Abstract: One aspect of this disclosure provides a finger baffle for a heating furnace. This embodiment includes an elongated support plate having a length, and at least one finger baffle extending outwardly and in a vertically oriented direction from the elongated support plate. The at least one finger baffle has a width that extends along the length of the elongated support plate. The finger baffle may be employed in a high-efficiency gas furnace.

Abstract: One aspect of this disclosure provides a heating chamber for a gas furnace that comprises opposing halves joined together. The joined opposing halves form a clamshell panel having at least one truncated corner located adjacent a curve located at a back end of a chamber path of the one or more clamshell heating chambers.

Abstract: One aspect of this disclosure provides a finger baffle for a heating furnace. This embodiment includes an elongated support plate having a length, and at least one finger baffle extending outwardly and in a vertically oriented direction from the elongated support plate. The at least one finger baffle has a width that extends along the length of the elongated support plate. The finger baffle may be employed in a high-efficiency gas furnace.

Abstract: One aspect of this disclosure provides a finger baffle for a heating furnace. This embodiment includes an elongated support plate having a length, and at least one finger baffle extending outwardly and in a vertically oriented direction from the elongated support plate. The at least one finger baffle has a width that extends along the length of the elongated support plate. The finger baffle may be employed in a high-efficiency gas furnace.

Abstract: One aspect of this disclosure provides a heating chamber for a gas furnace that comprises opposing halves joined together. The joined opposing halves form a clamshell panel having at least one truncated corner located adjacent a curve located at a back end of a chamber path of the one or more clamshell heating chambers.

Abstract: One aspect of this disclosure provides a heating chamber for a gas furnace that comprises opposing halves joined together. The joined opposing halves form a clamshell panel having at least one truncated corner located adjacent a curve located at a back end of a chamber path of the one or more clamshell heating chambers.

Abstract: A burner assembly for a fuel-fired heating furnace. The assembly comprises a burner body having an inlet opening to receive fuel delivered by a fuel control module, and, to receive an ambient source of primary air there-through. The furnace also comprises one or more burner heads connected to a common outlet opening of the burner body to receive a mixture of the fuel and the primary air.

Abstract: One aspect of this disclosure provides a finger baffle for a heating furnace. This embodiment includes an elongated support plate having a length, and at least one finger baffle extending outwardly and in a vertically oriented direction from the elongated support plate. The at least one finger baffle has a width that extends along the length of the elongated support plate. The finger baffle may be employed in a high-efficiency gas furnace.

Abstract: One aspect of this disclosure provides a finger baffle for a heating furnace. This embodiment includes an elongated support plate having a length, and at least one finger baffle extending outwardly and in a vertically oriented direction from the elongated support plate. The at least one finger baffle has a width that extends along the length of the elongated support plate. The finger baffle may be employed in a high-efficiency gas furnace.

Abstract: A furnace unit comprising a mounting panel, a burner assembly and a heat exchanger. The burner assembly is mounted to one side of said mounting panel, the burner assembly having at least one burner located therein. The heat exchanger is mounted to an opposite side of said mounting panel. The heat exchanger has at least one continuous combustion tube, wherein said combustion tube includes at least a first pass and a second pass. The first and second passes are interconnected by a curved pass of the combustion tube. One end of the combustion tube has a first opening that is coupled to the burner assembly. The combustion tube has at least three zones.

Abstract: A furnace unit that comprises a burner assembly having at least one burner located therein and a heat exchanger having at least one continuous combustion tube. One end of the combustion tube has a first opening that is coupled to the burner assembly. The combustion tube has at least three zones. A first surface of the first zone has a first non-straight angle with a second surface of the second zone. The second surface has a second non-straight angle with a third surface of the third zone. The first zone is nearest of the three zones to the burner assembly and the second zone is in-between the first zone and the third zone. The first, second and third zones are within a flame length configured to be emitted from the burner.

Abstract: One aspect of this disclosure provides a heating chamber for a gas furnace that comprises opposing halves joined together. The joined opposing halves form a clamshell panel having at least one truncated corner located adjacent a curve located at a back end of a chamber path of the one or more clamshell heating chambers.

Abstract: A burner assembly for a fuel-fired heating furnace. The assembly comprises a burner body having an inlet opening to receive fuel delivered by a fuel control module, and, to receive an ambient source of primary air there-through. The furnace also comprises one or more burner heads connected to a common outlet opening of the burner body to receive a mixture of the fuel and the primary air.

Abstract: One aspect of this disclosure provides a finger baffle for a heating furnace. This embodiment includes an elongated support plate having a length, and at least one finger baffle extending outwardly and in a vertically oriented direction from the elongated support plate. The at least one finger baffle has a width that extends along the length of the elongated support plate. The finger baffle may be employed in a high-efficiency gas furnace.

Abstract: A nitrogen oxide reduction baffle for a heat exchanger of a furnace and a gas furnace incorporating at least one such baffle. In one embodiment, the baffle includes: (1) a body having a predetermined length, cross-sectional configuration and longitudinal slot, the longitudinal slot having a predetermined width and position and (2) a locating structure coupled to the body and configured to place the body in a predetermined longitudinal location within a heat exchanger and orient the slot relative to the heat exchanger, the body laterally constrained within the heat exchanger when the body is located at the predetermined longitudinal location.

Abstract: An air-channeling baffle for a heat exchanger unit. The air-channeling baffle comprises a body having a long dimension and a short dimension that define a surface and an attachment structure coupled to the body. The attachment structure is configured to locate the body in a heat exchanger unit such that an incoming air flow reflected off of the surface and passes over ends of the long dimension towards terminally-located heat conduction tubes of the heat exchanger unit.

Abstract: A clamshell heat exchanger for use in a gas-fired direct combustion furnace. The exchanger comprises a first clamshell half and a second clamshell half that when joined with the first clamshell half forms a passageway having an inlet and an outlet. The passageway includes a U-bend located between the inlet and the outlet, wherein the U-bend includes a re-entrant sectional profile.

Abstract: An air-channeling baffle for a heat exchanger unit. The air-channeling baffle comprises a body having a long dimension and a short dimension that define a surface and an attachment structure coupled to the body. The attachment structure is configured to locate the body in a heat exchanger unit such that an incoming air flow reflected off of the surface and passes over ends of the long dimension towards terminally-located heat conduction tubes of the heat exchanger unit.

Abstract: A furnace unit that comprises a burner assembly having at least one burner located therein and a heat exchanger having at least one continuous combustion tube. One end of the combustion tube has a first opening that is coupled to the burner assembly. The combustion tube has at least three zones. A first surface of the first zone has a first non-straight angle with a second surface of the second zone. The second surface has a second non-straight angle with a third surface of the third zone. The first zone is nearest of the three zones to the burner assembly and the second zone is in-between the first zone and the third zone. The first, second and third zones are within a flame length configured to be emitted from the burner.

Abstract: A clamshell heat exchanger includes a first clamshell half and a second clamshell half. When joined, the first and second clamshell halves form a passageway having an inlet and an outlet. The passageway has a height and a depth. A ratio of the height to the depth is about 0.5 or less. The heat exchanger has an efficiency of at least about 70%.