U.S. patent application number 15/183777 was filed with the patent office on 2016-12-15 for single burn rate solid fuel heating appliance with managed airflow.
The applicant listed for this patent is UNITED STATES STOVE COMPANY. Invention is credited to Brandon Lane Barry.
Application Number | 20160363324 15/183777 |
Document ID | / |
Family ID | 57515782 |
Filed Date | 2016-12-15 |
United States Patent
Application |
20160363324 |
Kind Code |
A1 |
Barry; Brandon Lane |
December 15, 2016 |
SINGLE BURN RATE SOLID FUEL HEATING APPLIANCE WITH MANAGED
AIRFLOW
Abstract
A single combustion chamber, single burn rate solid fuel
combustion heating appliance (e.g., a wood stove) is provided. The
heating appliance includes a firebox having a top and a side and a
first secondary air manifold. The first secondary air manifold
extends longitudinally within the firebox proximate the top and the
side of the firebox. The first secondary air manifold has a
plurality of air orifices configured to provide secondary air to a
burn chamber of the heating appliance.
Inventors: |
Barry; Brandon Lane;
(Sewanee, TN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
UNITED STATES STOVE COMPANY |
South Pittsburg |
TN |
US |
|
|
Family ID: |
57515782 |
Appl. No.: |
15/183777 |
Filed: |
June 15, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62175954 |
Jun 15, 2015 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F24B 5/025 20130101;
F23L 1/00 20130101; F23L 9/02 20130101; F24B 13/004 20130101; F23B
60/00 20130101; F23M 9/02 20130101; F23B 90/04 20130101; F24B 1/26
20130101 |
International
Class: |
F24B 5/02 20060101
F24B005/02; F23L 1/00 20060101 F23L001/00; F24B 1/181 20060101
F24B001/181 |
Claims
1. A single combustion chamber, single burn rate solid fuel
combustion heating appliance comprising: a firebox having a top and
a side; a first secondary air manifold extending longitudinally
within the firebox, wherein the first secondary air manifold is
positioned proximate the top and the side of the firebox.
2. The solid fuel combustion heating appliance of claim 1, wherein
the side is a first side and the firebox further comprises a second
side opposite the first side, and wherein the solid fuel combustion
heating appliance further comprises a second secondary air manifold
extending longitudinally within the firebox, wherein the second
secondary air manifold is positioned proximate the top and the
second side of the firebox.
3. The solid fuel combustion heating appliance of claim 1, wherein:
the firebox has a front defined by a door having an upper half and
a lower half, said door having at least one opening therethrough in
the upper half of the door; and the at least one opening is
configured to receive primary combustion air from outside the solid
fuel combustion appliance.
4. The solid fuel combustion heating appliance of claim 1, wherein:
the firebox has a front defined by a door having an upper half and
a lower half, said door having at least one opening therethrough in
the upper half of the door, the at least one opening is configured
to receive primary combustion air from outside the solid fuel
combustion appliance; the door further comprises primary air intake
manifold attached to a firebox side of the door; and the primary
air intake manifold is configured to receive the primary combustion
air from the outside of the solid fuel combustion appliance and
provide the received primary combustion air to the lower half of
the door.
5. The solid fuel combustion heating appliance of claim 1, wherein:
the firebox has a front defined by a door having an upper half and
a lower half, said door having at least one opening therethrough in
the upper half of the door; and the at least one opening comprises
a plurality of openings spaced laterally across the door such that
primary air is intake and distribution into the firebox is
substantially equalized laterally across the firebox.
6. The solid fuel combustion heating appliance of claim 1, wherein:
the firebox further comprises a bottom comprising a metal layer;
the heating appliance further comprises a secondary air baffle
extending longitudinally below the bottom of the firebox of the
heating appliance; and the secondary air baffle is configured to
direct secondary air from a front of the heating appliance to a
rear of the heating appliance.
7. The solid fuel combustion heating appliance of claim 1, wherein:
the firebox further comprises a bottom; the heating appliance
further comprises a secondary air baffle extending longitudinally
below the bottom of the firebox of the heating appliance; the
secondary air baffle is configured to direct secondary air from a
front of the heating appliance to a rear of the heating appliance;
and wherein the secondary air baffle is a bottom heat shield of the
solid fuel combustion heating appliance.
8. The solid fuel combustion heating appliance of claim 1, wherein:
the firebox further comprises a bottom; the heating appliance
further comprises a secondary air baffle extending longitudinally
below the bottom of the firebox of the heating appliance; the
secondary air baffle is configured to direct secondary air from a
front of the heating appliance to a rear of the heating appliance;
and the heating appliance further comprises a bottom heat shield
below the secondary air baffle.
9. The solid fuel combustion heating appliance of claim 1, wherein:
the firebox further comprises a bottom comprising a metal layer and
an insulating layer; the heating appliance further comprises a
secondary air baffle extending longitudinally below the bottom of
the firebox of the heating appliance; and the secondary air baffle
is configured to direct secondary air from a front of the heating
appliance to a rear of the heating appliance.
10. The solid fuel combustion heating appliance of claim 1,
wherein: the firebox further comprises a bottom; the heating
appliance further comprises a secondary air baffle extending
longitudinally below the bottom of the firebox of the heating
appliance; the secondary air baffle is configured to direct
secondary air from a front of the heating appliance to a rear of
the heating appliance; the bottom of the firebox and the secondary
air baffle form a secondary air intake; and the heating appliance
further comprises a first secondary air tube in fluid communication
with the secondary air intake and the first secondary air
manifold.
11. The solid fuel combustion heating appliance of claim 1,
wherein: the firebox further comprises a bottom; the heating
appliance further comprises a secondary air baffle extending
longitudinally below the bottom of the firebox of the heating
appliance; the secondary air baffle is configured to direct
secondary air from a front of the heating appliance to a rear of
the heating appliance; the bottom of the firebox and the secondary
air baffle form a secondary air intake; the heating appliance
further comprises a first secondary air tube in fluid communication
with the secondary air intake and the first secondary air manifold;
the side is a first side; the firebox further comprises a second
side opposite the first side; the solid fuel combustion heating
appliance further comprises a second secondary air manifold
extending longitudinally within the firebox; the second secondary
air manifold is positioned proximate the top and the second side of
the firebox; and the heating appliance further comprises a second
secondary air tube in fluid communication with the secondary air
intake and the second secondary air manifold.
12. The solid fuel combustion heating appliance of claim 1,
wherein: the firebox further comprises a bottom; the heating
appliance further comprises a secondary air baffle extending
longitudinally below the bottom of the firebox of the heating
appliance; the secondary air baffle is configured to direct
secondary air from a front of the heating appliance to a rear of
the heating appliance; the bottom of the firebox and the secondary
air baffle form a secondary air intake; the heating appliance
further comprises a first secondary air tube in fluid communication
with the secondary air intake and the first secondary air tube; the
side is a first side; the firebox further comprises a second side
opposite the first side; the solid fuel combustion heating
appliance further comprises a second secondary air manifold
extending longitudinally within the firebox; the second secondary
air manifold is positioned proximate the top and the second side of
the firebox; the heating appliance further comprises a second
secondary air tube in fluid communication with the secondary air
intake and the second secondary air tube; the first secondary air
tube is integral with the first secondary air manifold; and the
second secondary air tube is integral with the second secondary air
manifold.
13. The solid fuel combustion heating appliance of claim 1,
wherein: the firebox further comprises a bottom; the heating
appliance further comprises a secondary air baffle extending
longitudinally below the bottom of the firebox of the heating
appliance; the secondary air baffle is configured to direct
secondary air from a front of the heating appliance to a rear of
the heating appliance; the bottom of the firebox and the secondary
air baffle form a secondary air intake; the heating appliance
further comprises a first secondary air tube in fluid communication
with the secondary air intake and the first secondary air tube; the
side is a first side; the firebox further comprises a second side
opposite the first side; the solid fuel combustion heating
appliance further comprises a second secondary air manifold
extending longitudinally within the firebox; the second secondary
air manifold is positioned proximate the top and the second side of
the firebox; the heating appliance further comprises a second
secondary air tube in fluid communication with the secondary air
intake and the second secondary air tube; and the heating appliance
further comprises a transverse secondary air manifold extending
laterally between the first secondary air manifold and the second
secondary air manifold proximate the front of the heating
appliance.
14. The solid fuel combustion heating appliance of claim 1,
wherein: the firebox further comprises a bottom; the heating
appliance further comprises a secondary air baffle extending
longitudinally below the bottom of the firebox of the heating
appliance; the secondary air baffle is configured to direct
secondary air from a front of the heating appliance to a rear of
the heating appliance; the bottom of the firebox and the secondary
air baffle form a secondary air intake; the heating appliance
further comprises a first secondary air tube in fluid communication
with the secondary air intake and the first secondary air tube; the
side is a first side; the firebox further comprises a second side
opposite the first side; the solid fuel combustion heating
appliance further comprises a second secondary air manifold
extending longitudinally within the firebox; the second secondary
air manifold is positioned proximate the top and the second side of
the firebox; the heating appliance further comprises a second
secondary air tube in fluid communication with the secondary air
intake and the second secondary air tube; the heating appliance
further comprises a transverse secondary air manifold extending
laterally between the first secondary air manifold and the second
secondary air manifold proximate the front of the heating
appliance; the first secondary air manifold has a plurality of
secondary air orifices configured to direct secondary air toward
the second side of the firebox; the second secondary air manifold
has a plurality of secondary air orifices configured to direct
secondary air toward the first side of the firebox; and the
transverse secondary air manifold has a plurality of secondary air
orifices configured to direct secondary air toward a rear of the
heating appliance.
15. The solid fuel combustion heating appliance of claim 1,
wherein: the firebox further comprises a bottom; the heating
appliance further comprises a secondary air baffle extending
longitudinally below the bottom of the firebox of the heating
appliance; the secondary air baffle is configured to direct
secondary air from a front of the heating appliance to a rear of
the heating appliance; the bottom of the firebox and the secondary
air baffle form a secondary air intake; the heating appliance
further comprises a first secondary air tube in fluid communication
with the secondary air intake and the first secondary air tube; the
side is a first side; the firebox further comprises a second side
opposite the first side; the solid fuel combustion heating
appliance further comprises a second secondary air manifold
extending longitudinally within the firebox; the second secondary
air manifold is positioned proximate the top and the second side of
the firebox; the heating appliance further comprises a second
secondary air tube in fluid communication with the secondary air
intake and the second secondary air tube; the heating appliance
further comprises a transverse secondary air manifold extending
laterally between the first secondary air manifold and the second
secondary air manifold proximate the front of the heating
appliance; the first secondary air tube has a plurality of
secondary air orifices configured to direct secondary air toward
the second side of the firebox; the second secondary air tube has a
plurality of secondary air orifices configured to direct secondary
air toward the first side of the firebox; and the transverse
secondary air manifold has a plurality of secondary air orifices
configured to direct secondary air toward a rear of the heating
appliance; and the first secondary air tube does not have any
secondary air orifices such that the first secondary air tube is
configured to conduct secondary air only from the secondary air
intake into the first secondary air manifold; and the second
secondary air tube does not have any secondary air orifices such
that the second secondary air tube is configured to conduct
secondary air only from the secondary air intake into the secondary
air manifold.
16. The solid fuel combustion heating appliance of claim 1,
wherein: the firebox further comprises a bottom; the heating
appliance further comprises a secondary air baffle extending
longitudinally below the bottom of the firebox of the heating
appliance; the secondary air baffle is configured to direct
secondary air from a front of the heating appliance to a rear of
the heating appliance; the bottom of the firebox and the secondary
air baffle form a secondary air intake; the side is a first side;
the firebox further comprises a second side opposite the first
side; the solid fuel combustion heating appliance further comprises
a second secondary air manifold extending longitudinally within the
firebox; the second secondary air manifold is positioned proximate
the top and the second side of the firebox; the heating appliance
further comprises a rear secondary air baffle; and the rear
secondary air baffle is configured to provide secondary combustion
air from the secondary air intake to the first secondary air
manifold and the second secondary air manifold.
17. The solid fuel combustion heating appliance of claim 1,
wherein: the firebox further comprises a bottom; the heating
appliance further comprises a secondary air baffle extending
longitudinally below the bottom of the firebox of the heating
appliance; the secondary air baffle is configured to direct
secondary air from a front of the heating appliance to a rear of
the heating appliance; the bottom of the firebox and the secondary
air baffle form a secondary air intake; the heating appliance
further comprises a first secondary air tube in fluid communication
with the secondary air intake and the first secondary air tube; the
side is a first side; the firebox further comprises a second side
opposite the first side; the solid fuel combustion heating
appliance further comprises a second secondary air manifold
extending longitudinally within the firebox; the second secondary
air manifold is positioned proximate the top and the second side of
the firebox; the heating appliance further comprises a rear
secondary air baffle; the rear secondary air baffle is configured
to provide secondary combustion air from the secondary air intake
to the first secondary air manifold and the second secondary air
manifold; and the rear secondary air baffle forms a rear of the
firebox.
18. The solid fuel combustion heating appliance of claim 1,
wherein: the firebox further comprises a bottom; the heating
appliance further comprises a secondary air baffle extending
longitudinally below the bottom of the firebox of the heating
appliance; the secondary air baffle is configured to direct
secondary air from a front of the heating appliance to a rear of
the heating appliance; the bottom of the firebox and the secondary
air baffle form a secondary air intake; the heating appliance
further comprises a first secondary air tube in fluid communication
with the secondary air intake and the first secondary air tube; the
side is a first side; the firebox further comprises a second side
opposite the first side; the solid fuel combustion heating
appliance further comprises a second secondary air manifold
extending longitudinally within the firebox; the second secondary
air manifold is positioned proximate the top and the second side of
the firebox; the heating appliance further comprises an upper
baffle extending between the first secondary air manifold and the
second secondary air manifold; and the upper baffle is configured
to form an exhaust path between the upper baffle and a top of the
heating appliance; the heating appliance further comprises a flue
extending from a top of the heating appliance proximate the rear of
the heating appliance; and the exhaust path conducts exhaust gases
toward the flue from adjacent the front of the firebox and top of
the firebox to the flue.
19. The solid fuel combustion heating appliance of claim 1,
wherein: the firebox further comprises a bottom; the heating
appliance further comprises a secondary air baffle extending
longitudinally below the bottom of the firebox of the heating
appliance; the secondary air baffle is configured to direct
secondary air from a front of the heating appliance to a rear of
the heating appliance; the bottom of the firebox and the secondary
air baffle form a secondary air intake; the heating appliance
further comprises a first secondary air tube in fluid communication
with the secondary air intake and the first secondary air tube; the
side is a first side; the firebox further comprises a second side
opposite the first side; the solid fuel combustion heating
appliance further comprises a second secondary air manifold
extending longitudinally within the firebox; the second secondary
air manifold is positioned proximate the top and the second side of
the firebox; the heating appliance further comprises an upper
baffle extending between the first secondary air manifold and the
second secondary air manifold; and the upper baffle is configured
to form an exhaust path between the upper baffle and a top of the
heating appliance; the heating appliance further comprises a flue
extending from a top of the heating appliance proximate the rear of
the heating appliance; the exhaust path conducts exhaust gases
toward the flue from adjacent the front of the firebox and top of
the firebox to the flue; the upper baffle is affixed to a top of
the first secondary air manifold and a top of the second secondary
air manifold.
20. The solid fuel combustion heating appliance of claim 1,
wherein: the firebox further comprises a bottom; the heating
appliance further comprises a secondary air baffle extending
longitudinally below the bottom of the firebox of the heating
appliance; the secondary air baffle is configured to direct
secondary air from a front of the heating appliance to a rear of
the heating appliance; the bottom of the firebox and the secondary
air baffle form a secondary air intake; the heating appliance
further comprises a first secondary air tube in fluid communication
with the secondary air intake and the first secondary air tube; the
side is a first side; the firebox further comprises a second side
opposite the first side; the solid fuel combustion heating
appliance further comprises a second secondary air manifold
extending longitudinally within the firebox; the second secondary
air manifold is positioned proximate the top and the second side of
the firebox; the heating appliance further comprises an upper
baffle extending between the first secondary air manifold and the
second secondary air manifold; and the upper baffle is configured
to form an exhaust path between the upper baffle and a top of the
heating appliance; the heating appliance further comprises a flue
extending from a top of the heating appliance proximate the rear of
the heating appliance; the exhaust path conducts exhaust gases
toward the flue from adjacent the front of the firebox and top of
the firebox to the flue; the upper baffle is affixed to a top of
the first secondary air manifold and a top of the second secondary
air manifold.; and. the heating appliance further comprises a
ceramic insulation layer resting on a top surface of the upper
baffle.
Description
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application is a non-provisional of U.S. patent
application Ser. No. 62/175,954 filed Jun. 15, 2015 entitled CAST
STOVE WITH MANAGED AIRFLOW which is herein incorporated by
reference in its entirety.
[0002] A portion of the disclosure of this patent document contains
material that is subject to copyright protection. The copyright
owner has no objection to the reproduction of the patent document
or the patent disclosure, as it appears in the U.S. Patent and
Trademark Office patent file or records, but otherwise reserves all
copyright rights whatsoever.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0003] Not Applicable
REFERENCE TO SEQUENCE LISTING OR COMPUTER PROGRAM LISTING
APPENDIX
[0004] Not Applicable
BACKGROUND OF THE INVENTION
[0005] The present invention relates generally to cast iron wood
stoves (i.e., heaters).
[0006] Metal castings (e.g., cast iron) are used to make single
burn rate, single chamber wood burning stoves. Fuel burn rates in
these stoves are typically relatively high burn rates (i.e., in
excess of 5 kilograms per hour). These stoves are cheap to produce,
hot to the touch, and relatively inefficient. Thus, these stoves
are generally used only for recreational or occasional use
applications (e.g., in a hunting cabin or in a shop). Many modern
stoves burn processed wood pellets instead of raw wood and have
complicated airflow management systems for variable burn rates and
high fuel efficiency. Until March 2015, these single chamber,
single burn rate stoves with fuel consumption rates in excess of 5
kg/hr were exempt from emissions limitations in the United States.
They are no longer exempt, but the same requirements of simplicity
and having the capacity to burn raw wood remain.
[0007] What is needed then is an improved single burn rate, single
chamber wood burning stove.
BRIEF SUMMARY OF THE INVENTION
[0008] Aspects of the present invention provide a single burn
chamber, single burn rate wood stove with managed airflow which
reduced emissions to within accepted limits. One aspect of the
present disclosure is a single combustion chamber, single burn rate
solid fuel combustion heating appliance including a firebox having
a top and a side; and a first secondary air manifold extending
longitudinally within the firebox, wherein the first secondary air
manifold is positioned proximate the top and the side of the
firebox.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0009] FIG. 1 is a perspective view of an embodiment of a single
burn rate cast wood stove of the present disclosure.
[0010] FIG. 2 is a cutaway view of a single burn rate cast wood
stove with airflow management taken along a longitudinal axis
thereof.
[0011] FIG. 3 is a cutaway view of a single burn rate cast wood
stove with airflow management taken perpendicular to a lateral axis
of the wood stove of FIG. 1 showing the back of the stove.
[0012] FIG. 4 is a cutaway view of a single burn rate cast wood
stove with airflow management taken perpendicular to a lateral axis
of the wood stove of FIG. 1 showing the front of the stove.
[0013] FIG. 5 is a detailed view of a primary air intake manifold
on a door of the single burn rate cast wood stove of FIG. 1.
[0014] FIG. 6 is an isometric view of a secondary air system of the
wood stove of FIG. 1.
[0015] FIG. 7 is an isometric view of another embodiment of a
secondary air system for a single burn rate cast wood stove.
[0016] FIG. 8 is a cutaway view of a single burn rate cast wood
stove utilizing the secondary air system of FIG. 6.
[0017] Reference will now be made in detail to optional embodiments
of the invention, examples of which are illustrated in accompanying
drawings. Whenever possible, the same reference numbers are used in
the drawing and in the description referring to the same or like
parts.
DETAILED DESCRIPTION OF THE INVENTION
[0018] While the making and using of various embodiments of the
present invention are discussed in detail below, it should be
appreciated that the present invention provides many applicable
inventive concepts that can be embodied in a wide variety of
specific contexts. The specific embodiments discussed herein are
merely illustrative of specific ways to make and use the invention
and do not delimit the scope of the invention.
[0019] To facilitate the understanding of the embodiments described
herein, a number of terms are defined below. The terms defined
herein have meanings as commonly understood by a person of ordinary
skill in the areas relevant to the present invention. Terms such as
"a," "an," and "the" are not intended to refer to only a singular
entity, but rather include the general class of which a specific
example may be used for illustration. The terminology herein is
used to describe specific embodiments of the invention, but their
usage does not delimit the invention, except as set forth in the
claims
[0020] As described herein, an upright position is considered to be
the position of apparatus components while in proper operation or
in a natural resting position as described herein. That is, an
upright position of a wood stove is that of a wood stove installed
on a level platform (e.g., floor) with the feet on the platform and
flue above the feet. Vertical, horizontal, above, below, side, top,
bottom and other orientation terms are described with respect to
this upright position during operation unless otherwise specified.
The term "when" is used to specify orientation for relative
positions of components, not as a temporal limitation of the claims
or apparatus described and claimed herein unless otherwise
specified. The terms "above", "below", "over", and "under" mean
"having an elevation or vertical height greater or lesser than" and
are not intended to imply that one object or component is directly
over or under another object or component.
[0021] The phrase "in one embodiment," as used herein does not
necessarily refer to the same embodiment, although it may.
Conditional language used herein, such as, among others, "can,"
"might," "may," "e.g.," and the like, unless specifically stated
otherwise, or otherwise understood within the context as used, is
generally intended to convey that certain embodiments include,
while other embodiments do not include, certain features, elements
and/or states. Thus, such conditional language is not generally
intended to imply that features, elements and/or states are in any
way required for one or more embodiments or that one or more
embodiments necessarily include logic for deciding, with or without
author input or prompting, whether these features, elements and/or
states are included or are to be performed in any particular
embodiment.
[0022] Referring to FIGS. 1-6, a single combustion chamber, single
burn rate solid fuel combustion heating appliance (i.e., stove or
heater) 10 has an outer shell 12 including cast metal (e.g., cast
iron). The stove 10 includes air introduction into the stove's
firebox 14 (i.e., main combustion chamber) to reduce and control
the particle and gas emissions. In one embodiment, the firebox 14
of the stove 10 is defined by the front door 16 of the stove 10, a
rear surface 18 of the cast shell 12, the bottom surface 20 of the
cast shell 12, opposing sides 22 and 24 of the cast shell 12, and
top 26.
[0023] Air is introduced to the firebox 14 through two manifolds: a
primary air manifold 28 and a secondary air manifold 30. Both
secondary and primary air 31a and 31b are pulled into the stove
through natural draft established by the flue 32 and chimney 34
connected to the stove 10. Primary air enters through at least one
primary air intake 36 and travels into the primary air intake
manifold 28 where it is distributed through a series of orifices in
the primary air intake manifold 28 and through an opening 38 at the
bottom of the primary air intake manifold 28. In some embodiments,
the primary air intake manifold 28 can be a singular hollow
passageway through which air from primary air intake 36 can pass
and exit out of the opening 38 in the bottom of the primary air
intake manifold 28. The primary air is the primary source that
feeds the fire in the firebox 14. In one embodiment, the front door
16 of the wood stove 10 includes a primary air intake 36 including
slits or openings in fluid communication with an interior of the
primary air intake manifold 28. The primary air intake manifold 28
then directs the air downward toward a bottom of the firebox 14
through bottom opening 38 in the primary air intake manifold 28. In
one embodiment, the primary air intake manifold 28 can be made from
stamped steel.
[0024] In some embodiments, the firebox 14 has a front defined by a
door 16 having an upper half 16a and a lower half 16b, said door 16
having at least one opening 36 therethrough in the upper half 16a
of the door; and the at least one opening 36 is configured to
receive primary combustion air 31a from outside the solid fuel
combustion appliance 10. The door 16 can further include a primary
air intake manifold 28 attached to a firebox side 16c of the door
16. The primary air intake manifold 28 is configured to receive the
primary combustion air 31a from the outside of the solid fuel
combustion appliance 10 and provide the received primary combustion
air 31a to the lower half 16b of the door 16. In some embodiments,
the at least one opening 36 can include a plurality of openings
spaced laterally across the door 16 and configured to receive
primary combustion air 31a from the outside of the fuel combustion
appliance, such that the primary combustion air 31a is
substantially equalized laterally across the firebox 14. In some
embodiments, the primary air orifices 36 in the door of the wood
stove 10 are in an upper half of the door 16, and the primary air
intake manifold 28 extends to or below the middle of the door 16,
or extends adjacent the lower half 16b of the door 16.
[0025] Another aspect of the present disclosure is a single
combustion chamber, single burn rate solid fuel combustion heating
appliance 10 including a firebox 14 having a top 26 and a side 22;
and a first secondary air manifold 46a extending longitudinally
within the firebox 14, wherein the first secondary air manifold 46
is positioned proximate the top 26 and the side 22 of the firebox
14.
[0026] In some embodiments, the side 22 is a first side and the
firebox 14 further comprises a second side 24 opposite the first
side, and wherein the solid fuel combustion heating appliance 10
further comprises a second secondary air manifold 46b extending
longitudinally within the firebox 14, wherein the second secondary
air manifold 46b is positioned proximate the top 26 and the second
side 24 of the firebox 14. In other words, the secondary air
manifolds 46 can be positioned adjacent opposing top corners 48 of
the firebox 14. The opposing top corners 48 of the firebox 14 in
which the secondary air manifolds 46 are positioned in can also be
described as the upper lateral corners or edges of the firebox
14
[0027] In some embodiments, the firebox 14 includes a bottom 20
comprising a metal layer. The heating appliance 10 can further
include a secondary air baffle 42 extending longitudinally below
the bottom 20 of the firebox 14 of the heating appliance 10. The
secondary air baffle 42 is configured to direct secondary air from
a front of the heating appliance to a rear of the heating
appliance. In some embodiments, the secondary air baffle 42 is or
can act as a bottom heat shield of the solid combustion heating
appliance 10. In other embodiments, the heating appliance 10 can
further include a bottom heat shield 43 below the secondary air
baffle 42. In such embodiments where the bottom 20 of the firebox
includes a metal layer, heat from the firebox can be transferred or
radiated from the bottom 20 of the firebox 14 such that secondary
air 31b air being directed from the front of the heating appliance
10 to the back of the heating appliance 10 can be preheated.
[0028] In other embodiments, the firebox 14 includes a bottom 20
including a metal layer and an insulating layer. In some
embodiments, the insulating layer can include a fireboard or other
suitable insulating material. In such embodiments, the insulating
layer can protect and insulate air being directed from the front of
heating appliance to the back of heating appliance from the heat
generated by firebox 14 such that secondary air 3 lb can remain at
a relatively low temperature.
[0029] The bottom 20 of the firebox 14 and the secondary air baffle
42 can form a secondary air intake 40. Secondary air 31b is drawn
in through the secondary air intake 40 and along the bottom 20 of
the heating appliance 10, the secondary air 31b being directed by
the secondary air baffle 42 toward the back of the heating
appliance 10. In other embodiments, secondary air baffle 42 may
include a top and bottom panel positioned beneath the bottom
surface 20 of the shell 12, such that secondary air 31b passes
between the top and bottom panels of the secondary air baffle 42.
In some embodiments, one or more of the top and bottom panels of
the secondary air baffle 42 can include a heat shield or be made of
a heat resistant material which can protect and insulate secondary
air 3 lb directed by secondary air baffle 42 toward the rear of
heating appliance 10 from the heat produced by the firebox 14, such
that secondary air 31b can pass through the secondary air baffle 42
and remain at a relatively low temperature. In such embodiments,
secondary air intake 40 can be defined by the top and bottom panels
of secondary air baffle 42.
[0030] The heating appliance 10 can further include a at least one
or a first secondary air tube 44a in fluid communication with the
secondary air intake 40 and the first secondary air manifold 46a.
The secondary air 31b is directed by the secondary air baffle 42
from the secondary air intake 40 and into the first secondary air
tube 44a, the first secondary air tube 44a providing the secondary
air 3 lb to the first secondary manifold 46a. The first secondary
air tube 44 can extend up the back of the firebox 14, the secondary
air tube 44 extending between the secondary air baffle 42 and the
first secondary air manifolds 46a. As such, the first secondary air
tube 44a can be configured to transmit secondary air 3 lb moved to
the rear of the heating appliance 10 by the secondary air baffle 42
to the first secondary air manifold 46a. The secondary air 31b
passes from the first secondary air tube 44a into the first
secondary air manifold 46a, where the secondary air 31b is
dispersed from the first secondary air manifold 46a into an upper
portion of the firebox 14.
[0031] In some embodiments, including second secondary air manifold
46b, the heating appliance can further include a second secondary
air tube 44b in fluid communication with the secondary air intake
40 and the secondary air manifold 46b. In other words, the heating
appliance 10 can include a pair of secondary air tubes 44, each
secondary air tube 44 fluidly communicating the secondary air
intake 40 and a corresponding secondary air manifold 46a or 46b.
The secondary air manifolds 46a and 46b can both extend
longitudinally (i.e., front to back) inside the firebox 14. In some
embodiments, the first secondary air tube 44a can be integral with
the first secondary air manifold 46a, and the second secondary air
tube 44b can be integral with the second secondary air manifold
46b. In some embodiments, a single rear secondary baffle can extend
between the secondary air baffle 42 and the secondary air manifolds
46a and 46b, the rear secondary baffle supplying air to both
secondary air manifolds 46a and 46b. In some embodiments, the rear
secondary baffle forms a rear of the firebox 14.
[0032] A series of orifices 50 in the secondary air manifolds 46a
and 46b introduce the secondary air 31b into the firebox 48 below
the top 26 of firebox 14. The first secondary air tube 44a has a
plurality of secondary air orifices 50 configured to direct
secondary air toward the second side 24 of the firebox 14. The
second secondary air tube 44b has a plurality of secondary air
orifices 50 configured to direct secondary air toward the first
side 22 of the firebox 14. In one embodiment, all of the orifices
50 are oriented in a plane substantially parallel to the bottom 20
of the firebox 14, and directly face the opposing secondary air
manifold 46. That is, the orifices 50 are positioned on an
interior, lateral side or portion of each of the secondary air
manifolds 46. The top 26 of firebox 14 makes the secondary air 31b
mix with the hot gasses produced by the fire in the firebox 14 and
burn off excess emissions generated from the solid fuel (wood or
wood pellets) burning in the firebox 14.
[0033] In some embodiments, the first secondary air tube 44a does
not have any secondary air orifices such that the first secondary
air tube 44a is configured to conduct secondary air only from the
secondary air intake 40 into the first secondary air manifold 46a.
Similarly, in some embodiments, the second secondary air tube 44b
does not have any secondary air orifices such that the second
secondary air tube 44b is configured to conduct secondary air only
from the secondary air intake 40 into the secondary air manifold
46b.
[0034] The heating appliance further comprises an upper baffle 51
extending between the first secondary air manifold 46a and the
second secondary air manifold 46b. The upper baffle 51 is
configured to form an exhaust path between the upper baffle 51 and
a top of the heating appliance 10. The heating appliance 10 further
comprises a flue 32 extending from a top of the heating appliance
10 proximate the rear of the heating appliance 10. The exhaust path
conducts exhaust gases toward the flue 32 from adjacent the front
of the firebox 14 and top 26 of the firebox to the flue 32. In some
embodiments, the upper baffle 51 can form the top 26 of the firebox
14, such that the upper baffle 51 is supported by or affixed to the
first and second secondary air manifolds 46a and 46b. In one
embodiment, the upper baffle 51 is stamped steel and is integral
with the secondary air manifolds 46.
[0035] A ceramic fiber blanket or ceramic insulation layer 52 rests
on top of or is attached to a top surface of the upper baffle 51.
The ceramic fiber blanket 52 insulates the upper baffle 26 and
serves to increase the temperature in the firebox 14 as the
combustion processes occur. After the secondary air 31b has reacted
with the hot gasses in the upper portion of the firebox 14, the
gases move forward toward the door 16 of the stove 10 and turn
above the upper baffle 26 near the front of the stove 10. The
exhaust gases then continue along the top of the stove 10 along the
upper baffle 26 toward the back of the stove 10 and exit the wood
stove 10 through the flue outlet 32 through the upper surface 23 of
the cast shell 12 of the wood stove 10. As the gases exit through
the flue outlet 32 they are slowed down by a damper 54.
[0036] In some embodiments, as shown in FIGS. 6-7, the heating
appliance or stove 10 can include a transverse secondary air
manifold 56 extending laterally between the first and second
secondary air manifolds 46a and 46b proximate the front of heating
appliance 10. In other words, transverse air manifold 56 can
between the opposing distal ends 58 of the two secondary air
manifolds 46a and 46b positioned at the front of heating appliance
10. The transverse secondary air manifold has a plurality of
secondary air orifices configured to direct secondary air toward a
rear of the heating appliance 10. In other words, transverse
secondary air manifold 56 can include a plurality of transverse
manifold orifices 60 oriented to disperse air in a rearward
direction and substantially transverse to the air exerted from the
plurality of orifices 50 in the secondary manifolds 46. Once the
air from secondary air manifolds 46 has circulated within firebox
14 to burn off excess emissions from the solid fuel, the air can be
recirculated within firebox 14 by the air dispersed from transverse
air manifold, 56 to further circulate and burn off excess emissions
from the solid fuel.
[0037] The combination of a bottom air baffle 42, secondary air
tubes 44, secondary air manifolds 46, primary air manifold 28,
upper baffle 26, and ceramic insulation blanket 52 allows this
single chamber, single burn rate wood stove to achieve improved
emissions levels that are emissions requirements compliant.
[0038] This written description uses examples to disclose the
invention and also to enable any person skilled in the art to
practice the invention, including making and using any devices or
systems and performing any incorporated methods. The patentable
scope of the invention is defined by the claims, and may include
other examples that occur to those skilled in the art. Such other
examples are intended to be within the scope of the claims if they
have structural elements that do not differ from the literal
language of the claims, or if they include equivalent structural
elements with insubstantial differences from the literal languages
of the claims.
[0039] It will be understood that the particular embodiments
described herein are shown by way of illustration and not as
limitations of the invention. The principal features of this
invention may be employed in various embodiments without departing
from the scope of the invention. Those of ordinary skill in the art
will recognize numerous equivalents to the specific procedures
described herein. Such equivalents are considered to be within the
scope of this invention and are covered by the claims.
[0040] All of the compositions and/or methods disclosed and claimed
herein may be made and/or executed without undue experimentation in
light of the present disclosure. While the compositions and methods
of this invention have been described in terms of the embodiments
included herein, it will be apparent to those of ordinary skill in
the art that variations may be applied to the compositions and/or
methods and in the steps or in the sequence of steps of the method
described herein without departing from the concept, spirit, and
scope of the invention. All such similar substitutes and
modifications apparent to those skilled in the art are deemed to be
within the spirit, scope, and concept of the invention as defined
by the appended claims.
[0041] Thus, although there have been described particular
embodiments of the present invention of a new and useful SINGLE
BURN RATE SOLID FUEL HEATING APPLIANCE WITH MANAGED AIRFLOW it is
not intended that such references be construed as limitations upon
the scope of this invention except as set forth in the following
claims.
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