CA2768914A1 - High efficiency water heater - Google Patents
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- CA2768914A1 CA2768914A1 CA 2768914 CA2768914A CA2768914A1 CA 2768914 A1 CA2768914 A1 CA 2768914A1 CA 2768914 CA2768914 CA 2768914 CA 2768914 A CA2768914 A CA 2768914A CA 2768914 A1 CA2768914 A1 CA 2768914A1
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Abstract
A boiler and method of operating a boiler are disclosed. Heat exchange conduits are positioned within an enclosed region of the boiler housing. A
burner delivers products of combustion into the enclosed region of the housing for heat exchange with water contained within the heat exchange conduits. A divider separates the enclosed region into a proximal portion into which the burner extends and a distal portion into which the burner does not extend. A baffle extends into the distal portion of the housing. The baffle and the housing together define a constricted region in the distal portion, and at least one heat exchange conduit is positioned within the constricted region. The divider and the baffle direct the flow of products of combustion in the proximal portion of the housing and the constricted region, thereby facilitating heat exchange between the products of combustion and water within the heat exchange conduits.
burner delivers products of combustion into the enclosed region of the housing for heat exchange with water contained within the heat exchange conduits. A divider separates the enclosed region into a proximal portion into which the burner extends and a distal portion into which the burner does not extend. A baffle extends into the distal portion of the housing. The baffle and the housing together define a constricted region in the distal portion, and at least one heat exchange conduit is positioned within the constricted region. The divider and the baffle direct the flow of products of combustion in the proximal portion of the housing and the constricted region, thereby facilitating heat exchange between the products of combustion and water within the heat exchange conduits.
Description
HIGH EFFICIENCY WATER HEATER
FIELD OF THE INVENTION
The present invention relates to a water heater such as a boiler and a method of operating the same.
BACKGROUND OF THE INVENTION
Water heaters and boilers such as those used as pool heaters typically include a burner for introducing hot combustion gases into a housing of the heater and a heat exchanger including hollow tube members fitted within the heater housing.
Water is circulated through the hollow tube members of the heat exchanger for heat exchange with the hot combustion gases introduced into the heater housing.
One example of such a water heater or boiler is described in U.S. Patent No.
6,644,393 to Roberts et al. Another example of such a water heater or boiler is described in U.S. Patent App. Publication No. US-2010/0221675 to Roberts et al.
22205025.2 1 Publication No. US-2010/0221675 describes a boiler generally including a housing defining an enclosed region and heat exchange conduits positioned within the housing and arranged into interior and exterior columns. A baffle is positioned between the interior and exterior columns, and the baffle and the housing together define a constricted region for directing the flow of products of combustion adjacent the heat exchange conduits of the exterior column.
Although the boilers of U.S. Patent No. 6,644,393 and Publication No. US-2010/0221675 each facilitates the exchange of heat between products of combustion and water, there remains a need to further refine water heaters and boilers to improve at least one of their performance, efficiency, cost and reliability.
SUMMARY OF THE INVENTION
According to one exemplary aspect of the invention, a water heater is provided.
The water heater comprises a housing defining a substantially enclosed region.
A
plurality of heat exchange conduits are at least partially positioned within the substantially enclosed region of the housing, wherein each heat exchange conduit has a first end spaced apart from a second end thereof and a water passageway defined between the first end and the second end. The heat exchange conduits are positioned in a substantially columnar arrangement. A burner is arranged along a burner axis and positioned to deliver products of combustion into the substantially enclosed region of the housing for heat exchange with water contained within the heat exchange conduits. A divider traverses the burner axis and at least partially separates the substantially enclosed region into a proximal portion into which the burner extends 22205025.2 2 and a distal portion into which the burner does not extend. A baffle extends in a direction generally along the burner axis and into the distal portion of the substantially enclosed region of the housing. The baffle is positioned radially inwardly of at least one of the heat exchange conduits. The baffle and the housing together define a constricted region in the distal portion of the substantially enclosed region of the housing. The at least one heat exchange conduit is positioned within the constricted region. The divider and the baffle are configured to direct the flow of products of combustion adjacent one or more heat exchange conduits in the proximal portion of the substantially enclosed region of the housing and adjacent the at least one heat exchange conduit positioned within the constricted region, thereby facilitating an exchange of heat between the products of combustion and water within the heat exchange conduits.
According to another exemplary aspect of the invention, a method of operating a boiler is provided. The boiler includes a heat exchanger positioned at least partially within a substantially enclosed region of a boiler housing, a burner positioned to deliver products of combustion into the enclosed region of the boiler housing, a divider at least partially separating the substantially enclosed region into a proximal portion into which the burner extends and a distal portion into which the burner does not extend, and a baffle extending into the distal portion of the substantially enclosed region of the housing. The method comprises the step of delivering products of combustion into the proximal portion of the enclosed region of the boiler housing for heat exchange with water contained within a portion of the heat exchanger that is at least partially positioned within the proximal portion. The products of combustion are directed into a constricted region of the boiler housing defined in the distal portion of the enclosed region between the baffle and the boiler housing for heat exchange with 22205025.2 3 water contained within another portion of the heat exchanger that is at least partially positioned within the constricted region.
According to yet another exemplary aspect of the invention, a method of assembling a boiler is provided. The boiler includes a heat exchanger positioned at least partially within a substantially enclosed region of a boiler housing and a burner positioned to deliver products of combustion into the enclosed region of the boiler housing. The method comprises the step of positioning a divider in the substantially enclosed region of a boiler housing, thereby at least partially separating the substantially enclosed region into a proximal portion into which the burner extends and a distal portion into which the burner does not extend. A baffle is positioned in the distal portion of the substantially enclosed region of the housing to define a constricted region in the distal portion of the substantially enclosed region of the housing. A portion of the heat exchanger is positioned at least partially within the proximal portion of the substantially enclosed region of the housing and another portion of the heat exchanger at least partially within the constricted region of the distal portion of the substantially enclosed region of the housing.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is best understood from the following detailed description when read in connection with the accompanying drawings. It is emphasized that, according to common practice, the various features of the drawings are not to scale. On the contrary, the dimensions of the various features are arbitrarily expanded or reduced for clarity. Included in the drawings are the following figures:
22205025.2 4 FIG. 1 is a perspective view of a first exemplary embodiment of a boiler.
FIG. 2 is a top plan view of the boiler of FIG. 1.
FIG. 3 is a cross-sectional view of the boiler of FIG. 2 taken along the lines 3-3.
FIG. 4 is a perspective view of the boiler of FIG. 1, wherein the headers of the heat exchanger and a wall of the boiler housing are omitted to reveal the exposed ends of the heat exchange conduits of the heat exchanger.
FIG. 5 is a cross-sectional side elevation view of the boiler of FIG. 2 taken along the lines 5-5.
FIG. 6 is an exploded view of the boiler of FIG. 1.
FIG. 7 is an exploded view of a header of the boiler of FIG. 1.
FIG. 8 is a cross-sectional side elevation view of second exemplary embodiment of a boiler that is shown schematically.
FIG. 9 is a top plan schematic view of the boiler of FIG. 8 shown partially assembled.
FIG. 10 is a cross-sectional schematic view of the heat exchanger of the boiler of FIG. 9 taken along the lines 10-10.
FIG. 11 is a cross-sectional side elevation view of third exemplary embodiment of a boiler that is shown schematically.
FIG. 12 is a top plan schematic view of the boiler of FIG. 11 shown partially assembled.
22205025.2 5 FIG. 13 is a cross-sectional schematic view of the heat exchanger of the boiler of FIG. 11 taken along the lines 13-13.
FIGS. 14A-14C depict front elevation, perspective, and top plan views, respectively, of another embodiment of a partially assembled boiler that is similar to the partially assembled boiler of FIG. 12.
DETAILED DESCRIPTION OF THE INVENTION
Although the invention is illustrated and described herein with reference to specific embodiments, the invention is not intended to be limited to the details shown.
Rather, various modifications may be made to the illustrated embodiments within the scope and range of equivalents of the claims and without departing from the invention. Also, the embodiments selected for illustration in the figures are not shown to scale and are not limited to the proportions shown.
Referring generally to the figures and according to one exemplary aspect of the invention, a water heater 10, 110, 210 is provided. The water heater 10, 110, comprises a housing 12, 112, 212 defining a substantially enclosed region. A
plurality of heat exchange conduits 27 and 29, 127 and 129, 227-229 are at least partially positioned within the substantially enclosed region of the housing 12, 112, 212, wherein each heat exchange conduit 27 and 29, 127 and 129, 227-229 has a first end spaced apart from a second end thereof and a water passageway defined between the first end and the second end. The heat exchange conduits 27 and 29, 127 and 129, 227-229 are positioned in a substantially columnar arrangement. A burner 20, 120, 22205025.2 6 220 is arranged along a burner axis 'L' and positioned to deliver products of combustion into the substantially enclosed region of the housing 12, 112, 212 for heat exchange with water contained within the heat exchange conduits 27 and 29, 127 and 129, 227-229. A divider 35, 135, 235 traverses the burner axis 'L' and at least partially separates the substantially enclosed region into a proximal portion 12A, 112A, 212A into which the burner 20, 120, 220 extends and a distal portion 12B, 112B, 212B into which the burner 20, 120, 220 does not extend. A baffle 37, 137, 237 extends in a direction generally along the burner axis'L' and into the distal portion 12B, 112B, 212B of the substantially enclosed region of the housing 12, 112, 212. The baffle 37, 137, 237 is positioned radially inwardly of at least one of the heat exchange conduits 27 and 29, 127 and 129, 227-229. The baffle 37, 137, 237 and the housing 12, 112, 212 together define a constricted region 'A', 'B', 'E' in the distal portion 12B, 112B, 212B of the substantially enclosed region of the housing 12, 112, 212. At least one heat exchange conduit 27 and 29, 127 and 129, 227-229 is positioned within the constricted region 'A', '13', 'E'. The divider 35, 135, 235 and the baffle 37, 137, 237 are configured to direct the flow of products of combustion adjacent one or more heat exchange conduits 27 and 29, 127 and 129, 227-229 in the proximal portion 12A, 112A, 212A of the substantially enclosed region of the housing 12, 112, 212 and adjacent the at least one heat exchange conduit 27 and 29, 127 and 129, 227-229 positioned within the constricted region `A', `B', 'E', thereby facilitating an exchange of heat between the products of combustion and water within the heat exchange conduits 27 and 29, 127 and 129, 227-229.
According to another aspect of the invention, a method of operating a boiler 10, 110, 210 is provided. The boiler 10, 110, 210 includes a heat exchanger 14, 114, 214 positioned at least partially within a substantially enclosed region of a boiler housing 22205025.2 7 12, 112, 212, a burner 20, 120, 220 positioned to deliver products of combustion into the enclosed region of the boiler housing 12, 112, 212, a divider 35, 135, 235 at least partially separating the substantially enclosed region into a proximal portion 12A, 112A, 212A into which the burner 20, 120, 220 extends and a distal portion 12B, 112B, 212B into which the burner 20, 120, 220 does not extend, and a baffle 37, 137, 237 extending into the distal portion 12B, 112B, 212B of the substantially enclosed region of the housing 12, 112, 212. The method comprises the step of delivering products of combustion into the proximal portion 12A, 112A, 212A of the enclosed region of the boiler housing 12, 112, 212 for heat exchange with water contained within a portion of the heat exchanger 14, 114, 214 that is at least partially positioned within the proximal portion 12A, 112A, 212A. The products of combustion are directed into a constricted region 'A', 'B', 'E' of the boiler housing 12, 112, 212 defined in the distal portion 12B, 112B, 212B of the enclosed region between the baffle 37, 137, 237 and the boiler housing 12, 112, 212 for heat exchange with water contained within another portion of the heat exchanger 14, 114, 214 that is at least partially positioned within the constricted region 'A', 'B', `E'.
According to yet another aspect of the invention, a method of assembling a boiler 10, 110, 210 is provided. The boiler 10, 110, 210 includes a heat exchanger 14, 114, 214 positioned at least partially within a substantially enclosed region of a boiler housing 12, 112, 212 and a burner 20, 120, 220 positioned to deliver products of combustion into the enclosed region of the boiler housing 12, 112, 212. The method comprises the step of positioning a divider 35, 135, 235 in the substantially enclosed region of a boiler housing 12, 112, 212, thereby at least partially separating the substantially enclosed region into a proximal portion 12A, 112A, 212A into which the burner 20, 120, 220 extends and a distal portion 12B, 112B, 212B into which the 22205025.2 8 burner 20, 120, 220 does not extend. A baffle 37, 137, 237 is positioned in the distal portion 12B, 112B, 212B of the substantially enclosed region of the housing 12, 112, 212 to define a constricted region 'A', 'B', 'E' in the distal portion 12B, 112B, 212B of the substantially enclosed region of the housing 12, 112, 212. A portion of the heat exchanger 14, 114, 214 is positioned at least partially within the proximal portion 12A, 112A, 212A of the substantially enclosed region of the housing 12, 112, 212 and another portion of the heat exchanger 14, 114, 214 at least partially within the constricted region 'A', 'B', 'E' of the distal portion 12B, 112B, 212B of the substantially enclosed region of the housing 12, 112, 212.
Referring now to FIGS. 1-6, a first exemplary embodiment of a boiler is designated by the numeral "10." The boiler 10 generally includes a housing 12 defining a substantially enclosed interior region, a heat exchanger 14 that is at least partially contained within the interior region of the housing 12, and a burner 20 that is mounted to the top cover of the housing 12 for introducing products of combustion into the interior of the housing 12 for heat exchange with fluid that is contained within the heat exchanger 14. Details of an exemplary burner 20 are described in U.S.
Patent No. 6,644,393.
Referring now to the components of the housing 12 of the boiler 10, the housing 12 generally includes a series of interconnected walls, flanges and covers defining an substantially enclosed interior region. The walls, flanges and covers enclose the housing 12 to limit or prevent products of combustion from inadvertently escaping from the interior region. The interconnected walls, flanges and covers of the housing 12 comprise a top cover 17, a bottom cover 21 , two side walls 19(1) and 19(2), a front panel 22, a flange 23 mounted beneath the top cover 17, and a flange 25 sandwiched between the side walls 19(1) and 19(2). The walls, flanges and covers 22205025.2 9 of the housing 12 may be welded together, or otherwise connected to each other using any device or method that is known to those skilled in the art.
Referring now to the heat exchanger 14 of the boiler 10, the heat exchanger 14 generally includes a vertical column of twelve heat exchange conduits 27(1) through 27(12), which are referred to collectively as conduits 27; another vertical column of twelve heat exchange conduits 29(1) though 29(12), which are referred to collectively as conduits 29; two headers 30 and 32 mounted to the front panel 22 that are configured to direct the flow of water through the conduits 27 and 29; an inlet conduit 16 fluidly coupled to the header 30 through which cool water (or other fluid) is delivered into the boiler 10; and an outlet conduit 18 that is fluidly coupled to the header 32 through which heated water (or other fluid) is distributed out of the boiler 10.
Each heat exchange conduit 27 and 29 is a substantially U-shaped fluid carrying conduit that includes two ends and a hollow passageway extending between those two ends for carrying fluid. Each end of the conduits 27, 29 is coupled to the front panel 22. The exterior surfaces of adjacent conduits 27 and 29 are positioned in direct contact or, may be separated by a pre-determined distance. Circular fins are spaced apart along the entire exterior surface of each heat exchange conduit 27, 29.
Gaps, which provide a passageway for the products of combustion, are disposed between adjacent fins of each heat exchange conduit 27, 29. The diameter of the exchange conduits 27 and 29 is substantially equivalent but may differ.
The second column of finned heat exchange conduits 29 is positioned radially outward and surrounds the first column of heat exchange conduits 27. The first column of finned heat exchange conduits 27 is vertically offset from the second 22205025.2 10 column of finned heat exchange conduits 29 by a distance that is equivalent to the radius dimension of the tubes 27 and 29. Each heat exchange conduit 27 has a common length and diameter. Similarly, each heat exchange conduit 29 has a common length and diameter. The common diameter of the conduits 27 is substantially equal to the common diameter of the conduits 29. The common length of the conduits 29 is slightly greater than the common length of the conduits 27.
Those skilled in the art will recognize that the shape, size and configuration of the heat exchange conduits 27 and 29 may vary from that shown and described without departing from the scope or the spirit of the invention. Although not shown, insulation ropes may be positioned between adjacent conduits. Exemplary insulation ropes are described in Publication No. US-2010/0221675.
The headers 30 and 32 of the heat exchanger 14 are configured to distribute water through the conduits 27 and 29 of the heat exchanger in a predetermined order.
FIG. 7 depicts an exploded view of the header 30. The details of the header 30, which are described hereinafter, also apply to the other header 32. The header 30 includes a five-walled and open-ended housing 40, a cover 42 that encloses the open face of the housing 40, and a divider 44 positioned within the housing 40 which is configured to direct the flow of water through the heat exchanger 14. The components of the header 30 may be welded or otherwise fastened together or optionally die cast.
The housing 40 includes two columns of apertures 46(1) and 46(2), through which the ends of the conduits 27 and 29 extend, respectively. The ends of the conduits 27 and 29 may be swaged, welded or otherwise fastened to the housing 40.
It should be understood that in the assembled form of the boiler 10, the ends of the conduits 27 and 29 extend through apertures formed in the front panel 22 and 22205025.2 11 corresponding apertures 46(1) and 46(2), respectively, that are formed in the housing 40.
The divider 44 is positioned within the interior region of the housing 40. The divider 44 includes a series of walls 47 that define five discrete water collection regions that are fluidly isolated from each other. In other words, the walls 47 prevent water in one collection region from leaking into an adjacent collection region. The water collection regions direct the flow of water through the conduits 27 and 29 of the heat exchanger 14 in a pre-determined order. The purpose of the water collection regions are described in greater detail with respect to FIG. 3.
The cover 42 includes an aperture 43 through which the inlet conduit 16 either extends or is coupled. Although not shown, the cover of the other header 32 includes an aperture through which the outlet conduit 18 extends. Depending upon the configuration of the dividers 44 and the conduits 27 and 29, the inlet conduit 16 may be positioned on the header 32 and the outlet conduit 18 may be positioned on the header 30, both conduits 16 and 18 may be positioned on the header 30, or, both conduits 16 and 18 may be positioned on the header 32, without departing from either the spirit or the scope of the invention.
In the assembled form of the boiler 10, the mounting surface 47 of the housing 40 is positioned against the exterior face of the front panel 22 of the housing 12. The cover 42, which is mounted over the housing 40, includes openings 49 which receive fasteners for mounting to the exterior face of the front panel 22 of the housing 12.
Referring back to FIGS. 5 and 6, an insulation member 31 is positioned directly above the heat exchange conduits 27 and 29. The insulation member 31 includes a central opening through which the burner 20 extends.
22205025.2 12 A baffle 33 is positioned near the base of the heat exchange conduits 27. The baffle 33 includes a flange 35 that extends along at least a portion of its circumference and a cylindrical wall 37 that extends vertically downward from the flange 35.
The flange 35 of the baffle 33 is positioned between two adjacent heat exchange conduits 27.
The flange 35 of the baffle 33 is a divider that traverses the burner axis'L' and at least partially separates the substantially enclosed region of the housing 12 into a proximal portion 12A into which the burner 20 extends and a distal portion 12B
into which the burner does not extend. The cylindrical wall 37 of the baffle 33 extends in a direction generally along the burner axis 'L' and into the distal portion 12B
of the substantially enclosed region of the housing 12. The cylindrical wall 37 is positioned radially inwardly of at least one of the heat exchange conduits 27.
The cylindrical wall 37 of the baffle 33 and the wall 19(2) of the housing 12 together define a constricted region 'A' in the distal portion 12B of the substantially enclosed region of the housing 12. At least one of the heat exchange conduits 27 and 29 is positioned within the constricted region 'A.' More particularly, as shown in FIG.
5, a total of seven heat exchange conduits 27 and 29 are at least partially positioned within the constricted region 'A.' The insulation member 31 and the baffle 33 operate in concert to force the products of combustion to flow radially outward and axially along the finned surfaces of the heat exchange conduits 27 and 29 to promote heat transfer between the products of combustion and the fluid in the conduits 27 and 29.
Referring now to the operation of the boiler 10, the burner 20 emits products of combustion once it is activated. Those products of combustion initially expand to fill 22205025.2 13 an interior region 70 of the housing that is circumscribed by the interior column of conduits 27, the insulation member 31 and the baffle 33. Once the products of combustion fill the interior region 70 of the housing 12, the products of combustion are forced to flow along the finned surfaces of the conduits 27 and 29 located in the proximal portion 12A of the housing 12. The products of combustion are then urged or forced to flow in a downward direction through the constricted region `A' that is disposed between the cylindrical wall 37 of the baffle 33 and the side wall 19(2). The products of combustion pass over the finned surfaces of three conduits 27 and four conduits 29 that are at least partially positioned in the constricted region 'A.' The products of combustion are then drawn downward through an exhaust opening 72 provided in the lower cover 21 of the boiler housing 12. Although not shown, an exhaust conduit may be coupled to the exhaust opening 72 for distributing the products of combustion out of the boiler 10.
As the products of combustion pass over the finned surfaces of the conduits 27 and 29, heat from the products of combustion is transferred to the water within the conduits 27 and 29 through convective and radiant heat transfer. The products of combustion flowing through the housing 12 release sufficient heat to cause the water vapor in the products of combustion to condense on the outer surfaces of the conduits 27 and 29.
As background, condensate is introduced through combustion as a byproduct of the combustion reaction, and hot combustion gases therefore contain relatively large quantities of moisture. When the hot combustion gas is cooled, the temperature of the gas drops. As this occurs, the amount of moisture that the gas can hold decreases and at some distance from the combustion source, the water condenses on any surface that is below the dew point of the gas mixture. The dew point is the 22205025.2 14 temperature to which a given parcel of air must be cooled, at constant barometric pressure, for water vapor to condense into water. Hydronic boilers are tailored to condense the water vapor in the combustion gases to capture the latent heat of vaporization of the water produced during the combustion process.
When the water vapor condenses to a liquid phase onto the surfaces of the conduits 27 and 29, latent energy is released as sensible heat onto the surfaces of the conduits 27 and 29, thereby transferring heat to the water that is contained within the conduits 27 and 29.
Referring still to the operation of the boiler 10, as the products of combustion are distributed through the housing 12 of the boiler 10, water is concurrently distributed through the heat exchanger 14. As water travels through each conduit 27 and 29 of the heat exchanger 14, the water is heated by the products of combustion that flow over the finned surfaces of each conduit 27 and 29 of the heat exchanger 14.
FIG. 3 depicts the flow path of water through the heat exchanger 14. In FIG.
3, the exposed ends of every conduit 27 and 29 includes a symbol designating water flow. The symbol 'I' denotes that water is entering the end of a conduit, whereas the symbol '0' denotes that water is exiting from the end of a conduit.
In operation, water is distributed through the inlet conduit 16 and into the first water collection region 1 that is circumscribed by the walls of the divider 44 of the header 30. It should be understood that every water collection region that is described hereinafter is circumscribed by walls of a divider of a particular header.
Upon entering the first water collection region 1, the water fills the first collection region 1 and flows into the conduits 27(11), 27(12), 29 (11) and 29(12).
22205025.2 15 The water travels through conduits 27(11), 27(12), 29(11) and 29(12) and exits into the second collection region 2 of the second header 32. The water then fills the second collection region 2 and flows into the conduits 27(10), 29(8), 29(9) and 29(10). The water travels through conduits 27(10), 29(8), 29(9) and 29(10) and exits into the third collection region 3 of the header 30. The water fills the third collection region 3 and flows into the conduits 29(4) through 29(7).
The water then travels through conduits 29(4) through 29(7) and exits into the fourth water collection region 4 of the header 32. The water fills the fourth water collection region 4 and flows into the conduits 29(1), 29(2) and 29(3). The water travels through conduits 29(1), 29(2) and 29(3) and exits into the fifth water collection region 5 of the header 30. The water fills the fifth water collection region 5 and flows into the conduits 27(1), 27(2) and 27(3). The water travels through conduits 27(1), 27(2) and 27(3) and exits into the sixth water collection region 6 of the header 32. The water fills the sixth water collection region 6 and flows into the conduits 27(4), 27(5) and 27(6).
The water then travels through conduits 27(4), 27(5) and 27(6) and exits into the seventh water collection region 7 of the header 30. The water fills the seventh water collection region 7 and flows into the conduits 27(7), 27(8) and 27(9).
The water then travels through conduits 27(7), 27(8) and 27(9) and exits into the eighth water collection region 8 of the header 32. The water at least partially fills the eighth water collection region 8 of the header 32 and flows into the outlet conduit 18 that extends from the header 32.
Those skilled in the art will recognize that various ways exist to direct the flow of water through the heat exchanger without departing from the scope or spirit of the 22205025.2 16 invention, and the invention is not limited to any particular flow path.
Additionally, the outlet and inlet ports may be positioned on the same header or on different headers (as in this exemplary embodiment).
Referring now to FIGS. 8-10, a second exemplary embodiment of a boiler is designated by the numeral "110." The boiler 110 is substantially similar to the boiler 10, and, thus, the description of the components of the boiler 10 is also applicable to the boiler 110. Differences between those boilers will be described hereinafter.
The heat exchanger 114 of the boiler 110 includes a vertical column of twelve heat exchange conduits 127(1) though 127(12), which are referred to collectively as conduits 127; another vertical column of eleven heat exchange conduits 129(1) though 129(11), which are referred to collectively as conduits 129, that is positioned radially outward of the conduits 127; and a single heat exchange conduit 128 that is positioned directly beneath the vertical columns of conduits 127 and 129. The structure of the conduits 127, 128 and 129 is substantially similar.
Unlike the conduits 27 and 29 of the boiler 10, the longitudinal axes of adjacent conduits 127 and 129 are not vertically offset from each other. In other words, the longitudinal axes of adjacent conduits 127 and 129 are in substantially the same plane. The conduits 127 are positioned on top of each other in columnar form.
The conduits 129 are also positioned on top of each other in columnar form, however, a space exists between conduits 129(9) and 129(10). The conduit 128 is positioned such that its longitudinal axis is equally spaced between the longitudinal axes of the adjacent conduits 127 and 129.
22205025.2 17 One insulation rope 136 is positioned between adjacent conduits 127 and 129.
Although not shown, additional insulation ropes may be positioned between other adjacent conduits 127 and/or 129.
A frusto-conical shaped insulation member 133 is positioned in the enclosed region of the housing 112 of the boiler 110 at a location that is beneath the burner 120 and radially inward of the conduits 127 and 129. The bottom surface 135 of the insulation member 133 traverses the burner axis 'L' and acts as a divider that at least partially separates the substantially enclosed region of the housing 112 into a proximal portion 112A into which the burner 120 extends and a distal portion into which the burner 120 does not extend. The insulation member 133 is composed of rigid insulation that is rated to withstand temperatures of approximately degrees Fahrenheit.
The boiler 110 includes three cylindrical baffles 140, 142 and 137 that are positioned to guide the products of combustion that are produced by the burner along the finned surface of the conduits 127 and 129. The first cylindrical baffle 140 is positioned in the proximal portion 112A of the housing 112 between the first column of heat exchange conduits 127 and the second column of heat exchange conduits 129.
The baffle 140 extends in a direction generally along the burner axis `L.' The cylindrical baffle 140 extends downward from the top cover of the housing 112 such that it extends vertically from an elevation that is adjacent conduits 127(1) and 129(1) to an elevation that is adjacent conduits 127(8) and 129(8).
The second cylindrical baffle 142 is positioned in the proximal portion 112A
of the housing 112 at a location that is radially outward of the conduits 129(3) through 129(9). The baffle 142 extends in a direction generally along the burner axis 'L.' The 22205025.2 18 bottom end of the baffle 142 is bowed inwardly toward the burner axis `L' of the boiler so as to be positioned either on or adjacent the conduit 127(10).
The third cylindrical baffle 137 is mounted to the underside of the insulation member 133 and is positioned adjacent conduits 127(11) and 127(12) in the distal portion 112B of the housing 112. The baffle 137 extends in a direction generally along the burner axis 'L.' The baffle 137 is positioned radially inwardly of at least one of the heat exchange conduits 127 and 129. The baffle 137 and the wall 119 of the housing 112 together define a constricted region 'B' in the distal portion 112B of the substantially enclosed region of the housing 112. At least one of the heat exchange conduits 127 and 129 is positioned within the constricted region 'B.' As shown in FIG.
8, a total of four heat exchange conduits 127 and 129, together with a single heat exchange conduit 128, are positioned within the constricted region 'B.' FIG. 9 depicts a top plan schematic view of the boiler 110 shown partially assembled. The partially-assembled boiler includes a heat exchanger 114 that is mounted to a front panel 122 of the housing 112. The heat exchanger 114 of the boiler 110 is substantially similar to the heat exchanger 14 of boiler 10, thus, the description of the heat exchanger 14 also applies to the heat exchanger 114 of the boiler 110. Differences between those heat exchangers will be described hereinafter.
As best shown in FIG. 9, the end portions of each conduit 127 and 129 are substantially straight, whereas the central portion of each conduit 127 and 129 is rounded. The straight end portions of each conduit 127 and 129 are spaced apart by an angle `Y' of approximately 120 degrees. The front panel 119 also includes two exterior facing surfaces, upon which the straight ends portions of the conduits 127 and 22205025.2 19 129 are attached. The two exterior facing surfaces of the front panel 119 are separated by the same angle'Y.' Referring now to the operation of the boiler 110, the burner 120 emits products of combustion once it is activated. The path of the products of combustion is depicted by the arrows in FIG. 8. As shown in FIG. 8, the products of combustion initially expand to fill an interior region 170 of the housing that is circumscribed by the interior column of conduits 127, the top cover 117 and the insulation member 133. Once the products of combustion fill the interior region 170 of the housing 112, the products of combustion are forced to flow through a constricted region 'C' that is defined between the baffles 140 and 142 in the proximal portion 112A of the housing.
The products of combustion flow over the finned surfaces of the conduits 129(1) through 129(9) that are positioned in the constricted region 'C.' The products of combustion are then forced to flow downward through an annular space 'D' that is defined between the baffle 142 and the exterior side wall 119 of the housing 112. The products of combustion then flow downward through the constricted region 'B' that is defined between the baffle 137 and the exterior side wall 119 of the housing 112 in the distal portion 112B of the housing 112. The products of combustion flow over the finned surfaces of the conduits 127(11), 127(12), 128, 129(10) and 129(11) that are positioned in the constricted region 'B.' The products of combustion are then drawn downward through an exhaust opening 176 provided in the lower cover of the boiler housing 112. An exhaust conduit 178 is coupled to the exhaust opening 176 for distributing the products of combustion out of the boiler 110.
Referring still to the operation of the boiler 110, as the products of combustion are distributed through the housing 112 of the boiler 110, water is concurrently 22205025.2 20 distributed through the conduits 127 and 129 of the heat exchanger 114. As water travels through each conduit 127 and 129 of the heat exchanger 114, the water is heated by the products of combustion that flow over the finned surfaces of each conduit 127 and 129 of the heat exchanger 114.
FIG. 10 depicts the flow path of water through the heat exchanger 114. In FIG.
10, the exposed ends of every conduit 127 and 129 includes a symbol designating water flow, The symbol 'I' denotes that water is entering the end of a conduit, whereas the symbol '0' denotes that water is exiting from the end of a conduit.
In operation, water is distributed through the inlet conduit (not shown) that is connected to the header 130 and into the first water collection region 1 of the header 130. The first water collection region 1 is circumscribed by the walls of the divider 148 of the header 130. It should be understood that every water collection region that is described hereinafter is circumscribed by the walls of a divider of a particular header.
Upon entering the first water collection region 1, the water fills the first collection region 1 and flows into the conduits 127(12), 129(11) and 128. The water travels through conduits 127(12), 129(11) and 128 and exits into the second collection region 2 of the second header 132. The water then fills the second collection region 2 and flows into the conduits 127(11), 129(9) and 129(10).
The water travels through conduits 127(11), 129(9) and 129(10) and exits into the third collection region 3 of the header 130. The water fills the third collection region 3 and flows into the conduits 129(6) through 129(8).
The water then travels through conduits 129(6) through 129(8) and exits into the fourth water collection region 4 of the header 132. The water fills the fourth water 22205025.2 21 collection region 4 and flows into the conduits 129(3), 129(4) and 129(5). The water travels through conduits 129(3), 129(4) and 129(5) and exits into the fifth water collection region 5 of the header 130. The water fills the fifth water collection region 5 and flows into the conduits 129(1) and 129(2). The water travels through conduits 129(1) and 129(2) and exits into the sixth water collection region 6 of the header 132.
The water fills the sixth water collection region 6 and flows into the conduits 127(1) and 127(2).
The water then travels through conduits 127(1) and 127(2) and exits into the seventh water collection region 7 of the header 130. The water fills the seventh water collection region 7 and flows into the conduits 127(3) and 127(4). The water then travels through conduits 127(3) and 127(4) and exits into the eighth water collection region 8 of the header 132. The water fills the eighth water collection region 8 of the header 132 and flows into the conduits 127(5) and 127(6). The water then travels through conduits 127(5) and 127(6) and exits into the ninth water collection region 9 of the header 130. The water fills the ninth water collection region 9 and flows into the conduits 127(7) and 127(8). The water then travels through conduits 127(7) and 127(8) and exits into the tenth water collection region 10 of the header 132.
The water fills the tenth water collection region 10 and flows into the conduits 127(9) and 127(10). The water then travels through conduits 127(9) and 127(10) and exits into the eleventh water collection region 11 of the header 130. The water at least partially fills the eleventh water collection region 11 and is distributed out of the heat exchanger 114 and the boiler 110 through the outlet conduit (not shown) that is connected to header 130.
Referring now to FIGS. 11-13, a third exemplary embodiment of a boiler is designated by the numeral "210." The boiler 210 is substantially similar to the boiler 22205025.2 22 10, and, thus, the description of the components of the boiler 10 is also applicable to the boiler 210. Differences between those boilers will be described hereinafter.
The heat exchanger 214 of the boiler 210 includes a vertical column of nine heat exchange conduits 227(1) though 227(9), which are referred to collectively as conduits 227. Another vertical column of five heat exchange conduits 229(1) though 229(5), which are referred to collectively as conduits 229, is positioned radially outward of the conduits 227. The structure of the conduits 227 and 229 is substantially similar.
A divider 233 is positioned beneath the burner 212. The divider 233 includes a flange 235 that is positioned between two adjacent heat exchange conduits 227(5) and 227(6). The flange 235 of the divider 233 traverses the burner axis 'L' and divides the substantially enclosed region of the housing 212 into a proximal portion 212A into which the burner 220 extends and a distal portion 212B into which the burner 220 does not extend.
A baffle 236 is positioned at an elevation beneath the divider 233. The baffle 236 includes a cylindrical wall 237 that extends in a direction generally along the burner axis 'L' and into the distal portion 212B of the substantially enclosed region of the housing 212. The cylindrical wall 237 is positioned radially inwardly of the vertical column of heat exchange conduits 227.
The cylindrical wall 237 of the baffle 236 and the wall 219(2) of the housing 212 together define a constricted region 'E' in the distal portion 212B of the substantially enclosed region of the housing 212. Three heat exchange conduits 227(7), 227(8) and 227(9) are positioned within the constricted region 'E.' 22205025.2 23 FIG. 12 depicts a top plan schematic view of the boiler 210 shown partially assembled. The partially-assembled boiler includes a heat exchanger 214 that is mounted to a front panel 222 of the housing 212. The partially-assembled boiler is similar to the partially-assembled boiler of FIG. 9, thus, the description of the partially-assembled boiler of FIG. 9 also applies to the partially-assembled boiler that is depicted in FIG. 12.
Referring now to the operation of the boiler 210, the burner 220 emits products of combustion once it is activated. The path of the products of combustion is depicted by the arrows in FIG. 11. As shown in FIG. 11, the products of combustion initially expand to fill an interior region 270 of the housing that is circumscribed by the interior column of conduits 227, the top cover 217 and the divider 233. Once the products of combustion fill the interior region 270 of the housing 212, the products of combustion are urged to flow radially outward along the finned surface of the heat exchange conduits 227(1) through 227(5) and 229(1) through 229(5).
The products of combustion are then urged to flow downward along the finned surfaces of the conduits 227(6) through 227(9) that are positioned in the constricted region `E.' The products of combustion are then drawn downward through an exhaust opening 276 provided in the lower cover of the boiler housing 212. An exhaust conduit 278 is coupled to the exhaust opening 276 for distributing the products of combustion out of the boiler 210.
Referring still to the operation of the boiler 210, as the products of combustion are distributed through the housing 212 of the boiler 210, water is concurrently distributed through the heat exchanger 214. As water travels through each conduit 227 and 229 of the heat exchanger 214, the water is heated by the products of 22205025.2 24 combustion that flow over the finned surfaces of each conduit 227 and 229 of the heat exchanger 214.
FIG. 13 depicts the flow path of water through the heat exchanger 214. In FIG.
13, the exposed ends of every conduit 227 and 229 includes a symbol designating water flow. The term 'IN' denotes that water is entering the exposed end of a conduit, whereas the term 'OUT' denotes that water is exiting from the exposed end of a conduit.
In operation, water is distributed through the inlet conduit (not shown) that is connected to header 230 and into the first water collection region 1 of the header 230.
The first water collection region 1 is circumscribed by the walls of the divider 248 of the header 230. It should be understood that every water collection region that is described hereinafter is circumscribed by walls of a divider of a particular header.
Upon entering the first water collection region 1, the water fills the first collection region 1 and flows into the conduits 227(7), 227(8) and 227(9). The water travels through conduits 227(7), 227(8) and 227(9) and exits into the second collection region 2 of the second header 232. The water then fills the second collection region 2 and flows into the conduits 229(3), 229(4) and 229(5). The water travels through conduits 229(3), 229(4) and 229(5) and exits into the third collection region 3 of the header 230. The water fills the third collection region 3 and flows into the conduits 229(1) and 229(2).
The water then travels through conduits 229(1) and 229(2) and exits into the fourth water collection region 4 of the header 232. The water fills the fourth water collection region 4 and flows into the conduits 227(1) and 227(2). The water travels through conduits 227(1) and 227(2) and exits into the fifth water collection region 5 of 22205025.2 25 the header 230. The water fills the fifth water collection region 5 and flows into the conduits 227(3) and 227(4). The water travels through conduits 227(3) and 227(4) and exits into the sixth water collection region 6 of the header 232. The water fills the sixth water collection region 6 and flows into the conduits 227(5) and 227(6).
The water then travels through conduits 227(5) and 227(6) and exits into the seventh water collection region 7 of the header 230. The water at least partially fills the seventh water collection region 7 and is distributed out of the heat exchanger 214 and the boiler 210 through the outlet conduit (not shown) that is connected to header 230. FIGS. 14A-14C depict front elevation, perspective, and top plan views, respectively, of another heat exchanger that is similar to the heat exchanger of FIG.
13.
FIGS. 14A-14C depict front elevation, perspective, and top plan views, respectively, of another embodiment of a partially assembled boiler 310. The partially-assembled boiler 310 includes a heat exchanger 314 that is mounted to a front panel 322 of a housing (not shown, but similar to housing 212). The partially-assembled boiler is similar to the partially-assembled boiler of FIG. 12, thus, the description of the partially-assembled boiler of FIG. 12 also applies to the partially-assembled boiler that is depicted in FIGS. 14A-14C. In the partially assembled boiler 310, the tubes of the heat exchanger 314 terminate in a single manifold (not shown).
The benefit of this design is that only one manifold is required because all of the tube ends 316 terminate in the same plane.
Referring now to the materials of the boilers that are described herein, the conduits of the heat exchanger are optionally formed from stainless steel, aluminum or coated copper; the headers are optionally composed of carbon steel; and the front 22205025.2 26 panel of the housing is optionally composed of stainless steel. The interior of the headers and the conduits, or any other component of the boiler 10 in the presence of water, may be lined with glass for safely distributing potable water. It should be understood by those skilled in the art that the individual components of the boiler may be formed from a variety of materials that either limit or prevent corrosion in the presence of water, without departing from the spirit or scope of the invention.
While preferred embodiments of the invention have been shown and described herein, it will be understood that such embodiments are provided by way of example only. Numerous variations, changes and substitutions will occur to those skilled in the art without departing from the spirit of the invention. For example, throughout the description of exemplary embodiments of the invention there is reference to exemplary paths of the water through headers of the heating system. It is contemplated that the path of the water is optionally modified so that the tube velocities may be changed to control pressure drop and flow rate through the appliance. Other modifications and variations are contemplated. Accordingly, it is intended that the appended claims cover all such variations as fall within the spirit and scope of the invention.
22205025.2 27
FIELD OF THE INVENTION
The present invention relates to a water heater such as a boiler and a method of operating the same.
BACKGROUND OF THE INVENTION
Water heaters and boilers such as those used as pool heaters typically include a burner for introducing hot combustion gases into a housing of the heater and a heat exchanger including hollow tube members fitted within the heater housing.
Water is circulated through the hollow tube members of the heat exchanger for heat exchange with the hot combustion gases introduced into the heater housing.
One example of such a water heater or boiler is described in U.S. Patent No.
6,644,393 to Roberts et al. Another example of such a water heater or boiler is described in U.S. Patent App. Publication No. US-2010/0221675 to Roberts et al.
22205025.2 1 Publication No. US-2010/0221675 describes a boiler generally including a housing defining an enclosed region and heat exchange conduits positioned within the housing and arranged into interior and exterior columns. A baffle is positioned between the interior and exterior columns, and the baffle and the housing together define a constricted region for directing the flow of products of combustion adjacent the heat exchange conduits of the exterior column.
Although the boilers of U.S. Patent No. 6,644,393 and Publication No. US-2010/0221675 each facilitates the exchange of heat between products of combustion and water, there remains a need to further refine water heaters and boilers to improve at least one of their performance, efficiency, cost and reliability.
SUMMARY OF THE INVENTION
According to one exemplary aspect of the invention, a water heater is provided.
The water heater comprises a housing defining a substantially enclosed region.
A
plurality of heat exchange conduits are at least partially positioned within the substantially enclosed region of the housing, wherein each heat exchange conduit has a first end spaced apart from a second end thereof and a water passageway defined between the first end and the second end. The heat exchange conduits are positioned in a substantially columnar arrangement. A burner is arranged along a burner axis and positioned to deliver products of combustion into the substantially enclosed region of the housing for heat exchange with water contained within the heat exchange conduits. A divider traverses the burner axis and at least partially separates the substantially enclosed region into a proximal portion into which the burner extends 22205025.2 2 and a distal portion into which the burner does not extend. A baffle extends in a direction generally along the burner axis and into the distal portion of the substantially enclosed region of the housing. The baffle is positioned radially inwardly of at least one of the heat exchange conduits. The baffle and the housing together define a constricted region in the distal portion of the substantially enclosed region of the housing. The at least one heat exchange conduit is positioned within the constricted region. The divider and the baffle are configured to direct the flow of products of combustion adjacent one or more heat exchange conduits in the proximal portion of the substantially enclosed region of the housing and adjacent the at least one heat exchange conduit positioned within the constricted region, thereby facilitating an exchange of heat between the products of combustion and water within the heat exchange conduits.
According to another exemplary aspect of the invention, a method of operating a boiler is provided. The boiler includes a heat exchanger positioned at least partially within a substantially enclosed region of a boiler housing, a burner positioned to deliver products of combustion into the enclosed region of the boiler housing, a divider at least partially separating the substantially enclosed region into a proximal portion into which the burner extends and a distal portion into which the burner does not extend, and a baffle extending into the distal portion of the substantially enclosed region of the housing. The method comprises the step of delivering products of combustion into the proximal portion of the enclosed region of the boiler housing for heat exchange with water contained within a portion of the heat exchanger that is at least partially positioned within the proximal portion. The products of combustion are directed into a constricted region of the boiler housing defined in the distal portion of the enclosed region between the baffle and the boiler housing for heat exchange with 22205025.2 3 water contained within another portion of the heat exchanger that is at least partially positioned within the constricted region.
According to yet another exemplary aspect of the invention, a method of assembling a boiler is provided. The boiler includes a heat exchanger positioned at least partially within a substantially enclosed region of a boiler housing and a burner positioned to deliver products of combustion into the enclosed region of the boiler housing. The method comprises the step of positioning a divider in the substantially enclosed region of a boiler housing, thereby at least partially separating the substantially enclosed region into a proximal portion into which the burner extends and a distal portion into which the burner does not extend. A baffle is positioned in the distal portion of the substantially enclosed region of the housing to define a constricted region in the distal portion of the substantially enclosed region of the housing. A portion of the heat exchanger is positioned at least partially within the proximal portion of the substantially enclosed region of the housing and another portion of the heat exchanger at least partially within the constricted region of the distal portion of the substantially enclosed region of the housing.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is best understood from the following detailed description when read in connection with the accompanying drawings. It is emphasized that, according to common practice, the various features of the drawings are not to scale. On the contrary, the dimensions of the various features are arbitrarily expanded or reduced for clarity. Included in the drawings are the following figures:
22205025.2 4 FIG. 1 is a perspective view of a first exemplary embodiment of a boiler.
FIG. 2 is a top plan view of the boiler of FIG. 1.
FIG. 3 is a cross-sectional view of the boiler of FIG. 2 taken along the lines 3-3.
FIG. 4 is a perspective view of the boiler of FIG. 1, wherein the headers of the heat exchanger and a wall of the boiler housing are omitted to reveal the exposed ends of the heat exchange conduits of the heat exchanger.
FIG. 5 is a cross-sectional side elevation view of the boiler of FIG. 2 taken along the lines 5-5.
FIG. 6 is an exploded view of the boiler of FIG. 1.
FIG. 7 is an exploded view of a header of the boiler of FIG. 1.
FIG. 8 is a cross-sectional side elevation view of second exemplary embodiment of a boiler that is shown schematically.
FIG. 9 is a top plan schematic view of the boiler of FIG. 8 shown partially assembled.
FIG. 10 is a cross-sectional schematic view of the heat exchanger of the boiler of FIG. 9 taken along the lines 10-10.
FIG. 11 is a cross-sectional side elevation view of third exemplary embodiment of a boiler that is shown schematically.
FIG. 12 is a top plan schematic view of the boiler of FIG. 11 shown partially assembled.
22205025.2 5 FIG. 13 is a cross-sectional schematic view of the heat exchanger of the boiler of FIG. 11 taken along the lines 13-13.
FIGS. 14A-14C depict front elevation, perspective, and top plan views, respectively, of another embodiment of a partially assembled boiler that is similar to the partially assembled boiler of FIG. 12.
DETAILED DESCRIPTION OF THE INVENTION
Although the invention is illustrated and described herein with reference to specific embodiments, the invention is not intended to be limited to the details shown.
Rather, various modifications may be made to the illustrated embodiments within the scope and range of equivalents of the claims and without departing from the invention. Also, the embodiments selected for illustration in the figures are not shown to scale and are not limited to the proportions shown.
Referring generally to the figures and according to one exemplary aspect of the invention, a water heater 10, 110, 210 is provided. The water heater 10, 110, comprises a housing 12, 112, 212 defining a substantially enclosed region. A
plurality of heat exchange conduits 27 and 29, 127 and 129, 227-229 are at least partially positioned within the substantially enclosed region of the housing 12, 112, 212, wherein each heat exchange conduit 27 and 29, 127 and 129, 227-229 has a first end spaced apart from a second end thereof and a water passageway defined between the first end and the second end. The heat exchange conduits 27 and 29, 127 and 129, 227-229 are positioned in a substantially columnar arrangement. A burner 20, 120, 22205025.2 6 220 is arranged along a burner axis 'L' and positioned to deliver products of combustion into the substantially enclosed region of the housing 12, 112, 212 for heat exchange with water contained within the heat exchange conduits 27 and 29, 127 and 129, 227-229. A divider 35, 135, 235 traverses the burner axis 'L' and at least partially separates the substantially enclosed region into a proximal portion 12A, 112A, 212A into which the burner 20, 120, 220 extends and a distal portion 12B, 112B, 212B into which the burner 20, 120, 220 does not extend. A baffle 37, 137, 237 extends in a direction generally along the burner axis'L' and into the distal portion 12B, 112B, 212B of the substantially enclosed region of the housing 12, 112, 212. The baffle 37, 137, 237 is positioned radially inwardly of at least one of the heat exchange conduits 27 and 29, 127 and 129, 227-229. The baffle 37, 137, 237 and the housing 12, 112, 212 together define a constricted region 'A', 'B', 'E' in the distal portion 12B, 112B, 212B of the substantially enclosed region of the housing 12, 112, 212. At least one heat exchange conduit 27 and 29, 127 and 129, 227-229 is positioned within the constricted region 'A', '13', 'E'. The divider 35, 135, 235 and the baffle 37, 137, 237 are configured to direct the flow of products of combustion adjacent one or more heat exchange conduits 27 and 29, 127 and 129, 227-229 in the proximal portion 12A, 112A, 212A of the substantially enclosed region of the housing 12, 112, 212 and adjacent the at least one heat exchange conduit 27 and 29, 127 and 129, 227-229 positioned within the constricted region `A', `B', 'E', thereby facilitating an exchange of heat between the products of combustion and water within the heat exchange conduits 27 and 29, 127 and 129, 227-229.
According to another aspect of the invention, a method of operating a boiler 10, 110, 210 is provided. The boiler 10, 110, 210 includes a heat exchanger 14, 114, 214 positioned at least partially within a substantially enclosed region of a boiler housing 22205025.2 7 12, 112, 212, a burner 20, 120, 220 positioned to deliver products of combustion into the enclosed region of the boiler housing 12, 112, 212, a divider 35, 135, 235 at least partially separating the substantially enclosed region into a proximal portion 12A, 112A, 212A into which the burner 20, 120, 220 extends and a distal portion 12B, 112B, 212B into which the burner 20, 120, 220 does not extend, and a baffle 37, 137, 237 extending into the distal portion 12B, 112B, 212B of the substantially enclosed region of the housing 12, 112, 212. The method comprises the step of delivering products of combustion into the proximal portion 12A, 112A, 212A of the enclosed region of the boiler housing 12, 112, 212 for heat exchange with water contained within a portion of the heat exchanger 14, 114, 214 that is at least partially positioned within the proximal portion 12A, 112A, 212A. The products of combustion are directed into a constricted region 'A', 'B', 'E' of the boiler housing 12, 112, 212 defined in the distal portion 12B, 112B, 212B of the enclosed region between the baffle 37, 137, 237 and the boiler housing 12, 112, 212 for heat exchange with water contained within another portion of the heat exchanger 14, 114, 214 that is at least partially positioned within the constricted region 'A', 'B', `E'.
According to yet another aspect of the invention, a method of assembling a boiler 10, 110, 210 is provided. The boiler 10, 110, 210 includes a heat exchanger 14, 114, 214 positioned at least partially within a substantially enclosed region of a boiler housing 12, 112, 212 and a burner 20, 120, 220 positioned to deliver products of combustion into the enclosed region of the boiler housing 12, 112, 212. The method comprises the step of positioning a divider 35, 135, 235 in the substantially enclosed region of a boiler housing 12, 112, 212, thereby at least partially separating the substantially enclosed region into a proximal portion 12A, 112A, 212A into which the burner 20, 120, 220 extends and a distal portion 12B, 112B, 212B into which the 22205025.2 8 burner 20, 120, 220 does not extend. A baffle 37, 137, 237 is positioned in the distal portion 12B, 112B, 212B of the substantially enclosed region of the housing 12, 112, 212 to define a constricted region 'A', 'B', 'E' in the distal portion 12B, 112B, 212B of the substantially enclosed region of the housing 12, 112, 212. A portion of the heat exchanger 14, 114, 214 is positioned at least partially within the proximal portion 12A, 112A, 212A of the substantially enclosed region of the housing 12, 112, 212 and another portion of the heat exchanger 14, 114, 214 at least partially within the constricted region 'A', 'B', 'E' of the distal portion 12B, 112B, 212B of the substantially enclosed region of the housing 12, 112, 212.
Referring now to FIGS. 1-6, a first exemplary embodiment of a boiler is designated by the numeral "10." The boiler 10 generally includes a housing 12 defining a substantially enclosed interior region, a heat exchanger 14 that is at least partially contained within the interior region of the housing 12, and a burner 20 that is mounted to the top cover of the housing 12 for introducing products of combustion into the interior of the housing 12 for heat exchange with fluid that is contained within the heat exchanger 14. Details of an exemplary burner 20 are described in U.S.
Patent No. 6,644,393.
Referring now to the components of the housing 12 of the boiler 10, the housing 12 generally includes a series of interconnected walls, flanges and covers defining an substantially enclosed interior region. The walls, flanges and covers enclose the housing 12 to limit or prevent products of combustion from inadvertently escaping from the interior region. The interconnected walls, flanges and covers of the housing 12 comprise a top cover 17, a bottom cover 21 , two side walls 19(1) and 19(2), a front panel 22, a flange 23 mounted beneath the top cover 17, and a flange 25 sandwiched between the side walls 19(1) and 19(2). The walls, flanges and covers 22205025.2 9 of the housing 12 may be welded together, or otherwise connected to each other using any device or method that is known to those skilled in the art.
Referring now to the heat exchanger 14 of the boiler 10, the heat exchanger 14 generally includes a vertical column of twelve heat exchange conduits 27(1) through 27(12), which are referred to collectively as conduits 27; another vertical column of twelve heat exchange conduits 29(1) though 29(12), which are referred to collectively as conduits 29; two headers 30 and 32 mounted to the front panel 22 that are configured to direct the flow of water through the conduits 27 and 29; an inlet conduit 16 fluidly coupled to the header 30 through which cool water (or other fluid) is delivered into the boiler 10; and an outlet conduit 18 that is fluidly coupled to the header 32 through which heated water (or other fluid) is distributed out of the boiler 10.
Each heat exchange conduit 27 and 29 is a substantially U-shaped fluid carrying conduit that includes two ends and a hollow passageway extending between those two ends for carrying fluid. Each end of the conduits 27, 29 is coupled to the front panel 22. The exterior surfaces of adjacent conduits 27 and 29 are positioned in direct contact or, may be separated by a pre-determined distance. Circular fins are spaced apart along the entire exterior surface of each heat exchange conduit 27, 29.
Gaps, which provide a passageway for the products of combustion, are disposed between adjacent fins of each heat exchange conduit 27, 29. The diameter of the exchange conduits 27 and 29 is substantially equivalent but may differ.
The second column of finned heat exchange conduits 29 is positioned radially outward and surrounds the first column of heat exchange conduits 27. The first column of finned heat exchange conduits 27 is vertically offset from the second 22205025.2 10 column of finned heat exchange conduits 29 by a distance that is equivalent to the radius dimension of the tubes 27 and 29. Each heat exchange conduit 27 has a common length and diameter. Similarly, each heat exchange conduit 29 has a common length and diameter. The common diameter of the conduits 27 is substantially equal to the common diameter of the conduits 29. The common length of the conduits 29 is slightly greater than the common length of the conduits 27.
Those skilled in the art will recognize that the shape, size and configuration of the heat exchange conduits 27 and 29 may vary from that shown and described without departing from the scope or the spirit of the invention. Although not shown, insulation ropes may be positioned between adjacent conduits. Exemplary insulation ropes are described in Publication No. US-2010/0221675.
The headers 30 and 32 of the heat exchanger 14 are configured to distribute water through the conduits 27 and 29 of the heat exchanger in a predetermined order.
FIG. 7 depicts an exploded view of the header 30. The details of the header 30, which are described hereinafter, also apply to the other header 32. The header 30 includes a five-walled and open-ended housing 40, a cover 42 that encloses the open face of the housing 40, and a divider 44 positioned within the housing 40 which is configured to direct the flow of water through the heat exchanger 14. The components of the header 30 may be welded or otherwise fastened together or optionally die cast.
The housing 40 includes two columns of apertures 46(1) and 46(2), through which the ends of the conduits 27 and 29 extend, respectively. The ends of the conduits 27 and 29 may be swaged, welded or otherwise fastened to the housing 40.
It should be understood that in the assembled form of the boiler 10, the ends of the conduits 27 and 29 extend through apertures formed in the front panel 22 and 22205025.2 11 corresponding apertures 46(1) and 46(2), respectively, that are formed in the housing 40.
The divider 44 is positioned within the interior region of the housing 40. The divider 44 includes a series of walls 47 that define five discrete water collection regions that are fluidly isolated from each other. In other words, the walls 47 prevent water in one collection region from leaking into an adjacent collection region. The water collection regions direct the flow of water through the conduits 27 and 29 of the heat exchanger 14 in a pre-determined order. The purpose of the water collection regions are described in greater detail with respect to FIG. 3.
The cover 42 includes an aperture 43 through which the inlet conduit 16 either extends or is coupled. Although not shown, the cover of the other header 32 includes an aperture through which the outlet conduit 18 extends. Depending upon the configuration of the dividers 44 and the conduits 27 and 29, the inlet conduit 16 may be positioned on the header 32 and the outlet conduit 18 may be positioned on the header 30, both conduits 16 and 18 may be positioned on the header 30, or, both conduits 16 and 18 may be positioned on the header 32, without departing from either the spirit or the scope of the invention.
In the assembled form of the boiler 10, the mounting surface 47 of the housing 40 is positioned against the exterior face of the front panel 22 of the housing 12. The cover 42, which is mounted over the housing 40, includes openings 49 which receive fasteners for mounting to the exterior face of the front panel 22 of the housing 12.
Referring back to FIGS. 5 and 6, an insulation member 31 is positioned directly above the heat exchange conduits 27 and 29. The insulation member 31 includes a central opening through which the burner 20 extends.
22205025.2 12 A baffle 33 is positioned near the base of the heat exchange conduits 27. The baffle 33 includes a flange 35 that extends along at least a portion of its circumference and a cylindrical wall 37 that extends vertically downward from the flange 35.
The flange 35 of the baffle 33 is positioned between two adjacent heat exchange conduits 27.
The flange 35 of the baffle 33 is a divider that traverses the burner axis'L' and at least partially separates the substantially enclosed region of the housing 12 into a proximal portion 12A into which the burner 20 extends and a distal portion 12B
into which the burner does not extend. The cylindrical wall 37 of the baffle 33 extends in a direction generally along the burner axis 'L' and into the distal portion 12B
of the substantially enclosed region of the housing 12. The cylindrical wall 37 is positioned radially inwardly of at least one of the heat exchange conduits 27.
The cylindrical wall 37 of the baffle 33 and the wall 19(2) of the housing 12 together define a constricted region 'A' in the distal portion 12B of the substantially enclosed region of the housing 12. At least one of the heat exchange conduits 27 and 29 is positioned within the constricted region 'A.' More particularly, as shown in FIG.
5, a total of seven heat exchange conduits 27 and 29 are at least partially positioned within the constricted region 'A.' The insulation member 31 and the baffle 33 operate in concert to force the products of combustion to flow radially outward and axially along the finned surfaces of the heat exchange conduits 27 and 29 to promote heat transfer between the products of combustion and the fluid in the conduits 27 and 29.
Referring now to the operation of the boiler 10, the burner 20 emits products of combustion once it is activated. Those products of combustion initially expand to fill 22205025.2 13 an interior region 70 of the housing that is circumscribed by the interior column of conduits 27, the insulation member 31 and the baffle 33. Once the products of combustion fill the interior region 70 of the housing 12, the products of combustion are forced to flow along the finned surfaces of the conduits 27 and 29 located in the proximal portion 12A of the housing 12. The products of combustion are then urged or forced to flow in a downward direction through the constricted region `A' that is disposed between the cylindrical wall 37 of the baffle 33 and the side wall 19(2). The products of combustion pass over the finned surfaces of three conduits 27 and four conduits 29 that are at least partially positioned in the constricted region 'A.' The products of combustion are then drawn downward through an exhaust opening 72 provided in the lower cover 21 of the boiler housing 12. Although not shown, an exhaust conduit may be coupled to the exhaust opening 72 for distributing the products of combustion out of the boiler 10.
As the products of combustion pass over the finned surfaces of the conduits 27 and 29, heat from the products of combustion is transferred to the water within the conduits 27 and 29 through convective and radiant heat transfer. The products of combustion flowing through the housing 12 release sufficient heat to cause the water vapor in the products of combustion to condense on the outer surfaces of the conduits 27 and 29.
As background, condensate is introduced through combustion as a byproduct of the combustion reaction, and hot combustion gases therefore contain relatively large quantities of moisture. When the hot combustion gas is cooled, the temperature of the gas drops. As this occurs, the amount of moisture that the gas can hold decreases and at some distance from the combustion source, the water condenses on any surface that is below the dew point of the gas mixture. The dew point is the 22205025.2 14 temperature to which a given parcel of air must be cooled, at constant barometric pressure, for water vapor to condense into water. Hydronic boilers are tailored to condense the water vapor in the combustion gases to capture the latent heat of vaporization of the water produced during the combustion process.
When the water vapor condenses to a liquid phase onto the surfaces of the conduits 27 and 29, latent energy is released as sensible heat onto the surfaces of the conduits 27 and 29, thereby transferring heat to the water that is contained within the conduits 27 and 29.
Referring still to the operation of the boiler 10, as the products of combustion are distributed through the housing 12 of the boiler 10, water is concurrently distributed through the heat exchanger 14. As water travels through each conduit 27 and 29 of the heat exchanger 14, the water is heated by the products of combustion that flow over the finned surfaces of each conduit 27 and 29 of the heat exchanger 14.
FIG. 3 depicts the flow path of water through the heat exchanger 14. In FIG.
3, the exposed ends of every conduit 27 and 29 includes a symbol designating water flow. The symbol 'I' denotes that water is entering the end of a conduit, whereas the symbol '0' denotes that water is exiting from the end of a conduit.
In operation, water is distributed through the inlet conduit 16 and into the first water collection region 1 that is circumscribed by the walls of the divider 44 of the header 30. It should be understood that every water collection region that is described hereinafter is circumscribed by walls of a divider of a particular header.
Upon entering the first water collection region 1, the water fills the first collection region 1 and flows into the conduits 27(11), 27(12), 29 (11) and 29(12).
22205025.2 15 The water travels through conduits 27(11), 27(12), 29(11) and 29(12) and exits into the second collection region 2 of the second header 32. The water then fills the second collection region 2 and flows into the conduits 27(10), 29(8), 29(9) and 29(10). The water travels through conduits 27(10), 29(8), 29(9) and 29(10) and exits into the third collection region 3 of the header 30. The water fills the third collection region 3 and flows into the conduits 29(4) through 29(7).
The water then travels through conduits 29(4) through 29(7) and exits into the fourth water collection region 4 of the header 32. The water fills the fourth water collection region 4 and flows into the conduits 29(1), 29(2) and 29(3). The water travels through conduits 29(1), 29(2) and 29(3) and exits into the fifth water collection region 5 of the header 30. The water fills the fifth water collection region 5 and flows into the conduits 27(1), 27(2) and 27(3). The water travels through conduits 27(1), 27(2) and 27(3) and exits into the sixth water collection region 6 of the header 32. The water fills the sixth water collection region 6 and flows into the conduits 27(4), 27(5) and 27(6).
The water then travels through conduits 27(4), 27(5) and 27(6) and exits into the seventh water collection region 7 of the header 30. The water fills the seventh water collection region 7 and flows into the conduits 27(7), 27(8) and 27(9).
The water then travels through conduits 27(7), 27(8) and 27(9) and exits into the eighth water collection region 8 of the header 32. The water at least partially fills the eighth water collection region 8 of the header 32 and flows into the outlet conduit 18 that extends from the header 32.
Those skilled in the art will recognize that various ways exist to direct the flow of water through the heat exchanger without departing from the scope or spirit of the 22205025.2 16 invention, and the invention is not limited to any particular flow path.
Additionally, the outlet and inlet ports may be positioned on the same header or on different headers (as in this exemplary embodiment).
Referring now to FIGS. 8-10, a second exemplary embodiment of a boiler is designated by the numeral "110." The boiler 110 is substantially similar to the boiler 10, and, thus, the description of the components of the boiler 10 is also applicable to the boiler 110. Differences between those boilers will be described hereinafter.
The heat exchanger 114 of the boiler 110 includes a vertical column of twelve heat exchange conduits 127(1) though 127(12), which are referred to collectively as conduits 127; another vertical column of eleven heat exchange conduits 129(1) though 129(11), which are referred to collectively as conduits 129, that is positioned radially outward of the conduits 127; and a single heat exchange conduit 128 that is positioned directly beneath the vertical columns of conduits 127 and 129. The structure of the conduits 127, 128 and 129 is substantially similar.
Unlike the conduits 27 and 29 of the boiler 10, the longitudinal axes of adjacent conduits 127 and 129 are not vertically offset from each other. In other words, the longitudinal axes of adjacent conduits 127 and 129 are in substantially the same plane. The conduits 127 are positioned on top of each other in columnar form.
The conduits 129 are also positioned on top of each other in columnar form, however, a space exists between conduits 129(9) and 129(10). The conduit 128 is positioned such that its longitudinal axis is equally spaced between the longitudinal axes of the adjacent conduits 127 and 129.
22205025.2 17 One insulation rope 136 is positioned between adjacent conduits 127 and 129.
Although not shown, additional insulation ropes may be positioned between other adjacent conduits 127 and/or 129.
A frusto-conical shaped insulation member 133 is positioned in the enclosed region of the housing 112 of the boiler 110 at a location that is beneath the burner 120 and radially inward of the conduits 127 and 129. The bottom surface 135 of the insulation member 133 traverses the burner axis 'L' and acts as a divider that at least partially separates the substantially enclosed region of the housing 112 into a proximal portion 112A into which the burner 120 extends and a distal portion into which the burner 120 does not extend. The insulation member 133 is composed of rigid insulation that is rated to withstand temperatures of approximately degrees Fahrenheit.
The boiler 110 includes three cylindrical baffles 140, 142 and 137 that are positioned to guide the products of combustion that are produced by the burner along the finned surface of the conduits 127 and 129. The first cylindrical baffle 140 is positioned in the proximal portion 112A of the housing 112 between the first column of heat exchange conduits 127 and the second column of heat exchange conduits 129.
The baffle 140 extends in a direction generally along the burner axis `L.' The cylindrical baffle 140 extends downward from the top cover of the housing 112 such that it extends vertically from an elevation that is adjacent conduits 127(1) and 129(1) to an elevation that is adjacent conduits 127(8) and 129(8).
The second cylindrical baffle 142 is positioned in the proximal portion 112A
of the housing 112 at a location that is radially outward of the conduits 129(3) through 129(9). The baffle 142 extends in a direction generally along the burner axis 'L.' The 22205025.2 18 bottom end of the baffle 142 is bowed inwardly toward the burner axis `L' of the boiler so as to be positioned either on or adjacent the conduit 127(10).
The third cylindrical baffle 137 is mounted to the underside of the insulation member 133 and is positioned adjacent conduits 127(11) and 127(12) in the distal portion 112B of the housing 112. The baffle 137 extends in a direction generally along the burner axis 'L.' The baffle 137 is positioned radially inwardly of at least one of the heat exchange conduits 127 and 129. The baffle 137 and the wall 119 of the housing 112 together define a constricted region 'B' in the distal portion 112B of the substantially enclosed region of the housing 112. At least one of the heat exchange conduits 127 and 129 is positioned within the constricted region 'B.' As shown in FIG.
8, a total of four heat exchange conduits 127 and 129, together with a single heat exchange conduit 128, are positioned within the constricted region 'B.' FIG. 9 depicts a top plan schematic view of the boiler 110 shown partially assembled. The partially-assembled boiler includes a heat exchanger 114 that is mounted to a front panel 122 of the housing 112. The heat exchanger 114 of the boiler 110 is substantially similar to the heat exchanger 14 of boiler 10, thus, the description of the heat exchanger 14 also applies to the heat exchanger 114 of the boiler 110. Differences between those heat exchangers will be described hereinafter.
As best shown in FIG. 9, the end portions of each conduit 127 and 129 are substantially straight, whereas the central portion of each conduit 127 and 129 is rounded. The straight end portions of each conduit 127 and 129 are spaced apart by an angle `Y' of approximately 120 degrees. The front panel 119 also includes two exterior facing surfaces, upon which the straight ends portions of the conduits 127 and 22205025.2 19 129 are attached. The two exterior facing surfaces of the front panel 119 are separated by the same angle'Y.' Referring now to the operation of the boiler 110, the burner 120 emits products of combustion once it is activated. The path of the products of combustion is depicted by the arrows in FIG. 8. As shown in FIG. 8, the products of combustion initially expand to fill an interior region 170 of the housing that is circumscribed by the interior column of conduits 127, the top cover 117 and the insulation member 133. Once the products of combustion fill the interior region 170 of the housing 112, the products of combustion are forced to flow through a constricted region 'C' that is defined between the baffles 140 and 142 in the proximal portion 112A of the housing.
The products of combustion flow over the finned surfaces of the conduits 129(1) through 129(9) that are positioned in the constricted region 'C.' The products of combustion are then forced to flow downward through an annular space 'D' that is defined between the baffle 142 and the exterior side wall 119 of the housing 112. The products of combustion then flow downward through the constricted region 'B' that is defined between the baffle 137 and the exterior side wall 119 of the housing 112 in the distal portion 112B of the housing 112. The products of combustion flow over the finned surfaces of the conduits 127(11), 127(12), 128, 129(10) and 129(11) that are positioned in the constricted region 'B.' The products of combustion are then drawn downward through an exhaust opening 176 provided in the lower cover of the boiler housing 112. An exhaust conduit 178 is coupled to the exhaust opening 176 for distributing the products of combustion out of the boiler 110.
Referring still to the operation of the boiler 110, as the products of combustion are distributed through the housing 112 of the boiler 110, water is concurrently 22205025.2 20 distributed through the conduits 127 and 129 of the heat exchanger 114. As water travels through each conduit 127 and 129 of the heat exchanger 114, the water is heated by the products of combustion that flow over the finned surfaces of each conduit 127 and 129 of the heat exchanger 114.
FIG. 10 depicts the flow path of water through the heat exchanger 114. In FIG.
10, the exposed ends of every conduit 127 and 129 includes a symbol designating water flow, The symbol 'I' denotes that water is entering the end of a conduit, whereas the symbol '0' denotes that water is exiting from the end of a conduit.
In operation, water is distributed through the inlet conduit (not shown) that is connected to the header 130 and into the first water collection region 1 of the header 130. The first water collection region 1 is circumscribed by the walls of the divider 148 of the header 130. It should be understood that every water collection region that is described hereinafter is circumscribed by the walls of a divider of a particular header.
Upon entering the first water collection region 1, the water fills the first collection region 1 and flows into the conduits 127(12), 129(11) and 128. The water travels through conduits 127(12), 129(11) and 128 and exits into the second collection region 2 of the second header 132. The water then fills the second collection region 2 and flows into the conduits 127(11), 129(9) and 129(10).
The water travels through conduits 127(11), 129(9) and 129(10) and exits into the third collection region 3 of the header 130. The water fills the third collection region 3 and flows into the conduits 129(6) through 129(8).
The water then travels through conduits 129(6) through 129(8) and exits into the fourth water collection region 4 of the header 132. The water fills the fourth water 22205025.2 21 collection region 4 and flows into the conduits 129(3), 129(4) and 129(5). The water travels through conduits 129(3), 129(4) and 129(5) and exits into the fifth water collection region 5 of the header 130. The water fills the fifth water collection region 5 and flows into the conduits 129(1) and 129(2). The water travels through conduits 129(1) and 129(2) and exits into the sixth water collection region 6 of the header 132.
The water fills the sixth water collection region 6 and flows into the conduits 127(1) and 127(2).
The water then travels through conduits 127(1) and 127(2) and exits into the seventh water collection region 7 of the header 130. The water fills the seventh water collection region 7 and flows into the conduits 127(3) and 127(4). The water then travels through conduits 127(3) and 127(4) and exits into the eighth water collection region 8 of the header 132. The water fills the eighth water collection region 8 of the header 132 and flows into the conduits 127(5) and 127(6). The water then travels through conduits 127(5) and 127(6) and exits into the ninth water collection region 9 of the header 130. The water fills the ninth water collection region 9 and flows into the conduits 127(7) and 127(8). The water then travels through conduits 127(7) and 127(8) and exits into the tenth water collection region 10 of the header 132.
The water fills the tenth water collection region 10 and flows into the conduits 127(9) and 127(10). The water then travels through conduits 127(9) and 127(10) and exits into the eleventh water collection region 11 of the header 130. The water at least partially fills the eleventh water collection region 11 and is distributed out of the heat exchanger 114 and the boiler 110 through the outlet conduit (not shown) that is connected to header 130.
Referring now to FIGS. 11-13, a third exemplary embodiment of a boiler is designated by the numeral "210." The boiler 210 is substantially similar to the boiler 22205025.2 22 10, and, thus, the description of the components of the boiler 10 is also applicable to the boiler 210. Differences between those boilers will be described hereinafter.
The heat exchanger 214 of the boiler 210 includes a vertical column of nine heat exchange conduits 227(1) though 227(9), which are referred to collectively as conduits 227. Another vertical column of five heat exchange conduits 229(1) though 229(5), which are referred to collectively as conduits 229, is positioned radially outward of the conduits 227. The structure of the conduits 227 and 229 is substantially similar.
A divider 233 is positioned beneath the burner 212. The divider 233 includes a flange 235 that is positioned between two adjacent heat exchange conduits 227(5) and 227(6). The flange 235 of the divider 233 traverses the burner axis 'L' and divides the substantially enclosed region of the housing 212 into a proximal portion 212A into which the burner 220 extends and a distal portion 212B into which the burner 220 does not extend.
A baffle 236 is positioned at an elevation beneath the divider 233. The baffle 236 includes a cylindrical wall 237 that extends in a direction generally along the burner axis 'L' and into the distal portion 212B of the substantially enclosed region of the housing 212. The cylindrical wall 237 is positioned radially inwardly of the vertical column of heat exchange conduits 227.
The cylindrical wall 237 of the baffle 236 and the wall 219(2) of the housing 212 together define a constricted region 'E' in the distal portion 212B of the substantially enclosed region of the housing 212. Three heat exchange conduits 227(7), 227(8) and 227(9) are positioned within the constricted region 'E.' 22205025.2 23 FIG. 12 depicts a top plan schematic view of the boiler 210 shown partially assembled. The partially-assembled boiler includes a heat exchanger 214 that is mounted to a front panel 222 of the housing 212. The partially-assembled boiler is similar to the partially-assembled boiler of FIG. 9, thus, the description of the partially-assembled boiler of FIG. 9 also applies to the partially-assembled boiler that is depicted in FIG. 12.
Referring now to the operation of the boiler 210, the burner 220 emits products of combustion once it is activated. The path of the products of combustion is depicted by the arrows in FIG. 11. As shown in FIG. 11, the products of combustion initially expand to fill an interior region 270 of the housing that is circumscribed by the interior column of conduits 227, the top cover 217 and the divider 233. Once the products of combustion fill the interior region 270 of the housing 212, the products of combustion are urged to flow radially outward along the finned surface of the heat exchange conduits 227(1) through 227(5) and 229(1) through 229(5).
The products of combustion are then urged to flow downward along the finned surfaces of the conduits 227(6) through 227(9) that are positioned in the constricted region `E.' The products of combustion are then drawn downward through an exhaust opening 276 provided in the lower cover of the boiler housing 212. An exhaust conduit 278 is coupled to the exhaust opening 276 for distributing the products of combustion out of the boiler 210.
Referring still to the operation of the boiler 210, as the products of combustion are distributed through the housing 212 of the boiler 210, water is concurrently distributed through the heat exchanger 214. As water travels through each conduit 227 and 229 of the heat exchanger 214, the water is heated by the products of 22205025.2 24 combustion that flow over the finned surfaces of each conduit 227 and 229 of the heat exchanger 214.
FIG. 13 depicts the flow path of water through the heat exchanger 214. In FIG.
13, the exposed ends of every conduit 227 and 229 includes a symbol designating water flow. The term 'IN' denotes that water is entering the exposed end of a conduit, whereas the term 'OUT' denotes that water is exiting from the exposed end of a conduit.
In operation, water is distributed through the inlet conduit (not shown) that is connected to header 230 and into the first water collection region 1 of the header 230.
The first water collection region 1 is circumscribed by the walls of the divider 248 of the header 230. It should be understood that every water collection region that is described hereinafter is circumscribed by walls of a divider of a particular header.
Upon entering the first water collection region 1, the water fills the first collection region 1 and flows into the conduits 227(7), 227(8) and 227(9). The water travels through conduits 227(7), 227(8) and 227(9) and exits into the second collection region 2 of the second header 232. The water then fills the second collection region 2 and flows into the conduits 229(3), 229(4) and 229(5). The water travels through conduits 229(3), 229(4) and 229(5) and exits into the third collection region 3 of the header 230. The water fills the third collection region 3 and flows into the conduits 229(1) and 229(2).
The water then travels through conduits 229(1) and 229(2) and exits into the fourth water collection region 4 of the header 232. The water fills the fourth water collection region 4 and flows into the conduits 227(1) and 227(2). The water travels through conduits 227(1) and 227(2) and exits into the fifth water collection region 5 of 22205025.2 25 the header 230. The water fills the fifth water collection region 5 and flows into the conduits 227(3) and 227(4). The water travels through conduits 227(3) and 227(4) and exits into the sixth water collection region 6 of the header 232. The water fills the sixth water collection region 6 and flows into the conduits 227(5) and 227(6).
The water then travels through conduits 227(5) and 227(6) and exits into the seventh water collection region 7 of the header 230. The water at least partially fills the seventh water collection region 7 and is distributed out of the heat exchanger 214 and the boiler 210 through the outlet conduit (not shown) that is connected to header 230. FIGS. 14A-14C depict front elevation, perspective, and top plan views, respectively, of another heat exchanger that is similar to the heat exchanger of FIG.
13.
FIGS. 14A-14C depict front elevation, perspective, and top plan views, respectively, of another embodiment of a partially assembled boiler 310. The partially-assembled boiler 310 includes a heat exchanger 314 that is mounted to a front panel 322 of a housing (not shown, but similar to housing 212). The partially-assembled boiler is similar to the partially-assembled boiler of FIG. 12, thus, the description of the partially-assembled boiler of FIG. 12 also applies to the partially-assembled boiler that is depicted in FIGS. 14A-14C. In the partially assembled boiler 310, the tubes of the heat exchanger 314 terminate in a single manifold (not shown).
The benefit of this design is that only one manifold is required because all of the tube ends 316 terminate in the same plane.
Referring now to the materials of the boilers that are described herein, the conduits of the heat exchanger are optionally formed from stainless steel, aluminum or coated copper; the headers are optionally composed of carbon steel; and the front 22205025.2 26 panel of the housing is optionally composed of stainless steel. The interior of the headers and the conduits, or any other component of the boiler 10 in the presence of water, may be lined with glass for safely distributing potable water. It should be understood by those skilled in the art that the individual components of the boiler may be formed from a variety of materials that either limit or prevent corrosion in the presence of water, without departing from the spirit or scope of the invention.
While preferred embodiments of the invention have been shown and described herein, it will be understood that such embodiments are provided by way of example only. Numerous variations, changes and substitutions will occur to those skilled in the art without departing from the spirit of the invention. For example, throughout the description of exemplary embodiments of the invention there is reference to exemplary paths of the water through headers of the heating system. It is contemplated that the path of the water is optionally modified so that the tube velocities may be changed to control pressure drop and flow rate through the appliance. Other modifications and variations are contemplated. Accordingly, it is intended that the appended claims cover all such variations as fall within the spirit and scope of the invention.
22205025.2 27
Claims (21)
1. A water heater comprising:
a housing defining a substantially enclosed region;
a plurality of heat exchange conduits at least partially positioned within the substantially enclosed region of the housing, each heat exchange conduit having a first end spaced apart from a second end thereof and a water passageway defined between the first end and the second end, the heat exchange conduits being positioned in a substantially columnar arrangement;
a burner arranged along a burner axis and positioned to deliver products of combustion into the substantially enclosed region of the housing for heat exchange with water contained within the heat exchange conduits;
a divider traversing the burner axis and at least partially separating the substantially enclosed region into a proximal portion into which the burner extends and a distal portion into which the burner does not extend;
a baffle extending in a direction generally along the burner axis and into the distal portion of the substantially enclosed region of the housing, the baffle being positioned radially inwardly of at least one of the heat exchange conduits, said baffle and said housing together defining a constricted region in the distal portion of the substantially enclosed region of the housing;
the divider and the baffle being configured to direct the flow of products of combustion adjacent one or more heat exchange conduits in the proximal portion of the substantially enclosed region of the housing and adjacent the at least one heat exchange conduit positioned within the constricted region, thereby facilitating an exchange of heat between the products of combustion and water within the heat exchange conduits.
a housing defining a substantially enclosed region;
a plurality of heat exchange conduits at least partially positioned within the substantially enclosed region of the housing, each heat exchange conduit having a first end spaced apart from a second end thereof and a water passageway defined between the first end and the second end, the heat exchange conduits being positioned in a substantially columnar arrangement;
a burner arranged along a burner axis and positioned to deliver products of combustion into the substantially enclosed region of the housing for heat exchange with water contained within the heat exchange conduits;
a divider traversing the burner axis and at least partially separating the substantially enclosed region into a proximal portion into which the burner extends and a distal portion into which the burner does not extend;
a baffle extending in a direction generally along the burner axis and into the distal portion of the substantially enclosed region of the housing, the baffle being positioned radially inwardly of at least one of the heat exchange conduits, said baffle and said housing together defining a constricted region in the distal portion of the substantially enclosed region of the housing;
the divider and the baffle being configured to direct the flow of products of combustion adjacent one or more heat exchange conduits in the proximal portion of the substantially enclosed region of the housing and adjacent the at least one heat exchange conduit positioned within the constricted region, thereby facilitating an exchange of heat between the products of combustion and water within the heat exchange conduits.
2. The water heater of claim 1, wherein at least one heat exchange conduit is positioned radially outwardly from at least one other heat exchange conduit.
3. The water heater of claim 1, wherein the baffle extends from the divider.
4. The water heater of claim 1, wherein the baffle and the divider are positioned to at least partially inhibit the flow of products of combustion between the divider and a proximal end portion of the baffle.
5. The water heater of claim 1, wherein a plurality of the heat exchange conduits in the proximal portion of the substantially enclosed region of the housing are positioned along an interior column and another plurality of the heat exchange conduits are positioned along an exterior column positioned radially outwardly from the interior column.
6. The water heater of claim 5, further comprising a header system for directing water from a heat exchange conduit in the interior column to a heat exchange conduit in the exterior column or vice versa.
7. The water heater of claim 5, further comprising a proximal baffle extending from a proximal wall of the housing and into the proximal portion of the substantially enclosed region of the housing.
8. The water heater of claim 7, the proximal baffle extending between the interior and exterior columns.
9. The water heater of claim 1, further comprising a proximal baffle extending from the divider and into the proximal portion of the substantially enclosed region of the housing.
10. The water heater of claim 1, wherein a plurality of the heat exchange conduits in the distal portion of the substantially enclosed region of the housing are positioned along an interior column and another plurality of the heat exchange conduits are positioned along an exterior column positioned radially outwardly from the interior column.
11. The water heater of claim 10, further comprising a flow divider positioned between the interior and exterior columns.
12. The water heater of claim 11, the flow divider comprising a refractory material.
13. A method of operating a boiler including a heat exchanger positioned at least partially within a substantially enclosed region of a boiler housing, a burner positioned to deliver products of combustion into the enclosed region of the boiler housing, a divider at least partially separating the substantially enclosed region into a proximal portion into which the burner extends and a distal portion into which the burner does not extend, and a baffle extending into the distal portion of the substantially enclosed region of the housing, said method comprising the steps of:
delivering products of combustion into the proximal portion of the enclosed region of the boiler housing for heat exchange with water contained within a portion of the heat exchanger that is at least partially positioned within the proximal portion;
and directing the products of combustion into a constricted region of the boiler housing defined in the distal portion of the enclosed region between the baffle and the boiler housing for heat exchange with water contained within another portion of the heat exchanger that is at least partially positioned within the constricted region.
delivering products of combustion into the proximal portion of the enclosed region of the boiler housing for heat exchange with water contained within a portion of the heat exchanger that is at least partially positioned within the proximal portion;
and directing the products of combustion into a constricted region of the boiler housing defined in the distal portion of the enclosed region between the baffle and the boiler housing for heat exchange with water contained within another portion of the heat exchanger that is at least partially positioned within the constricted region.
14. The method of claim 13 further comprising the step of distributing water through the heat exchanger.
15. The method of claim 13, wherein the delivering step comprises distributing the products of combustion over heat exchange surfaces of a first column of heat exchange conduits of the heat exchanger that are at least partially positioned in the proximal portion of the substantially enclosed region of the housing.
16. The method of claim 15, wherein the delivering step further comprises distributing the products of combustion into a constricted region of the boiler housing defined in the proximal portion of the enclosed region for heat exchange with water contained within a second column of heat exchange conduits of the heat exchanger that is at least partially positioned within the constricted region of the boiler housing defined in the proximal portion of the enclosed region.
17. A method of assembling a boiler including a heat exchanger positioned at least partially within a substantially enclosed region of a boiler housing and a burner positioned to deliver products of combustion into the enclosed region of the boiler housing, said method comprising the steps of:
positioning a divider in the substantially enclosed region of a boiler housing, thereby at least partially separating the substantially enclosed region into a proximal portion into which the burner extends and a distal portion into which the burner does not extend, and positioning a baffle in the distal portion of the substantially enclosed region of the housing to define a constricted region in the distal portion of the substantially enclosed region of the housing; and positioning a portion of the heat exchanger at least partially within the proximal portion of the substantially enclosed region of the housing and another portion of the heat exchanger at least partially within the constricted region of the distal portion of the substantially enclosed region of the housing.
positioning a divider in the substantially enclosed region of a boiler housing, thereby at least partially separating the substantially enclosed region into a proximal portion into which the burner extends and a distal portion into which the burner does not extend, and positioning a baffle in the distal portion of the substantially enclosed region of the housing to define a constricted region in the distal portion of the substantially enclosed region of the housing; and positioning a portion of the heat exchanger at least partially within the proximal portion of the substantially enclosed region of the housing and another portion of the heat exchanger at least partially within the constricted region of the distal portion of the substantially enclosed region of the housing.
18. The method of claim 17 further comprising the step of positioning a baffle in the proximal portion of the substantially enclosed region of the housing at least partially between a first column of heat exchange conduits of the heat exchanger and a second column of heat exchange conduits of the heat exchanger.
19. The method of claim 18 further comprising the step of positioning another baffle in the proximal portion of the substantially enclosed region of the housing radially outwardly from the second column of heat exchange conduits of the heat exchanger, thereby defining a constricted region between the baffles of the proximal portion of the substantially enclosed region of the housing within which at least a portion of the second column of heat exchange conduits is at least partially positioned.
20. The water heater of claim 1, said at least one heat exchange conduit being positioned within said constricted region.
21. The water heater of claim 1, wherein the first end and the second end of each heat exchange conduit are arranged in the same plane.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US201161444341P | 2011-02-18 | 2011-02-18 | |
| US61/444,341 | 2011-02-18 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2768914A1 true CA2768914A1 (en) | 2012-08-18 |
Family
ID=46671155
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2768914 Abandoned CA2768914A1 (en) | 2011-02-18 | 2012-02-21 | High efficiency water heater |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2768914A1 (en) |
-
2012
- 2012-02-21 CA CA 2768914 patent/CA2768914A1/en not_active Abandoned
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| Date | Code | Title | Description |
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Effective date: 20150223 |