Cover assembly, blower assembly and associated method

Abstract

A blower assembly is attached to a water heater having an exhaust opening, the assembly includes a tank cap attached to a tank of the heater. A recess surface formed in the exterior surface of the cap. A member has a first surface that is connected to the tank cap to form a cover plenum between the cap and the member. The blower includes a motor, an air moving member connected to the motor and a blower housing having an interior containing the fan. The blower housing has an input opening that communicates the blower housing interior with the member output opening. The blower housing, the member and the tank cap provide an exhaust gas flow path from the exhaust opening of the heater through the cover plenum, through the blower housing interior and out the output opening.

Claims

1. A water heater assembly having an exhaust opening on the exterior surface of the water heater with the exhaust opening having a center axis that defines mutually perpendicular axial and radial directions relative to the water heater and advances exhaust gases from the water heater to an exterior environment, the assembly comprising: a water heater having a tank, the water heater comprising a side wall and a tank cap located above the side wall, the side wall and the tank cap together defining an exterior surface of an upper portion of the water heater, said tank cap having a recess surface formed in the exterior surface thereof and configured to extend inwardly toward the water heater in the axial direction of the exhaust opening, wherein said recess surface is below the exterior surface of the tank cap, wherein said recess surface extends only partially along said exterior surface of the tank cap, and wherein said exterior surface comprises the uppermost surface of said tank cap; a member defining a first surface thereof and connected to said exterior surface of said tank cap to form a cover plenum between the recess surface of said tank cap and the first surface of said member, wherein said cover plenum is below the exterior surface of the tank cap, said member defining an output opening of said member that communicates with the cover plenum; and a blower connected to the member, the blower including: a motor; a fan connected to the motor for rotation of the fan with rotation of the motor; and a blower housing having an interior containing the fan, the motor being supported by the blower housing, the blower housing having an output opening having a center axis that defines mutually perpendicular axial and radial directions and that communicates the blower housing interior with the exterior environment, the blower housing further having an input opening that communicates the blower housing interior with the member output opening, wherein said blower input opening is axially aligned with and spaced axially above said member output opening, wherein the blower housing, the member and the tank cap are configured to provide an exhaust gas flow path from the exhaust opening of the heater through the cover plenum, through the blower housing interior and out the output opening.

2. The water heater assembly of claim 1; wherein the fan is connected to the motor by a motor shaft extending from the motor; and wherein the center axis of the blower housing output opening is substantially parallel to and spaced radially from the axis of rotation of the motor shaft and the fan axis of rotation, wherein the output opening is positioned axially above the heater exhaust opening when the blower housing is attached to the member.

3. The water heater assembly of claim 1, further comprising: the blower housing attached to the member to prevent dilution air from entering the blower housing interior.

4. The water heater assembly of claim 1, further comprising the blower housing being attached to the member with the blower housing sealing around the member and thereby providing a non-dilution air blower housing on the water heater.

5. The water heater assembly of claim 1, further comprising the interior structure of the blower housing including an interior wall that extends radially through the blower housing interior and is positioned axially between the water heater exhaust opening and the blower housing output opening when the blower housing is attached to the member.

6. The water heater assembly of claim 5, further comprising: the interior wall having an opening through the interior wall that is spaced radially and axially from the blower housing output opening and is spaced radially and axially from the water heater exhaust opening when the blower housing is attached to the member, wherein said interior wall opening defines said blower input opening.

7. The water heater assembly of claim 6, further comprising: the exhaust gas flow path passing through the interior wall opening.

8. The water heater assembly of claim 6, further comprising: the interior wall opening being axially aligned with the fan axis of rotation.

9. The water heater assembly of claim 6, further comprising the fan being positioned on one side of the interior wall and the water heater exhaust opening being positioned on an opposite side of the interior wall when the blower housing is attached to the member.

10. The water heater assembly of claim 2, further comprising: the motor shaft axis of rotation and fan axis of rotation being substantially coaxial and substantially parallel to the blower housing output opening center axis and the water heater exhaust opening center axis.

11. The water heater assembly of claim 5, further comprising: the interior wall having an opening with a center axis that is substantially coaxial with the fan axis of rotation.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Further features of the heater blower apparatus of the invention are set forth in the following detailed description of the preferred embodiment of the apparatus and in the drawing figures.

(2) FIG. 1 is a partially exploded plan view, partially in cross section, of a water heater cover assembly according to an embodiment of the present invention;

(3) FIG. 2 is a plan view, partially in cross section, of a water heater according to another embodiment of the present invention utilizing the heater cover assembly of FIG. 1;

(4) FIG. 3 is a top view, partially in cross section of a furnace blower assembly for use with the water heater of FIG. 2;

(5) FIG. 4 is a perspective view of the furnace blower assembly of FIG. 3 positioned on the water heater of FIG. 1;

(6) FIG. 5 is a plan view, partially in cross section, of the water heater of FIG. 2, showing some of the internal components of the water heater;

(7) FIG. 6 is a partially exploded plan view, partially in cross section of a furnace blower assembly with a member integral with a furnace blower assembly, according to another embodiment of the present invention;

(8) FIG. 7 is a partially exploded plan view, partially in cross section of a furnace blower assembly with a member integral with a cap, according to another embodiment of the present invention;

(9) FIG. 8 is a partially exploded plan view, partially in cross section of a furnace blower assembly with a cap integral with a tank, according to another embodiment of the present invention; and

(10) FIG. 9 is a flow chart of another embodiment of the present invention in the form of a method for sealing a furnace blower assembly.

DETAILED DESCRIPTION OF THE INVENTION

(11) According to an embodiment of the invention and referring to FIG. 1, a tank cap assembly 10 for use with a water heater 12 having an exhaust opening 14 on the exterior surface 16 of the water heater 12 is provided. The tank cap assembly 10 is adapted to be positioned between a water heater tank 18 and a heater blower assembly 20, said tank cap assembly 10 includes a body or tank cap 22 having a recess surface 24 formed in the exterior surface 26 of the body 22 and a member or cover 28.

(12) The member 28 defines a first surface 30 of the member 28. The member 24 is connected to the tank cap or body 22 to form a cover plenum 32 between the recess surface 24 of the cap 22 and the first surface 30 of the member 28. The cover plenum 32 is in communication with the exhaust opening 14 of the water heater 12.

(13) The member 28 defines an output opening 34 of the member 28 that communicates the cover plenum 32 with the heater blower assembly 20. The member 28 and the tank cap 22 provide an exhaust gas flow path 36 from the exhaust opening 14 of the water heater 12 through the cover plenum 32, and through the heater blower assembly 20.

(14) The tank cap 22 may have any suitable shape and may be shaped to cover top 38 of the tank 18. The cap 22 may be secured to the tank 18 by any suitable method, including but not limited to fasteners (not shown), welding, tape, belts or brackets (not shown), interference fit, or by glue and may alternatively be spaced from the tank.

(15) The tank cap 22 may be made of any suitable material and may, for example, be made of polymer, a metal or a composite material. The tank cap 22 may be made using any suitable manufacturing process. The tank cap 22 may, for example, be molded, cast, fabricated, poured, or machined.

(16) The member 28 may have any suitable shape and may be shaped to fit between the tank cap 22 and the blower assembly 20. The member 28 may be secured to the tank cap 22 and to the blower assembly 20 by any suitable methods, including but not limited to fasteners (not shown), welding, tape, belts or brackets (not shown), interference fit, or by glue.

(17) The member 28 may be made of any suitable material and may, for example, be made of polymer, a metal or a composite material. The member 28 may be made using any suitable manufacturing process. The member 28 may, for example, be molded, cast, fabricated, poured, or machined.

(18) Referring now to FIG. 2 and according to an aspect of the present invention, the tank cap assembly 10 may be provided wherein the tank cap recess surface 24 extends inwardly toward the heater 12 in the axial direction (arrow 40) of the exhaust opening 14.

(19) Extending the recess surface 24 inwardly in the direction of arrow 40 permits the blower housing assembly 20 to have a lesser blower height BH and thus to have a water heater 12 with an overall heater height HH that is minimal. Locations where water heaters are located, such as basements, may have low ceilings. The less height required using the cap of the present invention, permits the installation of higher efficiency water heaters with heater blower assemblies.

(20) As shown in FIG. 2, the blower housing assembly 20 may include a blower 42 having a motor 44, an air moving member or fan 46 connected to the motor 44 for rotation of the fan 46 with rotation of the motor 44, and a blower housing 48. The blower housing 48 may be of a one-piece construction using the member or cover 28 to assist in enclosing the housing 48. The blower housing 48 has an interior 50 containing the fan 46. The motor 44 is supported by the blower housing 48. The blower housing 48 has an output opening 52 and an input opening 54. The input opening 54 communicates the blower housing interior 50 with the cover plenum 32. The blower housing 48, the member 28 and the tank cap 22 are configured to provide the exhaust gas flow path 36 from the exhaust opening 14 of the heater 12 through the cover plenum 32, through the blower housing interior 50 and out the output opening 52.

(21) As shown in FIGS. 2-4, the blower assembly 20 may be provided wherein the blower assembly 20 is attachable to the water heater 12 having the exhaust opening 14 on the exterior surface 16 of the water heater 12 with the exhaust opening 14 having a center axis 56 that defines mutually perpendicular axial 58 and radial directions 60 relative to the heater 12 and advances exhaust gases 62 from the heater 12 to an exterior environment 64.

(22) As shown in FIGS. 2-4 and according to another aspect of the present invention, the blower assembly 20 may further include a center axis 64 of the blower housing output opening being substantially parallel to and spaced radially an offset distance ROD from a motor shaft axis of rotation 66 which is coincident with the fan axis of rotation. The output opening 34 of the cover 28 may be positioned axially above the heater exhaust opening 14 when the blower housing 48 is attached to the cover 28.

(23) As shown in FIGS. 2-4 and according to another aspect of the present invention, the blower assembly 20 may further include the blower housing 48 being attachable to the cover 28 to prevent dilution air 68 from entering the blower housing interior 50.

(24) As shown in FIGS. 2-4 and according to another aspect of the present invention, the blower assembly 20 may further include the blower housing 48 being attachable to the cover 28 with the blower housing 48 sealing around upper surface 70 of the cover 28 and thereby providing a non-dilution air blower housing 48 on the heater 12.

(25) As shown in FIGS. 2-4 and according to another aspect of the present invention, the blower assembly 20 may further include the interior structure 50 of the blower housing 48 including an interior wall 72 that extends radially through the blower housing interior 50 and is positioned axially between the heater exhaust opening 14 and the blower housing output opening 52 when the blower housing 48 is attached to the member or cover 28.

(26) As shown in FIGS. 2-4 and according to another aspect of the present invention, the blower assembly 20 may further include the interior wall 72 having an opening 74 through the interior wall that is spaced radially and axially from the blower housing output opening 52 and is spaced radially and axially from the heater exhaust opening 14 when the blower housing 48 is attached to the member or cover 28. The interior wall 72 may define the input opening 54 of the blower assembly 20

(27) According to another aspect of the present invention, the blower assembly 20 may further include the exhaust gas flow path 36 passing through the interior wall opening 74.

(28) According to another aspect of the present invention, the blower assembly 20 may further include interior wall opening 74 being axially aligned with the fan axis of rotation 66.

(29) As shown in FIGS. 2-4 and according to another aspect of the present invention, the blower assembly 20 may further include the fan 46 being positioned on one side of the interior wall 72 and the heater exhaust opening 14 being positioned on an opposite side of the interior wall 72 when the blower housing 48 is attached to the member 28.

(30) As shown in FIGS. 2-4, cover plenum 32, the blower assembly 20, the input opening 54 of the blower assembly, the output opening 52 of the blower assembly and the exhaust opening 14 may be positioned both axial and radially in the locations most suitable for the water heater configuration desired. As shown hi FIGS. 2-4 the blower assembly 20 is positioned axially above the cover plenum 32.

(31) As shown in FIGS. 2-4 the motor 44, the exhaust opening 14, the cover plenum 32, the input opening 54 of the blower assembly and the output opening 52 of the blower assembly may be positioned radially or offset radially with respect to each other. For example, and as shown in FIGS. 2-4, the center axis 56 of the exhaust opening 14 may be in alignment or coincident with the center axis 64 of the blower housing output opening 52. This coincident axes arrangement together with the reduced dimension BH makes the replacement or retrofit of a water heater with a water heater with the blower assembly of the present invention simpler.

(32) As shown in FIGS. 2-4, the center axis 64 of the blower housing output opening 52 may be radially offset a distance BOD from the center axis 56 of the heater exhaust opening 14. As shown in FIGS. 2-4 the distance BOD is zero.

(33) As shown in FIGS. 2-4, a center axis 76 of the blower housing input opening 54 may be radially offset a distance BID from the center axis 56 of the heater exhaust opening 14. The motor shaft axis of rotation 66 may be radially offset a distance MD from the center axis 56 of the heater exhaust opening 14.

(34) The interior 50 of the blower housing 48 and the cover plenum 32 serve as a portion of the exhaust gas flow path 36. The size and shape of the interior 50 of the blower housing 48 and the cover plenum 32 are chosen to obtain desired flow results.

(35) For example, and as shown in FIGS. 2-4, the interior 50 of the blower housing 48 has an involute or spiral portion 78 and a duct portion 80. The interior may have a uniform cross section and have an interior height IH (see FIG. 2). The spiral portion 78 is defined by a dimension BHR extending from motor shaft axis of rotation 66 to interior wall 79 of blower housing that increases in the direction of arrow 82 (see FIG. 3).

(36) For example, and as shown in FIG. 2-4, the plenum 32 formed by cap 22 may have any suitable size and shape to provide proper flow of exhaust gases 62 along the exhaust gas flow path 36. The plenum may have a uniform cross section and have an interior height PH (see FIG. 2). The cross section of the plenum may have any suitable shape and may as shown in dashed lines 88 to be oval with a length PL and width PW (see FIG. 3). The height PH, length PL and width PW should be chosen to provide ample are for the flow of gases 62 and to accommodate any tolerance variations during fabrication and assembly of the heater 12.

(37) Referring to FIGS. 3 and 4, the cover 28 may be used for an end face of the blower housing 48. When so used, the blower housing 48 may have a blower housing periphery 90 (shown partially in phantom in FIG. 3) that is positioned within a cover periphery 92, so that the cover 28 may seal interior 50 of the blower housing 48. Alternatively, the cover periphery 92 may be aligned with the blower housing periphery 90. Fastener holes 94 near the blower housing periphery 92 may be used to permit fasteners (not shown) to secure the blower housing 48 to the cover 28.

(38) The blower housing and the cover plenum may, if needed, include baffles or other restrictions (not shown) to increase the distance of the flow path 36 and to change pressure to slow the velocity of the flow to remove additional heat from the exhaust gases 62. Baffles or other restrictions 83 are typically positioned in water heater exhaust pipe or flue 84 where they serve to improve 37 heat transfer to the water.

(39) The construction of the blower housing 48 and the cover plenum 32 of the cap 22 described above creates a winding exhaust gas flow path through the cap 22 and the blower housing 48. On operation of the motor 44 and rotation of the fan 46 in the blower housing 48, exhaust gases 62 are drawn axially through the water heater exhaust pipe or flue 84 and the exhaust opening 14. The exhaust gases 62 then travel radially from the water heater exhaust opening 14 toward the cover plenum 32 formed in cap 22. The exhaust gases 62 are then directed axially into the cover plenum 32. The exhaust gases 62 then travel radially outwardly across the cover plenum 32 toward the input opening 54 of the blower housing 14. The exhaust gases 62 then flows axially through the input opening 54 of the blower housing 14 toward the center of the rotating fan 46. The exhaust gases 62 are then pushed radially by the rotating fan 46 through the fan circumference of rotation across the spiral portion 78 of the interior 50 of housing 48 and toward the duct portion 80, i.e. the output opening 52 in the housing duct portion 80.

(40) The exhaust gases 62 are then directed axially through the output opening 52. The winding flow path of the exhaust gases 62 through the blower housing 14 allows the gas to cool as it passes through the housing. In addition, the winding exhaust gas flow path through the blower housing 14 reduces stand-by losses of the water heater 26. To further reduce stand-by losses, the blower housing 48 could be modified with a damper (not shown) in the interior of the housing 48. The winding flow path of the exhaust gases 62 through the blower housing 48 is achieved inexpensively by the novel and non-obvious use of a cap recess to provide a cover plenum and to use the cover of the cap to form a portion of the blower housing.

(41) The heater blower apparatus 12 of the invention described above, when equipped with a properly designed water heater can assist in obtaining an improved energy factor (EF) required in the United States. The heater blower apparatus 12 of the invention described above, when equipped with a properly designed water heater can use an existing vent pipe.

(42) The heater blower apparatus 12 of the invention described above can replace current atmospheric draft hood water heaters, which cannot meet the improved energy factor (EF) required in the United States.

(43) Referring now to FIG. 5, the water heater 12 is shown in greater detail. 2. The water heater 12 includes a water tank 18, a jacket 19 surrounding the water tank, a burner plenum 17 adjacent the water tank 18, a fuel burner 21 within the burner plenum 17, a fuel supply line 23, a flue 84, and a water heater blower assembly, generally indicated at 20. The fuel burner 21 is configured and adapted to combust fuel (e.g., natural gas, LP gas, etc.) to produce combustion products or exhaust gases 62. The flue 84 includes flue baffle 83 for providing a rigorous flow path through the flue 84. The flue 84 has an upstream end 85 and a downstream end 86. The upstream end 85 of the flue 84 is in fluid communication with the burner plenum 17. The flue 84 is configured for passage of combustion products from the burner plenum 17 through the water tank 18 and toward the downstream end 86 of the flue 84 to heat water within the water tank 18. The water tank 18 includes a water inlet and a water outlet (not shown) for introducing unheated water into the tank and for passage of heated water out of the tank, respectively.

(44) The construction of the blower housing 14 with the recess described above also enables the water heater 12 to be assembled or retrofit to an existing water heater between the exhaust pipe and exhaust opening of the water heater and an axially aligned existing flue pipe.

(45) Referring now to FIG. 6 and according to another aspect of the present invention, a water heater 112 is shown. The water heater 112 is similar to the water heater 12 of FIGS. 1-5 except that the water heater 112 includes a heater blower assembly 120 that is different from the heater blower assembly 12 of FIGS. 1-5 in that the heater blower assembly 112 includes a heater blower housing 148 that includes member or cover 128. The cover 128 replaces the cover 28 of the water heater 12.

(46) Referring now to FIG. 7 and according to another aspect of the present invention, a water heater 212 is shown. The water heater 212 is similar to the water heater 12 of FIGS. 1-5 except that the water heater 212 includes a tank cap 222 that is different from the tank cap 22 of FIGS. 1-5 in that the tank cap 222 includes member or cover 228. The cover 228 replaces the cover 28 of the water heater 12.

(47) Referring now to FIG. 8 and according to another aspect of the present invention, a water heater 312 is shown. The water heater 312 is similar to the water heater 12 of FIGS. 1-5 except that the water heater 312 includes a tank cap 322 that is different from the tank cap 22 of FIGS. 1-5 in that the tank cap 322 is integral with water heater tank 318.

(48) According to another embodiment of the present invention, a method 400 for sealing a blower housing to a duct of a heater may be provided. The method includes step 410 of providing a cap, step 412 of forming a recess in the cap, step 414 of positioning the cap over the duct, step 416 of providing a member, step 418 of positioning the member over the cap to form a cover plenum from the recess between the cap and the member, step 420 of providing a flow path from the duct to the cover plenum, step 422 of providing a blower housing having an inlet thereof, and step 424 of providing a flow path from the cover plenum to the inlet of the blower housing.

(49) The embodiments of the non-dilution blower apparatus were chosen and described in order to best explain the principles of the invention and its practical application to thereby enable others skilled in the art to best utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated.

(50) As various modifications could be made in the constructions herein described and illustrated without departing from the scope of the invention, it is intended that all matter contained in the foregoing description or shown in the accompanying drawings shall be interpreted as illustrative rather than limiting. For example, the cap could be constructed of materials other than stamped or drawn sheet metal, and the blower housing with the cap having a recess to form a plenum could be employed on a heater other than a water heater. Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims appended hereto and their equivalents.

(51) When introducing elements/components/etc. of the methods and apparatus described and/or illustrated herein, the articles a, an, the, and the are intended to mean that there are one or more of the element(s)/component(s)/etc. The terms comprising, including, and having are intended to be inclusive and mean that there may be additional element(s)/component(s)/etc. other than the listed element(s)/component(s)/etc.

(52) This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.

(53) Described herein are exemplary methods, systems and apparatus utilizing a heater cap to provide a plenum for assisting air flow for a blower. Furthermore, the exemplary methods system and apparatus achieve improved performance and reduced cost. The methods, system and apparatus described herein may be used in any suitable application. However, they are particularly suited for water heater applications.

(54) Exemplary embodiments of the cap, blower, heater and methods are described above in detail. The heater its components are not limited to the specific embodiments described herein, but rather, components of the systems may be utilized independently and separately from other components described herein. For example, the components may also be used in combination with other machine systems, methods, and apparatuses, and are not limited to practice with only the systems and apparatus as described herein. Rather, the exemplary embodiments can be implemented and utilized in connection with many other applications.

(55) Although specific features of various embodiments of the disclosure may be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of the disclosure, any feature of a drawing may be referenced and/or claimed in combination with any feature of any other drawing.

(56) This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.