CATALYTIC BURNER

Abstract

A catalytic burner with electric start is provided. The method of using the catalytic burner comprises an electric-start device that may actuated via a switch or remotely via radio signal.

Claims

1. An electrically activated catalytic burner system comprising: a controller unit comprising a power source and a first pair of electrical contacts coupled to the power source; a catalytic burner system comprising: a fuel reservoir; a second pair of electrical contacts positioned on the fuel reservoir to enable contact between the first and second pair of electrical contacts when the catalytic burner system is positioned in the controller unit; and a catalytic burner disposed above the fuel reservoir and proximal to a wick that extends through a body tube of the catalytic burner into the fuel reservoir; and an electric ignition system.

2. The electrically activated catalytic burner system of claim 1, wherein the electric ignition system comprises a wire connected at a first end to the second pair of electrical contacts and connected at a second end to a wire coil formed around the body tube of the catalytic burner and in proximity to a portion of the wick.

3. The electrically activated catalytic burner system of claim 1, wherein electric ignition system includes a switch adapted to initiate ignition of the catalytic burner.

4. The electrically activated catalytic burner system of claim 1, wherein the controller unit further comprises a wireless radio adapted to receive a signal from a remote to initiate ignition of the catalytic burner.

5. The electrically activated catalytic burner system of claim 2, wherein a ceramic ring is disposed between the wire coil and the body tube.

6. The electrically activated catalytic burner system of claim 2, wherein the wire comprises an insulating sheath.

7. The electrically activated catalytic burner system of claim 1, wherein the body tube comprises perforations along an upper portion of the body tube.

8. An electrically activated catalytic burner system comprising: a controller unit comprising a power source and an electric ignition system; a catalytic burner system electrically coupled to the controller unit, the catalytic burner system comprising: a fuel reservoir; and a catalytic burner disposed above the fuel reservoir and proximal to a wick that extends into the fuel reservoir; and wherein the electric ignition system is coupled to the power source and to the catalytic burner via a wire to provide electrical power to the catalytic burner to begin a catalytic reaction.

9. The electrically activated catalytic burner system of claim 8, wherein the wire comprises a wire coil formed around a body tube of the catalytic burner and in proximity to a portion of the wick.

10. The electrically activated catalytic burner system of claim 8, wherein electric ignition system includes a switch adapted to initiate ignition of the catalytic burner.

11. The electrically activated catalytic burner system of claim 9, wherein a ceramic ring is disposed between the wire coil and the body tube.

12. The electrically activated catalytic burner system of claim 8, further comprising: wherein the catalytic burner system includes a top portion that is movable between a first position and a second position; wherein in the first position air can enter the catalytic burner system through a vent and combusted fuel can exit the catalytic burner system through an opening; and wherein in the second position flow of air through the vent impeded.

13. The electrically activated catalytic burner system of claim 12, further comprising: at least one tab coupled adjacent to the opening; wherein in the first position the at least one tab is moved away from the opening; wherein in the second position the at least on tab is moved towards the opening.

14. A method of using a catalytic burner device, the method comprising the steps of: providing a catalytic burner comprising a housing; providing a wick that contacts a fuel reservoir, wherein the wick is located at a first end of the housing; providing a catalyst substrate, wherein the catalyst substrate contacts a second end of the housing; providing a flow of fuel along the wick; heating the housing by providing electric power to an electric ignition source disposed in close proximity to the housing; and combusting the fuel flowing through the wick.

15. The method according to claim 14, further comprising the step of heating the catalyst substrate with the electric ignition source.

16. The method according to claim 14, wherein the combustion of the fuel heats the housing and the catalyst substrate.

17. The method according to claim 14, further comprising: extinguishing the combusting fuel by closing a first opening and a second opening of the catalytic burner device; and wherein the first opening is disposed above the catalyst substrate.

18. The method of claim 17, wherein closing the first opening comprises moving at least one tab to cover the first opening.

19. The method of claim 17, wherein closing the second opening comprises moving a top portion of the catalytic burner device to cover the second opening.

20. A method of extinguishing a catalytic burner device, the method comprising: moving a top portion of a the catalytic burner device toward a base of the catalytic burner device; wherein the moving causes at least one tab to move into a position that blocks a first opening of the catalytic burner device and blocks a second opening the catalytic burner device; and wherein blocking the first opening and the second opening extinguishes a catalytic burning reaction by inhibiting an inflow of air into the catalytic burner device.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0023] FIG. 1 illustrates a system for electrical activation of a catalytic burner;

[0024] FIG. 2A illustrates a side view of a catalytic burner;

[0025] FIG. 2B illustrates a top view the catalytic burner of FIG. 2A;

[0026] FIG. 2C illustrates a side view of the catalytic burner of FIG. 2A with a catalytic screen removed;

[0027] FIG. 3A illustrates a catalytic burner system with an air vent in an open position;

[0028] FIG. 3B illustrates the catalytic burner system of FIG. 3A, with the air vent in a closed position;

[0029] FIG. 3C illustrates a top view of the catalytic burner system of FIG. 3A, with a set of flaps in an open position;

[0030] FIG. 3D illustrates a top view of the catalytic burner system of FIG. 3A, with the set of flaps in a closed position;

[0031] FIG. 3E illustrates the catalytic burner system of FIG. 3A with a top portion removed; and

[0032] FIG. 3F illustrates the catalytic burner system of FIG. 3A a wick cover removed.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

[0033] Various embodiments of the present invention will now be described more fully with reference to the accompanying drawings. The invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein.

[0034] The use of start-up oxidants and/or fuels is preferred only until the catalyst has been heated to a temperature sufficient to enable operation with a fuel of choice and air as the oxidant. According to embodiments of the invention, methanol, ethanol, propanol, butanol, dimethyl ketone, ethyl acetate, methane, ethane, propane, butane, propylene glycol, dimethylformamide or any other suitable fuel known in the prior art can be used as the working fuel in embodiments of the invention.

[0035] FIG. 1 illustrates a system 100 for electrical activation of a catalytic burner. The system 100 includes a controller unit 102, a catalytic burner device 104, and a power supply 106. The controller unit 102 includes a pair of electrical contacts 108 that are adapted to contact a pair of electrical contacts 110 located, in a typical embodiment, on a bottom of a fuel reservoir 112 of the catalytic burner device 104. The pair of contacts 108 and 110 enables the controller unit 102 to transmit electrical power via a wire 114 to a catalytic burner 116. Power is supplied to the control unit 102 via the power supply 106. In alternative embodiments, the pair of electrical contacts 110 could be located on a side of the fuel reservoir 112. In such an embodiment, the pair of contacts 108 are positioned on the controller unit 102 to enable contact between the pair of contacts 108 and 110.

[0036] In a typical embodiment, the controller unit 102 includes means for controlling an amount of power delivered to the catalytic burner device 104. In a typical embodiment, the means includes a pc board that is adapted to control an amount of volts and amps delivered to the catalytic burner device 104. The controller unit 102 also includes an ignition activator 118. In a typical embodiment, the ignition activator 118 is a button. Activating the ignition activator 118 (e.g., pressing the button) causes the controller unit 102 to supply electrical power to the catalytic burner 116 to heat up the catalytic burner 116 to a temperature sufficient ignite fuel provided to the catalytic burner 116 via a wick 120 that extends from the catalytic burner 116 into the fuel reservoir 112. In other embodiments, the ignition activator 118 may be any of a variety of other switches.

[0037] In some embodiments, the ignition activator 118 may be activated remotely. For example, the controller unit 102 may include a wireless radio (e.g., WiFi, Bluetooth, cellular, and the like) to receive an instruction from a remote device to supply electrical power to the catalytic burner 116. The remote device may be a smart phone, a tablet, a remote, a computer system, and the like. Upon receiving an instruction from the remote device, the controller unit 102 supplies electrical power to the catalytic burner 116.

[0038] In a typical embodiment, the power supply 106 is adapted to connect to a standard wall outlet and converts alternating current (AC) to direct current (DC). DC power is supplied to the control unit 102. In some embodiments, instead of plugging into the wall outlet, the power supply 106 may be a battery pack. In some embodiments, the battery pack may be integrated into the control unit 102. The battery pack may use disposable batteries or a rechargeable pack. In some embodiments, the battery pack may be recharged by connecting the battery pack to a USB port.

[0039] Referring now to FIGS. 2A-2C, a side view of a catalytic burner 116 is shown. The catalytic burner 116 includes a tube body 122, a catalytic screen 124, and a ceramic ring 126 that surrounds an upper portion of the tube body 122. The catalytic screen 124 comprises the catalytic material that, when heated to the necessary temperature, maintains the catalytic reaction. As shown in FIGS. 2B and 2C, the wire 114 is wrapped around the tube body 122 to form a wire coil 115. When electrical power is supplied to the wire coil 115 by controller unit 102, the wire coil 115 is heated. Heat radiates from the wire coil 115 to the catalytic screen 124 to heat the catalytic screen 124. In a typical embodiment, the ceramic ring 126 is positioned between the tube body 122 and the wire coil 115 to prevent the wire coil 115 from shorting to tube body 122. In some embodiments, the ceramic ring 126 may be removed and the wire 114 of the wire coil 115 may be covered with an insulating sheath (e.g., see FIG. 2C). In some embodiments, both the ceramic ring 126 and a wire 114 with an insulating sheath may be used. In a typical embodiment, electrical power is supplied to the wire coil 115 until the catalytic screen 124 has been heated to a temperature suitable for carrying out the catalytic burning process.

[0040] Referring now generally to FIGS. 3A-3E, an embodiment of a catalytic burner system 200 is shown. The catalytic burner system 200 includes a catalytic burner 204 that can be docked as shown in a base 202. In a typical embodiment, the base 202 is similar to the controller unit 102 described above. For example, the base 202 is adapted to supply electric power to the catalytic burner 204. In a typical embodiment, the base 202 includes a pair of electrical contacts that are adapted to mate up with a pair of electrical contacts on a bottom of the catalytic burner 204. Thus, while the catalytic burner 204 is docked in the base 202, electrical power can be supplied to the catalytic burner 204 to begin the catalytic burning process. Once the catalytic burning process has begun, the catalytic burner system 200 may be removed from the base 200 and relocated to a desired location.

[0041] In the embodiment shown in FIGS. 3A-3D, the base 202 includes a power connection 206 to receive power from, for example, a wall outlet. In other embodiments, the base 202 may include a battery to supply the electrical power to the catalytic burner.

[0042] Referring now specifically to FIGS. 3A and 3C, the catalytic burner system 200 is shown in an open position. In the open position, a top portion 230 of the catalytic burner system 200 is extended up to uncover vents 234. The vents 234 permit an inflow of air into the catalytic burner 204 (best seen in FIG. 3E) to facilitate the catalytic combustion process. The top portion 230 includes an opening 236 that permits combusted fuel to exhaust. The opening 236 includes a plurality of tabs 238 (best seen in FIG. 3C) that, in the open position, hang down away from the opening 236 to permit the combusted fuel to exit the catalytic burner 204.

[0043] Referring now specifically to FIGS. 3B and 3D, the catalytic burner system 200 is shown in a closed position. In the closed position, the top portion 230 has been pushed down toward the base 202. Pushing the top portion 230 down causes the vents 234 to become covered up and the plurality of tabs 238 to fold upwards and inwards to seal off the opening 236. With the vents 234 covered, airflow to the catalytic burner 204 is cut off and the catalytic reaction will stop. The plurality of tabs 238 are shaped so that they block the opening 236 when the catalytic burner 204 is in the closed position. As shown in FIG. 3D, the plurality of tabs 238 includes 4 tabs. In other embodiments, the plurality of tabs 238 could be divided into more or fewer tabs as desired so long as the tabs come together in the closed position to block the opening 236.

[0044] Referring now specifically to FIG. 3E, the catalytic burner system 200 is shown with a cover 240 (best seen in FIGS. 3A and 3B) removed. The catalytic burner system 200 includes a fuel reservoir 212 that is similar to the fuel reservoir 112. A cavity 242 is formed in a volume between the base 202 and the fuel reservoir 212. In a typical embodiment, the cavity 242 accommodates components to control the supply of electrical power to the catalytic burner 204. In a typical embodiment, the catalytic burner system 200 includes a control board 250 that controls activation of the catalytic burner 204. The control board 250 applies a power pulse of fixed duration and duty cycle to the wire coil (such as wire coil 115) via wires 214 in response to an activation of the catalytic burner system 200 (e.g., a push of a button by a user, transmission of wireless signal instructing the catalytic burner system 200 to ignite, etc.). In some embodiments, the control board 250 is in communication with a module 252 that is adapted to receive an instruction that the catalytic burner system 200 should ignite. For example, the module 252 may include a receiver for receiving a wireless instruction to ignite, a button or switch that may be actuated to provide an instruction to ignite, or the like. In some embodiments, a power unit 254, which is coupled to the control board 250, provides the power pulse as controlled by the control board 250. In a typical embodiment, there is a lock-out time period, during which a second power pulse is prevented. This lock-out prevents multiple successive applications of power to the heater.

[0045] Referring now specifically to FIG. 3F, the catalytic burner system 200 is shown with the catalytic burner 204 removed. With the catalytic burner 204 removed, a wick 220 resting upon a tab 221 can be seen. The tab 221 helps position the wick 220 proximal to the catalytic burner 204 to maintain the catalytic reaction.

[0046] In certain embodiments of the invention where a tube-style housing is employed, the housing has a wall thickness ranging from 0.005 to 0.04 inches. A preferred wall thickness for a tubular housing is 0.01 inches. In an embodiment of the invention, the catalyzed substrate (20a) is wrapped around and/or over the tubular housing and held in place by connectors at a distance of 0.01 inches to 0.10 inches, and more preferably 0.05 inches from the outer surface of the tube.

[0047] In certain embodiments of the invention, the tubular body contains perforations around the circumferential portion of the tubular housing. The perforations permit a larger volume of vaporized fuel to reach the catalyst, in embodiments where the substrate containing the catalyst surrounds the tubular housing. The perforations may cover up to 90% of the surface of the tubular housing. In an embodiment of the invention, the perforations comprise 2% of the surface and are located along an upper circumferential portion of the tubular housing.

[0048] According to embodiments of the invention, the substrates comprising the catalyst are situated at a suitable distance from the wick to provide a limited region wherein the oxidation reaction temperature is lowered. Distribution of these catalytic surfaces provide for distribution of heat release within the burner. The catalytic substrates are sized to accomplish a nearly even temperature distribution along the burner. A nearly even temperature profile within the burner results in more uniform heat distribution. A more even temperature profile will also result in the lower maximum temperatures for the same heat release. Because the materials of construction of the burner dictate the maximum temperatures, even temperature profiles will increase the heat release possible for the same materials of construction.

[0049] Although various embodiments of the method and system of the present invention have been illustrated in the accompanying Drawings and described in the foregoing Specification, it will be understood that the invention is not limited to the embodiments disclosed, but is capable of numerous rearrangements, modifications, and substitutions without departing from the spirit and scope of the invention as set forth herein. It is intended that the Specification and examples be considered as illustrative only.