as "fluid system"), are
utilized herein
to generically describe a variety of different devices or systems that may
store, retain,
transport, convey, delivery, dispense, etc, a fluid, gas, slurry, or other
material or
mixture. By way of non-limiting example, fluid systems may include tanks,
reservoirs,
hoses, pumps, nozzles, spouts, and the like. The term "fluid system" and
similar terms
may, however, refer to other types of devices and industries, and is not
necessarily
limited to devices used to store or deliver fluids, nor to devices usable in a
particular
industry.
[0033] As used herein, a plurality of items, structural elements,
compositional
elements, and/or materials may be presented in a common list for convenience.
However, these lists should be construed as though each member of the list is
individually identified as a separate and unique member. Thus, no individual
member of
such list should be construed as a de facto equivalent of any other member of
the same
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list solely based on their presentation in a common group without indications
to the
contrary. Further, numerical data may also be expressed or presented herein.
It is to be
understood that such numerical data is used merely to illustrate example
operative
embodiments. Moreover, numerical data provided in range format is used merely
for
convenience and brevity and thus should be interpreted flexibly to include not
only the
numerical values explicitly recited as the limits of the range, but also to
include all the
individual numerical values or sub-ranges encompassed within that range as if
each
numerical value and sub-range is explicitly recited. Furthermore, such
numerical values
and ranges are intended to be non-limiting examples of example embodiments,
and
should not be construed as required for all embodiments unless explicitly
recited as
such in the claims.
[0034] Reference will now be made to the drawings to describe various
aspects of
exemplary embodiments of the invention. It is understood that the drawings are
diagrammatic and schematic representations of such exemplary embodiments, and
are
not limiting of the present invention, nor are any particular elements to be
considered
essential for all embodiments or that elements be assembled or manufactured in
any
particular order or manner. No inference should therefore be drawn from the
drawings
as to the necessity of any element.
[0035] In the following description, numerous specific details are set
forth in order
to provide a thorough understanding of the present invention. It will be
obvious,
however, to one of ordinary skill in the art that the present invention may be
practiced
without these specific details. In other cases, well known aspects of fluid
systems and
heating units, as well as methods and general manufacturing techniques are not
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described in detail herein in order to avoid unnecessarily obscuring the novel
aspects of
the present invention.
[0036] Figures 1-9 and the following discussion are intended to provide a
brief
general description of exemplary devices in which embodiments of the invention
may
be implemented. While a heating unit for warming a diesel exhaust fluid
storage and
dispensing system is described below, this is but one single example, and
embodiments
of the invention may be implemented with other types of systems. Accordingly,
throughout the specification and claims, the term "fluid" is intended to apply
broadly to
any type of material that can be stored and conveyed through a dispensing
system, such
as a system including hoses, pumps, and the like as described herein.
Furthermore,
while the embodiments described below are directed to a fluid system that
includes both
a storage tank and a dispensing system, the present invention may be employed
to warm
a fluid system that includes only a fluid tank or only a dispensing system.
For instance,
the present invention may be configured to provide heat to a fluid tank on a
vehicle,
such as a diesel exhaust fluid tank on a tractor. In other embodiments in
which a fluid
system includes both a storage tank and a dispensing system, the present
invention may
be configured to provide heat to either the storage tank or the dispensing
system.
[0037] Figures 1-9 thus illustrate one example of a heating unit 100
implementing
some aspects of the present invention. The heating unit in Figures 1-9 is only
one
example of a suitable system for warming fluid in a fluid system and is not
intended to
suggest any limitation as to the scope of use or functionality of an
embodiment of the
invention. Neither should the unit be interpreted as having any dependency or
requirement relating to any one or combination of components illustrated in
the unit.
CA 02747270 2011-07-25
[0038] Some embodiments may include a heating unit configured to
substantially
cover the entire outer perimeter of a fluid system, including substantially
the full height
of a fluid storage system as well as an associated fluid system dispensing
system. The
heating unit may include a heating element that provides heat and spreads the
heat over
at least portions of the surface of the heating unit. The heating unit may
also include an
insulation layer to prevent heat from being lost to an environment external to
an
enclosed area formed by the heating unit.
[0039] Figures 1 through 3 illustrate perspective views of an exemplary
embodiment of a heating unit 100 according to the present invention. Heating
unit 100
is generally configured as a fluid system warmer. The term "fluid system
warmer," as
used herein, broadly refers to a heating unit that is configured to
substantially receive,
surround, and/or enclose a fluid system, including storage and/or dispensing
devices,
and fluid stored therein and/or delivered therewith. Thus, heating unit 100
may also be
referred to herein as fluid system warmer 100. In the illustrated embodiment,
for
example, when assembled around a fluid system, heating unit 100 is generally
box
shaped so that it can substantially enclose a fluid system that is to be
warmed by heating
unit 100.
[0040] As seen in Figures 1 through 3, heating unit 100 includes a wall
module 102,
a lid or lid module 104, and a wall frame 106 that define an interior space in
which a
fluid system 108 can be disposed. Wall module 102 can be relatively flexible
so that is
can be wrapped around the outer vertical walls of wall frame 102 and fluid
system 108.
Lid 104 can be supported by wall module 102, wall frame 106, and fluid system
108.
With heating unit 100 assembled as shown in Figures 1-3, fluid system 108 is
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substantially enclosed by heating unit 100 such that heating unit 100 extends
around the
sides and over the top of fluid system 108.
[0041] Heating unit 100 is configured to provide heat to fluid system 108
and fluid
stored therein or delivered therewith. Furthermore, when heating unit 100 is
closed as
shown in Figure 1, heating unit 100 is configured to retain within the
interior space
formed by wall module 102 and lid 104 heat generated by heating unit 100. By
retaining the generated heat within the interior space, heating unit 100 is
able to warm
or maintain the fluid in fluid system 108 at a desired temperature.
[0042] Figure 2 illustrates one manner of accessing fluid system 108 when
heating
unit 100 is used to warm fluid system 108. Fluid system 108 can be accessed by
way of
lid 104. In the illustrated embodiment, lid 104 includes a first panel 110, a
second panel
112, and a third panel 114. First and third panels 110 and 114 function as
doors or
hatches which can be selectively opened and closed to facilitate access to
fluid system
108 within heating unit 100. First and third panels 110 and 114 pivot about
hinges 116
and 118, respectively. Each of first and third panels 110 and 114 can be
partially or
entirely opened to allow for access to fluid system 108.
[0043] For instance, as shown in Figure 2, first panel 110 can be pivoted
180 about
hinge 116 to a fully opened position. For example, first panel 110 can be
pivoted about
hinge 116 so that first panel 110 is folded back and rests upon second panel
112.
Opening first panel 110 as shown in Figure 2 can allow for convenient access
to fluid
dispensing system 120. Third panel 114 can be opened in a similar manner to
that of
first panel 110. In particular, third panel 114 can be pivoted 180 about
hinge 118 to a
fully opened position. For example, third panel 114 can be pivoted about hinge
118 so
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that third panel 114 is folded back and rests upon second panel 112. Opening
third
panel 114 in this manner can allow for convenient access to fluid storage
system 122.
100441 In addition to opening individual panels, multiple panels can be
opened at
the same time. For instance, each of panels 110 and 114 can be opened at the
same time
in the manner described above so as to provide access to both fluid storage
system 122
and fluid dispensing system 120. Similarly, two adjacent panels can be opened
together. By way of example, panels 110 and 112 can be opened together to
provide
greater access to fluid storage system 122 and/or fluid dispensing system 120.
More
particularly, panels 110 and 112 can be pivoted about hinge 118 so as to
uncover fluid
storage system 122 and fluid dispensing system 120. Likewise, panels 112 and
114 can
be pivoted about hinge 116 to uncover fluid storage system 122 and/or fluid
dispensing
system 120.
100451 As used herein, the term "hinge" is intended to broadly encompass
any
suitable structure that allows for panels 110, 112, and/or 114 to pivot open
as described
above. For instance, hinges 116 and 118 may be mechanical hinges that are
specifically
designed to allow for pivoting of adjacent components. Alternatively, lid 104
may
simply be formed with creases, seams, or the like that allow for the above-
described
pivoting of the various panels of lid 104.
100461 Rather than gaining access to fluid dispensing system 120 or fluid
storage
system 122 of fluid system 108 by opening panels 110, 112, and/or 114, lid 104
may
optionally include one or more access panels 124. In the illustrated
embodiment, access
panel 124 extends from first panel 110 down the outside of wall module 102.
When
access to fluid system 108 is desired, access panel 124 can be opened, such as
by lifting
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access panel 124 and folding it on top if first panel 110. Lifting access
panel 124
reveals a window 126 formed in wall module 102 and wall frame 106. With access
panel 124 lifted, access to fluid system 108 can be achieved through window
126.
Because window 126 is positioned on the side of heating unit 100 and since
window
126 is smaller than the openings created when first or third panels 110 and
114 are
opened, less heat is able to escape from the interior formed within heating
unit 100. As
a result, the fluid within fluid system 108 stays warmer without requiring
heating unit
100 to generate significant amounts of additional heat. As will be
appreciated, the
inclusion of window 126 and access panel 124 are optional since the panels of
lid 104
provide access inside of heating element 100
[0047] Lid 104 may include flaps 128 that extend from the peripheral edges
of lid
104. Flaps 128 can be integrally formed with lid 104 or can be secured to lid
104. In
one embodiment, flaps 128 extend about six inched over wall module 102. Flaps
128
can assist in retaining heat within the interior space of heating unit 100.
Likewise. flaps
128 can limit or prevent wind or air from entering the interior space of
heating unit 100.
[0048] With continued reference to Figures 1 and 2, particular attention is
now
directed to Figure 3, in which an exploded view of heating unit 100 and fluid
system
108 is illustrated. As depicted in Figure 3, fluid system 108 includes a fluid
dispensing
system 120 and a fluid storage system 122. In the illustrated embodiment,
fluid storage
system 122 includes a fluid tank or reservoir 130 that is adapted to have
fluid disposed
therein. Tank 130 is a positioned within a cage 132 that includes a support
base or floor
(not shown) upon which tank 130 can rest. Cage 132 can provide additional
structural
support to tank 130 as well as facilitating more convenient transportation of
tank 130. It
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will be understood by one of ordinary skill in the art that cage 132 is not a
necessary
component of fluid system 108. Rather, cage 132 can be used to provide
additional
advantages, such as convenience in transportation of fluid system 108.
[0049] Furthermore, cage 132 can also be used for mounting additional
components
of fluid system 108 thereon. For instance, as shown in Figure 3, fluid
dispensing
system 120 can be mounted on cage 132. Fluid dispensing system 120 can include
various conveyance devices, such as hoses, pipes, spouts, nozzles, pumps, and
the like.
Thus, fluid dispensing system 120 can be used to convey fluid stored within
tank 130 to
a destination, such as a vehicle tank for example. In embodiments where fluid
system
108 does not include cage 132, fluid dispensing system 120 can be mounted or
attached
to tank 130.
[0050] As seen in Figure 3, heating unit 100 is a modular heating unit
including, in
this example, wall module 102, lid module 104, and wall frame 106. Wall frame
106 is
designed to act as a wall around fluid dispensing system 120. More
specifically, wall
frame 106 is formed in a generally squared C-shape so that fluid dispensing
system 120
can fit through the opening in the C-shape, as depicted in Figure 2. Thus,
wall frame
106 acts as an extension of cage 132 or tank 130 so that fluid dispensing
system 120 is
enclosed by structurally sound materials.
[0051] Wall module 102 is designed to be wrapped or otherwise positioned
around
fluid system 108 and wall frame 106, thereby surrounding the vertical sides of
fluid
system 108 and wall frame 106 with wall module 102. Wall frame 106 and cage
132
(or tank 130 when case 132 is on present) act as a support structure for wall
module
102. Wall module 102 can be relatively flexible so that it can be rolled or
folded when
not in use. As a result of its flexibility, wall module 102 can be wrapped
around fluid
systems 108 and/or wall frames 106 of varying sizes and shapes. Regardless of
the
particular design of fluid system 108 or wall frame 106, wall module 102 can
be formed
flexible enough to conform to the overall shape of the particular fluid system
108 or
wall module 106. In any case, fluid system 108 and wall module 106 can act as
a
framework for wall module 102. In some embodiments, wall module 102 may have
structural framing incorporated therein. For instance, wall module may have
one or
more internal frames that provide support to wall module 102. Examples of
support
frames that could be incorporated into wall module 102 are disclosed in U.S.
Patent
Application No. 12/433,974, filed May 1, 2009, and entitled PALLET WARMER
HEATING UNIT.
[0052] In the illustrated embodiment, wall module 102 and lid 104 include
fasteners
134. Fasteners 134 can be used to securely hold wall module 102 around wall
frame
106 and fluid system 108. For instance, fasteners 134 positioned vertically
along
opposing ends 136 and 138 of wall module 102 can be used to couple opposing
ends
136 and 138 together when wall module 102 is positioned around wall frame 106
and
fluid system 108. Additional fasteners 134 positioned along the edges of lid
104 and
around wall module 102 can be used to couple lid 104 to wall module 102.
[0053] In some
embodiments, fasteners 134 may be selectively coupleable to allow
a wall module 102 to be selectively secured around fluid system 108 and wall
frame
106, or to allow one or more of lid panels 110, 112, and 114 to be selectively
secured to
wall module 102 or selectively detached from wall module 102 so that the lid
can be
21
CA 2747270 2018-12-12
CA 02747270 2011-07-25
opened. For instance, in the embodiment illustrated in Figures 1-3, fasteners
134
include clips secured to wall module 102 and lid module 104 via straps.
Alternatively,
fasteners 134 may include any other suitable devices that allow for selective
coupling.
For instance, fasteners 134 may include grommets that can be selectively
secured using
one or more adjustable bungee cords. Likewise, fasteners 134 may includes hook
and
loop type fasteners, such as VELCRO. For more permanent securement, fasteners
134
may be fastened by zip ties, rope, string, wire, or other appropriate
fasteners.
[0054] Attention is now directed to Figures 4 and 5, which illustrate
exploded views
of wall module 102 with exemplary components and the construction of wall
module
102, including materials used to assemble wall module 102. Figure 4
illustrates a
partially exploded view depicting the flexible nature of wall module 102 that
includes a
first cover layer 140, an insulation layer 142, a heating element 144, and a
second cover
layer 146. In some embodiments, heating element 144 includes a heat generating
strip
148 and a heat spreading element 150, each of which will be described in
greater detail
below. Heating unit 100 further includes an incoming electrical connector 152
and,
optionally, an outgoing electrical connector 154. While the example
illustrated in
Figure 4 is illustrated as partially exploded, some finished embodiments may
be
manufactured such that insulation layer 142 and heating element 144 may be
sealed
between first cover layer 140 and second cover layer 146. Sealing processes
and details
will be discussed in more detail below.
100551 Figure 5 illustrates a fully exploded view of wall module 102 so as
to more
clearly illustrate the individual components of wall module 102. As
illustrated in Figure
5, first and second cover layers 140 and 146 are generally planar sheets of
material that
22
CA 02747270 2011-07-25
are disposed on opposing sides of the internal components of wall module 102.
During
construction of wall module 102, first cover layer 140 is positioned as
illustrated in
Figure 5. Next, insulation layer 142 is positioned on top of first cover layer
140 and
heating element 144 is then positioned on top of insulation layer 142.
Finally, second
cover layer 146 is positioned on top of heating element 144. With the various
components of wall module 102 so positioned, the peripheral edges of first and
second
layers 102 and 108 can be joined, sealed, or otherwise closed.
[0056] As described herein, the various components of wall module 102 are
flexible
such that wall module 102 can be wrapped around objects, such as fluid system
108 and
wall frame 106, and rolled or folded up when not in use. In order to ensure
that wall
module 102 and its various components retain their shape and their positions
relative to
one another, the various components of wall module 102 can be attached to one
another.
For example, the various components of wall module 102 can be glued, bonded,
or
otherwise held together. Attaching the components of wall module 102 together
can
help to prevent the components from moving relative to one another within wall
module
102. Nevertheless, wall module 102 can be formed without the components
thereof
being attached together. Rather, the components can be placed next to one
another is
the desired arrangement and generally held in place simply by the
configuration of wall
module 102.
[0057] In embodiments where the components of wall module 102 are attached
together, attaching heating element 144 to insulation layer 142 ensures that
heating
element 144 will stay positioned next to insulation layer 142 and will not
sag, bunch, or
otherwise move within wall module 102. In particular, because insulation layer
142 is
23
CA 02747270 2011-07-25
formed of a stiffer material than heating element 144, attaching heating
element 144 to
insulation layer 142 provides stiffness to heating element 144. While
insulation layer
142 is referred to as being formed of a "stiffer" material, it will be
appreciated that in
some embodiments insulation layer 142 may still be flexible such that it can
be wrapped
around fluids system 108 and wall frame 106, for example. Similarly, heat
generating
strip 148 and heat spreading element 150 can be attached to one another to
ensure that
heat generating strip 148 is properly positioned on heat spreading element
150, even
after wall module 102 is rolled, folded, and used several times. Likewise,
heating
element 144 and/or insulation layer 142 can be attached to first and/or second
cover
layers 140 and 146 to prevent the internal components of wall module 102 from
moving
within first and second cover layers 140 and 146.
[0058] Figure 5
illustrates one exemplary embodiment in which various
components of wall module 102 are attached together. For convenience of
illustration,
incoming electrical connector 152 and outgoing electrical connector 154 are
omitted
from Figure 5. In the embodiment illustrated in Figure 5, there are three
interfaces
between the heating unit components for attachment between the components. As
used
herein, an attachment interface is a surface where two or more components of
wall
module 102 are attached together. The first attachment interface 156 is
between the top
surface of insulation layer 142 and the bottom surface of heating element 144.
As noted
herein, heating element 144 includes a heat generating strip 148 mounted on a
heat
spreading element 150. In the illustrated embodiment, the heat generating
strip 148 is
mounted on the bottom surface of heat spreading element 150 such that heat
generating
strip 148 is positioned between heating spreading element 150 and insulation
layer 142.
24
CA 02747270 2011-07-25
Attachment interface 156 is therefore between the top surface of insulation
layer 142
and the bottom surface of heat spreading element 150, with heat generating
element 148
mounted on heat spreading element 150 therebetween.
100591 The second attachment interface 158 is between the top surface of
heat
spreading element 150 and the bottom surface of second cover layer 146. The
third
attachment interface 159 is between the bottom surface of heat spreading
element 150
and the top surface of heat generating element 148. In other embodiments,
there is only
the first, second, or third attachment interface 156, 158, or 159. Still in
other
embodiments, there are additional attachment interfaces, such as between the
bottom
surface of insulation layer 142 and the top surface of first cover layer 140.
[0060] Attachment interfaces 156, 158, 159 can be created by attaching the
above
identified components of wall module 102 in any suitable manner so that the
components maintain their relative positions one to another. For instance, the
components may be attached to one other with an adhesive (e.g., glue), a
mechanical
fastener (e.g., clips, staples), a chemical bonding agent, a tape, or the
like. Additionally,
each component may be partially or entirely attached to adjacent components.
For
instance, an adhesive may be used to attach entire adjacent surfaces together.
Alternatively, tape may be used in discreet locations to attach adjacent
components
together.
[0061] In one exemplary embodiment, attachment interfaces 156, 158, and 159
are
created using an adhesive between the components of wall module 102. One such
adhesive suitable for attaching together the components of wall module 102 is
30-NF
FASTBONDTm available from 3M located in St. Paul, Minnesota. FASTBONDTm is a
CA 02747270 2011-07-25
non-flammable, heat resistant, polychloroprene based adhesive. In order to
properly
adhere the components of wall module 102 together with FASTBONDTm, the
interfacing surfaces should be clean and dry. With the surfaces prepared, a
uniform
coat of FASTBONDTm is applied to both interfacing surfaces. After applying,
the
FASI'BONDTM is allowed to dry completely, which typically takes about 30
minutes.
Once the FASTBONDTm on both surfaces is dry, the two FASTBONDTm coated
surfaces are joined together.
[0062] For example, when attaching insulation layer 142 to heat spreading
element
150, a coat of FASTBONDTm is applied to the top surface of insulation layer
142 and
the bottom surface of heat spreading element 150 over the top of heat
generating strip
148. Once the FASTBONDTm on each surface is dry, heat spreading element 150 is
positioned on top of insulation layer 142 and the two layers of FASTBONDTm
adhere to
one another. The same process can be followed to attach second cover layer 146
to the
top surface of heat spreading element 150 or to attach the first cover layer
140 to the
bottom surface of insulation layer 142.
100631 In the illustrated embodiment, second cover layer 146 is attached to
heating
element 144 and heating element 144 is attached to insulation layer 142.
Notably,
however, insulation layer 142 and heating element 144 can be left unattached
from first
and/or second cover layers 140 and 146. Not attaching insulation layer 142 and
heating
element 144 to first and/or second cover layers 140 and 146 provides for
flexibility and
give in wall module 102 when wall module 102 is folded, rolled, or wrapped
around an
object. Specifically, wall module 102 is configured to be wrapped around an
object
such that second cover layer 146 is adjacent the object and first cover layer
140 is
26
CA 02747270 2011-07-25
positioned away from the object (see Figure 1 in which first cover layer 140
is
showing). When first and/or second cover layers 140 and 146 are not attached
to
insulation layer 142 and/or heating element 144, first and/or second cover
layers 140
and 146 are able to move relative to insulation layer 142 and heating element
144 and
stretch as wall module 102 is wrapped around an object. Notably, these are
only
examples, and other attachment configurations may be used.
[0064] The
following discussion will now treat additional details and embodiments
of the various components of the wall module 102. Referring now to Figure 6
and as
noted above, in some embodiments heating element 144 includes a heat
generating strip
148. Heat generating strip 148 may be, for example, an electro-thermal
coupling
material or resistive element. In some embodiments, heat generating strip 148
may be a
copper, copper alloy or other conductor. In one embodiment, the conductor is a
network of copper alloy elements configured to generate about 9W of power per
linear
foot of heat generating strip 148. This may be achieved by selection of
appropriate
alloys for heat generating element 148 in combination with selection of
appropriate heat
generating element wire sizes and circuit configurations. The conductor may
convert
electrical energy to heat energy, and transfer the heat energy to the
surrounding
environment. Alternatively, heat generating element 148 may comprise another
conductor, such as semiconductors, ceramic conductors, other composite
conductors,
etc., capable of converting electrical energy to heat energy. Heat generating
strip 148
may include one or more layers for electrical insulation, temperature
regulation, and
ruggedization.
27
CA 02747270 2011-07-25
[0065] Notably, other heat sources may be used in addition to or as
alternatives to
heat generating strip 148. For example, some embodiments may include the use
of
exothermic chemical reactions to generate heat or heating tubes which a heated
liquid
runs through.
[0066] With continuing reference to Figure 6, heat generating strip 148 is
illustrated
with two heat generating conductors 160 and 162. One of the two conductors is
connected to a first terminal of the incoming electrical connector 152 while
the other
conductor is connected to a second terminal of the electrical connector 152.
The first
and second terminals may be connected to electrical sources as appropriate,
such as
generator supplied AC or DC sources, batteries, power inverters, etc. The two
conductors 160 and 162 may be connected at one end to create a closed circuit
allowing
current to flow through the two conductors to generate heat.
[0067] In the example illustrated in Figure 6, the two conductors are
connected
through a thermostat 164. In this example, thermostat 164 includes a bi-metal
strip
based temperature control that disconnects conductors 160 and 162 at a pre-
determined
temperature. Examples of predetermined temperatures may be 33 F, 60 F, 80 F,
100 F, and 120 F. Notably, these are only examples, and other temperatures may
be
alternatively used. This can be used to regulate the temperature of heating
unit 100 to
prevent overheating, or to maintain the temperature at a temperature of about
the pre-
determined temperature.
[0068] Embodiments may be implemented where the temperature is determined
by
selecting a thermostat 164 with a fixed temperature rating. Other embodiment
may be
implemented where the temperature setting of the thermostat can be adjusted to
a
28
CA 02747270 2011-07-25
predetermined temperature at manufacturing time. In some embodiments, the
thermostat may be user accessible to allow a user to adjust the thermostat
settings.
While in the example illustrated the thermostat is located at the ends of
conductors 160
and 162, it should be appreciated that in other embodiments the thermostat may
be
placed inline with one of conductors 160 and 162. Additionally, some
embodiments
may include low voltage control circuitry including temperature control
functionality,
which controls application of power to conductors 160 and 162 through methods
such
as pulse width modulation or any other technique to regulate temperature.
[0069] It should
further be appreciated that embodiments may be implemented
where other temperature or current protections are included. For example,
embodiments may include magnetic and/or thermal circuit breakers, fuses,
semiconductor based over-current protection, ground fault protection, arc
fault
protection, etc. In some embodiments, these may be located at the ends of
conductors
160 and 162 or inline with one or more of conductors 160 and 162 as
appropriate.
[0070]
Additionally, controlling temperature may be accomplished by controlling
the density of heat generating element 148. This may be accomplished by
controlling
spacing between different portions of heat generating element 148 allowing for
more or
less material used for heat generating element 148 to be included in the
heating unit
100. This method may be especially useful when heat generating elements have a
constant Wattage output per length of heat generating element. Thus a longer
heat
generating element 148 provides more heat than a shorter heat generating
element 148.
Figures 7A and 7B illustrate a comparative example where two alternative
embodiments are illustrated. Each of the embodiments illustrates a heating
element 144
29
CA 02747270 2011-07-25
of the same size, but with different heat generating elements densities. The
first
embodiment illustrates a heating element 144A with a less dense heat
generating
element 148A, while the second embodiment illustrates a heating element 144B
with a
more dense heat generating element 14813. In still further embodiments,
heating
element 144 may have different densities within the same heating element 144.
By way
of non-limiting example, wall module 102 may have a heating element 144 with a
heat
generating element 148 that has a certain density near the bottom of wall
module 102
and a different density near the top of wall module 102. For instance, heat
generating
element 148 may be spaced four inches apart on a portion of heating element
144 and 6
inches apart on another portion of heating element 144.
[00711 By way of
the method described herein, the temperature of the fluid within
fluid system 108 can be regulated. In particular, by way of a thermostat or
the selection
and configuration of the heating unit components, such as the spacing of heat
generating
element 148, the temperature of the fluid within fluid system 108 can be
maintained at a
desired temperature or within a desired temperature range. For example, when
diesel
exhaust fluid is stored in fluid system 108, it is important to maintain the
diesel exhaust
fluid above its freezing temperature of about 12 F. If the temperature of the
diesel
exhaust fluid is allowed to drop below about 12 F, the diesel exhaust fluid
could freeze
inside of fluid system 108, which would prevent fluid dispensing system 120
from
conveying the diesel exhaust fluid to a vehicle, for example. Additionally,
freezing of
fluids within pipes and hoses, such as may be included in fluid dispensing
system 120,
can cause the pipes or hoses to crack or otherwise fails, thereby requiring
replacement
or repair. In other applications, the fluid may have a specific range of
operating
CA 02747270 2011-07-25
temperature for optimal performance and/or may spoil if allowed outside of
this
temperature range. Thus, the thermostats, configuration of the heating unit
components,
and the temperature protection mechanisms described herein enable the fluid
within
fluid system 108 to be maintained within a desired temperature range or above
a critical
temperature. By way of example, some desired temperatures may be 13 F, 34 F,
45 F,
60 F, 80 F, and 110 F. Similarly, exemplary temperature ranges may be, for
example,
between 13 F and 50 F, between 65 F and 110 F, between 72 F and 90 F, and
between
75 F and 85 F.
[0072] Returning attention to Figure 6, as noted above, electrical heating
element
144 may further include a heat spreading element 150. In general terms, the
heat
spreading element 150 is a layer of material capable of drawing heat from heat
generating element 148 and distributing the heat energy away from heat
generating
element 148. Specifically, heat spreading element 150 may comprise a metallic
foil,
wire mesh, carbon mesh, graphite, a composite material, or other material.
[0073] Heat spreading element 150 in one embodiment is an electrically
conductive
material comprising carbon. Graphite is one example of an electrically
conductive
material comprising carbon. However, other suitable materials may include
carbon-
based powders, carbon fiber structures, or carbon composites. Those of skill
in the art
will recognize that material comprising carbon may further comprise other
elements,
whether they represent impurities or additives to provide the material with
particular
additional features. Materials comprising carbon may be suitable so long as
they have
sufficient thermal conductivity to act as a heat-spreading element. In one
embodiment,
the material comprising carbon comprises sufficient electrical conductivity to
act as a
31
CA 02747270 2011-07-25
ground connection, as will be discussed in more detail below. The heat
spreading
element 150 may further comprise a carbon derivative, or a carbon allotrope.
[0074] One example of a material suitable for a heat spreading element 150
is a
graphite-epoxy composite. The in-plane thermal conductivity of a graphite-
epoxy
composite material is approximately 370 watts per meter per Kelvin, while the
out of
plane thermal conductivity of the same material is 6.5 watts per meter per
Kelvin. The
thermal anisotropy of the graphite/epoxy composite material is then 57,
meaning that
heat is conducted 57 times more readily in the plane of the material than
through the
thickness of the material. This thermal anisotropy allows the heat to be
readily spread
out from the surface, which in turn allows for more heat to be drawn out of
heating
element 148.
[00751 Heat spreading element 150 may comprise a material that is thermally
isotropic in one plane. The theinially isotropic material may distribute the
heat energy
more evenly and more efficiently. One such material suitable for forming heat
spreading element 150 is GRAFOIL available from Graftech Inc. located in
Lakewood, Ohio. In particular, GRAFOIL is a flexible graphite sheet material
made
by taking particulate graphite flake and processing it through an
intercalculation process
using mineral acids. The flake is heated to volatilize the acids and expand
the flake to
many times its original size. The result is a sheet material that typically
exceeds 98%
carbon by weight. The sheets are flexible, lightweight, compressibly
resilient,
chemically inert, fire safe, and stable under load and temperature. The sheet
material
typically includes one or more laminate sheets that provide structural
integrity for the
graphite sheet.
32
CA 02747270 2011-07-25
[0076] Due to its crystalline structure, GRAFOIL is significantly more
thermally
conductive in the plane of the sheet than through the plane of the sheet. This
superior
thermal conductivity in the plane of the sheet allows temperatures to quickly
reach
equilibrium across the breadth of the sheet.
[0077] Typically, the GRAFOIL will have no binder, resulting in a very low
density, making the heated cover relatively light while maintaining the
desired thermal
conductivity properties. For example, the standard density of GRAFOIL is
about 1.12
g/ml. It has been shown that three stacked sheets of 0.030" thick GRAFOIL C
have
similar thermal coupling performance to a 0.035" sheet of cold rolled steel,
while
weighing about 60% less than the cold rolled steel sheet.
[0078] Another product produced by GrafTech Inc. that is suitable for use
as a heat
spreading element 150 is EGRAF SPREADERSHIELDTM. The thermal conductivity
of the SPREADERSHIELD TM products ranges from 260 to 500 watts per meter per
Kelvin within the plane of the material, and that the out of plane (through
thickness)
thermal conductivity ranges from 6.2 down to 2.7 watts per meter per Kelvin.
The
thermal anisotropy of the material ranges from 42 to 163. Consequently, a
thermally
anisotropic planar heat spreading element 150 serves as a conduit for the heat
within the
plane of heat spreading element 150, and quickly distributes the heat more
evenly over
a greater surface area than a foil. The efficient planar heat spreading
ability of the
planar heat spreading element 150 also provides for a higher electrical
efficiency, which
facilitates the use of conventional power supply voltages such as 120 volts on
circuits
protected by 20 Amp breakers, instead of less accessible higher voltage power
supplies.
In some embodiments, heat spreading element 150 is a planar thermal conductor.
In
33
CA 02747270 2011-07-25
certain embodiments, the graphite may be between 1 thousandth of an inch thick
and 40
thousandths of an inch thick. This range may be used because within this
thickness
range the graphite remains pliable and durable enough to withstand repeated
rolling and
unrolling as the heating unit 100 is unrolled for use and rolled up for
storage.
[0079] Heat spreading element 150 may comprise a flexible thermal
conductor. In
certain embodiments, heat spreading element 150 is formed in strips along the
length of
heat generating element 148. In alternative embodiments, heat spreading
element 150
may comprise a contiguous layer.
[0080] In some embodiments, heat spreading element 150 may include an
insulating
element forrned of a thin plastic layer on both sides of heat spreading
element 150. The
insulating element may additionally provide structure to the heat spreading
material
used in heat spreading element 150. For example, the insulating element may be
polyethylene terephthalate (PET) in the form of a thin plastic layer applied
to both sides
of heat-spreading element 150 comprising graphite. Those of skill in the art
will
appreciate that such a configuration may result in the insulating element
lending
additional durability to heat-spreading element 150 in addition to providing
electrical
insulation, such as electrical insulation from the electrical current in heat
generating
element 148. It should be noted that heating generating element 148 may
include its
own electrical insulation as well as described above.
[0081] In some embodiments, heat spreading element 150 may include a heat
conducting liquid such as water, oil, grease, etc.
[0082] In certain embodiments, heat generating element 148 is in direct
contact with
heat spreading element 150 to ensure efficient thenno-coupling. Alternatively,
heat
34
CA 02747270 2011-07-25
spreading element 150 and heat generating element 148 are integrally formed.
For
example, heat spreading element 150 may be formed or molded around heat
generating
element 148. Alternatively, heat generating strip 148 and heat spreading
element 150
may be adhesively coupled as described above.
100831 Notably, while temperature may be controlled with the use of
thermostats as
described above, other embodiments may implement other design criteria to
control
temperature. For example, some embodiments may use appropriate selection of
heat
spreading element 150 and/or the arrangement of heat generating element 148.
Illustratively, the heat retention properties of heat spreading element 150
may be a
factor in regulating temperatures at which a heating unit 100 will operate.
Further, the
density of heat generating element 148 with respect to the size of heating
unit 100 or
heat spreading element 150 can be used to set the operating temperatures or to
regulate
temperatures.
100841 Returning once again to Figures 4 and 5, Figures 4 and 5 illustrate
an
insulation layer 142. Insulation layer 142 may be used to reflect or direct
heat or to
prevent heat from exiting in an undesired direction. For example, it may be
desirable to
have all or most of the generated heat be directed towards a particular
surface of the
heating unit 100. In the embodiment illustrated in Figures 1 through 3, for
example, it
may be desirable to direct heat towards fluid system 108 while directing heat
away from
an exterior environment in which fluid system 108 is located. In the example
illustrated, it may be desirable to have heat directed towards the side of the
heating unit
100 which includes second cover layer 146, while directing heat away from the
side that
includes first cover layer 140. Insulation layer 142 may be used to accomplish
this task.
CA 02747270 2011-07-25
Some exemplary embodiments of heating unit 100 have been implemented where
about
95% of heat generated is directed towards a desired surface of the heating
unit.
[0085] Insulating layer 142 may include a sheet of polystyrene, cotton
batting,
GORE-TEX , fiberglass, foam rubber, etc. In certain embodiments, insulation
layer
142 may allow a portion of the heat generated by heat generating element 148
to escape
through first cover layer 140 if desired. For example, insulation layer 142
may include
a plurality of vents to transfer heat to first cover layer 140. In certain
embodiments,
insulation layer 142 may be integrated with either first cover layer 140 or
second cover
layer 146. For example, first cover layer 140 may include an insulation fill
or batting
positioned between two films of nylon.
[0086] In some embodiments, first and second cover layers 140 and 146 may
comprise a textile fabric. The textile fabric may include natural or synthetic
products.
For example, first and second cover layers 140 to 146 may comprise burlap,
canvas,
cotton or other materials. In another example, first and second cover layers
140 to 146
may comprise nylon, vinyl, or other synthetic textile material. First and
second cover
layers 140 to 146 may comprise a thin sheet of plastic, metal foil,
polystyrene, or other
materials.
[0087] In manufacturing heating unit 100, heating element 144 and
insulation layer
142 may be sealed between first and second cover layers 140 and 146. As
illustrated in
Figures 4 and 5, first and second cover layers 140 and 146 extend slightly
beyond
heating element 144 and insulation layer 142. This allows first and second
cover layers
140 and 146 to be sealed, such as by using an adhesive, heat welding, or
another other
appropriate method or combination of methods.
36
CA 02747270 2011-07-25
[0088] Lid or lid module 104 can be formed in a similar manner and with
similar
components as wall module 102. For example, Figure 8 illustrates a partially
exploded
view of lid 104. Lid 104 includes a first cover layer 166, two frames 168,
internal
components 170, and a second cover layer 172. First cover layer 166 is
generally
rectangular in shape and has two frames 168 laid next to each other on top of
first cover
layer 166, as shown in Figure 8. The illustrated embodiment of lid 104 also
includes
two sets of internal components 170. One set of the internal components 170 is
positioned within each of frames 168. With frames 168 and internal components
170 so
positioned on first cover layer 166, second cover layer 172 is placed over
frames 168
and internal components 170. The edges of first and second cover layers 166,
172 are
then coupled, attached, or otherwise secured together to hold frames 168 and
internal
components 170 therebetween. Additionally, the edges of first and second cover
layers
166, 172 can cooperate to form flaps 126 described above. For example, edges
of first
and second cover layers 166, 172 can be sized so that when the edges are
joined
together, such as through heat welding, the edges form flaps 126.
Alternatively,
additional material can be attached to first cover layer 166 and/or second
cover layer
172 to form flaps 126.
[0089] Furthermore, the area of first and second cover layers 166, 172
between
frames 168 can be joined together in a number of different ways to form hinges
116 and
118. For example, two walls or panels can be connected together to form the
hinge
therebetween. For instance, first and second panels 110 and 112 can be joined
together
to form hinge 116. Alternatively, a module can be formed and then an operation
can be
performed on the module to form the hinge. For example, lid 104 could be
formed with
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CA 02747270 2011-07-25
two frames 168, internal components 170, and cover layers 166 and 172. Once
lid 104
is so formed, an operation could be performed on lid 104 to create hinge 116
or 118.
Such operations may include various heat welding operations or other
appropriate
operations. In some embodiments, for example, lid 104 may have external vinyl
coverings which may allow for heat welding and heat seams to be formed in the
vinyl.
The heat welding and heat scams formed in the vinyl between frames 168 can
form
hinges 116 and 118. Alternatively, hinges 116 and 118 can be formed of any
mechanical hinge, such as those hinges well known in the art. For simplicity,
lid 104
illustrated in Figure 8 only includes two lid panels and one hinge, rather
than three lid
panels and two hinges as shown in Figures 1 through 3. It will be understood
that lid
104 can include one or more panels and one or more hinges without departing
from the
scope of the present invention.
100901 The size and
shape of lid 104 can be selected to correspond to the shape and
size of the interior space formed by wall module 102 when wall module 102 is
positioned around fluid system 108 and wall frame 106. Additionally, the
internal
components 170 of lid 104 can include all of the heating functionality
described in
connection with heating element 144 of wall module 102. Alternatively,
internal
components 170 may only include insulating and or heat spreading
functionality. In
particular, some embodiments of lid 104 may be implemented where internal
components 170 include heating elements having heat generating elements and
heat
spreading elements similar to those described above in connection with wall
module
102. Alternatively, various elements may not be included in lid 104, including
heat
generating elements and/or heat spreading element.
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CA 02747270 2011-07-25
[0091] For instance, Figure 9 illustrates one exemplary embodiment of
internal
components 170 of lid 104. In the illustrated embodiment, internal components
170
include an insulation layer 174 and a heat spreading layer 176 attached
together at
attachment interface 178. Insulation layer 174 can limit or prevent heat
generated by
heating unit 100 from escaping from the interior space within heating element
100 to an
environment external to heating unit 100. Heat spreading layer 176, as
described above,
can spread heat evenly over at least a portion of the surface of lid 104.
Spreading heat
over the interior surface of lid 104 can assist in evenly heating fluid system
108 and the
fluid disposed therein. It will be appreciated that internal components 170
can include
an insulation layer, a heat spreading element, a heat generating element, or
any
combination thereof.
100921 In some embodiments, lid 104 may be additionally insulated for
better heat
retention. For example, lid 104 may include double, triple, or some other
ratio of
insulation material in insulation layer 174 as compared to wall module 102. As
noted
herein, lid 104 may include flaps 126. Flaps 126 can be secured to other
portions of
heating unit 100 or otherwise arranged to prevent or inhibit wind from
entering heating
unit 100 or heat from escaping heating unit 100. In one embodiment, flaps 126
extend
about six inches over other sides of heating unit 100.
[0093] The embodiment shown in Figures 4 and 6 includes a 7-foot power cord
180
connected to the heat generating element 148. Other cord lengths may also be
implemented within the scope of embodiments of the invention. The power cord
may
additionally be to an incoming electrical connector such as an AC power plug,
bare wire
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CA 02747270 2011-07-25
connector, alligator clip connectors, a cigarette lighter plug connector or
other
appropriate connector for connecting the power cord to a source of power.
[0094] Notably, some embodiments may be implemented with interchangeable
incoming electrical connectors. For example, embodiments may include a kit
that
includes a two-pin auto connector. The kit may further include a wire without
an
additional connector connected to a mating two pin auto connector, a set of
alligator
clips connected to a mating two pin auto connector, and a cigarette lighter
plug
connected to a mating two pin auto connector. A user can then select an
appropriate
incoming electrical connector. For example, a user may select the wire without
an
additional connector if the heating unit is to be hard wired to an electrical
system, such
as an automobile, boat, or other electrical system. Cigarette lighter plugs or
alligator
clip connectors could be selected for more temporary connectors.
[0095] Some embodiments may also include various fault protections. For
example, embodiments may include an incoming electrical connector 152 which
includes ground fault circuit interruption capabilities so as to make heating
unit 100
suitable for use in wet or outdoor environment. Embodiments may include over
current
protection such as breakers or fuses. Embodiments may include arc fault
circuit
interruption capabilities to address problems related to fatigue of wires or
crushing of
wires.
10096] Embodiments may further include provisions for grounding heating
unit 100.
For example, heating unit 100 is illustrated as including an incoming
electrical
connector 152 in the form an AC plug, which includes two power terminals and a
grounding terminal. The power cord 180 may include three conductors, one
connected
CA 02747270 2011-07-25
to each power terminal of the incoming electrical conductor, and the third
connected the
grounding terminal. The two conductors connected each to a respective power
terminal
connect as described above to heat generating element 148. The third conductor
may be
connected so as to ground heating unit 100. This may be done, for example by
including an electrically conductive layer (not shown) in wall module 102
which is
electrically connected to the grounding terminal.
[0097] In an
alternative embodiment, due to the electrically conductive nature of
heat spreading elements 150 when a graphite based material is used for heat
spreading
elements 150, the grounding terminal may be electrically coupled to heat
spreading
element 150. This may be accomplished in one example, by using a ground
coupling in
the form of a spade connector or other connector which passes through a
protective
layer of the heat spreading element so as to be in electrical contact with the
conductive
portions of heat spreading element 150. In one embodiment, the ground
couplings
comprise planar rectangular metal connection blades that would normally be
used as the
hot and/or neutral connection blades of a power coupling such as a power
coupling
which connects to a power source. In one embodiment, ground coupling spade
connector further comprises barbs configured to cut into heat spreading
clement 150
and engage heat spreading element 150 such that the blade does not come loose.
In
alternative embodiments, the blade may be connected to heat spreading element
150
with an adhesive that does not electrically insulate heat spreading element
150 from the
blade. In addition, the plane of the blade may be placed parallel to the plane
of heat
spreading element 150 such that a maximum amount of the surface area of the
blade is
in direct contact with heat spreading element 150. Such a configuration may
increase
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CA 02747270 2011-07-25
the contact area between the two surfaces and results in a better electrical
and physical
connection. Furthermore, such a configuration can leverage the lower in-plane
resistivity of heat-spreading element 150.
[0098] Additionally, some embodiments may include one or more outgoing
electrical connector 154. This may be used, for example to allow chaining of
modules
and/or heating units together. In the example illustrated, the outgoing
electrical
connector 154 is connected electrically to the incoming electrical connector
152 through
conductors passing through wall module 102. Other embodiments may allow the
incoming electrical connector 152 and outgoing electrical connector 154 to be
more or
less proximate to each other as appropriate.
[0099] Grounding terminals of the outgoing electrical connector 154 may be
electrically connected to the grounding terminals of the incoming electrical
connector
152. This may be accomplished by wiring the terminals together or connecting
both
grounding connectors to the same grounding surface, such as a grounding layer,
or to
heat spreading element 150, as described above.
[00100] Some embodiments may further include timing circuitry such that a user
can
select when heating should occur. The timer may be an electronic controlled
device
supplied by the electrical connector 152 and may include internal switching
such as
relays or solid state switches for supplying power to heat generating element
150.
[001011 The modular nature of heating unit 100 facilitates ready assembly of
heating
unit 100. Wall module 102 can be relatively quickly set up and secured
together with
lid 104 placed thereon. Specifically, wall module 102 can be unfolded or
unrolled and
positioned around fluid system 108 and wall frame 106 quickly and easily.
Opposing
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CA 02747270 2011-07-25
ends 136 and 138 of wall module 102 can then be secured together with
fasteners 134
so that wall module 102 is secured around fluid system 108 and wall frame 106.
Lid
104 can then be placed on and, optionally, secured to wall module 102 with
fasteners
134.
[00102] Similarly,
the modular nature of heating unit 100 facilitates the quick and
ready disassembly of heating unit 100. In particular, fasteners 134 allow for
wall
module 102 and lid 104 to be quickly disconnected from one another. Once
disconnected, lid 104 can be removed from wall module 102 and folded or rolled
up for
storage or transport. Likewise, wall module 102 can be removed from fluid
system 108
by decoupling fasteners 134. Once disconnected, wall module 102 can be folded
or
rolled for storage or transport. The folded or rolled wall module 102 and lid
104 can
then be stacked and stored or transported while taking up a relatively small
amount of
space. Being able to disassemble heating unit 100 when not in use or when
being
transported saves significant amounts of storage/cargo space, thus enabling
additional
heating units or other materials to be stored/transported.
[00103] The present invention may be embodied in other specific forms without
departing from its spirit or essential characteristics. The described
embodiments are to
be considered in all respects only as illustrative and not restrictive. The
scope of the
invention is, therefore, indicated by the appended claims rather than by the
foregoing
description. All changes that come within the meaning and range of equivalency
of the
claims are to be embraced within their scope.
43
