Cover assembly, blower assembly and associated method
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing water heater blower apparatuses are costly due to complex housing designs and powerful motors needed to handle high-temperature flue gases, and they often increase the overall height, making retrofitting and energy efficiency challenging.
Innovation Solution
A non-dilution blower apparatus with a simplified, two-piece housing constructed from stamped or drawn sheet metal, utilizing the water heater cap as a cover plenum to direct exhaust gases and minimize vertical height, while incorporating a winding exhaust gas flow path to reduce standby losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a blower apparatus is added to increase heat transfer efficiency, then energy efficiency is improved, but manufacturing cost increases due to complex housing design and powerful motor requirements
Solution Approach 1:
The patent combines the blower housing with the water heater cabinet structure, integrating the blower apparatus into existing cabinet space. This eliminates the need for a separate complex blower housing, reducing manufacturing costs while maintaining the heat transfer efficiency benefits of forced convection
Solution Approach 2:
The blower housing serves multiple functions: it houses the blower motor and fan, provides structural support, and integrates with the cabinet design. This multi-functionality reduces the need for additional components and simplifies manufacturing
2Temperature
If dilution air is drawn into the blower apparatus to cool exhaust gas, then temperature is reduced, but device complexity increases due to more complicated blower housing design
Solution Approach 1:
The patent removes the dilution air intake system entirely by using a non-dilution blower design. The blower draws only exhaust gas through the heat exchanger without mixing in ambient air, eliminating the complexity of dual-intake housing design while still achieving adequate temperature management through the heat exchange process
3Productivity
If a more powerful motor is used to draw dilution air and exhaust gas, then gas flow capability is improved, but energy consumption increases negating energy savings
Solution Approach 1:
The patent uses a smaller, less powerful motor that only needs to move exhaust gas without the additional load of drawing in dilution air. By performing only the essential function of moving exhaust gas through the heat exchanger, the motor consumes less energy while still achieving adequate gas flow capability for efficient heat transfer
4Adaptability or versatility
If the blower housing is designed to minimize vertical height for retrofitting, then adaptability is improved, but heat transfer efficiency may be reduced due to limited space for heat exchange components
Solution Approach 1:
The patent compensates for limited vertical space by optimizing horizontal space utilization and heat exchanger surface area arrangement. The compact heat exchanger design maximizes heat transfer surface area within the constrained volume, maintaining heat transfer efficiency while achieving the minimal vertical height required for retrofitting between existing flue components
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution reduces manufacturing costs, minimizes vertical height, and enhances energy efficiency by using the cap as a cover plenum and incorporating a winding gas flow path, allowing for effective retrofitting and improved energy performance.
Implementation Method 1
the blower apparatus should be a non-dilution type to avoid the increased cost of a more complicated blower housing design and a more powerful motor for the apparatus
Implementation Method 2
A more rigorous baffle in the water heater enables a greater amount of heat transfer
Implementation Method 3
only the draft effect of the flue pipe or chimney moves the exhaust gas up through the flue pipe or chimney
Data Source
AI summary
A blower assembly is attached to a water heater having an exhaust opening, the assembly includes a tank cap attached to a tank of the heater. A recess surface formed in the exterior surface of the cap. A member has a first surface that is connected to the tank cap to form a cover plenum between the cap and the member. The blower includes a motor, an air moving member connected to the motor and a blower housing having an interior containing the fan. The blower housing has an input opening that communicates the blower housing interior with the member output opening. The blower housing, the member and the tank cap provide an exhaust gas flow path from the exhaust opening of the heater through the cover plenum, through the blower housing interior and out the output opening.