U.S. patent application number 11/859582 was filed with the patent office on 2008-03-27 for catch for condensates.
Invention is credited to David Glass, Jeff Hurlburt, Martin Wawrla.
Application Number | 20080072892 11/859582 |
Document ID | / |
Family ID | 39223598 |
Filed Date | 2008-03-27 |
United States Patent
Application |
20080072892 |
Kind Code |
A1 |
Wawrla; Martin ; et
al. |
March 27, 2008 |
CATCH FOR CONDENSATES
Abstract
The present invention relates to exhaust condensate removal
equipment for energy efficient heating apparatuses that may be
positioned either vertically or any angle off horizontal. The
device collects condensate from ducts and may be retrofit into
existing systems. The device has an inner chamber that collects and
directs condensates toward a drain nipple through which the
condensate is then removed from the sealed system. The system may
optionally include a reusable seal and clamp for ease of
maintenance or retrofitting an existing system.
Inventors: |
Wawrla; Martin; (Albany,
NY) ; Glass; David; (Glenville, NY) ;
Hurlburt; Jeff; (Troy, NY) |
Correspondence
Address: |
SCHMEISER, OLSEN & WATTS
22 CENTURY HILL DRIVE
SUITE 302
LATHAM
NY
12110
US
|
Family ID: |
39223598 |
Appl. No.: |
11/859582 |
Filed: |
September 21, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60826680 |
Sep 22, 2006 |
|
|
|
60826698 |
Sep 22, 2006 |
|
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Current U.S.
Class: |
126/307R |
Current CPC
Class: |
F23J 2900/13004
20130101; Y02B 30/00 20130101; Y02B 30/106 20130101; F24H 8/006
20130101; F23J 13/02 20130101; F23J 2213/202 20130101 |
Class at
Publication: |
126/307.00R |
International
Class: |
F23J 13/02 20060101
F23J013/02 |
Claims
1. A conduit section for drainage of flue gas condensate, said
conduit section comprising: a first end, for ingress of a stream of
flue gas, said first end having a first seal; a second end, for
egress of the stream of flue gas, said second end having a second
seal; a chamber within said conduit section, said chamber having a
first closed end and a second open end, said second open end facing
away from the ingress of the stream of flue gas; a drain portion
positioned on said chamber for flow of said condensates from said
chamber, wherein said conduit section is removably attachable as
all inline unit.
2. The conduit section of claim 1 wherein said conduit section is
installed as a unit into an existing exhaust conduit system to
remove condensate.
3. The conduit section of claim 1 further comprising: a first
conduit channel within said first end to position and support said
first seal; and a second conduit channel within said second end to
position and support said second seal.
4. The conduit section of claim 3 wherein said seal comprising a
resilient, flexible gasket body including a first surface, a second
surface and at least two edges, a plurality of angular protrusions
having a tip and a base, said protrusions disposed on the first
surface, a trough between said angular protrusions, wherein said
protrusions cover said trough and said tip contacts said base of an
adjacent angular protrusion when compressed, a compression cavity
having a center, said cavity disposed on the second surface beneath
said plurality of angular protrusions, wherein said center of said
compression cavity bows when the gasket body is sealed, and at
least two sealing walls positioned at said at least two edges.
5. The conduit section of claim 1 further comprising: a first
removable coupling device adjacent said first end; and a second
removable coupling device adjacent said second.
6. The conduit section of claim 1 further comprising: a butterfly
damper, said damper positioned within said first end of said
conduit.
7. The conduit section of claim 5 further comprising: a plurality
of compression grooves in said ends, said grooves adjacent said
removable coupling device, wherein said grooves contract when
compressed.
8. The conduit section of claim 5 further comprising: a hole
positioned adjacent said second end of said conduit; a worm screw
of said second removable coupling device positioned at said hole;
and a band attached to said worm screw, said band positioned within
said second end, wherein said second end acts as a female coupling
to an existing flue.
9. The conduit section of claim 1 wherein said first end and said
second end of said conduit are substantially similar in size.
10. The conduit section of claim 9 wherein said first end and said
end of said conduit have a substantially circular cross sectional
shape.
11. The conduit section of claim 1 wherein said chamber of said
first closed end is formed by a resistance weld between an internal
pipe and the conduit.
12. The conduit section of claim 1 is positioned in a horizontal
orientation and wherein said drain is oriented in a downward
angle.
13. The conduit section of claim 1 further comprising: a unit with
a burner exhausting a flue gas under a positive pressure; a
plurality of exhaust sections sealedly connected to said unit with
the burner to remove the flue gas under positive pressure, wherein
said conduit section is installed inline to remove condensate from
said plurality of exhaust sections.
14. An inline conduit condensate drain, said inline conduit
comprising: a inner conduit having a first diameter and an internal
exhaust outlet; an outer conduit having at least two attachment
portions with a second diameter larger than said first diameter of
said inner conduit, said inner conduit intersects and is sealedly
affixed within said outer conduit; a condensate chamber, wherein
said condensate chamber is formed in said outer conduit and
positioned above said intersection of said inner conduit and said
outer conduit, and wherein said condensate chamber is spaced away
from said inner conduit; and a drain portion positioned on said
condensate chamber, wherein said inline conduit is sealedly
attached between at least two other exhaust conduits.
15. The inline conduit of claim 14 further comprising: at least two
sealing channels within said outer conduit adjacent said at least
two attachment portions; and a gasket seal positioned within said
at least two sealing channels, said seal comprising a resilient,
flexible gasket body including a first surface, a second surface
and at least two edges, a plurality of angular protrusions having a
tip and a base, said protrusions disposed on the first surface, a
trough between said angular protrusions, wherein said protrusions
cover said trough and said tip contacts said base of an adjacent
angular protrusion when compressed, a compression cavity having a
center, said cavity disposed on the second surface beneath said
plurality of angular protrusions, wherein said center of said
compression cavity bows when the gasket body is sealed, and at
least two sealing walls positioned at said at least two edges.
16. The inline conduit section of claim 14 further comprising: a
valve body positioned within said outer conduit; an opening in said
valve body to allow flue gas to pass; and a valve covering said
opening.
17. The inline conduit of claim 14 further comprising: a flue gas
source under positive pressure, wherein said inline conduit is
attached externally to said flue gas source under positive
pressure.
18. The inline conduit of claim 14 wherein said inline conduit is
installed into a duct of a heater unit in a substantially
horizontal orientation.
19. A method for draining condensate from positive pressure flues
comprising: providing an inline conduit having a first end, for
ingress of a stream of flue gas, said first end having a first
seal, a second end, for egress of the stream of flue gas, said
second end having a second seal, a chamber within said conduit
section, said chamber having a first closed end and a second open
end, said second open end facing away from the ingress of the
stream of flue gas, a drain portion positioned on said chamber
adjacent for flow of said condensates from said chamber, wherein
said first seal and said second seal are both external a casing of
a flue gas source; providing a source of flue emissions under
positive pressure; and attaching said inline conduit externally to
said source of flue emissions under positive pressure.
20. The method of claim 19 further comprising: removing an existing
section of conduit for installation of said inline conduit.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The application claims benefit to U.S. Provisional
Application No. 60/826,680 and U.S. Provisional Application No.
60/826,698 both filed on Sep. 22, 2006, the contents of both are
incorporated in their entirety. The application also incorporates
in reference by their entirety U.S. Provisional Application No.
60/804,010 filed on Jun. 6, 2006.
FIELD OF THE INVENTION
[0002] The present invention relates to removing condensates from
vent systems connected to energy efficient heating equipment under
positive pressure.
BACKGROUND
[0003] In the past heating systems burning gas, oil, coal or even
wood had their exhaust emissions evacuated from a building by
negative pressure (draft) created in a flue by the temperature
differential between hot flue gases and ambient outside
temperatures. Unless these flues became obstructed, flue gas leaks
and potential carbon monoxide poisoning were avoided, as negative
pressure was maintained throughout the vent system. If the flue gas
composition in a negative pressure system was to be tested, the
technician would customarily drill a hole into the connector pipe,
then cover it with a simple patch without fear of leaks, due to the
negative pressure.
[0004] With the development of high efficiency heating equipment,
exhaust systems must be designed to match the heater's performance
requirements. Increasing efficiency means that more heat is kept in
a home, rather than sending it up and out a chimney flue. As a
consequence, flue gas temperatures are reduced to the point where
negative pressure within a vent system can no longer be created.
For that reason, and with the help of blowers on the heater, flue
gases are now mechanically expelled, thus creating positive
pressure in a vent system. At the same time, these cool flue gases
readily fall below dew point temperatures, creating significant
amounts of condensates within a vent system. These condensates can
be corrosive, of significant volume, need to be captured before
back-flowing into the heating equipment and need to be disposed of
properly.
SUMMARY OF THE INVENTION
[0005] A first aspect of the invention is a conduit section for
drainage of flue gas condensate, said conduit section comprising a
first end, for ingress of a stream of flue gas, said first end
having a first seal; a second end, for egress of the stream of flue
gas, said second end having a second seal; a chamber within said
conduit section, said chamber having a first closed end and a
second open end, said second open end facing away from the ingress
of the stream of flue gas; a drain portion positioned on said
chamber for flow of said condensates from said chamber, wherein
said conduit section is removably attachable as an inline unit.
[0006] A second aspect of the invention is an inline conduit
condensate drain, said inline conduit comprising a inner conduit
having a first diameter and an internal exhaust outlet an outer
conduit having at least two attachment portions with a second
diameter larger than said first diameter of said inner conduit,
said inner conduit intersects and is sealedly affixed within said
outer conduit; a condensate chamber, wherein said condensate
chamber is formed in said outer conduit and positioned above said
intersection of said inner conduit and said outer conduit, and
wherein said condensate chamber is spaced away from said inner
conduit; and a drain portion positioned on said condensate chamber,
wherein said inline conduit is sealedly attached between at least
two other exhaust conduits.
[0007] A third aspect of the invention is a method for draining
condensate from positive pressure flues comprising: providing an
inline conduit having a first end, for ingress of a stream of flue
gas, said first end having a first seal, a second end, for egress
of the stream of flue gas, said second end having a second seal, a
chamber within said conduit section, said chamber having a first
closed end and a second open end, said second open end facing away
from the ingress of the stream of flue gas, a drain portion
positioned on said chamber adjacent for flow of said condensates
from said chamber, wherein said first seal and said second seal are
both external a casing of a flue gas source; providing a source of
flue emissions under positive pressure; and attaching said inline
conduit externally to said source of flue emissions under positive
pressure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 shows an inline catch for condensates;
[0009] FIG. 2 shows a bottom view of the catch;
[0010] FIG. 3 shows a cross-sectional view of a gasket;
[0011] FIG. 4 shows a horizontal install of the inline catch for
condensates;
[0012] FIG. 5 shows a vertical install of the inline catch for
condensates; and
[0013] FIG. 6 shows a second embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0014] Although certain embodiments of the present invention will
be shown and described in detail, it should be understood that
various changes and modifications may be made without departing
from the scope of the appended claims. The scope of the present
invention will in no way be limited to the number of constituting
components, the materials thereof, the shapes thereof, the relative
arrangement thereof, etc., and are disclosed simply as an example
of and embodiment. The features and advantages of the present
invention are illustrated in detail in the accompanying drawings,
wherein like reference numerals refer to like elements throughout
the drawings.
[0015] An answer to the problems associated with a condensate that
forms within the flue of an energy efficient appliance with a
positive pressure exhaust system is to catch and drain the
byproduct of combustion, the corrosive effluent fluid that
condenses within the ducts. The exhausts of the energy efficient
systems must be sealed to prevent leakage of flue emissions that
are under pressure. The instant invention retains a seal while
removing the collected effluent from the ducts.
[0016] To remove condensation from either a new or a preexisting
flue duct the instant invention provides a conduit section 100 for
drainage of flue gas condensate, said conduit section 100 comprises
a first end 10, for ingress of a stream of flue gas 15, said first
end 10 having a first seal or gasket 20. The conduit section has a
second end 11, for egress of the stream of flue gas 15, said second
end 11 having a second seal or second gasket 30. The conduit
section 100 may be produced from a material such as either a metal
or a plastic. The conduit section 100 if produced of metal may be
steel, aluminum or other metallic compound. If metal it may be
stamped or formed from a sheet into a conduit section 100 that
could be round, oval square, rectangular or any other desired cross
section. If the conduit section 100 is plastic it could be made by
extrusion or injection molding into the desired length and
contour.
[0017] The conduit 100 has a chamber 40 within said conduit section
100, said chamber 40 having a first closed end 41 and a second open
end 42, said second open end 42 facing away from the ingress of the
stream of flue gas 15. The second open end 42 has at least a
portion directed to collect condensate as it runs down the inner
wall of said conduit 100. A drain portion or drain nipple 50 may be
positioned on said chamber 40 for flow of said condensates from
said chamber 40, wherein said conduit section 100 may be removably
attachable or permanently affixed as an inline unit into an
existing flue duct 250. The chamber 40 acts as a reservoir and must
have a leak proof seal between the inner wall of the conduit 100
and the outer wall adjacent the second open end 42 otherwise
leaking will occur causing water damage. The chamber 40, positioned
just above the intersection of the inner and outer portions of the
conduit, may be expanded and have a greater diameter from the
normal portion of the conduit section.
[0018] An equivalent alternative to the above describe embodiment
is possible where an expanded chamber 40, as shown in FIG. 1, is
mounted over an existing portion of the pipe, but engagement seal
92 is external and sealedly affixed to a pre-existing portion. The
outlet portion 94 may be of normal pipe diameter if placed within
the expanded region of the chamber 42. The condensate would flow
down the inner expanded wall of the chamber 40 and allow collection
of condensate without a reduced diameter inner section. The upper
end and lower end of the alternative conduit could either be
permanently or releasably sealed to the system to prevent water and
gas leaks.
[0019] The conduit section 100 can be installed into a system in
either a horizontal or a vertical orientation as shown in FIGS. 5
and 6 or any angle in between. When the conduit section 100 is
mounted any angle off vertical, it may be angled with the drain
portion 50 positioned at the lowest point of gravity. The drain
portion 50 may be connected to a tube or hose that may be sealed
from flue gas leakage by a loop filled with condensate and drain
the effluent to a proper point of disposal drain. The tube or hose
is sealed from the exhaust flow to prevent release of noxious fumes
or vapors harmful to the occupants.
[0020] The conduit section 100 may be installed as a unit into an
existing exhaust conduit system 250 to remove condensate, which
would entail removing a preexisting conduit section by either
cutting, unglueing or unbolting the segment of appropriate length
that coincides with the length of the inline conduit 100. The
section removed may either be a vertical or slanted section of the
existing conduit ease of installation being the main factor in
selecting the orientation of the pipe. The conduit section 100 then
sealedly replaces the removed section of the preexisting conduit to
collect condensate and prevent leaks from the system. The conduit
section 100 once placed inline may be sealed with a gasket, glued,
welded or otherwise made leakproof when installed in the
system.
[0021] The conduit section 100 may be removably installed to other
ducts by having a first conduit channel 60 within said first end 10
to position and support said first seal, which may be an adhesive,
which may prevent removal or for removability a first gasket 20,
200 and a second conduit channel 65 within said second end 11 to
position and support said second seal such as adhesive or for
removability a second gasket 30, 200. The gasket seal 200 may
comprise a resilient, flexible gasket body 210 including a first
surface 220, a second surface 225 and at least two edges 230, 235.
The gasket seal 200 may have a plurality of angular protrusions 240
having a tip 245 and a base 250, said protrusions 240 disposed on
the first surface 220, a trough 255 between said angular
protrusions 240, wherein said protrusions 240 cover said trough 255
and said tip 245 contacts said base 250 of an adjacent angular
protrusion 240 when compressed. The gasket 200 may also include a
compression cavity 260 having a center 265, said cavity 260
disposed on the second surface 225 beneath said plurality of
angular protrusions 245, wherein said center of said compression
cavity 265 bows when the gasket body 210 is sealed, and at least
two sealing walls 270, 275 positioned at said at least two edges
230, 235.
[0022] The gasket seal 200 may be compressed to form a seal by a
first removable coupling device 67 adjacent said first end 10 and a
second removable coupling device 62 adjacent said second end 11.
The coupling devices 62, 67 can be any fastener such as a band 70
with a worm gear 71 for selectively tightening or loosening of the
coupling device. The coupling device 62, 67 may also be a nylon
lock tie that would prevent loosening by its unidirectional locking
feature. The coupling device 62, 67 may be used in conjunction with
a plurality of compression grooves 80 in said ends 10, 11, said
grooves 80 adjacent said removable coupling device 62, 67, wherein
said grooves 80 contract when compressed. The plurality of grooves
80 may be spaced at equidistant intervals around the circumference
of the end 10 of the conduit 100 to prevent buckling of the conduit
100 and to allow for compression of the end 10.
[0023] The conduit section 100 may include a hole 75 positioned
adjacent said second end 11 of said conduit 100. A worm screw 71 of
said second removable coupling device 62 may be positioned at said
hole 75. A band 76 having grooves 77 is attached to said worm screw
71, said band 76 positioned within said second end 11, wherein said
second end 11 acts as a female coupling to an existing flue. The
second end 11 may be slid over the exposed end of an existing flue
system or a newly installed system comprising a plurality of ducts.
The conduit section 100 may have a first end 10 and said second end
11 of said conduit 100 that are substantially similar in size to
allow for easier introduction into a conventional duct. The conduit
section 100 may have a first end 10 and said end 11 of said conduit
100 that may have many shapes such as a substantially circular
cross sectional shape, rectangular shape, square shape, oval shape
or any other desired cross-sectional shape.
[0024] The conduit section 100 may be formed of a metal such as
steel or other similar alloy in the form of a cylinder. The conduit
100 may be formed from two parts 90, 91 that are joined together.
The chamber 40 may be formed by a resistance weld between an
internal pipe 90 and an external pipe 91 forming the conduit 100.
The resistance weld or interference fit seal 92 along with the
necked down section of internal pipe 90 acts as the base of the
chamber 40.
[0025] The conduit section 100 may include a butterfly damper 350,
said damper 350 may be positioned within said first end 10 of said
conduit 100 as shown in FIGS. 1 and 2. The butterfly damper 350 may
prevent drafts and unnecessary heat loss when the appliance 308 is
not in use. The conduit section 100 is for use in combination with
a unit with a burner 308 exhausting a flue gas 15 under a positive
pressure as shown in FIGS. 5 and 6. The conduit section 100 may be
attached to a plurality of exhaust sections 310 sealedly connected
to said unit with the burner 308 to remove the flue gas 15 under
positive pressure, wherein said conduit section 100 is installed
inline to remove condensate from said plurality of exhaust sections
310.
[0026] Another embodiment is an inline conduit condensate drain
500, said inline conduit 500 comprising a inner conduit 510 having
a first diameter 515 and an internal exhaust outlet 530.
Surrounding the inner conduit 510 is an outer conduit 520 having at
least two attachment portions 540, 545 with a second diameter 516
larger than said first diameter 515 of said inner conduit 510, said
inner conduit 510 intersects and is sealedly affixed within said
outer conduit 520. A condensate chamber 550, wherein said
condensate chamber 550 is formed in said outer conduit 520 and
positioned above said intersection 560 of said inner conduit 510
and said outer conduit 520, and wherein said condensate chamber 550
is spaced away from said inner conduit 510. To remove the effluent
that collects in the condensate chamber 550 a drain portion 555
positioned on said condensate chamber 550, wherein said inline
conduit is sealedly attached between at least two other exhaust
conduits 570, 571 or the appliance 308 attached to end 505.
[0027] The inline conduit 500 may be connected to the two other
exhaust conduits 570, 571 by using at least two sealing channels
580, 581 within said outer conduit 520 adjacent said at least two
attachment portions 540, 545. The conduit section 500 may be
removably installed to other ducts 570, 571 by having a reusable
seal or compression gasket 200 installed within the conduit section
between the conduit section 500 and the other ducts 570, 571. The
seal or gasket 200 may comprise a resilient, flexible gasket body
210 including a first surface 220, a second surface 225 and at
least two edges 230, 235. The seal or gasket 200 may have a
plurality of angular protrusions 240 having a tip 245 and a base
250, said protrusions 240 disposed on the first surface 220, a
trough 255 between said angular protrusions 240, wherein said
protrusions 240 cover said trough 255 and said tip 245 contacts
said base 250 of an adjacent angular protrusion 240 when
compressed. The seal or gasket 200 may also include a compression
cavity 260 having a center 265, said cavity 260 disposed on the
second surface 225 beneath said plurality of angular protrusions
245, wherein said center of said compression cavity 265 bows when
the gasket body 210 is sealed, and at least two sealing walls 270,
275 positioned at said at least two edges 230, 235.
[0028] The inline conduit section 500 may further comprise a valve
body 590 positioned within said outer conduit 520. There is an
opening 591 in said valve body 590 to allow flue gas 15 to pass and
a valve 592 covering said opening 591. The inline conduit 500
further comprises a flue gas source under positive pressure 600,
wherein said inline conduit is attached externally to said flue gas
source under positive pressure 600, which may be an exhaust outlet
of an appliance 308 or other fuel burning device 308. The inline
conduit 500 may be installed into a duct of a heater unit in a
substantially horizontal orientation as shown in FIG. 4.
[0029] A method for draining condensate from positive pressure
flues 600 may comprise the step of providing an inline conduit 100
having a first end 10, for ingress of a stream of flue gas 15, said
first end 10 having a first gasket or first seal 20, a second end
11, for egress of the stream of flue gas 15, said second end 11
having a second gasket or second seal 30, a chamber 40 within said
conduit section 100, said chamber 40 having a first closed end 41
and a second open end 42, said second open end 42 facing away from
the ingress of the stream of flue gas 15, a drain portion or drain
nipple 50 positioned on said chamber 40 adjacent for flow of said
condensates from said chamber 40, wherein said first gasket or
first seal 20 and said second seal or second gasket 30 are both
external a casing of a flue gas source 308. The running of a high
efficiency water heater 308, furnace would be sufficient for
providing a source of flue emissions under positive pressure 15.
The condensate would be collected by attaching said inline conduit
100 externally to said source of flue emissions under positive
pressure 15. The inline conduit 100 may be installed by removing an
existing section of conduit 310 for installation of said inline
conduit 100.
[0030] Various modifications and variations of the described
apparatus and methods of the invention will be apparent to those
skilled in the art without departing from the scope and spirit of
the invention. Although the invention has been described in
connection with specific embodiments, outlined above, it should be
understood that the invention should not be unduly limited to such
specific embodiments. Various changes may be made without departing
from the spirit and scope of the invention as defined in the
following claims.
* * * * *