U.S. patent application number 15/233594 was filed with the patent office on 2017-03-09 for heating apparatus with fan.
The applicant listed for this patent is CONTINENTAL APPLIANCES, INC., D.B.A. PROCOM. Invention is credited to David Deng.
Application Number | 20170067644 15/233594 |
Document ID | / |
Family ID | 46440476 |
Filed Date | 2017-03-09 |
United States Patent
Application |
20170067644 |
Kind Code |
A1 |
Deng; David |
March 9, 2017 |
HEATING APPARATUS WITH FAN
Abstract
A heating apparatus can have a sealed combustion chamber and a
burner. The heating apparatus can have an air shutter that controls
the amount of air that mixes with fuel directed toward the burner.
The air shutter can be controlled by rotating a shaft that connects
to the air shutter. The heating apparatus can also have a system of
channels along its front face which direct air along the front
face.
Inventors: |
Deng; David; (Diamond Bar,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
CONTINENTAL APPLIANCES, INC., D.B.A. PROCOM |
Brea |
CA |
US |
|
|
Family ID: |
46440476 |
Appl. No.: |
15/233594 |
Filed: |
August 10, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
13678346 |
Nov 15, 2012 |
9441840 |
|
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15233594 |
|
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|
|
61562846 |
Nov 22, 2011 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F24C 15/006 20130101;
F24B 1/189 20130101; F23C 7/008 20130101; F23L 13/02 20130101; F24C
3/006 20130101; F24B 1/1902 20130101; F23D 14/64 20130101; F23L
13/00 20130101; F24C 15/028 20130101; F24B 5/026 20130101 |
International
Class: |
F24B 1/19 20060101
F24B001/19; F23L 13/00 20060101 F23L013/00 |
Foreign Application Data
Date |
Code |
Application Number |
Nov 16, 2011 |
CN |
201120452598.X |
Claims
1. A heating apparatus comprising: a sealed combustion chamber; a
burner within the sealed combustion chamber; a fuel channel for
directing a fuel from a fuel source external the sealed combustion
chamber to the burner; an air shutter within the sealed combustion
chamber, said air shutter comprising a rotatable sleeve, the
rotatable sleeve configured to rotate about a shutter axis and
adjust the size of a shutter opening; an air shutter control
comprising a shaft, the air shutter control cooperating with the
air shutter such that rotating the shaft rotates the rotatable
sleeve; and wherein the shaft must rotate at least 180 degrees to
change the air shutter from a minimum airflow position to a maximum
airflow position.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser.
No. 13/678,346, filed Nov. 15, 2012, which is related to and claims
priority to Chinese Patent Application No. 201120452598.X, filed on
Nov. 16, 2011, and U.S. Provisional Application No. 61/562,846,
filed on Nov. 22, 2011, the entire contents of all of which are
hereby incorporated by reference herein and made a part of this
specification. U.S. Provisional Application Nos. 61/368,637, filed
Jul. 28, 2010, and 61/408,549, filed Oct. 29, 2010, are also hereby
incorporated by reference herein and made a part of this
specification. U.S. Pat. No. 7,434,447, filed on May 30, 2006, and
U.S. patent application Ser. No. 12/797,511, filed on Jun. 9, 2010,
are also hereby incorporated by reference herein and made a part of
this specification. Any and all applications for which a foreign or
domestic priority claim is identified in the Application Data Sheet
as filed with the present application are hereby incorporated by
reference under 37 CFR 1.57.
BACKGROUND OF THE INVENTION
[0002] Field of the Invention
[0003] Certain embodiments disclosed herein relate generally to
heating devices, and relate more specifically to fluid-fueled
heating devices, such as, for example, gas heaters, fireplaces,
stoves, and other heating devices.
[0004] Description of the Related Art
[0005] Many varieties of heaters, fireplaces, stoves, and other
heating devices utilize pressurized, combustible fluid fuels to
generate a desired heat output. Some such devices operate with
liquid propane gas, while others operate with natural gas. These
heating devices achieve high internal temperatures. However, such
devices and certain components thereof have various limitations and
disadvantages.
SUMMARY OF THE INVENTION
[0006] According to some embodiments, a heating apparatus can
comprise a sealed combustion chamber and a burner disposed within
the sealed combustion chamber. The gas fireplace assembly can also
comprise a fuel channel for directing fuel from a fuel source
external the sealed combustion chamber to the burner, and an air
shutter within the sealed combustion chamber that comprises a
rotatable sleeve configured to rotate about a shutter axis and
adjust the size of a shutter opening. The heating apparatus can
also comprise an air shutter control comprising a shaft, the air
shutter control mated with the air shutter such that rotating the
shaft rotates the rotatable sleeve.
[0007] According to some embodiments, a heating apparatus can
comprise a sealed combustion chamber and a burner disposed within
the combustion chamber. The combustion chamber can have a front
face viewable to a user when the fireplace is in use. The heating
apparatus can also comprise a combustion air inlet in fluid
communication with the sealed combustion chamber to provide air to
the burner and an exhaust air outlet in fluid communication with
the sealed combustion chamber to remove exhaust air from the
combustion chamber. An outer housing can surround at least a
portion of the sealed combustion chamber. A system of channels can
comprise at least two of a top channel above the front face, a left
side channel to the left of the front face, a right side channel to
the right of the front face, and a bottom channel below the front
face. The at least two channels can be configured to direct air to
the front face of the sealed combustion chamber, and at least one
fan can be positioned within the outer housing and configured to
direct air into the system of channels.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] In order to better understand the embodiments of the
disclosure and to see how it may be carried out in practice, some
preferred embodiments are next described, by way of non-limiting
examples only, with reference to the accompanying drawings, in
which like reference characters denote corresponding features
consistently throughout similar embodiments in the attached
drawings.
[0009] FIG. 1 is a schematic view of a heating device.
[0010] FIG. 2 is a perspective view of an embodiment of a heating
device.
[0011] FIG. 2A is a perspective view of an embodiment of a fuel
delivery system compatible with the heating device of FIG. 2.
[0012] FIG. 3 is a perspective view of another embodiment of a
heating device.
[0013] FIG. 3A is a partially disassembled perspective view of the
heating device of FIG. 3.
[0014] FIG. 3B is a perspective view of an embodiment of a fuel
delivery system compatible with the heating device of FIG. 3.
[0015] FIGS. 4A-D show front, side, back and top views of an
embodiment of an air shutter control.
[0016] FIG. 4E shows an exploded view of the air shutter control of
FIGS. 4A-D.
[0017] FIG. 5 shows the air shutter control of FIGS. 4A-D attached
to an air shutter.
[0018] FIG. 6 shows an embodiment of an air shutter control.
[0019] FIG. 7 is a perspective view of another embodiment of a
heating device.
[0020] FIG. 8 is a partially disassembled cross-section side view
of the heating device of FIG. 7.
[0021] FIG. 9 is a perspective view of a cooling structure.
[0022] FIG. 10 is a front view of the cooling structure of FIG.
9.
[0023] FIG. 11 is a cross-sectional side view of the cooling
structure of FIG. 9.
[0024] FIG. 12 is a perspective view of another embodiment of a
heating device.
[0025] FIG. 13 is a partially disassembled cross-section
perspective view of the heating device of FIG. 12.
[0026] FIG. 14 is a partially disassembled cross-section
perspective view of the heating device of FIG. 12.
[0027] FIG. 15 is partially disassembled cross-section perspective
view of the heating device of FIG. 12.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0028] Many varieties of space heaters, wall heaters, stoves,
fireplaces, fireplace inserts, gas logs, and other heat-producing
devices employ combustible fluid fuels, such as liquid propane and
natural gas. The term "fluid," as used herein, is a broad term used
in its ordinary sense, and includes materials or substances capable
of fluid flow, such as, for example, one or more gases, one or more
liquids, or any combination thereof. Fluid-fueled units, such as
those listed above, generally are designed to operate with a single
fluid fuel type at a specific pressure or within a range of
pressures. For example, some fluid-fueled heaters that are
configured to be installed on a wall or a floor operate with
natural gas at a pressure in a range from about 3 inches of water
column to about 6 inches of water column, while others are
configured to operate with liquid propane at a pressure in a range
from about 8 inches of water column to about 12 inches of water
column. Similarly, some gas fireplaces and gas logs are configured
to operate with natural gas at a first pressure, while others are
configured to operate with liquid propane at a second pressure that
is different from the first pressure. As used herein, the terms
"first" and "second" are used for convenience, and do not connote a
hierarchical relationship among the items so identified, unless
otherwise indicated.
[0029] Direct vent fireplaces provide efficient heating and do not
require a chimney for operation. A direct vent fireplace can direct
external ambient air through a combustion vent system for heat
generating combustion, and thus does not deprive interior living
spaces of oxygen or heated air. Direct vent fireplaces use a
balanced flow of combustion air and exhaust gas moving through the
combustion fluid intake and exhaust ducts to provide an
aesthetically desirable flame in the firebox. Desirable flame
characteristics can include, for example, appearing similar to a
natural wood-fire flame. The size, color and action of the flames
in the firebox can be adjusted by selectively balancing the flow of
combustion air and exhaust gas. A balanced flow also allows direct
vent fireplaces to function in a thermally efficient manner.
Accordingly, an important part of the fireplace insert's
installation is to properly balance the combustion air intake flow
and the exhaust gas flow. A direct vent fireplace can also provide
heat via radiant energy transmitted through the glass enclosure of
the fireplace front face. In addition, the combustion chamber
enclosure structure reaches elevated temperatures during fireplace
operation, e.g. the firebox, glass window, or the like. The
combustion chamber of a direct vent fireplace is desirably
"sealed." As will be appreciated by those of skill in the art, as
used herein a "sealed combustion chamber" is sealed to the extent
that it effectively seals the space desired to be heated (usually
an interior room) from (1) air from an external source (usually
ambient air from outdoors to be used in the combustion process and
(2) exhaust created from the combustion process.
[0030] In addition, in some instances, the appearance of a flame
produced by some fluid-fueled units is important to the
marketability of the units. For example, some gas fireplaces and
gas fireplace inserts are desirable as either replacements for or
additions to natural wood-burning fireplaces. Such replacement
units can desirably exhibit enhanced efficiency, improved safety,
and/or reduced mess. In many instances, a flame produced by such a
gas unit desirably resembles that produced by burning wood, and
thus preferably has a substantially yellow hue.
[0031] The amount of oxygen present in the fuel at a combustion
site of a unit (e.g., at a burner) can affect the color of the
flame produced by the unit. Accordingly, in some units, one or more
components of the unit are adjusted to regulate the amount of air
that is mixed with the fuel to create a proper air/fuel mixture at
the burner. Such adjustments can be influenced by the pressure at
which the fuel is dispensed.
[0032] The conventional insert-style fireplace insert is typically
installed and balanced by first sliding the insert into a close-fit
fireplace cavity so a limited access space is provided between the
fireplace insert and the cavity's walls. The installer reaches
through the limited access space to connect the fireplace insert to
the exhaust duct and the intake duct. The installer then balances
the flow of combustion air and the exhaust gas while the fire is
burning in the firebox in order to visually analyze the flame
characteristics. Limited access to the adjustment mechanisms for
the intake duct, the exhaust duct or an air shutter can make this
balancing a time-consuming and labor intensive process requiring
multiple adjustments of the adjustment mechanisms during
installation.
[0033] Some fluid-fueled fireplace units generate hot surfaces
about the various features of the fireplace. For example,
fireplaces having a sealed, or semi-sealed, or partially sealed
window or viewing space on the front face of the unit can reach
unsafe temperatures due to the risk of burning the skin, or
igniting other objects in close proximity to or touching such a
surface. In addition, thermal cycling experienced by the viewing
space structure, or glass window, subjects the glass to increased
loads that can reduce the durability of the structure. The
proximity of the glass portion of a front face to the intense heat
emitted by the fireplace burner increases these types of concerns
and the maintenance costs of the gas fireplace.
[0034] Certain embodiments disclosed herein reduce or eliminate one
or more of the foregoing problems associated with existing
fluid-fueled devices and/or provide some or all of the desirable
features detailed herein. Although certain embodiments discussed
herein are described in the context of directly vented heating
units, such as fireplaces and fireplace inserts, it should be
understood that certain features, principles, and/or advantages
described are applicable in a much wider variety of contexts,
including, for example, vent-free heating units, gas logs, heaters,
heating stoves, cooking stoves, barbecue grills, water heaters, and
any flame-producing and/or heat-producing fluid-fueled unit or
appliance, including without limitation units that include a burner
of any suitable variety.
Direct Vent Fireplace
[0035] For clarity and convenience, a direct vent fireplace without
the cooling structure discussed above will first be described with
reference to FIGS. 1-5. It will be understood that one or more of
the features of the fireplaces of FIGS. 1-2A and 3-5 could be used
in other embodiments of the fireplaces discussed herein, such as
the fireplaces of FIGS. 7-8 and FIGS. 12-15. FIGS. 1 and 2
illustrate an embodiment of a fireplace, fireplace insert,
heat-generating unit, or heating device 10 configured to operate
with a source of combustible fuel. In various embodiments, the
heating device 10 is configured to be installed within a suitable
cavity, such as the firebox of a fireplace or a dedicated outer
casing. The heating device 10 can extend through a wall 12, in some
embodiments.
[0036] The heating device 10 includes a housing 20. The housing 20
can include metal or some other suitable material for providing
structure to the heating device 10 without melting or otherwise
deforming in a heated environment. The housing 20 can define a
window 22. In some embodiments, the window 22 comprises a sheet of
substantially clear material, such as tempered glass, that is
substantially impervious to heated air but substantially
transmissive to radiant energy.
[0037] The heating device 10 can include a sealed chamber 14. The
sealed chamber 14 can be sealed to the outside with the exception
of the air intake 24 and the exhaust 26. Heated air does not flow
from the sealed chamber to the surroundings; instead air, for
example from in an interior room, can enter an inlet vent 13 into
the housing 20. The air can pass through the housing in a conduit,
or channel 15, passing over the outside of the sealed chamber 14
and over the exhaust 26. Heat can be transferred to the air which
can then pass into the interior room through outlet vent 16.
[0038] In some embodiments, the heating device 10 includes a grill,
rack, or grate 28, as in FIG. 2. The grate 28 can provide a surface
against which artificial logs may rest, and can resemble similar
structures used in wood-burning fireplaces. In certain embodiments,
the housing 20 defines one or more mounting flanges 30 used to
secure the heating device 10 to a floor and/or one or more walls.
The mounting flanges 30 can include apertures 32 through which
mounting hardware can be advanced. Accordingly, in some
embodiments, the housing 20 can be installed in a relatively fixed
fashion within a building or other structure.
[0039] As shown, the heating device 10 includes a fuel delivery
system 40, which can have portions for accepting fuel from a fuel
source, for directing flow of fuel within the heating device 10,
and for combusting fuel. In the embodiment illustrated in FIG. 2,
portions of an embodiment of the fuel delivery system 40 that would
be obscured by the heating device 10 are shown in phantom.
Specifically, the illustrated heating device 10 includes a floor 50
which forms the bottom of the sealed combustion chamber 14 and the
components shown in phantom are positioned beneath the floor
50.
[0040] With reference to FIG. 2A, an example of a fuel delivery
system is shown. The fuel delivery system 40 can include a
regulator 120. The regulator 120 can be configured to selectively
receive a fluid fuel (e.g., propane or natural gas) from a source
at a certain pressure. In certain embodiments, the regulator 120
includes an input port 121 for receiving the fuel. The regulator
120 can define an output port 123 through which fuel exits the
regulator 120. Accordingly, in many embodiments, the regulator 120
is configured to operate in a state in which fuel is received via
the input port 121 and delivered to the output port 123. In certain
embodiments, the regulator 120 is configured to regulate fuel
entering the port 121 such that fuel exiting the output port 123 is
at a relatively steady pressure. The regulator 120 can function in
ways similar to the pressure regulators disclosed in U.S. Pat. No.
7,434,447, filed on May 30, 2006, and U.S. patent application Ser.
No. 12/797,511, filed on Jun. 9, 2010, incorporated by reference
herein.
[0041] The output port 123 of the regulator 120 can be coupled with
a source line or channel 125. The source line 125, and any other
fluid line described herein, can comprise piping, tubing, conduit,
or any other suitable structure adapted to direct or channel fuel
along a flow path. In some embodiments, the source line 125 is
coupled with the output port 123 at one end and is coupled with a
control valve 130 at another end. The source line 125 can thus
provide fluid communication between the regulator 120 and the
control valve 130.
[0042] The control valve 130 can be configured to regulate the
amount of fuel delivered to portions of the fuel delivery system
40. Various configurations of the control valve 130 are possible,
including those known in the art as well as those yet to be
devised. In some embodiments, the control valve 130 includes a
millivolt valve. The control valve 130 can comprise a first knob or
dial 131 and a second dial 132. In some embodiments, the first dial
131 can be rotated to adjust the amount of fuel delivered to a
burner 135, and the second dial 132 can be rotated to adjust a
setting of a thermostat. In other embodiments, the control valve
130 comprises a single dial 131.
[0043] In many embodiments, the control valve 130 is coupled with a
burner transport line or channel 137 and a pilot transport or
delivery line 141. The burner transport line 137 can be coupled
with a nozzle assembly 140 which can be further coupled with a
burner delivery line 143. The nozzle assembly 140 can be configured
to direct fuel received from the burner transport line 132 to the
burner delivery line or channel 143.
[0044] The pilot delivery line 141 is coupled with a safety pilot,
pilot assembly, or pilot 180. Fuel delivered to the pilot 180 can
be combusted to form a pilot flame, which can serve to ignite fuel
delivered to the burner 135 and/or serve as a safety control
feedback mechanism that can cause the control valve 130 to shut off
delivery of fuel to the fuel delivery system 40. Additionally, in
some embodiments, the pilot 180 is configured to provide power to
the control valve 130. Accordingly, in some embodiments, the pilot
180 is coupled with the control valve 130 by one or more of a
feedback line 182 and a power line 183.
[0045] The pilot 180 can comprise an igniter or an electrode
configured to ignite fuel delivered to the pilot 180 via the pilot
delivery line 141. Accordingly, the pilot 180 can be coupled with
an igniter line 184, which can be connected to an igniter actuator,
button, or switch 186. In some embodiments, the igniter switch 186
is mounted to the control valve 130. In other embodiments, the
igniter switch 186 is mounted to the housing 20 of the heating
device 10. The pilot 180 can also comprise a thermocouple. Any of
the lines 182, 183, 184 can comprise any suitable medium for
communicating an electrical quantity, such as a voltage or an
electrical current. For example, in some embodiments, one or more
of the lines 182, 183, 184 comprise a metal wire.
[0046] The burner delivery line 143 is situated to receive fuel
from the nozzle assembly 140, and can be connected to the burner
135. The burner 135 can comprise any suitable burner, such as, for
example, a ceramic tile burner or a blue flame burner, and is
preferably configured to continuously combust fuel delivered via
the burner delivery line 143.
[0047] The flow of fuel through the fuel delivery system 40, as
shown, will now be described. A fuel is introduced into the fuel
delivery system 40 through the regulator 120 which then proceeds
from the regulator 120 through the source line or channel 125 to
the control valve 130. The control valve 130 can permit a portion
of the fuel to flow into the burner transport line or channel 132,
and can permit another portion of the fuel to flow into the pilot
transport line or channel 141. The fuel flow in the burner
transport line 132 can proceed to the nozzle assembly 140. The
nozzle assembly 140 can direct fuel from the burner transport line
or channel 132 into the burner delivery line or channel 143. In
some embodiments, fuel flows through the pilot delivery line or
channel 141 to the pilot 180, where it is combusted. In some
embodiments, fuel flows through the burner delivery line or channel
143 to the burner 135, where it is combusted.
[0048] An air shutter 150 can also be along the burner delivery
line 143. The air shutter 150 can be used to introduce air into the
flow of fuel prior to combustion at the burner 135. This can create
a mixing chamber 157 where air and fuel is mixed together prior to
passing through the burner delivery line 143 to the burner 135. The
amount of air that is needed to be introduced can depend on the
type of fuel used. For example, propane gas at typical pressures
needs more air than natural gas to produce a flame of the same
size.
[0049] The air shutter 150 can be adjusted by increasing or
decreasing the size of a window 155. The window 155 can be
configured to allow air to pass into and mix with fuel in the
burner delivery line 143.
[0050] The air shutter 150, along with the burner 135 and the pilot
180 can be within the sealed combustion chamber 14. Because the
combustion chamber 14 is sealed, it can be difficult to access
components within the combustion chamber 14. For this reason some
of the components are within the combustion chamber 14 but many are
not. In some embodiments, only the components necessary for
combustion are within the chamber 90 and all others are outside the
chamber 14. For example, the other components can be in the channel
15 of the housing 20 (FIG. 1). It is necessary for connecting
pipes, lines or channels and some parts of other components to pass
into the sealed combustion chamber 14 and remain partially inside
the sealed combustion chamber 14 and partially outside. Fittings
can be used to allow the necessary components to pass into the
chamber 14 while otherwise sealing the entry point into the sealed
combustion chamber 14.
[0051] As the air shutter 150 is within the sealed combustion
chamber 14, it can be difficult to adjust to the proper setting. In
some currently available heaters, a long screw is used to adjust
the air shutter. The long screw passes into the sealed combustion
chamber through a fitting and the end attaches to the air shutter.
Advancing or withdrawing the screw into or out of the sealed
combustion chamber can move the air shutter to adjust the size of
the window. A long screw can be cumbersome and does not provide any
indication to the user as to the position of the air shutter.
[0052] FIGS. 3, 3A and 3B illustrate another embodiment of a
heating device 10' and a fuel delivery system 40' compatible with
the heating device 10'. Numerical reference to components is the
same as previously described, except that a prime symbol (') has
been added to the reference. Where such references occur, it is to
be understood that the components are the same or substantially
similar to previously-described components.
[0053] As can be seen in FIG. 3, a direct vent heating device 10'
can have a housing 20' which encloses a sealed chamber 14' with a
burner 135' inside the sealed chamber. FIG. 3A shows the heating
device 10' in a partially disassembled view. For example, part of
the outer housing 20', such as vents 13', 16' have been removed, as
has the floor 50'. This view shows some of the components of the
heating device 10', such as parts of the fuel delivery system
40'.
[0054] Turning now to FIG. 3B an embodiment of a fuel delivery
system 40' is shown that can be compatible with many different
heating devices including the heating device shown in FIG. 3. The
fuel delivery system 40' can include many of the components
previously described with respect to FIG. 2A, such as a pilot
assembly 180', an igniter 186' and a control valve 130'.
[0055] Also shown in FIG. 3B is a basket 52. The inner portion 54
of the basket 52 can be part of the sealed chamber 14'. The basket
52 can be used to store certain parts of the heating device such as
components of the fuel delivery system 40' within the sealed
chamber 14'. The basket 52 can also attach to the floor 50' and can
be configured to allow certain components, pipes, wires, etc. to
pass through the basket 52. Gaskets 56 can be used to seal access
points into the basket 52, floor 50' or other parts of the sealed
chamber 14'.
[0056] FIGS. 4A-E illustrate one embodiment of an improved air
shutter control 60. In some embodiments, the air shutter control 60
can replace the nozzle assembly 140 in FIG. 2A, similar to the
configuration shown in FIG. 3B. The burner transport line 137' can
connect to an inlet 62 on the air shutter control 60. Fuel can be
directed from the inlet 62 through a valve 64 to an injector
orifice or nozzle 66. The fuel can be injected into the mixing
chamber 157' to mix with air introduced through the air shutter
150' to pass into the burner delivery line 143' to then be
delivered to the burner 135' for combustion.
[0057] Looking now at FIG. 5, as shown, an air shutter 150' can
comprise a cylinder or other shape with a slot 80 sized to fit on
ledge 68 of the valve 64. The air shutter 150' can be configured to
move with the valve 64. In some embodiments, the air shutter 150'
can be fastened on to the valve 64 either at the ledge 68 or
otherwise. This can be done, for example, with a friction fit
between the slot 80 and the ledge 68. In some embodiments, the
nozzle 66 can also be configured to move with the valve. In some
embodiments, the valve 64, the nozzle 66 and the air shutter 150'
all rotate about the same axis. In some embodiments, the nozzle 66
and the air shutter 150' are coaxial.
[0058] The air shutter 150' can also have a slot or hole 82. In
some embodiments, the burner delivery line 143' has a corresponding
slot or hole 84. The overlap between the holes 82 and 84 can create
a window 155' that can allow air to pass into the mixing chamber
157' to mix with the fuel.
[0059] The air shutter control 60 can have a user interface surface
70. The user interface surface 70 can be used to control the
position of the air shutter 150' and conversely the amount of air
that can enter the mixing chamber 157'. The user interface surface
70 can comprise a knob connected to the valve 64. In other
embodiments, not shown, the user interface surface 70 can comprise
other types of mechanical controls such as a lever, a wheel, a
switch, or some other device to transfer a user's movement to move
the air shutter 150'. In other embodiments, also not shown, the
user interface surface 70 can comprise an electrical or computer
control, including but not limited to electrical buttons,
electrical switches, a touch screen, etc.
[0060] According to some embodiments, the user interface surface 70
can be outside of the sealed combustion chamber 14' and the air
shutter 150' can be inside of the sealed combustion chamber 14'.
For example, the flange 76 can be used as a fitting to attach the
air shutter control 60 to a basket 52 or to a wall of or the floor
50' of the sealed combustion chamber 14'. The injector orifice 66
and the part of the valve attached to the air shutter can be inside
the sealed combustion chamber 14' while the rest of the valve, the
flange 76 and the user interface surface 70 can be outside of the
sealed combustion chamber 14'.
[0061] FIG. 6 illustrates another embodiment of an air shutter
150''''. Numerical reference to components that are the same as
previously described use the same number but include a quadruple
prime symbol (''''). Where such references occur, it is to be
understood that the components are the same or substantially
similar to previously-described components.
[0062] In FIG. 6, as in some embodiments described above, the air
shutter can have a body which defines a slot or hole 82'''' that
overlaps with a corresponding slot or hole 84'''' in the burner
delivery line, creating a window 155'''' that can allow air to pass
into the mixing chamber 157'''' to mix with the fuel.
[0063] The air shutter can have a gear member 85 with a plurality
of shutter teeth 87 on its outer surface. The air shutter can also
have an air shutter control 60'''' with a user interface surface
70'''' that is able to control the air shutter by means of a shaft
73 to which is secured to control teeth 75 that cooperate with the
shutter teeth 87. When a user rotates the user interface surface,
the shaft 73 and control teeth 75 rotate, the control teeth
applying a force to the shutter teeth 87 which rotates the shutter
teeth, the body of the shutter and, thereby, the slot or hole
82'''', increasing or decreasing the size of the window. In some
embodiments the control teeth 75 are part of a collar 79 that
surrounds the shaft 73. In other embodiments the control teeth are
part of the shaft itself.
[0064] In various embodiments the shutter teeth 87 and control
teeth 75 have a variety of designs. They can be cut, for example,
as spur gears, bevel gears, helical gears, or any other tooth
design known in the art. Additionally, various embodiments may have
different tooth designs for the shutter teeth 87 and the control
teeth 75. For example, the control teeth may be cut as a worm gear
while the shutter teeth may be cut as a spur gear or a helical
gear.
[0065] The gear ratio between the shutter teeth 87 and control
teeth 75 can vary across different embodiments. In some embodiments
where spur gears are used, the ratio of shutter teeth to control
teeth can be between about 1.5 and about 2. In some embodiments it
can be between about 2 and about 3, between about 3 and about 5,
between about 4 and about 7, or between about 5 and about 8. In
some embodiments the ratio can be greater than 8. In some
embodiments, the ratio can be between about 1.5 and about 8,
between about 2 and about 8, between about 3 and about 8, between
about 4 and about 8, or between about 5 and about 8. In some
embodiments, it can be between about 1.5 and about 16, between
about 2 and about 16, between about 4 and about 16, between about 6
and about 16, or between about 8 and about 16.
[0066] Desirably, but not always, at least 120 degrees of rotation
of the user interface surface 70'''' (and/or shaft 73) is required
to change the air shutter from a minimum airflow position with the
window 155'''' fully closed or substantially fully closed, to a
maximum airflow position with the window 155'''' fully open or
substantially fully open. In other embodiments the gear ratio can
be configured such that the user interface surface 70'''' must
rotate at least 150, 180, 210, 240, 270, 300, 330, or 360 degrees
in order to change the air shutter from a minimum airflow position
to a maximum airflow position. This air shutter adjustment offers
the user improved control over the airflow that mixes with the
fuel. In embodiments where even more precise control of the airflow
is desired, the gear ratio can be set such that more than a 360
degree rotation of the user interface surface 70'''' is required to
change the air shutter from a minimum airflow position to a maximum
airflow position. In various embodiments at least 420, 480, 540,
600, 660, or 720 degrees of rotation may be required.
[0067] In some embodiments, it can be preferable for the user
interface 70'''' and/or the shaft to rotate between about 120 and
about 360 degrees to change the air shutter from a minimum airflow
position to a maximum airflow position. In some embodiments, the
user interface and shaft may rotate between about 120 and about 720
degrees, between about 180 and about 720 degrees, between about 360
and about 720 degrees, or between about 540 and 900 degrees to
change the air shutter from a minimum airflow position to a maximum
airflow position. In some embodiments, the user interface and shaft
may rotate between about 120 and about 180 degrees, between about
180 and about 270 degrees, between about 270 and about 360 degrees,
between about 360 and about 450 degrees, between about 450 and
about 540 degrees, between about 540 degrees and about 630 degrees,
or between about 630 and about 720 degrees to change the air
shutter from a minimum airflow position to a maximum airflow
position.
[0068] In some embodiments the size of the window 155'''' formed
between the air shutter slot or hole 82'''' and the burner delivery
line slot or hole 84'''' can be adjusted. With reference to FIG. 6,
the size of the window can be defined in terms of an angle .theta.
formed by two lines emanating from the center of a cross-section of
the shutter and in the same plane as the cross-section, where one
line passes through a first edge of the window 155'''' when fully
open, and where the second line passes through a second edge of the
window 155'''' when fully open. For example, a window 155'''' that
occupies a third of the circumference of the shutter when the
window is fully open would have an angle .theta. of 120 degrees.
Various embodiments of the air shutter can have a window that is at
least 5, 10, 20, 30, 40, 45, 50, 60, 70, 80, 90, 100, 110, 120,
130, 140, 150, 160, 170, or 180 degrees. Various embodiments of the
air shutter can have a window that is less than 5, 10, 20, 30, 40,
45, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170, or
180 degrees. Varying the rotation required to change the air
shutter from a minimum airflow position to a maximum airflow
position can be done by adjusting the gear ratio, as described
above, by adjusting the size of the window, or by adjusting both
the gear ratio and the size of the window.
[0069] Additionally, some embodiments can have two separate air
shutter controls, an air shutter control with a gear ratio set for
coarse control of the air shutter and an air shutter control with a
gear ratio set for fine control of the air shutter. The air shutter
control set for coarse control can interlock with the shutter teeth
at one side of the gear member, and the air shutter control set for
fine control can interlock with the shutter teeth at another side
of the gear member. Both of the air shutter controls can have
different gear ratios with respect to the shutter teeth, such that
the coarse air shutter control requires less angular motion than
the fine air shutter control to make the same adjustment to the air
shutter. Alternatively, an air shutter can have two gear members,
one of which interfaces with a coarse air shutter control and
another of which interfaces with a fine air shutter control.
[0070] The shaft position relative to the axis of rotation of the
shutter depends on the design of the shutter teeth 87 and the
control teeth 75. In some embodiments the shaft 73 is substantially
perpendicular to the axis of rotation of the shutter 150'''', as
illustrated by FIG. 6. While not a necessary part of the invention,
a shaft substantially perpendicular to the axis of rotation of the
shutter 150'''' offers some advantages. For example, it will
typically allow the air shutter control 60'''' to be on the same
side of the gas fireplace assembly as the dials for the control
valve, in contrast to the positioning seen in FIG. 3B. Having the
air shutter control and the dials for the control valve near each
other can simplify operation of the gas fireplace assembly.
[0071] As discussed with respect to various embodiments above, the
air shutter control 60'''' can have a user interface surface 70''''
that can comprise a knob, other types of mechanical controls, or an
electrical or computer control. In embodiments of FIG. 6 with an
electrical or computer control, a stepper motor can be used to
rotate the shaft 73, allowing for precision control of the air
shutter 150''''. The air shutter control can also be designed to
provide some indication of the position of the air shutter.
[0072] Additional details of the air shutter 150'''' and the air
shutter control are disclosed in U.S. patent application Ser. No.
12/797,446, which is hereby incorporated by reference in its
entirety.
Direct Vent Fireplace with Cooling Structure
[0073] The embodiments described in FIGS. 1-5 disclose a gas
fireplace assembly with several control system embodiments to
control the performance parameters of the gas fireplace. Although
the description of the embodiments of FIGS. 7 and 8 provided below
do not include specific details of a control system, it is
understood that the following direct vent fireplace with cooling
structure embodiments can include any of the above described
control systems, in whole or in part, and any combination thereof
of the various components or features of the control systems
described above.
[0074] In the illustrated embodiments of FIGS. 7 and 8, another
embodiment of a direct vent gas fireplace assembly, or heating
device 10'', is shown. Numerical reference to components is the
same as previously described, except that a double prime symbol
('') has been added to the reference. Where such references occur,
it is to be understood that the components are the same or
substantially similar to previously-described components.
[0075] FIG. 7 shows a perspective view of the heating device 10''
in an assembled view, with the exception of the front grill of the
inlet vent 13'' having been removed for clarity. The control system
and fuel delivery system details are not shown; however, the
control system and fuel delivery system can be any of the
embodiments or a combination thereof, as described in detail above.
FIG. 8 shows the heating device 10'' in a partially disassembled
view. For example, part of the control system and fuel delivery
system has been removed for clarity.
[0076] The heating device 10'' can include a housing 20'' that
encloses a sealed combustion chamber 14'' with a burner 135''
inside the sealed combustion chamber. The sealed chamber 14'' can
be sealed to the outside with the exception of the air intake 24''
and the exhaust 26''. Heated air does not flow from the sealed
chamber 14'' to the surroundings; instead air, for example from in
an interior room, can enter an inlet vent 13'' into the housing
20''. The heating device 10'' can further include an air
circulation system 80 having one or more of a heating channel 15'',
inlet vent 13'', climate control outlet vent or exhaust 16'',
cooling fan 82, cooling channel 84, and climate control fan 86.
[0077] As shown, the air circulation system 80 can be configured to
deliver heated air to the interior room, or interior space, where
the heating device 10'' is installed, and to deliver cooling air to
a front face 17 of the heating device 10''.
[0078] The heating channel, conduit, or passage 15'' can be
disposed about, and extend proximate, the external surface of the
sealed combustion chamber 14''. The channel 15'' can include a
spaced gap between the sealed combustion chamber 14'' and the
fireplace housing 20''. The channel 15'' can be located on one or
more sides of the fireplace assembly. For example, as shown, the
channel 15'' can be located on the bottom side, the back side, and
the top side of the fireplace assembly. In some embodiments, the
channel 15'' can be located on the right side and/or left side of
the fireplace assembly. The fluid channel 15'' can be sufficiently
proximate to the combustion chamber to heat the fluid, or room air,
which is delivered through the channel 15''. In some embodiments,
the channels can share a wall with the housing defining the
combustion chamber 14''.
[0079] With continued reference to FIGS. 7 and 8, the channel 15''
can be configured to receive interior room air, or climate control
air, from the climate control air inlet vent 13'', deliver the
climate control air about a proximity of the sealed combustion
chamber 14'', and expel heated climate control air out of the
climate control outlet vent 16''. Heat emitted by the combustion of
fuel and combustion air can be transferred to the climate control
air delivered through channel 15'' and generate the heated air.
[0080] The term "climate control" as used herein, is a broad term
used in its ordinary sense, and includes features directed to the
distribution of warmed fluid, such as, for example, interior room
air, outside ambient air, or the like, and any combination thereof,
to influence or control the room temperature where the fireplace is
installed. For example, climate control air is distinguished from
combustion air; however, in some embodiments, climate control air
can provide the source of combustion air to the chamber 14'',
and/or the combustion air source can provide at least a portion of
the climate control air.
[0081] The climate control fan 86 is configured to deliver, or
blow, air through the channel 15''. The climate control fan 86 can
be located adjacent the channel 15'', or generally positioned
anywhere in fluid communication to the channel 15'' flow path. The
climate control fan 86 can have a variety of typical fan features,
e.g. directed flow vents, variable speed controls, or the like. The
climate control fan 86 can be a transflow, or centrifugal,
configuration fan. In some embodiments, the climate control fan 86
can be an array of one or more axial propeller fans. In some
embodiments, the air flows through the channel 15'' by natural
convection, without the assistance of a fan.
[0082] The air circulation system 80 can include a second channel,
or the cooling channel 84. The cooling channel 84 can be configured
to deliver output air from the cooling fan 82 to front face 17,
i.e. the exterior surface of the window 22''. In the illustrated
embodiment in FIG. 8, the cooling channel 84 extends under the
floor 50'' of the sealed combustion chamber in a forward direction
toward the front face 17, and then extends upward on a lower
portion of the front face 17.
[0083] The cooling channel 84 can include a cooling exhaust vent 88
located at the downstream end of the cooling channel. The cooling
exhaust vent 88 can be positioned proximate or adjacent to, the
window 22'' and front face 17. The air can cool the exterior
surface of the window 22'' to a surface temperature that can be
safe to the touch. The cooling channel 84 can deliver a portion of
air received by the channel 15'' through the inlet vent 13''. In
some embodiments, the cooling channel can be configured to receive
air directly from any air source, e.g. the interior room, outside
ambient air, or the like. In addition, the cooling channel 84 and
cooling fan 82 can deliver air from a dedicated inlet vent.
[0084] As shown, the cooling exhaust vent 88 generally extends, or
spans, substantially the full width of the fireplace assembly's
front face 17. In some embodiments, the cooling exhaust vent 88 can
span a portion of the front face, e.g. 1/4, 1/2, 3/4, substantially
the entire width, or the like, across the front face 17. The vent
88 can be configured to direct air evenly across and over the
window 22'' exterior surface via a constant geometry exit area
across the vent 88 width. In some embodiments, the cooling exhaust
vent 88 can be configured to direct increased proportions of the
cooling air flow mass to specific portions of the window. For
example, increased cooling air flow can be directed to localized
hot spots that have relatively higher surface temperatures, or to
portions of the window 22 most likely to incur user contact, such
as adjacent a control knob or a door or window handle.
[0085] In addition, though FIG. 8 shows the cooling exhaust vent 88
only on the bottom of the window, it is to be understood that the
cooling exhaust vent 88 can be located at many different locations
along the front face 17. For example, the cooling exhaust vent 88
can be located along one or more of the sides, the top, and/or the
bottom of the front face 17. In addition, the cooling exhaust vent
88 can include one or more cooling fans 82 and can comprise one or
more cooling channels 84 which may or may not be connected.
[0086] FIGS. 9-11 illustrate one embodiment of the cooling
structure where it comprises multiple cooling channels. In the
illustrated embodiment, the cooling structure comprises three
connected cooling channels: a bottom channel 61, a left side
channel 63, and a right side channel 65. In FIGS. 10 and 11, the
arrows represent the path of airflow through the cooling
structure.
[0087] In some embodiments, the rear side 53 of the cooling
structure can have a window mounted to it, and the air that exits
the cooling structure will directly cool the exterior surface of
the window, as described above. In other embodiments, the cooling
structure can have windows mounted to the rear side 53 and the
front side 51 such that the air that exits the cooling structure
will enter the space between the windows to thereby cool the front
window.
[0088] As illustrated in FIG. 10, some air that exits the bottom
channel can exit directly toward the front face, helping cool it,
while some air that exits the bottom channel can flow into other
channels. In some embodiments, as described above, all of the air
that exits the bottom channel can go to immediately cool the front
face. In other embodiments, all of the air that exits the bottom
channel can enter other channels.
[0089] Air can exit the channels to cool the front face through a
variety of means. In some channels, the air can exit through one or
more larger outlets 81. In other channels, the air can exit through
a plurality of smaller outlets 83 that can be round, ovular, or any
other shape. Still other channels such as the bottom channel
illustrated in FIGS. 9-11 can be configured such that air exits
through multiple types of openings, such as larger 81 or smaller
outlets 83. Additionally or alternatively, channels can be
configured such that air exiting the channel to cool the front face
can exit at varying angles relative to the length of the channel.
For example, the bottom channel illustrated in FIGS. 9-11 is
configured such that air exiting through the smaller outlets 83
exits at a different angle than air exiting through the larger
outlets 81.
[0090] It is understood that any type or combination of openings
that allow air to exit the channels to cool the front face can be
used. Similarly, any exit angle or combination of exit angles can
be used in the cooling structure. Different sizing and positioning
of openings can focus airflow on desired areas, such as areas with
relatively high surface temperatures or areas more likely to incur
user contact, as discussed above. Additional channels can provide
additional locations to position openings. For example, in some
embodiments, the cooling structure can be the same as the
embodiment illustrated by FIGS. 9-11, but with openings in the top
channel sized and spaced substantially similar to those used in the
side channels 63, 65.
[0091] Returning to FIG. 8, the cooling fan 82 is configured to
blow air through the cooling channel 84. In embodiments where there
are multiple cooling channels 84, as illustrated in FIGS. 9-11, the
cooling fan 82 can blow air into one or more of the cooling
channels. The following disclosure regarding the cooling fan 82 is
understood to apply equally to embodiments with multiple cooling
channels as it does to embodiments with a single cooling channel.
Descriptions of the cooling channel 84 refer to one, some, or all
of the cooling channels.
[0092] The cooling fan 82 can be located adjacent the cooling
channel 84 and the channel 15'', or generally positioned anywhere
in fluid communication to the cooling channel 84 and the channel
15'' flow path. As mentioned previously, the cooling channel 84 and
cooling fan 82 can deliver air from a dedicated inlet vent which
may or may not be connected to the channel 15''. The cooling fan 82
can have a variety of typical fan features, e.g. directed flow
vents, variable speed controls, or the like. The cooling fan 82 can
be a transflow, or centrifugal, configuration fan. In some
embodiments, the cooling fan 82 can be an array of one or more
axial propeller fans.
[0093] The cooling fan 82 can generally span a sufficient width of
the cooling channel 84 to provide a consistent and even flow of
cooling air across a substantial portion of the window 22''. In
some embodiments, the cooling fan 82 can span 1/4, 1/2, 3/4, the
entire width, or any other sufficient portion of the cooling
channel 84 width, or the window 22'' width, that is sufficient to
deliver cooling air over the window 22''. The cooling fan 82 can be
sized to provide sufficient capacity, or air mass flow rate
capability, to cool the exterior surface of the window 22'' to safe
temperatures. The cooling airflow exiting the vent 88 can generally
flow up substantially the full height off the window 22''. In some
embodiments, the cooling air can flow over a portion of the window
22'' height, e.g. 1/4, 1/2, 3/4, substantially the entire height,
or the like, up the window 22''. The cooling fan 82 can be
positioned under the sealed combustion chamber 14'' and generally
upstream of the climate control fan 86; thus, the cooling fan can
be located between the inlet vent 13'' and the climate control fan
86. In some embodiments, the climate control fan 86 can be located
upstream of the cooling fan 82.
[0094] The cooling fan 82 can generally be positioned in a first
half of the channel 15'' extending from the air inlet vent 13''. As
described above, the channel 15'' can define a flow path from the
front face 17 under the floor 50'', up the back side of the chamber
14'', and over the top side of the chamber 14'' to the outlet vent
16''. In some embodiments, the cooling fan 82 can be positioned in
a first 1/4, 1/3, 2/3, or any portion thereof, of the channel 15''
flow path. Similarly, the cooling fan 82 can be positioned in any
portion of the channel 15'' such that the air drawn into and blown
out of the fan 82 is not substantially heated by the combustion in
the sealed combustion chamber 14''. In some embodiments, heated air
can be drawn into the cooling fan 82 and directed to the window
22''. In some embodiments, the cooling fan 82 can be located
outside of the channel 15''.
[0095] The cooling fan 82 can include a control module, which is
not shown, that is coupled to, and can control, the operation of
the fan 82 and the burner 135''. The control module can cool the
window 22'' by activating the fan 82 when the burner 135'' is in
operation, or activated. The control module can further deactivate,
or turn off, the burner 135'' when the control module receives
input, or a lack thereof, that the cooling fan 82 is not
functioning properly. In this manner, the burner 135'' turns off
and prevents the window 22'' from becoming excessively hot.
[0096] In some embodiments, the control module controls the cooling
fan 82 to remain on and blowing cooling air to the window 22''
after the burner 135'' is deactivated. In some embodiments, the
cooling fan 82 is controlled to remain on for a predetermined
amount of time after the burner 135'' is turned off. The cooling
fan can remain on for two, five, ten, or any number of minutes to
maintain a cool window temperature. The extended cooling fan
operation prevents excessive window temperatures that can result
from the transfer of residual heat in the walls, or structure, of
the sealed combustion chamber, or firebox. The predetermined time
can be factory set, or can be adjusted by the user during or after
installation. In some embodiments, the predetermined time can be
adjusted via a control module interface, which is not shown.
[0097] In some embodiments, the fireplace assembly can include a
thermocouple proximate the window 22'', or more preferably an
exterior surface of window 22''. The thermocouple can provide a
feedback control system with the control module that can keep the
cooling fan 82 activated until the window achieves a predetermined
safe temperature. The predetermined temperature can be factory set
or selected by the user after installation.
[0098] The direct vent heating device 10'' can provide efficient
heating and does not require a chimney for safe operation. The
direct vent heating device 10'' can direct outside ambient air
through a combustion vent system 90 for heat generating combustion,
and thus does not deprive interior living spaces of oxygen or
heated air.
[0099] The heating device 10'' can include a combustion vent system
90, or flue, that can extend outward from the heating device 10''
and be directed horizontally through an external wall or vertically
to a roof. As shown, the vent system 90 includes two collinear
ducts, the inner and outer flue, or the combustion air intake duct
24'' and the combustion air exhaust duct 26''. The illustrated air
exhaust 26'' is smaller in diameter than air intake 24'', and air
exhaust 26'' extends within the larger air intake 24'' and
generally shares a common longitudinal axis. The internal air
exhaust 26'' generally directs combustion exhaust gas out of the
fireplace. The external air intake 24'' generally draws external,
or outside, air into the fireplace through the annular space
between the smaller diameter combustion exhaust 26'' and the larger
diameter air intake 24''. External air is generally the ambient air
outside of the building structure being heated. In some
embodiments, the air intake 24'' can be the smaller diameter and
extend within the larger diameter air exhaust 26''. The collinear
vent system can improve the system efficiency of heating device
10'' because the air entering in the annular space is warmed by
passing over and about the heated combustion exhaust 26'' prior to
combustion at the burner 135''.
Dual Direct Vent and Vent Free Fireplace
[0100] The embodiments described in FIGS. 1-8 disclose a gas
fireplace assembly with several control system embodiments to
control the performance parameters of the gas fireplace and a
cooling structure for a face of the fireplace. Although the
description of the embodiments of FIGS. 12-15 provided below does
not include specific details of a control system, it is understood
that the following duel direct vent and vent-free fireplace
embodiments can include any of the above described control systems,
in whole or in part, and any combination of the various components
or features of the control systems described above.
[0101] In the illustrated embodiments of FIGS. 12-15, another
embodiment of a heating device 10''', a dual-function direct vent
and vent free gas fireplace assembly, is shown. The heating device
10''' is able to function in either a direct vent configuration or
a vent free configuration. A direct vent fireplace, as described
above, can be vented out through the wall or through the roof to
the exterior of a structure, building, or home. A vent free gas
fireplace does not require an external vent or a chimney, rather
the exhaust is vented directly into the interior of a structure,
building, or home. The heating device 10''' can include many
similar characteristics and/or features as the heating device 10''
of FIGS. 7 and 8. Numerical reference to components is the same as
previously described, except that a triple prime symbol (''') has
been added to the reference. Where such references occur, it is to
be understood that the components are the same or substantially
similar to previously-described components.
[0102] With reference to FIG. 12, the dual-function direct vent and
vent free gas fireplace 10''' is shown in an assembled view. The
control system and fuel delivery system details are not shown;
however, the control system and fuel delivery system can be any of
the embodiments or a combination thereof, as described in detail
above or as further described below. FIG. 13 shows the heating
device 10''' in a partially disassembled cross-section view. For
example, parts of the control system and the fuel delivery system
have been removed for clarity.
[0103] With reference to FIGS. 12 and 13, the heating device 10'''
desirably can function as both a direct vent fireplace system or as
a vent free fireplace system. The dual system fireplace desirably
can provide suitable heat in a variety of scenarios, improving the
operability of the fireplace in general, e.g. operable both with
and without a source of electricity. The fireplace 10''' can
advantageously include at least two features that can accommodate
the interchangeable direct vent and vent free configurations within
the single fireplace. These features can include a closing
mechanism for a combustion chamber exhaust outlet 95 and a
removably installed sealed door 92 and/or window 22'''.
[0104] The fireplace 10' can include an exhaust pipe 26''' that can
maintain fluid communication between the sealed combustion chamber
14''' and the ambient environment for expelling the combustion
exhaust from the burner 135''' disposed in the sealed combustion
chamber. As has been explained herein, the exhaust pipe 26''' is
used in the direct vent configuration. The combustion chamber
outlet 95 at the exhaust pipe 26''' can include an exhaust cover,
or baffle 96, that can be positioned over the combustion chamber
exhaust outlet 95 to seal the combustion chamber 14''' from the
ambient environment. This can allow the heating device 10''' to be
used in the vent free configuration.
[0105] The exhaust cover 96 can fit over the exhaust outlet 95 and
prevent heated air from exiting the chamber 14''' and colder
external ambient air from entering the chamber. The cover 96 can
have a sealing member, or gasket, non-metallic interface, or the
like, to facilitate the sealing feature of the cover. The sealing
member can be capable of exposure to the high temperatures of the
chamber 14'''.
[0106] It should be noted that the exhaust cover 96 as shown, does
not cover the air intake 24'. In some embodiments, the fireplace
10''' can continue to draw, via a pressure differential between the
air intake and the combustion at the burner, or the like, external
ambient air to combust at the burner 135'''. In some embodiments,
the air intake 24' can similarly be closed when using the heating
device 10''' in the vent free configuration. As will be described
in more detail below, for vent free operation the window 22''' can
be opened or removed to allow for proper exhaust and/or air inflow.
As will be understood, opening or removing the door 92 and/or
window 22''' unseals the previously sealed combustion chamber 14'''
and allows for the exchange of air and exhaust between the
combustion chamber and its surroundings.
[0107] With particular reference to FIG. 13, the cover 96 can be
pivotably coupled to a controller, or arm member 98, that desirably
can selectively open or close the exhaust outlet 95. The controller
98 can position the cover 96 over the exhaust pipe 26''' to
completely close the exhaust, or can position the cover adjacent
the exhaust 26''' to completely open the exhaust. In addition, the
controller 98 can position the cover 96 anywhere between these two
positions. Alternatively the cover could have a number or fixed
positions or only partially cover and/or uncover the exhaust pipe
26'''. The controller 98 can be any form of motion inducing device,
e.g. mechanically via a cam, an arm, or the like, or
electronically, pneumatically, magnetically, or the like.
[0108] The controller 98 can be coupled to the cover 96 and
removably coupled, e.g. magnetically, spring-loaded, interference
fit, or the like, to the window 22''' at a window coupling 97. The
controller 98 can release from the window coupling 97 when the
window is opened or removed from a face of the fireplace. The cover
96 and/or controller 98 can be biased such that the cover 96 moves
to the closed position when the controller 98 is released from the
window coupling 97. The cover 96 and/or controller 98 can be biased
by a spring, or the like, to pivotably or laterally move into
position over the exhaust outlet 95. Thus, the exhaust outlet 95
can be automatically closed, or substantially sealed, upon opening
or removal of the window 22'''. This can facilitate moving the
heating device to the vent free fireplace configuration.
[0109] In some embodiments, the cover 96 can be positioned by other
automated, or automatic, means upon opening or removal of the
window and/or door, which are known to those of ordinary skill in
the art. In some embodiments, the controller 98 can be a spring
loaded member in a compressed configuration with the window
installed, thereby urging the cover 96 away from the exhaust;
however, removal of the window uncompresses the spring and urges
the cover 96 toward the exhaust 26'. In some embodiments, the
controller 98 can be one or more arm members coupled to an interior
surface of the combustion chamber, e.g.
[0110] top, front, back, right side, left side, or the bottom of
the combustion chamber. In some embodiments, the controller 98 can
be a solenoid powered to prevent spring-biased movement of the
cover 96 over the exhaust 26''', and upon loss of electricity the
solenoid allows the spring-biased cover 96 to seal off the exhaust
pipe 26' from the chamber.
[0111] The fireplace 10''' can be modified from the direct vent
configuration to the vent free configuration manually or
automatically. In some embodiments, the exhaust cover can be moved
to the closed position to close and seal the chamber exhaust, via
any of the various means described above as well as similar or
equivalent means not described. In the event of a loss of
electricity, proper functioning of the fireplace electronic
components may be prevented. For example, electronically controlled
fuel valves, regulators, and/or circulation fans may not work. To
maintain continued heat generation to a building interior, the
direct vent fireplace 10''' can be readily and safely converted to
a vent free fireplace 10''' by closing the cover 96 and opening the
sealed face of the chamber 14'''.
[0112] The fireplace 10''' can include a door 92 disposed on the
front face of the fireplace, coupled, in one embodiment, by at
least one hinge 91. The door 92 can include a frame disposed about
a window 22'''. The frame can be any suitable material, e.g.
metallic, or the like. The window 22''' can provide a clear visual
of the flame, logs, or the like, disposed within the chamber and
configured to provide a natural flame appearance. The door 92 can
lockingly seal and engage the chamber 14'''. The door can include a
handle 94 that can control a locking, or latching mechanism, and
provide a feature to securely and safely hold onto, or grab, the
door 92 to open, close, or generally control the door.
[0113] The window 22''' and/or door 92 can establish a sealed side
face of the sealed combustion chamber 14''' when the fireplace
10''' is configured to operate as a direct vent heating device. In
particular, the window 22''' can establish the front side face of
the fireplace. In some embodiments, the side of the fireplace 10'''
can be any face, or surface, of the fireplace that extends from the
bottom to the top of the fireplace, or an intermediate portion
thereof. In some embodiments, the window 22''' can be removable to
provide an open front face of the fireplace 10''' and provide the
heat transfer from the fireplace through the open face to the
building interior, rather than, or in combination with, fan-driven
forced ventilation. In some embodiments, the window 22''' can be
positioned on any face of the fireplace 10''', e.g. front, back,
right, left, top, or bottom.
[0114] The window 22''' can be a variety of different
configurations, e.g. single piece, multi-piece, framed, with or
without handles, or the like. The window 22''' can be fabricated
and have material characteristics similar to the windows 22, 22',
22'' described above. In some embodiments, only a portion of the
window 22''' can be removed from sealed engagement with the
fireplace front side face, or any face thereof. In some
embodiments, the entire window 22''' or a portion of the window
22'' can be completely removed from the face of the heating device,
such that the window is either installed on the fireplace or not
installed on the fireplace. In some embodiments, the window 22'''
can be removed from the door 92. In some embodiments, the window,
or portion thereof, is hingedly, such as by hinges 91, or the like,
coupled to the fireplace 10''', and can be rotated or pivoted about
the coupling to disengage the sealed interface between the window
and the fireplace 10''' front face 17'. The window can be pivotably
controlled by a rotatable handle, much like a typical casement
window device. The window can be slidably movable to open all or a
portion of the fireplace face. In some embodiments, a multi-piece
window can be rotated and folded away from the front face of the
fireplace.
[0115] Though a window 22''' is described above, it should be
understood that a window is not required and that the window can be
replaced with other structures, including heat radiating
structures. Also, any part of the heating device 10''' can be
opened or removed to move the heating device 10''' to the vent free
configuration, so long as by so doing the combustion chamber is no
longer sealed allowing the free exchange of air and exhaust between
the combustion chamber and the interior room environment, or the
environment where the heating device is located. For example, the
heating device 10''' can be a cast iron stove/fireplace or have the
appearance of a cast iron stove/fireplace. In such an embodiment,
it is unlikely that there will be a window, but a door may be
located at the front face, or on another surface that can serve the
same or similar purposes as the window described herein.
[0116] In some embodiments, opening the window or door can expose
an inlet vent that was previously blocked to allow air to enter
through the newly exposed and opened inlet.
[0117] In some embodiments, the fuel delivery system can include
electronic controllers and/or electronic mechanisms, e.g.
electronic regulator, valves, air shutter, or the like (not shown).
The fuel delivery system components can be similar to the fuel
delivery system 40 described above, or the systems and devices
disclosed in the incorporated U.S. Pat. No. 7,434,447 and U.S.
patent application Ser. No. 12/797,511. Upon loss of electricity,
the electronic regulator, and/or fuel valve, can be configured to
automatically shut down, or deactivate, to prevent accumulation of
uncombusted fuel within the combustion chamber 14''' should the
flame at the burner 135''' extinguish. In some embodiments, the
electric valve assembly controlling direct vent combustion can
become inoperable when electric power is lost to the fireplace
10'''. In some embodiments, a loss of electricity to the fireplace
10''' can render the unit useless as a heat source.
[0118] In some embodiments, the fuel delivery system can
advantageously include a both a manual and an automatic control
valve, where the control valve is used to control the amount of
fuel flowing to the burner. The manual valve can be configured to
provide less fuel to the burner and thereby provide a lower energy
output as compared to the automatic control valve. The manual valve
can be operated manually by a control knob on the fireplace 10'''.
The reduced energy, e.g. decreased BTU/hr output of the flame, or
the like, can eliminate or reduce the volume of combustion air
emissions emitted into the building interior and maintain safe air
quality conditions, even with the combustion chamber exhaust outlet
95 covered, or closed, by the exhaust cover 96. In some
embodiments, the burner and/or flame characteristics can be
controlled by the first knob 131''' and/or the second knob
132'''.
[0119] In some embodiments, the coupling 97 can be part of a
circuit, such that opening the window also opens the circuit. The
circuit can be connected to the electronic powered automatic
control valve which powers down when the circuit is opened. Fuel
flow can then be directed to the manual valve operating at a lower
BTU/hr rating. Alternatively, a button switch may be depressed or
released when the window is opened or removed, thereby deactivating
the automatic control valve.
[0120] In some embodiments, the fuel delivery system can
advantageously include a second valve and/or other fuel system
components (not shown), that can be manually opened, controlled,
and ignited. The second valve can, either alone, or in combination
with a second burner (not shown), provide a lower energy output. In
some embodiments, the valve can be operated manually by a control
knob 99 disposed on an outer surface of the fireplace 10'''. The
reduced energy, e.g. decreased BTU/hr output of the flame, or the
like, can eliminate or reduce the volume of combustion air
emissions emitted into the building interior and maintain safe air
quality conditions, even with the combustion chamber exhaust outlet
95 covered, or closed, by the exhaust cover 96. In some
embodiments, the burner and/or flame characteristics can be
controlled by the first knob 131''' and/or the second knob
132'''.
[0121] With reference to FIG. 12, the dual-function direct vent and
vent free fireplace 10''' can further include one or more oxygen
depletion sensors (ODS) 106. The ODS can include the various
features and characteristics disclosed in U.S. Pat. No. 7,434,447
and U.S. patent application Ser. No. 12/797,511, incorporated by
reference as described above. The ODS can include a pilot and a
thermocouple arranged such that the flame from the pilot heats the
thermocouple and the heat indicates oxygen levels, for example
reduced oxygen levels can result in an extinguished pilot flame and
decreased thermocouple temperatures. The oxygen depletion sensor
can indicate when oxygen levels reach dangerous low levels. In some
embodiments, the ODS can always be operational, for example, when
the fireplace 10''' is operating in the direct vent mode and
external ambient air provides the combustion air to the burner. In
some embodiments, the ODS can become operational upon opening or
removal of the window 22''' and the closure of the exhaust 26'''.
The ODS can be particularly suitable for operation in embodiments
whereby the external ambient air intake is closed in the vent free
configuration.
[0122] In some embodiments, the fireplace 10''' can include
multi-fuel capability, allowing the fireplace to operate on one
fuel among a group of multiple types of fuel, e.g. natural gas,
propane, or the like. Such a dual fuel configuration, described
above, and further described in incorporated U.S. Pat. No.
7,434,447 and U.S. patent application Ser. No. 12/797,511, can
provide a regulator configured to function within distinct pressure
ranges, ranges that are typical of the proposed gases, or fuels,
for the fireplace operation.
[0123] Turning now to FIGS. 14 and 15, the flow circulation path
within the fireplace 10''' is shown for an embodiment of a direct
vent configuration. The fireplace 10''' is shown with two
circulation fans, a first fan 100 for a combustion vent system 90'
and a second fan 86' for a heating air circulation system 80'.
Together the two flow systems 80' and 90' can provide complete, or
substantially complete, combustion and consistent heat transfer to
the room interior where the fireplace 10''' is installed and
functioning in a direct vent configuration.
[0124] The circulation flow path of the combustion vent system 90'
is shown by the arrows depicted in FIG. 14. The combustion vent
system 90' can include a combustion air intake 24''', an exhaust
26''', a combustion air channel 25, a baffle 102, and a combustion
fan 100. The combustion system 90' can be configured similar to the
systems and embodiments described above, bringing external ambient
air from the air intake 24''', into the combustion chamber 14'''
and then expelling the exhaust air out the exhaust 26''' to the
external ambient environment. Thus, the interior air generally does
not take part in the combustion process and can generally avoid
being either the combustion air or mingling with the exhaust
emission from the fireplace.
[0125] The combustion air intake and exhaust are desirably
collinear as described above with respect to heating device 10'''.
The combustion air channel 25 can be a spaced gap between two
panels of the chamber 14''', such as between an interior panel 34
and an exterior panel 36 that establish the outside boundary, or
surfaces, of the sealed combustion chamber 14'''. The channel 25
desirably extends along a top portion of the chamber 14''', then
down a rear portion of the chamber to the base of a floor. The
channel 25 desirably exits to the burner 135''' at the bottom of
the combustion chamber 14''', where the combustion air drawn into
the chamber via the combustion fan 100 desirably is directed to the
burner and to the window 22'''. The interior panel, or conduit
panel 36, desirably can be parallel to the rear firebox panel 34
within the sealed combustion chamber 14'''.
[0126] The combustion fan desirably can be disposed within the
combustion chamber 14''' to direct the incoming ambient combustion
air toward the burner 135''' and the window 22'''. In some
embodiments, the baffle 102 can be disposed adjacent the floor and
can direct the combustion air toward the window 22''' and/or the
burner 135'''. The use of combustion fan 100 to force combustion
air toward the burner can increase, or improve, the mixing of fuel
and combustion air thereby improving combustion characteristics at
the burner flame. For example, improved combustion can result in
cleaner combustion of the fuel and reduced air pollutants in the
combustion emissions of the fireplace 10'''.
[0127] The combustion fan 100 can generally be positioned in any
suitable arrangement within the chamber 14'''. In some embodiments,
the combustion fan 100 can be positioned in a first 1/4, 1/3, 2/3,
the final 1/4, 1/3, or any portion thereof, of the heating channel
25 flow path, or accordingly, of the floor portion of the heating
channel 15'''. Similarly, the combustion fan 100 can be positioned
in any portion of the channel 15''', e.g. a first 1/4, 1/3, 2/3,
the final 1/4, 1/3, or any portion thereof, such that the air drawn
into and blown out of the fan 100 is not substantially over-heated
by the combustion in the sealed combustion chamber 14'''. In some
embodiments, the combustion fan 100 can be located outside of the
channel 15'''.
[0128] In some embodiments, ambient air can be drawn into the
combustion fan 100 and directed to the window 22'''. As shown, the
baffle 102 is angled with respect to the window 22 such that air
directed at the baffle 102 will flow upwards towards the burner
135''' or towards the window 22'''. As can also be seen, a small
gap is formed between the burner 135''' and the baffle 102. This
small gap can direct air flow to the window 22'''. This air flow
directed at the window can include ambient air at a lower
temperature than the exhaust air. As will be understood, the lower
portion of the window may be in close contact with the flames and
heat from combustion at the burner 135'''. Directing a flow of air
at the lower portion of the window can help cool the window
22'''.
[0129] The combustion airflow pushed by the combustion fan 100 can
generally flow up substantially the full height off the window
22''' on the chamber inside surface. In some embodiments, the
combustion air can flow over a portion of the window 22''' height,
e.g. 1/4, 1/2, 3/4, substantially the entire height, or the like,
up the window 22'''. In other embodiments, the combustion air can
flow over a portion of the window 22''' after first flowing through
cooling channels as described with reference to FIGS. 9-11. The
combustion fan 100 can be positioned within the sealed combustion
chamber 14'' and generally upstream of the baffle 102; thus, the
combustion fan 100 can be located between the air intake 24''' and
the window 22'''.
[0130] The circulation flow path of the fluid circulation system
90' is shown by the arrows depicted in FIG. 15. The fluid
circulation system 90' can include a vent inlet 13''', a heating
channel 15''', a climate control outlet vent or exhaust 16''', and
climate control fan 86'. The fluid circulation system 80' brings
interior air into a flow path disposed about the combustion chamber
14'''. Though the vent inlet 13''' is shown on the top of the
fireplace 10''', the vent inlet can function in a similar manner as
those discussed previously, including vent inlet 13 shown in FIG. 1
to draw into the fireplace 10''' to be heated within the
fireplace.
[0131] Advantageously, the interior air can cool the rear firebox
panel 34 surfaces of the fireplace 10''' chamber, and cool the
glass window 22''' while at the same time absorbing heat energy and
heating the air flow within the channel 15''', and then dispersing
the heated air out of the fireplace to heat the room interior.
[0132] As can be seen, the window 22''' can be a dual paned window
having a first pane 93 and a second pane 95. The second pane 95 can
form part of the sealed chamber and can be closest to the burner
135'''. The channel 15''' can run between the two panes of window
22''', cooling the window and decreasing the burn risk and fire
risk. Even when the fan 86' is not on or running, the dual paned
window creates an added barrier between the glass closest to the
flames and the room interior. This barrier can also be effective to
reduce the burn and fire risks.
[0133] The heating channel 15''' can extend from the air vent inlet
13''' disposed about the flue, or the combustion air intake 24'''
at a top portion of the heating device 10''', rearward between the
top portion of the fireplace and the top portion of the chamber
14'''. The channel 15''' then progresses downward and behind the
rear firebox panel 34 of the chamber 14''' to the volume underneath
the floor. The channel 15''' then proceeds from under the floor
through the space gap between the two panes 93, 95 of the dual
paned window 22''' on the door 92. The heating channel 15''' can
vary according to suitable geometry, and can take any form set
forth above. It can also comprise multiple cooling channels along
the front face, as described with reference to FIGS. 9-11. The
interior air exchanges heat from the chamber 14''' generally
continuously as the air travels through the at least three portions
(rear, bottom, front) of the channel 15'''. In particular, the
heating air forced through by the climate control fan 86' can cool
the front face window 22''' to prevent the surface from becoming
excessively hot during use of the fireplace 10'''.
[0134] The climate control fan 86' can be disposed in the heating
channel 15'''. The fan 86' draws interior air into the fireplace
through the air vent inlet 13'''. The fan 86' can have the various
characteristics described above with respect to cooling fan 82
and/or climate control fan 86.
[0135] The climate control fan 86' can generally be positioned in a
first half, or a first two-thirds, of the channel 15''' extending
from the air inlet vent 13'''. As described above, the channel
15''' can define a flow path from the top surface of the fireplace
10''', down the back side of the chamber 14''', and under the floor
of the combustion chamber 14''' to the window 22''' between the
first pane 93 and the second pane 95, then out the outlet vent
16'''.
[0136] In some embodiments, the climate control fan 86' can be
positioned in a first 1/4, 1/3, 2/3, or any portion thereof, of the
channel 15''' flow path. Similarly, the climate control fan 86' can
be positioned in any portion of the channel 15' such that the air
drawn into and blown out of the fan 86' is not substantially
over-heated by the combustion in the sealed combustion chamber
14'''. In some embodiments, heated air can be drawn into the
climate control fan 86' and directed to the window 22'''. In some
embodiments, the climate control fan 86' can be located outside of
the channel 15'''.
[0137] Although this invention has been disclosed in the context of
certain preferred embodiments and examples, it will be understood
by those skilled in the art that the present invention extends
beyond the specifically disclosed embodiments to other alternative
embodiments and/or uses of the invention and obvious modifications
and equivalents thereof. In addition, while a number of variations
of the invention have been shown and described in detail, other
modifications, which are within the scope of this invention, will
be readily apparent to those of skill in the art based upon this
disclosure. It is also contemplated that various combinations or
subcombinations of the specific features and aspects of the
embodiments may be made and still fall within the scope of the
invention. Accordingly, it should be understood that various
features and aspects of the disclosed embodiments can be combined
with or substituted for one another in order to form varying modes
of the disclosed invention. Thus, it is intended that the scope of
the present invention herein disclosed should not be limited by the
particular disclosed embodiments described above, but should be
determined only by a fair reading of the claims that follow.
[0138] Similarly, this method of disclosure, is not to be
interpreted as reflecting an intention that any claim require more
features than are expressly recited in that claim. Rather, as the
following claims reflect, inventive aspects lie in a combination of
fewer than all features of any single foregoing disclosed
embodiment. Thus, the claims following the Detailed Description are
hereby expressly incorporated into this Detailed Description, with
each claim standing on its own as a separate embodiment.
* * * * *