Patent Application
20100173255
This Invention relates to apparatuses and systems for reducing pollution and to HVAC units and furnaces, as well as HVAC systems and buildings containing such equipment, and methods of making such apparatuses. Particular embodiments concern devices that reduce NOx emissions when placed in heat exchanger tubes where combustion takes place.
Various fuels have been burned for some time to produce heat for various purposes including heating spaces that people occupy, such as within buildings, vehicles, or the like. Combustion of fuels has produced various pollutants that have been released into the atmosphere, and alterations have been made to equipment to reduce the quantity of certain pollutants that have been emitted.
In a specific example, a number of different fuels have been burned within heat exchanger tubes in furnaces and various solid devices have been placed within the heat exchanger tubes that have reduced the production of oxides of Nitrogen (NOx) during the combustion process. Such solid devices or baffles have accomplished a reduction in NOx emissions and have performed satisfactorily when natural gas has been burned in the furnace.
Examples of NOx-reduction devices or baffles are described in U.S. Pat. Nos. 5,146,910, 5,472,339, 5,546,925, 5,649,529, 5,730,116, and 6,485,294, for instance.
In some installations, liquefied petroleum (LP) gas (or LPG) has been burned in furnaces, and soot has built up on stainless steel NOx-reduction baffles, restricting the heat exchanger tubes. As a result, it has been necessary in the prior art to remove the baffles (e.g., device 30) when such furnaces were used with LP. For LP applications, the baffles (e.g., device 30) have been removed in the field. Installers of such furnaces, however, have not always removed the baffles (e.g., device 30) when such furnace were used with LP, which has resulted in shut down of the furnace, the need for a service call, and subsequent customer dissatisfaction with the furnace. In addition, in various prior art NOx-reduction baffle configurations (e.g., device 30), increased levels of noise were produced, flames were quenched when starting (e.g., when starting a furnace), or both.
Needs or potential for benefit or improvement exist for devices or apparatuses that reduce pollution, such as NOx emissions, from furnaces, for example, but that do not require special installation procedures such as removal or alteration of the device or apparatus (e.g., device 30) when the furnace or unit is used with an alternative fuel, such as LP, for instance. Needs or potential for benefit or improvement also exist for devices or apparatuses that reduce pollution, such as NOx emissions, from furnaces, for example, that are suitable for use in HVAC systems or units, for example that more-effectively reduce pollution (e.g., NOx emissions) that are inexpensive, that can be readily manufactured, that are easy to install, that are reliable, that have a long life, that are light weight, that do not collect soot, that can withstand high temperatures, or a combination thereof, as examples.
Needs or potential for benefit or improvement also exist for devices or apparatuses that reduce pollution, such as NOx emissions, from furnaces, for example, that are quiet and that do not quench the flame when starting. In addition, needs or potential for benefit or improvement exist for furnaces and HVAC units that include such devices or apparatuses that reduce pollution, as well as buildings having such units, systems, devices, or apparatuses.
Further, needs or potential for benefit or improvement exist for methods of manufacturing such furnaces, HVAC units, buildings, systems, devices, and apparatuses. Other needs or potential for benefit or improvement may also be described herein or known in the HVAC or pollution-control industries. Room for improvement exists over the prior art in these and other areas that may be apparent to a person of ordinary skill in the art having studied this document.
The drawings illustrate, among other things, various examples of embodiments of the invention, and certain examples of characteristics thereof. Different embodiments of the invention include various combinations of elements or acts shown in the drawings, described herein, known in the art, or a combination thereof, for instance.
This invention provides, among other things, NOx-reduction apparatuses and methods of making or implementing such apparatuses, as well as furnaces, HVAC units, HVAC systems, and buildings having such NOx-reduction apparatuses, as examples. A number of embodiments of NOx-reducing apparatuses include or are made of wire, which may be wound into a helix or into a modified helix, for example. Some embodiments have support members, for example, extending outside of the helix to hold the helix away from the heat exchanger (e.g., from the inside surface or wall, for instance, of a tube), for instance, which may form a particular modified helix. Other embodiments may include a modified helix that includes alternating bends and straight sections, as another example.
Various embodiments provide, for example, as an object or benefit, that they partially or fully address or satisfy one or more of the needs, potential areas for benefit, or opportunities for improvement described herein, or known in the art, as examples. Certain embodiments provide, for example, devices or apparatuses that reduce pollution, such as NOx emissions, from furnaces, for example. Some embodiments specifically do not require special installation procedures such as removal or alteration of the device or apparatus when the furnace or unit is used with an alternative fuel, such as LP, for instance. Particular embodiments provide devices or apparatuses that reduce pollution, such as NOx emissions, from furnaces, for example, that are suitable for use in HVAC systems or units, for instance, that more-effectively reduce pollution (e.g., NOx emissions), that are inexpensive, that can be readily manufactured, that are easy to install, that are reliable, that have a long life, that are light weight, that do not collect soot, that can withstand high temperatures, that are quiet, that do not quench the flame upon starting, or a combination thereof, as examples.
In addition, particular embodiments provide, as objects or benefits, for instance, furnaces or HVAC units that include such devices or apparatuses that reduce pollution, or buildings having such units, systems, devices, or apparatuses, as further examples. Further, some embodiments provide methods of manufacturing such furnaces, HVAC units, buildings, systems, devices, or apparatuses, as examples. In addition, various other embodiments of the invention are also described herein, and other benefits of certain embodiments may be apparent to a person of ordinary skill in the art.
Specific embodiments of the invention include an apparatus for reducing NOx production in a heat exchanger in which combustion takes place and through which products of combustion pass. In various embodiments, the apparatus may include, for instance, a wire formed into a helix having a helix diameter, and multiple support members extending outside of the helix diameter to hold the helix away from the heat exchanger. In certain embodiments, the support members may have a support member diameter and the support member diameter may be substantially larger than the helix diameter, the support members may be helical, or both, as examples. In a number of embodiments the support members may include the wire, or may even consist entirely of the wire, as examples. In various embodiments, the support members may include bights in the wire, twists in the wire, loops in the wire, or a combination thereof, for instance. In particular embodiments, the support members may be spaced at multiple locations around the helix, for example, at locations substantially equally spaced around the helix.
Further, in different embodiments, the helix may have a varying helix diameter along the helix, or may have a substantially uniform helix diameter along the helix, as examples. In a number of embodiments, apparatuses may include an attachment member, for example, extending from the helix for attaching the apparatus. In various embodiments, the attachment member may include the wire, or may even consist entirely of the wire, as examples. Moreover, in certain embodiments, the wire may be Nichrome wire, the support members may be sized and configured to hold the helix substantially concentric with a heat exchanger tube, the helix may have an interior volume that is empty, or a combination thereof, as examples. Still other embodiments include a furnace that includes such an apparatus, or a building that includes such a furnace, as other examples.
Other embodiments of the invention include an apparatus for reducing NOx production in a heat exchanger that includes a wire formed into a modified helix having smaller helical turns and larger turns, and the larger turns may be spaced between groups of smaller helical turns such that the larger turns substantially center the smaller helical turns in at least a portion of the heat exchanger when the apparatus is installed therein. The smaller helical turns and the larger turns may have a common centerline, for example. In particular embodiments the wire may include Nichrome, for example.
Other embodiments of the invention include a furnace that includes multiple of the apparatus for reducing NOx production. In these embodiments, the furnace may include a heat exchanger that has multiple heat exchanger tubes in which combustion takes place and through which products of combustion pass, and each heat exchanger tube may contain at least one of the apparatus for reducing NOx production, for instance. In a number of embodiments, for each apparatus and for each heat exchanger tube, for example, the larger turns substantially center the smaller helical turns in the heat exchanger tube when the apparatus is installed in the heat exchanger tube. Other embodiments include an HVAC unit that includes such a furnace as well as an air conditioning system, as another example.
Still other specific embodiments of the invention include, for example, a furnace that includes, for instance, at least one heat exchanger in which combustion takes place and through which products of combustion pass, and a NOx-reducing apparatus within the heat exchanger. In particular embodiments, the apparatus includes, for instance, an elongated wire having a length, and the wire may be shaped to form a modified helix, and may include, for example, multiple bends along the length of the wire, each bend having a substantially identical radius and having a substantially identical angle. In a number of embodiments, the angle of each bend in the wire may be less than 180 degrees, for example, and adjacent bends along the length of the wire may be separated by straight sections of the wire. In certain embodiments, each straight section may have a substantially identical dimension along the length of the wire, for instance.
Yet other embodiments of the invention include a method, for example, of making a NOx-reducing apparatus for use in a heat exchanger in which combustion takes place and through which products of combustion pass. Such a method may include, for instance, at least the acts of obtaining wire, winding the wire, and cutting the wire. Further, the wire may be wound to form a modified helix having smaller helical turns and larger turns, and the larger turns may be spaced between groups of smaller helical turns. In a number of embodiments, the smaller helical turns and the larger turns may have a substantially common centerline, for example. Some embodiments may also include, for instance, an act of installing the wire in the heat exchanger.
Moreover, a number of methods may further include an act of instructing a furnace installer that a furnace that includes the wire can burn natural gas, and also instructing the furnace installer that the furnace that includes the wire can burn LP gas, without instructing the furnace installer to omit the wire for use with LP gas, for example. Furthermore, a number of such embodiments may further include an act of advertising that an apparatus that includes the wire can burn natural gas and that an apparatus that includes the wire can burn LP gas, as another example. In addition, various other embodiments of the invention are also described herein.
Although not shown in
Specific embodiments 60, 110, 140, 190, and 240 of NOx reduction apparatuses shown in
Certain embodiments include a building (e.g., 260) that includes an HVAC unit (e.g., 262), HVAC system (e.g., 261), air conditioning unit (e.g., 263), furnace (e.g., 10), or an apparatus or device (e.g., for reducing NOx emissions, for instance, embodiments 60, 110, 140, 190, and 240) described herein, or an HVAC unit, HVAC system, or air conditioning unit, having an apparatus described herein, as examples. Such a building (e.g., 260) may include walls (e.g., 2601 and 2602) and a roof (e.g., 2603), and may form an enclosure (e.g., 2605) or enclose an occupied space (e.g., 2606), for example. A building (e.g., 260) or HVAC system (e.g., 261) may include, besides an HVAC unit (e.g., 262), supply (e.g., 264) and return (e.g., 2642) air ductwork, registers (e.g., 265), an air filter (e.g., 2643), a thermostat or controller (e.g., 266), and a condensation drain, or a combination thereof, for example. HVAC units (e.g., 262) may include a compressor, an evaporator fan (e.g., 16), a condenser fan, motors for the compressor and fans (e.g., 165 for fan 16), a housing (e.g., 18), wiring, controls (e.g., thermostat 266), refrigerant tubing (e.g., 2631), an expansion valve, and the like, for instance. In different embodiments, HVAC units may be packaged units or may be spit systems (e.g., 262), as examples.
Certain embodiments are, or include, an apparatus for reducing NOx production in a burner tube, a heat exchanger, (e.g., 15) or a heat exchanger tube (e.g., 11, 12, 13, 14, or a combination thereof) in which combustion takes place and through which products of combustion pass, for instance. In a number of embodiments, the heat exchanger (e.g., 15) or heat exchanger tube (e.g., 11, 12, 13, or 14) may be round or circular (e.g., in cross section) and may have an inside dimension, such as an inside diameter (e.g., 41 shown in
Referring to
In various embodiments of an apparatus for reducing NOx production in a heat exchanger (e.g., 15) or heat exchanger tube (e.g., 11, 12, 13, or 14) in which combustion takes place and through which products of combustion pass, the apparatus may include a wire (e.g., 61, 101, 141, 191, or 241) formed into a body shape (e.g., a helix or a modified helix) having at least one lateral body dimension (e.g., helix diameter 81, 161, or 181), for example. A helix (e.g., 64, 114, 144, or 194) is an example of such a body shape, and diameter is an example of such a lateral dimension. But other shapes may be used in other embodiments (e.g., modified helix 244 shown in
In a number of embodiments, the apparatus (e.g., 60, 110, 140, 190, or 240) may be self-supporting, meaning that it does not need other structure (e.g., besides the apparatus or wire, such as wire 61, 101, 141, 191, or 241, and the heat exchanger (e.g., 15) or heat exchanger tube, for example, 11, 12, 13, or 14) to support the apparatus or wire within the heat exchanger or tube, for instance. In contrast, in the prior art embodiment 30 shown in
In some embodiments, the apparatus (e.g., 60, 110, 140, 190, or 240) may require only the support members (e.g., 63, 143, 193, or 233), an attachment member (e.g., 66, 116, 146, 196, or 246), or both, for example, to support the apparatus within a heat exchanger or tube (e.g., 11, 12, 13, or 14), center or substantially center the apparatus (e.g., 60, 110, 140, 190, or 240) within the heat exchanger tube (e.g., 11, 12, 13, or 14), or both, as examples. Various embodiments may omit or not require sheet metal support members (e.g., 33) within the heat exchanger tube (e.g., 11, 12, 13, 14, or a combination thereof), for example, in contrast to the prior art shown in
In various embodiments, the wire (e.g., 61, 101, 141, 191, or 241) formed into a body shape having at least one lateral body dimension (e.g., apparatus (e.g., 60, 110, 140, 190, or 240) may be combined with an attachment member (e.g., 66, 116, 146, 196, or 246) extending from the body shape (e.g., helix or modified helix) for attaching the apparatus (e.g., 60, 110, 140, 190, or 240), for instance, to the heat exchanger (e.g., 15) or heat exchanger tube (e.g., 11, 12, 13, or 14). In various embodiments, the attachment member (e.g., 66, 116, 146, 196, or 246) may include or consist of the wire (e.g., 61, 101, 141, 191, or 241), as examples. Examples of attachment members (e.g., 66, 116, 146, 196, or 246) are shown in
A number of embodiments of an apparatus (e.g., 60, 110, 140, 190, or 240), for instance, for reducing NOx production in a heat exchanger (e.g., 15) or a heat exchanger tube (e.g., 11, 12, 13, or 14, for instance, having an inside diameter 41), may include or consist of a wire (e.g., 61, 101, 141, 191, or 241) formed into a modified helix.
In various embodiments, the support members (e.g., 63, 143, 193, or 233) consist entirely of the wire (e.g., as shown in
As shown in
In a number of embodiments, the helix (e.g., 64, 114, 144, or 194) has multiple turns and the support members (e.g., 63, 143, or 193) are located at regular numbers of turns along the helix (e.g., 64, 114, 144, or 194).
Further, in embodiment 240 shown in
In some embodiments (e.g., 60, 110, 140, and 190), the support members (e.g., 63, 143, or 193 shown in
As mentioned, certain embodiments include an attachment member (e.g., 66, 116, 146, 196, or 246 shown in
In some embodiments (e.g., with or without a hook such as 157 or 197, or a right angle bend such as 77, 127, or 257) the attachment member may include a loop, for example, at the end of the wire, for instance, for attaching the apparatus to the heat exchanger (e.g., 15) or heat exchanger tube (e.g., 11, 12, 13, or 14), for example, at or near the burner (e.g., 115, 125, 135, or 145) or at the entrance end (e.g., 111), for instance. In some embodiments, the loop may have a loop diameter that is greater than the helix diameter (e.g., 81, 161, or 181), for example. In particular embodiments, such a loop diameter may be less than the outside diameter of the heat exchanger or heat exchanger tube (e.g., 11, 12, 13, or 14), prior to installation of the apparatus (e.g., NOx reduction apparatus) in the heat exchanger or heat exchanger tube (e.g., 11, 12, 13, or 14), and the loop may have or may form an interference fit with the heat exchanger or heat exchanger tube (e.g., when installed). In various embodiments, such a loop may extend for more than 180 degrees (e.g., more than half way around the heat exchanger tube), for less than 360 degrees (e.g., less than half way around the heat exchanger tube), or both, as examples.
In particular embodiments, the helix (e.g., 64 or 114 shown in
In various embodiments, the wire (e.g., 61, 101, 141, 191, or 241) may be positioned (e.g., all, mostly, or except for any support member or attachment member) away from the inside surface of the heat exchanger (e.g., 15) or heat exchanger tube (e.g., 11, 12, 13, or 14). In certain embodiments, for example, the helix diameter (e.g., 81, 161, or 181) is less than ¾ of the inside diameter (e.g., 41) of the heat exchanger tube (e.g., 11, 12, 13, or 14), less than ⅔ of the inside diameter (e.g., 41) of the heat exchanger tube, less than ⅗ of the inside diameter (e.g., 41) of the heat exchanger tube, or less than ½ of the inside diameter (e.g., 41) of the heat exchanger tube (e.g., 11, 12, 13, or 14), for instance. On the other hand, in some embodiments, the helix diameter (e.g., 81, 161, or 181) is greater than ½ of the inside diameter (e.g., 41) of the heat exchanger tube (e.g., 11, 12, 13, or 14), greater than ¼ of the inside diameter (e.g., 41) of the heat exchanger tube, greater than ⅓ of the inside diameter (e.g., 41) of the heat exchanger tube, greater than ⅜ of the inside diameter (e.g., 41) of the heat exchanger tube, or greater than 7/16 of the inside diameter (e.g., 41) of the heat exchanger tube (e.g., 11, 12, 13, or 14), as examples. In some specific embodiments, for instance, the helix diameter (e.g., 81, 161, or 181) is about ½ of the inside diameter (e.g., 41) of the heat exchanger tube (e.g., 11, 12, 13, or 14). As used herein, unless stated otherwise, “about” means plus or minus ten (10) percent. In particular embodiments, the helix diameter (e.g., 81, 161, or 181) may be less than one (1) inch, less than ⅞ inch, less than ¾ inch, less than 11/16 inch, or less than ⅝ inch, as examples. Further, in the same or different embodiments, the helix diameter (e.g., 81, 161, or 181) may be greater than 7/16 inch, greater than one half (½) inch, greater than 9/16 inch, or greater than ⅝ inch, as examples. Examples of certain helix diameters (e.g., 81, 161, or 181) include 0.706 inches outside diameter and 0.625 inches inside diameter, as examples.
In some embodiments, the wire (e.g., 61, 101, 141, 191, or 241) may have a length for example, from the attachment member (e.g., 66, 116, 146, 196, or 246), through the support members (e.g., 63, 143, 193, or 233), and through the coil that is the farthest from the attachment member (e.g., coil 69, 119, 159, 199 or 259). In a number of embodiments, the wire (e.g., 61, 101, 141, 191, or 241) may have a substantially constant cross section along the length of the wire. As used herein, “substantially constant” means constant to within plus or minus ten (10) percent in any major dimension. In particular embodiments, the wire (e.g., 61, 101, 141, 191, or 241) may have a circular cross section, and in various embodiments, the wire may have a hollow cross section or may be solid, as examples.
In certain embodiments, the wire (e.g., 61, 101, 141, 191, or 241) may be Nichrome wire, for example, or stainless steel wire. In some embodiments, other materials may be used that are suitable to withstand the temperatures present. As used herein, Nichrome wire includes nickel and chromium as its two largest ingredients. Nichrome wire may include nickel as its largest single alloy ingredient, for example, or may even be mostly (e.g., more than half) nickel for instance. In some embodiments, Nichrome wire may include at least 70 percent nickel and at least 15 percent chromium, for example. In some embodiments, Nichrome wire may include at least 75 percent nickel and at least 17 percent chromium, for another example. In certain embodiments, Nichrome wire may include at least 79 percent nickel and at least 19 percent chromium, for instance. Further, in particular embodiments, Nichrome wire may be about (e.g., plus or minus ½ of 1 percent) 80 percent nickel and 20 percent chromium, for example. In some embodiments, porcupine wire or electrical resistance heating element wire may be used, for instance, which may be selected to adequately resist oxidation in the high-temperature environment present in a heat exchanger (e.g., 15) or heat exchanger tubes (e.g., 11, 12, 13, 14, or a combination thereof).
In some embodiments, the helix or modified helix (e.g., 64, 114, 144, 194 or 233) may have an interior volume (e.g., 80, 160, 180, or 220) shown in
Certain embodiments are, or are part of, a device for obtaining energy by burning a fuel. A furnace (e.g., furnace 10 shown in FIG. 1) is an example of such a device. Some such devices include, for example, (among other things) a location for burning the fuel (e.g., burner 115, 125, 135, 145, heat exchanger 15 or heat exchanger tubes 11, 12, 13, or 14, or a combination thereof), a mechanism for harnessing the energy from burning the fuel (e.g., heat exchanger 15), an enclosed passageway for containing products of combustion from the burning of the fuel (e.g., heat exchanger tube 11, 12, 13, or 14), and a wire (e.g., wire 61, 101, 141, 191, or 241 or embodiments 60, 110, 140, 190, or 240 shown in
Further embodiments are, or are part of, a device for changing and controlling temperature of an occupied space (e.g., 2606) or for heating an occupied space (e.g., a furnace, such as furnace 10 shown in
Other embodiments are devices for obtaining energy by burning a fuel that include, for example, a location for burning the fuel (e.g., burners 115, 125, 135, 145, or a combination thereof), a mechanism for harnessing the energy from burning the fuel (e.g., heat exchanger similar to heat exchanger 15), an enclosed passageway for containing products of combustion from the burning of the fuel (e.g., similar to heat exchanger tubes, 11, 12, 13, 14, or a combination thereof), and multiple fins that extend into the enclosed passageway (e.g., into the heat exchanger tube). In some such embodiments, the enclosed passageway or heat exchanger tube (e.g., at least the portion where combustion takes place) is ceramic, the multiple fins are ceramic, the enclosed passageway or heat exchanger tube (e.g., or a portion thereof) and the multiple fins are one piece of material, or a combination thereof, as examples. Ceramic fins may need to be fairly thin, in some embodiments. In a number of embodiments, the fins are used to enhance combustion or to reduce the production of pollutants, such as for NOx reduction, for example. In various embodiments, the device may be a furnace (e.g., similar to furnace 10), an HVAC unit (e.g., similar to HVAC unit 262 that may include direct expansion air conditioning 263 and a furnace 10), a building (e.g., 260) having an HVAC system (e.g., similar to 261) or a furnace, or the like, as examples.
In some embodiments, the enclosed passageway or heat exchanger tube (e.g., similar to 11, 12, 13, 14, or a combination thereof, or portion thereof) may have at least one wall and the multiple fins may be connected to the wall. Further, in some embodiments, the multiple fins may extend radially inward from the wall, may each be substantially perpendicular to the wall, may each have a substantially identical dimension in a direction perpendicular to the wall, or a combination thereof, as examples. As used herein, “substantially perpendicular” means perpendicular (e.g., to a line tangent to the wall at the point of intersection) to within plus or minus ten (10) degrees. In addition, as used herein, “substantially identical” means identical (e.g., in dimension or angle) to within plus or minus ten (10) percent. In some embodiments, the enclosed passageway, heat exchanger, or heat exchanger tube (e.g., similar to 11, 12, 13, 14, or a combination thereof) may have a center, and a distance from the wall to the center, and the fins may extend more than a third of the distance from the wall toward the center, less than two thirds of the distance from the wall toward the center, or about half of the distance from the wall toward the center, as examples. On the other hand, in some embodiments, the fins may extend more than half of the distance from the wall toward the center.
In some embodiments, the multiple fins may include at least five fins, at least six fins, at least eight fins, at least ten fins, or at least twelve fins, as examples. Further, in some embodiments, the multiple fins may specifically consist of twelve fins. Further still, in some embodiments, the multiple fins may all have substantially identical dimensions. In some embodiments, multiple of the fins may be substantially parallel with the centerline, or in certain embodiments, all of the fins may be parallel with the centerline. As used herein, “substantially parallel” means parallel to within 10 degrees, and “parallel” means parallel to within 5 degrees. Moreover, in some embodiments, multiple of the fins may be substantially coplanar with the centerline. As used herein, “substantially coplanar” means coplanar to within 10 degrees, and “coplanar” means coplanar to within 5 degrees. In some embodiments, all of the fins may be coplanar with the centerline, as another example. On the other hand, in some embodiments, multiple of the fins may wind helically about the centerline. Embodiments that include a ceramic material may include or consist essentially of a magnesium iron aluminum cyclosilicate, for example, such as Cordierite, for instance. In other embodiments, other ceramic materials having suitable properties may be used.
In some embodiments, a wire configuration (e.g., porcupine element) may be employed for NOx reduction (e.g., in a furnace, heat exchanger, or heat exchanger tube, such as 11, 12, 13, 14, or a combination thereof) that has been used in electric heater elements to heat an occupied space (e.g., 2606) or air delivered thereto. Besides the different embodiments of apparatuses (e.g., 60, 110, 140, 190, or 240) described above (or including at least some embodiments thereof), in some embodiments, the apparatus (e.g., 60, 110, 140, 190, or 240) may include an elongated body or wire (e.g., 61, 101, 141, 191, or 241) having a length, which may be shaped to form a modified helix (e.g., 64, 114, 144, or 194 plus support members 63, 143, or 193, or modified helix 244), for example. In some embodiments, the wire (e.g., 241 shown in
In some embodiments, adjacent bends (e.g., 233) along the length of the wire (e.g., 241) may be separated by straight sections (e.g., 231) of the wire, for example. In some embodiments, each straight section (e.g., 231) may have a substantially identical dimension along the length of the wire (e.g., 241), for instance.
In various embodiments, the wire (e.g., 61, 101, 141, 191, or 241) may have a substantially constant cross section along the length of the wire, a substantially circular cross section, a solid cross section, a hollow cross section, or a combination thereof (e.g., to the extent possible), for example. Further, in some embodiments, the radius of each bend (e.g., 233) is substantially constant along the bend. In particular embodiments, each bend (e.g., 233) may have a mid point (e.g., 237 shown in
In some embodiments, the wire (e.g., 61, 101, 141, 191, or 241) may include Nichrome, or the apparatus (e.g., 60, 110, 140, 190, or 240) may consist essentially of Nichrome wire, as examples, and, in some embodiments, may be devoid of other structure (e.g., sheet metal support 33 shown in
Besides equipment such as pollution-reduction apparatuses and devices (e.g., 60, 110, 140, 190, or 240), furnaces (e.g., 10), HVAC units (e.g., 262), HVAC systems (e.g., 261), and buildings (e.g., 260), various embodiments include a number of methods, including methods of making, obtaining, providing, and using such equipment, apparatuses, or devices. In a number of embodiments, different methods may include, in various sequences, certain acts. Various examples are methods of making or implementing certain NOx-reducing apparatuses (e.g., 60, 110, 140, 190, or 240) for use in a heat exchanger (e.g., 15) or heat exchanger tube (e.g., 11, 12, 13, 14, or a combination thereof), for example.
In some embodiments, various methods (e.g., method 270 shown in
In some embodiments, forming the wire (e.g., act 272) may include forming multiple bights (e.g., support members 143 or main bends 167) in the wire (e.g., 61, 101, 141, 191, or 241), winding the wire to form a helix (e.g., 64, 114, 144, or 194) having a helix diameter (e.g., 81, 161, or 181), or both, as examples. In some embodiments, the wire (e.g., 141) may be formed (e.g., in act 272), for example, so that the bights project outward from the helix (e.g., 144) beyond the helix diameter (e.g., 161). In some such embodiments, the act of forming the wire (e.g., act 272) may include winding the wire around a mandrel, for example. In certain embodiments, an act of forming the wire (e.g., act 272) may include an act of twisting the bights in the wire (e.g., to form support members 193 shown in
In some embodiments (e.g., 60 and 110 shown in
Further, certain embodiments (e.g., of making or implementing a NOx reducing apparatus) may include an act of instructing an installer (e.g., act 275). An installer (e.g., of furnace 10, HVAC unit 262, or HVAC system 261) may be instructed (e.g., in act 275) with written instructions, drawings, or both, provided with the product (e.g., furnace 10 or HVAC unit 262) or on packaging, through a website, by e-mail, through advertising, through sales information, printed in a manual, or the like, as examples. In some embodiments, instructions may be provided (e.g., in act 275) verbally, using pictures or video, or in person, as other examples. In some embodiments, the act of instructing an installer (e.g., act 275) includes instructing that the furnace (e.g., 10, for instance, containing the wire, for instance, 61, 101, 141, 191, or 241) can burn natural gas, instructing the installer that the furnace can burn LP gas, or both. In some embodiments, such an act (e.g., 275) may be accomplished, for example, without instructing the installer to omit the wire (e.g., wire 61, 101, 141, 191, or 241 or apparatus 60, 110, 140, 190, or 240) for use with LP gas.
Various embodiments may also (or instead) include an act of advertising (e.g., act 276), for instance, that the wire (e.g., 61, 101, 141, 191, or 241) reduces NOx, that an apparatus (e.g., 60, 110, 140, 190, or 240) including the wire can burn natural gas and can also burn LP gas, or a combination thereof, as examples. Advertising (e.g., in act 276) may be performed through a website, by e-mail, through sales literature, by mail, through mass media, through an audio or video transmission (or both) or recording, through sales people, through distributors, on product packaging, or the like, as examples. Further, some embodiments include an act of measuring emissions (e.g., act 277), such as NOx production from an apparatus (e.g., 60, 110, 140, 190, or 240) or a furnace (e.g., 10), for instance, that includes the wire (e.g., 61, 101, 141, 191, or 241), for example, to verify that the NOx production does not exceed a regulatory standard. In different embodiments, some or all HVAC units (e.g., 262) or furnaces (e.g., 10) may be tested (e.g., in act 277). In some cases, HVAC units (e.g., 262) or furnaces (e.g., 10) may be tested after being in service for a significant period of time or at various periods of time, as examples. In different embodiments, wires (e.g., 61, 101, 141, 191, or 241) or apparatuses (e.g., formed in act 272) may be sold, or units (e.g., furnace 10 or HVAC unit 262) having such apparatuses or wires may be sold, for example, to the public, through distributors, to building (e.g., 260) owners, to contractors, or the like, as examples. Sales may be made by advertising (e.g., in act 276) and taking orders, as examples.
Various examples of embodiments, for instance, are methods of reducing NOx emissions from a furnace (e.g., 10), the furnace having at least one heat exchanger (e.g., 15) or heat exchanger tube (e.g., 11, 12, 13, 14, or a combination thereof) and at least one burner mechanism (e.g., 115, 125, 135, 145, or a combination thereof) configured, for example, to form a flame within the heat exchanger or heat exchanger tube. In these examples, the flame has dimensions and a temperature, and the method may include an act of adding, within the heat exchanger (e.g., 15) or heat exchanger tube (e.g., 11, 12, 13, 14, or a combination thereof), at least one baffle, for instance. In some embodiments, the baffle is made of a solid material selected to withstand the temperature of the flame, for example, and in some embodiments, the baffle is shaped or selected to have dimensions, and is positioned, so that the baffle fits within the dimensions of the flame, such that, when the furnace is in operation, any deleterious soot that forms on the baffle is burned off, for instance, even if LP gas is burned in the furnace (e.g., 10).
In some such embodiments, the act of adding or installing, within the heat exchanger (e.g., 15) or heat exchanger tube (e.g., 11, 12, 13, 14, or a combination thereof), at least one baffle, may include adding at least one wire (e.g., 61, 101, 141, 191, or 241) within the heat exchanger tube (e.g., where combustion takes place), for instance (e.g., act 274). In some embodiments, the wire may have multiple bends (e.g., 233), may be shaped to form a modified helix (e.g., 244), or both. Further, in some embodiments, the multiple bends (e.g., 233) in the wire (e.g., 241) each have a substantially identical radius, each have a substantially identical angle, each have an angle that is greater than 135 degrees, each have an angle that is greater than 150 degrees, each have an angle that less than 180 degrees, each have an angle that less than 175 degrees, or a combination thereof, as example. Moreover, in some embodiments, the act (e.g., act 274) of adding, within the heat exchanger tube (e.g., 11, 12, 13, 14, or a combination thereof), at least one baffle, may include adding the at least one wire (e.g., 241) wherein adjacent bends (e.g., 233) along the wire are separated by straight sections (e.g., 231) of the wire. In some embodiments, each straight section (e.g., 231) may have a substantially identical length, each bend (e.g., 233) may have a first half (e.g., 238) and a second half (e.g., 239), the angle of each bend (e.g., 233) and the length of each straight section (e.g., 231) may be selected so that the first half (e.g., 238) of a first bend (e.g., 2331) crosses the second half (e.g., 239) of a third bend (e.g., 2333) (i.e., wherein the first and third bends are numbered starting on an end of the wire, such as the end having attachment member 246), or a combination thereof, as examples (e.g., as shown in
In some embodiments, the act of adding, within the heat exchanger (e.g., similar to 15) or heat exchanger tube (e.g., similar to 11, 12, 13, 14, or a combination thereof), at least one baffle (e.g., similar to act 274), may include adding (e.g., where combustion takes place) multiple fins that extend into the heat exchanger tube, as another example. In certain embodiments, the act of adding, within the heat exchanger tube, at least one baffle, may include adding at least one baffle that includes ceramic or that consists essentially of ceramic, as examples. In some embodiments, the act of adding, within the heat exchanger tube, at least one baffle, may include adding at least one baffle that is part of a common piece of material as at least a portion of the heat exchanger tube, adding at least one baffle that is connected to the wall of the heat exchanger tube, adding at least one baffle that extends radially inward from the wall, adding multiple baffles that are each substantially perpendicular to the wall, or a combination thereof, as examples.
Further, some embodiments may include acts of adding multiple baffles that each have a substantially identical overall dimension in a direction perpendicular to the wall, adding multiple baffles that each extend more than a third of the distance from the wall toward the center, adding multiple baffles that each extend less than two thirds of the distance from the wall toward the center, adding multiple baffles that extend about half of the distance from the wall toward the center, or a combination thereof. Furthermore, in some embodiments, the heat exchanger tube (e.g., similar to 11, 12, 13, 14, or a combination thereof) may have at least one wall, a center, and a distance from the wall to the center, and the act of adding, within the heat exchanger tube, at least one baffle (e.g., similar to act 274), may include adding multiple baffles that extend more than half of the distance from the wall toward the center. In some embodiments, the act of adding, within the heat exchanger tube, at least one baffle, may include adding at least five fins, adding at least six fins, adding at least eight fins, adding at least ten fins, adding at least twelve fins, or adding precisely twelve fins, as examples. Further, in some embodiments, the act of adding, within the heat exchanger tube, at least one baffle, may include adding multiple baffles that all have substantially identical dimensions, forming the baffle(s) by extrusion, adding at least one baffle that includes a ceramic material, adding at least one baffle consisting essentially of a ceramic material (e.g., Cordierite), or a combination thereof, as further examples. In some embodiments, the baffles or fins may be extruded, for example.
In some embodiments, manufacture of the apparatus (e.g., 60, 110, 140, 190, or 240) or wire (e.g., 61, 101, 141, 191, or 241) may be automated in whole or in part (e.g., in acts 272 and 273). In some embodiments, for example, a spring lathe coiler machine may be used to make wire NOx inserts, for instance (e.g., in act 272 of method 270). An example of such a machine is a Fortuna Federn (Austria) Machine handled by Phoenix Machinery, Des Plaines, Ill., for instance. Various embodiments may include or use a machine similar to this one, for example, which may further include with an attachment to create a bight and, in some embodiments, twist it (e.g., to make the embodiments shown in
1) Feeding the wire (e.g., 191) and clamping it to where a short length extends beyond the mandrel. (In some embodiments, this extension could become an additional spacer/leg, less twisted-bight, in some embodiments.)
2) The machine makes 2 turns) (720° and stops.
3) The bight-n-twist tool extends and makes the first spacer/leg (e.g., support member 193). (In some embodiments, the lathe and feed would track the material usage for creating the bight.)
4) The bight-n-twist tool retracts clear of the spacer/leg (e.g., support member 193).
5) The machine makes a ⅓ turn) (120° and stops.
6) The bight-n-twist tool extends and makes a second spacer/leg (e.g., support member 193). (In a number of embodiments, the lathe and feed would track the material usage for creating the bight.)
7) The bight-n-twist tool retracts clear of the spacer/leg (e.g., support member 193).
8) The machine makes a ⅓ turn)(120° and stops.
9) The bight-n-twist tool extends and makes the third spacer/leg (e.g., support member 193). (In some embodiments, the lathe and feed tracks the material usage for creating the bight.)
10) The bight-n-twist tool retracts clear of the spacer/leg (e.g., support member 193). (In some embodiments, this completes the end set of spacer/legs.)
11) The machine makes 7 turns) (2,520° and stops (e.g., forming a section of helix 194).
12) Steps 3 through 7 are then repeated.
13) Steps 11 and 12 are repeated 3 more times.
14) The machine makes 2⅓ turns) (780° and stops.
15) The mandrel retracts out of the bight.
16) A length of material is fed which will become the extend hook or attachment mechanism (e.g., attachment member 196 with hook 197).
17) The part is then cut free (e.g., in act 273) with the cut-off tool. The part (e.g., apparatus or embodiment 190) is complete except for the extended, for instance, 4″ hook (e.g., attachment member 196 with hook 197).
In some embodiments, the extended 4″ hook (e.g., attachment member 196 with hook 197), for example, is then formed in a separate operation which, in different embodiments, may be either automated or hand fed. In some embodiments, this separate operation may share a common base and combined controls with the spring lathe coiler machine, for example.
The “Double-Helix” or “Compound-Helix” NOx insert embodiments (e.g., 60 and 110) shown in
Various embodiments include various combinations of the acts, structure, components, and features described herein or shown in the drawings. Moreover, certain procedures may include acts such as obtaining or providing various components described herein, obtaining or providing components that perform functions described herein, advertising or selling products that perform functions described herein, or that contain structure or instructions to perform functions described herein, for instance, through distributors, dealers, or over the Internet, as examples. The invention also contemplates various means for accomplishing the various functions described herein or that are apparent from the structure and acts described.
This patent application claims priority to U.S. Provisional Patent Application No. 61/142,554, filed on Jan. 5, 2009, having the same title and inventors, the contents of which are incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 61142554 | Jan 2009 | US |
