GB2422894A

GB2422894A - Method of manufacturing a baffle plate assembly

Info

Publication number: GB2422894A
Application number: GB0601010A
Authority: GB
Inventors: Stephen William John Grant
Original assignee: Alley Enterprises Ltd
Current assignee: Alley Enterprises Ltd
Priority date: 2006-01-17
Filing date: 2006-01-17
Publication date: 2006-08-09
Anticipated expiration: 2026-01-17
Also published as: GB0601010D0; GB2422894B

Abstract

A method of manufacturing a baffle plate assembly 11 for an enclosed boiler 1 of the type comprising a substantially rectangular combustion enclosure 2 formed by a base wall 3 and a front wall 4, side walls 5 and a rear wall 6 upstanding on the base wall 3, which upstanding walls 4, 5, 6 are hollow and arranged for carrying system water to be heated. In use, the front wall 4, side walls 5 and the rear wall 6 of the enclosure 2 form, with the sides of an interior tank 8 and each baffle plate assembly 11, 12 a passageway for flue gases through the boiler 1 from a gas inlet 13 located adjacent the base wall 3 of the enclosure 2 to a gas outlet flue. The method comprises forming baffle mounting plates 20, 22, a baffle dividing plate 24 and a baffle guide plate 50 having elongate baffle dividing plate embracing legs 52, 54. Such a method eliminates the requirement to cut openings out of baffle plate components, whilst also enabling the baffle plate assembly 11 to be independently formed and joined.

Description

-I- -

"A boiler"

Introduction

The present invention relates to a boiler and in particular to an enclosed boiler, such as an oil fired boiler.

There are many constructions of such boilers and the present invention is specifically directed to improvements in the invention of European Patent No. EP 0616676B, the disclosure of which is included herein in it's entirety by way of reference. This is a very efficient construction of enclosed boiler. However, since this invention was devised there have been developments directed to improving and making more efficient the method of constructing baffle assemblies for use with boilers of the general type described in EP 0616676B.

It is therefore an object of the present invention to provide an improved method of constructing baffle assembly based on the principles of the boiler described in the aforementioned European Patent No. 0616676B.

It is acknowledged that the term comprise' may, under varying jurisdictions be provided with either an exclusive or inclusive meaning. For the purpose of this specification, and unless otherwise noted explicitly, the term comprise shall have an inclusive meaning - i.e. that it may be taken to mean an inclusion of not only the listed components it directly references, but also other non-specified components.

Accordingly, the term comprise' is to be attributed with as broader interpretation as possible within any given jurisdiction and this rationale should also be used when the terms comprised' and/or comprising' are used.

Further aspects of the present invention will become apparent form the ensuing

description which is given by way of example only.

* a S.. ** S * S S * * * . * * S * I S * * * S. * * S * * * . S S S ** * S S. I S atements of Invention According to the invention, there is provided a method of manufacturing a baffle plate assembly for an enclosed boiler of the type comprising: a substantially rectangular combustion enclosure formed by a base wall, upstanding front, side and rear walls on the base wall, and a top wall, in which at least a portion of the upstanding front, side and rear walls arranged for carrying water to be heated; at least one interior tank in the enclosure, which tank extends between the front and rear walls of the enclosure to divide the enclosure in two baffle plate assembly receiving sub-enclosures, each for supporting therein at least one baffle plate assembly, the front, rear and side enclosure walls forming, with the each baffle plate assembly and the enclosure walls, a passageway for flue gases through the boiler from a gas inlet located adjacent the base wall of the enclosure through the baffle plate assembly in one of the sub- enclosures to a common gas flue located in the top wall of the enclosure, the method comprising the steps, not necessarily sequentially of: forming a front baffle mounting plate, a top baffle mounting plate and at least one baffle dividing plate having a pair of side faces and an upward, a downward and front and rear facing peripheral edges, the baffle dividing plate being formed with a plurality of protruding tabs on its upward facing peripheral edge for engagement with respective notches in the top baffle mounting plate, which baffle dividing plate also comprises a plurality of protruding tabs on its front facing edge for engagement with respective notches in the front baffle mounting plate to define there between an opening through which flue gases move; S..

* * S.. * * * S * S S * * * * S S S S * * * S. * S S * * * * S $ S 55. * *. S S cutting a notch in at least one substantially rectangular base plate to form a substantially U- shaped baffle guide plate having two elongate baffle dividing plate embracing legs; cutting a U-shaped channel forming bend line in one of the legs intermediate its ends; cutting at least one baffle guide plate receiving notch in the rear facing peripheral edge of the baffle dividing plate; bending the baffle dividing plate embracing leg upwards about the U- shaped channel forming bend line; inserting the baffle guide plate formed into the baffle guide plate receiving notch so that the baffle dividing plate embracing legs extend around the side faces of baffle dividing plate to form, with the side and rear walls of the enclosure and the front and top baffle mounting plates, a baffle assembly passageway for directing flue gases through the opening between the front baffle plate and baffle dividing plate and then around the front edge of the baffle dividing plate and along one side face of the baffle dividing plate between the top baffle mounting plate and one of the elongate baffle dividing plate embracing legs and then around the rear peripheral edge of the baffle dividing plate and along the other side face of the baffle dividing plate between the top baffle mounting plate and other of the elongate baffle dividing plate embracing legs and then up the bent portion of the baffle dividing plate embracing leg and through an opening in the top baffle mounting plate to the gas flue.

Such a method for constructing a baffle plate assembly is particularly advantageous as it will eliminate the requirement to cut openings out of baffle plate components through which flue gases are intended to pass. In particular, the provision of a baffle guide plate having an elongate leg which can be bent upwards to provide a passageway through the assembly for flue gases is particularly advantageous.

* * *** S S * S S S * S S * * S * S * S S S S. S S * * * S S * S S * . S. S S Furthermore the provision of a connection system of tabs and notches for joining the components of the baffle plate assembly together is particularly advantageous as it will enable the separate plates of the baffle plate assembly to be independently formed and joined together on site, which will not only reduce transportation costs but also increase the ease with which the baffle plate assembly can be constructed and taken apart for cleaning.

In another embodiment of the invention, the baffle guide plate is tack welded to the sides of the baffle dividing plate.

In another embodiment of the invention, a baffle plate assembly manipulation hole is cut out of the front baffle mounting plate.

In another embodiment of the invention a further baffle guide plate having two elongate baffle dividing plate embracing legs is formed and inserted into a further receiving notch cut out of the rear peripheral edge of the baffle dividing plate, the baffle guide plate then being tack welded to the sides of the baffle dividing plate.

In another embodiment of the invention, an additional tab is formed on the front peripheral edge of the baffle dividing plate, which additional tab is inserted into a further receiving notch formed in the front mounting plate.

In another embodiment of the invention, the method comprises the further step of forming a baffle plate assembly extension component, the baffle plate assembly being positioned, when in the enclosure, substantially vertically on top of the baffle plate assembly extension component to provide an extended passageway for flue gases through the enclosure.

In another embodiment of the invention, the baffle plate assembly extension component is formed with a baffle plate assembly extension component dividing plate having an upward facing peripheral edge which provides a landing or mounting surface for receiving thereon the baffle dividing plate of the baffle plate assembly.

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Petailed Description of the Invention

The invention will be more clearly understood from the following description of some embodiments thereof, given by way of example only, with reference to the accompanying drawings, in which: Fig. 1 is a front sectional view of a boiler enclosing a plurality of baffle plate assemblies formed in accordance with the present invention; Fig. 2 is a side sectional view of the boiler shown in Fig. 1, Fig. 3 is an exploded view of a baffle plate assembly shown in Fig. 1, Fig. 4 is a perspective view of the baffle plate assembly shown in Fig. 3 fully assembled, Fig. 5 is an exploded view of the baffle plate assembly shown in Fig. 3 having an additional baffle guide plate; Fig. 6 is a perspective view of the baffle plate assembly shown in Fig. 5 fully assembled; Fig. 7 is an exploded view of a further construction of baffle plate assembly component for use with the baffle plate assemblies shown in Figs. 1 to 6, and Fig. 8 is a perspective view of the baffle plate assembly component shown in Fig. 7 fully assembled.

Referring to the drawings, and initially to Figs. 1 and 2 thereof, there is illustrated an enclosed boiler, indicated generally by the reference numeral 1, comprising a substantially rectangular combustion enclosure 2 formed by a base wall 3 and a front wall 4, side walls 5 and a rear wall 6 upstanding on the base wall 3, which upstanding walls are hollow and arranged for carrying water to be heated. Also shown is a top wall 7. The boiler 1 further comprises an interior tank 8 which extends between the S. .

S I 555 5 S 4 I S S I, * S I a I S * S S S IS I a S * * S a I S S I Is I 4 front wall 4 and the rear waIl 6 of the enclosure 2 to divide the enclosure 2 into two baffle plate assembly receiving sub-enclosures 9 and 10, each for supporting therein at least one baffle plate assembly, indicated generally by the reference numerals 11 and 12 (see Fig. 3).

While the operation of the boiler, in accordance with the invention, does not form part of this invention, it will be appreciated that, in use, the front wall 4, side walls 5 and the rear wall 6 of the enclosure 2 form, with the sides of the interior tank 8 and each baffle plate assembly 11 and 12, a passageway for flue gases through the boiler 1 from a gas inlet 13 located adjacent the base wall 3 of the enclosure 2 through the baffle plate assembly 11 and 12 in one of the sub-enclosures 9 and 10 to a common gas flue 14 located in the top wall 7 of the enclosure 2.

With reference now to Figs. 3 and 4, the method of manufacturing the baffle plate assemblies shown in Fig. 1 will now be described, in which reference will be made to the formation of a single baffle plate assembly, indicated generally by the reference numeral 11. Shown in Fig. 3 is a front baffle mounting plate 20, a top baffle mounting plate 22 and a baffle dividing plate 24 having side faces 26 and 27 (view obscured) and an upward facing peripheral edge 28, a downward facing peripheral edge 30, a front facing peripheral edge 32 and a rear facing peripheral edge 34. The baffle dividing plate 24 is formed with a plurality of protruding tabs 36 on the upward facing peripheral edge 28 for engagement with respective notches 38 in the top baffle mounting plate 22. The baffle dividing plate 24 also comprises at least one protruding tab 40 on its front facing edge 32 for engagement with a respective notch 42 in the front baffle mounting plate 20 to together define there between an opening 44 (see Fig. 4) through which flue gases move.

It does not require any description to explain how the front baffle mounting plate 20, top baffle mounting plate 22 and baffle dividing plate 24 and associated tabs and notches are respectively formed as known fabrication and machining methods may be used.

Also shown is a rectangular base plate, indicated generally by the reference numeral 46, out of which has been cut a notch 48 to form a substantially U-shaped baffle a I I 0 * * I I I 0 a I I I, I I I I I 4 I 40 * a *4 I I guide plate 50 having two elongate baffle dividing plate embracing legs 52 and 54. A U-shaped channel forming bend line 56 is cut (for example, by laser cutting) in the leg 54 intermediate its ends and a baffle guide plate receiving notch 58 is cut in the rear facing peripheral edge 34 of the baffle dividing plate 24. The baffle dividing plate embracing leg 54 is then bent upwards about the U-shaped channel forming bend line 56 and the baffle guide plate 50 formed is then inserted into the baffle guide plate receiving notch 58 50 that the baffle dividing plate embracing legs 52 and 54 extend around the side faces 26 and 27 of the baffle dividing plate 24. The baffle guide plate is then tack welded to the sides 26 and 27 of the baffle dividing plate 24. In the instance shown, the front baffle mounting plate 20 also includes a baffle assembly manipulation hole 60 which may be used by an operator to manipulate the baffle plate assembly 11 into position within one of the baffle plate assembly receiving sub- enclosure 9 and 10 (see Fig. 1).

Fig. 4 shows a baffle plate assembly 11 fully assembled which is ready to be inserted into one of the baffle plate assembly receiving subenclosures 9 and 10 of the boiler 1, as shown in Figs. 1 and 2. It should be appreciated that the baffle plate assembly 12 shown in Fig. 1 is identical to the baffle plate assembly 11 shown in Fig. 4. When inserted, the baffle dividing plate embracing legs 52 and 54 form, with the side walls 5 and the rear wall 6 of the enclosure 2 and the inward facing surfaces of the front baffle mounting plate 20 and top baffle mounting plate 22, a passageway for directing gases through the opening 44 and then around the front peripheral edge 32 of the baffle dividing plate 24 and along one side 26 of the baffle dividing plate 24 between the top baffle mounting plate 22 and the baffle dividing plate embracing leg 52 and then around the rear peripheral edge 34 and along the other side face 27 of the baffle dividing plate 24 between the top baffle mounting plate 22 and the baffle dividing plate embracing leg 54. The gases then flow up the bent portion of the baffle dividing plate embracing leg 54 and through an opening 62 formed in the top baffle mounting plate 22 to the gas flue 14 (see Fig. 1).

With reference now to Figs. 5 and 6, there is shown the baffle plate assembly illustrated in Fig. 4, again identified by the same reference numeral 11, comprising a further baffle guide plate 64, which baffle guide plate is also U-shaped having two elongate baffle dividing plate embracing legs 66 and 68. In the instance shown, a U- ,I.

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I I I S * , * I. I I I * * * S S $3 S S S. S S shaped channel forming bend line 70 is cut in the leg 66 intermediate its ends and a further baffle guide plate receiving notch 72 is also cut in the rear facing peripheral edge 34 of the baffle dividing plate 24. The baffle dividing plate embracing leg 66 is then bent upwards about the U-shaped channel forming bend line 70 and the baffle guide plate 64 formed is then inserted into the receiving notch 72 so that the baffle dividing plate embracing legs 66 and 68 extend around the side faces 26 and 27 of the baffle dividing plate 24. The baffle guide plate 64 is also tack welded to the sides 26 and 27 of the baffle dividing plate 24. In the instance shown, the baffle dividing plate 24 comprises an additional tab 41 which is received into a further receiving notch 72 formed in the front mounting plate 20.

Fig. 6 shows a baffle plate assembly 11 fully assembled with a pair of baffle guide plates 50 and 64 mounted to the baffle dividing plate 24, which baffle plate assembly is ready to be inserted into one of the baffle plate assembly receiving sub-enclosures 9 and 10 of the boiler 1, as shown in Figs. I and 2.

It should be appreciated that, when inserted, the baffle dividing plate embracing legs 66 and 68 form, with the side walls 5 and the rear wall 6 of the enclosure 2 and the inward facing surfaces of the front baffle mounting plate 20 and the downward facing surface of the baffle guide plate 50, an additional passageway level for directing gases through the opening 44 and then around the front peripheral edge 32 of the baffle dividing plate 24 and along one side 28 of the baffle dividing plate 24 between the downward facing surface of the baffle dividing plate embracing leg 52 and the upward facing surface of the baffle dividing plate embracing leg 68, then around the rear peripheral edge 34 and along the other side face 26 of the baffle dividing plate 24, this time between the downward facing surface of the baffle dividing plate embracing leg 54 and the upward facing surface of the baffle dividing plate embracing leg 66. The gases then flow up the bent portion of the baffle dividing plate embracing leg 66 and then again around the front peripheral edge 32 of the baffle dividing plate 24 between an opening 74 formed between the protruding tabs 40 and 41. The gases then continue through the baffle plate assembly 11 around the baffle guide plate 50 and out of the gas flue as described above.

Figs. 7 and 8 both show a construction for a baffle plate assembly extension * * S.. * *.S * S S S S * . * S * * * S S S S. S S * . S S S S S 55 S 5 S S S. S S 5 S component, indicated generally by the reference numeral 75, for use with the baffle plate assembly 11 shown in Figs. 3 to 6. In the instance shown, the baffle plate assembly extension component 75 comprises a baffle plate assembly extension component dividing plate 76 having an upward facing peripheral edge 84 which provides a landing or mounting surface for receiving thereon the baffle dividing plate 24 (of the baffle plate assembly 11). In use, the baffle plate assembly 11 is positioned substantially vertically on top of the baffle plate assembly extension component 75 to provide an extended passageway for flue gases through the enclosure 2. The downward facing peripheral edge 30 of the baffle dividing plate 24 is positioned on the upward facing peripheral edge 84 of the baffle plate assembly extension component dividing plate 76 when in the boiler sub-enclosure. The baffle plate assembly extension component dividing plate 76 also comprises a pair of protruding tabs 78 and 80.

Also shown is a baffle plate assembly extension component guide plate 82, which is formed in the same way as the baffle guide plates 50 and 64 of the baffle plate assembly 11 to have a pair of U-shaped elongate baffle plate assembly extension component dividing plate embracing legs 86 and 88. The baffle plate assembly extension component guide plate 82 is inserted into a notch 85 cut out of the dividing plate 76 so that the baffle plate assembly extension component dividing plate embracing legs 86 and 88 also extend around the side faces of the baffle plate assembly extension component dividing plate 76. The embracing leg 88 comprises a Ushaped channel forming bend line 90, about which bend line 90 the leg 88 is bent upwards so that the leg 88 follows the contour of the tab 78.

It should be appreciated that when the baffle plate assembly extension component guide plate 82 is inserted onto the dividing plate 76 and then placed into a boiler with the baffle assembly 11 a passageway for flue gases is then created. In the instance shown, the passageway extends through an opening 92 and then around the sides of the dividing plate 76 (between the underside of the embracing leg 50 and the upward facing surfaces of embracing legs 86 and 88) and then up the bend formed in the embracing leg 88 and into the opening 44 of the baffle plate assembly 11 (see Fig. 4). The flue gases then proceed through the baffle plate assembly as described above with respect to Figs. 3 to 6 and out of the gas flue as described above.

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* S S * S S S * S S * 5 1 5 5 S. S S S S S S S S S *S S * S * 5* 5 5 S S -10- - The invention is not limited to the embodiment hereinbefore described, but may be varied in both construction and detail within the scope of the claims.

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Claims

A method of manufacturing a baffle plate assembly for an enclosed boiler of the type comprising: a substantially rectangular combustion enclosure formed by a base wall, upstanding front, side and rear walls on the base wall, and a top wall, in which at least a portion of the upstanding front, side and rear walls arranged for carrying water to be heated; at least one interior tank in the enclosure, which tank extends between the front and rear walls of the enclosure to divide the enclosure in two baffle plate assembly receiving sub-enclosures, each for supporting therein at least one baffle plate assembly, the front, rear and side enclosure walls forming, with the each baffle plate assembly and the enclosure walls, a passageway for flue gases through the boiler from a gas inlet located adjacent the base wall of the enclosure through the baffle plate assembly in one of the sub- enclosures to a common gas flue located in the top wall of the enclosure, the method comprising the steps, not necessarily sequentially of: forming a front baffle mounting plate, a top baffle mounting plate and at least one baffle dividing plate having a pair of side faces and an upward, a downward and front and rear facing peripheral edges, the baffle dividing plate being formed with a plurality of protruding tabs on its upward facing peripheral edge for engagement with respective notches in the top baffle mounting plate, which baffle dividing plate also comprises a plurality of protruding tabs on its front facing edge for engagement with respective notches in the front baffle mounting plate to define there between an opening through which flue gases move; S S ass S **5 * * a S a * S a a I S S I S II S * * a I a

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a. a S * I cutting a notch in at least one substantially rectangular base plate to form a substantially U-shaped baffle guide plate having two elongate baffle dividing plate embracing legs; cutting a U-shaped channel forming bend line in one of the legs intermediate its ends; cutting at least one baffle guide plate receiving notch in the rear facing peripheral edge of the baffle dividing plate; bending the baffle dividing plate embracing leg upwards about the U- shaped channel forming bend line; inserting the baffle guide plate formed into the baffle guide plate receiving notch so that the baffle dividing plate embracing legs extend around the side faces of baffle dividing plate to form, with the side and rear walls of the enclosure and the front and top baffle mounting plates, a baffle assembly passageway for directing flue gases through the opening between the front baffle plate and baffle dividing plate and then around the front edge of the baffle dividing plate and along one side face of the baffle dividing plate between the top baffle mounting plate and one of the elongate baffle dividing plate embracing legs and then around the rear peripheral edge of the baffle dividing plate and along the other side face of the baffle dividing plate between the top baffle mounting plate and other of the elongate baffle dividing plate embracing legs and then up the bent portion of the baffle dividing plate embracing leg and through an opening in the top baffle mounting plate to the gas flue.
2. A method as claimed in claim 1, in which the baffle guide plate is tack welded to the sides of the baffle dividing plate.
3. A method as claimed in claim 1 or claim 2, in which a baffle plate assembly manipulation hole is cut out of the front baffle mounting plate.

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4. A method as claimed in claim in preceding claim, in which a further baffle guide plate having two elongate baffle dividing plate embracing legs is formed and inserted into a further receiving notch cut out of the rear peripheral edge of the baffle dividing plate, the baffle guide plate then being tack welded to the sides of the baffle dividing plate.
5. A method as claimed in claim in 4, in which an additional tab is formed on the font peripheral edge of the baffle dividing plate, which additional tab is inserted into a further receiving notch formed in the front mounting plate.
6. A method as claimed in any preceding claim, comprising the further step of forming a baffle plate assembly extension component, the baffle plate assembly being positioned, when in the enclosure, substantially vertically on top of the baffle plate assembly extension component to provide an extended passageway for flue gases through the enclosure.
7. A method as claimed in claim 6, in which the baffle plate assembly extension component is formed with a baffle plate assembly extension component dividing plate having an upward facing peripheral edge which provides a landing or mounting surface for receiving thereon the baffle dividing plate of the baffle plate assembly.
8. A method of constructing a baffle plate assembly substantially as hereinbefore described with reference to and as illustrated in the accompanying drawings.

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