Information
-
Patent Grant
-
6511290
-
Patent Number
6,511,290
-
Date Filed
Wednesday, August 30, 200023 years ago
-
Date Issued
Tuesday, January 28, 200321 years ago
-
Inventors
-
Original Assignees
-
Examiners
- Look; Edward K.
- McAleenan; James M
Agents
-
CPC
-
US Classifications
Field of Search
US
- 415 2121
- 415 204
- 415 206
- 415 2112
- 415 2141
- 285 322
- 285 323
- 285 331
- 285 361
- 285 376
- 285 377
- 285 378
- 285 379
- 285 380
- 285 381
- 285 382
- 285 383
- 285 384
- 285 385
- 285 386
- 285 387
- 285 388
- 285 389
- 285 390
- 285 391
- 285 13
- 285 14
- 403 365
- 403 367
- 403 371
- 403 373
-
International Classifications
-
Abstract
A blower for a furnace is provided with an exhaust flange having a compressible end portion, and a flexible fitting adapted to receive an exhaust pipe is insertable into an interior of the exhaust flange. A clamp compresses the compressible end portion about the flexible fitting and the exhaust pipe to secure the exhaust pipe to the blower. A drain may be provided adjacent the compressible end portion to remove condensate which may be entrained in the exhaust gases from the exhaust pipe, exhaust fitting and exhaust flange.
Description
BACKGROUND OF THE INVENTION
(1) Field of the Invention
This invention relates to blowers used on high efficiency furnaces and, more particularly, to an exhaust interface formed on a discharge pipe of a blower housing.
(2) Background of the Invention
Blowers are commonly used in high efficiency furnaces (e.g. 90% efficiency) for drawing combustion air into the furnace and for removing exhaust gases from the furnace. Generally, these blowers are located downstream of a combustion chamber or combustion tubes in the furnace, depending upon the style of furnace, and propel exhaust gases out the furnace through an exhaust pipe that vents to outside atmosphere.
FIGS. 1 and 2
show the typical arrangement of a blower
20
of the prior art. The blower
20
includes a blower motor
22
and a blower housing
24
. In
FIG. 1A
, the blower motor has been removed from its center mount
26
on top of the blower housing
24
to show greater detail of the blower housing
24
. The blower housing
24
has an upstanding annular wall
28
extending between a top piece
30
and a bottom piece
32
. The top piece
30
is molded to include the center mount recess
26
to receive the blower motor
22
. The annular wall
28
, top piece
30
, and bottom piece
32
form a volute
34
for the blower housing
24
. An impeller
22
, operably connected to a shaft of the blower motor
22
rotates in the volute
34
when the blower
20
is energized to draw exhaust gases through an inlet hole (not shown) in the center of the bottom piece
32
. The gases are then compressed in the volute
34
and directed into a discharge pipe
36
that extends outward and away from the volute
34
.
FIG. 2
shows the general arrangement of the blower installed in a furnace
38
. The blower is mounted on a blower mounting surface
40
on the furnace
38
where the inlet hole (not shown) of the blower housing
24
is positioned to allow the impeller to draw exhaust gases directly from the combustion chamber or combustion tubes (not shown) into the blower housing
24
. The discharge pipe
36
is coupled to an exhaust pipe
42
using a double booted rubber gasket
46
to vent the exhaust gases to atmosphere. In the prior art, the blower housing
24
and exhaust pipe
42
are commonly made from a polypropylene or polyvinyl chloride (PVC) plastic material.
Greater detail of the double booted gasket
46
of the prior art is shown in FIG.
1
B. The double booted rubber gasket
46
is a cylindrically shaped tubular member with first and second ends
48
,
50
. The first end
48
has a first internal annular groove
52
that forms a first annular socket
54
that fits on a boss end
56
of the discharge pipe
36
of the blower housing
24
. To secure the double booted rubber gasket
46
to the discharge pipe
36
of the blower housing
24
, a first hose clamp
58
is typically used. The second end
50
of the double booted gasket
46
has a similar arrangement with a tubular insert
60
concentrically disposed within the gasket
46
to form a second internal annular groove
62
. The exhaust pipe
42
is received within the second internal annular groove
62
and is secured to the double booted gasket
46
by tightening a second hose clamp
64
. The second internal annular groove
62
has a groove root
66
with baffles
68
to collect condensate that is entrained in the exhaust gas stream. This condensate is collected at the root
66
and is removed from the double booted gasket
46
through drain portals
70
on the sides of the double booted gasket
46
that communicate with the groove root
66
.
The use of the double booted gasket
46
has several drawbacks. The double booted gasket
46
is a complex part that must be manufactured in an intricate molding process. Because the gasket
46
is an added part to be fitted between the blower housing
24
and the exhaust pipe
42
, it complicates the installation process. Further, as is readily apparent to those of skill in the art, a pair of pipe clamps must be aligned and screwed tight to complete the installation which takes some time and careful attention. The added part also increases the expense of the blower
20
and the installation of the blower
20
on the furnace
38
.
The double booted gasket
46
must also be made from a relatively strong material that must withstand industry standards for mechanical strength and exhaust system integrity. Generally, in this application on a high efficiency furnace, the double booted gasket
46
must be able to maintain its connection to the discharge pipe
36
with a 25 ft-lb torque exerted on the exhaust pipe
42
(the “twist” condition). The gasket
46
must also maintain its connection to the discharge pipe
36
with a 50 lb. parallel pull out force exerted axially along the exhaust pipe
42
(the “pull-out” condition). Because the double booted gasket
46
has one hose clamp connection with the discharge pipe
36
and another hose clamp connection with the exhaust pipe
42
, the double booted gasket
46
has two points for failure. Thus, the gasket
46
is susceptible to failure at either one of these two connections which represent the most likely point of failure.
What is needed in the art is a method of improving the connection between the blower housing
24
and the exhaust pipe
36
such that the industry standard mechanical tests for strength and exhaust system integrity are maintained while providing a less expensive part with an easier install procedure.
SUMMARY OF THE INVENTION
It is, therefore, an object of the present invention to provide an exhaust interface for a blower that simplifies the connection between the blower housing and the exhaust pipe while meeting the requisite industry standards for strength and exhaust system integrity.
The blower of the present invention includes a blower housing and a blower motor. The blower housing has an impeller and a discharge pipe for directing exhaust gases out and away from the blower. The discharge pipe has a first end that is formed adjacent the housing and an opposite second end that is spaced from the housing, or volute. The second end includes an exhaust flange with an annular socket and a plurality of resilient teeth extending axially outwardly from the second end and circumferentially spaced around the annular socket.
The blower includes an exhaust fitting that has an outer cylinder with a front end and an axially opposite back end, and a generally tubular insert disposed within the outer cylinder. An annular back wall extends between the outer cylinder and tubular insert. The tubular insert is attached to the annular back wall at the back end of the outer cylinder such that the tubular insert extends outward and away from the back wall and through the front end of the outer cylinder. The tubular insert forms an annular groove in the front end of the exhaust fitting.
The exhaust fitting is received in the annular socket of the exhaust flange, and the exhaust pipe is received in the annular groove. A clamping means such as preferably a pipe clamp for radially compressing the plurality of circumferentialy spaced teeth on the exhaust flange may be used to secure the exhaust pipe within the exhaust fitting and the exhaust fitting within the annular socket of the exhaust flange.
The exhaust fitting and exhaust flange are preferably keyed so that the exhaust fitting may be assembled in the annual socket on the exhaust flange in only one circumferential orientation. The exhaust flange preferably has an integral drain for removing condensate in the exhaust gases. In this configuration, the exhaust fitting may have a guttering system adjacent the back wall of the annular groove that directs condensate from the exhaust pipe into the drain on the exhaust flange. Preferably, each of the circumferentialy spaced teeth has a proximal end which is cantileverly attached to the second end of the discharge pipe and a distal end which is spaced away from the proximal end. The distal end of each of the teeth may have an annular ridge that extends radially outward and engages a portion of the clamping means to prevent the clamping means from sliding off the teeth when the clamping means is tightened around the teeth. The clamping means is preferably a pipe clamp, as in the prior art. The discharge pipe, exhaust flange, and volute of the blower housing are preferably monolithically constructed as the exhaust flange may be molded as a mold insert as the blower housing is molded.
BRIEF DESCRIPTION OF THE SEVERAL VIEW OF THE DRAWINGS
Further objects and features of the invention are revealed in the following detailed description of the preferred embodiment of the invention and in the drawings, wherein:
FIG. 1A
is a perspective view of a blower housing of the prior art;
FIG. 1B
is a cross-sectional side view of a double booted gasket of the prior art;
FIG. 2
is an exploded view of the blower and double booted gasket of the prior art;
FIG. 3
is an exploded view of a blower of the present invention;
FIG. 4
is a partial, front, perspective view of an exhaust fitting inserted into the blower housing of
FIG. 3
;
FIG. 5
is a top plan view of a blower housing of the blower of
FIG. 3
with a partial, sectional view of an exhaust flange;
FIG. 6
is a rear, perspective view of the exhaust fitting of
FIG. 4
; and
FIG. 7
is a front, perspective view of an exhaust fitting of FIG.
4
.
Corresponding reference characters indicate corresponding parts throughout the several views of the drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 3
shows a blower
100
of the present invention in its arrangement in a furnace
101
. The blower
100
includes a blower motor
102
and a blower housing
104
. The blower housing
104
has an annular upstanding wall
106
extending between a top piece
108
and bottom piece
110
. The bottom piece
110
is mounted on a blower mounting surface
112
in the furnace
101
, or the furnace bonnet, and has a center hole (not shown) through which exhaust gases are drawn into the blower housing
104
.
FIGS. 4 and 5
provide greater detail of the blower housing
104
. The top piece
108
has an annular recessed area
114
adapted to hold the blower motor
102
. The top piece
108
has mounting screws
116
for securely fastening the motor
102
to the blower housing
104
and a through hole
118
to allow a shaft on the blower motor
102
to pass into the housing
104
. The blower motor shaft (not shown) is operably connected to an impeller (not shown) rotatably disposed within the blower housing
104
. The upstanding annular wall
106
, and top and bottom pieces
108
,
110
form a volute
120
. The blower housing
104
also includes a discharge pipe
122
for directing exhaust gases pressurized in the volute
120
out of the blower housing
104
. An outermost end
124
of the discharge pipe
122
has an exhaust flange
126
that allows the blower
100
to be connected to the exhaust pipe
42
.
The Figures show a blower housing
104
having a top piece
108
with the discharge pipe
122
, an upstanding wall
106
, and exhaust flange
126
, and a relatively flat, separate bottom piece
110
. It is also possible to construct the bottom piece with the upstanding annular wall, discharge pipe, and exhaust flange and a separate top piece that attaches to the bottom piece to enclose the blower housing. The bottom piece may also have the upstanding wall, discharge pipe, and exhaust flange constructed monolithically. The bottom piece may also be made from a polypropylene material.
FIG. 4
shows an exhaust fitting
128
of the present invention installed in the exhaust flange
126
to form an exhaust interface
130
for the blower
100
and the exhaust pipe
42
. The exhaust flange
126
is formed on the outermost end
124
of the discharge pipe
122
and has an outer cylinder portion
132
extending around the discharge pipe
122
. The outer cylinder portion
132
has a rear annular wall
134
that connects the outer cylinder portion
132
to the discharge pipe
122
and forms an internal shoulder
136
inside the outer cylinder portion
132
for the exhaust fitting
128
to rest against when the exhaust fitting
128
is installed in the exhaust flange
126
. The rear annular wall
134
and internal shoulder
136
are shown in the partial sectional view in FIG.
5
. The outer cylinder portion
132
has an inner diameter that is preferably larger than the bore of the discharge pipe
122
. This arrangement prevents a restriction in the discharge path of the exhaust gases when the exhaust fitting
128
is installed in the exhaust flange
126
. The rear annular wall
134
and outer cylinder portion
132
define an annular socket
138
on the end of the discharge pipe
122
. The annular socket
138
has an interior that is sized to receive the exhaust fitting
128
and prevent the exhaust fitting
128
from twisting out of the annular socket
138
.
As shown in
FIGS. 4 and 5
, the outer cylinder portion
132
of the exhaust flange
126
has an annular ridge
140
, and a plurality of axial slots
142
extending inwardly from the outermost edge
124
of the outer cylinder portion
132
. The slots
142
are circumferentially spaced around the annular socket
138
and form a plurality of resilient teeth
144
. Each of the teeth
144
has a proximal end
146
and distal end
148
. The proximal end
146
is cantileverly attached to the outer cylinder portion
132
so that the tooth
144
may flex radially inward into the annular socket
138
. The distal end of each tooth
148
includes a portion of the annular ridge
140
formed on the outermost edge
124
of the outer cylinder portion
132
.
To allow the teeth
144
to compress radially inward, the outermost edge of each of the slots
142
is wider than the portion of the slot
142
near the proximal edge of each tooth
144
. To provide a keying alignment between the exhaust flange
126
and the exhaust fitting
128
, a slot in the outer cylinder portion
132
is preferably widened to function as a key slot
150
.
Positioned between the outermost edge
124
of the outer cylinder portion
132
and the rear annual wall
134
is a drain
152
. The drain
152
extends outward and away from the outer cylinder portion
132
and communicates with the annular socket
138
. Preferably, the drain
152
, the outer cylinder portion
132
and the discharge pipe
122
are monolithically formed.
FIGS. 6 and 7
show the preferred embodiment of the exhaust fitting
128
. The exhaust fitting
128
has a first tube portion
154
and a second tube portion
156
with each tube portion
154
,
156
having first and second ends
158
,
160
and an annular side wall
162
extending between the first and second tube portions
154
,
156
at the first end
158
. Preferably, the second tube portion
156
is positioned concentrically within the first tube portion
154
. The arrangement of the first and second tube portions
154
,
156
and the annular side wall
162
create an annular groove
164
in the second end
160
of the exhaust fitting
128
. Preferably, the second tube portion
156
is axially longer than the first tube portion
154
such that the second tube portion
156
extends through the second end
160
of the first tube portion
154
.
The first tube portion
154
preferably has a circumferential slot
166
which is relieved through the annular side wall
162
. The slot
166
communicates with the annular groove
164
, and when the exhaust fitting
128
is installed in the exhaust flange
126
, the slot
166
ultimately communicates with the drain
152
. The first tube portion
154
has an outer surface
168
and a key
170
extending outward from the outer surface
168
that is received in the key slot
150
on the exhaust flange
126
when the exhaust fitting
128
is installed in the exhaust flange
126
. The key arrangement between the exhaust flange
126
and the exhaust fitting
128
ensures alignment and communication between the slot
166
and the drain
152
to ensure the removal of condensate entrained in the exhaust gas. Preferably, a plurality of stops
172
are circumferentialy spaced around the inside of the annular groove
164
. The stops
172
are arranged in the annular groove
164
to permit communication around the groove
164
and into the slot
166
and drain
152
. The stops
172
hold the end of the exhaust pipe
42
off the bottom of the annular groove
164
, when the exhaust pipe
42
is installed in the exhaust fitting
128
. This arrangement permits condensate forming in the exhaust pipe to collect in the annular groove
164
, flow to the slot
166
, and out of the exhaust system via the drain
152
.
The first tube portion
154
preferably has a circumferential lip
174
extending radially outward on its outer surface
168
on the first end
158
. The lip
174
functions as a positive stop to abut the circumferential ridge
140
on the outer cylinder portion
132
of the exhaust flange
126
when the exhaust fitting
128
is installed in the exhaust flange
126
. The outer surface
168
of the first tube portion
158
is sized to be slidingly received in the annular socket
138
of the exhaust flange
126
. When the exhaust fitting
128
is installed in the exhaust flange
126
, the annular side wall
162
of the exhaust fitting
128
preferably abuts the internal shoulder
136
in the annular socket
138
of the exhaust flange
126
. The depth of the annular socket
138
provides proper support for the exhaust fitting
128
.
During installation of the blower
100
in the furnace
101
and connection of the blower
100
to the exhaust pipe
42
, the blower
100
may be attached to the blower mounting surface
112
and the exhaust fitting
128
may be inserted into the exhaust flange
126
. Preferably, the exhaust fitting
128
is assembled with the exhaust flange
126
in only one orientation using the key
170
and key slot
150
arrangement on the exhaust interface
130
. Once the exhaust fitting
128
is inserted in the exhaust flange
126
, the exhaust pipe
42
may be inserted into the annular groove
164
such that the exhaust pipe
42
rests upon the stops
172
inside the annular groove
164
. A clamping means
176
, such as band clamp or common hose clamp, may be installed around the circumferentialy spaced teeth
144
on the outer cylinder portion
132
. The clamping means
176
may then be tightened, radially deflecting the teeth
144
inward to compress the teeth
144
against the outer surface
168
of the first tube portion
154
and the exhaust pipe
42
.
Because the exhaust fitting
128
is preferably made from a rubber material, the pressure exerted from the teeth
144
may be transmitted directly to the exhaust pipe
42
to ensure a tight fit. The size and length of the annular socket
138
and the annular groove
164
allow the exhaust interface
130
to meet the industry standards for torque and parallel force failure.
In operation, condensate entrained in the exhaust gases is collected in the annular groove
164
provided in the exhaust fitting
128
and is directed to the slot
166
where it is removed to the appropriate collection facility in the furnace
101
.
As will be appreciated by those skilled in the art, the exhaust interface
130
of the present invention is less complex than the prior art and uses less parts, thus decreasing the cost of the blower
100
. The exhaust flange may be formed with a die insert that is installed in the mold when forming the conventional blower.
Although a band clamp is shown as the clamping means
176
to radially compress the teeth
144
inward to secure the exhaust pipe
42
in the exhaust fitting
128
and the exhaust fitting
128
in the exhaust flange
126
, other clamping means may be used. The clamping means may include a ring which is threadably attached to the outer cylinder portion of the discharge pipe. The ring may be rotated and tightened so as to compress the teeth radially inward. The clamping means may also include a hose clamp or other strap clamp which is tightened by tangential force exerted on the strap.
As various changes could be made in the above construction without departing from the scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in any limiting sense. The invention therefore shall be solely limited by the scope of the claims set forth below.
Claims
- 1. A blower for a furnace comprising a blower housing having an exhaust flange, said exhaust flange having a compressible end portion, and a flexible fitting inserted within said flange and adapted to receive an exhaust pipe that receives and evacuates gases from within said blower, and a clamp for compressing the compressible end portion about the flexible fitting and the exhaust pipe to thereby secure the exhaust pipe to the blower wherein said compressible end portion further comprises a plurality of teeth formed in said end portion and about the periphery thereof;each of said teeth has a ridge formed substantially at its end, said ridge comprising an upstanding portion extending radially outward therefrom; each of said exhaust flange and exhaust fitting have a guttering system for collecting condensate within the exhaust pipe, exhaust flange, and exhaust fitting and directing it out of said blower and exhaust pipe; and a key formed in one of said exhaust flange and exhaust fitting and a slot formed in the other of said exhaust flange and exhaust fitting to thereby restrict the assembly thereof to a given orientation and place the guttering system of each in communication; and said fitting further comprises a stop for positioning the exhaust pipe within the fitting.
- 2. The blower housing of claim 1 wherein the exhaust fitting has a circumferential lip on its outer surface that abuts the ridge on each of the exhaust flange teeth when the fitting is installed in the flange.
- 3. The blower housing of claim 1 wherein said slot is formed on said exhaust flange between two adjacent teeth.
- 4. The blower housing of claim 1 wherein said fitting has a groove on one of its side faces to receive the exhaust pipe and the stop is formed in a base of the groove thereby positioning a butt end of the exhaust pipe in a spaced apart relationship from the groove base.
- 5. The blower housing of claim 1 wherein said exhaust flange and blower housing, are monolithically formed.
- 6. The blower of claim 1 wherein said fitting includes a cylindrical portion for extending into the exhaust pipe as it is assembled to the blower.
- 7. The blower of claim 6 further comprising a motor secured to an impeller within the blower.
- 8. The blower housing of claim 6 wherein the exhaust fitting cylindrical portion has an inner surface for containing the gases as the gases pass from the exhaust flange to the exhaust pipe, said cylindrical portion inner surface provides a substantially uniform transition from the exhaust flange to the exhaust pipe.
- 9. An exhaust fitting for connecting an exhaust pipe to a discharge pipe of a blower housing for a furnace wherein the blower housing discharge pipe extends outward from the housing and directs exhaust gases from an interior of the blower housing to the exhaust pipe, the discharge pipe has a distal end and flexible teeth circumferentially spaced around the distal end, the exhaust fitting comprising:a tube shaped member having a generally cylindrical exterior surface dimensioned to be received in an interior of the discharge pipe and a generally cylindrical interior surface for containing the exhaust gases when the tube shaped member is inserted in the discharge pipe, the tube shaped member having a groove on one of its end faces between the cylindrical exterior and interior surfaces dimensioned to receive the exhaust pipe, the tube shape member being made of a resilient material such that when the exhaust pipe is inserted in the tube member groove and the tube shaped member is inserted in the discharge pipe, compression of the discharge pipe circumferential teeth against the exhaust fitting cylindrical exterior surface secures the exhaust pipe in the groove.
- 10. The exhaust fitting of claim 9 further comprising at least one circumferential slot through the tube shaped member exterior surface into the groove and a keyed relationship between the exhaust fitting and the discharge pipe that allows the tube member circumferential slot to be aligned with a drain port provided on the discharge pipe when the exhaust fitting is installed in the discharge pipe distal end.
- 11. The exhaust fitting of claim 10 further comprising at least one stop formed in a base of the tube shaped member groove to hold a butt end of the exhaust pipe in a spaced apart relationship from the groove base when the exhaust pipe is installed in the groove.
- 12. The exhaust fitting of claim 10, wherein the tube shaped member cylindrical exterior surface has a circumferential lip that engages the discharge pipe distal end when the exhaust fitting is installed is installed in the discharge pipe distal end.
- 13. A discharge pipe for a blower housing for a furnace, the discharge pipe extending out from the blower housing to direct exhaust gases away from the blower housing, the discharge pipe having a center axis extending along its length, the discharge pipe comprising:a distal end of the discharge pipe with a plurality of axial slots and teeth on the discharge pipe distal end circumferentially spaced about the distal end; a drain formed on the discharge pipe distal end; and an exhaust fitting insertable into the discharge pipe distal end, the exhaust fitting having an outer tube portion and a inner tube portion concentrically disposed within the outer tube portion with a rear annular wall extending between the outer and inner tube portions thereby forming an annular groove within the exhaust fitting to receive the exhaust pipe when the exhaust pipe is installed in the exhaust fitting, the groove having a drain hole that communicates with the discharge pipe drain when the exhaust fitting is installed in the discharge pipe distal end.
- 14. The discharge pipe of claim 13 further comprising a clamping device for securing the exhaust fitting in the exhaust flange, the clamping device being positionable over the teeth to compress the teeth radially inward against the outer tube portion and against the exhaust pipe when the exhaust fitting is installed in the discharge pipe distal end and the exhaust pipe is installed in the exhaust fitting groove.
- 15. The discharge pipe of claim 13 wherein the discharge pipe distal end has an interior shoulder extending radially from an interior surface of the discharge pipe and the exhaust fitting rear annular wall engages against the interior shoulder when the exhaust fitting is inserted in the discharge pipe.
- 16. The discharge pipe of claim 13 wherein the exhaust fitting has a circumferential lip on an exterior surface of the outer tube portion opposite the rear annular wall and the circumferential lip engages with the discharge pipe distal end when the exhaust fitting is inserted in the discharge pipe.
- 17. The discharge pipe of claim 13 further comprising a key formed in one of the discharge pipe distal end and the exhaust fitting and a slot formed in the other of the discharge pipe distal end and exhaust fitting to thereby restrict the assembly thereof to a given orientation thereby aligning the discharge pipe drain and exhaust fitting drain hole.
US Referenced Citations (17)