Abstract:
The present invention relates to exhaust condensate removal equipment for energy efficient heating apparatuses that may be positioned either vertically or any angle off horizontal. The device collects condensate from ducts and may be retrofit into existing systems. The device has an inner chamber that collects and directs condensates toward a drain nipple through which the condensate is then removed from the sealed system. The system may optionally include a reusable seal and clamp for ease of maintenance or retrofitting an existing system.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS  
       [0001]     The application claims benefit to U.S. Provisional Application No. 60/826,680 and U.S. Provisional Application No. 60/826,698 both filed on Sep. 22, 2006, the contents of both are incorporated in their entirety. The application also incorporates in reference by their entirety U.S. Provisional Application No. 60/804,010 filed on Jun. 6, 2006. 
     
    
     FIELD OF THE INVENTION  
       [0002]     The present invention relates to removing condensates from vent systems connected to energy efficient heating equipment under positive pressure.  
       BACKGROUND  
       [0003]     In the past heating systems burning gas, oil, coal or even wood had their exhaust emissions evacuated from a building by negative pressure (draft) created in a flue by the temperature differential between hot flue gases and ambient outside temperatures. Unless these flues became obstructed, flue gas leaks and potential carbon monoxide poisoning were avoided, as negative pressure was maintained throughout the vent system. If the flue gas composition in a negative pressure system was to be tested, the technician would customarily drill a hole into the connector pipe, then cover it with a simple patch without fear of leaks, due to the negative pressure.  
         [0004]     With the development of high efficiency heating equipment, exhaust systems must be designed to match the heater&#39;s performance requirements. Increasing efficiency means that more heat is kept in a home, rather than sending it up and out a chimney flue. As a consequence, flue gas temperatures are reduced to the point where negative pressure within a vent system can no longer be created. For that reason, and with the help of blowers on the heater, flue gases are now mechanically expelled, thus creating positive pressure in a vent system. At the same time, these cool flue gases readily fall below dew point temperatures, creating significant amounts of condensates within a vent system. These condensates can be corrosive, of significant volume, need to be captured before back-flowing into the heating equipment and need to be disposed of properly.  
       SUMMARY OF THE INVENTION  
       [0005]     A first aspect of the invention is a conduit section for drainage of flue gas condensate, said conduit section comprising a first end, for ingress of a stream of flue gas, said first end having a first seal; a second end, for egress of the stream of flue gas, said second end having a second seal; a chamber within said conduit section, said chamber having a first closed end and a second open end, said second open end facing away from the ingress of the stream of flue gas; a drain portion positioned on said chamber for flow of said condensates from said chamber, wherein said conduit section is removably attachable as an inline unit.  
         [0006]     A second aspect of the invention is an inline conduit condensate drain, said inline conduit comprising a inner conduit having a first diameter and an internal exhaust outlet an outer conduit having at least two attachment portions with a second diameter larger than said first diameter of said inner conduit, said inner conduit intersects and is sealedly affixed within said outer conduit; a condensate chamber, wherein said condensate chamber is formed in said outer conduit and positioned above said intersection of said inner conduit and said outer conduit, and wherein said condensate chamber is spaced away from said inner conduit; and a drain portion positioned on said condensate chamber, wherein said inline conduit is sealedly attached between at least two other exhaust conduits.  
         [0007]     A third aspect of the invention is a method for draining condensate from positive pressure flues comprising: providing an inline conduit having a first end, for ingress of a stream of flue gas, said first end having a first seal, a second end, for egress of the stream of flue gas, said second end having a second seal, a chamber within said conduit section, said chamber having a first closed end and a second open end, said second open end facing away from the ingress of the stream of flue gas, a drain portion positioned on said chamber adjacent for flow of said condensates from said chamber, wherein said first seal and said second seal are both external a casing of a flue gas source; providing a source of flue emissions under positive pressure; and attaching said inline conduit externally to said source of flue emissions under positive pressure. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0008]      FIG. 1  shows an inline catch for condensates;  
         [0009]      FIG. 2  shows a bottom view of the catch;  
         [0010]      FIG. 3  shows a cross-sectional view of a gasket;  
         [0011]      FIG. 4  shows a horizontal install of the inline catch for condensates;  
         [0012]      FIG. 5  shows a vertical install of the inline catch for condensates; and  
         [0013]      FIG. 6  shows a second embodiment of the invention. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0014]     Although certain embodiments of the present invention will be shown and described in detail, it should be understood that various changes and modifications may be made without departing from the scope of the appended claims. The scope of the present invention will in no way be limited to the number of constituting components, the materials thereof, the shapes thereof, the relative arrangement thereof, etc., and are disclosed simply as an example of and embodiment. The features and advantages of the present invention are illustrated in detail in the accompanying drawings, wherein like reference numerals refer to like elements throughout the drawings.  
         [0015]     An answer to the problems associated with a condensate that forms within the flue of an energy efficient appliance with a positive pressure exhaust system is to catch and drain the byproduct of combustion, the corrosive effluent fluid that condenses within the ducts. The exhausts of the energy efficient systems must be sealed to prevent leakage of flue emissions that are under pressure. The instant invention retains a seal while removing the collected effluent from the ducts.  
         [0016]     To remove condensation from either a new or a preexisting flue duct the instant invention provides a conduit section  100  for drainage of flue gas condensate, said conduit section  100  comprises a first end  10 , for ingress of a stream of flue gas  15 , said first end  10  having a first seal or gasket  20 . The conduit section has a second end  11 , for egress of the stream of flue gas  15 , said second end  11  having a second seal or second gasket  30 . The conduit section  100  may be produced from a material such as either a metal or a plastic. The conduit section  100  if produced of metal may be steel, aluminum or other metallic compound. If metal it may be stamped or formed from a sheet into a conduit section  100  that could be round, oval square, rectangular or any other desired cross section. If the conduit section  100  is plastic it could be made by extrusion or injection molding into the desired length and contour.  
         [0017]     The conduit  100  has a chamber  40  within said conduit section  100 , said chamber  40  having a first closed end  41  and a second open end  42 , said second open end  42  facing away from the ingress of the stream of flue gas  15 . The second open end  42  has at least a portion directed to collect condensate as it runs down the inner wall of said conduit  100 . A drain portion or drain nipple  50  may be positioned on said chamber  40  for flow of said condensates from said chamber  40 , wherein said conduit section  100  may be removably attachable or permanently affixed as an inline unit into an existing flue duct  250 . The chamber  40  acts as a reservoir and must have a leak proof seal between the inner wall of the conduit  100  and the outer wall adjacent the second open end  42  otherwise leaking will occur causing water damage. The chamber  40 , positioned just above the intersection of the inner and outer portions of the conduit, may be expanded and have a greater diameter from the normal portion of the conduit section.  
         [0018]     An equivalent alternative to the above describe embodiment is possible where an expanded chamber  40 , as shown in  FIG. 1 , is mounted over an existing portion of the pipe, but engagement seal  92  is external and sealedly affixed to a pre-existing portion. The outlet portion  94  may be of normal pipe diameter if placed within the expanded region of the chamber  42 . The condensate would flow down the inner expanded wall of the chamber  40  and allow collection of condensate without a reduced diameter inner section. The upper end and lower end of the alternative conduit could either be permanently or releasably sealed to the system to prevent water and gas leaks.  
         [0019]     The conduit section  100  can be installed into a system in either a horizontal or a vertical orientation as shown in  FIGS. 5 and 6  or any angle in between. When the conduit section  100  is mounted any angle off vertical, it may be angled with the drain portion  50  positioned at the lowest point of gravity. The drain portion  50  may be connected to a tube or hose that may be sealed from flue gas leakage by a loop filled with condensate and drain the effluent to a proper point of disposal drain. The tube or hose is sealed from the exhaust flow to prevent release of noxious fumes or vapors harmful to the occupants.  
         [0020]     The conduit section  100  may be installed as a unit into an existing exhaust conduit system  250  to remove condensate, which would entail removing a preexisting conduit section by either cutting, unglueing or unbolting the segment of appropriate length that coincides with the length of the inline conduit  100 . The section removed may either be a vertical or slanted section of the existing conduit ease of installation being the main factor in selecting the orientation of the pipe. The conduit section  100  then sealedly replaces the removed section of the preexisting conduit to collect condensate and prevent leaks from the system. The conduit section  100  once placed inline may be sealed with a gasket, glued, welded or otherwise made leakproof when installed in the system.  
         [0021]     The conduit section  100  may be removably installed to other ducts by having a first conduit channel  60  within said first end  10  to position and support said first seal, which may be an adhesive, which may prevent removal or for removability a first gasket  20 ,  200  and a second conduit channel  65  within said second end  11  to position and support said second seal such as adhesive or for removability a second gasket  30 ,  200 . The gasket seal  200  may comprise a resilient, flexible gasket body  210  including a first surface  220 , a second surface  225  and at least two edges  230 ,  235 . The gasket seal  200  may have a plurality of angular protrusions  240  having a tip  245  and a base  250 , said protrusions  240  disposed on the first surface  220 , a trough  255  between said angular protrusions  240 , wherein said protrusions  240  cover said trough  255  and said tip  245  contacts said base  250  of an adjacent angular protrusion  240  when compressed. The gasket  200  may also include a compression cavity  260  having a center  265 , said cavity  260  disposed on the second surface  225  beneath said plurality of angular protrusions  245 , wherein said center of said compression cavity  265  bows when the gasket body  210  is sealed, and at least two sealing walls  270 ,  275  positioned at said at least two edges  230 ,  235 .  
         [0022]     The gasket seal  200  may be compressed to form a seal by a first removable coupling device  67  adjacent said first end  10  and a second removable coupling device  62  adjacent said second end  11 . The coupling devices  62 ,  67  can be any fastener such as a band  70  with a worm gear  71  for selectively tightening or loosening of the coupling device. The coupling device  62 ,  67  may also be a nylon lock tie that would prevent loosening by its unidirectional locking feature. The coupling device  62 ,  67  may be used in conjunction with a plurality of compression grooves  80  in said ends  10 ,  11 , said grooves  80  adjacent said removable coupling device  62 ,  67 , wherein said grooves  80  contract when compressed. The plurality of grooves  80  may be spaced at equidistant intervals around the circumference of the end  10  of the conduit  100  to prevent buckling of the conduit  100  and to allow for compression of the end  10 .  
         [0023]     The conduit section  100  may include a hole  75  positioned adjacent said second end  11  of said conduit  100 . A worm screw  71  of said second removable coupling device  62  may be positioned at said hole  75 . A band  76  having grooves  77  is attached to said worm screw  71 , said band  76  positioned within said second end  11 , wherein said second end  11  acts as a female coupling to an existing flue. The second end  11  may be slid over the exposed end of an existing flue system or a newly installed system comprising a plurality of ducts. The conduit section  100  may have a first end  10  and said second end  11  of said conduit  100  that are substantially similar in size to allow for easier introduction into a conventional duct. The conduit section  100  may have a first end  10  and said end  11  of said conduit  100  that may have many shapes such as a substantially circular cross sectional shape, rectangular shape, square shape, oval shape or any other desired cross-sectional shape.  
         [0024]     The conduit section  100  may be formed of a metal such as steel or other similar alloy in the form of a cylinder. The conduit  100  may be formed from two parts  90 ,  91  that are joined together. The chamber  40  may be formed by a resistance weld between an internal pipe  90  and an external pipe  91  forming the conduit  100 . The resistance weld or interference fit seal  92  along with the necked down section of internal pipe  90  acts as the base of the chamber  40 .  
         [0025]     The conduit section  100  may include a butterfly damper  350 , said damper  350  may be positioned within said first end  10  of said conduit  100  as shown in  FIGS. 1 and 2 . The butterfly damper  350  may prevent drafts and unnecessary heat loss when the appliance  308  is not in use. The conduit section  100  is for use in combination with a unit with a burner  308  exhausting a flue gas  15  under a positive pressure as shown in  FIGS. 5 and 6 . The conduit section  100  may be attached to a plurality of exhaust sections  310  sealedly connected to said unit with the burner  308  to remove the flue gas  15  under positive pressure, wherein said conduit section  100  is installed inline to remove condensate from said plurality of exhaust sections  310 .  
         [0026]     Another embodiment is an inline conduit condensate drain  500 , said inline conduit  500  comprising a inner conduit  510  having a first diameter  515  and an internal exhaust outlet  530 . Surrounding the inner conduit  510  is an outer conduit  520  having at least two attachment portions  540 ,  545  with a second diameter  516  larger than said first diameter  515  of said inner conduit  510 , said inner conduit  510  intersects and is sealedly affixed within said outer conduit  520 . A condensate chamber  550 , wherein said condensate chamber  550  is formed in said outer conduit  520  and positioned above said intersection  560  of said inner conduit  510  and said outer conduit  520 , and wherein said condensate chamber  550  is spaced away from said inner conduit  510 . To remove the effluent that collects in the condensate chamber  550  a drain portion  555  positioned on said condensate chamber  550 , wherein said inline conduit is sealedly attached between at least two other exhaust conduits  570 ,  571  or the appliance  308  attached to end  505 .  
         [0027]     The inline conduit  500  may be connected to the two other exhaust conduits  570 ,  571  by using at least two sealing channels  580 ,  581  within said outer conduit  520  adjacent said at least two attachment portions  540 ,  545 . The conduit section  500  may be removably installed to other ducts  570 ,  571  by having a reusable seal or compression gasket  200  installed within the conduit section between the conduit section  500  and the other ducts  570 ,  571 . The seal or gasket  200  may comprise a resilient, flexible gasket body  210  including a first surface  220 , a second surface  225  and at least two edges  230 ,  235 . The seal or gasket  200  may have a plurality of angular protrusions  240  having a tip  245  and a base  250 , said protrusions  240  disposed on the first surface  220 , a trough  255  between said angular protrusions  240 , wherein said protrusions  240  cover said trough  255  and said tip  245  contacts said base  250  of an adjacent angular protrusion  240  when compressed. The seal or gasket  200  may also include a compression cavity  260  having a center  265 , said cavity  260  disposed on the second surface  225  beneath said plurality of angular protrusions  245 , wherein said center of said compression cavity  265  bows when the gasket body  210  is sealed, and at least two sealing walls  270 ,  275  positioned at said at least two edges  230 ,  235 .  
         [0028]     The inline conduit section  500  may further comprise a valve body  590  positioned within said outer conduit  520 . There is an opening  591  in said valve body  590  to allow flue gas  15  to pass and a valve  592  covering said opening  591 . The inline conduit  500  further comprises a flue gas source under positive pressure  600 , wherein said inline conduit is attached externally to said flue gas source under positive pressure  600 , which may be an exhaust outlet of an appliance  308  or other fuel burning device  308 . The inline conduit  500  may be installed into a duct of a heater unit in a substantially horizontal orientation as shown in  FIG. 4 .  
         [0029]     A method for draining condensate from positive pressure flues  600  may comprise the step of providing an inline conduit  100  having a first end  10 , for ingress of a stream of flue gas  15 , said first end  10  having a first gasket or first seal  20 , a second end  11 , for egress of the stream of flue gas  15 , said second end  11  having a second gasket or second seal  30 , a chamber  40  within said conduit section  100 , said chamber  40  having a first closed end  41  and a second open end  42 , said second open end  42  facing away from the ingress of the stream of flue gas  15 , a drain portion or drain nipple  50  positioned on said chamber  40  adjacent for flow of said condensates from said chamber  40 , wherein said first gasket or first seal  20  and said second seal or second gasket  30  are both external a casing of a flue gas source  308 . The running of a high efficiency water heater  308 , furnace would be sufficient for providing a source of flue emissions under positive pressure  15 . The condensate would be collected by attaching said inline conduit  100  externally to said source of flue emissions under positive pressure  15 . The inline conduit  100  may be installed by removing an existing section of conduit  310  for installation of said inline conduit  100 .  
         [0030]     Various modifications and variations of the described apparatus and methods of the invention will be apparent to those skilled in the art without departing from the scope and spirit of the invention. Although the invention has been described in connection with specific embodiments, outlined above, it should be understood that the invention should not be unduly limited to such specific embodiments. Various changes may be made without departing from the spirit and scope of the invention as defined in the following claims.