Patent Publication Number: US-2022228773-A1

Title: Improvements in or relating to liquid heating and storage apparatus

Description:
TECHNICAL FIELD 
     This disclosure relates generally to liquid heating and storage apparatus and components therefor. One particular application concerns gas fired water heaters. It is to be understood however that reference to this particular application is not to be taken as a limitation as to the scope of the disclosure. 
     BACKGROUND ART 
     Gas fired water heaters typically comprise a storage tank for holding the water to be heated, a combustion chamber having a burner therein for heating the water within the storage tank and a flue tube for discharging the combustion gases from the combustion chamber. Under certain operating conditions moisture or condensation can form inside the flue tube as a result of the combustion process. The condensate generally forms on an inner surface of the flue tube and tends to flow back into the combustion chamber. When the condensate evaporates inside the combustion chamber the vapour travels into the flue tube and as a result reduces the volume available for the combustion gases therein. Flue tubes are often provided with baffling to assist in the heat transfer process in the flue with the passage of the combustion gases there through. The existence of vapour within the flue can mean that the baffling will be less effective thereby reducing the performance of the water heater. 
     SUMMARY OF DISCLOSURE 
     In a first aspect embodiments are disclosed of a condensate collector which is suitable for use in apparatus for heating and storing liquid, the apparatus comprising: a liquid storage tank a combustion chamber adjacent a lower end of the liquid storage tank, a flue having an entry and an exit end, the flue being disposed above the combustion chamber and in fluid communication therewith, and the condensate collector includes a receptacle which in use is in the region of the entry end of the flue, a discharge outlet for discharging condensate collected in the receptacle for subsequent transfer to a drain. 
     The arrangement is such that, if during the combustion process condensate forms within the flue, the condensate will flow towards the flue entry end into the condensate collector receptacle whereafter, it can flow from the discharge outlet to a drain. As a result of this arrangement, the dispersal of condensate within the combustion chamber is reduced. By limiting the amount of condensate within the combustion chamber, the performance of the apparatus is improved. For example, the arrangement enables the flue to have more baffling therein. 
     In certain embodiments the receptacle comprises a generally annular shaped channel having a base, an inner side wall, an outer peripheral side wall and an open top side. In certain embodiments the inner side wall has a height from the base to the top side which is greater than that of the outer side wall. In certain embodiments, when in use the open top side is disposed adjacent or partially within the entry end of the flue, the flue comprising a flue tube, having an inner side at the entry end, and the open top side is substantially aligned with the inner side. 
     In certain embodiments the condensate collector further includes a mounting bracket for mounting the collector within the combustion chamber. In certain embodiments the collector further includes a transfer conduit having one end operatively connected to the discharge outlet and the other end operatively connected to a drain. In certain embodiments the transfer conduit comprises a first arm and a second arm arranged end to end, the first arm being disposed adjacent a side wall of the combustion chamber and being in operative communication with the drain and the second arm extending from the first arm and being in operative connection with the receptacle. In certain embodiments the first arm and the second arm each comprise an open channel. In certain embodiments the transfer conduit is disposed below the receptacle and extends to one side thereof. 
     In certain embodiments the apparatus further includes a burner within the combustion chamber, the receptacle and flue tube being disposed above the burner and in substantial alignment therewith when in use. 
     In a second aspect, embodiments are disclosed of apparatus for heating and storing liquid, the apparatus comprising: a liquid storage tank a combustion chamber adjacent a lower end of the liquid storage tank, a flue having an entry and an exit end, the flue being disposed above the combustion chamber and in fluid communication therewith, a condensate collector at least partially disposed within the combustion chamber, the condensate collector including a receptacle in the region of the entry end of the flue, a discharge outlet in fluid communication with the receptacle and being operatively connected to a drain external of the combustion chamber. 
     In certain embodiments the condensate collector may be as described earlier in either its broad or more narrow form. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Notwithstanding any other forms which may fall within the scope of the method and apparatus set forth in the summary, specific embodiments of the method and apparatus will now be described by the way of example and with reference to the accompanying drawing in which: 
         FIG. 1  is a schematic sectional view of a gas water heater according to one embodiment; 
         FIG. 2  is a schematic sectional view of part of a gas water heater according to one embodiment; 
         FIG. 3  is a schematic plan view of a conduit collector according to one embodiment; 
         FIG. 4  is a side elevation of the conduit collector shown in  FIG. 3 ; 
         FIG. 5  is an end elevation of the conduit collector shown in  FIGS. 3 and 4  viewed from one end; 
         FIG. 6  is an end elevation of the conduit collector shown in  FIGS. 3 to 5  viewed from the other end; 
         FIG. 7  is a schematic view of apparatus according to another embodiment; 
         FIG. 8  is a schematic sectional view of apparatus according to yet another embodiment; 
         FIG. 9  is a schematic sectional view of apparatus according to yet another embodiment; 
         FIG. 10  is a schematic sectional view of apparatus according to yet another embodiment; and, 
         FIG. 11  is an underside view of the apparatus shown in  FIG. 10 . 
     
    
    
     DETAILED DESCRIPTION 
     Referring to  FIG. 1  there is illustrated a gas water heater apparatus  10 . The apparatus  10  includes a storage tank  12  in which water to be heated is held. The tank  12  is generally elongated in form and has an upper end  13  and a lower end  15 . In its operating position the tank  12  is arranged in a generally upright orientation. The apparatus further includes an outer wall or jacket  14  which substantially surrounds the tank  12  and is spaced therefrom. 
     The apparatus further includes a combustion chamber  20  which is disposed below the tank  12 . The combustion chamber  20  comprises a side wall  22 , a bottom wall  23  and an upper wall  24  which is of domed shape and immediately adjacent the tank  12 . The upper wall  24  has an opening  17  therein through which combustion gases can be expelled from the combustion chamber  20 . As shown the upper wall  24  may form the lower wall of the tank  12 . A flue tube  26  extends through the tank  12  and has an entry end  28  at the combustion chamber  20  and an exit end  30  remote from the combustion chamber  20 . Combustion gases are caused to pass from the combustion chamber  20 , the outlet  17  and through the flue tube  26  out of the exit end  30  and thereafter discharged appropriately. 
     The apparatus further includes a gas burner  34  within the combustion chamber  20 . As shown, the gas burner  34  is arranged below and in axial alignment with the flue tube  26 . A gas controller  32  and temperature sensor  38  are also provided. 
       FIG. 2  illustrates apparatus according to one embodiment. The same reference numerals as used in  FIG. 1  have been used to identify like parts in  FIG. 2 . As shown in  FIG. 2  the flue tube  26  has a flue side wall  25  which has an inner side wall surface  27  which includes an inner end section  29  at the entry end  28  and a main section  31  downstream thereof. The section  29  is of greater cross-sectional dimension than section  31 . 
     The inner side wall surface  27  has a tapered section  21  between the main section  31  and the inner end section  29 . The angle of inclination of the tapered section  21  can be such that condensate tends to form on the inner surface  27  and maintain contact therewith as it travels along it towards the entry end  28  without separating from the inner surface at any region. 
     As shown, the apparatus  10  includes a condensate collector  40  which, in some embodiments, is disposed within the combustion chamber  20 , in an installed position. As best illustrated in  FIGS. 3 to 6  the condensate collector  40  includes a receptacle  42  which, in the form shown comprises a generally annular shaped channel  44  having a base wall  47 , an inner side wall  48 , an outer peripheral side wall  50 , and an open top side  46 . As shown, when in use the receptacle  42  is positioned immediately adjacent the entry end  28  of the flue tube  26  and is sized so that the open side  46  substantially aligns with the inner surface  29  of the entry end  28  of the flue tube  26 . Thus, during operation of the apparatus any condensate produced which tends to form on the inner surface  29  of the flue tube and will flow into the receptacle  42 . 
     As shown in  FIG. 2 , the inner side wall  48  has a height from the base wall  47  to the open top side  46  which is greater than the height of the outer peripheral side wall  50 . This difference in height is a preference, and the walls  48  and  50  could be the same height, or wall  50  larger than wall  48 . As shown, the inner side wall  48  can be immediately located at the entry end of the flue tube  26  or extend partially into the tube. As shown, the inner side wall  48  has a cross-sectional dimension which is less than the cross-sectional dimension of the inner surface  29  of the flue tube  26  at the entry end  28  and further, the cross sectional dimension of the outer peripheral side wall  50  is greater than the cross-sectional dimension of the inner surface  29  of the flue tube  26  at the entry end  28  thereof. Thus, the inner surface  29  of the entry end  28  of the flue tube  26  is substantially aligned directly above the open top side  46  of the channel  44 . As such any condensate formed on the inner surface  29  during operation of the apparatus can flow directly into the receptacle. As shown, the cross-sectional dimension of the outer peripheral sidewall  50  is equal to or greater than the cross-sectional dimension of the main section  31  of the inner surface of the flue tube  26 . Preferably all cross-sectional dimensions referred to are circular. 
     The configuration of the annular shaped channel  44  ensures that there is a clear passage maintained for the flow of combustion gases from the burner  34  to the flue tube  26 . That is to say, the annular channel  44  does not substantially inhibit this flow. This is assisted by the diameter of the aperture through the annular shaped channel  44  being sized so as to be the same as or larger than the diameter of the main section  31  of flue tube  26 . 
     The condensate collector  40  further includes a discharge outlet  53  from which condensate collected in the receptacle  42  can be discharged. The collector further includes a transfer conduit  52  which comprises a first arm  58  mounted to the side wall of the combustion chamber by a mounting bracket  65  ( FIGS. 4 to 6 ) and a second arm  60 , the arms being arranged end to end with the second arm  60  extending to the receptacle  42 . Thus, the receptacle is held in a cantilevered configuration in position by the second arm  60 . This is best illustrated in  FIG. 2 . The transfer conduit  52  is arranged in close proximity to the walls of the combustion chamber  20  and does not to a significant extent encroach into the main region of the combustion chamber. That is to say, the combustion chamber remains substantially unobstructed. As shown, the first arm  58  and the second arm  60  comprise open sided channels, which in the form shown are V-shaped. 
     As will be readily understood, the transfer conduit  52  can be manufactured in a single piece instead of having two arms  58  and  60 , or depending upon the shape of the combustion chamber, it may be assembled from more than two pieces. 
     In use, the burner  34  is ignited so as to heat the water within the tank  12 . The combustion gases produced in the combustion chamber  20  flow through the flue tube  26 . Condensate formed tends to mostly occur on the inner surface of the flue tube  26 . The condensate tends to flow towards the entry end  28  passing out of the tube into the channel  44 . From the channel  44  any collected conduit passes through the transfer conduit  52  and into the drain. 
     In the embodiment shown in  FIG. 7 , the channel  44  is positioned within the flue tube  26  at the entry end  28  thereof. The outer peripheral side wall  50  of the channel  44  may be secured to the inner surface  29 . This may be effected in any suitable fashion such as welding by the use of suitable fasteners. The channel  44  can have a discharge outlet which can be connected to a transfer conduit  52  in a similar fashion so that shown in  FIGS. 2 to 6 . 
     In the embodiment of  FIG. 8  the entry end  28  extends into the combustion chamber  20 . In this embodiment the side wall of the flue tube  26  is configured so as to provide for the channel  44 . As shown the edge section of the side wall is extended inwardly and upwardly towards the exit end of the flue tube hereby providing for the channel  44 . 
     In the embodiment of  FIG. 9  the entry end  28  of the flue tube  26  and the upper wall  24  of the combustion chamber  20  are configured to provide for the channel  44 . To this end the upper wall  24  has an opening  17  therein for the passage of combustion gases. The opening  17  has an upwardly turned lip  19 . The edge of the entry end  28  overlies the opening such that there is a space between the flue side wall and the lip  19  thereby forming the channel  44 . A discharge outlet  53  provides fluid communication between the channel  44  and the transfer conduit  52 . 
     In the embodiment of  FIGS. 10 and 11  the entry end  28  of the flue tube  26  extends into the combustion chamber. In this embodiment the outer peripheral wall  50  is secured to the inner surface of the upper wall  24  of the combustion chamber  20 . As shown the entry end  28  of the flue tube  26  is within the channel  44 . The upper edger of the peripheral wall  50  has a number of slots therein which define a plurality of discharge outlets  53 . In operation the channel  44  fills with condensate from the flue tube  26  which then passes out of the outlets  53  and is caused to travel along the inner surface of the walls of the combustion chamber until it reaches the bottom wherefrom it is discharges to a drain. 
     While the transfer conduit  52  is described above as being made from one or more open channel or v-shaped sections, it will be readily understood that the transfer conduit  52  can instead be manufactured from tubular sections. It is expected however, that open channel or v-shaped sections will not be readily blocked, whereas there may be a risk of tubular section becoming blocked over time. 
     As will be appreciated the condensate collector in its various forms described above may be retrofitted to existing heating and storage systems. 
     In the forgoing description of preferred embodiments, specific terminology has been resorted to for the sake of clarity. However, the invention is not intended to be limited to specific terms so selected, and it is to be understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar technical purpose. Terms such as “front” and “rear”, “inner” and “outer”, “above”, “below”, “upper” and “lower” and the like are used as words of convenience to provide reference points and are not to be construed as limiting terms. 
     The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as, an acknowledgement or admission or any form of suggestion that prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavour to which this specification relates. 
     In this specification the word “comprising” is to be understood in its “open” sense, that is, in the sense of “including”, and thus not limited to its “closed” sense, that is the sense of “consisting only of”. A corresponding meaning is to be attributed to the corresponding words “comprise”, “comprised” and “comprises” where they appear. 
     In addition, the foregoing describes only some embodiments of the invention(s), and alterations, modifications, addition and/or changes can be made thereto without departing from the scope and spirit of the disclosed embodiments, the embodiments being illustrative and not restrictive. 
     Furthermore, invention(s) have been describe in connection with what are presently considered to be the most practical and preferred embodiments, it is to be understood that the invention is not to be limited to the disclosed embodiments, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the invention(s). Also, the various embodiments described above may be implemented in conjunction with other embodiments, e.g. aspects of one embodiment may be combined with aspects of another embodiment to realise yet other embodiments. Further, each independent feature or component of any given assembly may constitute an additional embodiment. 
     The reference numerals in the following claims do not in any way limit the scope of the respective claims. 
     
       
         
           
               
            
               
                   
               
               
                 TABLE OF PARTS 
               
            
           
           
               
               
            
               
                 Item 
                 Part 
               
               
                   
               
            
           
           
               
               
            
               
                 10 
                 Apparatus 
               
               
                 12 
                 Liquid storage tank 
               
               
                 13 
                 Upper end 
               
               
                 14 
                 Outer wall or jacket 
               
               
                 15 
                 Lower end 
               
               
                 19 
                 Lip 
               
               
                 20 
                 Combustion chamber 
               
               
                 21 
                 Tapered flue section 
               
               
                 22 
                 Side wall 
               
               
                 23 
                 Bottom wall 
               
               
                 24 
                 Upper wall 
               
               
                 25 
                 Flue side wall 
               
               
                 26 
                 Flue tube 
               
               
                 27 
                 Inner surface 
               
               
                 28 
                 Entry end 
               
               
                 29 
                 Inner end section 
               
               
                 30 
                 Exit end 
               
               
                 31 
                 Main section 
               
               
                 32 
                 Gas controller 
               
               
                 34 
                 Burner 
               
               
                 38 
                 Temperature sensor 
               
               
                 40 
                 Condensate collector 
               
               
                 42 
                 Receptacle 
               
               
                 44 
                 Channel 
               
               
                 46 
                 Open side 
               
               
                 47 
                 Base 
               
               
                 48 
                 Inner side wall 
               
               
                 50 
                 Outer peripheral side wall 
               
               
                 52 
                 Transfer conduit 
               
               
                 53 
                 Discharge outlet 
               
               
                 54 
                 Inlet end 
               
               
                 56 
                 Outlet end 
               
               
                 58 
                 First arm 
               
               
                 60 
                 Second arm 
               
               
                 66 
                 Drain channel