Patent Application
20190056104
The present subject matter relates generally to gas fueled water heater appliances, and more particularly to gas fueled water heater appliances having features limiting flame propagation.
A variety of energy sources are used in creating hot water for commercial and residential use including electric, solar, and various fuels. Natural gas and propane are preferred by some customers due to, for example, the relatively quick heating rate. These fuels are supplied as a gas that is burned in a combustion chamber to provide heat energy to raise the water temperature.
Temperatures in the combustion chamber are relatively high and can, for example, reach 600 degrees Fahrenheit or higher during normal operation. A flame is created by burning a mixture of the gaseous fuel and air. Proper combustion requires that the air and fuel are provided within a particular ratio to ensure, for example, complete combustion and avoid wasted fuel or the production of unwanted by-products such as carbon monoxide.
In certain existing water heater appliances, such as residential gas fueled water heater appliances, one or more flame traps are typically provided below the combustion chamber. Generally, such flame traps prevent flames (e.g., from passing out of the combustion chamber). Moreover, the ignition of flammable vapors present outside of the water heater may be prevented. Common systems may include a single metal sheet with a plurality of small openings (e.g., louvers, perforations, or holes). The openings may further permit air into the combustion chamber to sustain or permit combustion at the burner. In order to prevent flames from passing through the flame trap, the openings may typically be limited to sizes no greater than five hundredths of an inch.
However, challenges exist for these common existing systems. As an example, if a water heater appliance is installed in a dusty area containing above average levels of, for example, dirt, oil, or lint, the holes of the flame trap for the water heater can become clogged. The lack of enough air can cause the temperature of the combustion chamber to become too hot or cause an undesirable increase in Carbon Monoxide levels. As another example, existing flame traps may be difficult to manufacture. The relatively small dimensions and low tolerances of the flame traps may require a cumbersome precision or fine blanking process in order to form the plurality of holes. As yet another example, existing systems may lack sufficient structural support. Exposure to flames and/or the high heat environment of a combustion chamber may cause a flame trap to deform or “oil can,” which may thus undermine performance of the flame trap or create unwanted noise during operation.
Accordingly, a gas fueled heater appliance with features for preventing flame propagation would be desirable. In particular, it would be advantageous to provide a gas fueled heater appliance with features to address one or more of the above-identified challenges.
Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.
In one aspect of the present disclosure, a gas fueled water heater appliance is provided. The gas fueled water heater appliance may include a tank for storage of water for heater, a chamber wall, a gas burner, and a flame arrestor. The chamber wall may define a combustion chamber. The gas burner may be positioned adjacent to the tank and within the combustion chamber to heat the water in the tank. The flame arrestor may be positioned beneath the gas burner along a vertical direction. The flame arrestor may include a bottom plate and a top plate. The bottom plate may include an upper surface and a lower surface. The bottom plate may define a non-permeable region and a perforated region. The perforated region may include a plurality of apertures extending through the top plate from the upper surface to the lower surface. The top plate may be positioned above the bottom plate along the vertical direction. The top plate may include an upper surface and a lower surface. The top plate may define a non-permeable region and a perforated region. The perforated region may include a plurality of apertures extending through the top plate from the upper surface to the lower surface. The perforated region of the bottom plate may be axially offset from the perforated region of the top plate.
In another aspect of the present disclosure, a gas fueled water heater appliance is provided. The gas fueled water heater appliance may include a tank for storage of water for heater, a chamber wall, a gas burner, and a flame arrestor. The chamber wall may define a combustion chamber. The gas burner may be positioned adjacent to the tank and within the combustion chamber to heat the water in the tank. The flame arrestor may be positioned beneath the gas burner along a vertical direction. The flame arrestor may include a bottom plate, a top plate, and a baffle. The bottom plate may include an upper surface and a lower surface. The bottom plate may define a non-permeable region and a perforated region. The perforated region may include a plurality of apertures extending through the top plate from the upper surface to the lower surface. The top plate may be positioned above the bottom plate along the vertical direction. The top plate may include an upper surface and a lower surface. The top plate may define a non-permeable region and a perforated region. The perforated region may include a plurality of apertures extending through the top plate from the upper surface to the lower surface. The baffle may be positioned between the lower surface of the top plate and the upper surface of the bottom plate.
These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.
A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures.
Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.
From line 104, water travels into tank 102 through a cold water dip tube 122 that generally extends along a vertical direction V towards the bottom 114 of tank 102. After being heated, water exits tank 102 by travelling vertically upward and out through outlet line 106. Anode rod 126 provides protection against corrosion attacks on tank 102 and other metal components of water heater 100. A pressure relief valve 128 provides for a release of water from tank 102 in the event the pressure rises above a predetermined amount.
Water heater 100 includes a combustion chamber 110 in which a gas burner 108 is centrally located. Gas burner 108 is supplied with a gaseous fuel (e.g., propane or natural gas). Air travels into combustion chamber 110 through flame arrestor 200 after passing through air intake 112 in cabinet 130. The resulting mixture of air and gas is ignited and burned to heat bottom 114 of tank 102 and its water contents. Hot combustion gas 120 exits combustion chamber 110 through a vent or flue 124 centrally located within tank 102. Heat exchange with flue 124 also helps heat water in tank 102. A baffle 120 promotes this heat exchange. Gas 120 exits water heater 100 though vent hood 136, which may be connected with additional vent piping (not shown).
A thermostat 116 measures the temperature of water in tank 102 and provides a signal to gas control valve module 118. As used herein, “a signal” is not limited to a single measurement of temperature and, instead, may include multiple measurements over time or continuous measurements over time. The signal may be provided through, for example, changes in current, voltage, resistance, or others. Depending upon whether the desired temperature has been reached as determined, for example, from the signal from thermostat 116, gas control valve module 118 regulates the flow of gas to burner 108.
Referring now to
A thermo-electric device 156 is positioned adjacent to the pilot burner 148 and igniter 158. Thermo-electric device 156 may be a thermopile that can convert heat from pilot burner 148 into electrical energy, which can be used, for example, to power gas valve control module 118. Thermopile 156 may be constructed from, for example, a plurality of thermocouples connected in a series, for example. For this exemplary embodiment, a bracket 166 is used to position pilot burner 148, igniter 158, and thermopile 156 near gas burner 108.
Turning now to
Although
As shown in
Within each perforated region 222, a plurality of apertures 224 (see
As shown, each aperture 224 defines a diameter Da (e.g., minimum diameter perpendicular to the vertical direction V and/or central axis A) between the upper surface 212 and the lower surface 214. In some such embodiments, the diameter Da is constant from the upper surface 212 to the lower surface 214. The diameter Da of each aperture 224 may be any suitable length for permitting the passage of air and necessary flame quenching through the same aperture 224. In certain embodiments, an aperture 224 (e.g., each aperture 224 or, alternatively, less than every aperture 224) includes a diameter Da that is greater than five hundredths of an inch (i.e., Da>0.05 in). Advantageously, top plate 202 may limit or prevent apertures 224 from becoming clogged by foreign objects, such as dirt, oil, lint, etc.
Optionally, the apertures 224 of a respective perforated region 222 may be closely spaced to each other (e.g., horizontally or along a plane perpendicular to the vertical direction V). For instance, the spacing or portion of solid material between each adjacent aperture 224 of a respective perforated region 222 may be less than the diameter Da (e.g., minimum diameter) of a single aperture 224.
In contrast to the perforated regions 222, each non-permeable region 220 is substantially solid. Specifically, each non-permeable region 220 is hermetically closed. Each non-permeable region 220 may thus be free of any void that would permit the passage of air between the upper surface 212 and the lower surface 214. In some such embodiments, the material of top plate 202 may be continuous from the lower surface 214 to the upper surface 212.
As shown, especially in
In additional or alternative embodiments, one or more ridges 232, 234 separate or delineate discrete regions (e.g., unique perforated regions 222 and/or unique pairs of a perforated region 222 and a non-permeable region 220). For instance, such ridges 232, 234 may be embossed along top plate 202 to extend towards bottom plate 204 (e.g., when assembled). In certain embodiments, a discrete circumferential ridge 232 and radial ridge 234 are included. As shown, a circumferential ridge 232 extends along the circumferential direction C about the central axis A. In the illustrated embodiments, multiple circumferential ridges 232 are formed in parallel and spaced apart along the radial direction R. In turn, each circumferential ridge 232 separates at least two unique pairs of a corresponding perforated region 222 and non-permeable region 220 along the radial direction R. A radial ridge 234 extends along the radial direction R from the central axis A. In the illustrated embodiments, multiple radial ridges 234 are formed at discrete angles relative to the central axis A (i.e., at different positions along the circumferential direction C). In turn, each radial ridge 234 separates at least two unique pairs of a corresponding perforated region 222 and non-permeable region 220.
As shown in
Within each perforated region 228, a plurality of apertures 230 (see
As shown, each aperture 230 defines a diameter Da (e.g., minimum diameter perpendicular to the vertical direction V and/or central axis A) between the upper surface 216 and the lower surface 218. In some such embodiments, the diameter Da is constant from the upper surface 216 to the lower surface 218. The diameter Da of each aperture 230 may be any suitable length for permitting the passage of air and necessary flame quenching through the same aperture 230. In certain embodiments, an aperture 230 (e.g., each aperture 230 or, alternatively, less than every aperture 230) includes a diameter Da that is greater than five hundredths of an inch (i.e., Da>0.05 in). Advantageously, bottom plate 204 may limit or prevent apertures 230 from becoming clogged by foreign objects, such as dirt, oil, lint, etc.
Optionally, the apertures 230 of a respective perforated region 228 may be closely spaced to each other (e.g., horizontally or along a plane perpendicular to the vertical direction V). For instance, the spacing or portion of solid material between each adjacent aperture 230 of a respective perforated region 228 may be less than the diameter Da of the apertures 230.
In contrast to the perforated regions 228, each non-permeable region 226 is substantially solid. Specifically, each non-permeable region 226 is hermetically closed. Each non-permeable region 226 may thus be free of air void that would permit the passage of air between the upper surface 216 and the lower surface 218. In some such embodiments, the material of bottom plate 204 may be continuous from the lower surface 218 to the upper surface 216.
As shown, especially in
In additional or alternative embodiments, one or more ridges 232, 234 separate or delineate discrete regions (e.g., unique perforated regions 228 and/or unique pairs of a perforated region 228 and a non-permeable region 226). For instance, such ridges 232, 234 may be embossed along bottom plate 204 to extend towards top plate 202 (e.g., when assembled). In certain embodiments, a discrete circumferential ridge 232 and radial ridge 234 are included. As shown, a circumferential ridge 232 extends along the circumferential direction C about the central axis A. In the illustrated embodiments, multiple circumferential ridges 232 are formed in parallel and spaced apart along the radial direction R. In turn, each circumferential ridge 232 separates at least two unique pairs of a corresponding perforated region 228 and non-permeable region 226 along the radial direction R. A radial ridge 234 extends along the radial direction R from the central axis A. In the illustrated embodiments, multiple radial ridges 234 are formed at discrete angles about the central axis A (e.g., separate points along the circumferential direction C). In turn, each radial ridge 234 separates at least two unique pairs of a corresponding perforated region 228 and non-permeable region 226.
Turning especially to
Optionally, one or more ridges 232, 234 may support top plate 202 on bottom plate 204. For instance, the radial ridges 234 and circumferential ridges 232 of top plate 202 may be aligned (e.g., vertically aligned) with the radial ridges 234 and circumferential ridges 232 of bottom plate 204. In turn, the ridges 232, 234 of bottom plate 204 may engage the ridges 232, 234 of top plate 202, in support therewith.
As shown, some embodiments of flame arrestor 200 include portions of top plate 202 and bottom plate 204 at axially offset positions. In other words, at least a portion of top plate 202 is spaced apart from a portion of bottom plate 204 relative to (e.g., from or about) a common axis or direction. For example, a perforated region 222 of top plate 202 may be axially offset from a perforated region 228 of bottom plate 204. Specifically, the perforated region 222 of top plate 202 may be offset from the perforated region 228 of the bottom plate 204 relative to the central axis A and/or vertical direction V. Thus, the perforated regions 222 and 228 may be positioned at different distances and/or angles from the central axis A.
In some embodiments, the perforated region 222 of the top plate 202 is offset (e.g., spaced apart) from the perforated region 228 of the bottom plate 204 along the radial direction R. In additional or alternative embodiments, the perforated region 222 of the top plate 202 is offset (e.g., spaced apart) from the perforated region 228 of the bottom plate 204 along the circumferential direction C. If a plurality of perforated regions 222, 228 are included in top plate 202 and/or bottom plate 204, each perforated region 222 of top plate 202 may be axially offset from each perforated region 228 of bottom plate 204 (e.g., along one or more of the radial direction R or the circumferential direction C).
In contrast to the perforated regions 222 and 228, a portion of a non-permeable region 220 of top plate 202 may axially overlap with a portion of a non-permeable region 226 of bottom plate 204. Specifically, a segment of a non-permeable region 220 of top plate 202 may overlap a segment of a non-permeable region 226 of bottom plate 204 relative to the central axis A and/or vertical direction V. In such embodiments, the overlapping segments of the non-permeable regions 220 and 226 are vertically aligned with each other. In turn, the overlapping segment of the non-permeable region 226 of the bottom plate 204 is positioned directly beneath the overlapping segment of the non-permeable region 220 of the top plate 202 (i.e., along the vertical direction). Moreover, the overlapping segments are positioned at the same location (e.g., point) along the radial direction R and the circumferential direction C.
As illustrated in
In exemplary embodiments, such as those shown in
Turning particularly to
Generally, baffle 206 includes one or more solid or non-permeable portions, such as guide panels 240, extending beneath top plate 202 and above bottom plate 204. In the exemplary embodiments of
As illustrated, especially in
As shown in
Turning specifically to
This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.
