Description A DEVICE FOR BLOCK-TYPE HEATER

Technical Field

[1] The present invention relates to a block type heater, and more particularly, to a heater which is manufactured in the shape of a block so that block type heaters can be connected with one another in longitudinal and transverse directions so as to heat the entire floor of a room as the occasion demands while ordinarily heating or fomenting a portion of the human body using a block type heater. Also, the present invention relates to a heater which is constructed by dividing a frame into a plurality of cells so that overheating is prevented and heat can be provided in a uniformly distributed manner. Background Art

[2] As is generally known in the art, a heating apparatus, which is widely used in houses, uses a hot water pipe. Since the heating apparatus operates a boiler using fuel such as oil or gas and heats an entire indoor space, it may be effective in the wintertime. However, when it is necessary to heat only a desired portion of the human body in the case of an aged person or a patient as the occasion demands, inconvenience and inefficiency can result in some cases. Also, the radiation of far infrared rays generated from the Korean underfloor heating system called Ondol can not be anticipated.

[3] Under these situations, an electric mattress and an electric blanket are used for local heating. Since these electric products have a problem in that they generate electromagnetic waves noxious to the human body, it is normal that a coated layer is formed on the electric products by coating a substance capable of absorbing the noxious electromagnetic waves. However, while the electric mattress and the electric blanket constructed in this way can intercept electromagnetic waves, they unfortunately cannot transmit far infrared rays helpful to the human body.

[4] Far infrared rays are electromagnetic waves that have a wavelength range of 3 ~

1,000 μm. Because the far infrared rays can perform an excellent heating function compared to visible rays and radiation energy as heat is transferred directly and momentarily, heating can be quickly effected, and a considerable energy saving effect can be accomplished. Therefore, far infrared rays are widely applied for dry heating, heat therapy, health promotion articles, and interior decoration materials. In particular, it has been known that far infrared rays having a wavelength range of 3 ~ 14 μm are absorbed into the human body, are highly effective for the resonance of molecules constituting the organs of the human body, and activate the molecular motion of substances by a resonant absorption function so as to facilitate the synthesis and

enhance the activity of all substances constituting the human body. Hence, far infrared rays can influence the actions of the enzyme system, hormones and bioactive constituents so that metabolism can be promoted. In this way, heat therapy can be provided.

[5] The conventional electric mattress and electric blanket constructed to radiate far infrared rays are generally structured such that a powder obtained by pulverizing yellow earth and minerals (substances for radiating far infrared rays) is coated on the surface of fiber, etc. so that far infrared rays can be radiated from the powder, or the powder is mixed with raw materials for preparing synthetic resin and fiber is produced using the resultant mixture so that far infrared rays can be radiated from the fiber. However, since an amount of powder used for this purpose is small, an amount of far infrared rays radiated from the powder cannot but be insufficient, and consequently the far infrared ray radiation effect is not as substantial as desired. In addition, not only are lots of labor and working hours required to process the substances such as the yellow earth and minerals, but also manufacturing processes are complicated, whereby the manufacturing cost increases.

[6] Also, a conventional electric mat constructed to radiate far infrared rays is generally structured such that minerals for radiating far infrared rays are processed into a specified size and shape and the processed minerals are arranged in a preset form and are heated using heating lines so that far infrared rays can radiate from the minerals, or powder obtained by pulverizing substances for radiating far infrared rays is mixed with other materials, and the resultant mixture is treated to have a preset shape so that far infrared rays can be radiated from the resultant structure. Nevertheless, since the manufacturing processes are complicated, lots of labor and working hours are required. Also, because the substances for radiating far infrared rays are arranged in intervals or only locally, far infrared rays are also generated in intervals or only locally so that far infrared rays cannot be uniformly generated over the entire mat. Further, since the weight and volume of the mat are large, it is difficult to transport and store the mat.

[7] While a piece of flat stone used for flooring a room over a Korean hypocaust radiates a large amount of far infrared rays and provides excellent heat storage and fomentation effect, it can not be applied to the pattern of a modern residence such as an apartment and a western style house, and it is difficult to carry the mat, whereby convenient use of the mat is impeded. Disclosure of Invention Technical Problem

[8] Accordingly, the present invention has been made in an effort to solve the problems occurring in the related art, and an object of the present invention is to provide a heater

which can render heat therapy to or heat or foment a portion of the human body and is constructed to allow several heaters to be connected with or disconnected from one another so as to selectively heat the entire floor of a room as the occasion demands.

[9] Another object of the present invention is to provide a heater in which partition walls are built in a frame so as to prevent overheating and divide the frame into a plurality of cells, and a buffer space is defined among the cells so as to adjust the degree of heat transfer.

[10] Still another object of the present invention is to provide a heater which contains tourmaline and zeolite so as to originally prevent the generation of electromagnetic waves and enhance far infrared radiation effect. Technical Solution

[11] In order to achieve the above objects, according to one aspect of the present invention, there is provided a heater comprising a lower plate having therein heat supply devices for generating heat energy; and an upper plate coupled to the lower plate so as to help blood circulation in the skin using heat and to thereby promote metabolism of the human body.

[12] The lower plate and the upper plate are coupled to each other in such a way as to constitute a heater frame, and the frame is fabricated in the shape of a block as a minimum unit for partially heating or fomenting of the human body and is used in place of a cushion. The minimum unit has transverse and longitudinal lengths of 40 to 50 cm, respectively. A plurality of frames each constituting the block are arranged to adjoin with one another in a transverse or longitudinal direction so as to be used in place of Ondol (flooring containing heated pipes) or the floor of a room so that it is possible to heat or foment the entire human body.

[13] The lower plate has a plurality of barriers which divide a space in the lower plate into a plurality of cells to prevent overheating. In the lower plate divided into the plurality of cells by the barriers, a buffer cell is defined at inner ends of the cells to serve as a buffer space for providing a heat transfer path and preventing overheating. Holes are defined through the barriers which are formed between the respective cells and between the cells and the buffer cell, to serve as heat transfer paths. The lower plate is formed of polycarbonate to improve heat resistance and impact resistance.

[14] The upper plate is mainly formed of nylon, and tourmaline is mixed with nylon so as to radiate far infrared rays and enhance the heating effect. Assuming the sum of nylon, tourmaline and zeolite is 100%, tourmaline has a relative mixing ratio of 6-10%.

[15] In order to form the upper plate, zeolite is mixed with nylon and tourmaline so as to radiate anions and enhance the heating effect. Assuming that the sum of nylon, tourmaline and zeolite is 100%, zeolite has a relative mixing ratio of 1-3%.

[16] The upper plate is formed to have a plane, boundary grooves are defined in correspondence to the respective barriers which form boundaries among the cells, and a width and a depth of the boundary grooves increase from inner ends towards outer ends thereof so that heat transferred from an inside of the heater can be uniformly distributed to an outside, the boundary grooves being defined in a streamline-like shape at the outer ends thereof.

[17] The heat supply devices comprise electric heaters which are composed of heater coils. The heater coils are independently mounted in the respective cells, do not interfere with one another, and are bent several times in a zigzag style so as to be capable of uniformly heating the entire heater, and wherein, in order to prevent overheating, an interval between bent portions of the heater coils is set to be greater than at least 20 mm.

[18] The heater further comprises heat storage devices for storing latent heat of the heater coils so as to store generated heat. The heat storage devices comprise ceramics for heat accumulation capability. Each heat storage device is divided into lower and upper ceramics so as to be capable of accumulating latent heat in both upward and downward directions, the heater coil is placed between the lower and upper ceramics, a receiving groove in which the heater coil is to be received is defined in the lower ceramic, and both ends of the heater coil project out of sidewalls of the lower and upper ceramics so that both ends of the heater coil are exposed to the outside and a remaining portion of the heater coil is covered by the lower and upper ceramics. In order to improve heat accumulation capability of the ceramics, white clay and magnesium oxide are mixed with a ceramic substance at a ratio of 65 to 75% and a ratio of 2 to 3%, respectively.

[19] An inlet housing serving as a port to charge the heat supply devices of the respective cells, a charge lamp for informing whether charging is implemented or not, and an adjustment switch for adjusting a charging time are arranged on an outer surface of the heater frame.

Advantageous Effects

[20] According to the construction of the present invention, advantages are provided as described below.

[21] First, since a frame is designed and manufactured as a unit standard, it is appropriate to mass-produce a heater. Also, since a number of heaters can be used in a manner such that they are arranged in longitudinal and transverse directions in conformity with a user's choice, user convenience can be improved.

[22] Second, since the frame is formed by being divided into an upper part and a lower part, assembly and disassembly can be easily conducted. Also, since a heat supply device is disposed in each cell defined in a lower frame, customers' demands regarding

the prevention of overheating can be met.

[23] Third, since tourmaline and zeolite are mixed in an upper plate formed of nylon, far infrared and anion radiation can be increased, and the generation of electromagnetic waves is prevented.

[24] Fourth, while a lower plate is formed of polycarbonate and the upper plate is formed of nylon, the upper plate is boiled in boiling water, whereby the impact resistance and heat resistance of the frame can be enhanced. Brief Description of Drawings

[25] FIG. 1 is a perspective view illustrating the construction of a heater in accordance with an embodiment of the present invention;

[26] FIGs. 2 and 3 are exploded perspective views illustrating the construction of the heater in accordance with the embodiment of the present invention; and

[27] FIGs. 4 and 5 are an exploded perspective view and a plan view illustrating the construction of a heater in accordance with another embodiment of the present invention.

[28] <Description of Reference Numerals for Main Parts in Drawings>

[29] 100: frame 110: heat supply device

[30] 120: heat storage device 122: lower ceramic

[31] 124: upper ceramic 130: pyrostat

[32] 140: inlet housing 142: charge lamp

[33] 144: adjustment switch 146: LED

[34] 150: lower plate 150': inner case

[35] 152: cell 154: buffer cell

[36] 180: upper plate 182: boundary groove

Best Mode for Carrying out the Invention

[37] Reference will now be made in greater detail to preferred embodiments of a heater according to the invention, examples of which are illustrated in the accompanying drawings.

[38] As shown in FIGs. 1, 2 and 3, a heater according to the present invention is characterized in that the heater is manufactured in the shape of a block such that a frame can be constructed to allow a number of heaters to be used separately or arranged together so as to define a small-sized or large-sized heater system in conformity with a user's choice. Therefore, a heater frame 100 is composed of a lower plate 150 in which a heat supply device 110 and a heat storage device 120 for generating, supplying and storing heat energy are disposed, and an upper plate 180 which can open and close the lower plate 150 and radiate far infrared rays and anions to improve fomenting performance.

[39] As described above, the lower plate 150 and the upper plate 180 are coupled to each

other to constitute the heater frame 100. Therefore, while the frame 100 is fabricated in such a way as to satisfy a specified standard and performs partial heating or fomenting, the net heat of fomenting can be selectively performed by arranging a plurality of frames 100 each fabricated in the unit of a block. For example, when assuming that the frame 110 is fabricated to have a transverse or longitudinal length of 40 ~ 50 cm, the rectangular frame can be used in place of a cushion on the seat of a chair. Also, if the plurality of frames are disposed in a transverse or longitudinal direction, the resultant structure can be used in place of a bed, the Ondol (heating from underneath) of a room, or a floor of a living room.

[40] The inside of the frame 100 is divided into a plurality of cells 152. That is to say, the lower plate 150 is compartmented into several spaces by a plurality of barriers. A buffer cell 154 for serving as a heat transfer space and preventing overheating is defined at the inward end portions of respective cells 152. The lower plate 150 and the barriers are formed integrally with each other using polycarbonate (PC). Holes (not numbered) for serving as heat transfer paths are defined through the barriers which are formed between the buffer cell 154 and the respective cells 152. Therefore, due to the presence of the buffer cell 154, average heat can be maintained at the center portion of the heater.

[41] The reason why the lower plate 150 is formed using PC although it can be formed of

ABS (acrylonitrile butadiene styrene) resides in that PC not only has excellent in- jectability but also can prevent heat from being lost through the bottom or sidewalls of the lower plate 150. In other words, PC has excellent heat resistance and is not deformed up to 130°C (ABS is deformed at 6O ⁰ C) when the heater is heated to a high temperature. In particular, even if shocks are applied to the heater from the exterior or it is dropped onto the floor, since PC exhibits excellent impact resistance, it can be appropriately used for forming a case.

[42] Meanwhile, as shown in FIGs. 4 and 5, the lower plate can be constructed in such a way as to be divided into an inner case 150' and an outer case 150 so as to render an aesthetically appealing outer design. While actual component parts are mounted to the inner case 150', the inner case 150' is concealed and only the outer case 150 can be seen when the lower plate is viewed from the outside. The outer case 150 can have various configurations depending upon designs. It is preferred that an insulation material be contained in the inner surface of the outer case 150 so that heat is not dissipated toward the outer case 150 and thereby unnecessary consumption of heat energy can be prevented. Also, by the fact that the lower plate is divided into the inner and outer cases to have a double-cased structure, it is possible to effectively prevent heat from being dissipated to the outside.

[43] At this time, it is preferred that the inner case 150' be formed of a separate insulation

material different from PC. In the embodiment of the present invention, the inner case 150' is formed of Cerakwool. Cerakwool has a maximum use temperature of l,200°C or over and very low heat conductivity at a high temperature, and thereby ensures excellent heat insulation effect. Since Cerakwool has a density less than that of firebrick, it is characterized in that heat loss due to heat accumulation decreases.

[44] While not shown in a drawing, embossments are formed on the lower surface of the lower plate 150 (the lower surface of the outer case in the case of the double-cased case). Due to this fact, as the lower plate is spaced apart from a floor by a predetermined distance, the lower plate is prevented from tilting even when the floor is uneven. Namely, a plurality of embossments serve as frictional elements for preventing the lower plate 150 from sliding on the floor.

[45] Thus, the structure of the frame and the material of the lower plate play a decisive role in saving energy while improving heat efficiency. Conversely, the material of the upper plate 180 is distinguished from that of the lower plate 150. The upper plate 180 is fabricated while concentrating on improving the functionality in such a way as to radiate far infrared rays and anions. While the upper plate 180 is formed of nylon as a main material, tourmaline and zeolite are mixed with the nylon in predetermined ratios.

[46] Since tourmaline has electrical characteristics for generating electricity, it has a surface activation effect for anions that gradually increases as temperature rises. Also, even when tourmaline is in the form of a fine powder, the characteristics thereof are not changed, and each particle of powder exhibits the electrical characteristics, so that far infrared rays and anions are radiated using the temperature of the human body.

[47] Zeolite has a large number of nano-sized pores, and in general, water molecules completely occupy the pores. If heat of a specific temperature is applied, the water molecules filled in the pores evaporate and emit vapor. Specifically, since zeolite has excellent adsorption and cation exchange performance, it has peculiar characteristics in that it adsorbs and holds other substances such as gas and the like besides moisture and then slowly discharges the adsorbed substances. Thus, zeolite generates and radiates a large amount of anions and supplies fresh oxygen to skin cells at a high speed.

[48] According to an embodiment of the present invention, in the composition of nylon, tourmaline and zeolite, when assuming the sum of the three constituents is 100%, nylon has a mixing ratio of 88 ~ 92%, tourmaline 6 ~ 10%, and zeolite 1 - 3%.

[49] If the mixing ratio of tourmaline exceeds 10%, the reactivity of tourmaline with respect to the human body increases, and the degree of cleansing reaction is likely to become serious. If the mixing ratio of tourmaline exceeds 20%, tourmaline abruptly reacts with the human body, and the cleansing reaction can suddenly occur so that the skin turns red and feels itchy. Conversely, if the mixing ratio of tourmaline is less than 6%, the effect of mixing tourmaline is not so substantial, and a reaction promoting the

health of a human body may not result.

[50] If the mixing ratio of zeolite exceeds 3%, zeolite actively stimulates the motion of tourmaline, by which a queen bee effect is caused. In particular, if the mixing ratio of zeolite exceeds 5%, zeolite strongly stimulates the motion of tourmaline, by which the queen bee effect is likely to become serious. If the mixing ratio of zeolite is less than 1%, the effect of zeolite to stimulate tourmaline becomes insufficient.

[51] The upper plate 180 has boundary grooves 182 which are defined in correspondence to the respective barriers which form boundaries among the cells. The width and depth of the boundary grooves 182 increase from inner ends towards outer ends thereof. Specifically, the boundary grooves 182 are defined in a streamline-like shape at the outer ends thereof. This is to modify heat flow so that heat transferred from the inside of the heater can be uniformly distributed to the outside.

[52] Electric heaters are used as heat supply devices 110. In the embodiment of the present invention, the heat supply devices 110 comprise CG heater coils. The heater coils are independently mounted in the respective cells 152 and do not interfere with one another. The heater coils are bent several times in a zigzag style so as to be capable of uniformly heating the entire heater. Only both ends of the heater coils are in proximity to each other. In order to prevent overheating, the interval between the bent portions of the heater coils is set to be greater than at least 20 mm.

[53] The heat storage devices 120 comprise ceramics which have excellent heat accumulation capability. Each heat storage device 120 is divided into lower and upper ceramics 122 and 124 so as to be capable of accumulating latent heat in both upward and downward directions. The heat supply device 110 is placed between the lower and upper ceramics 122 and 124. That is to say, a receiving groove having the same sectional shape as the heater coil is defined in the lower ceramic 122, and the heater coil is received in the receiving groove. Both ends of the heater coil project out of the sidewalls of the lower and upper ceramics 122 and 124. In this way, both ends of the heater coil are exposed to the outside and the remaining portion of the heater coil is covered by the lower and upper ceramics 122 and 124.

[54] Both ends of the heater coil are formed of carbon. The heat storage device 120 has a horizontal bracket (not numbered) for primarily fastening the heater coil so that it does not fluctuate forward, rearward, leftward nor rightward on a horizontal plane and a pair of vertical brackets (not numbered) for secondarily fastening the heater coil so that it does not fluctuate upward and downward on a vertical plane.

[55] The lower and upper ceramics 122 and 124 are formed of a ceramic substance through ceramics which are well known in the art. At this time, in order to improve heat accumulation capability, white clay and magnesium oxide are mixed with the ceramic substance. Whit clay is mixed at a ratio of 65 to 75%, and magnesium oxide is

mixed at a ratio of 2 to 3%. In order to improve the heat retention capability of the lower and upper ceramics 122 and 124, it is preferred that the resultant mixture be baked at a temperature of 1,200 ⁰ C to 1,40O ⁰ C.

[56] The heat supply devices 110 and the heat storage devices 120 are disposed for the respective cells. Because the buffer cell 154 is defined at the inner ends of the respective cells so as to prevent overheating, the corner portions of the respective cells which adjoin the buffer cell 154 are partially removed or rounded such that cutting parts are formed.

[57] Pyrostats 130 are provided in the respective cells 152. The pyrostats 130 serve as automatic temperature adjusters which always keep the temperature in respective cells constant. Each pyrostat 130 has a bimetal which has two sheets of different metals which possess different coefficients of thermal expansion. The degree to which the bimetal is bent in the form of a bow varies depending upon a temperature change, as a result of which the switches of the heat supply devices are turned on and off.

[58] An inlet housing 140 is installed on a side surface of the lower plate 150 so as to be connected to an electric cord when charging the heater. In general, the electric cord is composed of an electric wire having a predetermined length. One end of the electric cord has a plug which is to be coupled to an outlet, and the other end of the electric cord has a connection terminal which is to be connected with an electric product. The connection terminal can be selectively attached to and detached from the inlet housing 140. After charging is finished, the inlet housing 140 is closed by a cover so that foreign substances are not introduced into the inlet housing 140. A charge lamp 142 is additionally provided on a side of the inlet housing 140 so as to inform whether charging is implemented or not.

[59] Also, an adjustment switch 144 for adjusting a charging time is arranged in the form of a dial. By printing Arabic numbers of 1 to 5 on the adjustment switch 144, the amount of charging time can be selected, whereby user convenience can be improved. The surface of the adjustment switch 144 is formed with depressions and prominences so that the adjustment switch 144 can be easily manipulated.

[60] A color LED 146 for displaying charging time is provided on a side. The LED can be simply composed of an LED for displaying a state before charging, an LED for displaying a state during charging, and an LED for displaying a state after charging, which have different light emitting colors. An alarm bell for informing completion of charging may be additionally provided so as to indicate the charging state in an audible manner.

[61] The temperature of the heater is adjustable within the range of 2O ⁰ C to 7O ⁰ C, and the set temperature is displayed on an LED display window. The temperature can be adjusted even when the heater is being operated as the occasion demands. As described

above, since the pyrostats are installed, heating can be uniformly implemented at a preset temperature.

[62] Hereafter, a method for fabricating the upper plate in the heater according to the present invention, constructed as mentioned above, will be described.

[63] First, tourmaline mineral having purity of no less than 99% and zeolite mineral capable of radiating anions of no less than 2,000 per 1 cc are respectively prepared. Then, tourmaline mineral and zeolite mineral are pulverized into micro-powder. Nylon resin is also prepared in the shape of powder and is mixed with tourmaline powder and zeolite powder prepared as described above. The mixed powder obtained through the primary mixing as described above is formed into briquettes which have a size appropriate for injection. The raw material formed into the shape of briquettes is dried in a sufficient manner. Finally, the dried briquettes are heated to a temperature of 12O ⁰ C, and then, the upper plate is injection-molded.

[64] The completely formed upper plate is boiled at a temperature greater than 100°C. The reason for this is that because of the characteristics of a case and nylon, if the upper plate is not boiled, the strength of the upper plate becomes excessively great, so that, when the upper plate is dropped onto a floor, it is likely to easily break due to poor durability of the product. However, in the case where the upper plate is boiled in boiling water, a phenomenon occurs in which the nylon substance becomes twisted as if it were the entangled rhizomes of arrowroot plants. As a consequence, since the durability of the upper plate is increased, the upper plate can have sufficient elasticity and strength.

[65] At this time, the upper plate is boiled in boiling water of greater than 100°C for 50 to

120 minutes. If the upper plate is boiled for a time less than 40 minutes, durability becomes poor while strength is substantial, whereby the upper plate is likely to easily break. If the upper plate is boiled for more than 150 minutes, as the tourmaline and zeolite constituents which are mixed when forming the upper plate are dissolvable in water, the constituents are likely to be discharged into water. In particular, since zeolite can be seriously discharged into water, attention should be paid not to boil the upper plate for more than the present time.

[66] As is apparent from the above description, the technical concepts of the heater according to the present invention, constructed as mentioned above, reside in that the heater is manufactured in the shape of a block such that a frame can be constructed to allow a number of heaters to be used separately or arranged together in conformity with a user's preference, barriers are built in the frame in order to divide the space in the frame into a plurality of cells and control heat generation so that overheating is prevented and heat can be provided in a uniformly distributed manner, and tourmaline and zeolite are mixed when forming a top plate to come into contact with the skin of

the human body so that generation of electromagnetic waves is prevented and a far infrared radiation effect can be enhanced.

[67] Although preferred embodiments of the present invention have been described for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims.