The present invention generally relates to fuel-fired heating appliances and, in representatively illustrated embodiments thereof, more particularly provides specially designed fuel-fired water heaters with low NOx burners having integral venturi fuel/air inlet structures therein, and being integrated with flammable vapor ignition resistance (FVIR) platforms.
Residential gas-fired water heaters are required to meet reduced NOx emission standards effective in 2005 for certain Air Quality Management Districts (AQMD's) of California and Texas. Recently, various gas-fired water heaters have been redesigned to provide them with flammable vapor ignition resistance (FVIR) in accordance with the Z21 ANSI standards. Significant tooling investment has been made to create new water heater platforms, complete with flame arrestors, damper plate assemblies with combustion air shutoff devices, and perforated jacket assemblies to channel and filter air.
It would be desirable to incorporate in these FVIR-redesigned water heaters low NOx fuel burners, which would provide the water heaters with the required lowered NOx emission rates, in a manner which would reduce or eliminate the need for platform redesigns. It is to this goal that the present invention is primarily directed.
In carrying out principles of the present invention, in accordance with a preferred embodiment thereof, a fuel-fired heating appliance, representatively but not by way of limitation a gas-fired water heater, is provided with a low NOx fuel burner which is integrated with a flammable vapor ignition resistance (FVIR) platform. In illustrated embodiments thereof, the water heater comprises a combustion chamber separated from a plenum area by a wall structure, an inlet space for receiving combustion air from outside the water heater, and a fuel burner.
The fuel burner has a hollow body with an outlet portion thereof projecting from the wall structure into the combustion chamber, and an inlet portion projecting from the wall structure into the plenum area. The inlet portion of the fuel burner has a venturi inlet structure associated therewith and operative to flow combustion air from the inlet space into the inlet portion of the burner body. To lower the NOx emissions of the burner, preferably all of the primary combustion air delivered to the burner comes from outside of the water heater and is illustratively flowed to the venturi inlet structure via the plenum area.
Illustratively, the fuel burner is a radiant burner having a perforate flame-holding wall section, which may be of a metal mesh construction, which is disposed on the outlet portion of the burner body. This perforate wall section provides the water heater with flammable vapor ignition resistance, the flame-holding wall section serving to preclude flame outflow from the combustion chamber. This flammable vapor ignition resistance may be augmented by disposing flame quenching openings in the bottom wall structure of the combustion chamber by, for example, placing a perforated flame arrestor plate therein.
According to one aspect of the invention, the venturi inlet structure of the burner is formed as an integral portion of its inlet portion disposed within the plenum area, thus integrating a low NOx burner with an FVIR platform. Alternatively, the venturi inlet structure, which is representatively an air inlet conduit structure extending through the plenum area or simply a venturi opening formed in an outer wall of the burner body inlet portion, may be a separate structure attached to the burner body inlet portion. Fuel is supplied to the burner via a fuel supply tube suitably routed through an interior portion of the water heater to the burner.
In one illustrated embodiment thereof, the water heater is also provided with a combustion shutoff system functioning to automatically terminate combustion in response to the presence of a predetermined, unacceptably high temperature within the combustion chamber which may be caused, for example, by the combustion therein of extraneous flammable vapors ingested from outside the water heater. In a representative embodiment thereof, the combustion shutoff system is operative to terminate combustion air flow to the burner and comprises a temperature sensing structure disposed within the combustion chamber an linked to a spring-loaded damper structure releasable by the temperature sensing structure, to close the inlet of the burner venturi inlet structure, in response to the combustion chamber temperature reaching a set point temperature of the temperature sensing structure.
In illustrated representative embodiments thereof, the water heater has an inner wall structure defining a tank for holding water to be heater, a combustion chamber extending downwardly from a lower end of the tank and having a bottom wall structure, and a skirt wall depending from a bottom peripheral portion of the combustion chamber and circumscribing a plenum area separated from the combustion chamber by the bottom wall structure, the skirt wall having an opening therein.
An outer wall structure outwardly circumscribes the inner wall structure and defines therewith an air inlet space at least partially circumscribing the skirt wall, the outer wall structure having a combustion air inlet opening area extending therethrough into the air inlet space. The fuel burner is illustratively a radiant burner and has a hollow body with an upper outlet portion thereof projecting from the combustion chamber bottom wall structure into the combustion chamber, and a lower inlet portion projecting from the bottom wall structure into the plenum area, the inlet portion having a venturi inlet structure associated therewith and having an inlet communicated with the air inlet space in a manner permitting combustion air entering the air inlet space through said combustion air inlet opening area from outside the water heater to be drawn into said inlet of the venturi inlet structure. Preferably, all of the primary combustion air delivered to the burner flows through its venturi inlet structure, comes from outside of the water heater, and is flows flowed to the inlet of the venturi structure via the interior of the skirted plenum area.
The water heater also includes fuel delivery apparatus for delivering fuel from a source thereof to the interior of said lower inlet portion of said hollow body for mixture with combustion air flowed thereinto via said venturi inlet structure. Representatively, the fuel delivery apparatus includes a fuel supply tube appropriately routed through an interior portion of the water heater to operatively supply fuel gas, from a source thereof, to the burner.
According to various other aspects of the invention, the flame-holding wall section of the radiant burner is removable from the balance of the burner for cleaning and inspection purposes, the combustion air inlet opening area includes a series of air filtering perforations formed in the outer wall structure, and the water heater may have incorporated therein the aforementioned combustion shutoff system together with the flammable vapor ignition resistance structure which includes the flame-holding wall section of the radiant burner.
In accordance with further features of the invention, in illustrated embodiments of the water heater the bottom wall structure of the combustion chamber is defined by a peripheral portion of the fuel burner captively and supportingly retained in a circumferential rolled portion of the inner wall structure. In another illustrated embodiment of the water heater the bottom wall structure of the combustion chamber is separate from the fuel burner and has an opening through which the fuel burner vertically extends. The fuel burner is releasably interlocked with the bottom wall structure and is downwardly removable from the combustion chamber through the opening in the separate bottom wall structure. The fuel burner is releasably interlocked with the bottom wall structure by cooperating tab and slot structures on the fuel burner and bottom wall structure, and is interlockable with and releasable from the bottom wall structure by rotating the fuel burner relative to the bottom wall structure about a vertical axis.
When released from the bottom wall structure the fuel burner may be removed from the water heater by withdrawing the released fuel burner outwardly through aligned access openings in the inner and outer wall structures. The venturi inlet structure of this burner embodiment has a cover member secured thereto and adapted to cover the access opening in the inner wall structure when the fuel burner is supportingly interlocked with the bottom wall structure.
According to another aspect of the invention, in one embodiment thereof the water heater further includes a flue pipe extending upwardly from a central portion of the lower end of the tank. The upper outlet portion of the hollow burner body has a nonperforate central top side portion underlying the flue pipe, and the perforate flame holding wall section of the burner at least partially circumscribes this nonperforate central top side portion and slopes downwardly and inwardly towards it. In this manner, clogging of the flame-holding wall section by scale falling from the interior of the flue pipe is substantially reduced.
Various combustion air inlet flow paths through the interior of the water heater are representatively utilized in illustratively depicted embodiments of the water heater. These combustion air inlet flow paths include one in which the inlet of the venturi inlet structure receives combustion air from the air inlet space via the interior of the plenum area, another in which the inlet of the venturi inlet structure is disposed within the plenum area, and a further one in which the inlet of the venturi inlet structure is disposed within the air inlet space, and the water heater further includes an inlet passage for flowing combustion air from outside the water heater through the air inlet opening area and into the plenum area for delivery outwardly therefrom, via the skirt wall opening, into the air inlet space.
As will be readily appreciated by those of skill in this particular art, the present invention is not limited to water heaters, but could also be advantageously incorporated in other types of fuel-fired heating appliances such as, for example, boilers and fuel-fired air heating furnaces. Additionally, while the various water heater embodiments representatively illustrated and described herein have been indicated as incorporating radiant fuel burners therein, it will also be readily appreciated by those of skill in this particular art that other types of fuel burners could alternatively be utilized if desired without departing from principles of the present invention.
Cross-sectionally illustrated in schematic form in
A vertically oriented tubular metal outer wall structure, representatively in the form of a metal jacket 30, outwardly circumscribes the inner wall structure 12 and forms therewith an annular space, an upper portion of which is filled with a suitable insulation material 32, and a lower end portion of which forms an annular air inlet or receiving space 34 which outwardly circumscribes the skirt wall 22. A circumferentially spaced series of combustion air inlet openings 36 extend through a lower end portion of the jacket 30 into the annular space 34.
Water heater 10 also includes a radiant gas burner 40, the hollow body of which is formed from abutting upper and lower metal pan structures 42,44 having circular peripheral edge flange portions supportingly received in a circumferentially rolled portion 46 of the inner wall structure 12. As can be seen in
On the top side of the burner 40 is a metal mesh burner screen structure 48 (see.
As can best be seen in
The burner screen 48 provides the water heater 10 with flammable vapor ignition resistance (FVIR) to substantially prevent flames within the combustion chamber 20 (caused, for example, by ignition of extraneous flammable vapors ingested into the combustion chamber) from downwardly exiting the combustion chamber 28, the various small openings in the screen area 48 serving as flame quenching openings that permit fuel and air to upwardly traverse the screen, but preclude the passage of flames downwardly therethrough.
As illustrated in
During firing of the burner 40, fuel gas 66 is discharged from the nozzle 64 into the interior of the burner 40, and combustion air 68 from outside the water heater 10 sequentially flows inwardly through the combustion air inlet openings 36 into the annular space 34, from the annular space 34 into the skirt plenum area 24 via the skirt wall openings 26, and from the skirt plenum area 24 into the interior of the burner 40 through its integral venturi inlet opening 58. Combustion air 68 entering the interior of the burner 40 in this manner is mixed with the discharged fuel gas 66 to form a fuel/air mixture that passes upwardly through the removable burner screen 48 and is suitably ignited to form the previously mentioned hot combustion products within the combustion chamber 20 and heat the stored tank water 16.
As can be seen, all of the primary combustion air supplied to the burner 40 comes from outside the water heater 10. Accordingly, the NOx emissions generated by the burner 40 are quite low. Thus, the representatively illustrated water heater 10, in a simple, efficient and economical manner, integrates a low NOx fuel burner with a flammable vapor ignition resistance structure.
A first alternate embodiment 10a of the previously described water heater 10 is schematically shown in
In the water heater 10a, the removable burner screen 48a has a fully domed configuration, and the combustion air inlet openings 36a formed in the jacket wall 30a are particulate filtering perforations operative to filter out, for example, lint, dirt and oil from combustion air 68a entering the annular space 34a to reduce potential clogging of the burner screen 48a. As an alternative to these filtering perforations in the jacket wall 30a, a separate filtering structure could be appropriately installed in a suitable mounting opening in the jacket wall 30a. The integral burner venturi inlet opening 58a disposed within the skirt plenum 24a faces downwardly and forms a portion of a combustion shutoff system 70 incorporated in the water heater 10a.
The combustion shutoff system 70 functions to terminate combustion in the combustion chamber 20a, representatively by precluding further combustion air flow to the burner 40a, in response to the detection of an undesirably high temperature in the combustion chamber 20a which may be caused, for example, by the combustion therein of ingested extraneous flammable vapors from outside the water heater 10a. Combustion shutoff system 70 representatively includes a temperature sensing structure 72 disposed within the combustion chamber 20a and linked to a spring-loaded shutoff damper assembly 74 which is normally held in its indicated open position in which it permits combustion air 68a to flow into the interior of the burner 48a through its integral venturi inlet opening 58a.
Upon detecting a predetermined, undesirably high temperature within the combustion chamber 20a, the temperature sensing structure 72 permits the damper structure 74 to be spring-driven upwardly in a manner causing the damper structure 74 to close off the burner inlet opening 58a. The temperature sensing structure 72 is located over a perforated arrestor plate 76 (see
Like the previously described water heater 10, the water heater 10a desirably integrates a low NOx fuel burner with an FVIR platform in a simple, efficient and economical manner.
Cross-sectionally illustrated in schematic form in
Water heater 10b representatively does not incorporate the previously described combustion shutoff system 70 therein, and, compared to the water heater 10a, has a somewhat modified burner configuration. Specifically, as shown in
A third alternate embodiment 10c of the previously described water heater 10 shown in
In the water heater 10c shown in
Horizontally extending outwardly from a lower portion of the burner 40c which projects downwardly into the skirt plenum area 24c is a venturi conduit 90 having, at its outer end, the venturi inlet 58c. Conduit 90 extends outwardly through an access opening 92 in the skirt wall 22c, with an outer end portion of the conduit 90 being fixedly secured within a removable access cover 94 extending across the access opening 92. As illustrated, the inlet opening 58c of the venturi conduit 90 is disposed within the annular space 34c for receiving fuel 66c from the discharge orifice 64c. An access opening 96 is formed through the jacket 30c, in alignment with the combustion chamber access opening 92, with a removable cover 98 extending across the access opening 96.
With the covers 94,98 removed, the burner 40c is installed within the water heater 10c by inserting the burner body inwardly through the aligned access openings 96,92 in an orientation in which the burner tabs 88 underlie the plate notches 86 and the access cover 94 is closely adjacent the access opening 92. The burner 40c is then moved upwardly to place an upper burner portion within the combustion chamber 20c and move the burner tabs 88 upwardly through the plate notches 86. Finally, the inserted burner 40c is rotated about the indicated vertical axis 100 to cause the tabs 88 to overlie the plate 84 and operatively support the burner 40c within the water heater 40c. This also brings the cover member 94 into a covering relationship with the access opening 92. The other removable cover 98 is then installed over the jacket access opening 96. TO remove the installed burner 40c for inspection and cleaning, this process is simply reversed. The wire mesh top side section 102 of the installed burner 40c, in conjunction with the indicated perforated flame arrestor plates 76c installed in the plate 84, provides the water heater 10c with flammable vapor ignition resistance.
The indicated particulate filtering perforations 68c formed in the jacket 30c are positioned diametrically oppositely from the venturi conduit inlet 58c and communicate with an enclosed passageway 104 extending through annular space 34c and opening into the skirt plenum area 24c. During firing of the water heater 10c, combustion air 68c from outside the water heater 10c flows sequentially through the combustion air inlet perforations 36c into the interior of the skirt plenum area 24c via the enclosed passageway 104, outwardly from the skirt plenum area into the annular space 34c through the air transfer openings 26c, and then into the venturi conduit inlet 58c for mixture with fuel 66c being discharged from the fuel nozzle 64c to form the fuel/air mixture ignited by the burner 40c.
Like the previously described water heaters 10, 10a and 10b, the water heater 10c desirably integrates a low NOx fuel burner with an FVIR platform in a simple, efficient and economical manner.
While various principles of the present invention have been representatively illustrated and described herein as being incorporated in a fuel-fired water heater, it will be readily appreciated by those of skill in this particular art that the present invention is not limited to water heaters, but could also be advantageously incorporated in other types of fuel-fired heating appliances such as, for example, boilers and fuel-fired air heating furnaces.
Additionally, while the various water heater embodiments representatively illustrated and described herein have been indicated as incorporating radiant fuel burners therein, it will also be readily appreciated by those of skill in this particular art that other types of fuel burners could alternatively be utilized if desired without departing from principles of the present invention.
The foregoing detailed description is to be clearly understood as being given by way of illustration and example only, the spirit and scope of the present invention being limited solely by the appended claims.
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