The present invention relates generally to fireplace accessories and, more particularly, to a heat exchanger apparatus adaptable to a wide array of fireplace sizes and useful for improving the heating efficiency of a fireplace,
Conventional fireplaces are inefficient sources of heat for the room in which they are located as the majority of the heat generated by the combustion process escapes through the chimney. Fireplace fires also require large volumes of combustion air, which if drawn from the interior space of the room, result in significant heat loss from the room as heated room air is also exhausted through the chimney. Cold air drafts in the interior space also result since the heat loss through the chimney causes cold air to be drawn in from the outside though door and window openings.
In an effort to increase the efficiency of fireplaces, fireplace inserts have been used. These devices generally comprise a large metal box situated partially within the fireplace and extending into the room in which the fireplace is located. Wood or other fuel is burned within the large metal box, which has openings for supplying combustion air and for expelling combustion gasses to the chimney. Room air circulated around the large metal box is heated and returned to the room without commingling with the combustion air stream. While such inserts have been designed to retain the visual appeal and rustic charm of an open flame, their heat transfer efficiency is limited, allowing substantial amounts of energy to be exhausted through the chimney to the outside. Furthermore, in operation the portions of the large metal box adjacent to the room tend to become extremely hot, which can be very hazardous if small children are present.
U.S. Pat. No. 4,357,930 and its progeny disclose a fireplace heating system for heating the room air incorporating a compact heat exchanger mounted at the top portion of the combustion chamber of the fireplace and extending across the location where the chimney flue connects with the top portion of the combustion chamber. A conventional fireplace door may be used to prevent room air from being exhausted through the chimney and isolate hotter portions of the fire from accidental contact by room occupants. A fan is provided for circulating room air through the heat exchanger in a manner so that the hot combustion gases heat up the room air being circulated therethrough without commingling. The design of the compact heat exchanger directs hot combustion gasses through torturous pathways to increase heat transfer, the complex design of the pathways results in increased fabrication costs for the heat exchanger assembly compared to more conventional heat exchange methods.
It would be desirable to provide an improved fire place heat exchanger apparatus suitable for use in existing or newly constructed fireplaces that further increases thermal efficiency of a fireplace, reduces the amount of heat energy exhausted through the chimney, and that can be economically fabricated from inexpensive yet durable materials.
Accordingly, it is an object of the present invention to provide an improved heat exchanger device that increases the efficiency and performance of fireplace heating systems thereby enabling a fireplace to effectively heat a home or provide a significant supplemental heat source,
It is another object of the present invention to provide a heat exchanger apparatus for use in a fireplace to provide a supplemental heat system for an enclosed building. The present invention is particularly adaptable to homes heated by heat pumps or other systems for which a supplemental heating system is particularly desirable when outside temperatures are cold (e.g., below 40 F.).
It is another object of the present invention to provide a heat exchanger apparatus for use in a fireplace that segregates combustion air flow from the room heating air flow thereby eliminating loss of heated room air through the chimney.
It is a further object of the present invention to provide a heat exchanger apparatus for use in a fireplace that is readily adaptable for heating room air in an adjacent room or a liquid heat transfer medium for heating a room area remotely located from the fireplace.
It is a further object of the present invention to provide a heat exchanger apparatus that is easily adapted for use in a variety of fireplace sizes and arrangements, including free-standing fireplaces, and in conjunction with existing doors covering fireplace openings.
It is a still further object of the present invention to provide a heat exchanger that is capable of lowering flue gas temperatures to the extent that alternate, preferably less expensive flue materials may be used thereby offsetting costs of the heat exchanger apparatus.
It is a still further object of the present invention to provide an improved fireplace heat exchanger apparatus that is durable in construction, inexpensive of manufacture carefree of maintenance, easily assembled, and simple and effective to use.
These and other objects are achieved by providing an improved fireplace heat exchanger apparatus incorporating one or more generally first hollow members located in the combustion chamber generally situated adjacent the rearward wall of the combustion chamber. The longitudinal axes of the hollow members are oriented generally vertically. Each first hollow member has an internally disposed second hollow member thereby creating an annular space between the interior surface of the first hollow member and the exterior surface of the second hollow member. Ducting is provided to direct air/gas flow through the heat exchanger in a controlled manner. The interior portion of the second hollow member is configured to accept an air flow from a room and returning it thereto while the annular space is configured to accept a flow of combustion gasses from the combustion chamber and direct it toward a chimney. Alternatively, a heat conducting liquid may be directed through the interior portion of the second hollow member and used to transport heat energy to a remote location. The respective flows are directed through the heat exchanger in a counter-flow arrangement.
The advantages of this invention will be apparent upon consideration of the following detailed disclosure of the invention, especially when taken in conjunction with the accompanying drawings wherein:
Many of the fastening, connection, processes and other means and components utilized in this invention are widely known and used in the field of the invention described, and their exact nature or type is not necessary for an understanding and use of the invention by a person skilled in the art and they will not therefore be discussed in significant detail. Furthermore, the various components shown or described herein for any specific application of this invention can be varied or altered as anticipated by this invention and the practice of a specific application of any element may already by widely known or used in the art by persons skilled in the art and each will likewise not therefore be discussed in significant detail, when referring to the figures, like parts are numbered the same in all of the figures, unless otherwise noted.
In
There is also disclosed in
In accordance with the invention, there is provided a heat exchanger assembly 40 comprising one or more elongate heat exchanger cores 42 and means for mounting the same within combustion chamber 10, generally adjacent to back wall 14 and preferably vertically oriented Heat exchanger assembly 40 preferably incorporates an even number of heat exchanger cores 42 to enable efficient room air and combustion gas connections with the heat exchanger assembly 40. Flue baffle 22 is positioned to extend across the throat 19 in the top portion of the combustion chamber 10 to seal the connection between combustion chamber 10 and chimney flue 20. At least one flue opening 28 is provided in baffle 22 to provide combustion gasses created when the gas log burner 20 is in operation a controlled passage from combustion chamber 10 to chimney flue 20.
Elements of the heat exchanger assembly 40 may be held in position by anchoring tabs (not shown) secured directly into the walls 14, 16 of the fireplace which provide connection points for elements of the heat exchanger assembly. Such anchor tabs are suitable for use in fireplaces being modified to use the present invention or fireplaces initially constructed to use the invention. Alternatively, a free-standing support structure may be provided to enable the heat exchanger assembly 40 to be self-supporting within the fireplace, thereby eliminating the need to breach the interior walls of the fireplace with anchor bolts. The design of a free-standing support structure is ideally suited for retrofit applications and is, therefore, adjustable to suit a variety of fireplace sizes and configurations. Materials selected for support members, whether a free-standing frame or anchor tabs, are typically iron or steel and are selected for durability in when exposed to hot combustion gasses in the fireplace and relatively low cost.
Referring now to
Hot combustion gasses enter the outer-most heat exchanger cores near the top of the heat exchanger assembly, shown as double flow arrows in
Each heat exchanger core 42 is made of a materials to provide a highly heat conductive arrangement. To that end, inner hollow member 44 is constructed of a heat conductive material, such as aluminum, effectively conduct heat from the hot combustion gasses flowing through the annular passageway 48 to the heating medium flowing through the inner hollow member 44. Outer hollow member 46, which is directly exposed to the combustion occurring at burner 30, is likewise constructed of a highly heat conductive material, but one that is also more suitable for the combustion chamber environment, such as steel and, more specifically, stainless steel.
In the preferred embodiment, the heat exchanger assembly 40 is configured such that inlet and outlet openings for the inner hollow members 44 and the annular passageways 48 are generally adjacent and proximate a common end of the assembly 40. For illustrative purposes, two heat exchanger cores shown in
The aluminum inner hollow members 44 and other aluminum parts of the heat exchanger cores 42, such as the heating medium turnaround adapters 64, are anodized flat black. This improves the heat transfer properties of these parts by improving the heat transfer coefficient thereof. The overall heat transfer effectiveness of the heat exchanger assembly 40 is improved by the addition of a radiant energy reflector 50 (shown also in
Each heat exchanger core 42 is constructed and arranged to increase the dwell time of hot combustion gasses in the annular passageway thereby increasing the heat transfer between the relatively hotter combustion gasses and the relatively cooler heating medium. The object is to extract as much thermal energy as possible in a relatively compact space. By doing so, materials of construction for the chimney flue can be selected having to withstand much lower temperatures, as low as 150F, thereby allowing less expensive materials to be used for the chimney flue, such as PVC. To this end, the heat exchanger cores are configured to cause a vortex flow of the combustion gases as they flow through the annular passageway. The vortex flow is caused by at least one nozzle disc 70, which is connected to the inner and outer hollow members and positioned proximate to the inlet end of the annular passageway 48. As hot combustion gasses pass through nozzle disc 70, the gasses are forced to swirl about the annular passageway, generally circulating around the inner hollow structure 44 as the gasses proceed along the length of the heat exchanger core 42. Referring to
Referring now to
Conduit design may include adjustable and/or flexible air supply and return conduit 80, 90 to enable the plenums to be installed in a variety of fireplace sizes and configurations. While imperative for retro-fit installations where the exact fireplace dimensions are unknown when the conduits are fabricated, such flexibility may also benefit purpose-built fireplace installations by enabling a single conduit design to be used on a range of fireplace sizes. Such flexible design streamlines production and inventory requirements thereby reducing overall cost of production of the invention.
While the embodiment shown in
In an alternate embodiment, a liquid heat transfer medium is circulated through the inner hollow members whereupon it absorbs heat energy from the hot combustion gasses. The heated liquid can then be easily conveyed to other locations where the heat energy is extracted to provide heat to a room or another area. An ideal remote location would be a heat exchanger positioned in the existing heating system for a house whereby the heat energy from the fireplace is efficiently distributed to the entire heated portion of a house or building structure. Such an application provides further benefit to heat pump systems which require a supplemental heat source when outside air temperatures fall below certain levels. Heat energy from the fireplace can replace expensive electric resistance heating elements often used as supplemental heat sources for heat pumps, potentially lowering energy costs. Due to the modular arrangement of the heat exchanger assembly, a combination of room air from a room adjacent the fireplace and a heat transfer liquid directed to a heat exchanger in a different location may be accommodated enabling a single fireplace to effectively heat greater portions of a house, thereby further increasing the effectiveness of the fireplace as a supplemental heating source.
Referring now to
It will be understood that changes in the details, materials, steps and arrangements of parts which have been described and illustrated to explain the nature of the invention will occur to and may be made by those skilled in the art upon a reading of this disclosure within the principles and scope of the invention. The foregoing description illustrates the preferred embodiment of the invention; however, concepts, as based upon the description, may be employed in other embodiments without departing from the scope of the inventions. Accordingly, the following claims are intended to protect the invention broadly as well as in the specific form shown.