Patent Application
20210317985
The presently disclosed subject matter relates generally to an air distribution baffle, and more particularly to an air distribution baffle disposed within a fluid heating device for uniformly distributing a flow of air for optimal combustion.
Fluid heating devices, such as tankless gas water heaters, are commonly used in residential and industrial applications to provide on-demand heated water supply. Tankless gas water heaters can include a burner assembly that can receive air and fuel. The air and fuel can be mixed together and ignited to cause combustion within the burner assembly to generate heat through a heat exchanger, and water can be passed through the heat exchanger to become heated. As water heater manufacturers increasingly strive to provide increasingly energy efficient devices, it can be difficult to achieve efficient combustion, and thus, efficient heating of water, particularly in tankless gas water heaters.
Combustion requires a combination of air and fuel, and the air-fuel ratio can impact combustion efficiency. For ideal combustion, an adequate supply of air can be provided to completely burn a predetermined amount of fuel. Consequently, optimal combustion efficiency can depend on distribution of air from an air moving device (e.g., including a blower) to a burner assembly.
A major problem associated with tankless gas water heaters can be uneven heating of the passing fluid. This can be caused by nonuniform distribution of primary air and post-combustion secondary air entering the burner assembly. When the flow of air is unequal, portions of the burner assembly can receive different amounts of air. This can result in areas of the burner assembly receiving an excess amount of air, while other areas receive too little air. Further, nonuniform distribution of air can negatively impact combustion efficiency as the combustion rate can vary within the burner assembly. Relatedly, when the distribution of air entering the burner assembly is not uniform, the burner assembly can contain areas of higher temperatures than surrounding areas of the burner assembly. These areas with higher temperatures can generate an exceedingly long flame that can cause flame impingement. Continued instances of flame impingement can reduce the lifespan and efficiency of a fluid heating device.
Traditional attempts to provide uniform distribution of primary and secondary air can include the use of air vanes and louvers. However, multiple sheets of material and complex tools can be required in order to manufacturer air vanes or multiple plates with louvers, resulting in high costs and increased manufacturing time.
For these reasons, a need exists for systems, devices, and methods for effectively distributing a flow of air from an air moving device to a burner assembly to improve combustion efficiency and heat transfer efficiency within a fluid heating device.
These and other problems can be addressed by examples and implementations of the technology disclosed herein.
The disclosed technology includes an air distribution baffle configured to increase the uniformity of the distribution of a flow of air within a burner assembly of a fluid heating device. The air distribution baffle can include a substantially flat portion extending along a base plane of the air distribution baffle and a raised portion extending upwardly from the base plane. The raised portion can include apertures arranged in a predetermined pattern or arrangement.
The disclosed technology also includes a fluid heating device that can include an outer shell having a fluid inlet, a fluid outlet, and a fuel inlet; a burner assembly including an ignitor; and a heat exchanger in fluid communication with the burner assembly. A fluid inlet pipe can extend from the fluid inlet to the heat exchanger, a fluid outlet pipe can extend from the heat exchanger to the fluid outlet, and a fuel inlet pipe can extend from a fuel inlet to the burner assembly. The fluid heating device can include an air moving device, which can be disposed proximate the burner assembly and can be configured to transfer or move combustion gases from the burner assembly toward the heat exchanger. The fluid heating device can include an air distribution baffle disposed between the air moving device and the ignitor, and the air distribution baffle can be configured to distribute a flow of air from the air moving device toward the burner assembly. The air distribution baffle can have a flat portion and a raised portion. The fluid device can also include an exhaust vent.
The disclosed technology also includes a fluid heating device kit including a fluid heating device that includes a burner assembly. The fluid heating device kit can include a first air distribution baffle and a second air distribution baffle. The first air distribution baffle can be different from the second air distribution baffle. The first air distribution baffle can be configured for operation of the fluid heating device at a first elevation and the second air distribution baffle can be configured for operation of the fluid heating device at a second elevation that is different from the first elevation.
These and other aspects of the present disclosure are described in the Detailed Description below and the accompanying figures. Other aspects and features of the present disclosure will become apparent to those of ordinary skill in the art upon reviewing the following description of specific examples of the present disclosure in concert with the figures. While features of the present disclosure may be discussed relative to certain examples and figures, all examples of the present disclosure can include one or more of the features discussed herein. Further, while one or more examples may be discussed as having certain advantageous features, one or more of such features may also be used with the various other examples of the disclosure discussed herein. In similar fashion, while examples may be discussed below as devices, systems, or methods, it is to be understood that such examples can be implemented in various devices, systems, and methods of the present disclosure.
Reference will now be made to the accompanying figures, which are not necessarily drawn to scale, and wherein:
The disclosed technology relates to an air distribution baffle disposed in a fluid heating device that provides uniform distribution of a flow of air from an air moving device to a burner to achieve optimal combustion.
Examples of the disclosed technology are discussed herein with reference to heating “fluid” or “water.” It is to be appreciated that the disclosed technology can be used with a variety of fluids, including water. Thus, while some examples may be described in relation to heating water specifically, all examples of the disclosed technology can be used with fluids other than water unless otherwise specified.
The disclosed technology will be described more fully hereinafter with reference to the accompanying drawings. This disclosed technology can, however, be embodied in many different forms and should not be construed as limited to the examples set forth herein. The components described hereinafter as making up various elements of the disclosed technology are intended to be illustrative and not restrictive. Many suitable components that would perform the same or similar functions as components described herein are intended to be embraced within the scope of the disclosed electronic devices and methods. Such other components not described herein can include, but are not limited to, for example, components developed after development of the disclosed technology.
In the following description, numerous specific details are set forth. But it is to be understood that examples of the disclosed technology can be practiced without these specific details. In other instances, well-known methods, structures, and techniques have not been shown in detail in order not to obscure an understanding of this description. References to “one embodiment,” “an embodiment,” “example embodiment,” “some embodiments,” “certain embodiments,” “various embodiments,” etc., indicate that the embodiment(s) of the disclosed technology so described can include a particular feature, structure, or characteristic, but not every embodiment necessarily includes the particular feature, structure, or characteristic. Further, repeated use of the phrase “in one embodiment” does not necessarily refer to the same embodiment, although it can.
Throughout the specification and the claims, the following terms take at least the meanings explicitly associated herein, unless the context clearly dictates otherwise. The term “or” is intended to mean an inclusive “or.” Further, the terms “a,” “an,” and “the” are intended to mean one or more unless specified otherwise or clear from the context to be directed to a singular form.
Unless otherwise specified, the use of the ordinal adjectives “first,” “second,” “third,” etc., to describe a common object, merely indicate that different instances of like objects are being referred to, and are not intended to imply that the objects so described should be in a given sequence, either temporally, spatially, in ranking, or in any other manner.
Unless otherwise specified, all ranges disclosed herein are inclusive of stated end points, as well as all intermediate values. By way of example, a range described as being “from approximately 2 to approximately 4” includes the values 2 and 4 and all intermediate values within the range. Likewise, the expression that a property “can be in a range from approximately 2 to approximately 4” (or “can be in a range from 2 to 4”) means that the property can be approximately 2, can be approximately 4, or can be any value therebetween.
Referring now to the drawings,
The fluid heating device 100 can include an outer shell 102 having a fluid inlet 104, a fluid outlet 106, and a fuel inlet 108. The fluid heating device 100 can further include a controller 110 configured to operating the process of heating fluid. The controller 110 can receive a signal from a flow sensor 138 to determine whether fluid is flowing into, through, and/or out of the fluid heating device. As an example, and as shown in
The outer shell 102 can be made of one or more suitable materials to allow the fluid heating device 100 to operate effectively while maintaining durability in light of one or more conditions under which the fluid heating device 100 and/or its associated components can be exposed. The outer shell 102 can be made of one or more materials, including but not limited to, aluminum, stainless steel, cooper, plastic, and ceramic.
The fluid inlet tube 114 can be a pipe or any other vessel that can deliver unheated fluid from an external source to the heat exchanger 124 within the fluid heating device 100. The fluid heating device 100 can include a flow sensor 138, which can be attached or connected to a tube configured to transport fluid. The flow sensor 138 can be coupled, directly or indirectly, to the fluid inlet 104. Alternatively or in addition, the flow sensor 138 can be attached to an external or internal surface of the fluid inlet tube 114. The fluid outlet tube 116 can be a pipe or any other vessel that can deliver heated water from the heat exchanger 124 to a source external to the fluid heating device 100. The flow sensor 138 can be coupled, directly or indirectly, to the fluid outlet 106. Alternatively or in addition, the flow sensor 138 can be attached to an external or internal surface of the fluid outlet tube 116.
The controller 110 can include one or more processors and memory storing instructions that, when executed by the processor(s), cause the controller 110 to perform certain actions. For example, the controller 110 can be configured to receive data from various sensors and components of the fluid heating device 100, determine actions to be performed by one or more components based on the received data, and output instructions for one or more components of the fluid heating device 100 to perform those actions. The controller 110 can be mounted on the fluid heating device 100 or disposed within the fluid heating device 100. The controller 110 can be located remotely from the fluid heating device 100. The controller 110 can receive a signal (e.g., via a transceiver) from one or more flow sensors 138 that unheated fluid is entering the fluid heating device 100 via the fluid inlet tube 114 (or that fluid is flowing through or out of the fluid heating device). The controller 110 can output instructions to the air moving device 112 to begin operating and to the fuel inlet 108 to allow fuel to enter the burner assembly 118 through the fuel inlet tube 120. The ignitor 122 disposed within the burner assembly 118 can be or include any source of heat, spark, or ignition that can be ignited or otherwise initiated, such as a flame or one or more burner strips, when a demand for heated water is detected. For example, the ignitor 122 can be in electrical communication with the controller 110 such that the controller 110 can send instructions to the ignitor 122 to ignite.
The air moving device 112 can facilitate transferring a flow of air toward the burner assembly 118 and transferring heated combustion gases from the burner assembly 118 toward the heat exchanger 124. The air moving device 112 can be a fan, blower, or any other device that can force heat generated by combustion gases toward the heat exchanger 124. The air moving device 112 can have a mouth 132 disposed at one end. The air moving device 112 can be configured to operate at a single speed. Alternatively or in addition, the air moving device 112 can be configured to operate at two or more speeds. The air moving device 112 can be configured to adjust its speed (and thus the air flow rate) based on at least the amount of fuel being inputted into the fluid heating device 100, the type of fuel being used, a predetermined or user-inputted temperature of the fluid, or a predetermined or user-inputted air flow rate. Alternatively, the controller 110 can send instructions to the air moving device 112 to operate at a constant speed (e.g., for a one or more predetermined periods of time). Alternatively or in addition, the controller 110 can send instructions to the air moving device 112 to operate at variable speeds (e.g., for one or more predetermined periods of time).
The burner assembly 118 can be disposed proximate the air moving device 112 and the heat exchanger 124. The burner assembly 118 can include a first area 128 and a second area 130. The first area 128 can be in adjacent to the air moving device 112. The first area 128 can be or include the bottom portion of the burner assembly 118. The first area 128 can include an aperture on a bottom surface 140, and the aperture can be sized to attach or connect to the mouth 132 of the air moving device 112. The second area 130 can include the ignitor 122 and can be adjacent to the heat exchanger 124. The second area 130 can be or include the top portion of the burner assembly 118. The burner assembly 118 can include a passage between the first area 128 and the second area 130 to allow the flow of air to be transferred from the first area 128 to the second area 130. Alternatively or in addition, the burner assembly 118 can omit any barriers between the first area 128 and the second area 130 (e.g., the first and second areas 128, 130 are portions of a singular chamber, as illustrated in
The heat exchanger 124 can include one or more tubes or coils disposed within a chamber of the heat exchanger 124. The tubes or coils can be configured to provide a large surface area exposed to the heat generated by the ignitor 122 as the heat passes over the coils. The coils can be made of a thermally conductive material, such as aluminum or copper, so that heat can be absorbed by the coil. One end of the coils can be connected to the fluid inlet tube 114 such that unheated fluid entering the heat exchanger 124 can travel through the coils. As the unheated fluid circulates through the coils, the fluid can become heated by the generated combustion gases. A second end of the coils can be connected to the fluid outlet tube 116 such that the heated fluid can exit via the fluid outlet tube 116. The fluid heating device 100 can include a temperature sensor 136 that can be disposed proximate the fluid outlet tube 116 or some other location downstream from an outlet of the heat exchanger 124. The temperature sensor 136 can detect a temperature of fluid at or near the location of the temperature sensor and send to the controller 110 one or more signals indicative of the temperature of the heated fluid. The controller 110 can receive the temperature signals and output instructions for the fuel valve to close if the fluid temperature is greater than or equal to a predetermined temperature or remain open if the fluid is less than the predetermined temperature.
The vent 126 can be fluidly connected to the heat exchanger 124 to safely output exhaust gases into the external environment. The vent 126 can extend through the top of the heat exchanger 124 and the top surface of the outer shell 102.
An air distribution baffle 200 can be disposed between the air moving device 112 and the ignitor 122. Alternatively or in addition to, the air distribution baffle 200 can be disposed within the first area 128 of the burner assembly 118, as illustrated in
The air distribution baffle 200 can be made from a single piece of material. The material can include one or more metals, such as aluminum, stainless steel, and cooper. The air distribution baffle 200 can be affixed to a surface of the burner assembly 118. Alternatively or in addition to, the air distribution baffle 200 can be affixed to a surface of the first area 128 of the burner assembly 118. Alternatively, the air distribution baffle 200 can be affixed to a surface of the baffle housing. A variety of means of affixing the air distribution baffle 200 can be used, including but not limited to, one or more screws, adhesive, and welding.
The flat portion 202 and the raised portion 204 can have the same length. Alternatively, the flat portion 202 and the raised portion 204 can have different lengths. In one example, the length of the flat portion 202 and the raised portion 204 can be between approximately 100 millimeters and approximately 300 millimeters. In one example, the length of the flat portion 202 and the raised portion 204 of the air distribution baffle 200 can depend on the dimensions of the burner assembly 118.
The raised portion 204 of the air distribution baffle 200 can have one or more faces 210. Each face 210 of the raised portion 204 can be substantially smooth. Alternatively, one or more of the faces 210 of the raised portion 204 can include rigids, protrusions, or the like. One, some, of all of the faces 210 can have one or more corresponding apertures 208. The raised portion 204 can include any number of apertures 208. As a non-limiting example, the raised portion 204 can include a total number of apertures 208 that is between approximately 10 and approximately 200 apertures 208. As other non-limiting examples, the raised portion 204 can include between approximately 10 and approximately 20 apertures 208 on some or all faces of the raised portion 204, and/or the raised portion 204 can include between approximately 20 and approximately 30 apertures 208 on some or all faces of the raised portion 204. The apertures can have any shape, including but not limited to, circular, ovular, triangular, rectangular, square, and/or polygonal. Each aperture 208 can have a predetermined diameter. The predetermined diameter can be between approximately 1 millimeter and approximately 10 millimeters. For example, the predetermined diameter can be between approximately 3 millimeters and approximately 5 millimeters. Each aperture 208 can have the same diameter. Alternatively, one or some of the apertures 208 can have different diameters. For example, one or more of the faces 210 can each include multiple apertures 208 of a common size. That is, the apertures 208 of a given face 210 can be of a common size, but the size of apertures can differ from face 210 to face 210. The diameter of each aperture 208 can depend on the face 210 on which the aperture 208 is disposed, the desired flow rate of the air entering the burner assembly 118, the amount and/or type of fuel entering the burner assembly 118, the size of the burner assembly 118 and/or fluid heating device 100, the number of apertures 208 disposed on each face 210, the number of apertures 208 disposed on the raised portion 204, and the like.
The air distribution baffle 200 can be designed to increase or maximize efficiency of a fluid heating device 100 installed in a particular geographic region and/or at a particular elevation.
By way of example, in geographic locations at an elevation greater than sea level, a greater amount of air flow can be necessary in order to obtain optimal combustion. In these locations, one option can be to increase the diameter of the apertures 208 such that the apertures 208 have a larger diameter as compared to the diameter of apertures 208 in fluid heating devices 100 located at sea level, for example. Thus, depending on the particular region, elevation, or other factors, the size of the baffle 200 itself can differ, the number of apertures 208 can differ, the size of some or all of the apertures 208 can differ, and/or the configuration of the apertures 208 can differ.
The apertures 208 can be disposed on each face 210 in a predetermined pattern or arrangement. The predetermined pattern can be the same for each face 210 of the raised portion 204. Alternatively, the predetermined pattern can be different for each face 210 of the raised portion 204. Alternatively or in addition, one or more faces 210 of the raised portion 204 can omit apertures 208.
The predetermined pattern can include a single row 220 of apertures 208 on one, some, or all faces 210. The row 220 of apertures 208 can span the entire length or substantially the entire length of the face 210. Alternatively, the row 220 of apertures 208 can span only one or more portions of the length of one, some, or all faces 210. The predetermined pattern can include a plurality of rows 220 of apertures 208 on one, some, or all faces 210, and each row 220 can span at least a portion of the length of the respective face 210. For example, one, some, or all faces 210 can have between approximately 10 and approximately 30 apertures 208. One, some, or all faces 210 can have between approximately 15 and approximately 20 apertures 208. The one or more rows 220 of apertures 208 can be linear. Alternatively, the one or more rows 220 of apertures 208 can be nonlinear. By way of example, the row 220 of apertures 208 can have a wave-like or zig-zag configuration, a sinusoidal configuration, or any other useful pattern.
The row 220 of apertures 208 can be divided into one or more section, as illustrated in
One or more of the apertures 208 can be covered in order to achieve variable air flow rates. The apertures 208 can be covered by a plate or any material that can effectively prevent air flow through the aperture 208. One or more apertures 208 can be selectively covered to achieve a desired air flow rate. One, some, or all faces 210 of the raised portion 204 can include the same number of covered apertures 208 and the same arrangement of covered apertures 208.
Alternatively, one, some, or all faces 210 of the raised portion 204 can include a different number of covered apertures 208 and/or a different arrangement of covered apertures 208 to achieve a different air flow rate from some or all faces 210 of the raised portion 204. The number and arrangement of covered apertures 208 can depend on the desired air flow rate, type and/or amount of fuel, the number of apertures 208 on the respective faces 210, the number of apertures 208 disposed on the raised portion 204, and the like.
The air distribution baffle 200 can provide a greater flow of secondary air to the orifices in the burner assembly 118 as compared to a fluid heating device 100 without the air distribution baffle 200. A greater flow of secondary air to the orifices can foster combustion without diminishing flame stability. When the ignitor 122 includes one or more flames, the air distribution baffle 200 can also reduce the occurrence of flame impingement, and thus, an improve the life span and efficiency of the fluid heating device 100.
The disclosed technology can also include a method of manufacturing an air distribution baffle 200 for inserting into a fluid heating device 100. The method of manufacturing the air distribution baffle 200 can include providing a single piece of material. The material can include one or more materials, including but not limited to, aluminum, cooper, stainless steel, plastic, and ceramic. The single piece of material can be formed into a substantially rectangular shape. At least a portion of the single piece of material can be shaped to create a raised portion 204. In one example, the raised portion 204 can be approximately half of the width of the piece of material. Alternatively, the raised portion 204 can be greater than half of the width of the piece of material or less than half of the width of the piece of material. The raised portion 204 can be formed by applying heat and/or pressure or by using appropriate machinery.
The method of manufacturing the air distribution baffle 200 can further include puncturing apertures 208 into the raised portion 204 using appropriate machinery. The apertures 208 can be punctured according to a predetermined pattern along at least one face of the raised portion. Further, one or more openings 302 can be punctured along a length of the flat portion 202.
The method of manufacturing the air distribution baffle 200 can further include covering one or more apertures 208 with a plate or any piece of material that can minimize or prevent a flow of air. One or more apertures 208 can be covered according to a predetermined pattern along at least one face of the raised portion 204.
The method of manufacturing the air distribution baffle 200 can include inserting the air distribution baffle 200 between an air moving device 112 and an ignitor 122 disposed within the burner assembly 118. In one example, the air distribution baffle 200 can be inserted into a first area 128 of the burner assembly 118. Alternatively, the air distribution baffle 200 can be inserted into a baffle housing that is positioned below the burner assembly 118. The air distribution baffle 200 can be inserted such that the raised portion 204 can be proximate the mouth 132 of the air moving device 112. The air distribution baffle 200 can be affixed to a bottom surface 140 of the first area 128 of the burner assembly 118 or a bottom surface of the baffle housing. In one example, screws or similar attachment means can be inserted into the one or more openings 302 punctured along the length of the flat portion 202. Alternatively or in addition to, adhesive can be applied to the air distribution baffle and/or the burner assembly to affix the air distribution baffle 200 to the first area 128 or baffle housing. Alternatively or in addition to, the air distribution baffle 200 can be welded to the bottom surface 140 of the first area 128 or the bottom surface of the baffle housing. Alternatively, the air distribution baffle can be removeable from the fluid heating device 100, such as for maintenance or cleaning.
The disclosed technology can also include a fluid heating device 100 and two or more air distribution baffles 200 that can be installed in the fluid heating device 100. A first air distribution baffle 200 can include features and/or elements configured to increase efficiency of the fluid heating device 100 when operating at a first elevation range, and a second air distribution baffle 200 can include features and/or elements configured to increase efficiency of the fluid heating device 100 when operating at a second elevation range that is different from the first elevation range. For example, the first and second air distribution baffles 200 can have different shapes (e.g., shapes of the respective raised portions 204), apertures 208 of different diameters, different arrangements or patterns of apertures 208, different numbers of apertures 208, or the like. These differences can alter the flow of incoming air in accordance with some or all of the elements described herein. By way of example, the first air distribution baffle can provide increased efficiency for a fluid heating device 100 operating at an elevation in an elevation range between approximately 0 feet (approximately 0 meters) above sea level and approximately 3,000 feet (approximately 900 meters) above sea level, and the second air distribution baffle can provide increased efficiency for the same fluid heating device 100 operating at an elevation in an elevation range between approximately 3,000 feet (approximately 900 meters) above sea level and approximately 10,000 feet (approximately 3,000 meters) above sea level. A third air distribution baffle can be provided and can provide increased efficiency for the same fluid heating device 100 operating at an elevation in an elevation range between approximately 7,000 feet (approximately 2,100 meters) above sea level and approximately 10,000 feet (approximately 3,000 meters) above sea level. These ranges are for illustration only, and the disclosed technology includes any number of baffles 200, each configured to increase efficiency of the fluid heating device 100 in a respective elevation range. For example, the disclosed technology includes three, four, five or more baffles, each of which is configured increase efficiency of the fluid heating device 100 in a separate, respective elevation range. Further, the elevation ranges targeted by each individual baffle 200 can differ depending on the desired precision. For example, a system can include the two or three example baffles described above, and/or can include two different example baffles, with the first baffle providing increased efficiency for elevations between approximately 0 feet (approximately 0 meters) and approximately 5,000 feet (approximately 1,500 meters) and the second baffle providing increased efficiency for elevations between approximately 5,000 feet (approximately 1,500 meters) and approximately 10,000 feet (approximately 3,000 meters).
Certain examples and implementations of the disclosed technology are described above with reference to block and flow diagrams according to examples of the disclosed technology. It will be understood that one or more blocks of the block diagrams and flow diagrams, and combinations of blocks in the block diagrams and flow diagrams, respectively, can be implemented by computer-executable program instructions. Likewise, some blocks of the block diagrams and flow diagrams do not necessarily need to be performed in the order presented, can be repeated, or do not necessarily need to be performed at all, according to some examples or implementations of the disclosed technology. It is also to be understood that the mention of one or more method steps does not preclude the presence of additional method steps or intervening method steps between those steps expressly identified. Additionally, method steps from one process flow diagram or block diagram can be combined with method steps from another process diagram or block diagram. These combinations and/or modifications are contemplated herein.
