U.S. patent application number 11/288062 was filed with the patent office on 2006-07-13 for dual function high efficiency water heater.
Invention is credited to Grzegorz Loniewski, Piotr Loniewski, Agnieszka Nightlinger, Scott Nightlinger.
Application Number | 20060150927 11/288062 |
Document ID | / |
Family ID | 32712002 |
Filed Date | 2006-07-13 |
United States Patent
Application |
20060150927 |
Kind Code |
A1 |
Nightlinger; Scott ; et
al. |
July 13, 2006 |
Dual function high efficiency water heater
Abstract
This gas-fired water heater has a shell sealed at opposite ends
within an insulated storage tank, defining a water-tight chamber
with inlet and outlet water connections thereto. The shell
preferably is a one-piece casting of aluminum alloy, with a
circular array of impervious passages between its opposite ends.
Each passage is defined by a curved wall segment spaced inwardly
adjacent the tank and a pair of side walls converging inwardly from
opposite ends of each curved wall segment to an inboard corner,
where the adjacent corners and side walls are spaced apart radially
and circumferentially respectively yielding water contact against
all exterior passage surfaces. A burner under the storage tank
generates hot flue gases that vent through the passages for heating
the chamber water. A rib can project inwardly from the curved wall
segment into each flow passage, adding heat transfer to the wall
segment and contacted water.
Inventors: |
Nightlinger; Scott; (Mount
Prospect, IL) ; Nightlinger; Agnieszka; (Mount
Propspect, IL) ; Loniewski; Grzegorz; (Mount
Prospect, IL) ; Loniewski; Piotr; (Warszawa,
PL) |
Correspondence
Address: |
Charles F. Lind
2210 E. Sherwood
Arlington Hts.
IL
60004
US
|
Family ID: |
32712002 |
Appl. No.: |
11/288062 |
Filed: |
November 28, 2005 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
10345790 |
Jan 16, 2003 |
|
|
|
11288062 |
Nov 28, 2005 |
|
|
|
Current U.S.
Class: |
122/17.1 |
Current CPC
Class: |
F24H 1/205 20130101 |
Class at
Publication: |
122/017.1 |
International
Class: |
F24H 1/00 20060101
F24H001/00 |
Claims
1-27. (canceled)
28-35. (canceled)
36. A gas-fired natural draft water heater, comprising the
combination of a vertically aligned insulated cylindrical
water-tight sealed storage tank having lower and upper headers, a
burner underlying the lower header operable to generate hot flue
gases, and cold water inlet and hot water outlet connections in the
tank for conveying water there through; a water-tight thermally
conductive flue pipe extending axially and generally concentrically
of the storage tank between sealed end connections in the headers
for conveying the flue gases through the tank, with the water in
the tank being annular of and substantially contacting all of the
exterior surfaces of the flue pipe; said flue pipe having inlet and
outlet end segments sealed to the headers and an intermediate
segment larger in cross-section than the end segments; said
intermediate segment being continuous and comprised of consecutive
upstream, intermediate and downstream contours, where said
intermediate contour extends axially of the cylindrical tank, and
said upstream and downstream contours are extended transversely of
the cylindrical tank; and an impervious baffle mounted in the
intermediate flue pipe segment and disposed transversely of the
cylindrical tank, with the baffle peripheral edge being spaced from
the intermediate contour of the flue pipe segment operable for
defining an annular flue gas flow path around the baffle and
transversely of the tank wall for increasing heat transfer between
the flue gas and adjacent tank water.
37. A water heater according to claim 36, further comprising a
coiled pipe in the annular chamber for absorbing and transferring
heat from the hot water contained in said chamber to an additional
water line.
38. A gas-fired water heater, comprising the combination of a
vertically aligned insulated generally cylindrical storage tank, an
inner shell within the tank, means sealing the shell and tank
together at respective lower and upper ends whereby a closed
water-tight chamber is defined therebetween, and inlet and outlet
connections for the chamber operable to convey water there through;
said shell having a circular array of impervious axially extended
passages between the lower and upper chamber ends, each passage
being defined by exterior walls including a curved wall segment
spaced inwardly adjacent the tank and a pair of side walls
converging inwardly from the opposite ends of each curved wall
segment to meet at an inboard liquid-tight corner, and the adjacent
passage side walls and inboard corners being circumferentially and
radially separated respectively defining starlike extensions of the
chamber whereby chamber water can contact all of the exterior
passage surfaces; and a burner underlying the storage tank operable
to generate hot flue gases; and headers adjacent respective lower
and upper open ends of the passages for conducting said flue gases
through the passages and away from burner and the water heater.
39. A water heater according to claim 38, further comprising a
radial rib extended inwardly from the curved wall segment into each
flow passage, adding heating exposure to the wall segment from flue
gases passing through the passages.
40. A water heater according to claim 38, further comprising the
curved wall segments together having their exterior surface shaped
in general as a truncated cone smaller at
41. A gas-fired water heater according to claim 38, further
comprising the inner shell being cast as a single piece of an
aluminum alloy.
42. A water heater according to claim 38, with said means sealing
the shell and tank together comprising the shell having an annular
partially closed top end wall and an outwardly projected annular
bottom end lip, and said tank overlying said shell and having an
annular top end wall and an annular bottom end flange suited to
butt flush against said shell top end wall and said bottom end lip,
and means securing the end walls and said lip and flange together
in sealed association.
43. A water heater according to claim 38, further comprising a
radial rib extended inwardly from the curved wall segment into each
flow passage, adding heating exposure to the wall segment from flue
gases passing through the passages, and the curved wall segments
together having their exterior surface shaped in general as a
truncated cone smaller at the upper end.
44. A gas-fired water heater according to claim 43, further
comprising the inner shell being cast as a single piece of an
aluminum alloy.
45. A water heater according to claim 44, with said means sealing
the shell and tank together comprising the shell having an annular
partially closed top end wall and an outwardly projected annular
bottom end lip, and said tank overlying said shell and having an
annular top end wall and an annular bottom end flange suited to
butt flush against said shell top end wall and said bottom end lip,
and means securing the end walls and said lip and flange together
in sealed association.
46. A water heater according to claim 44, further comprising a
coiled pipe in the annular chamber for absorbing from the hot water
contained in said chamber, and inlet and outlet connections through
the tank operable to convey an additional water line to the coiled
pipe.
Description
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0001] Not Applicable
REFERENCE TO A MICROFICHE APPENDIX
[0002] Not Applicable
BACKGROUND OF THE INVENTION
[0003] 1. Technical Field of Invention
[0004] This invention relates to a water heater in which combustion
products are caused to flow past a tank to heat water in the tank,
particularly for domestic use such as showering and washing the
dishes or clothes, as well as for space heating in a building.
[0005] 2. Description of the Prior Art
[0006] In a conventional gas fired/fueled water heater of prior art
U.S. Pat. Nos. 4,672,919; 5,020,512; 5,199,385; 5,335,646, etc., a
gas burner is located beneath the lower end of the water tank in a
combustion chamber. A central vertical flue pipe is provided
through the tank for discharge of the waste combustion or flue
gases. Water in the tank is heated by the heat from the burner in
the combustion chamber and from the waste gases passing upward
through the central flue pipe, which serves as a heat transfer
surface for heating water. Different flue baffles are placed into
the flue pipe to increase the amount of heat transmission through
the flue pipe. The thermal efficiency of such water heaters is
usually 76-80%. The reason for such a low thermal efficiency is the
high temperature of the outlet flue gases, which can reach
200.degree. C.
[0007] A multi-flue construction can be used to increase the
productivity of water heaters (e.g. by U.S. Pat. Nos. 4,157,077;
4,512,289; 4,531,509; 5,027,749). However, these constructions are
very complicated, generally being expensive and complex, and
contain numerous welds, which shorten a water heater's life.
Moreover, special means are required to prevent sediment buildup
the tank, e.g. as in U.S. Pat. No. 5,341,770.
[0008] Furthermore, it is known that hot water heaters may have two
separate hot water outlets, one for domestic hot water and the
other for a heating system in a building. Examples of such devices
are shown in U.S. Pat. Nos. 2,937,625; 4,222,350; 5,228,413;
5,372,185.
[0009] 3. Object and Advantages of the Invention
[0010] It is an object of the present invention to provide a water
heater with a constant thermal efficiency of 85-95% during a
heater's life, for residential use as well as for commercial use
with a manufacturing cost that is not greater than other ordinary
residential models of the same productivity and much less than the
cost of ordinary commercial models.
[0011] The current invention provides the following advantages:
[0012] 1) Increased water heater operating efficiency to 85-95%, by
improving heat recovery from flue gases to water. [0013] 2)
Increased water heater power, without decreased operating
efficiency and without increased water heater dimensions. [0014] 3)
Simple construction, easily implemented at low cost. [0015] 4)
Replacement of a typically separate water heater and boiler with a
single unit, by performing dual functions such as showering and
washing the dishes or clothes, as well as a heating system in a
building. [0016] 5) Reduced cost for water heating, by improving
heater efficiency during the water heater's life and by dual
function implementation. [0017] 6) Prolonged water heater lifespan,
by eliminating sediment accumulation within the water heater
tank.
[0018] Other objects and advantages of the present invention will
become apparent to those skilled in the art from the drawings, the
detailed description of the preferred embodiment, and the appended
claims.
BRIEF SUMMARY OF THE INVENTION
[0019] There is a need for a dual function, relatively simple, and
highly efficient water heater in which combustion products are
caused to flow past a tank to heat water. In accordance with the
present invention, a water heater is provided that includes an
insulated water tank with a flue pipe extending vertically through
the tank for the discharge of waste combustion or flue gases, a
burner below the tank, and a burner control means. The flue pipe
comprises a water-surrounded and radially-expanded means for
increasing heat recovery from the flue gases. The radially-expanded
means comprises a chamber for the flow of the flue gases. The
chamber includes a means for directing the flue gases toward the
inner surface of the radially-expanded means. In a further
improvement, the water heater comprises a means for transferring
heat from the water in the tank to an additional water line,
preferably for heating potable water for domestic use such as
showering and washing the dishes or clothes. In a still further
improvement (FIG. 1c), the burner control means possesses an
additional means for adjusting burner power depending on water
temperature in the water tank.
[0020] In accordance with the invention, in the second alternative
preferred embodiment as shown in (FIG. 1a, FIG. 1b, and FIG. 1c),
the means for directing the flue gases constitutes a tank
containing water in a heat exchange relationship with the water in
the main heater tank of the water heater. In a still further
modification (FIG. 1c), the tank for directing the flue gases
comprises at least two interconnected sections.
[0021] In accordance with the invention, the third alternative
preferred embodiment (FIG. 2 and FIG. 3) provides a water heater
having an additional heat exchanger for heating water for potable
use, a burner with control means, and a water housing containing
the water to be heated. The water housing comprises an inner ribbed
means and a separate outer shell tightly interconnected and sealed
together, between which is contained the water to be heated and the
heat exchanger. In the preferred embodiment, the outer shell is in
the shape of a cylinder with one partially closed top end and one
open bottom end. The partially closed top end possesses a machined
flange face sealing surface on the inside surface of the top end,
and the open bottom end possesses a machined flange face sealing
surface on the bottom side of a lip perpendicularly extending from
the outside of the outer shell. The inner ribbed means is
preferably in the shape of a truncated cone with one partially
closed top end and one open bottom end. The partially closed top
end possesses a machined flange face sealing surface on the outside
surface of said top end, and said open bottom end possesses a
machined flange face sealing surface on the top side of a lip
extending from the outside of the inner ribbed means. The flange
face sealing surface on the top end of both the inner ribbed means
and outer shell are tightly sealed and connected together, and the
flange face sealing surface on the lip of the bottom end of both
the inner ribbed means and outer shell are tightly sealed and
connected together. The opening of the partially closed top end of
both the inner ribbed means and outer shell provides for the
discharge of the combustion gases from the water heater, and the
opening of the bottom end of the inner ribbed means provides for
the entry of the hot combustion gases to the water heater.
[0022] In a further improvement, the burner control means possesses
an additional means for adjusting burner power, depending on water
temperature in the water housing.
[0023] In a still further improvement, the inner ribbed means
constitutes a cast shell comprising a plurality of ribs for
absorbing and transferring heat from the combustion gases.
[0024] In a still further improvement, the ribs are
radially-starlike situated in the inner cast shell.
[0025] In a still further improvement, at least some of the ribs
possess inner water cooling passages to maximize heat transfer.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0026] In the drawings which illustrate the present invention,
[0027] FIG. 1 is an elevated cross-sectional view showing a first
preferred embodiment of a water heater according to the present
invention.
[0028] FIG. 1a is an elevated cross-sectional view illustrating a
second preferred embodiment of a water heater according to the
present invention.
[0029] FIG. 1b is an elevated cross-sectional view illustrating a
similar embodiment to FIG. 1a.
[0030] FIG. 1c is an elevated cross-sectional view illustrating a
second similar embodiment to FIG. 1a.
[0031] FIG. 2 is a side elevated cross-sectional view illustrating
a third preferred embodiment of the water heater according to the
present invention.
[0032] FIG. 3 is a top cross sectional view taken along line A-A of
FIG. 2.
DETAILED DESCRIPTION OF THE INVENTION
[0033] The detailed description is presented to illustrate the
present invention but is not intended to limit it.
[0034] In more detail, a typical water heater, in which combustion
products are caused to flow past a tank to heat water in the tank,
comprises a gas burner located beneath the lower end of the tank in
a combustion chamber. A central vertical flue pipe is provided
through the tank for discharge of the waste combustion or flue
gases. Water in the tank is heated through the bottom end of the
tank by the heat from the burner in the combustion chamber and from
the waste gases passing upwardly through the central flue pipe, the
walls of which also serve as a heat transfer surface for heating
water. In order to increase the amount of heat transmission through
the flue pipe, and to increase the productivity and efficiency of
the water heater, a preferred embodiment of a water heater is shown
best in FIG. 1. According to the invention, the improved water
heater includes a water chamber 21 surrounded by a typical
cylindrical tank 11 with upper concave shaped end 22 and lower
convex shaped end 14. The water tank 11 having a water inlet stub
pipe 31 leads to the lower portion of the tank, and water outlet
stub pipe 30 located at the upper end 22 of tank 11 is surrounded
by a layer of insulation 32 on the side and top. An outer jacket 33
surrounds the insulation 32 to protect it from mechanical damage. A
burner 12 situated in a burning chamber 13 and located under the
lower end 14 of the tank 11 is adapted to combust gas such as
natural gas or propane or some other combustible material such as
oil. While the invention is disclosed in respect to a gas-fired
water heater, it is equally applicable to water heaters which burn
other combustible fuels. Such water heaters are intended to fall
within the scope of the claims. A cylindrically shaped steel flue
pipe 16 passes through the bottom end 14 extending vertically
through the tank 11 for removing flue gases from the burning
chamber 13. The concave shaped bottom end 14 directs hot gases into
the flue pipe 16. The flue pipe 16 comprises a water surrounded
inner tank (means) 18 for increasing heat recovery from the flue
gases. The water surrounded inner tank 18 in the shape of a boiler
drum with openings in the covers 19 and 20 is welded on a part of
the length of the flue pipe 16, dividing the flue pipe 16 into two
separate pieces 16a and 16b. The inner tank 18 comprises a chamber
18a for the flow of the hot flue gases, and the chamber 18a
comprises a thin-walled steel container (means) 25 for directing
the flue gases toward the inner surface of the water surrounded
inner tank 18. The thin-walled steel container (means) 25 is in a
shape similar to the water surrounded inner tank 18 and is filled
with thermal insulation 26. The container is equipped with two
spacers 27 and 27a for its central positioning in the water
surrounded inner tank 18. The water heater also comprises a copper
helically coiled heat exchanger 17 for transferring heat from the
water in the water chamber 21 to an additional water line,
preferably for heating water for domestic use such as showering and
washing the dishes or clothes. A helically coiled heat exchanger 17
is placed in the water space between the top ends 20 and 22 of the
two cylindrical pressure tanks 11 and 18 and is connected to
couplings 23 and 24 which are welded into the top end 22 of the
outer water tank 11. The stud pipes 30 and 31 of the outer water
tank 11 allow connectivity to the home's heating system. The water
heater contains a typical gas burner 12 placed in the burner
chamber 13. The gas burner 12 is operated with an improved burner
control means 15 similar to a typical gas control valve. The burner
control means 15 possesses an additional valve (means) (not shown)
for adjusting the power of the burner 12 depending on water
temperature in the water tank 11, whereby increasing the efficiency
of the water heater. The outer jacket 33 surrounding the insulation
32 also constitutes a base 34 supporting the water heater
construction over the floor's surface. The lower uninsulated part
of the base 34 possesses air flow openings 35 supporting the gas
burning process in the burning chamber 13.
[0035] Heated combustion gases produced by the burner 12 impinge
against the bottom 14 of the outer tank 11 to cause heat transfer
therethrough to the water in the chamber 21. The hot burned gases
further rise upward from the burning chamber 13 through the opening
36 in the flue pipe 16a to the chamber 18a of the inner tank 18
where they flow along the walls of the inner tank 18 to the flue
pipe 16b allowing the gases to flow out from the water heater to a
chimney (not shown).
[0036] A second alternative embodiment of the water heater
according to the invention is shown in FIG. 1a, FIG. 1b, and FIG.
1c. The alternative embodiments are similar to the embodiment shown
in FIG. 1. In the second alternative embodiment, the means 25 for
directing the flue gases toward the inner surface of the inner tank
18 constitutes a tank containing water in a heat exchange
relationship with the water in the water chamber 21. The tank 25
directing the flue gases is connected in a flow-through manner to
the water in the water chamber 21 with two pipes--an inflow pipe 28
and an outflow pipe 29. As shown in FIG. 1a, the inflow pipe 28 is
connected to the water chamber 21 with an inflow stub tube 31 and
the outflow pipe 29 is connected to the water chamber 21 with an
outflow stub tube 30 delivering the hot water to the home heating
system (not shown). As shown in FIG. 1b, the inflow pipe 28 of the
tank is connected to the water chamber 21 through the concave
bottom end 14 of the tank 11. As shown in FIG. 1c, the tank (means)
25 directing the flue gases toward the inner surface of the inner
tank 18 comprises three interconnected sections 25a. Such a
structure further increases contact area between flue gases and the
water surrounded walls to maximize heat transfer.
[0037] The water heater as shown in FIG. 1c, comprises an
additional control means 15a situated on the side of the water
heater and connected to the main burner control means 15. The
additional control means 15a, constitutes a temperature sensor that
sends a signal to the additional gas control valve (not shown) in
the burner control means 15 depending on the water temperature in
the water chamber 21 to adjust the power of the burner 12.
[0038] In a third alternative embodiment of the water heater shown
in FIG. 2 and FIG. 3, the water heater comprises a heat exchanger
17, a burner 12 with a burner control means 15 and a water housing
10. The water housing 10 comprises a separate inner cast shell 41
(inner ribbed means) and separate outer shell 40, which are tightly
sealed and interconnected on their ends 42, 44 and 43, 45. The
chamber 21 between the inner cast shell 41 and the outer shell 40
contains circulated water to be heated and a heat exchanger 17,
which constitutes a copper pipe helically coiled around the inner
cast shell 41. The inner cast shell 41 comprises sixteen ribs 48
for absorbing and transferring heat from the combustion gases to
the circulated water, which is located in the chamber 21 between
shells 40 and 41. Eight of the ribs 48 possess channels 49 filled
with circulating water to maximize heat transfer from the flue
gases. The ribs 48 are radially placed, starlike, in the inner cast
shell 41. The inner cast shell 41 made out of an aluminum alloy is
in the shape of a truncated cone with one partially closed top end
45 and one open bottom end 44. The partially closed top end 45
possesses a machined flange face sealing surface on the outside
surface of the top end 45. The open bottom end 44 also possesses a
machined flange face sealing surface on the top side of the lip
extending out from the bottom end 44.
[0039] The outer shell 40 made of cast iron is in the shape of a
cylinder with one partially closed top end 43 and one open bottom
end 42. The partially closed top end 43 possesses a machined flange
face sealing surface on the inside surface of the top end 43. The
open bottom end 42 possesses a machined flange face sealing surface
on the bottom side of a lip 42 that perpendicularly extends from
the outside of the bottom end 42 of the outer shell 40.
[0040] The flange face sealing surface on the top end of both
shells 40 and 41 are connected together with bolts 46 and sealed
with a sealing ring 47a installed between the sealing surfaces.
[0041] Also the flange sealing surface on the lip of the bottom end
42 and 44 of both shells 40 and 41 are connected together with the
same kind of bolts 46 and sealed with a sealing ring 47 located
between their sealing surfaces.
[0042] The coiled heat exchanger 17 is connected to the inflow and
outflow couplings 23 and 24 placed in the partially closed top end
43 of the cast iron outer shell 40. The water heated by the
exchanger 17 is for potable use.
[0043] The outer shell 40 also includes two stub tubes 30 and 31
for connecting to a heating system in a building (not shown). The
water heater contains a typical gas burner 12 placed in the burning
chamber 13, which is controlled with an improved gas control valve
15 placed on the side of the outer shell 40. The improved gas
control valve possesses an additional valve (not shown) for
adjusting the power of the burner 12 depending on water temperature
in the water chamber 21. The outer shell 40 is surrounded by a
layer of insulation 32 on the side and top. An outer jacket
surrounds the insulation 32 to protect it from mechanical damage.
The outer jacket 33 also constitutes a base 34 supporting the water
heater construction over the floor's surface. The lower uninsulated
part of the base 34 possesses air flow openings 35 supporting the
gas burning process in the burning chamber 13.
[0044] Hot combustion gases produced by the burner 12, in the
burning chamber 13, impinge against the ribbed surface 50 of the
inner cast shell 41, which allows for heat transfer therethrough to
the water in the chamber 21. The hot burned gases rise upward along
the ribs 48 and ribbed surface 50, transmitting its heat through
the walls 51 (FIG. 3) to the water chamber 21. The flue gases flow
out through the flue channels 52 to the pipe 53 and outside to the
chimney (not shown).
* * * * *