LOW EMISSION WOOD BURNING STOVE

Abstract

A wood burning stove is configured to produce low emissions and provide high efficiency. The stove includes a housing, a firebox disposed in the housing, a first air flow channel, a secondary air flow channel, and a lower primary air conduit. The secondary air flow channel includes a plurality of secondary air apertures configured to supply secondary air to a combustible gas emitted by a fire. The lower primary air conduit includes a plurality of conduit apertures configured to supply a second primary air flow into the firebox. Also disclosed are methods of operating such a stove.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority to, and any other benefit of, U.S. Provisional Patent Application No. 63/304,199, filed Jan. 28, 2022, the entire disclosure of which is incorporated herein by reference in its entirety.

TECHNICAL FIELD

The present application relates generally to wood burning stoves and, more particularly, to wood burning stoves having increased efficiency and reduced emissions.

BACKGROUND OF THE INVENTION

Wood burning stoves have been used for hundreds of years to heat homes and other structures or locations. Wood burning stoves have become commonplace in buildings for both residential and commercial applications, particularly where a fireplace is not feasible or desired, for providing heat, decorative purposes, and/or value enhancement. In certain situations, wood burning stoves may be inserted into fireplace boxes. Wood burning stoves may also be preferred over fireplaces because the wood burning stoves have the capability to heat large spaces efficiently and many wood burning stoves are able to burn for extended periods of time without refueling or reloading.

Wood burning stoves are economical sources of heat as they burn renewable fuel sources such as wood for heat. However, like other heat sources that use combustion, wood burning stoves produce particulate emissions and wood burning stoves may not produce heat as efficiently as other sources of heat production. Accordingly, there is a need for higher efficiency wood burning stoves with reduced particulate emissions.

SUMMARY

In one embodiment, a lower primary air conduit for use in a wood burning stove includes a body, an intake, and a plurality of conduit apertures. The lower primary air conduit may deliver a flow of air for primary combustion of a fuel in a firebox of a wood burning stove.

In another embodiment, a wood burning stove includes a housing and a firebox. The stove also includes a primary air flow channel configured to provide a first flow of primary air into the firebox. The stove also includes a secondary air flow channel configured to provide secondary air into the firebox. The stove further includes a lower primary air conduit configured to provide a second flow of primary air into the firebox.

In another embodiment, a method for providing heat from a wood burning stove is disclosed. The method includes the steps of providing fuel into a firebox of the wood burning stove, igniting the fuel in the firebox, providing a first primary air flow into the firebox from a first air flow channel, providing a secondary air flow into the firebox from at least one secondary air tube, providing a second primary air flow into the firebox from a lower primary air conduit, providing a flow of air into a shroud of the stove, and moving heated air out of side vents of the shroud.

A further understanding of the nature and advantages of the present invention are set forth in the following description and claims, particularly when considered in conjunction with the accompanying drawings in which like parts bear like reference numerals.

BRIEF DESCRIPTION OF THE DRAWINGS

To further clarify various aspects of embodiments of the present disclosure, a more particular description of the certain embodiments will be made by reference to various aspects of the appended drawings. It is appreciated that these drawings depict only typical embodiments of the present disclosure and are therefore not to be considered limiting of the scope of the disclosure. Moreover, while the figures can be drawn to scale for some embodiments, the figures are not necessarily drawn to scale for all embodiments. Embodiments and other features and advantages of the present disclosure will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:

FIG. 1 illustrates an elevated side perspective view of a wood burning stove, according to an exemplary embodiment of the present disclosure;

FIG. 2 illustrates a front view of the wood burning stove of FIG. 1;

FIG. 3 illustrates a rear view of the wood burning stove of FIG. 1;

FIG. 4 illustrates a side view of the wood burning stove of FIG. 1;

FIG. 5 illustrates a top view of the wood burning stove of FIG. 1;

FIG. 6 illustrates an elevated side perspective view of the wood burning stove of FIG. 1 with the door removed;

FIGS. 7 and 8 illustrate elevated side perspective views of the wood burning stove of FIG. 1 with the door, upper housing, and upper air flow paths removed;

FIG. 9 illustrates an elevated side perspective view of the wood burning stove of FIG. 1 with the door, upper flow path, firebricks, and top, front, and sides of the housing removed;

FIG. 10 illustrates an elevated side perspective view of the wood burning stove of FIG. 1 with the door, upper flow path, and top, front, and sides of the housing removed;

FIG. 11 illustrates an illustrated elevated side perspective view of firebricks in a firebox, according to an exemplary embodiment of the present disclosure;

FIG. 12 illustrates a cross-sectional side view of the wood burning stove of FIG. 1;

FIGS. 13 and 14 illustrate exploded elevated side perspective views of a wood burning stove, according to an exemplary embodiment of the present disclosure;

FIG. 15 illustrates an elevated side perspective view of an ash bin of a wood stove, according to an exemplary embodiment of the present disclosure;

FIG. 16 illustrates an elevated side perspective view of a door of a wood stove, according to an exemplary embodiment of the present disclosure;

FIGS. 17A and 17B illustrated side perspective views of an ash plug of a wood stove, according to an exemplary embodiment of the present disclosure;

FIG. 18 illustrates an elevated side perspective view of a secondary air flow frame of a wood burning stove, according to an exemplary embodiment of the present disclosure;

FIGS. 19A and 19B illustrate side perspective views of a secondary air tube of a wood burning stove, according to an exemplary embodiment of the present disclosure;

FIG. 20 illustrates a side perspective view of another secondary air tube of a wood burning stove, according to an exemplary embodiment of the present disclosure;

FIGS. 21A-21D illustrate views of a lower primary air conduit of a wood burning stove, according to an exemplary embodiment of the present disclosure;

FIG. 22 illustrates a cross-sectional schematic view of air flows in a wood burning stove, according to an exemplary embodiment of the present disclosure;

FIG. 23 illustrates an elevated side perspective view of a damper for a wood burning stove, according to an exemplary embodiment of the present disclosure;

FIG. 24 illustrates an elevated side perspective view of a shroud for a wood burning stove, according to an exemplary embodiment of the present disclosure;

FIG. 25 illustrates an elevated side perspective view of a blower for a wood burning stove, according to an exemplary embodiment of the present disclosure;

FIGS. 26-29 illustrate schematic views of a wood burning stove connected to a chimney, according to an exemplary embodiment of the present disclosure;

FIG. 30 illustrates steps of a method for providing heat from a wood burning stove, according to an exemplary embodiment of the present disclosure; and

FIG. 31 illustrates an elevated side perspective view of another wood burning stove, according to an exemplary embodiment of the present disclosure.

DETAILED DESCRIPTION

The following description refers to the accompanying drawings, which illustrate specific embodiments of the present disclosure. Other embodiments having different structures and operation do not depart from the scope of the present disclosure.

Referring to FIGS. 1-14, a wood burning stove 10 is depicted according to one embodiment. The stove 10 includes a housing 12. The housing 12 may be any suitable shape or size. In the illustrated embodiment, the housing 12 is generally cubical and includes a front side 14, a rear side 16, a first or left side 18, a second or right side 20, a top 22, and a base 24, which may be used to allow the stove 10 to stand on a surface.

The stove 10 includes a firebox 26 disposed within the housing 12. The firebox 26 may include a front wall 28, a rear wall 30, a first or left side wall 32, a second or right side wall 34, a ceiling 36, and a floor 38. The floor 38 may be sized, shaped, or otherwise configured to receive a solid fuel source, such as wood, and the firebox 26 may be sized, shaped, or otherwise configured to permit the fuel to burn. The floor 38 may also include a floor aperture 40 (FIG. 9) disposed generally in the middle of the floor 38 which may allow ash or other debris to be removed from the firebox 26, as described below. In the illustrated embodiment, the firebox 26 is generally box shaped. However, the firebox 26 may be any suitable shape, size, or configuration. For example, the firebox 26 may be curved, rounded, triangular, spherical, or any other suitable shape.

As shown in FIGS. 6-8 and 10-11, the firebox 26 may also include one or more firebricks 42 disposed on one or more of the floor 38, the front wall 28, the rear wall 30, the left side wall 32, and the right side wall 34 to refract or maintain heat in the firebox 26, such as when a fuel is burned in the firebox 26. The firebricks 42 may be thermal refractory bricks used in lining fireboxes, stoves, or fireplaces and may be made of any suitable material, such as fire clay, and may be able to withstand high temperatures, such as temperatures in excess of 2000° F. The firebricks 42 may be positioned within the firebox 26 to increase the thermal retention of the firebox 26 and may be positioned so as not to obstruct the floor aperture 40 or an opening into the firebox 26, as described below. As shown in the illustrated embodiment, the firebricks 42 may be generally rectangular in shape. However, the firebricks 42 may any suitable size, shape, or configuration. For example, the firebricks 42 may be in the shape of triangles, pentagons, hexagons, or any other suitable shape and the sides and edges may be tapered, rounded, chamfered, or any other suitable shape or configuration. In the illustrated embodiment, the stove 10 includes firebricks 42 of five different sizes and shapes (see A, B, C, D, and E in FIG. 11). However, the stove 10 may have any suitable combination of firebricks 42. 44

While the firebox 26 is described as including one or more firebricks 42 disposed on one or more of the floor 38, the front wall 28, the rear wall 30, the left side wall 32, and the right side wall 34, other embodiments are contemplated. For example, one or more of the floor 38, the front wall 28, the rear wall 30, the left side wall 32, and the right side wall 34 may comprise or be composed of one or more firebricks 42.

As shown in FIGS. 13-14, the stove 10 may also include one or more ceramic fiberboards 44 disposed in an upper portion of the firebox 26 opposite the floor 38. The one or more ceramic fiberboards 44 may be disposed on the underside or below the ceiling 36 of the firebox 26 and configured to retain or refract heat within the firebox 26. The one or more ceramic fiberboards 44 may be disposed next to each other along the surface of the ceiling 36 of the firebox 26 and substantially cover the surface of ceiling 36. The ceramic fiberboards 44 may have a similar composition to the one or more firebricks 42 and may be made of any suitable material, such as fire clay, and may and may be able to withstand high temperatures, such as temperatures in excess of 2000° F.

As shown in FIGS. 14, the stove 10 may optionally include a ceramic blanket 46 disposed in an upper portion of the firebox 26 opposite the floor 38. The ceramic blanket 46 may be disposed on the underside of the ceiling 36 of the firebox 26 above the one or more ceramic fiberboards 44 or may be disposed on the underside or below the one or more ceramic fiberboards 44. The ceramic blanket 46 may be disposed along the surface of the ceiling 36 or the surfaces of the one or more ceramic fiberboards 44 and may substantially cover the surface of the ceiling 36 and or the one or more ceramic fiberboards 44. The ceramic blanket 46 may have a similar composition to the one or more firebricks 42 and/or the one or more ceramic fiberboards 44 and may be made of any suitable material, such as fire clay, and may and may be able to withstand high temperatures, such as temperatures in excess of 2000° F. In other embodiments, the ceramic blanket 46 may define the ceiling 36 of the firebox 26.

As shown in FIGS. 6-7, the stove 10 may include a housing opening 48 in the front side 14 of the housing 12 and extending into the firebox 26. The housing opening 48 may be sized, shaped, and otherwise configured such that a user may load a fuel source, such as wood, into the firebox 26 through the housing opening 48.

As shown in FIGS. 1-4 and 12-16, the housing 12 may also include a door 50 which may be moveable between an open and closed position which may open and close the housing opening 48. The door 50 may be sized, shaped, and configured such that the door 50 substantially seals the firebox 26 and retains heat within the firebox 26 when the door is in the closed position. In the illustrated embodiment, the door 50 is pivotably attached to the front side 14 of the housing 12 on one side of the housing opening 48 such that the door 50 may be pivoted between the open and closed positions. For example, the door 50 may be pivotably attached to the front side of the housing 12 with a hinge such that it is pivotable between open and closed positions. However, the door 50 may be affixed to the housing 12 and moveable between the open and closed positions in any suitable manner. For example, the door 50 may be slidably affixed to the front side 14 of the housing 12 such that the door 50 may be slid along the front side 14 to open and close the housing opening 48. Optionally, the door 50 may have a glass portion or window 52 such that a user may at least partially view the contents of the firebox 26 when the door 50 is in the closed position.

The door 50 may include a lever 54 which may be used to secure the door 50 to the housing 12 when the door 50 is in the closed position. The lever 54 may include a flange 56 which extends inwardly into the housing 12 from the door 50 when the door 50 is in the closed position. The flange 56 may be rotated by rotational movement of the lever 54 and may be secured in or by a hook 60 extending inwardly from the front side 14 of the housing 12 into the firebox 26, such as by a clockwise rotational movement of the lever 54. The flange 56 may be released from the hook 60 via opposite rotational movement of the lever 54, such as a counterclockwise rotational movement of the lever 54, such that the door 50 may be freely moveable between the open and closed positions. Optionally, the lever 54 may also include a handle 58 at an end of the lever 54 which may be comfortably and safely grasped by a user to manipulate the position of the lever 54 and the door 50. The handle 58 may have any suitable shape, size, or configuration such that a user may comfortably and safely grasp the handle 58 during operation of the stove 10. For example, the handle 58 may be designed, shaped, or otherwise configured such that the handle 58 is at least relatively cool to the touch when a fuel source is burned in the firebox 26.

As shown in FIGS. 12-14, the housing 12 may have a lower portion 25 disposed below the firebox 26 which includes an ash bin 62 disposed substantially below the floor aperture 40 of the firebox 26. The ash bin 62 may be configured to receive ashes or other debris from the firebox 26 through the floor aperture 40 and allow a user to remove the ash or other debris from the stove 10. In the illustrated embodiment, the ash bin 62 is substantially rectangular. However, it will be appreciated that the ash bin 62 may have any suitable shape. For example, the ash bin 62 may be triangular, rounded, or any other suitable shape. The ash bin 62 may be slidably removed from the housing 12 such that a user may remove the ash bin 62 from the housing 12 to dispose of the contents of the ash bin 62.

Further, as shown in FIGS. 12-14 and 17A-17B, the stove 10 may also include an ash plug 64 which is sized and shaped to be at least partially disposed in the floor aperture 40 and to prevent fuel from falling from the firebox 26 into the ash bin 62 when the ash plug 64 is in place in the floor aperture 40. The ash plug 64 may be sized, shaped, or otherwise configured to prevent ash or other debris from falling through the floor aperture 40 and to substantially prevent the flow of air through the floor aperture 40 when the fuel is combusted in the firebox 26. The ash plug 64 may have a plug portion 66 sized and shaped to fit in the floor aperture 40 and a hook portion 68 configured to be grasped by a user. The ash plug 64 may be sized, shaped, and configured such that a user may grasp the hook portion 68 when the fuel is not burning in the firebox 26, remove the ash plug 64 from the floor aperture 40, sweep the ashes through the floor aperture 40 and into the ash bin 62, empty the ash bin 62, such as in a suitable container, and replace the plug portion 66 in the floor aperture 40.

In one embodiment, as best shown in FIGS. 17A-17B, the ash plug 64 may also include a platform 70 between the plug portion 66 and the hook portion 68 which extends outwardly and defines a substantially flat surface. The ash plug 64 may be sized, shaped, or otherwise configured such that the platform 70 is substantially the same height as the firebricks 42 disposed on the floor 38 of the firebox 26 when the ash plug 64 is disposed in the floor aperture 40 and substantially covers the portion of the floor 38 the firebricks 42 do not cover, thereby defining a substantially continuous and substantially level surface for a fuel to be placed in the firebox 26. Further, the platform 70 may include one or more supports 72 which extend downwardly from the platform 70 and are configured to keep the platform 70 at substantially the same height as the firebricks 42 disposed on the floor 38 of the firebox 26 when the plug portion 66 is disposed in the floor aperture 40. The supports 72 may also be sized, shaped, or otherwise configured such that the ash plug 64 may adequately support fuel placed in the firebox 26 for combustion.

As shown in FIGS. 3, 4, 8, 12, and 22, the housing 12 may include a fresh air intake or rear air opening 74 disposed in a lower portion of the rear side 16 of the housing 12. The rear air opening 74 may be disposed below the firebox 26 and be configured to deliver a flow of primary air into the lower portion 25 housing 12 from outside the stove 10. The rear air opening 74 may be sized, shaped, or otherwise configured to supply a desired amount of air from outside the stove 10 into the firebox 26 as detailed below. Optionally, the rear air opening 74 may be combined with or connected to a pipe or other suitable conduit to receive air from a remote location, such as from outside the room or building in which the stove 10 is located (FIG. 29).

Referring to FIGS. 12 and 22, the housing 12 may further include a first air flow channel 76 configured to deliver a first flow of primary air into the firebox 26. As used herein, the term “primary air” refers to air supplied for a first or primary combustion of a fuel source, such as wood, in the firebox 26 which produces or emits smoke which may include a combustible gas. The term “secondary air” refers to air supplied for a secondary combustion in the firebox 26 which is the burning of combustible gas emitted by the first or primary combustion. The first air flow channel 76 may be positioned, oriented, or otherwise configured to increase heat output of the stove 10, to increase the efficiency of the stove 10, and/or to reduce the particulate emissions from the stove 10.

The first air flow channel 76 may extend from the lower portion 25 of the housing 12 to an upper portion of the firebox 26 to supply primary air to the firebox 26. The first air flow channel 76 may have an inlet 78 disposed substantially above the rear air opening 74 and configured to receive air from the rear air opening 74 and/or the lower portion 25 of the housing 12. The inlet 78 may be located in a rear portion of the housing 12 between the firebox 26 and the rear side 16 of the housing 12 at the same or similar height to the floor 38 of the firebox 26. The inlet 78 may have any suitable size, shape, or configuration suitable to receive a flow of air from the rear air opening 74 and/or the lower portion 25 of the housing 12 to deliver to the firebox 26, as described below. For example, the inlet 78 of the first air flow channel 76 may be substantially rectangular. However, the inlet 78 may have any other suitable configuration. For example, the inlet 78 may be rounded, triangular, elliptical, or any other suitable shape.

The first air flow channel 76 may extend upwardly from the inlet 78 through the housing 12 between the rear side 16 of the housing 12 and the rear wall 30 of the firebox 26 to an upper portion of the housing 12 near the top 22 of the housing 12. The first air flow channel 76 may then divide and extend along the rear wall 30 to the left and right side walls 32, 34 along an underside of the top 22 of the housing 12. The first air flow channel 76 may then extend along the top of the housing 12 from the rear side 16 of the housing 12 to the front side 14 of the housing 12 between the top 22 of the housing 12 and the ceiling 36 of the firebox 26 along both the left and right side walls 32, 34. The two portions extending along the left and right side walls 32, 43 may then converge along the front side 14 of the housing 12. The first air flow channel 76 may then extend downwardly along a portion of the front side 14 of the housing 12. Optionally, the first air flow channel 76 may extend at least partially into the door 50. The first air flow channel 76 may have an outlet 80 (FIG. 22) configured to deliver primary air into the firebox 26. The outlet 80 may be in be in or extend through the front wall 28 of the firebox 26 in an upper portion of the firebox 26 near the ceiling 36 of the firebox 26. The outlet 80 may be oriented downwardly at an angle to direct primary air toward a fuel source disposed on the floor 38 of the firebox 26. For example, the outlet 80 may be oriented to direct primary air toward the floor aperture 40.

Referring to FIGS. 1-2, 4-8, 22, and 23, the stove 10 may also include a first or primary damper 82 having a rod portion 84 and a stopper portion 86 configured to permit or control the amount of air flow through the first air flow channel 76. The rod portion 84 of the primary damper 82 may extend through a damper aperture 90 in an upper portion of the front side 14 of the housing 12 near the top 22 of the housing 12 and into the first air flow channel 76. The rod portion 84 may be sized, shaped, and otherwise configured such that the stopper portion 86 of the primary damper 82 may be disposed in a rear portion of the first air flow channel 76 (e.g., the portion of the first air flow channel 76 between the rear wall 30 of the firebox 26 and the rear side 16 of the housing 12) and be at least partially moveable between the rear side 16 of the housing 12 and an upper portion of the first air flow channel 76 (e.g., the portion of the first air flow channel 76 between the rear portion of the first air flow channel 76 and the front side 14 of the housing 12). The primary damper 82 may be slidable or otherwise moveable through the damper aperture 90 (FIG. 2) in an upper portion of the front side 14 of the housing 12 such that the stopper portion 86 of the primary damper 82 is moveable, slidable, or otherwise positionable between a closed, partially opened, and opened configuration. The stopper portion 86 of the primary damper 82 may be sized, shaped, or otherwise configured such that, in the closed position, the stopper portion 86 may seal or otherwise prevent the flow of air from the rear portion of the first air flow channel 76 to the upper portion of the first air flow channel 76. For example, the rod portion 84 of the primary damper 82 may be pulled or otherwise moved away from the front side 14 of the housing 12 such that the stopper portion 86 of the primary damper 82 is moved toward the upper portion of the first air flow channel 76 to restrict or prevent the flow of air from the rear portion of the first air flow channel 76 into the upper portion of the first air flow channel 76 and thereby prevent the flow of air through the first air flow channel 76 into the firebox 26. Further, in the open position, the rod portion 84 may be pushed into the housing 12 such that the stopper portion 86 is disposed the furthest distance opposite the upper portion of the first air flow channel 76, thereby permitting a maximum amount of air to flow from the rear portion of the first air flow channel 76 into the upper portion of the first air flow channel 76. In the partially open position, the rod portion 84 of the primary damper 82 may my slid or otherwise moved such that the stopper portion 86 is between the closed position and the open position, thereby permitting a desired amount of airflow between no airflow and the maximum amount of airflow. The primary damper 82 may be slidable or positionable between a high burn position permitting a maximum amount of air to flow through the first air flow channel 76, a medium burn position permitting an intermediate amount of air to flow through the first air flow channel 76, and a low burn position permitting a low or negligible amount of air to flow through the first air flow channel 76 or prevent the flow of air through the first air flow channel.

The stove 10 and/or primary damper 82 may also have any suitable alternative configuration to control the amount of air supplied to the firebox 26. For example, the primary damper 82 may be positioned in the stove 10 such that the stopper portion 86 of the primary damper 82 is disposed in the upper portion of the first air flow channel 76 and may be moved, slid, or otherwise positioned such that the stopper portion 86 may close or prevent airflow from the rear portion of the first air flow channel 76, such as by abutment with an opening of the rear portion of the first air flow channel 76. In such embodiment, the primary damper 82 may be moved to the closed position by sliding or moving the primary damper 82 through the damper aperture 90 toward the rear side 16 of the housing 12 until the stopper portion 86 abuts and/or prevents the flow of air from the rear portion of the first air flow channel 76. The primary damper 82 may then be moved to the partially open position by moving or sliding the stopper portion 86 toward the front side 14 of the housing 12 to permit some amount of air flow from the rear portion of the first air flow channel 76 into the upper portion of the first air flow channel 76. The primary damper 82 may be moved to the open position by moving or sliding the stopper portion 86 toward the front side 14 of the housing 12 to permit a maximum amount of air flow from the rear portion of the first air flow channel 76 into the upper portion of the first air flow channel 76.

It will be appreciated that the stove 10 may have other suitable locations and configurations of the primary damper 82. In another embodiment, as shown in FIG. 31, the primary damper 82 of the stove 10 extends into the housing 12 through the right side 20 of the housing 12. In such a configuration, the primary damper 82 may be similarly used to permit or control the amount of air flow through the first air flow channel 76, as described above. The stove 10 may also have other suitable primary damper 82 configurations. For example, the primary damper 82 may extend into the housing 12 through the left side 18 of the housing, through the rear side 16 of the housing 12, or through the top 22 of the housing 12 to similarly to permit or control the amount of air flow through the first air flow channel 76, as described above.

In some embodiments, the primary damper 82 may also include a damper handle 88 which may be grasped by a user such that the user is not burned or otherwise injured when grasping the damper handle 88 when the fuel is burned in the firebox 26. While the stove 10 is depicted as having one damper, the stove 10 may have any suitable number and configuration of dampers. For example, the stove 10 may have a damper configured to control airflow through each of the air flow channels as described herein.

Referring to FIGS. 7, 8, 12-14, 18-20, and 22, the stove 10 may also include a secondary air flow channel 92 (shown in FIGS. 12 and 22) configured to deliver a flow of secondary air to the firebox 26. The secondary air flow channel 92 may include a secondary air flow frame 94 with an inlet configured to receive a flow of air into the secondary air flow frame 94. The inlet of the secondary air flow frame 94 may be in communication with the first air flow channel 76 to receive a flow of air from the first air flow channel 76. For example, the inlet of the secondary air flow frame 94 may receive a flow of air from the rear portion of the first air flow channel 76 below the upper portion of the first air flow channel 76. The inlet of the secondary air flow frame 94 may receive air from the first air flow channel 76 at a location below the stopper portion 86 of the primary damper 82 such that the flow of air from the first air flow channel 76 into the secondary air flow frame 94 is not substantially affected by the position of the stopper portion 86 of the primary damper 82. The secondary air flow channel 92, and components thereof, may be positioned, oriented, or otherwise configured to increase heat output of the stove 10, increase the efficiency of the stove 10, and/or to reduce the particular emissions from the stove 10.

The secondary air flow frame 94 may be substantially rectangular and U-shaped with a rear portion which extends from the inlet in communication with the first air flow channel 76 along the rear wall 30 of the firebox 26 toward the left and right side walls 32, 34 of the firebox 26. The secondary air flow frame 94 may also have leg portions which extend from the rear wall 30 of the firebox 26 toward the front wall 28 along the left and right side walls 32, 34, respectively. The leg portions may be disposed on and extend along the left and right side walls 32, 34 of the firebox 26 or may be inset from the left and right side walls 32, 34, respectively. The leg portions of the secondary air flow frame 94 may have one or more frame apertures 95 disposed in an inner or medial side of the leg portions to accommodate and/or provide secondary air to secondary air tubes, as described below. The secondary air flow frame 94 may be sized, shaped, positioned, or otherwise configured such that the leg portions of the secondary air flow frame 94 are disposed in an upper portion of the firebox 26. The secondary air flow frame 94 may also include one or more dampers which may regulate the flow of secondary air through the secondary air flow frame 94.

As shown in FIGS. 7-8, 12-15, 18-20, and 22, the secondary air flow channel 92 of the stove 10 may also include or be defined by one or more secondary air tubes 96 disposed in an upper portion of the firebox 26 and configured to deliver a flow of secondary air to the firebox 26. The secondary air tubes 96 may be disposed between the frame apertures 95 of the secondary air flow frame 94. The secondary air tubes 96 may be connected to the secondary air flow frame 94 in flow communication to receive a flow of air from the secondary air flow frame 94. The secondary air tubes 96 may be connected to the secondary air flow frame 94 such that the secondary air tubes 96 are disposed above the floor 38 of the firebox 26 and below the ceiling 36 of the firebox 26, the one or more ceramic fiberboards 44, and/or the ceramic blanket 46 and may be disposed substantially parallel to the front wall 28 and the rear wall 30. In the illustrated embodiment, the stove 10 includes three secondary air tubes 96 (a first secondary air tube 96a, a second secondary air tube 96b, and a third secondary air tube 96c). However, it will be appreciated that the stove 10 may include any number of secondary air tubes 96. For example, the stove 10 may have one, two, or four or more secondary air tubes 96. Further, in the illustrated embodiment, the secondary air tubes 96 are substantially cylindrical in shape. However, it will be appreciated that the secondary air tubes 96 may have any suitable shape, size, or configuration. For example, the secondary air tubes 96 may be rectangular in shape or may incorporate any number of bends along the length of the secondary air tube 96.

Each secondary air tube 96 may include an air intake or entrance 98 in each end of the secondary air tube 96 configured to receive secondary air from the frame apertures 95 of secondary air flow frame 94 and one or more exits or secondary air apertures 100 disposed along the length of the secondary air tube 96 and configured to allow the secondary air to exit the secondary air tube 96 and thereby mix with a combustible gas emitted by a fire located in the firebox 26. The secondary air tubes 96 may be sized and shaped such that the secondary air tubes 96 substantially extend between each corresponding pair of frame apertures 95 of the secondary air flow frame 94 and substantially fill or cover the frame apertures 95 of the secondary air flow frame 94 such that the secondary air from the secondary air flow frame 94 may flow through the frame apertures 95 into both air intakes 98 of each secondary air tube 96.

Each secondary air tube 96 may also include one or more tabs 102 disposed at one of the ends of the secondary air tube 96 near the air intake 98. The tab 102 may be positioned on the secondary air tube 96 and configured such that the secondary air tube 96 may be affixed to the secondary air flow frame 94 in the desired position or orientation, such as detailed below. The tab 102 may be affixed or connected to the secondary air flow frame 94 by any suitable means. For example, the tab 102 may be affixed or connected to the secondary air flow frame 94 by welding, a fastener, or any other suitable means. Alternatively, in other embodiments, the secondary air tubes 96 may be integral with the secondary air flow frame 94.

Referring to FIG. 22, the secondary air flow channel 92 may be configured to deliver a flow of secondary air into the firebox 26 to mix with a combustible gas emitted by a fire located in the firebox 26 and thereby provide a secondary combustion within the firebox 26. The flow of secondary air may enter the lower portion 25 of the housing 12 through the rear air opening 74 and then flow upwardly into the first air flow channel 76 toward the secondary air flow channel 92. The secondary air may flow from the first air flow channel 76 into the rear portion of the secondary air flow frame 94 and into the leg portions of the secondary air flow frame 94. The secondary air may then flow from the leg portions of the secondary air flow frame 94 into the secondary air tubes 96 through the frame apertures 95 into the air intakes 98 and flow out the secondary air apertures 100 into an upper portion of the firebox 26.

The secondary air flow frame 94 and the secondary air tubes 96 may be positioned, oriented, or otherwise configured such that secondary air may flow through the secondary air flow channel 92 and out of the secondary air apertures 100 in the desired amount, position, and orientation for secondary combustion in the firebox 26. For example, the secondary air flow frame 94 and the secondary air tubes 96 may be positioned, oriented, or otherwise configured to increase heat output of the stove 10, increase the efficiency of the stove 10, and/or reduce the particulate emissions from the stove 10.

The secondary air flow frame 94 may be sized, shaped, positioned, or otherwise configured to provide the desired amount of air flow through the secondary air flow channel 92, such as to increase heat output of the stove 10, to increase the heating efficiency of the stove 10, and/or to reduce particulate emissions from combustion in the stove 10. In one embodiment, the secondary air flow frame is tilted or angled upwardly from the connection with the first air flow channel 76 such that the portion of the secondary air flow frame 94 nearer the front wall 28 of the firebox 26 is higher (e.g., farther away from the floor 38 of the firebox 26) than the portion of the secondary air flow frame 94 connected to the first air flow channel 76. For example, the secondary air flow frame 94 may be angled upwardly between about 0° and 20° from a horizontal plane extending outwardly from the connection of the secondary air flow frame 94 and the first air flow channel 76, such as between about 2° upwardly and about 10° upwardly, such as about 5° upwardly.

The secondary air tubes 96 may be sized, shaped, positioned, or otherwise configured to provide the desired amount and orientation of air flow from the secondary air flow channel 92. The secondary air tubes 96 may include any number and configuration of secondary air apertures 100 such that the secondary air flows out of the secondary air apertures 100 in the desired amount, position, and orientation. In one embodiment, each of the secondary air tubes 96 includes a plurality of secondary air apertures 100 disposed linearly along a length of the secondary air tubes 96. The secondary air apertures 100 may be evenly spaced along the length of the secondary air tubes 96 with a center hole distance between each secondary air aperture 100 between about 0.25 inches and about 1.0 inch, such as between about 0.35 inches and about 0.75 inches, such as having about a 0.5 inch center hole distance between each secondary air aperture 100. In the illustrated embodiment, each secondary air tube 96 includes 34 secondary air apertures 100 evenly spaced along a length of the secondary air tube 96. However, the secondary air tubes 96 may have any suitable spacing or configuration of secondary air apertures 100. For example, the secondary air tubes 96 may have an uneven distribution of secondary air apertures 100, such as with the secondary air apertures 100 being grouped closer to one or both of the air intakes 98, grouped closer to a medial portion of the secondary air tube 96, or any other suitable configuration.

Referring to FIGS. 7, 8, 12-15, 18-20, and 22, the secondary air tubes 96 may be attached to the secondary air flow frame 94 with the tab 102 such that the secondary air tube 96 and/or secondary air apertures 100 are oriented to provide secondary air into the firebox 26 in the desired direction or orientation. The tabs 102 of the secondary air tubes 96 may be affixed to secondary air flow frame 94 at an angle with the horizontal plane such that the secondary air tubes 96 and/or secondary air apertures 100 are disposed at an angle in the firebox 26. For example, the tabs 102 of the secondary air tube 96 may be attached to the secondary air flow frame 94 at an upward angle to the horizontal plane between about 0° and about 90°, such as between about 20° and 60° upward relative to the horizontal plane, such as about 35° upward relative to the horizontal plane.

The secondary air apertures 100 may be disposed or oriented along the secondary air tubes 96 relative to the tab 102 such that the secondary air exits the secondary air apertures 100 in the desired direction or orientation. The secondary air apertures 100 may also be sized, shaped, or otherwise configured such that the desired amount of secondary air flows out of each of the secondary air tubes 96. In the illustrated embodiment, the stove 10 includes three secondary air tubes 96 with a first secondary air tube 96a disposed closer to the front wall 28, a second secondary air tube 96b disposed between the other two secondary air tubes 96, and a third secondary air tube 96c disposed closer to the rear wall 30. However, it will be appreciated that the stove 10 may include any number of secondary air tubes 96 in any suitable configuration.

As shown in FIGS. 19A and 19B, the secondary air apertures 100 of the first secondary air tube 96a may be sized, spaced, oriented, or otherwise configured to supply a desired amount of secondary air into the firebox 26. The secondary air apertures 100 of the first secondary air tube 96a may be disposed or oriented relative to the tab 102 of the first secondary air tube 96a such that the secondary air apertures 100 of the first secondary air tube 96a deliver secondary air into the firebox 26 at the angle desired for secondary combustion. For example, the secondary air apertures 100 of the first secondary air tube 96a may be disposed opposite the tab 102 at an angle (clockwise around the circumference of the tube) between about 90° and about 210° relative to the orientation of the tab 102 of the first secondary air tube 96a, such as between about 120° and about 160° relative to the orientation of the tab 102, such as about 145° relative to the orientation of the tab 102. The secondary air apertures 100 of the first secondary air tube 96a may also be sized to deliver secondary air into the firebox 26 at the amount desired for secondary combustion. For example, the secondary air apertures 100 of the first secondary air tube 96a may have a diameter between about 0.10 inches and about 0.25 inches, such as between about 0.15 inches and about 0.20 inches, such as about 0.195 inches.

As shown in FIG. 20, the secondary air apertures 100 of the second secondary air tube 96b may be sized, spaced, oriented, or otherwise configured to supply a desired amount of secondary air into the firebox 26. The secondary air apertures 100 of the second secondary air tube 96b may be disposed or oriented relative to the tab 102 of the second secondary air tube 96b such that the secondary air apertures 100 of the second secondary air tube 96b deliver secondary air into the firebox 26 at the angle desired for secondary combustion. For example, the secondary air apertures 100 of the second secondary air tube 96b may be disposed in line with the tab 102 at an angle (clockwise around the circumference of the tube) between about 0° and about 20° relative to the orientation of the tab 102 of the second secondary air tube 96b, such as between about 2° and about 10° relative to the orientation of the tab 102, such as about 5° relative to the orientation of the tab 102. The secondary air apertures 100 of the second secondary air tube 96b may also be sized to deliver secondary air into the firebox 26 at the amount desired for secondary combustion. For example, the secondary air apertures 100 of the second secondary air tube 96b may have a diameter between about 0.10 inches and about 0.25 inches, such as between about 0.15 inches and about 0.20 inches, such as about 0.18 inches.

The secondary air apertures 100 of the third secondary air tube 96c may also be sized, spaced, oriented, or otherwise configured to supply a desired amount of secondary air into the firebox 26. The secondary air apertures 100 of the third secondary air tube 96c may be disposed or oriented relative to the tab 102 of the third secondary air tube 96c such that the secondary air apertures 100 of the third secondary air tube 96c deliver secondary air into the firebox 26 at the angle desired for secondary combustion. For example, the secondary air apertures 100 of the third secondary air tube 96c may be disposed in line the tab 102 at an angle (clockwise around the circumference of the tube) between about 0° and about 20° relative to the orientation of the tab 102 of the third secondary air tube 96c, such as between about 2° and about 10° relative to the orientation of the tab 102, such as about 5° relative to the orientation of the tab 102. The secondary air apertures 100 of the second secondary air tube 96b may also be sized to deliver secondary air into the firebox 26 at the amount desired for secondary combustion. For example, the secondary air apertures 100 of the third secondary air tube 96c may have a diameter between about 0.10 inches and about 0.25 inches, such as between about 0.11 inches and 0.20 inches, such as about 0.15 inches.

While the secondary air tubes 96 are described as having 34 secondary air apertures 100 evenly spaced along the secondary air tube 96, the secondary air tubes 96 may have any suitable configuration of secondary air apertures 100. For example, the secondary air tubes 96 may have any number of secondary air apertures 100 (such as between 1 and 33 secondary air apertures 100 or 35 or more secondary air apertures 100), the secondary air apertures 100 may not be linearly disposed along the secondary air tube 96 (such as being oriented in different radial directions along the length of the secondary air tubes 96), the secondary air apertures 100 may not be evenly distributed along the secondary air tubes 96 (such as unevenly distributed or grouped closer together along medial portions of the secondary air tubes 96), and/or the secondary air apertures 100 may have different shapes. Further, each secondary air tube 96 may have a different number and/or configuration of secondary air apertures 100.

As shown in FIGS. 6, 7, 9, 10, 12-14, 21A-21D, and 22, the stove 10 may also include a lower primary air conduit 104 which may supply a third flow of air or a second flow of primary air into the firebox 26. The lower primary air conduit 104 may be generally L-shaped and extend from the lower portion 25 of the housing 12 into the firebox 26 through the floor 38 of the firebox 26 near the front wall 28. The lower primary air conduit 104 may have a body with an intake portion or base portion 105 and an outlet or neck portion 107 extending upwardly from the base portion 105. The lower primary air conduit 104 may include a lower intake 106 disposed in a bottom of the base portion 105 configured to receive air from the lower portion 25 of the housing 12. For example, a bottom of the base portion 105 may be open and define the lower intake 106 such that the lower intake 106 may receive air from the lower portion 25. The neck portion 107 may be substantially hollow with an opening or passage connecting an inner portion of the neck portion 107 with the lower intake 106 such that air from the lower portion 25 flows into an inside portion of the neck portion 107. The neck portion 107 may include one or more conduit apertures 108 disposed in one or more faces of the neck portion 107. The conduit apertures 108 may be configured to supply air from the lower intake 106 into the firebox 26. For example, the conduit apertures 108 may be disposed in a rear wall or face 107a of the neck portion 107 to supply air from the lower intake toward the rear wall 30 of the firebox 26. The base portion 105 may extend rearwardly from the rear face 107a of the neck portion 107 such that a portion of the base portion 105 may be disposed rearwardly of the conduit apertures 108 in the neck portion 107.

The lower primary air conduit 104 may have any suitable size, shape, or configuration to provide a desired flow of primary air into the firebox 26. For example, the lower primary air conduit 104 may be sized, shaped, or otherwise configured to increase heat output of the stove 10, to increase the heating efficiency of the stove 10, and/or to reduce particulate emissions from combustion in the stove 10. In the illustrated embodiment, the base portion 105 of the lower primary air conduit 104 is substantially box-shaped with an open bottom and the neck portion 107 is substantially a half cylinder with conduit apertures 108 disposed in the curved rear face 107a of the neck portion 107. The neck portion 107 also includes a front face 107b which may be substantially planar. The neck portion 107 may be disposed above a front portion of the base portion 105 of the lower primary air conduit 104 such that the planar front face 107b of the neck portion 107 is substantially continuous with a front wall or face of the base portion 105. The lower primary air conduit 104 may be disposed in the front of the firebox 26 such that the front face of the base portion 105 and the front face 107b of the neck portion 107 are substantially aligned with the front wall 28 of the firebox 26. One or more conduit apertures 108 may be disposed in the rear wall of the neck portion 107 to provide a flow of air from the lower portion 25 toward the rear wall 30 of the firebox 26.

The lower primary air conduit 104 may extend to any suitable height in the firebox 26 to provide the desired flow of primary air. For example, the lower primary air conduit 104 may extend to a height between about 2.0 inches and about 3.6 inches above the floor 38 of the firebox 26, such as between about 2.5 inches and about 3.3 inches above the floor 38 of the firebox 26, such as about 2.8 inches above the floor 38 of the firebox 26. In one embodiment, the one or more conduit apertures 108 are disposed and configured to direct air from the lower primary air conduit 104 away from the front wall 28 of the firebox 26 and into a lower and central portion of the firebox 26.

While the neck portion 107 of the lower primary air conduit 104 has been described as being generally a half cylinder shape with the curved portions (e.g., rear face 107a) directed toward the center of the firebox 26 and a box-shaped base portion 105 which extends toward the rear wall 30 of the firebox 26, it will be understood that the lower primary air conduit 104 may have any suitable sizes, shapes, or configurations. For example, the neck portion 107 of the lower primary air conduit 104 may be cylindrical, rectangular, conical, triangular, or any other suitable shape, and the base portion 105 may be cylindrical, half cylindrical, conical, triangular, funnel shaped, or any other suitable shape.

In one embodiment, as best shown in FIGS. 21A-21C, the lower primary air conduit 104 has three conduit apertures 108 (a first conduit aperture 108a, a second conduit aperture 108b, and a third conduit aperture 108c) disposed in the curved rear face 107a of the neck portion 107 of the lower primary air conduit 104. The conduit apertures 108a, 108b, 108c, may be disposed in the neck portion 107 to provide flows of air at different directions into the firebox 26. In some embodiments, the first conduit aperture 108a is disposed along a curved or angled portion of the rear face 107a of the neck portion 107 and directed toward the left side and/or rear wall 30, 32 of the firebox 26, the second conduit aperture 108b is disposed in a central portion of the rear face 107a of the neck portion 107 and directed substantially toward the rear wall 30 of the firebox 26, and the third conduit aperture 108c is disposed along a curved or angled portion of the rear face 107a of the neck portion 107 and directed toward the right side and/or rear walls 30, 34 of the firebox 26. However, the neck portion 107 may have any suitable number and/or configuration of conduit apertures 108. For example, the neck portion 107 may have one, two, or four or more conduit apertures 108 disposed in any suitable configuration to deliver primary air to the firebox 26, such as in different directions. Further the aperture(s) may be provided in a variety of shapes, including, for example, circular (as shown), elongated horizontal slot-shaped, or elongated vertical slot-shaped apertures.

In the illustrated embodiment, the second conduit aperture 108b is disposed below (e.g., closer to the floor 38 of the firebox 26) the first and third conduit apertures 108a, 108c. However, the conduit apertures 108 may have any suitable configuration. For example, all conduit apertures 108 may be disposed at substantially the same height, the first and third conduit apertures 108a, 108c may be disposed below the second conduit aperture 108b, one of the first and third conduit apertures 108a, 108c may be disposed below the second conduit aperture 108b and the other of the first and third conduit apertures 108a, 108c may be disposed above the second conduit aperture 108b, or any other suitable configuration.

The lower intake 106 may be sized, shaped, or otherwise configured to supply the desired amount of primary air into and through the lower primary air conduit 104. For example, the lower intake 106 may be substantially half-circular and have a diameter between about 0.25 inches and about 0.50 inches, such as between about 0.30 inches and about 0.40 inches, such as about 0.344 inches. However, the lower intake 106 may have any suitable size, shape, or configuration. For example, the lower intake 106 may be triangular, rectangular, circular, elliptical, or any other suitable shape.

The conduit apertures 108 may be sized, shaped, or otherwise configured such that primary air is fed into the firebox 26 from the conduit apertures 108 in the desired amount for primary combustion. The first and third conduit apertures 108a, 108c may be substantially circular and have any suitable diameter. For example, the first and third conduit apertures 108a, 108c may be substantially circular and each have a diameter between about 0.20 inches and about 0.50 inches, such as between about 0.25 inches and about 0.35 inches, such as about 0.3125 inches. The second conduit aperture 108b may be substantially circular and have any suitable diameter. For example, the second conduit aperture 108b may be substantially circular and have a diameter between about 0.15 inches and about 0.40 inches, such as between about 0.20 inches and about 0.30 inches, such as about 0.25 inches. However, the conduit apertures 108 may have any suitable size, shape, or configuration. For example, the conduit apertures 108 may be triangular, rectangular, elliptical, or any other suitable shape.

The conduit apertures 108 may be positioned, oriented, or otherwise configured such that primary air is fed into the firebox 26 in the desired direction(s) or orientation(s). For example, the conduit apertures 108 may be oriented or otherwise configured to increase heat output of the stove 10, increase the heating efficiency of the stove 10, and/or to reduce particulate emissions from combustion in the stove 10. The first and third conduit apertures 108a, 108c may be disposed in the rear face 107a of the neck portion 107 and angled or oriented to direct primary air into the firebox 26 at an angle between the rear wall 30 and the left and right side walls 32, 34, respectively, as desired for primary combustion. The first and third conduit apertures 108a, 108c may each be oriented or otherwise configured at an angle with respect to a vertical plane extending rearward (e.g., toward the rear wall 30) from a medial portion of the lower primary air conduit 104, such as to at least partially direct flows of primary air toward the left and right side walls 32, 34. For example, the first and third conduit apertures 108a, 108c may be positioned in the rear face 107a of the neck portion 107 at an angle with respect to the vertical plane extending rearwardly from the medial portion of the rear face 107a between about 30° and about 60° toward the left or right side wall 32, 34, respectively, such as between about 40° and about 50°, such as about 45°. The first and third conduit apertures 108a, 108c may be angled oppositely with respect to the vertical plane extending rearwardly from the medial portion of the rear face 107a. The second conduit aperture 108b may be disposed in the rear face 107a of the neck portion 107 and oriented or otherwise configured to direct a flow of primary air substantially rearward from the lower primary air conduit 104. However, the second conduit aperture 108b may have any suitable orientation. For example, the second conduit aperture 108b may be angled between about 0° and about 20° toward either the left or right side wall 32, 34, such as between about 0° and about 10° toward either the left or right side wall 32, 34.

The conduit apertures 108 disposed in the rear face 107a of the neck portion 107 may also be positioned in the lower primary air conduit 104 relative to the floor 38 of the firebox 26 in any suitable manner to provide the desired flow of primary air for primary combustion in the firebox 26. For example, the conduit apertures 108 may be positioned to increase heat output of the stove 10, increase the heating efficiency of the stove 10, and/or to reduce particulate emissions from combustion in the stove 10. The second conduit aperture 108b may be positioned at any suitable location in the neck portion 107 to direct primary air at the desired height or location into the firebox 26. For example, the second conduit aperture 108b may be disposed in the rear face 107a of the neck portion 107 and elevated between about 0 inches and about 2.0 inches above the floor 38 of the firebox 26, such as between about 0.5 inches and 1.5 inches above the floor 38 of the firebox 26, such as about 1 inch above the floor 38 of the firebox 26. The first and third conduit apertures 108a, 108c may also be disposed in the rear face 107a of the neck portion 107 and positioned at any suitable location in the neck portion 107 to direct primary air at the desired height or location into the firebox 26. For example, the first and third conduit apertures 108a, 108c may be elevated between about 0.4 inches and about 2.6 inches above the floor 38 of the firebox 26, such as between about 0.8 inches and about 2.0 inches above the floor 38 of the firebox 26, such as about 1.4 inches above the floor 38 of the firebox 26.

The lower primary air conduit 104 may provide a third flow of air or a second flow of primary air into the firebox 26 for a primary combustion of a fuel placed in the firebox 26. Air may flow into the housing 12 through the rear air opening 74 into the lower portion 25 of the housing 12. The air may then flow from the lower portion 25 of the housing 12 into the base portion 105 of the lower primary air conduit 104 through the lower intake 106, into the neck portion 107 of the lower primary air conduit 104, and then into the firebox 26 through the one or more conduit apertures 108 of the lower primary air conduit 104, such as conduit apertures 108 disposed in the neck portion 107 of the lower primary air conduit 104.

In the illustrated embodiment, as best shown in FIGS. 21A-21B, the lower primary air conduit 104 includes fourth and fifth conduit apertures 108d, 108e disposed in the base portion 105 of the lower primary air conduit 104. The fourth and fifth conduit apertures 108d, 108e may be positioned in the base portion 105 in any suitable manner to provide the desired flow of primary air for primary combustion in the firebox 26. For example, the fourth and fifth conduit apertures 108d, 108e may be positioned to increase heat output of the stove 10, increase the heating efficiency of the stove 10, and/or to reduce particulate emissions from combustion in the stove 10. The fourth and fifth conduit apertures 108d, 108e may be sized and shaped to direct a second flow of primary air upwardly from the base portion 105 and toward a central portion of the firebox 26 for a primary combustion of a fuel. However, in other embodiments, the lower primary air conduit 104 may not have fourth and fifth conduit apertures 108d, 108e. For example, the base portion 105 of the lower primary air conduit 104 may be solid without fourth or fifth conduit apertures 108d, 108e in the lower portion.

As shown in FIGS. 1-6, the stove 10 may include a flue 112 in the top 22 of the housing 12 and in communication with the firebox 26. The flue 112 may be configured such that exhaust or emissions generated by the combustion of fuel in the firebox 26 may flow out of or exit the firebox 26 and the stove 10. The flue 112 may include a collar 114 disposed around the flue 112 which extends upwardly and may be connected to a chimney, as detailed below.

Turning now to FIGS. 26-29, the stove 10 may be connected to a chimney 116 to permit exhaust or emissions generated by the combustion of fuel in the firebox 26 to flow out of a structure or location in which the stove 10 is located.

As shown in FIGS. 26-29, the stove 10 may include one or more chimney connectors 118 configured to connect the stove 10 to the chimney 116 and allow exhaust or emissions generated by combustion of fuel in the firebox 26 to flow out of or exit the chimney 116. The chimney connectors 118 may be connected or otherwise configured to vent air out from inside the stove 10 to a location outside the house or structure in which the stove 10 is located. The chimney connectors 118 may be substantially straight, bent, or curved to direct the stove 10 exhaust as desired. The chimney connectors 118 may be connected to the housing 12, other chimney connectors 118, and/or the chimney 116. For example, as shown in FIG. 26, one or more chimney connectors 118 may be attached to the collar 114 of the flue 112 such that the exhaust of the stove 10 may vent from the flue 112 to the chimney 116, such as with the use of a chimney collar 120 and a thimble 122. The thimble 122 may provide an air flow entrance into the chimney 116 and the chimney collar 120 may provide an airtight seal around the connections of two chimney connectors 118, between one of the chimney connectors 118 and the thimble 122, or between one of the chimney connectors 118 and a portion of the structure. Additionally, as shown in FIG. 27, one or more chimney connectors 118 may be attached to the stove 10 such that the exhaust of the stove 10 may vent through a non-combustible structure wall, such as into an external chimney 124 with a chimney cap 126 meant to provide a vented cover for the external chimney 124 (or chimney 116). Further, as shown in FIGS. 28 and 29, the chimney connectors 118 may be attached to the stove 10 in a substantially vertical configuration such that the exhaust of the stove 10 may vent through a roof of a structure, such as into an external chimney 124 with a chimney cap 126

As shown in FIGS. 1-8, 13-14, and 24 the stove 10 may include a shroud 109 configured to provide heat from combustion in the firebox 26 of the stove 10 into the room or area in which the stove 10 is located. The shroud 109 may extend around the rear side 16 of the housing 12 and around at least a part of the left and right sides 18, 20 of the housing 12. In one embodiment, the shroud 109 is integral with the rear side 16 of the housing 12 and at least parts of the left and right sides 18, 20 of the housing 12. The shroud 109 may comprise a singular piece or may comprise multiple components. The shroud 109 may be configured such that air within the shroud 109 may be heated by combustion in the firebox 26. The shroud 109 may include one or more side vents 111 disposed at the end of the shroud 109 on the left and right sides 18, 20 of the housing 12 which may allow heated air from within the shroud 109 to flow out of the shroud 109 and thereby provide heat to the area surrounding the stove 10.

The shroud 109 may also include a rear vent 113 configured to take in, pull in, or receive air from outside the stove 10. The rear vent 113 may have any suitable size, shape, or configuration to pull in or receive outside air into the shroud 109 as desired. The rear vent 113 may be substantially rectangular and disposed in a rear portion of the shroud 109 which may correspond to the rear side 16 of the housing 12. The rear vent 113 may be disposed in the rear portion of the shroud 109 and me be disposed in the lower middle portion of the shroud 109 corresponding to the rear side 16 of the housing 12. The rear vent 113 may be an opening or may include one or more baffles which may direct the flow of air through the shroud 109 as desired. However, the rear vent 113 may have any suitable size, shape, position, or configuration. For example, the rear vent 113 may be circular, triangular, or any other suitable shape and may be disposed in any suitable location in the shroud 109. Additionally, the shroud 109 may include one or more interior baffles which may direct air within the shroud 109 as desired, such as from the rear vent 113 to the side vents 111.

As shown in FIGS. 14 and 25, the stove 10 may also include a fan or blower 110 configured to supply air from outside the stove 10 into and through the shroud 109 to supply a desired amount of heat to the area surrounding the stove 10. The blower 110 may provide air from outside the stove 10 into the shroud 109 to be heated and then expelled through the side vents 111. The blower 110 may be disposed on the shroud 109, such as in the rear vent 113. The blower 110 and rear vent 113 may be configured such that the blower 110 may be attached to the shroud 109, such as with one or more fasteners, and the blower 110 may substantially fill the rear vent 113 when attached to the shroud 109.

The blower 110 may include a motorized fan to provide an increased flow of air into the shroud 109 from outside the stove 10. For example, the blower may be motorized or powered to provide air into the shroud 109. The blower 110 may have a variety of settings or be configured to provide airflow at any desired amount to provide the desired amount of heat or air output out of side vents 111 of the shroud 109. For example, the blower 110 may have a low setting for low airflow, a medium setting for medium airflow, and a high setting for high airflow to provide the desired output out of the side vents 111 of the shroud 109.

The stove 10, including any combination of the component parts described above, may be configured to provide a suitable or desired heat output range, particulate emissions rate, and/or efficiency. The stove 10 may have an increased heat output range. For example, the stove 10 may be configured to have a heat output range between about 10,000 BTU/hour and about 90,000 BTU/hour, such as between about 30,000 BTU/hour and about 70,000 BTU/hour, such as between about 40,000 BTU/hour and about 50,000 BTU/hour. The stove 10 may also be configured to have an improved particulate emissions rate and/or improved weighted particulate emissions rate, wherein the weighted particulate emissions rate is a weighted average of the particulate emissions rates of the stove 10 in high, medium, and low burn modes. For example, the stove 10 may have a particulate emissions rate between about 0.5 grams/hour and about 2.5 grams/hour, such as between about 0.75 grams/hour and about 1.5 grams/hour, such as about 0.99 grams/hour. The stove 10 may also have a weighted particulate emissions rate between about 0.5 grams/hour and about 2.5 grams/hour, such as between about 0.75 grams/hour and about 1.5 grams/hour, such as about 0.99 grams/hour. The stove 10 may further be configured to have an increased efficiency or higher heating value (“HHV”). For example, the stove 10 may have an efficiency between about 60% HHV and about 85% HHV, such as between 65% HHV and 70% HHV, such as about 70% HHV or about 75% HHV

FIG. 30 shows steps according to an exemplary method 200 for providing heat from a wood burning stove. It will be appreciated that the illustrated method and associated steps may be performed in a different order, with illustrated steps omitted, with additional steps added, or with a combination of reordered, combined, omitted, or additional steps.

At step 202, a primary damper (e.g., primary damper 82) is moved to the open position. At step 204, kindling and fuel are provided into the firebox (e.g., firebox 26). The fuel may be wood, such as cord wood, which is combustible in the firebox and the kindling may include smaller pieces of fuel, such as wood, paper, or other suitable material. At step 206, the kindling and/or fuel in the firebox may be ignited, such as by a match, lighter, torch, or other suitable igniter. At step 208, a first primary air flow is provided to the firebox from a first air flow channel (e.g., first air flow channel 76) for primary combustion of the fuel and/or kindling in the firebox. At step 210, a secondary air flow is provided to the firebox from one or more secondary air tubes (e.g., secondary air tubes 96) for secondary combustion of the fuel and/or kindling in the firebox. At step 212, a second primary air flow is provided to the firebox from a lower primary air conduit (e.g., lower primary air conduit 104). The second primary air flow may be provided to the firebox through one or more conduit apertures in the lower primary air conduit, such as conduit apertures in a neck portion of the lower primary air conduit and/or conduit apertures in a base portion of the lower primary air conduit. At step 214, air from outside the stove is provided into a shroud of the stove to be heated. In some embodiments, the air may be provided into the shroud by a blower or fan. At step 216, a door (e.g., door 50) to the stove is partially closed which may still permit some air flow into the firebox from outside the stove. At step 218, the door is closed fully and may be secured to the housing of the stove, such as by a lever (e.g., by rotation of lever 54). Alternatively, step 216 may be omitted and the door may be closed without partially closing the door first. At step 220, the primary damper is moved to the desired position for combustion in the firebox, such as the fully open position for a desired high burn setting, a partially open position for a medium burn setting, or a closed position for a low burn setting. At step 222, heated air within the shroud is moved out of one or more side vents in the shroud to provided heated air to the area surrounding the stove. In some embodiments, the heated air may be moved through the shroud by a blower or fan.

While various inventive aspects, concepts and features of the disclosures may be described and illustrated herein as embodied in combination in the exemplary embodiments, these various aspects, concepts, and features may be used in many alternative embodiments, either individually or in various combinations and sub-combinations thereof. Unless expressly excluded herein all such combinations and sub-combinations are intended to be within the scope of the present application. Still further, while various alternative embodiments as to the various aspects, concepts, and features of the disclosures—such as alternative materials, structures, configurations, methods, devices, and components, alternatives as to form, fit, and function, and so on—may be described herein, such descriptions are not intended to be a complete or exhaustive list of available alternative embodiments, whether presently known or later developed. Those skilled in the art may readily adopt one or more of the inventive aspects, concepts, or features into additional embodiments and uses within the scope of the present application even if such embodiments are not expressly disclosed herein.

Additionally, even though some features, concepts, or aspects of the disclosures may be described herein as being a preferred arrangement or method, such description is not intended to suggest that such feature is required or necessary unless expressly so stated. Still further, exemplary or representative values and ranges may be included to assist in understanding the present application, however, such values and ranges are not to be construed in a limiting sense and are intended to be critical values or ranges only if so expressly stated.

Parameters identified as “approximate” or “about” a specified value are intended to include both the specified value and values within 5% or within 10% of the specified value, unless expressly stated otherwise. Further, it is to be understood that the drawings accompanying the present disclosure may, but need not, be to scale, and therefore may be understood as teaching various ratios and proportions evident in the drawings.

Moreover, while various aspects, features and concepts may be expressly identified herein as being inventive or forming part of a disclosure, such identification is not intended to be exclusive, but rather there may be inventive aspects, concepts, and features that are fully described herein without being expressly identified as such or as part of a specific disclosure, the disclosures instead being set forth in the appended claims. Descriptions of exemplary methods or processes are not limited to inclusion of all steps as being required in all cases, nor is the order that the steps are presented to be construed as required or necessary unless expressly so stated. The words used in the claims have their full ordinary meanings and are not limited in any way by the description of the embodiments in the specification.

Claims

1. A lower primary air conduit for use in a wood burning stove, the lower primary air conduit comprising:

a base portion and a neck portion disposed above the base portion;

an intake disposed in a bottom of the base portion; and

a plurality of conduit apertures disposed in a rear face of the neck portion, with the base portion extending rearward of the rear face of the neck portion;

wherein the plurality of conduit apertures are configured to direct a flow of primary air into a firebox of the wood burning stove.

2. The lower primary air conduit according to claim 1, wherein the plurality of conduit apertures are oriented in different directions.

3. The lower primary air conduit according to claim 1, wherein the plurality of conduit apertures comprises a middle conduit aperture that is oriented to direct the flow of primary air rearwardly.

4. The lower primary air conduit according to claim 1, wherein the plurality of conduit apertures comprises at least one side conduit aperture that is oriented at a 45° angle away from the middle conduit aperture.

5. The lower primary air conduit according to claim 1, wherein the lower primary air conduit includes three conduit apertures.

6. The lower primary air conduit according to claim 1, wherein the neck portion includes a planar front face opposite the rear face.

7. A wood burning stove comprising:

a housing;

a firebox enclosed by the housing;

a primary air flow channel configured to provide a first flow of primary air into the firebox;

a secondary air flow channel configured to provide secondary air into the firebox; and

a lower primary air conduit configured to provide a second flow of primary air into the firebox;

wherein a portion of the secondary air flow channel is disposed above the primary air flow channel and the lower primary air conduit is disposed below the primary air flow channel.

8. The wood burning stove according to claim 7, further comprising at least one secondary air tube disposed in the secondary air flow channel.

9. The wood burning stove according to claim 8, wherein each of the at least one secondary air tube has a plurality of secondary air apertures.

10. The wood burning stove according to claim 7, where the lower primary air conduit has a plurality of conduit apertures.

11. The wood burning stove according to claim 10, wherein the conduit apertures are oriented in different directions.

12. The wood burning stove according to claim 7, wherein the stove has a weighted particulate emissions rate less than 1.0 grams per hour.

13. The wood burning stove according to claim 7, wherein the lower primary air conduit comprises:

a base portion and a neck portion disposed above the base portion;

an intake disposed in a bottom of the base portion; and

a plurality of conduit apertures disposed in a rear face of the neck portion;

wherein the plurality of conduit apertures are configured to direct the second flow of primary air rearwardly into the firebox.

14. A method for providing heat from a wood burning stove, the method comprising the steps:

providing fuel in a firebox of the wood burning stove;

igniting the fuel in the firebox;

providing a first primary air flow into the firebox from a first air flow channel;

providing a secondary air flow into the firebox from at least one secondary air tube;

providing a second primary air flow into the firebox from a lower primary air conduit;

providing a flow of air into a shroud of the stove; and

moving heated air out of side vents of the shroud.

15. The method for providing heat from a wood burning stove according to claim 14, further including the step of moving a primary damper to one of a closed position, a partially open position, and an open position.

16. The method for providing heat from a wood burning stove according to claim 14, wherein the second primary air flow into the firebox is provided from a plurality of conduit apertures in the lower primary air conduit.

17. The method for providing heat from a wood burning stove according to claim 16, wherein the plurality of conduit apertures in the lower primary air conduit are oriented in different directions.

18. The method for providing heat from a wood burning stove according to claim 14, wherein the wood burning stove comprises three secondary air tubes with a plurality of apertures.

19. The method for providing heat from a wood burning stove according to claim 14, wherein a weighted particulate emissions rate from the wood burning stove is less than 1.0 gram per hour.

20. The method for providing heat form a wood burning stove according to claim 14, wherein the flow of air into the shroud is provided from a blower.