U.S. patent application number 12/060570 was filed with the patent office on 2009-10-01 for water heater with high efficiency baffles.
This patent application is currently assigned to AOS HOLDING COMPANY. Invention is credited to Jason R. Abele, Benjamin J. Bolton, Hyungsik Lee, Robert F. Poehlman, Jr..
Application Number | 20090241858 12/060570 |
Document ID | / |
Family ID | 41115219 |
Filed Date | 2009-10-01 |
United States Patent
Application |
20090241858 |
Kind Code |
A1 |
Lee; Hyungsik ; et
al. |
October 1, 2009 |
WATER HEATER WITH HIGH EFFICIENCY BAFFLES
Abstract
A water heater for exchanging heat between hot gasses and water
within the water heater. The water heater includes a water tank, a
conduit for allowing flow of the gasses therethrough, the conduit
extending through the tank and promoting heat exchange between the
gasses and water in the tank, and a baffle extending within the
conduit for affecting the flow of the gasses. The baffle includes a
sheet bent in a zig-zag manner and having a number of plate
sections. Each plate section has a through-flow portion allowing
the gasses to flow therethrough. The sheet also has a number of
first bends and a number of second bends, the first bends
alternating with the second bends such that each plate section is
defined between one first bend and one second bend.
Inventors: |
Lee; Hyungsik; (Mequon,
WI) ; Poehlman, Jr.; Robert F.; (Cudahy, WI) ;
Abele; Jason R.; (Milwaukee, WI) ; Bolton; Benjamin
J.; (Elm Grove, WI) |
Correspondence
Address: |
MICHAEL BEST & FRIEDRICH LLP
100 E WISCONSIN AVENUE, Suite 3300
MILWAUKEE
WI
53202
US
|
Assignee: |
AOS HOLDING COMPANY
Wilmington
DE
|
Family ID: |
41115219 |
Appl. No.: |
12/060570 |
Filed: |
April 1, 2008 |
Current U.S.
Class: |
122/18.3 ;
29/890.03 |
Current CPC
Class: |
F24H 9/0026 20130101;
Y10T 29/4935 20150115; F24H 1/205 20130101 |
Class at
Publication: |
122/18.3 ;
29/890.03 |
International
Class: |
F24H 1/00 20060101
F24H001/00 |
Claims
1. A water heater for exchanging heat between hot gasses and water
within the water heater, the water heater comprising: a water tank:
a conduit for allowing, flow of the gasses therethrough, the
conduit extending through the tank and promoting heat exchange
between the gasses and water in the tank; and a baffle extending
within the conduit for affecting the flow of the gasses, the baffle
including a sheet bent in a zig-zag manner and having a number of
plate sections, each plate section having a through-flow portion
allowing the gasses to flow therethrough, the sheet also having a
number of first bends and a number of second bends, the first bends
alternating with the second bends such that each plate section is
defined between one first bend and one second bend.
2. The water heater of claim 1, wherein the baffle is operable to
create a swirl-type flow of gasses through the conduit.
3. The water heater of claim 1, wherein the through-flow portion of
one plate section is adjacent to one of the first bend and the
second bend, and the through-flow portion of an adjacent plate
section is adjacent to the other of the first bend and the second
bend.
4. The water heater of claim 1, wherein each plate section includes
an upper portion and a lower portion, the through-flow portion of
all plate sections being adjacent to the same one of the upper
portion and the lower portion.
5. The water heater of claim 1, wherein each plate section includes
a front portion and a rear portion, the through-flow portion of one
plate section being adjacent to one of the front portion and rear
portion, and the through-flow portion of another plate section
adjacent to the one plate section being adjacent to the other of
the front portion and rear portion.
6. The water heater of claim 1, wherein each plate section includes
a right portion and a left portion, the through-flow portion of one
plate section being in one of the right portion and the left
portion, and the through-flow portion of an adjacent plate section
being in the other of the right portion and the left portion.
7. The water heater of claim 1, wherein the baffle is oriented such
that the first bends are aligned on a first plane and the second
bends are aligned on a second plane, the first plane being
substantially parallel to the second plane.
8. The water heater of claim 1, wherein each of the first bends
defines a line along which the bend is formed, the line defined by
one first bend being substantially parallel to the line defined by
another first bend.
9. The water heater of claim 1, wherein each of the first bends
defines a line along which the first bend is formed and each of the
second bends defines a line along which the second bend is formed,
the line defined by the first bends being substantially parallel to
the lines defined by the second bends.
10. The water heater of claim 1, wherein each plate section defines
a plane, the planes defined by every other plate section being
substantially parallel to one another.
11. The water heater of claim 1, wherein the through-flow portion
of each plate section is defined by substantially perpendicular
first and second edges of the plate section, with the first edges
of all plate sections being substantially parallel and the second
edges of all plate sections being substantially parallel.
12. The water heater of claim 1, wherein the conduit is oriented
vertically.
13. The water heater of claim 1, wherein all of the first and
second bends define substantially equal angles between adjacent
plate sections.
14. The water heater of claim 13, wherein the angles are between
about 50 degrees and about 80 degrees.
15. The water heater of claim 14, wherein the angles are about 70
degrees.
16. The water heater of claim 13, wherein the water heater is a
storage-type water heater and wherein the angles are between about
62 degrees and about 75 degrees.
17. The water heater of claim 13, wherein the water heater is an
instantaneous water heater and wherein the angles are between about
52 degrees and about 65 degrees.
18. The water heater of claim 1, wherein each plate section has a
second through-flow portion.
19. A water heater comprising: a water tank; a device for producing
heated gasses; a conduit through which the heated gasses flow in a
direction of gas flow, the conduit extending through the tank and
promoting heat transfer between the gasses and water in the tank;
and a baffle extending within the conduit for increasing the heat
transfer between the gasses and the water, the baffle including a
sheet of material bent in a zig-zag manner to form a plurality of
sheet sections, each section extending in a different direction
from adjacent sections, and each section having therein a flow
opening that is out of alignment in the direction of gas flow with
the flow openings in adjacent sections, such that gasses passing
through a flow opening in a section must change direction to pass
through the flow opening in the adjacent section.
20. The water heater of claim 19, wherein the conduit is generally
circular in cross-section, and wherein each section is defined by a
generally elliptical shape.
21. The water heater of claim 20, wherein the conduit has a
longitudinal axis, and wherein the flow openings of adjacent
sections are offset approximately 180 degrees about the axis,
causing a swirling flow of gasses through the conduit.
22. The water heater of claim 21, wherein the conduit extends
generally vertically and has a lower end, and wherein the device
for producing heated gas includes a burner beneath the lower end of
the conduit.
23. The water heater of claim 22, wherein each section extends at
an angle between approximately 27 to 38 degrees relative to
horizontal.
24. The water heater of claim 20, wherein each flow opening defines
a sector having an included angle of approximately 90 degrees.
25. The water heater of claim 19, wherein each section includes a
second flow opening such that gasses passing through the flow
opening and the second flow opening in one section must flow in a
zig-zag direction to pass through the flow opening and the second
flow opening in the adjacent section.
26. A method of manufacturing a water heater comprising: providing
a water heater having a water tank, a device for producing heated
gasses, and a conduit through which the heated gasses flow in a
direction of gas flow, the conduit extending through the tank;
providing a substantially planar sheet of material; bending the
sheet of material in a zig-zag manner to form a plurality of
substantially planar sheet sections, each section extending in a
different direction from adjacent sections; forming each section
with a flow opening; and placing the baffle within the conduit so
that each flow opening is out of alignment in the direction of gas
flow with the flow openings in adjacent sections, such that gasses
passing through a flow opening in a section must change direction
to pass through the flow opening in the adjacent section.
27. The method of claim 26, wherein the flow openings are formed
before bending the sheet.
28. A water heater for exchanging heat between hot gasses and water
within the water heater, the water heater comprising: a water tank;
a conduit for allowing flow of the gasses therethrough, the conduit
extending vertically through the tank and promoting heat exchange
between the gasses and water in the tank; and a baffle extending
within the conduit for affecting the flow of the gasses, the baffle
being operable to create a swirl-type flow of gasses through the
conduit and including a sheet bent in a zig-zag manner, the sheet
having a number of plate sections, each plate section having a
through-flow portion allowing the gasses to flow therethrough, the
sheet also having a number of first bends and a number of second
bends, the first bends alternating with the second bends such that
each plate section is defined between one first bend and one second
bend, wherein all of the first bends and the second bends define
substantially equal angles between adjacent plate sections, the
angles being between about 50 degrees and about 80 degrees, and
wherein the through-flow portion of one plate section is adjacent
to one of the first bend and the second bend, and the through-flow
portion of an adjacent plate section is adjacent to the other of
the first bend and the second bend.
Description
BACKGROUND
[0001] The present invention relates to a water heater including a
water tank and a conduit for hot gasses in heat exchange
relationship with water within the tank.
SUMMARY
[0002] In one aspect, the invention provides a water heater for
exchanging heat between hot gasses and water within the water
heater. The water heater includes a water tank, a conduit for
allowing flow of the gasses therethrough, the conduit extending
through the tank and promoting heat exchange between the gasses and
water in the tank. The water heater also includes a baffle
extending within the conduit for affecting the flow of the gasses.
The baffle includes a sheet bent in a zig-zag manner and having a
number of plate sections. Each plate section has a through-flow
portion allowing the gasses to flow therethrough. The sheet also
has a number of first bends and a number of second bends. The first
bends alternate with the second bends such that each plate section
is defined between one first bend and one second bend.
[0003] In another aspect, the invention provides a water heater
including a water tank, a device for producing heated gasses, and a
conduit through which the heated gasses flow in a direction of gas
flow. The conduit extends through the tank and promotes heat
transfer between the gasses and water in the tank. The water heater
also includes a baffle extending within the conduit for increasing
the heat transfer between the gasses and the water. The baffle
includes a sheet of material bent in a zig-zag manner to form a
plurality of sheet sections. Each section extends in a different
direction from adjacent sections, and each section has therein a
flow opening that is out of alignment in the direction of gas flow
with the flow openings in adjacent sections, such that gasses
passing through a flow opening in a section must change direction
to pass through the flow opening in the adjacent section.
[0004] In another aspect, the invention provides a method of
manufacturing a water heater. The method includes providing a water
heater having a water tank, a device for producing heated gasses,
and a conduit through which the heated gasses flow in a direction
of gas flow, the conduit extending through the tank. The method
also includes providing a substantially planar sheet of material,
bending the sheet of material in a zig-zag manner to form a
plurality of substantially planar sheet sections, each section
extending in a different direction from adjacent sections, and
forming each section with a flow opening. The method also includes
placing the baffle within the conduit so that each flow opening is
out of alignment in the direction of gas flow with the flow
openings in adjacent sections, such that gasses passing through a
flow opening in a section must change direction to pass through the
flow opening in the adjacent section.
[0005] In another aspect, the invention provides a water heater for
exchanging heat between hot gasses and water within the water
heater. The water heater includes a water tank, and a conduit for
allowing flow of the gasses therethrough. The conduit extends
vertically through the tank and promotes heat exchange between the
gasses and water in the tank. The water heater also includes a
baffle extending within the conduit for affecting the flow of the
gasses. The baffle is operable to create a swirl-type flow of
gasses through the conduit and includes a sheet bent in a zig-zag
manner. The sheet has a number of plate sections, each plate
section having a through-flow portion allowing the gasses to flow
therethrough. The sheet also has a number of first bends and a
number of second bends, the first bends alternating with the second
bends such that each plate section is defined between one first
bend and one second bend. All of the first bends and the second
bends define substantially equal angles between adjacent plate
sections, the angles being between about 50 degrees and about 80
degrees. The through-flow portion of one plate section is adjacent
to one of the first bend and the second bend, and the through-flow
portion of an adjacent plate section is adjacent to the other of
the first bend and the second bend.
[0006] Other aspects of the invention will become apparent by
consideration of the detailed description and accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a perspective view of an exemplary water heater
including a baffle according to one embodiment of the present
invention.
[0008] FIG. 2 is a perspective view of the baffle shown in FIG.
1.
[0009] FIG. 2A is a detailed view of the baffle shown in FIG.
2.
[0010] FIG. 3 is a view of a plate for forming the baffle shown in
FIG. 1.
[0011] FIG. 4 is a perspective view of a baffle according to
another embodiment of the present invention.
[0012] FIG. 5 is a view of a plate for forming the baffle shown in
FIG. 4.
[0013] FIG. 6 is an elevation view of the baffle shown in FIG.
1.
DETAILED DESCRIPTION
[0014] Before any embodiments of the invention are explained in
detail, it is to be understood that the invention is not limited in
its application to the details of construction and the arrangement
of components set forth in the following description or illustrated
in the following drawings. The invention is capable of other
embodiments and of being practiced or of being carried out in
various ways. Also, it is to be understood that the phraseology and
terminology used herein is for the purpose of description and
should not be regarded as limiting. The use of "including,"
"comprising," or "having" and variations thereof herein is meant to
encompass the items listed thereafter and equivalents thereof as
well as additional items. Unless specified or limited otherwise,
the terms "mounted," "connected," "supported," and "coupled" and
variations thereof are used broadly and encompass both direct and
indirect mountings, connections, supports, and couplings. Further,
"connected" and "coupled" are not restricted to physical or
mechanical connections or couplings.
[0015] FIGS. 1, 2 and 6 illustrate a baffle 10 for a water heater
according to one embodiment of the present invention. FIG. 1
illustrates an exemplary water heater 15 including the baffle 10.
More particularly, the water heater 15 includes a base pan 20, a
tank 25 supported by the base pan 20 and containing water, an
insulating jacket 30 surrounding the tank 25, a control system 35,
a burner 40 disposed in a combustion chamber 45 beneath the tank
25, a water inlet pipe 50, a water outlet pipe 55, and a flue
system 60 including a flue tube 65 and the baffle 10 within the
flue tube 65. The flue tube 65 has a longitudinal axis 68. During
operation of the water heater 15, gas fuel is provided to the
burner 40 through a conduit 70. Products of combustion or hot
gasses flow up through the flue tube 65 and heat the water through
the wall of the flue tube 65. Other constructions of the water
heater also fall within the scope of the invention. While the water
heater 15 is a storage- or tank-type water heater, in other
constructions the water heater can be an instantaneous- or
tankless-type water heater.
[0016] With particular reference to the flue system 60 illustrated
in FIG. 1, a hanger or cross-bar 85 supports the baffle 10 within
the flue tube 65. However other suitable means to support the
baffle 10 fall within the scope of the invention. The baffle 10
extends longitudinally within the flue tube 65 to affect the flow
of the hot gasses (further explained below). In the illustrated
construction, the baffle 10 is positioned within the flue tube 65
to leave a space 90 between the lower end of the baffle 10 and the
lower end of the flue tube 65. For example, the space 90 can
facilitate mounting the flue tube 65 and baffle 10 on a glass
coating machine that coats the inside and outside of the flue tube
65 and the baffle 10 with a protective glass coating to resist
degradation of the flue tube 65 and baffle 10. Because the baffle
10 is recessed with respect to the lower end of the flue tube 65,
the baffle 10 is less likely to be overheated by extreme
temperatures in the combustion chamber 45. The space 90 may be, for
example, about three inches in length but such length may vary
based on manufacturing parameters.
[0017] According to one construction of the present invention, the
baffle 10 is manufactured from a relatively flat plate or sheet of
material. For example, the manufacturing process of the baffle 10
can include stamping or cutting the material to form a sheet 95 as
shown in FIG. 3. In the illustrated construction, the sheet 95 has
a number of plate sections 100, each plate section 100 forming an
oval or ellipsoid shape, with a cut-out or flow opening 110, as
described below. The sheet 95 can be manufactured of mild (i.e.,
low carbon) steel, stainless steel, Inconel, nickel alloy, or other
suitable materials. It is to be understood that other processes
and/or methods of processing a material to form the sheet 95 fall
within the scope of the invention.
[0018] With reference to FIG. 3, the sheet 95 extends
longitudinally forming a succession of substantially planar plate
sections 100 along a reference axis 102. The sheet 95 also includes
a number of bend portions 105, with each bend portion 105 formed
between two adjacent plate sections 100 and defined by a relatively
narrow portion of the sheet 95 along the axis 102. During a
manufacturing process of the baffle 10 (see FIG. 2), the sheet 95
is preferably bent or deformed at the bend portions 105 in an
accordion-like or zig-zag manner. More particularly, the baffle 10
includes alternating first bends 125 and second bends 130. The
first bends 125 and second bends 130 are formed at the bend
portions 105 of the sheet 95. For the purposes of description only,
the terms "first bend" and "second bend" refer to the two
directions in which the sheet 95 is bent at the bend portions 105.
However, it is within the scope of the invention to bend or deform
the sheet 95 differently than shown in FIGS. 1-3 and 6.
[0019] Plate sections 100 defining the first bends 125 and second
bends 130 define an angle therebetween based on heat exchange
requirements, such as the type of water heater. The magnitude of
the angle formed at the first bends 125 is substantially the same
with respect to the magnitude of the angle formed at the second
bends 130. For a storage type water heater (e.g., water heater 15),
the angle between adjacent plate sections 100 is approximately
between 62 and 75 degrees. More preferably, the angle between
adjacent plate sections 100 is about 70 degrees. For instantaneous
water heaters, the angle between adjacent plate sections 100 is
approximately between 52 and 65 degrees. More preferably, the angle
between adjacent plate sections 100 is about 60 degrees. It is to
be understood that other angles defined by adjacent plate sections
100 fall within the scope of the invention and are dependent on
design characteristics, such as heat exchange requirements. For
example, an alternate construction of the baffle 10 can include
plate sections 100 forming different angles therebetween at
different sections of the baffle 10 to allow a faster (or slower)
gas flow through the conduit 65, thus adjusting heat exchange rates
at different sections of the conduit 65.
[0020] Each plate section 100 includes an approximately oval or
ellipsoid shape mainly defined by an outer edge 108. The ellipsoid
shape of each plate section 100 allows the baffle 10 to snugly fit
within the flue tube 65, which generally has a circular
cross-section. Each plate section 100 includes a through-flow
portion (also identified as a flow opening) 110, as mentioned
above, defined by a first edge 115 and by a second edge 120. The
through-flow portions 110 are designed to allow hot gasses
therethrough during operation of the water heater 15. As shown in
FIGS. 1 and 2, each plate section 100 has its through-flow portion
110 out of alignment in the direction of gas flow (upward in the
drawings) with respect to the through-flow portions 110 in adjacent
plate sections 100, such that gasses passing through a through-flow
portion 110 in a plate section 110 must change direction to pass
through the through-flow portion 110 in the adjacent plate section
110.
[0021] The first edge 115 and the second edge 120 are each formed
as a relatively straight cut-out or line. More particularly, the
first edge 115 and the second edge 120 form a sector having an
included angle of about 90 degrees. In addition, the first edge 115
of one plate section 100 is substantially parallel to the first
edge 115 of an adjacent plate section 100. Also, the second edge
120 of one plate section 100 is substantially parallel to the axis
102 and to the second edge 120 of an adjacent plate section 100.
Other constructions of the sheet 95 can include through-flow
portions having different shapes.
[0022] In the construction illustrated in FIGS. 2 and 6, the baffle
10 is designed to fit within the flue tube 65 such that the outer
edges 108 of the plate sections 100 and the bend portions 105
(forming first bends 125 and second bends 130) contact or are very
close to the inner wall of the flue tube 65. As a consequence, the
baffle 10 regulates and/or affects the flow of the hot gasses
generated in the combustion chamber 45. For example, the
through-flow portions 110 of adjacent plate sections 100 are offset
from one another (e.g., offset by 180 degrees), thus allowing the
baffle 10 to create a flow of the hot gasses in a swirl pattern
135. In addition, the apertures defined by the through-flow
portions 110 and the flue tube 65 positively affect the flow rate
of the hot gasses therethrough.
[0023] With respect to FIGS. 2 and 2A, each plate section 100 can
also be described as having a front portion and a rear portion, a
right portion and a left portion, and an upper portion and a lower
portion to define the position of the through-flow portions 110. In
the illustrated construction, it can be observed that any two
adjacent plate sections 100 are joined by either a first bend 125
or a second bend 130. If the through-flow portion 110 of one plate
section 100 is formed adjacent the first bend 125, the through-flow
portion 110 of an adjacent plate section 100 is formed adjacent the
second bend 130, and vice versa.
[0024] Still with reference to FIGS. 2 and 2A, all plate sections
100 have their through-flow portions 110 in the same one of the
upper portion and the lower portion. In the illustrated
construction, each through-flow portion 110 is in the lower portion
of the plate section 100, but they could be in the upper portions.
Another characteristic of the baffle 10 is that if the through-flow
portion 110 of one plate section 100 is in the front portion, the
through-flow portion 110 of an adjacent plate section 100 is in the
rear portion, and vice versa. Yet another characteristic of the
baffle 10 is that if the through-flow portion 110 of one plate
section 100 is in the right portion, the through-flow portion 110
of an adjacent plate section 100 is in the left portion, and vice
versa.
[0025] The baffle 10 can be viewed still another way. Each of the
first bends 125 defines a line, and each of the second bends 130
defines a line parallel to the lines of the first bends and
parallel to the lines of other second bends. The lines of the first
bends 125 define a first plane 150 (FIG. 6), and the lines of the
second bends 130 define a second plane 155. The first plane 150 is
substantially parallel to the second plane 155 and parallel to the
axis 68 of the flue tube 65. FIG. 6 also shows that the planes
defined by every other plate section 100 are substantially
parallel.
[0026] FIGS. 4 and 5 illustrate a baffle 200 that is another
embodiment of the present invention. The baffle 200 has many
features in common with the baffle 10, and common elements have
been given the same reference numerals.
[0027] Each plate section 100 of the baffle 200 includes a
half-oval or half elliptical portion 223, mainly defined by arcuate
outer edges 225, and an elongated portion 230. The outer edges 225
of the portion 223 are designed to contact the inner-surface of the
flue tube 65. Each plate section 100 also includes a first
through-flow portion 233 and a second through-flow portion 235 such
that the elongated portion 230 is defined therebetween. The first
through-flow portion 233 is defined by generally perpendicular
first and second edges 240 and 245. Similarly, the second
through-flow portion 235 is defined by generally
perpendicular-third and fourth edges 250 and 255. In the
illustrated construction, the second edge 245 and the fourth edge
255 are substantially parallel to one another, and the first edge
240 and the third edge 250 are collinear and substantially
perpendicular to the axis 68.
[0028] Similar to the embodiment shown in FIGS. 2 and 2A, each
plate section 100 can be described as having an upper portion and a
lower portion. In the illustrated construction, the through-flow
portions 233, 235 are in the lower portion of each plate section
100. The through-flow portions 233, 235 could alternatively be in
the upper portion of each plate section 100.
[0029] In other alternative constructions (not shown), the plate
sections can have other numbers of flow-through portions, and the
flow-through portions can have other shapes.
[0030] Various features and advantages of the invention are set
forth in the following claims.
* * * * *