Patent Publication Number: US-2016221001-A1

Title: Electrostatic blower and methods of assembling the same

Description:
BACKGROUND OF THE INVENTION 
     The embodiments described herein relate generally to electrostatic blowers, and more particularly, to methods and systems for exhausting a flue gas from a gas-fired appliance. 
     Gas-fired appliances are used to ignite a fuel for heating purposes. A typical gas-fired appliance such as, for example, a gas-fired water heater, ignites natural gas to heat water for further use by a facility such as a home or other building. Conventionally, during combustion of the fuel, the gas-fired appliance generates flue gases. For at least efficiency and safety reasons, the flue gases should be vented from the gas-fired appliance and away from the facility. 
     Some gas-fired appliances are categorized by an efficiency rate. Condensing appliances are sometimes categorized having a 90% efficiency rating and non-condensing appliances are sometimes categorized having an 80% efficiency rating. Save conventional condensing appliances generate the flue gas to induce a natural convection, based on pressure differences, which allows the flue gas to flow from a combustion zone and into a vent. Conventional non-condensing appliances, however, may generate the flue gas with a lower temperature as compared to the temperature of condensing appliances. 
     With lower combustion temperatures than conventional condensing appliances, conventional non-condensing appliances may use an electromechanical fan or blower that is coupled to an outlet of the combustion zone. The fan is configured to move the flue gas from the combustion zone and through the vent. The fan, however, may increase the manufacturing, operational and/or maintenance costs of the non-condensing appliance. Moreover, the added fan may increase the space needed for the non-condensing appliance. Still further, the fan may produce unwanted noise during operation of the non-condensing appliance. 
     BRIEF DESCRIPTION OF THE INVENTION 
     In one aspect, an electrostatic blower for moving a flue gas is provided. The electrostatic blower includes a power source and a housing coupled to the power source. The housing includes an inlet end and a discharge end. A corona discharge device is coupled to the power source and to the housing. The corona discharge device is configured to ionize the flue gas. The electrostatic blower includes a collector device coupled to the housing at a position downstream from said corona discharge device with respect to a flow of the flue gas within said housing. The collector is configured to attract the ionized flue gas from the corona discharge device. 
     In another aspect, a gas appliance is provided. The gas appliance includes a combustor configured to combust a fuel and to generate a flue gas. An electrostatic blower is coupled to the combustor and includes a power source and housing coupled to the power source. The housing includes an inlet end and a discharge end. A corona discharge device is coupled to the power source and to the housing. The corona discharge device is configured to ionize the flue gas. The gas appliance also includes a collector device coupled to the housing at a position downstream from said corona discharge device with respect to a flow of the flue gas within said housing. The collector device is configured to attract the ionized flue gas from the corona discharge device. A vent is coupled to the discharge end. 
     Still further, in another aspect, a method of assembling an electrostatic blower is provided. The method includes coupling a power source to a housing having an inner surface, an outer surface, an inlet end and a discharge end. A plurality of corona wires is coupled to the inner surface and near the inlet end. The method also includes coupling the power source to the plurality of corona wires. Further, the method includes coupling a plurality of collector plates to the inner surface and near the discharge end. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective of an exemplary electrostatic blower. 
         FIG. 2  is a schematic view of the electrostatic blower shown in  FIG. 1  coupled to a combustion system. 
         FIG. 3  illustrates an exemplary flowchart illustrating a method of assembling an electrostatic blower. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The embodiments described herein relate to electrostatic blowers and methods of assembling the electrostatic blower. The embodiments relate to an electrostatic blower that is coupled to a combustion system to facilitate exhausting flue gases from the combustion system. More particularly, the embodiments relate to a corona discharge device and a collector device coupled to a non-condensing gas-fired appliance. It should be understood that the embodiments described herein for electrostatic blowers are not limited to non-condensing, gas-fired appliances, and further understood that the descriptions and figures that utilize corona discharge wires, collector plates, and a water heater are exemplary only. 
       FIG. 1  is a perspective of an electrostatic blower  100 .  FIG. 2  is a schematic view of electrostatic blower  100  coupled to a combustion system  102 . Electrostatic blower  100  includes a housing  104 , a power source  106 , a corona discharge device  108 , and a collector device  110 . Housing  104  includes an inlet end  112 , a discharge end  114 , and a body  116  located between inlet end  112  and discharge end  114 . In the exemplary embodiment, body  116  includes an inner surface  118  and an outer surface  120 . Inner surface  118  is tubular shape to form a flow channel  122  between inlet end  112  and discharge end  114 . Alternatively, inner surface  118  may include any shape to enable housing  104  to function as described herein. Moreover, body  116  includes a temperature resistant, dielectric insulation material such as, but not limited to, a temperature resistant polymer material. In the exemplary embodiment, inner surface  118  is configured to direct a flue gas  134  within flow channel  122 , and in particular, to direct a flow of flue gas  134  from inlet end  112  and toward discharge end  114 . 
     Power source  106  is coupled to housing  104  and includes a power supply  124 , an appliance logic controller  126 , and a high voltage power supply  128 . Power source  106  further includes a ground  130  coupled to appliance logic controller  126  and to high voltage power supply  128 . 
     Appliance logic controller  126  is coupled to a gas-fired appliance  132  of combustion system  102 . In the exemplary embodiment, gas-fired appliance  132  includes a non-condensing appliance  133  such as, but not limited to, a water heater. Non-condensing appliance  133  is configured to generate flue gas  134  at a temperature that minimizes and/or eliminates condensate production in at least housing  104 . A common cause of vent failure for combustion systems  102  is condensation which occurs when water vapor  136  generated in a combustion process cools below a dew point. As water vapor  136  condenses, water vapor  136  combines with combustion by-products  140  present in flue gas  134  to form an acidic solution (not shown). A resultant acid (not shown) will collect and eventually degrade and/or destroy joints and seams (not shown) within combustion system  102 , and in particular, within housing  104 . 
     Non-condensing appliance  133  is configured to generate flue gas  134  having a temperature from about 200° F. to about 600° F. More particularly, non-condensing appliance  133  is configured to generate flue gas  134  having a temperature from about 335° F. to about 550° F. Alternatively, non-condensing appliance  133  may generate flue gas  134  having any temperature to minimize and/or eliminate formation of condensation. Moreover, in an alternate embodiment, gas-fired appliance  132  may include a condensing appliance. 
     Power supply  124  includes an ON/OFF switch  142  configured to control input voltage  144 , for example 115 v provided by power source  106 . In the exemplary embodiment, high velocity power supply  127  is coupled to ON/OFF switch  142 , corona discharge device  108 , and collector device  110 . In the exemplary embodiment, a shielded high voltage cable  146  couples high voltage power supply  128  to corona discharge device  108  and a ground  198  couples high voltage power supply  128  to collector device  110 . High voltage power supply  128  is configured to generate and transmit a supply voltage  150  to corona discharge device  108  to facilitate energizing corona discharge device  108  which ionizes flue gas  134  as described herein. In the exemplary embodiment, high voltage power supply  128  is configured to generate and transmit supply voltage  150  from about 20 Kv to about 80 Kv to corona discharge device  108 . More particularly, high voltage power supply  128  is configured to generate and transmit supply voltage  150  of about 30 Kv to corona discharge device  108 . Alternatively, high voltage power supply  128  is configured to supply any supply voltage  150  amount to corona discharge device  108  to enable efficient ionization of flue gas  134  by corona discharge device  108 . 
     Corona discharge device  108  is coupled to housing  104  near inlet end  112  and includes an electrode  152  having a first charge  153  such as, for example, a positive charge. In the exemplary embodiment, electrode  152  includes a plurality of electrical wires  154  coupled to high voltage power supply  128  and inner surface  118 . More particularly, each electrical wire  154  includes a first wire end  156  coupled to a first portion  158  of inner surface  118  and a second wire end  160  coupled to a second portion  162  of inner surface  118 . Each electrical wire  154  further includes a wire body  164  coupled to first wire end  156  and second wire end  158  and extending within flow channel  122 . A support ring  165  facilitates coupling electrical wires  154  to inner surface  118 . Electrical wires  154  are configured to ionize flue gas  134  present within flow channel  122  as described herein. 
     Collector device  110  is coupled to housing  104  at a position that is downstream of corona discharge device  108  with respect to flow of flue gas  134  through housing  104  from inlet end  112  and toward discharge end  114 . In an embodiment, collector device  110  is coupled to housing  104  near discharge end  114 . Collector device  110  includes an electrode  166  having a second charge  155  which is opposite first charge  153 . In the exemplary embodiment, electrode  166  has a negative charge. Electrode  166  includes a plurality of metal plates  168  coupled to high voltage power supply  128  through ground  148 . Each plate is further coupled to inner surface  118 . More particularly, each plate  168  includes a first plate end  170  coupled to first portion  158  and a second plate end  172  coupled to second portion  162 . Plates  168  further include a plate body  174  located between first plate end  170  and second plate end  172  and extending within flow channel  122 . A support ring  169  facilitates coupling plates  168  to inner surface  118 . Plates  168  are configured to attract flue gas  134  that has been ionized by corona discharge device  108  as described herein. 
     Electrical wires  154  and plates  168  are coupled to inner surface  118  and spaced from each other by a distance  176 . In the exemplary embodiment, distance  176  is from about one inch to about twelve inches. More particularly, distance  176  is about three inches. Alternatively, distance  176  can be less than about one inch and more than about twelve inches. Distance  176  is sized to facilitate ionization of flue gas  134  by electrical wires  154  and facilitate attraction of ionized flue gas  134  by and toward plates  168 . Moreover, distance  176  is sized to minimize and/or eliminate arcing between electrical wires  154  and plates  168  while facilitating ionization, attraction, and, movement of flue gas  134  present in flow channel  122 . Wires  154  and plates  168  may include any number, shape, size, material composition, location placement, and orientations to enable electrostatic blower  100  to function as described herein. 
     In the exemplary embodiment, electrostatic blower  100  further includes a vent  178  coupled to housing  104 . More particularly, vent  178  includes a first vent end  180  coupled to discharge end  114  and a second vent end  182  in flow communication to an environment  184  such as atmospheric environment. Vent  178  includes a pipe, conduit, and/or a duct coupled to discharge end  114  to facilitate venting or exhausting flue gas  134  from housing  104 . Moreover, vent  178  includes a corona discharge ring  186  coupled near first vent end  180 . 
     During an exemplary operation, power source  106  delivers input voltage  144 , such as 115v, to high voltage power supply  128  and to appliance logic controller  126 . Appliance logic controller  126  is configured to activate a combustor  188  to ignite a fuel  190  to produce heat. Flue gas  134  is created by the ignited fuel  190 . In the exemplary embodiment, combustor  188  generates flue gas  134  having a temperature from about 200° F. to about 600° F. to minimize and/or eliminate condensation by flue gas  134  within housing  104 . Flue gas  134  includes air and combustion by-products and is configured to enter housing  104  at inlet end  112 . Inlet end  112  directs flue gas  134  into flow channel  122  and toward corona discharge device  108 . 
     High voltage power supply  128  is configured to receive input voltage  144  from power source  106 . Moreover, high voltage power supply  128  is configured generate and transmit supply voltage  150  to corona discharge device  108 . In the exemplary embodiment, high voltage power supply  128  transmits supply voltage  150  to corona discharge device  108  a voltage in a range from about 20 Kv to about 80 Kv. Electrical wires  154  are configured to receive supply voltage  150  and produce a current  192 . 
     Current  192  is configured to flow from electrical wires  154  and into flue gas  134  present in flow channel  122  to facilitate a breakdown of flue gas  134 , known as corona discharge. More particularly, current  192  ionizes flue gas  134  to facilitate forming ions  194  of flue gas  134 . Collector plates  168  are configured to attract ions  194 , based on opposite second charge  155  of plates  168 . The ion attraction facilitates movement of ions  194  from electrical wires  154  and toward plates  168 . While moving toward collector plates  168 , ions  194  collide with other gas molecules  195  such as, for example air molecules and combustion by-product molecules, present within flow channel  122 , to facilitate creating a head pressure  196  which moves ions  194  and other gas molecules  195  within flow channel  122 . Ions  194  and collided gas molecules  195  combine and move from corona discharge device  108  and toward collector plates  168 . 
     Plates  168  are configured to attract ions  194  to facilitate neutralizing ions  194  based on opposite, second flue charge  155  of plates  168  as compared to positive first charge  153  of electrical wires  154 . Head pressure  196  continues to move flue gas  134 , from corona discharge device  108 , through flow channel  122 , and past collector plates  168 . Vent  178  is configured to direct flue gas  134  from collector plates  168  and into environment such as atmospheric environment  184  which is located away from non-condensing appliance  133 . Corona discharge ring  186  is configured to distribute the electric field gradient within vent  178  to facilitate minimizing and/or eliminating corona discharge effects within vent  178 . 
       FIG. 3  illustrates an exemplary flowchart illustrating a method  300  of assembling an electrostatic blower, for example electrostatic blower  100  (shown in  FIG. 1 ). The electrostatic blower includes a housing, for example housing  104  (shown in  FIG. 1 ), which has an inner surface and an outer surface, for example inner surface  118  and outer surface  120  (shown in  FIG. 1 ). The electrostatic blower further includes a power source, such as power source  106  (shown in  FIG. 2 ), an appliance logic controller, for example appliance logic controller  126  (shown in  FIG. 1 ), a corona discharge device, such as corona discharge device  108  (shown in  FIG. 1 ), and a collector device, for example collector device (shown in  FIG. 1 ). 
     Method  300  includes coupling  302  the power source to the housing. A plurality of corona wires, for example corona wires  154  (shown in  FIG. 1 ), of the corona discharge device, is coupled  304  to the housing inner surface near a housing inlet end, such as inlet end  112  (shown in  FIG. 1 ). The power source is also coupled  306  to the corona wires. Method  300  also includes coupling  308  a plurality of collector plates, for example collector plates (shown in  FIG. 1 ), to the inner surface and near the discharge end. In the exemplary method  300 , coupling the collector plates to the inner surface includes coupling the collector plates to the inner surface at a distance, such as distance  176  (shown in  FIG. 2 ), from the plurality of wires at about three inches. Moreover, in the exemplary method  300 , a vent, for example vent (shown in  FIG. 1 ), is coupled  310  to the discharge end. Method  300  further includes coupling  312  the appliance logic controller to the power source. 
     A technical effect of the systems and methods described herein includes at least one of: using a fanless motor less draft inducer to move flue gas; (b) ionizing flue gas with an electrostatic blower, (c) neutralizing the ionized flue gas, (d) venting the flue gas, (e) increasing an operating efficiency of combustion system, and (f) decreasing manufacturing installation, operations and maintenance costs. 
     The exemplary embodiment described herein facilitate mobbing and venting flue gases from a combustion system, such as a water heater or furnace, and away from a facility. More particularly, the embodiment described herein use an electrostatic blower to ionize the flue gas and to attack the ionized flue gas to a collector. The electrostatic blower facilitates movement of the flue gas from the combustion system without the use of an electromechanical fan and/or motor. The embodiments described herein decrease work space and noise of the combustion system. Still further, the exemplary embodiments increase efficiency and reduce operating and maintenance costs associated with the combustion system and/or electrostatic blower. 
     Exemplary embodiments of an electrostatic blower and methods for assembling the electrostatic blower are described above in detail. The methods and systems are not limited to the specific embodiments described herein, but rather, components of systems and/or steps of the methods may be utilized independently and separately from other components and/or steps described herein. For example, the methods may also be used in combination with other manufacturing systems and methods, and are not limited to practice with only the systems and methods as described herein. Rather, the exemplary embodiment can be implemented and utilized in connection with many other combustion applications. 
     Although specific features of various embodiments of the invention may be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of the invention, any feature of a drawing may be referenced and/or claimed in combination with any feature of any other drawing. 
     This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.