Patent Document

CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation of U.S. application Ser. No. 12/101,658, filed on Apr. 11, 2008, now allowed, which claims priority under 119(a-e) to New Zealand Provisional Application No. 554452, filed on Apr. 11, 2007. The disclosures of each of the above-identified applications are hereby incorporated herein by reference in their entireties. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The invention relates to an air control regulator for a fireplace, furnace, boiler, or equivalent thereof. 
       BACKGROUND OF THE INVENTION 
       [0003]    Operation of fireplaces generally requires, air inflow leading to a firebox. Examples of fireboxes include, but are not limited to furnaces, boilers, or an equivalent thereof. Fireboxes and can be incorporated into a manifold system comprising a network of pipes having an air inlet pipe able to “suck in” or draw in air as needed by the combustion process during operation. Air is critical in combustion and effects the combustion rate and heat output. 
         [0004]    Existing means to control air include manifolds or pipe systems with several holes or vents. Some manifolds can have capped ends with movable vent covers. These types of systems are normally manually operated and adjusted according to changing conditions associated with any environmental fluctuations such as, for example, changes in temperature and wind. Problems with often arise with these systems when a fire is starved of air, or, conversely, when there is too much air which can cause the fire to burn too quickly and consume more fuel than is necessary. 
       OBJECTS OF THE INVENTION 
       [0005]    It is an object of the invention to provide an air control regulator having a modest manufacturing cost, automatic or self regulating operation, simple installation, few moving parts. It is a further object of the invention to provide an air control regulator capable of being retrofitted to existing fireboxes, and capable of being combined with new fireboxes. It is a further object of the invention to provide an air control regulator having a compact design that enables fitting in most situations, and that is capable of accommodating variables in firebox size, chimney length, fuel size, stoking procedures, fuel-rich start and stoking. It is a further object of the invention to provide an air control regulator having a lean fuel burn. It is a further object of the invention to provide an air control regulator that is manually adjustable and discreet in operation. It is a further object of the invention to provide an air control regulator capable of coping with high and low winds and wind surges. It is a further object of the invention to provide an air control regulator having a safe operation and increased fuel efficiency. It is a further object of the invention to provide an air control regulator having reduced peak temperatures and emissions. It is a further object of the invention to provide an air control regulator capable of being overridden. It is a further object of the invention to provide an air control regulator having less of a likelihood of sudden influxes of extreme heat. It is a further object of the invention to provide an air control regulator capable of limiting the extent of chimney fires by limiting air availability during combustion. It is a further object of the invention to provide an air control regulator capable of tolerating a cold start. 
       SUMMARY OF THE INVENTION 
       [0006]    The present invention can be generally described as an air control regulator comprising a body, preferably cylindrical in outer configuration, being attachable to an air inlet of a firebox, furnace, boiler, or equivalent thereof. The body further comprises a movable disc which is constructed and adapted to slide along a first support rod in one direction in response to incoming air and in the opposite direction in response to gravity, thereby regulating the size of an air passage for incoming air such that combustion efficiency of the firebox is improved. 
         [0007]    Preferably, the first support rod is adjustably supported by a crossbar mounted diametrically on the body of the control regulator. 
         [0008]    Preferably, a second support rod is adjustably supported by the bar wherein an upper disk stop member is mounted thereon. Preferably, the upper disk stop member has an aperture to allow the first support rod to slidably pass through and further prevent the disc from moving any further upwards when in use. 
         [0009]    Preferably, the first support rod has a lower disc stop member to prevent the disc from moving any lower when in use. 
         [0010]    In the preferred embodiment, the body has an interior ovaloid opening having a plurality of arc-shaped depressions and scalloped lips. The ovaloid opening leads into a venturi shaped chamber having tapered walls. Air flow entering the ovaloid opening forms into a plurality of air columns, as it contacts the plurality of arc-shaped depressions. The number of air columns is dependent upon the number of arc-shaped depressions. 
         [0011]    In a preferred embodiment, the disc has a plurality of apertures to allow air to pass therethrough. 
         [0012]    Preferably, the control regulator is connectable to a combustion chamber. 
         [0013]    When a fire is drawing sufficient air, the airflow will lift the disc off the lower disc stop member and raise it into the venturi chamber. The upper disc stop member, which is vertically adjustable with the second support rod, limits the upward vertical movement of the disc. The plurality of air columns in the venturi chamber maintain the disc in a steady position. The weight of the disc, acting under the force of gravity, then causes the disc to move downward, pushing the flow of air against the tapered sides of the venturi chamber and narrowing the air flow passage. This movement slowly dampens the volume of the air drawn air into the combustion chamber or the fireplace, and allows the disc member to continue to descend slowly towards the lower portion of the venturi chamber. Once the disc is in the lower portion of the venture chamber, air flows around the disc, through the openings between the ovaloid perimeter and the disc. At this stage, the disc is no longer supported by columns of air and descends to a resting position on the lower disc stop member. The result is a lean burning combustion that either extinguishes the fire or is capable of being repeated by re-stoking the foregoing cycle. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0014]      FIG. 1  is a cross sectional view of the control regulator. 
           [0015]      FIG. 2  is a forward view of the control regulator. 
           [0016]      FIG. 3  is a top-plain view of a typical firebox manifold arrangement with the control regulator being fitted thereon. 
           [0017]      FIG. 4  is a side view of the same arrangement illustrated in  FIG. 3 . 
           [0018]      FIG. 5  is another side view of the arrangement illustrated in  FIG. 3 . 
           [0019]      FIG. 6  is a perspective view of the inlet end of the control regulator. 
           [0020]      FIG. 7  is a graphical representation of the efficiency of the control regulator in a firebox in comparison with a firebox without the regulator. 
       
    
    
     DETAILED DESCRIPTION 
       [0021]    The following description will describe the invention in relation to preferred embodiments of the invention. The invention is in no way limited to these preferred embodiments. Possible variations and modifications would be readily apparent without departing from the scope of the invention. 
         [0022]    As depicted in  FIG. 1 , control regulator  1  comprises a body  4 , preferably having a substantially cylindrical outer shape, a length  5 , variable inner and outer diameters  12  and  13 , a non-attachable end  6 , and an attachable end  7 . The attachable end  7  has internal threads  8  for attaching the control regulator to a firebox manifold  2  or equivalent thereof, as shown in  FIGS. 3-5 . Other means of affixing the control regulator are equally possible, including but not limited to press fitting or external threading. Incoming air enters body  4  via non-attachable end  6 , flows through the body, and exits from attachable end  7 . 
         [0023]    Body  4  has outer walls defining an outer wall surface  9  and inner walls defining an inner wall surface  10 . Outer wall surface  9  and inner wall surface  10  further define a variable wall thickness having an inner diameter  12 , and outer diameter  13  which vary along the length  5 . In one embodiment, the shoulder  14  of the outer wall is shaped in a stepped manner to facilitate removable affixing of the control regulator to any external device such as a manifold  2 . The outer walls can be shaped and dimensioned as desired. Non attachable end  6  has a leading outer corner edge  15  and inner corner edge  16 . 
         [0024]    Inner wall surface  10  may or may not be similar in shape to outer wall surface  9 . As shown in  FIG. 1 , inner wall surface  10  defines an internal configuration comprising a lower first portion  20 , leading upwardly to a second portion  21 , a third portion  22  above the second portion, and uppermost, a fourth portion  23 . In a preferred embodiment, the inner wall surface  10  is shaped in a stepped fashion comprising tapered and angled or curved portions forming a venturi chamber. 
         [0025]    As shown in  FIG. 1 , fourth portion  23  has substantially parallel inner and outer walls, with internal threading  8 , for engaging a pipe, manifold  2 , or any equivalent air receiving means which can be connected to a firebox. 
         [0026]    As further depicted in  FIG. 1 , first portion  20  tapers inwardly before leading into the venturi chamber formed by the upper portions of the body  4 . The venturi chamber includes a choked section above circumferential line  25 . Inner surface  24 , located within second portion  21 , does not form a general single curvature, but comprises a series on interconnected differing curves being made up of different diameters and ovaloids. First portion  20  which is located at the inlet or front face of regulator body  4  can be formed as planar slopes or, in the preferred embodiment shown in  FIG. 2 , may consist of several interconnected curvilinear slopes of different curve diameters which are three semi-diameters spaced equidistant around the inner edge of regulator body  4 . The semi-diameters are angled in and towards the centre of the body. While three semi-circular diameters are shown in  FIG. 2 , the number of diameters may be greater or lesser than three. 
         [0027]    Control regulator  1  has a support crossbar  30  extending across the diameter of regulator body  4 , and is located near attachable end  7  of the body  4 . Support bar  30  has ends  31  and  32  supported by the thickness of the body walls at ends  31  and  32 . Support bar  30  can be removably fixed and adjustably attached by first fixing means  34  such as being threadingly, engaged and/or being keyed in place with screw fixing means or some other equivalent which can be accessed from the shoulder  14 . As depicted in  FIG. 1 , support bar  30  is located in third portion  22 . Support bar  30  can be adjusted rotationally in an arc and longitudinally. Support bar  30  is further comprised of a hollow or solid cross section having a determined thickness, diameter, and shape that can be circular or square. Support bar  30  is further comprised of two spaced apart apertures  35  and  36 . 
         [0028]    Apertures  35  and  36  are sized to allow passage of first and second support rods  40  and  41  therethrough so that support rods  40  and  41  are oriented substantially parallel with the body length  5  and with each other. First support rod  40 , acts as a guide for movement of the disc  43 , and is further comprised of lower disc stop member  42 . Disc  43  has a central hole, and is disposed about first support rod  40 , and is vertically movable along it. Lower disc stop member  42  is located near non-attachable end  6 . First support rod  40  is adjustably and slidably supported near attachable end  7 . Preferably, support bar  30  is further comprised of a second fixing member  37  for affixing first support rod  40 . Second fixing member  37  is preferably comprised of a guide pin and locking screw extending within support bar  30  and abutting the side of first support rod  40 . The guide pin and locking screw can be unscrewed or screwed to allow first support rod  40  to move up or down. As depicted in  FIG. 1 , first support rod  40  is centrally located in the body  4 . First support rod  40  can be mounted and positioned such that first support rod  40  can be laterally and rotationally adjusted if desired. 
         [0029]    Support bar  30  is further comprised of a third fixing member  38  for fixing second support rod  41 . Third fixing member  38  preferably comprises a guide pin and locking screw located within the length of support bar  30 . One end of third fixing member  38  abuts second support rod  41 , and the other end of third fixing member  38  contacts and is coincident with the outer wall surface  9  to permit adjustment of third fixing member as desired. Second support rod  41  provides a fixed support for an upper disc stop member  45 . Upper disc stop member  45  is preferably comprised of a first aperture  46  to allow first support rod  40  to slide therethrough. Second support rod  41  can be independently adjusted to position upper disc stop member  45  as desired. When first support rod  40  moves up, disc  43  eventually contacts upper disc stop member  45  and is restricted from any further upward movement. 
         [0030]    As illustrated in  FIG. 2 , disc member  43  has at least one aperture  47  and a disc diameter that is smaller than the main internal diameter of body  4  so that disc  43  can slidably move up and or down first support rod  40  between upper and lower disc stop members  45  and  42 , thus choking the air flow as desired. Preferably, upper disc stop member  45  covers any aperture(s) in disc  43 . Preferably, disc  43  is further comprised of a centrally located, aperture  48 . Aperture  48  allows disc  43  to slidably attach to first support rod  40 . Disc  43  can be made of a specified gauge and material type according to the desired performance required. 
         [0031]    As shown in  FIG. 2 , first portion  20  is comprised of a plurality of arc-shaped depressions  49 , an ovaloid opening  50 , and a plurality of scalloped edges  51 . In a preferred embodiment, there are three arc-shaped depressions  49  and three scalloped edges  51 , spaced equidistantly around the lip  16  of ovaloid opening  50 . When air passes into ovaloid opening  50 , three air columns are formed as the air flow contacts arc-shaped depressions  49 . Different numbers of arc-shaped depressions and scalloped edges are possible. The number of air columns formed is dependent on the number of arc-shaped depressions. 
         [0032]    Control regulator  1  can be incorporated into an existing firebox. As depicted in  FIGS. 3-5 , control regulator  1  can be retrofitted to an existing firebox by drilling or punching a hole into the rear of the firebox. Manifold  2  can be in the form of a “T” section with capped ends  53 , metering vents  54 , and an elbow-shaped section for attachment of the control regulator  1  which can be varied according to the size of the regulator and firebox. The metering vents  54  can also be sized in accordance with their compatibility with control regulator  1 . Retrofitting control regulator  1  will not interfere with the operation of any controllable air vents on an existing firebox. 
         [0033]    The control regulator  1  automatically controls and limits the amount of air flowing into an enclosed firebox, combustion chamber, furnace, or equivalent thereof, which, in turn, affects the heat output. The moving disc  43  regulates the airflow by slidably moving up and down first support rod  40  between the lower and upper disc stop members  42  and  45 . 
         [0034]    Control regulator  1  is in an open position when disc  43  rests on lower disc stop member  42 . When disc  43  rests in the open position air is free to enter body  4 . When a fire is ignited, drawn air flows past disc  43  through the first portion  20 , and forms a plurality of air columns as a result of contacting the plurality of arc-shaped depressions and scalloped edges comprising first portion  20 . When the fire is drawing sufficient air, disc  43  will be lifted past the ovaloid opening  50  into the venturi chamber—formed by second and third portions  21  and  23 . Upper disc stop member  45 , which is preferably adjustable vertically with second support rod  41 , limits the maximum flow of the air. Disc  43  is steadily supported by the resulting plurality of air columns. Subsequently, the force of gravity causes the weight of disc  43  to direct the air flow on to the tapered sides of the venturi chamber, slowly damping the volume and speed of air drawn into the combustion chamber of the firebox. Disc  43  will then slowly descend toward ovaloid opening  50  at which point air begins passing disc  43  through a plurality of apertures between the ovaloid opening  50  and the disc  43 . At this stage, the disc is no longer supported by columns of air and descends to a resting position. The result is a lean burning combustion that either extinguishes or is repeated by re-stoking the foregoing cycle. 
         [0035]      FIG. 7 , depicts a graphical comparison of temperature in degrees Celsius (Y axis) versus time (X axis) taken at the rear of a firebox at 30 minute intervals for (1) an unmodified firebox; (2) a closed firebox with the control regulator with air vents closed and air tube removed; and (3) a closed firebox with the control regulator air vents closed and air tube removed. 
         [0036]    The difference in peak firebox temperatures between (1) and (2) is 100 degrees Celsius. After three hours the difference between (1) and (2) shows the control regulator having a marked advantage. At the five hour point, unmodified firebox (1) has extinguished while modified firebox (2) is still running at 150 degrees Celsius. At the five hour point (2) has maintained a higher level of effectiveness over (1) by approximately 50%. Therefore the control regulator has a marked effect on the heat output over time by maintaining heat output for a longer period and reducing peak temperatures. 
         [0037]    It will of course be realized that while the foregoing has been given by way of illustrative example of this invention, all, such and other modifications and variations thereto as would be apparent to persons skilled in the art are deemed to fall within the scope and ambit of this invention as is herein described.

Technology Category: y