Water heater with multiple heat exchanging stacks
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IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
F24H-001/18
F24H-001/00
출원번호
US-0111670
(2011-05-19)
등록번호
US-8807093
(2014-08-19)
발명자
/ 주소
Steinhafel, Michael B.
출원인 / 주소
Bock Water Heaters, Inc.
대리인 / 주소
Stiennon & Stiennon
인용정보
피인용 횟수 :
4인용 특허 :
17
초록▼
A water heater has a tank having an upper and a lower domes which are penetrated by tubular flues in a 1-1-5 arrangement of a first flue connected to a second flue which in turn is connected to tertiary condensing flues. A gas-fired burner on the upper dome fires into the first flue. Both the first
A water heater has a tank having an upper and a lower domes which are penetrated by tubular flues in a 1-1-5 arrangement of a first flue connected to a second flue which in turn is connected to tertiary condensing flues. A gas-fired burner on the upper dome fires into the first flue. Both the first and second flue have heat exchange capacity enhanced by a multiplicity of rectangular metal fins welded in a helical arrangement. Some or all of the fins in the first flue may be stainless steel, while the remaining fins may be a different material, such as mild steel. The first and second flues are arranged to remove approximately 82-89 percent of the heat generated by the burner with minimal or no formation of condensate. Approximately 5.5-9 percent of the heat generated by combustion in the burner is removed in third flues where condensation takes place.
대표청구항▼
1. A water heater comprising: a water tank having a lower dome and an upper dome, and a tank wall extending therebetween;a first flue defining a first flue wall, the first flue extending between the upper dome and the lower dome, the first flue joining the upper dome to define an opening through the
1. A water heater comprising: a water tank having a lower dome and an upper dome, and a tank wall extending therebetween;a first flue defining a first flue wall, the first flue extending between the upper dome and the lower dome, the first flue joining the upper dome to define an opening through the upper dome, and joining the lower dome to define an opening through the lower dome, the first flue having an inner surface to which a first multiplicity of radially inwardly extending metal fins are attached by a weld, without extending through the first flue wall;a burner mounted to the first flue so as to fire along the first flue;a controller connected to the burner to vary the BTU output of the burner;a second flue defining a second flue wall, the second flue extending along a length between the upper dome and the lower dome and spaced from the first flue, the second flue joining the upper dome to define an opening through the upper dome, and joining the lower dome to define an opening through the lower dome, the second flue having an inner surface to which a second multiplicity of radially inwardly extending metal fins are attached by a weld, without extending through the second flue wall;a first thermal junction box mounted to one of the upper dome or the lower dome and forming a passageway between the first flue and the second flue, the first junction box opposite the burner so that flue gases pass through the first flue and then pass through the second flue; andwherein the multiplicity of metal fins in the first flue begin at a location spaced downstream from the burner such that the multiplicity of metal fins are exposed to lower temperature, and the multiplicity of metal fins in the first flue extend along the first flue inner surface to the first thermal junction box, and wherein the second multiplicity of metal fins extend along the second flue inner surface. 2. The water heater of claim 1 further comprising: a plurality of third flues extending between the upper dome and the lower dome and spaced from the first flue and the second flue, the plurality of third flues joining the upper dome to define a plurality of openings through the upper dome, and joining the lower dome to define a plurality of openings through the lower dome;a second thermal junction box mounted to the upper dome and into which the second flue and the plurality of third flues open so that the second thermal junction box forms a passageway between the second flue and each third flue of the plurality of third flues; anda final junction box mounted to the lower dome and covering the opening through the lower dome defined by the third flues, the final junction box connecting to a condensate drain and a combustion gas exhaust pipe. 3. The water heater of claim 1 wherein the first flue is constructed of mild steel, and the second flue is also constructed of mild steel and wherein at least about one half of the first multiplicity of metal fins in the first flue which are positioned closest to the burner are formed of a first metal with a capacity of continuous use at a first maximum temperature, and the second multiplicity of metal fins in the second flue are formed of a second metal different than the first metal with a capacity of continuous use at a second maximum temperature less than the first maximum temperature. 4. The water heater of claim 3 wherein the first maximum temperature is about 2000° F., and the second maximum temperature is about 1000° F. 5. The water heater of claim 3 wherein the first metal is 309S stainless steel and second metal is mild steel. 6. The water heater of claim 1 wherein the first thermal junction box has an inner lining of insulation. 7. The water heater of claim 2 wherein the plurality of openings through the upper dome defined by the third flues and the opening through the upper dome defined by the second flue within the second thermal junction box are arranged so that the plurality of openings through the upper dome defined by the third flues are substantially equally spaced along an arc of a circle centered on the opening through the upper dome defined by the second flue. 8. The water heater of claim 2 wherein there are at least five and no more than ten third flues, and the third flues are all of the same shape and have a maximum dimension of at least 2 inches and no greater than 5 inches. 9. The water heater of claim 1 wherein each fin of the first multiplicity of metal fins has a generally rectangular plan having two long sides and two short sides and a thickness of about 1/16 to about 5/16 inches and is welded to extend inwardly from the first flue inner surface; and wherein each fin of the second multiplicity of metal fins has a generally rectangular plan having two long sides and two short sides and a thickness of about 1/16 to about 5/16 inches and is welded to extend inwardly from the second flue inner surface. 10. A water heater comprising: a water tank having a lower dome and an upper dome, and a cylindrical tank wall extending therebetween;a first cylindrical flue defining a first flue wall, the first cylindrical flue extending between the upper dome and the lower dome, the first cylindrical flue joining the upper dome to define an opening through the upper dome, and joining the lower dome to define an opening through the lower dome, the first cylindrical flue having an inner surface to which a first multiplicity of discrete radially inwardly extending metal fins are attached by a weld, without extending through the first flue wall;a burner positioned on the upper dome and mounted to fire down the first cylindrical flue toward the opening in the lower dome;a controller connected to the burner to vary the BTU output of the burner;a second cylindrical flue defining a second flue wall, the second cylindrical flue extending between the upper dome and the lower dome and spaced from the first cylindrical flue, the second cylindrical flue joining the upper dome to define an opening through the upper dome, and joining the lower dome to define an opening through the lower dome, the second cylindrical flue having an inner surface to which a second multiplicity of discrete radially inwardly extending metal fins are attached by a weld, without extending through the second flue wall;a first thermal junction box mounted to the lower dome and forming a passageway between the first cylindrical flue and the second cylindrical flue;a plurality of third cylindrical flues extending between the upper dome and the lower dome and spaced from the first cylindrical flue and the second cylindrical flue, the plurality of third cylindrical flues joining the upper dome to define a plurality of third openings through the upper dome, and joining the lower dome to define a plurality of openings through the lower dome;a second thermal junction box mounted to the upper dome and into which the second cylindrical flue and the plurality of third cylindrical flues open so that the second thermal junction box forms a passageway between the second cylindrical flue and each third cylindrical flue; anda final junction box mounted to the lower dome and covering the openings through the lower dome defined by the plurality of third cylindrical flues, the final junction box connecting to a condensate drain and a combustion gas exhaust pipe. 11. The water heater of claim 10 wherein the first cylindrical flue is constructed of mild steel, and the second cylindrical flue is also constructed of mild steel and wherein at least about one half of the metal fins in the first cylindrical flue which are positioned downstream of and closest to the burner are formed of a first metal with a capacity of continuous use at a first maximum temperature, and the metal fins in the second flue are formed of a second metal different than the first metal with a capacity of continuous use temperature less than the first maximum temperature. 12. The water heater of claim 11 wherein the first maximum temperature is about 2000° F. and the second maximum temperature is about 1000° F. 13. The water heater of claim 11 wherein the first metal is 309S stainless steel and the second metal is mild steel. 14. The water heater of claim 10 wherein the first thermal junction box has an inner lining of insulation. 15. The water heater of claim 10 wherein the plurality of openings through the upper dome defined by each of the plurality of third cylindrical flues and the opening through the upper dome defined by the second cylindrical flue within the second thermal junction box are arranged so that the plurality of openings through the upper dome defined by the plurality of third cylindrical flues are substantially equally spaced along an arc of a circle centered on the opening through the upper dome defined by the second cylindrical flue. 16. The water heater of claim 10 wherein there are at least five and no more than ten third cylindrical flues, and the third cylindrical flues are all of the same diameter and have a diameter of at least 2 inches and no greater than 5 inches. 17. The water heater of claim 10 wherein each fin of the first multiplicity of metal fins has a generally rectangular plan having two long sides and two short sides and a thickness of about 1/16 to about 5/16 inches and is welded to extend inwardly from the first cylindrical flue inner surface; and wherein each fin of the second multiplicity of metal fins has a generally rectangular plan having two long sides and two short sides and a thickness of about 1/16 to about 5/16 inches and is welded to extend inwardly from the second cylindrical flue inner surface. 18. The water heater of claim 10 wherein the plurality of third cylindrical flues are glass lined and have stainless steel baffles hanging from each of the plurality of third openings through the upper dome, to increase turbulence within the plurality of third cylindrical flues. 19. A water heater comprising: a water tank having a lower dome and an upper dome, and a cylindrical tank wall extending therebetween;a first cylindrical flue defining a first flue wall, the first cylindrical flue extending between the upper dome and the lower dome, the first cylindrical flue joining the upper dome to define an opening through the upper dome, and joining the lower dome to define an opening through the lower dome, the first cylindrical flue having an inner diameter to which a first multiplicity of discrete metal fins are attached by a weld, without extending through the first flue wall;wherein at least some of the discrete metal fins in the first cylindrical flue which are positioned downstream of and closest to the burner are formed of a first metal with a capacity of continuous use at a first maximum temperature;a burner positioned on the upper dome and mounted to fire down the first cylindrical flue toward the opening in the lower dome;a second cylindrical flue defining a second flue wall, the second cylindrical flue extending between the upper dome and the lower dome and spaced from the first cylindrical flue, the second cylindrical flue joining the upper dome to define an opening through the upper dome, and joining the lower dome to define an opening through the lower dome, the second cylindrical flue having an inner diameter to which a second multiplicity of discrete metal fins are attached by a weld, without extending through the second flue wall;wherein at least some of the discrete metal fins in the second flue are of a second metal different than the first metal with a capacity of continuous use at a second maximum temperature lower than the first maximum temperature;a first thermal junction box mounted to the lower dome and forming a passageway between the first cylindrical flue and the second cylindrical flue;a plurality of third cylindrical flues extending between the upper dome and the lower dome and spaced from the first cylindrical flue and the second cylindrical flue, the plurality of third cylindrical flues joining the upper dome to define a plurality of openings through the upper dome, and joining the lower dome to define a plurality of openings through the lower dome;a second thermal junction box mounted to the upper dome and into which the second cylindrical flue and the plurality of third cylindrical flues open so that the second thermal junction box forms a passageway between the second cylindrical flue and each of the plurality of third cylindrical flues; anda final junction box mounted to the lower dome and covering the openings through the lower dome defined by the plurality of third cylindrical flues, the final junction box connecting to a condensate drain and a combustion gas exhaust pipe. 20. The water heater of claim 11 wherein the first maximum temperature is about 2000° F., and the second maximum temperature is about 1000° F.
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