Water heater having a low NOx burner integrated with FVIR platform

• US 6,994,056 B1
• Filed: 09/03/2004
• Issued: 02/07/2006
• Est. Priority Date: 09/03/2004
• Status: Active Grant

• Current Assignee: Rheem Manufacturing Company (Paloma Co., Ltd.)
• Original Assignee: Rheem Manufacturing Company (Paloma Co., Ltd.)
• Inventors: Boros, Jozef
• Primary Examiner(s): WILSON, GREGORY A
• Application Number:
  US10/934,648
• Time in Patent Office: 522 Days
• Field of Search: 122/14.1, 122/14.2, 122/14.31
• US Class Current: 122/14.1
• CPC Class Codes: F23D 14/04 induction type, e.g. Bunsen burner
• CPC Class Codes: F23M 2900/11021 Means for avoiding accidental fires in rooms where the combustion device is located
• CPC Class Codes: F24H 1/205 with furnace tubes
• CPC Class Codes: F24H 9/1881 using fluid fuel

Abstract

Various embodiments of fuel-fired low NOx water heaters are provided with burners having built-in venturi inlet sections for receiving fuel from a source thereof and combustion air from outside of the water heater. The burners are integrated in various manners with flammable vapor ignition resistance (FVIR) platforms to thereby reduce the tooling costs necessary to provide the water heaters with both lowered NOx emissions and flammable vapor ignition resistance.

Claims

1. A fuel-fired heating appliance comprising:

a combustion chamber separated from a plenum area by a wall structure;

an inlet space for receiving combustion air from outside said appliance; and

a fuel burner having a hollow body with an outlet portion thereof projecting from said wall structure into said combustion chamber, and an inlet portion thereof projecting from said wall structure into said plenum area, said inlet portion having a venturi inlet structure associated therewith, communicated with said inlet space, and operative to flow combustion air from said inlet space into said inlet portion of said hollow body, said wall structure being defined by a peripheral portion of said fuel burner.

2. The fuel-fired heating appliance of claim 1 wherein:

said venturi inlet structure is operative to flow combustion air from said inlet space into said inlet portion of said hollow body via said plenum area.

3. The fuel-fired heating appliance of claim 1 wherein:

said appliance is a fuel-fired water heater.

4. The fuel-fired heating appliance of claim 3 wherein:

said water heater is a gas-fired water heater.

5. The fuel-fired heating appliance of claim 1 wherein:

said fuel burner is a radiant fuel burner.

6. The fuel-fired heating appliance of claim 1 wherein:

said venturi inlet structure is an integral portion of said inlet portion of said hollow fuel burner body.

7. The fuel-fired heating appliance of claim 6 wherein;

said venturi inlet structure includes an outer wall opening formed in said inlet portion of said hollow fuel burner body.

8. The fuel-fired heating appliance of claim 1 wherein:

said venturi inlet structure includes an inlet conduit structure extending outwardly from said inlet portion of said hollow fuel burner body.

9. The fuel-fired heating appliance of claim 8 wherein:

said inlet space is external to said plenum area, and

said inlet conduit structure has an outer inlet end opening disposed in said inlet space.

10. The fuel-fired heating appliance of claim 1 wherein:

substantially all of the primary combustion air utilized by said fuel burner during firing thereof is delivered to said fuel burner through said venturi inlet structure.

11. A fuel-fired heating appliance comprising:

a combustion chamber separated from a plenum area by a wall structure;

an inlet space for receiving combustion air from outside said appliance; and

a fuel burner having a hollow body with an outlet portion thereof projecting from said wall structure into said combustion chamber, and an inlet portion thereof projecting from said wall structure into said plenum area, said inlet portion having a venturi inlet structure associated therewith, communicated with said inlet space, and operative to flow combustion air from said inlet space into said inlet portion of said hollow body,

said wall structure being separate from said fuel burner and having an opening through which said fuel burner extends between said combustion chamber and said plenum area.

12. A fuel-fired heating appliance comprising:

a combustion chamber separated from a plenum area by a wall structure;

an inlet space for receiving combustion air from outside said appliance; and

a fuel burner having a hollow body with an outlet portion thereof projecting from said wall structure into said combustion chamber, and an inlet portion thereof projecting from said wall structure into said plenum area, said inlet portion having a venturi inlet structure associated therewith, communicated with said inlet space, and operative to flow combustion air from said inlet space into said inlet portion of said hollow body,

said venturi inlet structure including an inlet conduit structure extending outwardly from said inlet portion of said hollow fuel burner body, said inlet conduit structure having an outer inlet end opening disposed within said plenum area.

13. A fuel-fired heating appliance comprising:

a combustion chamber separated from a plenum area by a wall structure;

an inlet space for receiving combustion air from outside said appliance; and

a fuel burner having a hollow body with an outlet portion thereof projecting from said wall structure into said combustion chamber, and an inlet portion thereof projecting from said wall structure into said plenum area, said inlet portion having a venturi inlet structure associated therewith, communicated with said inlet space, and operative to flow combustion air from said inlet space into said inlet portion of said hollow body said wall structure being defined by a peripheral portion of said fuel burner; and

a combustion shutoff system operative to terminate combustion in said fuel-fired heating appliance in response to the temperature in said combustion chamber reaching a predetermined unacceptably high temperature.

14. The fuel-fired heating appliance of claim 13 wherein:

said combustion shutoff system is operative to terminate combustion air flow to said fuel burner in response to the temperature in said combustion chamber reaching said predetermined unacceptably high temperature.

15. The fuel-fired heating appliance of claim 14 wherein:

said combustion shutoff system is operative to block combustion air inflow through said venturi inlet structure in response to the temperature in said combustion chamber reaching said predetermined unacceptably high temperature.

16. A fuel-fired heating appliance comprising:

a combustion chamber separated from a plenum area by a wall structure;

an inlet space for receiving combustion air from outside said appliance; and

a fuel burner having a hollow body with an outlet portion thereof projecting from said wall structure into said combustion chamber, and an inlet portion thereof projecting from said wall structure into said plenum area, said inlet portion having a venturi inlet structure associated therewith, communicated with said inlet space, and operative to flow combustion air from said inlet space into said inlet portion of said hollow body; and

a flammable vapor ignition resistance system operative to prevent flame outflow from said combustion chamber.

17. The fuel-fired heating appliance of claim 16 wherein:

said fuel burner is a radiant fuel burner,

said fuel burner outlet portion has a perforate flame holding outer wall section, and

said flammable vapor ignition resistance system includes said perforate flame holding outer wall section.

18. The fuel-fired heating appliance of claim 16 wherein:

said flammable vapor ignition resistance system includes flame quenching openings associated with said wall structure and communicating said plenum area with said combustion chamber.

19. A fuel-fired water heater comprising:

an inner wall structure defining a tank for holding water to be heated, a combustion chamber extending downwardly from a lower end of said tank and having a bottom wall structure, and a skirt wall depending from a bottom peripheral portion of said combustion chamber and circumscribing a plenum area separated from said combustion chamber by said bottom wall structure, said skirt wall having an opening therein;

an outer wall structure outwardly circumscribing said inner wall structure and defining therewith an air inlet space at least partially circumscribing said skirt wall, said outer wall structure having a combustion air inlet opening area extending therethrough into said air inlet space;

a fuel burner having a hollow body with an upper outlet portion thereof projecting from said bottom wall structure into said combustion chamber, and a lower inlet portion projecting from said bottom wall structure into said plenum area, said inlet portion having a venturi inlet structure associated therewith and having an inlet communicated with said air inlet space in a manner permitting combustion air entering said air inlet space through said combustion air inlet opening area from outside said water heater to be drawn into said inlet of said venturi inlet structure; and

fuel delivery apparatus for delivering fuel from a source thereof to the interior of said lower inlet portion of said hollow body for mixture with combustion air flowed thereinto via said venturi inlet structure.

20. The fuel-fired water heater of claim 19 wherein:

said fuel-fired water heater is a gas fired water heater.

21. The fuel-fired water heater of claim 20 wherein:

said combustion air inlet opening area includes a series of air filtering perforations formed in said outer wall structure.

22. The fuel-fired water heater of claim 20 wherein:

said fuel burner is a radiant fuel burner having, on said upper outlet portion of said hollow body, a perforate flame holding wall section.

23. The fuel-fired water heater of claim 22 wherein:

said perforate flame holding wall section is of a metal mesh construction.

24. The fuel-fired water heater of claim 22 wherein:

said perforate flame holding wall section is removable from said upper outlet portion of said hollow body for inspection and cleaning purposes.

25. The fuel-fired water heater of claim 22 wherein:

said water heater further comprises a flue pipe extending upwardly from a central portion of said lower end of said tank,

said upper outlet portion of said hollow body has a nonperforate central top side portion underlying said flue pipe, and

said perforate flame holding wall section at least partially circumscribes said nonperforate central top side portion and slopes downwardly and inwardly towards it.

26. The fuel-fired water heater of claim 19 wherein:

essentially all of the primary combustion air delivered from outside of said water heater to said fuel burner, during firing thereof, via said venturi inlet structure.

27. The fuel-fired water heater of claim 19 wherein:

said bottom wall structure of said combustion chamber is defined by a portion of said fuel burner.

28. The fuel-fired water heater of claim 27 wherein:

said bottom wall structure of said combustion chamber is a peripheral portion of said fuel burner captively and supportingly retained in a circumferential rolled portion of said inner wall structure.

29. The fuel-fired water heater of claim 19 wherein:

said bottom wall structure of said combustion chamber is separate from said fuel burner and has an opening through which said fuel burner vertically extends.

30. The fuel-fired water heater of claim 29 wherein:

said fuel burner is releasably interlocked with said bottom wall structure and is downwardly removable from said combustion chamber through said opening in said bottom wall structure.

31. The fuel-fired water heater of claim 30 wherein:

said fuel burner is releasably interlocked with said bottom wall structure by cooperating tab and slot structures on said fuel burner and said bottom wall structure.

32. The fuel-fired water heater of claim 31 wherein:

said fuel burner is interlockable with and releasable from said bottom wall structure by rotating said fuel burner relative to said bottom wall structure about a vertical axis.

33. The fuel-fired water heater of claim 30 wherein:

when released from said bottom wall structure said fuel burner may be removed from said water heater by withdrawing the released fuel burner outwardly through aligned access openings in said inner and outer wall structures.

34. The fuel-fired water heater of claim 33 wherein:

said venturi inlet structure has a cover member secured thereto and adapted to cover said access opening in said inner wall structure when said fuel burner is interlocked with said bottom wall structure.

35. The fuel-fired water heater of claim 19 wherein:

said inlet of said venturi inlet structure receives combustion air from said air inlet space via the interior of said plenum area.

36. The fuel-fired water heater of claim 19 wherein:

said inlet of said venturi inlet structure is disposed within said plenum area.

37. The fuel-fired water heater of claim 19 wherein:

said inlet of said venturi inlet structure is disposed within said air inlet space, and

said fuel-fired water heater further comprises an inlet passage for flowing combustion air from outside said water heater through said air inlet opening area and into said plenum area for delivery outwardly therefrom, via said skirt wall opening, into said air inlet space.

38. The fuel-fired water heater of claim 19 wherein:

said fuel delivery apparatus includes a fuel delivery tube sequentially extending inwardly through said combustion chamber and said upper outlet portion of said fuel burner body, and then into said lower inlet portion of said fuel burner body, said fuel delivery tube having a discharge portion disposed within said lower inlet portion of said fuel burner body.

39. The fuel-fired water heater of claim 19 wherein:

said fuel delivery apparatus includes a fuel delivery tube sequentially extending inwardly through said outer and inner wall structures and then into said lower inlet portion of said fuel burner body, said fuel delivery tube having a discharge portion disposed within said lower inlet portion of said fuel burner body.

40. The fuel-fired water heater of claim 19 wherein:

said fuel delivery apparatus includes a fuel delivery tube extending inwardly through said outer wall structure into said air inlet space,

said inlet of said venturi inlet structure is disposed in said air inlet space, and

said fuel delivery tube has a discharge portion positioned to discharge fuel into said inlet of said venturi inlet structure.

41. The fuel-fired water heater of claim 19 further comprising:

a flammable vapor ignition resistance system operative to prevent flame outflow from said combustion chamber.

42. The fuel-fired water heater of claim 41 wherein:

said fuel burner is a radiant fuel burner,

said fuel burner outlet portion has a perforate flame holding outer wall section, and

said flammable vapor ignition resistance system includes said perforate flame holding outer wall section.

43. The fuel-fired water heater of claim 41 wherein:

said flammable vapor ignition resistance system includes flame quenching openings associated with said bottom wall structure of said combustion chamber and communicating said plenum area with said combustion chamber.

44. The fuel-fired water heater of claim 19 further comprising:

a combustion shutoff system operative to terminate combustion in said fuel-fired heating appliance in response to the temperature in said combustion chamber reaching a predetermined unacceptably high temperature.

45. The fuel-fired water heater of claim 44 wherein:

said combustion shutoff system is operative to terminate combustion air flow to said fuel burner in response to the temperature in said combustion chamber reaching said predetermined unacceptably high temperature.

46. The fuel-fired water heater of claim 45 wherein:

said combustion shutoff system is operative to block combustion air inflow through said venturi inlet structure in response to the temperature in said combustion chamber reaching said predetermined unacceptably high temperature.

47. The fuel-fired water heater of claim 46 wherein:

said combustion shutoff system includes a temperature sensing structure disposed in said combustion chamber and linked to a spring-loaded damper structure held by said temperature sensing structure in an open position permitting combustion air flow into said inlet of said venturi inlet section, said temperature sensing structure being operative to permit said damper structure to be spring-driven to a closed position, in which it blocks combustion air flow into said inlet, in response to detecting said unacceptably high temperature within said combustion chamber.