Water heater appliance exhaust system for recreational vehicles

Abstract

A water heater appliance for a recreational vehicle is provided. The water heater appliance includes a cabinet, a heat exchanger positioned within the cabinet, and a combustion chamber positioned within the cabinet. The combustion chamber is in thermal communication with the heat exchanger. The water heater appliance also includes an exhaust tube fluidly coupled to the combustion chamber, and an exhaust box fluidly coupled to the exhaust tube. The exhaust box includes a first divider positioned in line with the exhaust tube, a second divider at least partially positioned below the exhaust tube, and an exhaust outlet positioned below the exhaust tube.

Description

FIELD OF THE INVENTION

[0001] The present subject matter relates generally to recreational vehicle water heaters, and more particularly to exhaust systems therein.BACKGROUND OF THE INVENTION

[0002] Water heaters for use with recreational vehicles (RV) typically include a water tank in combination with an internal heating element. Most internal heating elements in water heaters used in recreational vehicles are dual fuel: liquid petroleum gas and electric heating. The water heater is mounted on the recreational vehicle in a convenient position connected to cold water supply and hot water outlet pipes, respectively receiving cold water from a suitable water supply source and for directing heated water for use in cooking, bathing, and the like.

[0003] Standard recreational vehicle water heaters include an exhaust tube to the outside air in order to exhaust combustion products from the water heater out of the recreational vehicle. If water and / or wind enter into the exhaust tube it may cause damage to components within the water heater, particularly to the heat exchanger which is typically used to heat the water. In a standard recreational vehicle water heater, the exhaust tube includes a one-way damper to prevent wind and water from entering through the exhaust tube. In some cases, the one-way damper may get stuck in either a closed or open position, such as while the recreational vehicle is in motion, or if debris were to enter into the exhaust tube. Advantageously, removing the one-way damper from the exhaust tube may reduce cost and complexity of assembly.

[0004] Accordingly, a water heater appliance with an exhaust system that uses less parts and decreases cost would be desirable. Further, a water heater appliance, for a recreational vehicle, with an exhaust system that reduces wind and water from entering the water heater appliance without a one-way damper would be advantageous.BRIEF DESCRIPTION OF THE INVENTION

[0005] Aspects and advantages of the invention will be set forth in part in the following description, or may be apparent from the description, or may be learned through practice of the invention.

[0006] In one example embodiment, a water heater appliance for a recreational vehicle is provided. The water heater appliance defines a vertical direction, a lateral direction, and a transverse direction. The vertical, lateral, and transverse directions are mutually perpendicular. The water heater appliance includes a cabinet defining a front side, a back side, a first side, and a second side. The water heater appliance also includes a heat exchanger positioned within the cabinet, and a combustion chamber positioned within the cabinet. The combustion chamber includes a burner assembly. The combustion chamber is in thermal communication with the heat exchanger. An exhaust tube is fluidly coupled to the combustion chamber. The water heater appliance further includes an exhaust box. The exhaust box defines a front side, a back side, a first side, a second side, a top side, and a bottom side. The exhaust box is fluidly coupled to the exhaust tube at the back side of the exhaust box. The exhaust box includes a first divider extending between the first side and the second side of the exhaust box. The first divider is positioned in line with the exhaust tube. The exhaust box also includes a second divider extending between the first side and the second side of the exhaust box. The second divider is positioned at least partially below the exhaust tube. An exhaust outlet is positioned at the front side of the exhaust box.

[0007] In another example embodiment, a water heater appliance for a recreational vehicle is provided. The water heater appliance defines a vertical direction, a lateral direction, and a transverse direction. The vertical, lateral, and transverse directions are mutually perpendicular. The water heater appliance includes a cabinet, a heat exchanger positioned within the cabinet, and a combustion chamber positioned within the cabinet. The combustion chamber is in thermal communication with the heat exchanger. The water heater appliance also includes an exhaust tube fluidly coupled to the combustion chamber, and an exhaust box fluidly coupled to the exhaust tube. The exhaust box includes a first divider positioned in line with the exhaust tube, a second divider positioned at least partially below the exhaust tube, and an exhaust outlet positioned below the exhaust tube.

[0008] These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures.

[0010] FIG. 1 provides a front view of an example embodiment of a water heater appliance for a recreational vehicle, according to aspects of the present subject matter.

[0011] FIG. 2 provides a perspective view of the water heater appliance of FIG. 1, with a door of the water heater appliance removed, according to aspects of the present subject matter.

[0012] FIG. 3 provides a perspective, sectional view of the water heater appliance of FIG. 1, according to aspects of the present subject matter.

[0013] FIG. 4 provides a side, sectional view of an exhaust box of the water heater appliance of FIG. 2, according to one aspect of the present subject matter.

[0014] FIG. 5 provides a side, sectional view of the exhaust box of FIG. 4, according to another aspect of the present subject matter.

[0015] FIG. 6 provides a side, sectional view of the exhaust box of FIG. 4, according to another aspect of the present subject matter.

[0016] Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present invention.DETAILED DESCRIPTION OF THE INVENTION

[0017] Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.

[0018] As used herein, the terms “first,”“second,” and “third” may be used interchangeably to distinguish one component from another and are not intended to signify location or importance of the individual components. The terms “includes” and “including” are intended to be inclusive in a manner similar to the term “comprising.” Similarly, the term “or” is generally intended to be inclusive (i.e., “A or B” is intended to mean “A or B or both”). In addition, here and throughout the specification and claims, range limitations may be combined and / or interchanged. Such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise. For example, all ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other. The singular forms “a,”“an,” and “the” include plural references unless the context clearly dictates otherwise.

[0019] Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “generally,”“about,”“approximately,” and “substantially,” are not to be limited to the precise value specified.

[0020] Referring now to FIGS. 1 through 3, an example water heater appliance will be described in accordance with example aspects of the present subject matter. Specifically, FIG. 1 provides a front view of an example water heater appliance 100, FIG. 2 provides a perspective view of water heater appliance 100, and FIG. 3 provides a perspective, cross-sectional view of water heater appliance 100. As illustrated, water heater appliance 100 generally defines a vertical direction V, a lateral direction L, and a transverse direction T, each of which is mutually perpendicular, such that an orthogonal coordinate system is generally defined.

[0021] According to example embodiments, water heater appliance 100 may include a cabinet 107 that is generally configured for containing and / or supporting various components of water heater appliance 100 and which may also define one or more internal chambers or compartments of water heater appliance 100. In this regard, as used herein, the terms “cabinet,”“housing,” and the like are generally intended to refer to an outer frame or support structure for appliance 100, e.g., including any suitable number, type, and configuration of support structures formed from any suitable materials, such as a system of elongated support members, a plurality of interconnected panels, or some combination thereof. It should be appreciated that cabinet 107 does not necessarily require an enclosure and may simply include an open structure supporting various elements of appliance 100. By contrast, cabinet 107 may enclose some or all portions of the interior of cabinet 107. It should be appreciated that cabinet 107 may have any suitable size, shape, and configuration while remaining within the scope of the present subject matter.

[0022] In general, cabinet 107 may extend in the transverse direction T between a front side 131 and a back side 132, in the vertical direction V between a top side 135 and a bottom side 136, and in the lateral direction L between a first side 133 and a second side 134. In general, water heater appliance 100 may include a panel, e.g., a door 102, coupled to cabinet 107, as shown in FIG. 1 in a closed position, and removed in FIG. 2 for clarity in showing within cabinet 107. In general, door 102 may be mounted to cabinet 107 via hinges 106, e.g., hinges 106 may rotatably couple door 102 to cabinet 107. Opening door 102 about hinge 106 may permit selective access to internal components within cabinet 107, such as a burner assembly 110, a heat exchanger 120 and / or, an exhaust box 200, each of which are described in greater detail below. In general, door 102 of water heater appliance 100 may include a slot, such as an exhaust port 103, for an exhaust outlet 104, as will be described in greater detail below.

[0023] In the present example embodiment, water heater appliance 100 may include a heat exchanger 120 positioned within cabinet 107. Heat exchanger 120 may generally provide heat to water flowing through water heater appliance 100. For example, water heater appliance 100 may be a dual-fuel water heater. Thus, water heater appliance 100 may be configured for heating water by either combusting liquid petroleum gas, such as liquid propane (LP). In general, water heater appliance 100 may also include a combustion chamber 112 within cabinet 107 for combusting liquid propane. As such, combustion chamber 112 may include a burner assembly 110 extending therein, and combustion chamber 112 may be in thermal communication with heat exchanger 120. In general, burner assembly 110 may include a gas inlet (not labeled) and a sparker or igniter 142 for igniting fuel within combustion chamber 112. In other words, burner assembly 110 may combust fuel within combustion chamber 112, thus providing heat to heat exchanger 120 for heating water passing through water heater appliance 100. Accordingly, water may enter water heater appliance 100 and be heated by heat exchanger 120, before being distributed to other appliances or outlets for use in cooking, bathing, and the like.

[0024] In general, burner assembly 110 may be in fluid communication with a gas control valve 140 to control the flow of gas to combustion chamber 112. Burner assembly 110 may generally create combustion products, such as exhaust gases within combustion chamber 112. In general, the created combustion products may exit water heater appliance 100 to ambient atmosphere. In particular, water heater appliance 100 may include an exhaust tube 108 fluidly coupled to combustion chamber 112. For example, exhaust tube 108 may extend between an inlet 109 positioned at combustion chamber 112 and an outlet 111 along the transverse direction T. In some example embodiments, a blower assembly 144 may be fluidly coupled between combustion chamber 112 and exhaust tube 108. Blower assembly 144 may generally be configured to pull exhaust from heat exchanger 120, through exhaust tube 108, and force the exhaust out of water heater appliance 100 to ambient atmosphere.

[0025] In the present example embodiment, an exhaust box 200 may be positioned at outlet 111 of exhaust tube 108. Exhaust box 200 may generally be a rectangular, stainless-steel box. In particular, exhaust box 200 may define a front side 201, a back side 202, a first side 203, a second side 204, a top side 205, and a bottom side 206. Exhaust box 200 may be fluidly coupled to exhaust tube 108 at back side 202 of exhaust box 200. In general, exhaust box 200 may include exhaust outlet 104 positioned at front side 201 of exhaust box 200, e.g., exhaust outlet 104 may be integral to exhaust box 200 and may extend through exhaust port 103 in door 102 of water heater appliance 100. As such, the created combustion products from burner assembly 110 may exit from water heater appliance 100 to ambient atmosphere from combustion chamber 112 through exhaust tube 108, into exhaust box 200, and through exhaust outlet 104.

[0026] In general, exhaust box 200 may include a first divider 210 extending between first side 203 and second side 204 of exhaust box 200. In general, first divider 210 may be positioned in-line with exhaust tube 108. For example, first divider 210 may span across the diameter (not labeled) of exhaust tube 108, thus splitting the exhaust flow path 1000, as illustrated in FIG. 4 as two (2) flow path 1000 coming from exhaust tube 108. Furthermore, exhaust box 200 may include a second divider 220 extending between first side 203 and second side 204 of exhaust box 200. In general, second divider 220 may be positioned below exhaust tube 108, as will be explained further herein.

[0027] Turning now to FIGS. 4 through 6, an example exhaust box 200 will be described in accordance with example aspects of the present subject matter. Specifically, FIG. 4 provides a side, sectional view of exhaust box 200 with an exhaust flow path (e.g., flow path 1000) illustrated, FIG. 5 provides the side, sectional view of exhaust box 200 with a wind and water rejection flow path (e.g., flow path 2000) illustrated, and FIG. 6 provides the side, sectional view of exhaust box 200 with another wind and water rejection flow path (e.g., flow path 3000) illustrated.

[0028] Looking specifically at FIG. 4, exhaust box 200 may be seen extending, generally in the transverse direction T, between exhaust tube 108 at back side 202 of exhaust box 200 and exhaust outlet 104 at front side 201 of exhaust box 200. In particular, a step portion 230 may extend from front side 201 of exhaust box 200. In general, step portion 230 may be shorter than front side 201 of exhaust box 200 with respect to the vertical direction V. In particular, front side 201 may define a first height 280 from bottom side 206 of exhaust box 200, and step portion may define a second height 282 from bottom side 206 of exhaust box 200, wherein the second height 282 (e.g., the height of step portion 230) may be shorter than the first height 280 (e.g., the height of first portion 201). Further, exhaust outlet 104 may be positioned at, or extend from, step portion 230 at front side 201 of exhaust box 200. In particular, exhaust outlet 104 may be shorter than step portion 230 with respect to the vertical direction V. In particular, exhaust outlet 104 may define a third height 284 from bottom side 206 of exhaust box 200, wherein the third height 284 (e.g., the height of exhaust outlet 104) may be shorter than the second height 282 (e.g., the height of step portion 230). Additionally, extending between top side 205 and front side 201 of exhaust box 200 may be a sloped panel 208, such that exhaust box 200 forms a piecewise, or stepping, funnel between back side 202 and exhaust outlet 104 along the transverse direction T.

[0029] As seen in FIG. 4, exhaust outlet 104 may generally be positioned below exhaust tube 108, with respect to the vertical direction V. In particular, a top height 300 of exhaust outlet 104 (e.g., the highest point of the opening (not labeled) of exhaust outlet 104) may be positioned in the vertical direction V below a bottom height 400 of exhaust tube 108 (e.g., the lowest point of outlet 111 of exhaust tube 108). Accordingly, wind and / or water entering exhaust box 200 through exhaust outlet 104 may be reduced or restricted from directly entering exhaust tube 108, thus reducing potential damage to components within water heater appliance 100.

[0030] Looking now specifically at first divider 210, first divider 210 may define a first angle α. In general, first divider 210 may be bent along first angle α such that first divider 210 bends generally downward in the vertical direction V from the transverse direction T. More specifically, first divider 210 may include a first segment 212 which extends generally in the transverse direction T from back side 202 of exhaust box 200 before bending downwards along first angle α, whereby a second segment 214 of first divider 210 extends downwards in both the transverse direction T and vertical direction V to a tip 218 of first divider 210. In general, first angle α may be an obtuse angle, e.g., first angle α may be any suitable angle between ninety degrees (90°) and one hundred and eighty degrees (180°), such as between one hundred degrees (100°) and one hundred and seventy degrees (170°), such as between one hundred and twenty degrees (120°) and one hundred and sixty degrees (160°). While first divider 210 is described in terms of first segment 212 and second segment 214, first divider 210 may be a singular piece of sheet metal fastened or welded within exhaust box 200.

[0031] Looking now specifically at second divider 220, second divider 220 may define a second angle β. In general, second divider 220 may be bent along second angle β such that second divider 220 first extends one way with respect to the transverse direction T and bends back to extend the other way with respect to the transverse direction T. More specifically, second divider 220 may include a first segment 222 adjacent to bottom side 206 of exhaust box 200, wherein a second segment 224 bends upwards towards back side 202 of exhaust box 200. In some example embodiments, before reaching bottom height 400 of exhaust tube 108, second divider 220 may bend along second angle β whereby a third segment 226 may extend towards front side 201 of exhaust box 200, e.g., forward with respect to the transverse direction T and upwards with respect to the vertical direction V, to a tip 228 at one end of second divider 220. In general, second angle β may be an acute angle, e.g., second angle β may be any suitable angle between zero degrees (0°) and ninety degrees (90°) such as between ten degrees (10°) and eighty degrees (80°), such as between twenty degrees (20°) and seventy degrees (70°). While second divider 220 is described in terms of first segment 222, second segment 224, and third segment 226, second divider 220 may be a singular piece of sheet metal fastened or welded within exhaust box 200.

[0032] As illustrated, third segment 226 of second divider 220 may generally extend, with respect to the transverse direction T, towards front side 201 of exhaust box 200, and, in some example embodiment, may also extend upwards with respect to the vertical direction V. In such embodiments, tip 228 of second divider 220 may include a downward tilt 229, with respect to the vertical direction V, in order to direct incoming wind and / or water down and out of exhaust outlet 104, as will be described in greater detail hereinbelow.

[0033] Referring now to FIG. 5, wind and water rejection flow path 2000 is illustrated in exhaust box 200. In general, wind and water rejection flow path 2000 provides an example scenario where wind and / or water may flow directly into exhaust outlet 104 along the transverse direction T. In general, second segment 224 and third segment 226 may form a “C” shape, whereby wind and / or water flowing along flow path 2000 may be redirected along the “C” shape and back towards exhaust outlet 104. Additionally, flow path 2000 may be redirected towards tip 228 of second divider 220, whereby the downward tilt 229 of tip 228 may further direct wind and / or water down and out of exhaust outlet 104.

[0034] Referring now to FIG. 6, wind and water rejection flow path 3000 is illustrated in exhaust box 200. In general, wind and water rejection flow path 3000 provides an example scenario where wind and / or water may flow into exhaust outlet 104 at an angle between the vertical direction V and the transverse direction T. Some wind and / or water flowing along flow path 3000 may be directed towards a top portion (not labeled) of exhaust outlet 104, whereby the wind and / or water flowing along flow path 3000 may be redirected by the top portion (not labeled) of exhaust outlet 104 towards the “C” shape of second segment 224 and third segment 226 and back then towards exhaust outlet 104. Additionally, the downward tilt 229 of tip 228 may further direct wind and / or water down and out of exhaust outlet 104. Additionally or alternatively, some wind and / or water flowing along flow path 3000 may be directed towards a top portion (not labeled) of step portion 230, whereby the wind and / or water flowing along flow path 3000 may be redirected by the top portion (not labeled) of step portion 230 towards tip 218 of first divider 210. In particular, tip 218 may further direct the wind and / or water down along flow path 3000 and out of exhaust outlet 104.

[0035] As may be seen from the above, a water heater appliance for a recreational vehicle may include an exhaust box configured to reduce or restrict wind and / or water from entering the water heater appliance. Specifically, the exhaust box may be a box with two sheet metal dividers in geometries within to channel exhaust out and reduce or prevent wind and / or water from entering. A first piece of sheet metal is secured within the housing to split an exhaust tube in half and divert exhausted gas down and out of an exhaust outlet. The second piece of sheet metal may be folded at an acute angle in order to direct wind and / or water that enters through the exhaust outlet, back out of the exhaust outlet. Accordingly, the water heater appliance may include an exhaust system without a one-way damper, advantageously using less parts and decreasing costs.

[0036] 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 include 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.

Claims

1. A water heater appliance for a recreational vehicle, the water heater appliance defining a vertical direction, a lateral direction, and a transverse direction, the vertical, lateral, and transverse directions mutually perpendicular, the water heater appliance comprising:a cabinet defining a front side, a back side, a first side, and a second side;a heat exchanger positioned within the cabinet;a combustion chamber positioned within the cabinet, the combustion chamber comprising a burner assembly, the combustion chamber in thermal communication with the heat exchanger;an exhaust tube fluidly coupled to the combustion chamber; andan exhaust box defining a front side, a back side, a first side, a second side, a top side, and a bottom side, the exhaust box fluidly coupled to the exhaust tube at the back side of the exhaust box, the exhaust box comprising:a first divider extending between the first side and the second side of the exhaust box, the first divider positioned in line with the exhaust tube;a second divider extending between the first side and the second side of the exhaust box, the second divider positioned at least partially below the exhaust tube; andan exhaust outlet positioned at the front side of the exhaust box.

2. The water heater appliance of claim 1, further comprising a step portion extending from the front side of the exhaust box, wherein the front side of the exhaust box defines a first height from the bottom side of the exhaust box and the step portion defines a second height from the bottom side of the exhaust box, the second height of the step portion being shorter than the first height of the front side of the exhaust box, with respect to the vertical direction.

3. The water heater appliance of claim 2, wherein the exhaust outlet is positioned at the step portion, the exhaust outlet defining a third height from the bottom side of the exhaust box, the third height of the exhaust outlet being shorter than the second height of the step portion, with respect to the vertical direction.

4. The water heater appliance of claim 1, wherein a top height of the exhaust outlet is positioned below a bottom height of the exhaust tube, with respect to the vertical direction.

5. The water heater appliance of claim 1, wherein the first divider defines a first angle, the first divider bent along the first angle.

6. The water heater appliance of claim 5, wherein the first angle is an obtuse angle.

7. The water heater appliance of claim 1, wherein the second divider defines a second angle, the second divider bent along the second angle.

8. The water heater appliance of claim 7, wherein the second angle is an acute angle.

9. The water heater appliance of claim 1, wherein the second divider comprises a tip at one end of the second divider, the tip configured to tilt downward with respect to the vertical direction.

10. A water heater appliance for a recreational vehicle, the water heater appliance defining a vertical direction, a lateral direction, and a transverse direction, the vertical, lateral, and transverse directions mutually perpendicular, the water heater appliance comprising:a cabinet;a heat exchanger positioned within the cabinet;a combustion chamber positioned within the cabinet, the combustion chamber in thermal communication with the heat exchanger;an exhaust tube fluidly coupled to the combustion chamber; andan exhaust box fluidly coupled to the exhaust tube, the exhaust box comprising:a first divider positioned in line with the exhaust tube;a second divider positioned at least partially below the exhaust tube; andan exhaust outlet positioned below the exhaust tube.

11. The water heater appliance of claim 10, further comprising a step portion extending from the front side of the exhaust box, wherein the front side of the exhaust box defines a first height from the bottom side of the exhaust box and the step portion defines a second height from the bottom side of the exhaust box, the second height of the step portion being shorter than the first height of the front side of the exhaust box, with respect to the vertical direction.

12. The water heater appliance of claim 11, wherein the exhaust outlet is positioned at the step portion, the exhaust outlet defining a third height from the bottom side of the exhaust box, the third height of the exhaust outlet being shorter than the second height of the step portion, with respect to the vertical direction.

13. The water heater appliance of claim 10, wherein a top height of the exhaust outlet is positioned below a bottom height of the exhaust tube, with respect to the vertical direction.

14. The water heater appliance of claim 10, wherein the first divider defines a first angle, the first divider bent along the first angle.

15. The water heater appliance of claim 14, wherein the first angle is an obtuse angle.

16. The water heater appliance of claim 10, wherein the second divider defines a second angle, the second divider bent along the second angle.

17. The water heater appliance of claim 16, wherein the second angle is an acute angle.

18. The water heater appliance of claim 10, wherein the second divider comprises a tip at one end of the second divider, the tip configured to tilt downward with respect to the vertical direction.

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