TRAPEZOIDAL AIR DISTRIBUTION BAFFLE

Abstract

The disclosed technology includes an air distribution baffle for distributing a flow of air from an air moving device to a burner assembly within a fluid heating device. The air distribution baffle can include a substantially flat portion and a raised portion extending upwardly from the substantially flat portion. The raised portion can include one or more faces having one or more apertures. The apertures can be arranged in a predetermined pattern or arrangement designed to provide a more uniform distribution of air flow and thus increase the combustion efficiency of the fluid heating device.

Description

FIELD OF THE DISCLOSURE

The presently disclosed subject matter relates generally to an air distribution baffle, and more particularly to an air distribution baffle disposed within a fluid heating device for uniformly distributing a flow of air for optimal combustion.

BACKGROUND

Fluid heating devices, such as tankless gas water heaters, are commonly used in residential and industrial applications to provide on-demand heated water supply. Tankless gas water heaters can include a burner assembly that can receive air and fuel. The air and fuel can be mixed together and ignited to cause combustion within the burner assembly to generate heat through a heat exchanger, and water can be passed through the heat exchanger to become heated. As water heater manufacturers increasingly strive to provide increasingly energy efficient devices, it can be difficult to achieve efficient combustion, and thus, efficient heating of water, particularly in tankless gas water heaters.

Combustion requires a combination of air and fuel, and the air-fuel ratio can impact combustion efficiency. For ideal combustion, an adequate supply of air can be provided to completely burn a predetermined amount of fuel. Consequently, optimal combustion efficiency can depend on distribution of air from an air moving device (e.g., including a blower) to a burner assembly.

A major problem associated with tankless gas water heaters can be uneven heating of the passing fluid. This can be caused by nonuniform distribution of primary air and post-combustion secondary air entering the burner assembly. When the flow of air is unequal, portions of the burner assembly can receive different amounts of air. This can result in areas of the burner assembly receiving an excess amount of air, while other areas receive too little air. Further, nonuniform distribution of air can negatively impact combustion efficiency as the combustion rate can vary within the burner assembly. Relatedly, when the distribution of air entering the burner assembly is not uniform, the burner assembly can contain areas of higher temperatures than surrounding areas of the burner assembly. These areas with higher temperatures can generate an exceedingly long flame that can cause flame impingement. Continued instances of flame impingement can reduce the lifespan and efficiency of a fluid heating device.

Traditional attempts to provide uniform distribution of primary and secondary air can include the use of air vanes and louvers. However, multiple sheets of material and complex tools can be required in order to manufacturer air vanes or multiple plates with louvers, resulting in high costs and increased manufacturing time.

For these reasons, a need exists for systems, devices, and methods for effectively distributing a flow of air from an air moving device to a burner assembly to improve combustion efficiency and heat transfer efficiency within a fluid heating device.

SUMMARY

These and other problems can be addressed by examples and implementations of the technology disclosed herein.

The disclosed technology includes an air distribution baffle configured to increase the uniformity of the distribution of a flow of air within a burner assembly of a fluid heating device. The air distribution baffle can include a substantially flat portion extending along a base plane of the air distribution baffle and a raised portion extending upwardly from the base plane. The raised portion can include apertures arranged in a predetermined pattern or arrangement.

The disclosed technology also includes a fluid heating device that can include an outer shell having a fluid inlet, a fluid outlet, and a fuel inlet; a burner assembly including an ignitor; and a heat exchanger in fluid communication with the burner assembly. A fluid inlet pipe can extend from the fluid inlet to the heat exchanger, a fluid outlet pipe can extend from the heat exchanger to the fluid outlet, and a fuel inlet pipe can extend from a fuel inlet to the burner assembly. The fluid heating device can include an air moving device, which can be disposed proximate the burner assembly and can be configured to transfer or move combustion gases from the burner assembly toward the heat exchanger. The fluid heating device can include an air distribution baffle disposed between the air moving device and the ignitor, and the air distribution baffle can be configured to distribute a flow of air from the air moving device toward the burner assembly. The air distribution baffle can have a flat portion and a raised portion. The fluid device can also include an exhaust vent.

The disclosed technology also includes a fluid heating device kit including a fluid heating device that includes a burner assembly. The fluid heating device kit can include a first air distribution baffle and a second air distribution baffle. The first air distribution baffle can be different from the second air distribution baffle. The first air distribution baffle can be configured for operation of the fluid heating device at a first elevation and the second air distribution baffle can be configured for operation of the fluid heating device at a second elevation that is different from the first elevation.

These and other aspects of the present disclosure are described in the Detailed Description below and the accompanying figures. Other aspects and features of the present disclosure will become apparent to those of ordinary skill in the art upon reviewing the following description of specific examples of the present disclosure in concert with the figures. While features of the present disclosure may be discussed relative to certain examples and figures, all examples of the present disclosure can include one or more of the features discussed herein. Further, while one or more examples may be discussed as having certain advantageous features, one or more of such features may also be used with the various other examples of the disclosure discussed herein. In similar fashion, while examples may be discussed below as devices, systems, or methods, it is to be understood that such examples can be implemented in various devices, systems, and methods of the present disclosure.

BRIEF DESCRIPTION OF THE FIGURES

Reference will now be made to the accompanying figures, which are not necessarily drawn to scale, and wherein:

FIG. 1A illustrates a diagram of an example fluid heating device with an air distribution baffle, according to the disclosed technology;

FIG. 1B illustrates a diagram of an example burner assembly including an air distribution baffle, according to the disclosed technology;

FIG. 2A illustrates a top view of an example air distribution baffle, according to the disclosed technology;

FIG. 2B illustrates a side view of an example air distribution baffle, according to the disclosed technology;

FIG. 3A illustrates an angled view of an example air distribution baffle, according to the disclosed technology;

FIG. 3B illustrates a front view of an example air distribution baffle, according to the disclosed technology;

FIGS. 4A-4E illustrate variations of example air distribution baffles, according to the disclosed technology;

FIG. 5 illustrates air flow rate associated with an example air distribution baffle, according to the disclosed technology.

DETAILED DESCRIPTION

The disclosed technology relates to an air distribution baffle disposed in a fluid heating device that provides uniform distribution of a flow of air from an air moving device to a burner to achieve optimal combustion.

Examples of the disclosed technology are discussed herein with reference to heating “fluid” or “water.” It is to be appreciated that the disclosed technology can be used with a variety of fluids, including water. Thus, while some examples may be described in relation to heating water specifically, all examples of the disclosed technology can be used with fluids other than water unless otherwise specified.

The disclosed technology will be described more fully hereinafter with reference to the accompanying drawings. This disclosed technology can, however, be embodied in many different forms and should not be construed as limited to the examples set forth herein. The components described hereinafter as making up various elements of the disclosed technology are intended to be illustrative and not restrictive. Many suitable components that would perform the same or similar functions as components described herein are intended to be embraced within the scope of the disclosed electronic devices and methods. Such other components not described herein can include, but are not limited to, for example, components developed after development of the disclosed technology.

In the following description, numerous specific details are set forth. But it is to be understood that examples of the disclosed technology can be practiced without these specific details. In other instances, well-known methods, structures, and techniques have not been shown in detail in order not to obscure an understanding of this description. References to “one embodiment,” “an embodiment,” “example embodiment,” “some embodiments,” “certain embodiments,” “various embodiments,” etc., indicate that the embodiment(s) of the disclosed technology so described can include a particular feature, structure, or characteristic, but not every embodiment necessarily includes the particular feature, structure, or characteristic. Further, repeated use of the phrase “in one embodiment” does not necessarily refer to the same embodiment, although it can.

Throughout the specification and the claims, the following terms take at least the meanings explicitly associated herein, unless the context clearly dictates otherwise. The term “or” is intended to mean an inclusive “or.” Further, the terms “a,” “an,” and “the” are intended to mean one or more unless specified otherwise or clear from the context to be directed to a singular form.

Unless otherwise specified, the use of the ordinal adjectives “first,” “second,” “third,” etc., to describe a common object, merely indicate that different instances of like objects are being referred to, and are not intended to imply that the objects so described should be in a given sequence, either temporally, spatially, in ranking, or in any other manner.

Unless otherwise specified, all ranges disclosed herein are inclusive of stated end points, as well as all intermediate values. By way of example, a range described as being “from approximately 2 to approximately 4” includes the values 2 and 4 and all intermediate values within the range. Likewise, the expression that a property “can be in a range from approximately 2 to approximately 4” (or “can be in a range from 2 to 4”) means that the property can be approximately 2, can be approximately 4, or can be any value therebetween.

Referring now to the drawings, FIG. 1A illustrates a diagram of a fluid heating device 100 including an air distribution baffle 200. The components and arrangements shown in FIG. 1A are not intended to limit the disclosed embodiments as the components used to implement the disclosed processes and features may vary. That is, while certain principles of the present invention are described as being incorporated in a gas-fired tankless water heater, this example is non-limiting, and it will be readily appreciated by those skilled in the art that fuel-fired heating appliances of other types may be alternatively utilized. For example, the arrangements shown in FIG. 1A can be used with alternative designs of an air distribution baffle 200, such as the various designs discussed herein.

The fluid heating device 100 can include an outer shell 102 having a fluid inlet 104, a fluid outlet 106, and a fuel inlet 108. The fluid heating device 100 can further include a controller 110 configured to operating the process of heating fluid. The controller 110 can receive a signal from a flow sensor 138 to determine whether fluid is flowing into, through, and/or out of the fluid heating device. As an example, and as shown in FIG. 1A, the flow sensor 138 can be disposed proximate the fluid inlet 104 where unheated fluid can flow into the fluid heating device 100 via a fluid inlet pipe or tube 114. In response to receiving flow data from the flow sensor 138 indicating that fluid is moving through the fluid heating device 100, the controller 110 can send a signal for an air moving device 112 disposed within the outer shell 102 to begin operating such that a flow of air can be directed toward a burner assembly 118 disposed proximate and/or adjacent to the air moving device 112 or an air outlet associated with the air moving device 112. The controller 110 can further send a signal to a fuel valve 134 to open and allow fuel to enter the burner assembly 118 via a fuel inlet pipe or tube 120. An air distribution baffle 200 can be positioned between the air moving device 112 and the burner assembly 118 (or between an air inlet and combustion portion of the burner assembly 118) to facilitate transferring the flow of air from the air moving device 112 toward the burner assembly 118. As fuel and air enter the burner assembly 118, the controller can send a signal to an ignitor 122 disposed within the burner assembly 118 to ignite, thereby causing the fuel-air mixture to combust. A heat exchanger 124 can be in fluid communication with the burner assembly 118 such that combustion gases can flow through tubes or other portions of the heat exchanger 124. The target fluid can be flowed through a separate portion of the heat exchanger 124 that is fluidly isolated from the tubes or other portion of the heat exchanger 124 through which the combustion gases are flowing. Accordingly, heat from the combustion gases can be transferred to the fluid flowing through the heat exchanger 124 without intermingling the fluid and combustion gases. A fluid outlet pipe or tube 116 can output heated fluid from the heat exchanger 124 to an external location, such as a faucet. A vent 126 extending from the outer shell 102 can release exhaust gases.

The outer shell 102 can be made of one or more suitable materials to allow the fluid heating device 100 to operate effectively while maintaining durability in light of one or more conditions under which the fluid heating device 100 and/or its associated components can be exposed. The outer shell 102 can be made of one or more materials, including but not limited to, aluminum, stainless steel, cooper, plastic, and ceramic.

The fluid inlet tube 114 can be a pipe or any other vessel that can deliver unheated fluid from an external source to the heat exchanger 124 within the fluid heating device 100. The fluid heating device 100 can include a flow sensor 138, which can be attached or connected to a tube configured to transport fluid. The flow sensor 138 can be coupled, directly or indirectly, to the fluid inlet 104. Alternatively or in addition, the flow sensor 138 can be attached to an external or internal surface of the fluid inlet tube 114. The fluid outlet tube 116 can be a pipe or any other vessel that can deliver heated water from the heat exchanger 124 to a source external to the fluid heating device 100. The flow sensor 138 can be coupled, directly or indirectly, to the fluid outlet 106. Alternatively or in addition, the flow sensor 138 can be attached to an external or internal surface of the fluid outlet tube 116.

The controller 110 can include one or more processors and memory storing instructions that, when executed by the processor(s), cause the controller 110 to perform certain actions. For example, the controller 110 can be configured to receive data from various sensors and components of the fluid heating device 100, determine actions to be performed by one or more components based on the received data, and output instructions for one or more components of the fluid heating device 100 to perform those actions. The controller 110 can be mounted on the fluid heating device 100 or disposed within the fluid heating device 100. The controller 110 can be located remotely from the fluid heating device 100. The controller 110 can receive a signal (e.g., via a transceiver) from one or more flow sensors 138 that unheated fluid is entering the fluid heating device 100 via the fluid inlet tube 114 (or that fluid is flowing through or out of the fluid heating device). The controller 110 can output instructions to the air moving device 112 to begin operating and to the fuel inlet 108 to allow fuel to enter the burner assembly 118 through the fuel inlet tube 120. The ignitor 122 disposed within the burner assembly 118 can be or include any source of heat, spark, or ignition that can be ignited or otherwise initiated, such as a flame or one or more burner strips, when a demand for heated water is detected. For example, the ignitor 122 can be in electrical communication with the controller 110 such that the controller 110 can send instructions to the ignitor 122 to ignite.

The air moving device 112 can facilitate transferring a flow of air toward the burner assembly 118 and transferring heated combustion gases from the burner assembly 118 toward the heat exchanger 124. The air moving device 112 can be a fan, blower, or any other device that can force heat generated by combustion gases toward the heat exchanger 124. The air moving device 112 can have a mouth 132 disposed at one end. The air moving device 112 can be configured to operate at a single speed. Alternatively or in addition, the air moving device 112 can be configured to operate at two or more speeds. The air moving device 112 can be configured to adjust its speed (and thus the air flow rate) based on at least the amount of fuel being inputted into the fluid heating device 100, the type of fuel being used, a predetermined or user-inputted temperature of the fluid, or a predetermined or user-inputted air flow rate. Alternatively, the controller 110 can send instructions to the air moving device 112 to operate at a constant speed (e.g., for a one or more predetermined periods of time). Alternatively or in addition, the controller 110 can send instructions to the air moving device 112 to operate at variable speeds (e.g., for one or more predetermined periods of time).

The burner assembly 118 can be disposed proximate the air moving device 112 and the heat exchanger 124. The burner assembly 118 can include a first area 128 and a second area 130. The first area 128 can be in adjacent to the air moving device 112. The first area 128 can be or include the bottom portion of the burner assembly 118. The first area 128 can include an aperture on a bottom surface 140, and the aperture can be sized to attach or connect to the mouth 132 of the air moving device 112. The second area 130 can include the ignitor 122 and can be adjacent to the heat exchanger 124. The second area 130 can be or include the top portion of the burner assembly 118. The burner assembly 118 can include a passage between the first area 128 and the second area 130 to allow the flow of air to be transferred from the first area 128 to the second area 130. Alternatively or in addition, the burner assembly 118 can omit any barriers between the first area 128 and the second area 130 (e.g., the first and second areas 128, 130 are portions of a singular chamber, as illustrated in FIG. 1A). The combination of the flow of air, incoming fuel from the fuel inlet tube 120, and heat/ignition generated by the ignitor 122 can result in combustion within the burner assembly 118. The burner assembly 118 can further include orifices disposed on one or more of the side walls. For a particular burner assembly configured to receive a secondary supply of air, the orifices can receive such secondary air. The supply of secondary air to the burner assembly can help promote and maintain combustion.

The heat exchanger 124 can include one or more tubes or coils disposed within a chamber of the heat exchanger 124. The tubes or coils can be configured to provide a large surface area exposed to the heat generated by the ignitor 122 as the heat passes over the coils. The coils can be made of a thermally conductive material, such as aluminum or copper, so that heat can be absorbed by the coil. One end of the coils can be connected to the fluid inlet tube 114 such that unheated fluid entering the heat exchanger 124 can travel through the coils. As the unheated fluid circulates through the coils, the fluid can become heated by the generated combustion gases. A second end of the coils can be connected to the fluid outlet tube 116 such that the heated fluid can exit via the fluid outlet tube 116. The fluid heating device 100 can include a temperature sensor 136 that can be disposed proximate the fluid outlet tube 116 or some other location downstream from an outlet of the heat exchanger 124. The temperature sensor 136 can detect a temperature of fluid at or near the location of the temperature sensor and send to the controller 110 one or more signals indicative of the temperature of the heated fluid. The controller 110 can receive the temperature signals and output instructions for the fuel valve to close if the fluid temperature is greater than or equal to a predetermined temperature or remain open if the fluid is less than the predetermined temperature.

The vent 126 can be fluidly connected to the heat exchanger 124 to safely output exhaust gases into the external environment. The vent 126 can extend through the top of the heat exchanger 124 and the top surface of the outer shell 102.

An air distribution baffle 200 can be disposed between the air moving device 112 and the ignitor 122. Alternatively or in addition to, the air distribution baffle 200 can be disposed within the first area 128 of the burner assembly 118, as illustrated in FIG. 1A and FIG. 1B. The air distribution baffle 200 can be oriented such that a raised portion 204 can be proximate the air moving device 112. The first area 128 can further include an inlet to receive the mouth 132 of the air moving device 112. The first area 128 can receive the flow of air from the mouth 132 of the air moving device 112 and the flow of air can be uniformly directed over the raised portion 204 and toward the ignitor 122 disposed within the second area 130 of the burner assembly 118. Alternatively or in addition to, the air distribution baffle 200 can be disposed in a separate baffle housing disposed between the air moving device 112 and the burner assembly 118. The baffle housing can be in fluid communication with the air moving device 112 and the burner assembly 118. In this configuration, the baffle housing can receive the flow of air from the mouth 132 of the air moving device 112 and the flow of air can be uniformly directed over the raised portion 204 and toward the ignitor 122 disposed within burner assembly 118. The baffle housing can include an open top surface that can allow the flow of air to enter the burner assembly 118. Alternatively, the baffle housing can include a passage in fluid communication with the burner assembly 118 that can allow the flow of air to transfer from the baffle housing to the burner assembly 118.

The air distribution baffle 200 can be made from a single piece of material. The material can include one or more metals, such as aluminum, stainless steel, and cooper. The air distribution baffle 200 can be affixed to a surface of the burner assembly 118. Alternatively or in addition to, the air distribution baffle 200 can be affixed to a surface of the first area 128 of the burner assembly 118. Alternatively, the air distribution baffle 200 can be affixed to a surface of the baffle housing. A variety of means of affixing the air distribution baffle 200 can be used, including but not limited to, one or more screws, adhesive, and welding.

FIG. 2A illustrates a top view of an example air distribution baffle 200. The air distribution baffle 200 can have a flat portion 202 and a raised portion 204. The flat portion 202 can be substantially aligned with a base plane 232 such that the flat portion 202 can be flush with a surface of the first area 128 of the burner assembly 118 or a surface of the baffle housing when the air distribution baffle 200 is installed. The flat portion 202 can be substantially smooth. Alternatively, the flat portion 202 can include one or more rigids, protrusions, or the like. The flat portion 202 can include one or more openings 302 disposed along a length of the flat portion 202, as illustrated in FIGS. 3A and 3B. The one or more openings 302 can affix the air distribution baffle 200 to the surface of the first area 128 of the burner assembly 118 or the surface of the baffle housing. The one or more openings 302 can receive a screw, bolt, or other attachment mechanism. Alternatively or in addition, the air distribution baffle 200 can be affixed to the surface of the first area 128 or the baffle housing by welding, adhesive, or the like.

FIG. 2B illustrates a side view of an example air distribution baffle 200. The raised portion 204 can extend upwardly from the base plane 232 aligned with the flat portion 202, as illustrated in FIG. 2B. The raised portion 204 can have a maximum height 230. The raised portion 204 can have a substantially uniform height such that the height of the raised portion 204 at any given point is approximately the maximum height (e.g., as shown in FIG. 4C). Alternatively, the raised portion 204 can have a substantially nonuniform height such that the height of the raised portion 204 varies and the raised portion 204 has a maximum height 230 (e.g., as shown in FIGS. 4A, 4B, 4D and 4E). The maximum height 230 of the raised portion 204 can be between approximately 10 millimeters to approximately 14 millimeters. As will be appreciated, the dimensions of the air distribution baffle 200, including the maximum height 230 of the raised portion 204, can vary dependent on the dimensions of a given burner assembly 118.

The flat portion 202 and the raised portion 204 can have the same length. Alternatively, the flat portion 202 and the raised portion 204 can have different lengths. In one example, the length of the flat portion 202 and the raised portion 204 can be between approximately 100 millimeters and approximately 300 millimeters. In one example, the length of the flat portion 202 and the raised portion 204 of the air distribution baffle 200 can depend on the dimensions of the burner assembly 118.

The raised portion 204 of the air distribution baffle 200 can have one or more faces 210. Each face 210 of the raised portion 204 can be substantially smooth. Alternatively, one or more of the faces 210 of the raised portion 204 can include rigids, protrusions, or the like. One, some, of all of the faces 210 can have one or more corresponding apertures 208. The raised portion 204 can include any number of apertures 208. As a non-limiting example, the raised portion 204 can include a total number of apertures 208 that is between approximately 10 and approximately 200 apertures 208. As other non-limiting examples, the raised portion 204 can include between approximately 10 and approximately 20 apertures 208 on some or all faces of the raised portion 204, and/or the raised portion 204 can include between approximately 20 and approximately 30 apertures 208 on some or all faces of the raised portion 204. The apertures can have any shape, including but not limited to, circular, ovular, triangular, rectangular, square, and/or polygonal. Each aperture 208 can have a predetermined diameter. The predetermined diameter can be between approximately 1 millimeter and approximately 10 millimeters. For example, the predetermined diameter can be between approximately 3 millimeters and approximately 5 millimeters. Each aperture 208 can have the same diameter. Alternatively, one or some of the apertures 208 can have different diameters. For example, one or more of the faces 210 can each include multiple apertures 208 of a common size. That is, the apertures 208 of a given face 210 can be of a common size, but the size of apertures can differ from face 210 to face 210. The diameter of each aperture 208 can depend on the face 210 on which the aperture 208 is disposed, the desired flow rate of the air entering the burner assembly 118, the amount and/or type of fuel entering the burner assembly 118, the size of the burner assembly 118 and/or fluid heating device 100, the number of apertures 208 disposed on each face 210, the number of apertures 208 disposed on the raised portion 204, and the like.

The air distribution baffle 200 can be designed to increase or maximize efficiency of a fluid heating device 100 installed in a particular geographic region and/or at a particular elevation.

By way of example, in geographic locations at an elevation greater than sea level, a greater amount of air flow can be necessary in order to obtain optimal combustion. In these locations, one option can be to increase the diameter of the apertures 208 such that the apertures 208 have a larger diameter as compared to the diameter of apertures 208 in fluid heating devices 100 located at sea level, for example. Thus, depending on the particular region, elevation, or other factors, the size of the baffle 200 itself can differ, the number of apertures 208 can differ, the size of some or all of the apertures 208 can differ, and/or the configuration of the apertures 208 can differ.

The apertures 208 can be disposed on each face 210 in a predetermined pattern or arrangement. The predetermined pattern can be the same for each face 210 of the raised portion 204. Alternatively, the predetermined pattern can be different for each face 210 of the raised portion 204. Alternatively or in addition, one or more faces 210 of the raised portion 204 can omit apertures 208.

The predetermined pattern can include a single row 220 of apertures 208 on one, some, or all faces 210. The row 220 of apertures 208 can span the entire length or substantially the entire length of the face 210. Alternatively, the row 220 of apertures 208 can span only one or more portions of the length of one, some, or all faces 210. The predetermined pattern can include a plurality of rows 220 of apertures 208 on one, some, or all faces 210, and each row 220 can span at least a portion of the length of the respective face 210. For example, one, some, or all faces 210 can have between approximately 10 and approximately 30 apertures 208. One, some, or all faces 210 can have between approximately 15 and approximately 20 apertures 208. The one or more rows 220 of apertures 208 can be linear. Alternatively, the one or more rows 220 of apertures 208 can be nonlinear. By way of example, the row 220 of apertures 208 can have a wave-like or zig-zag configuration, a sinusoidal configuration, or any other useful pattern.

The row 220 of apertures 208 can be divided into one or more section, as illustrated in FIG. 2A. In this configuration, each section can include a predetermined number of apertures 208. Each section can include the same or different predetermined number of apertures 208. Within each section, the apertures 208 can be spaced equally apart. The space separating each section can be greater than the space between each aperture 208. By way of example, and as illustrated in FIG. 2A, the raised portion 204 can include three faces 210. One, some, or all faces 210 can include a row 220 of apertures 208 and each row 220 of apertures 208 can be divided into a first end section, a center section, and a second end section, each section separated by a space. The space separating the first end section from the center section and the space separating the center section from the second end section can be the same or different.

One or more of the apertures 208 can be covered in order to achieve variable air flow rates. The apertures 208 can be covered by a plate or any material that can effectively prevent air flow through the aperture 208. One or more apertures 208 can be selectively covered to achieve a desired air flow rate. One, some, or all faces 210 of the raised portion 204 can include the same number of covered apertures 208 and the same arrangement of covered apertures 208.

Alternatively, one, some, or all faces 210 of the raised portion 204 can include a different number of covered apertures 208 and/or a different arrangement of covered apertures 208 to achieve a different air flow rate from some or all faces 210 of the raised portion 204. The number and arrangement of covered apertures 208 can depend on the desired air flow rate, type and/or amount of fuel, the number of apertures 208 on the respective faces 210, the number of apertures 208 disposed on the raised portion 204, and the like.

FIG. 3A illustrates an angled view of the air distribution baffle 200. FIG. 3B illustrates a front view of the air distribution baffle 200. As illustrated in FIGS. 3A and 3B, the air distribution baffle 200 can include a flat portion 202 with three openings 302 as a means for attaching the air distribution baffle to a surface, and a raised portion 204. As shown in the example air distribution baffle 200 illustrated by FIGS. 3A and 3B, the raised portion 204 can include three faces 210, each face 210 having an identical predetermined pattern of apertures 208 with no apertures 208 covered.

FIGS. 4A-4E illustrate different variations of the air distribution baffle 200. Each variation includes a flat portion 202 aligned with the base plane 232 and a raised portion 204 extending upwards from the base plane 232. The raised portion 204 of each variation can have a predetermined three-dimensional shape and/or cross-sectional shape (e.g., substantially semi-cylindrical shape, substantially hemispherical shape, substantially rectangle-shaped cross-section, substantially trapezoid-shaped cross-section) with a maximum height 230. In each of the variations, the flow of air can be directed from the air moving device 112 and over the raised portion 204, such that a uniform distribution of air can reach the ignitor 122 within the burner assembly 118. In one example, the shape of the flow of air over the raised portion 204 can substantially resemble the shape of the raised portion 204.

FIG. 4A illustrates the raised portion 204 of the air distribution baffle 200 can have a cross-sectional shape that is substantially trapezoidal. The raised portion can include a first face 412a, a second face 414a, and a third face 416a. The first face 412a and the third face 416a can be configured to create between approximately an angle 402 with the base plane 232. In one example, the angle 402 can be between approximately 40 degrees and approximately 50 degrees. The first face 412a and the third face 416a can be configured to create the same angle 402. Alternatively, the first face 412a and the third face 416a can be configured to create different angles 402. In one example, the first face 412a, the second face 414a, and the third face 416a can have equal widths. Alternatively, the second face 414a can have a different width than the width of the first face 412a and the third face 416a.

FIG. 4B illustrates the raised portion 204 of the air distribution baffle 200 can have a cross-sectional shape that is substantially pyramidal. The raised portion 204 can include a first face 412b and a second face 414b. The first face 412b and the second face 414b can create an angle 402 between approximately 40 degrees to approximately 50 degrees from the base plane 232. In one example, the first face 412b and the second face 414b can create the same angle 402. Alternatively, the first face 412b and the second face 414b can create different angles 402. In one example, the first face 412b and the second face 414b can have equal widths. Alternatively, the second face 414b can have a different width than the width of the first face 412b.

FIG. 4C illustrates the raised portion 204 of the air distribution baffle 200 can have a cross-sectional shape that is substantially rectangular. Alternatively, the raised portion 204 of the air distribution baffle 200 can have a cross-sectional shape that is substantially cuboid. In this configuration, the raised portion 204 can include a first face 412c, a second face 414c, and a third face 416c. The first face 412c and the third face 416c can be perpendicular to the base plane 232.

FIG. 4D illustrates the raised portion 204 of the air distribution baffle 200 can have a cross-sectional shape that is substantially ovular. Similarly, FIG. 4E illustrates the raised portion 204 of the air distribution baffle 200 can have a cross-sectional shape that is substantially semi-circular (e.g., a substantially semi-cylindrical three-dimensional shape). In each of the variations illustrated in FIGS. 4D and 4E, the raised portion 204 can include one face 412d, 412e having apertures 208 arranged in a predetermined pattern. The predetermined pattern can include rows 220 along the length of the raised portion 204. In one example, the apertures 208 can be disposed such that there are three rows 220 of apertures 208 along the length of the raised portion 204. By way of example, the predetermined pattern can include a first row 220 of apertures 208 can be disposed on the ascending arc, a second row 220 of apertures 208 can be disposed at the peak, and a third row 220 of apertures 208 can be disposed on the descending arc of the raised portion 204.

FIG. 5 illustrates the difference in air flow rate when an air distribution baffle 200 is disposed within the fluid heating device 100. The predetermined pattern of apertures 208 and the selective covering of one or more apertures 208 disposed on the raised portion 204 can cause the flow of air to travel in a plurality of paths and a plurality of velocities. The shape of the raised portion 204 can uniformly distribute the flow of air from the air moving device 112 toward the ignitor 122 within the burner assembly 118. As illustrated in FIG. 5, the air distribution baffle 200 can allow the flow of air to become localized, and thus, able to achieve optimal combustion. By way of example, if the ignitor 122 includes 15 burner strips, without an air distribution baffle 200, the flow of air would likely not be uniformly distributed across all 15 burner strips. This could potentially result in uneven thermal transfer of heat to the fluid passing through the fluid heating device 100. The air distribution baffle 200 can further provide increased efficiency of combustion even when the amount of fuel entering the burner assembly 118 is low, and thus, requiring the air moving device 112 to operating at a lower speed. Optimal combustion can result in improved thermal transfer of heat to the fluid flowing through the fluid heating device 100.

The air distribution baffle 200 can provide a greater flow of secondary air to the orifices in the burner assembly 118 as compared to a fluid heating device 100 without the air distribution baffle 200. A greater flow of secondary air to the orifices can foster combustion without diminishing flame stability. When the ignitor 122 includes one or more flames, the air distribution baffle 200 can also reduce the occurrence of flame impingement, and thus, an improve the life span and efficiency of the fluid heating device 100.

The disclosed technology can also include a method of manufacturing an air distribution baffle 200 for inserting into a fluid heating device 100. The method of manufacturing the air distribution baffle 200 can include providing a single piece of material. The material can include one or more materials, including but not limited to, aluminum, cooper, stainless steel, plastic, and ceramic. The single piece of material can be formed into a substantially rectangular shape. At least a portion of the single piece of material can be shaped to create a raised portion 204. In one example, the raised portion 204 can be approximately half of the width of the piece of material. Alternatively, the raised portion 204 can be greater than half of the width of the piece of material or less than half of the width of the piece of material. The raised portion 204 can be formed by applying heat and/or pressure or by using appropriate machinery.

The method of manufacturing the air distribution baffle 200 can further include puncturing apertures 208 into the raised portion 204 using appropriate machinery. The apertures 208 can be punctured according to a predetermined pattern along at least one face of the raised portion. Further, one or more openings 302 can be punctured along a length of the flat portion 202.

The method of manufacturing the air distribution baffle 200 can further include covering one or more apertures 208 with a plate or any piece of material that can minimize or prevent a flow of air. One or more apertures 208 can be covered according to a predetermined pattern along at least one face of the raised portion 204.

The method of manufacturing the air distribution baffle 200 can include inserting the air distribution baffle 200 between an air moving device 112 and an ignitor 122 disposed within the burner assembly 118. In one example, the air distribution baffle 200 can be inserted into a first area 128 of the burner assembly 118. Alternatively, the air distribution baffle 200 can be inserted into a baffle housing that is positioned below the burner assembly 118. The air distribution baffle 200 can be inserted such that the raised portion 204 can be proximate the mouth 132 of the air moving device 112. The air distribution baffle 200 can be affixed to a bottom surface 140 of the first area 128 of the burner assembly 118 or a bottom surface of the baffle housing. In one example, screws or similar attachment means can be inserted into the one or more openings 302 punctured along the length of the flat portion 202. Alternatively or in addition to, adhesive can be applied to the air distribution baffle and/or the burner assembly to affix the air distribution baffle 200 to the first area 128 or baffle housing. Alternatively or in addition to, the air distribution baffle 200 can be welded to the bottom surface 140 of the first area 128 or the bottom surface of the baffle housing. Alternatively, the air distribution baffle can be removeable from the fluid heating device 100, such as for maintenance or cleaning.

The disclosed technology can also include a fluid heating device 100 and two or more air distribution baffles 200 that can be installed in the fluid heating device 100. A first air distribution baffle 200 can include features and/or elements configured to increase efficiency of the fluid heating device 100 when operating at a first elevation range, and a second air distribution baffle 200 can include features and/or elements configured to increase efficiency of the fluid heating device 100 when operating at a second elevation range that is different from the first elevation range. For example, the first and second air distribution baffles 200 can have different shapes (e.g., shapes of the respective raised portions 204), apertures 208 of different diameters, different arrangements or patterns of apertures 208, different numbers of apertures 208, or the like. These differences can alter the flow of incoming air in accordance with some or all of the elements described herein. By way of example, the first air distribution baffle can provide increased efficiency for a fluid heating device 100 operating at an elevation in an elevation range between approximately 0 feet (approximately 0 meters) above sea level and approximately 3,000 feet (approximately 900 meters) above sea level, and the second air distribution baffle can provide increased efficiency for the same fluid heating device 100 operating at an elevation in an elevation range between approximately 3,000 feet (approximately 900 meters) above sea level and approximately 10,000 feet (approximately 3,000 meters) above sea level. A third air distribution baffle can be provided and can provide increased efficiency for the same fluid heating device 100 operating at an elevation in an elevation range between approximately 7,000 feet (approximately 2,100 meters) above sea level and approximately 10,000 feet (approximately 3,000 meters) above sea level. These ranges are for illustration only, and the disclosed technology includes any number of baffles 200, each configured to increase efficiency of the fluid heating device 100 in a respective elevation range. For example, the disclosed technology includes three, four, five or more baffles, each of which is configured increase efficiency of the fluid heating device 100 in a separate, respective elevation range. Further, the elevation ranges targeted by each individual baffle 200 can differ depending on the desired precision. For example, a system can include the two or three example baffles described above, and/or can include two different example baffles, with the first baffle providing increased efficiency for elevations between approximately 0 feet (approximately 0 meters) and approximately 5,000 feet (approximately 1,500 meters) and the second baffle providing increased efficiency for elevations between approximately 5,000 feet (approximately 1,500 meters) and approximately 10,000 feet (approximately 3,000 meters).

Certain examples and implementations of the disclosed technology are described above with reference to block and flow diagrams according to examples of the disclosed technology. It will be understood that one or more blocks of the block diagrams and flow diagrams, and combinations of blocks in the block diagrams and flow diagrams, respectively, can be implemented by computer-executable program instructions. Likewise, some blocks of the block diagrams and flow diagrams do not necessarily need to be performed in the order presented, can be repeated, or do not necessarily need to be performed at all, according to some examples or implementations of the disclosed technology. It is also to be understood that the mention of one or more method steps does not preclude the presence of additional method steps or intervening method steps between those steps expressly identified. Additionally, method steps from one process flow diagram or block diagram can be combined with method steps from another process diagram or block diagram. These combinations and/or modifications are contemplated herein.

Claims

1. An air distribution baffle configured to uniformly distribute a flow of air within a burner assembly of a fluid heating device, the air distribution baffle comprising:

a substantially flat portion extending along a base plane associated with the air distribution baffle; and

a raised portion extending upwardly from the base plane, the raised portion including apertures formed therethrough.

2. The air distribution baffle of claim 1, wherein the raised portion has a first face, a second face, and a third face such that the raised portion has a substantially trapezoidal cross-sectional configuration.

3. The air distribution baffle of claim 2, wherein each of the first face and the third face extends from the base plane at an approximately 45 degree angle.

4. The air distribution baffle of claim 1, wherein the raised portion has a substantially semicylindrical cross-sectional shape.

5. The air distribution baffle of claim 1, wherein each of the apertures has a diameter between approximately 3 millimeters and approximately 5 millimeters.

6. The air distribution baffle of claim 1, wherein each of the apertures has a common diameter.

7. The air distribution baffle of claim 1, wherein a first aperture has a first diameter and a second aperture has a second diameter that is different from the first diameter.

8. The air distribution baffle of claim 1, wherein the raised portion includes one or more faces and at least some of the apertures form a predetermined pattern on at least one of the one or more faces.

9. The air distribution baffle of claim 8, wherein the predetermined pattern includes one or more rows of apertures disposed on at least a portion of the raised portion.

10. The air distribution baffle of claim 1, wherein a first face of the raised portion has a first predetermined pattern and a second face of the raised portion has a second predetermined pattern that is identical to the first predetermined pattern.

11. The air distribution baffle of claim 1, wherein the raised portion has a maximum height of between approximately 10 millimeters and approximately 14 millimeters.

12. The air distribution baffle of claim 1, wherein the at least one face includes between approximately 15 and 20 apertures.

13. A fluid heating device comprising:

an outer shell having a fluid inlet, fluid outlet, and a fuel inlet;

a burner assembly including an ignitor;

a heat exchanger in fluid communication with the burner assembly;

a fluid inlet pipe extending from the fluid inlet to the heat exchanger;

a fluid outlet pipe extending from the heat exchanger to the fluid outlet;

a fuel inlet pipe extending from a fuel inlet to the burner assembly;

an air moving device disposed proximate the burner assembly and configured to move combustion gases from the burner assembly toward the heat exchanger;

an air distribution baffle disposed between the air moving device and the ignitor and configured to distribute a flow of air flowing from the air moving device to the burner assembly, the air distribution baffle having a flat portion and a raised portion; and

an exhaust vent.

14. The fluid heating device of claim 13, wherein the burner assembly comprises a first portion and a second portion, the first portion including the air distribution baffle and the second portion including the ignitor.

15. The fluid heating device of claim 14, wherein the air distribution baffle is attached to a bottom surface of the first portion of the burner assembly.

16. The fluid heating device of claim 15, wherein the flat portion of the air distribution baffle includes one or more openings configured to attach the air distribution baffle to the bottom surface.

17. The fluid heating device of claim 13, wherein the raised portion of the air distribution baffle has a predetermined cross-sectional shape and a plurality of apertures disposed thereon.

18. The fluid heating device of claim 13, wherein the raised portion of the air distribution baffle is aligned with at least a portion of an outlet of the air moving device.

19. A fluid heating device kit comprising:

a fluid heating device having a burner assembly; and

a first air distribution baffle and a second air distribution baffle, each having a respective substantially flat portion and a respective raised portion, the first air distribution baffle being different from the second air distribution baffle such that the first air distribution baffle is configured to increase combustion efficiency of the fluid heating device when the fluid heating device is operating at a first elevation and the second air distribution baffle is configured to increase combustion efficiency of the fluid heating device when the fluid heating device is operating at a second elevation that is different from the first elevation.

20. The fluid heating device kit of claim 19, wherein:

the raised portion of the first air distribution baffle has a first shape and a first size and includes a first number of first apertures arranged in a first arrangement, at least some of the first apertures having a first diameter,

the raised portion of the second air distribution baffle has a second shape and a second size and includes a second number of second apertures arranged in a second arrangement, at least some of the second apertures having a second diameter, and

at least one of the first shape, first size, first number of first apertures, first diameter, and first arrangement differs from the second shape, second size, second number of second apertures, second diameter, and second arrangement, respectively.