Note: Descriptions are shown in the official language in which they were submitted.
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INVENTION TITLE
AIR INTAKE MODULATOR AND METHOD OF USING
DESCRIPTION
BACKGROUND OF THE INVENTION
[Para 1] 1. Field of the Invention.
[Para 2] The present invention relates generally to air flow modulating
devices, and
more specifically to air flow modulating devices that operate mechanically to
adjust air flow.
[Para 3] 2. Background Information.
[Para 4] Air intake terminals and devices are well known. Air intake
terminals or devices
may be used in conjunction with fuel-fired or sealed combustion condensing
appliances,
particularly heating appliances. Generally, fuel-fired or combustion heating
appliances
have intake and venting terminals. These terminals may comprise conduits that
have one
end attached to the combustion heating appliance and one end connected to an
air source
external to the area or building being heated by the heating appliance.
[Para 5] Fuel-fired or sealed combustion condensing appliances require a
constant draft
of air for proper operation and efficient consumption of fuel. The draft
through a fuel-fired
or sealed combustion condensing appliance may be affected by pressure
differences across
the appliance. For example, numerous changes in environment may cause pressure
changes at, and through, the air intake terminal. Such changes include, but
are not limited
to, wind induced pressure effects, changes in ambient barometric pressure,
debris caught in
an intake terminal and/or ice or snow blocking the intake conduit. These
environmental
changes may be undesirable because they affect the desired pressure
differential across the
air intake terminal and air venting terminal.
[Para 6] While the prior art has provided examples of features of air
intake terminals
and devices that people find useful, there is always room for further
improvement.
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SUMMARY OF THE INVENTION
[Para 7] Although intake terminals and devices may be known for fuel-fired
or sealed
combustion condensing appliances, the inventor has realized improvements
thereon.
Applicant has realized that known intake terminals and devices fail to teach
intake devices
that provide automatic, mechanical and immediate modulation of outdoor to
indoor
combustion air as needed to minimize fluctuations in a fuel-fired or sealed
combustion
condensing appliance operation due to inadequate combustion air. Such
adjustment may
increase the efficiency of the sealed combustion condensing appliance.
Applicant has
realized the deficiencies of the prior art and has combined the below
objectives in a novel
manner to provide an intake terminal or device that has been developed for at
least the
purpose of being able to mechanically, automatically and immediately modulate
combustion
air from an outdoor source to an indoor source and back again, as needed.
[Para 8] The present invention is directed toward an intake air flow
modulating device
for sealed combustion condensing appliances using outdoor air for combustion,
comprising
a conduit having concentric cross-sections, a flapper, a mount, an axle and a
screw. A T-
shaped conduit may be placed on a horizontal or vertical portion of an
external air intake
conduit in such a manner as the top of the "r may run along an external air
path and the
bottom of the "T" may be generally perpendicular to the external air path. A
mount may be
fit into an end of the bottom of the "T" and the flapper may be connected to
an axle located
in the mount. The flapper may rotate about the axle. The screw may be inserted
into a
bottom half of the flapper and may be used to adjust the sensitivity of the
flapper to
variations in pressure across the air intake conduit.
[Para 9] An object of the invention is to provide an air modulating device
and method
that allows for automatic simultaneous modulation of outdoor and indoor
combustion air as
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needed to minimize fluctuations in operation and efficiency of sealed
combustion
condensing appliances due to inadequate combustion air.
[Para 10] A further object of the invention is to provide an air modulating
device that may
be utilized with a sealed combustion, condensing appliance to overcome a
frosted or snow
blocked intake pipe; debris (e.g., leaves, insects, etc) blocked intake pipe;
an increase in
static pressure due to direct or indirect wind; and improperly installed
piping systems (e.g.,
systems installed with conduits that are too long or conduits that have too
many bends).
[Para 11] A yet further object of the invention is to eliminate temporary
nuisance calls for
service by allowing the attached appliance to operate although the air intake
conduit may be
at least partially disrupted.
[Para 12] A yet further object of the invention is to provide an air
modulating device that
comprises an indicator of normal and compromised combustion air flow to a
sealed
combustion condensing appliance.
[Para 13] The above summary of the present invention is not intended to
describe each
illustrated embodiment, aspect, or every implementation of the present
invention. The
figures and detailed description that follow more particularly exemplify these
and other
embodiments and further aspects of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[Para 14] The invention may be more completely understood in consideration
of the
following description of various embodiments of the invention in connection
with the
accompanying drawings, in which:
[Para 15] FIG. 1 is a perspective view of an embodiment of the invention.
[Para 16] FIG. 2 is a perspective view of features of the invention.
[Para 17] FIG. 3 is a front view of the features of the invention shown in
FIG. 2.
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[Para 18] FIG. 4 is a side view of the features of the invention shown in
FIG. 2.
[Para 19] FIG. 5 is a top view of the features of the invention shown in
FIG. 2.
[Para 20] FIG. 6 is a perspective view of features of the invention.
[Para 21] FIG. 7 is a back view of the features of the invention shown in
FIG. 6.
[Para 221 FIG. 8 is a side view of the features of the invention shown in
FIG. 6.
[Para 23] FIG. 9 is a top view of the features of the invention shown in
FIG. 6.
[Para 24] FIG. 10 is a perspective view of features of the invention.
[Para 25] FIG. 11 is a front view of the features of the invention shown in
FIG. 10.
[Para 26] FIG. 12 is a side view of the features of the invention shown in
FIG. 10.
[Para 27] FIG. 13 is top view of the features of the invention shown in
FIG. 10.
[Para 28] FIG. 14 is a perspective view of a portion of an embodiment of
the invention.
[Para 29] FIG. 15 is a perspective view of an embodiment of the invention.
[Para 30] FIG. 16 is an elevation view of a structure depicting features of
the invention.
[Para 311 While the invention is amenable to various modifications and
alternative forms,
specifics thereof have been shown by way of example in the drawings and will
be described
in detail. It should be understood, however, that the intention is not
necessarily to limit the
invention of the particular embodiments described.
DETAILED DESCRIPTION OF THE INVENTION
[Para 32] The invention, certain embodiments thereof depicted in Figs. 1-
16, is directed
to an air modulating device 10 for sealed combustion condensing appliances
generally
using outdoor air for combustion, comprising a T-shaped conduit 12 having
concentric
cross-sections, a flapper 20, a mount 24, an axle 26, and a screw 22, and the
method of
installing and using the device. Sealed combustion condensing appliances may
be
appliances that burn fuel for warm air heating, such as a furnace 110, water
space heating,
water heating, boiler heating, radiant heating, warmth, cooking, decorative
purposes or
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other purposes. Typical fuels burned by combustion appliances may include gas
(i.e.,
natural gas and liquefied petroleum), kerosene, oil, coal, wood and other
combustibles.
Device 10 is especially useful in environments that require a condensing
action. Appliances
that operate by venting gas that is relatively cool, i.e., no more than
approximately 140
degrees Fahrenheit above the dew point (i.e., a typical condensing appliance)
are well suited
for use of device 10. Such appliances typically have a blower to assist in the
combustion
action. A condensing action assists in lowering the temperature of vented
gases. Since
temperatures are relatively low with a condensing appliance, a device such as
device 10 may
be made from plastic such as PVC and endure the relatively modest
temperatures. Typically
the maximum temperature when using PVC is 158 degrees, for using ABS is 180
degrees,
and for using CPVC is 212 degrees Fahrenheit. Appliances that operate from
wood or coal
or oil typically do not use condensing units since the temperatures are too
high (i.e., the flu
temperature with an oil burner may be as high as 300 degrees Fahrenheit or
greater).
Appliances that operate on LP and natural gas/methane or other gas typically
have
condensing units so the exhaust air is relatively cool. With condensing and/or
pressurized
systems, automatic adjustment of the flows of gasses is desired. Applicant
appreciates that
automatic adjustment of device 10 allows for improved air flow and improves
the overall
efficient operation of the appliance.
[Para 33] As seen in Figs. 14, 15 and 16, T-shaped conduit 12 of device 10
may be
placed on a horizontal or vertical portion of an external (combustion) air
intake conduit 50
in such a manner as a top of the "T" may have a first air flow intake path 15'
generally along
an external air path 15 flowing thereth rough and a bottom of the "T",
substantially
perpendicular to the top, may have a second air flow intake path 17' (see
Figure 1 and
Figure 14) along an internal air flow path 17. "External" means external to a
structure 100
which surrounds device 10 and "internal" means internal to the structure 100
surrounding
device 10. In operation, when a first air intake conduit (e.g., a conduit 50
receiving external
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air) encounters any situation that limits or obstructs the intake air volume
for the
combustion appliance, such a furnace 110, the device 10 may operate to allow a
sealed
combustion condensing appliance to intake air from a second intake conduit
(e.g., a conduit
receiving internal air).
[Para 341 As seen in fig. 1, air modulating device 10 may comprise a T-
shaped conduit
12, a flapper 20 and a mount 24. T-shaped conduit 12 may have a first portion
14 that
may be concentric along axis A and a second portion 16 that may be concentric
along axis
B. Axis A may be substantially perpendicular to Axis B. Although conduit 12 is
depicted as
T-shaped in figure 1, conduit 12 may take on any shape or size, or may be made
of any
number of pieces of conduit or piping. T-shaped Conduit 12, itself, may be of
a single
molded piece of material or may be two or more conduits or piping or tubing
connected
together to form the general T-shape or other shape. Further, first portion 14
of T-shaped
conduit 12 may be integrally formed with a further conduit at least partially
having a
concentric axis along axis A and drawing air from an external air source
(e.g., an external
air source may be a source of air located external to an area or building 100
surrounding
the sealed combustion condensing appliance in communication with the air
modulating
device 10), or first portion 14 may be connected to the further conduit(s) at
least partially
having a concentric axis along axis A and drawing air from the external air
source. Such
further conduit(s) at least partially having a concentric axis along axis A
may at least
partially form a combustion air (i.e., intake) pipe for the sealed combustion
condensing
appliance. First portion 14 may have a first end 14a and a second end 14b,
generally
separated by any length; for example, length L. Conduit 12 and any other
conduits may be
made of any material; for example, conduit 12 and other conduits may be made
of polyvinal
chloride ("PVC").
[Para 35] Second portion 16 of T-shaped conduit 12 may be at least
substantially
perpendicular to first portion 14. In alternative aspects second portion 16
may have a
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concentric axis B that is not generally perpendicular to axis A. Second
portion 16 may
communicate with an interior air source (e.g., an interior air source may be a
source of air
located internal to an area or building 100 surrounding the sealed combustion
condensing
appliance that is in communication with the air modulating device 10) and have
an inner
diameter, G. At a first end 16a, second portion 16 may be connected, or
integrally formed,
with first portion 14. At a second end 16b, which may form a plane
substantially
perpendicular to axis B, a mount 24 may be fitted into an opening 44 of T-
shaped conduit
12. A diameter of mount 24 may be substantially equal to or less than an inner
diameter of
second portion 16. Further, a glue or adhesive or other sealant may be used to
secure
mount 24 to an interior of second portion 16. For example, a room temperature
vulcanization ("RTV") type sealant may be applied to an inner circumference of
second end
16b of second portion 16 and mount 24 may be held securely in place with the
applied RTV
sealant. In alternative aspects mount 24 may be secured to an exterior of
second portion
16.
[Para 36] Mount 24 combined with flapper 20 may operate with second portion
16 to
modulate intake flow from an exterior source of air to an interior source of
air or a
combination thereof, as shown in Figs. 1 and 15. Figs. 10, 12 and 13 depict
mount 24 with
an exterior portion 24a and an interior portion 24b and a thickness T,
therebetween.
Exterior portion 24a may have a width or diameter M, which may be
substantially equal in
measurement to outer width or diameter G' of second portion 16 (depicted in
Fig. 14).
Mount 24 may have a mount opening 32 and an axle 26 spanning from a first side
32a of
mount opening 32 to a second side 32b of mount opening 32. For example, and as
depicted in Figs. 10 and 11, mount opening 32 may be defined by first side
32a, second
side 32b, third side 32c and fourth side 32d. Mount opening 32 may have a
distance D"
between first side 32a and second side 32b and distance D" may vary along
opening 32.
Further, mount opening 32 may have a distance D" between third side 32c and
fourth side
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32d and distance D" may vary along opening 32. Axle 26 may be off-centered
with
respect to mount opening 32 and a general inner diameter of second portion 16.
For
example, as seen in Fig. 11, a distance D from axle 26 to a third side 32c of
mount opening
32 may be greater than a distance D' from axle 26 to a fourth side 32d of
mount opening
32. In the example, third side 32c may be a top side of mount opening 32 with
respect to
axle 26 and fourth side 32d may be a bottom side of mount opening 32 with
respect to axle
26. Further, although sides 32a-d may take on any shape, sides 32a and 32b may
be
generally parallel, and sides 32c and 32d may generally form arcs, as shown in
Figs. 10 and
11. Yet further, sides 32c and 32d may be generally concave with respect to a
viewing point
at axle 26.
[Para 37] Flapper 20, having a front side 40 and a back side 42, may attach
to mount 24
by any known connection means. For example, as depicted in Figs. 7 and 8,
connection
means for attaching flapper 20 to mount 24 may include an axle snap 28 on a
back side 42
of flapper 20, where axle snap 28 may snap to axle 26 and allow flapper 20 to
rotate about
axle 26. Axle snap 28 may abut an apron 34 and a neck 36 of flapper 20, as
seen in Fig. 8.
Axle snap 28 may be integrally formed with flapper 20 if desired. Axle snap 28
is
configured to snap onto, or be friction fitted with, axle 26. It may be
appreciated that
flapper 20 may be snapped onto mount 24 by pressing flapper 20 onto mount 24
at axle
snap 28. Axle snap 28 may have resilient portions to allow for a snapping
action. Axle
snap 28 preferably includes curved surfaces in order to efficiently rotate
about or on axle
26. The connection means used to connect flapper 20 to mount 24 may be any
connection
means that is capable of allowing flapper 20 to rotate about an axis. For
example, as an
alternative to, or in combination with, flapper 20 connecting to axle 26,
flapper 20 may
connect to sides 32a, 32b of mount 24 or other portions of mount 24 that allow
flapper 20
to rotate about an axis.
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[Para 38] Flapper 20 may rotate about axle 26 to any number of positions.
Flapper 20
may be considered to be in an open position when air is flowing through mount
opening 32.
Flapper 20 may be considered to be in a closed position when both apron 34 and
apron
riser 38 of flapper 20 are in contact with mount 24. During the closed
position, air may be
substantially blocked from passing through mount opening 32. Flapper 20 may
rotate from
a first or closed position to a second or open position in response to a
change in pressure
level of intake conduit SO. The change in pressure level may be from a first
pressure level
to a second pressure level. Intake air that is flowing into the apparatus and
through intake
pipe 50 flows in the intake direction as shown with reference to arrow C of
Fig. 14.
[Para 391 Flapper 20 may be of any shape, size and material capable of
providing an air-
tight covering of mount opening 32 and rotating about an axis. Further,
flapper 20 may be
of any uniformity; for example, and preferably, flapper 20 may be generally
uniform in
thickness and weight and may have a generally flat surface. In alternative
aspects the
thickness of flapper 20 may vary throughout. As depicted in Figures 6-9, an
example of a
structure of flapper 20 may comprise an apron 34 (e.g., an "apron"), a neck 36
and an apron
riser 38. Apron 34, neck 36 and apron riser 38 may be integrally formed or
connected by
any known connection technique. Apron 34 and apron riser 38 may be spaced
apart a
distance F and neck 36 may bridge the distance F between apron 34 and apron
riser 38.
Apron 34 and apron riser 38 may be at any angle with respect to the other; for
example,
apron 34 and apron riser 38 may be substantially parallel with respect to the
other part.
Neck 36 may form any angle(s) with respect to apron 34 and apron riser 38; for
example,
when apron 34 and apron riser 38 are substantially parallel to the other, neck
36 may be
substantially perpendicular to apron 34 and apron riser 38. Further, the angle
between
apron 24 and neck 36 may differ from the angle between neck 36 and apron riser
38.
[Para 40] Parts 34, 36, 38 of flapper 20 may be any shape or size capable
of covering
mount opening 32. As depicted in Figs. 7 and 8, apron 34 may have an arc
portion 34a
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with a height H and width W. Width W of arc portion 34a may be greater than
distance D".
Apron 34 may have an apron extension portion 34b extending from arc portion
34a, where
apron extension portion 34b has a height H' and width W'. Width W' may be
equal to or
less than distance D". Apron 34 may have any height substantially equal to
height H plus
height H'. Apron extension portion 34b may be integrally formed with, or
connected to, arc
portion 34b. Apron 34 may also comprise at least one adjuster hole 30.
Adjuster hole 30
may be threaded and may operate to receive an adjuster or adjustment screw 22
(e.g., a
threaded screw).
[Para 41] Neck 36 may extend from apron extension portion 34b, or other
portion, of
apron 34. Neck 36 may have a width W' or a width less than or equal to width
W' and neck
36 may span a distance F (See Fig. 7 and Fig. 8). Distance F may be
substantially equal to
thickness T, which may contribute to allowing flapper 20 to create an airtight
seal with
mount 24 when flapper 20 is in a closed position. Neck 36 may have any height
capable of
providing a structural connection between apron 34 and apron riser 38. Neck 36
may have
a top side 36a and a bottom side 36b. Top side 36a may include an indicator to
indicate
proper operation of the appliance. For example, top side 36a may be painted a
first color
(e.g. green) for the purpose of indicating air intake conduit and the sealed
combustion
condensing appliance are operating under normal operation conditions.
Alternatively top
side 36a may be made of a colored plastic in order to operate as an indicator.
Generally,
the indicator on top side 36a is viewable when flapper 20 is in a closed
position.
[Para 42] As shown in Figs. 2,3 and 6-9, apron riser 38 may extend from
neck 36.
Apron riser may have a height H" and a width W". Width W" may be any width;
for
example, a width W" may be greater than W' and less than width W. Further,
width W" may
be greater than distance D". Height H" may be any height; for example, a
height H" may
be greater than distance D. The heights and widths of apron 34 and apron riser
38 may be
_ designed to cover at least mount opening 32. For example, the height of
flapper (i.e., the
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sum of H, H' and H") may be greater than distance D" and both widths W, W" may
be
greater than distance D". Apron riser 38 may have a covered portion 38a.
Covered portion
38a may be a portion of apron riser 38 that is covered by mount 24 when
flapper 20 is in a
closed position and at least partially viewable when flapper 20 is in an open
position.
Covered portion 38a may include an indicator. For example, covered portion 38a
may be
colored (e.g., colored red) and indicate a situation where intake conduit is
at least partially
blocked, obstructed or not operating properly (i.e., when such obstruction
occurs, flapper
20 rotates due to changes in air intake pressure, thus exposing an alert
indicator that is
presented on at least part of covered portion 38a). Mount 24 may also include
an indicator
portion represented by reference numeral 25 as shown in Fig. 10. When flapper
20 rotates,
indicator portion 25 is exposed. The greater the rotation of flapper 20, the
greater the
exposure of indicator 25. Typically flapper 20 would have to rotate a
relatively great angle
in order for indicator 25 to be exposed to the view of a person that is
standing. When
flapper 20 rotates a large angle, the amount of blockage would typically be
very great or
even extreme, thus warranting an indicator. In further aspects, multiple
indicators may be
used in conjunction, where different colors are selected. For instance, a
green indicator
may be positioned at 36a to signify normal operation, a yellow indicator at
38a as a
cautionary indication, and a red indicator at 25 as an emergency or alert.
Alternative
indicator means may also be used. Other types of indicators may be utilized to
signal a
user that a source of exterior air flow through intake conduit 50 may be at
least partially
obstructed. For example, another type of indicator may be a mechanical
indicator such as a
whistle that is heard when interior air flows through second portion 16 at a
specified rate.
The other type(s) of indicator(s) may be located at any advantageous location
of device 10.
[Para 43] Connection of Device 10 to a Sealed Combustion Condensing
appliance
[Para 44] Air modulating device 10 may be installed with a conduit system
when a sealed
combustion condensing appliance is initially installed in a building, or air
modulating device
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may be retrofitted and installed on an already existing conduit system of a
previously
installed sealed combustion condensing device. Further, device 10 may be used
on vertical
or horizontal piping or conduit systems associated with sealed combustion
condensing
appliances.
[Para 45] Device 10 may be installed by locating a combustion pipe (i.e.,
an intake pipe)
50. Intake or combustion pipe 50 may be located by checking an installation
manual for the
location of that pipe or by operating the sealed combustion condensing
appliance (not
shown) connected with the conduit system and ensuring which conduit is
allowing air into
the sealed combustion condensing appliance. It may be possible to determine
which
conduit is allowing air into the sealed combustion condensing appliance by
placing a hand
or other object over an exterior end (not shown) of conduit 50 and confirming
the conduit is
sucking air into the sealed combustion condensing appliance. Prior to
installing device 10,
but after intake conduit 50 has been located, it may be necessary to ensure
the sealed
combustion condensing appliance is not operating.
[Para 46] Device 10 may be installed along intake conduit 50 at any
location. If device 10
is to be installed in a sealed combustion condensing appliance retrofitting
process, the
process may begin by marking the existing conduit 50 twelve to twenty inches
from the
attached sealed combustion condensing appliance (e.g., the conduit 50 may be
marked
twelve to twenty inches above the attached sealed combustion condensing
appliance,
assuming the intake conduit is positioned above the appliance input location).
This location
may allow an installed device 10 to be located at or near eye level. A first
cut may be made
at this mark using any known cutting means. For example, a PVC saw or hacksaw
may be
utilized to make the cut and any other required cuts. A second mark and a
second cut may
be made on the intake conduit at a position farther away from the sealed
combustion
condensing appliance than the first mark and cut. The distance between the
first mark and
the second mark may be any distance greater than the length of an inner
diameter G of
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second portion 16 of T-shaped conduit 12 and less than length L of first
portion 14 of T-
shaped conduit 12, as seen in Fig. 14. Once the first cut and the second cut
have been
made, a piece of intake conduit 50 may be removed and that piece may be
discarded. The
remaining ends of conduit 50 that received the first two cuts may be deburred
and any
loose material may be removed from the sealed combustion condensing appliance
location
and piping. Such removal may be accomplished through a vacuuming technique or
other
removal process.
[Para 47] After making the first two cuts and removing pieces of intake
conduit 50, intake
conduit 50 may be checked for the purpose of verifying intake conduit 50 is
free of any
debris along the entire length from the second cut to an exterior end of the
conduit 50.
Such check may be accomplished by pushing an object (e.g., a cloth) through
conduit 50
from the second cut to the outdoors with a flexible tool (e.g., a fishtape),
sucking and
removing debris in the conduit 50 by use of a vacuuming technique, blowing air
through
conduit 50 to push debris through conduit 50 to an exterior location, or by
any other
known debris removal or check technique.
[Para 48] After ensuring all debris is removed from intake conduit 50 and
the areas
around the sealed combustion condensing appliance, device 10 may be installed
on intake
conduit 50. RTV silicone sealant, or other similar sealant, may be applied to
a free end 54
of a portion 52 of intake conduit 50 connected to the sealed combustion
condensing
appliance. Once the sealant has been applied, device 10 may be attached
thereto by sliding
second end 14b of first portion 14 onto section 52 of conduit 50 and the
applied RTV
silicone sealant. After device 10 has been placed on section 52 of intake
conduit 50,
second portion 16, flapper 20 and mount 24 (flapper 20 and mount 24 are
removed from
Fig. 14 for clarity purposes) may be facing any direction; for example, a
forward direction
(e.g., a forward direction may be a direction that is in the same direction as
a front side of
an attached sealed combustion condensing appliance). It is understood that
other
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techniques commonly known in the art may be utilized for connecting various
conduits to
each other.
[Para 49] After connecting device 10 to section 52 of intake conduit SO
attached to a
sealed combustion condensing appliance, a cut interior end 58 of a section 56
of intake
conduit 50 that is connected to an exterior air source may be connected to
first end 14a of
first portion 14. Prior to the application of any sealant to cut interior end
58, it should be
ensured that the cut interior end 58 is capable of substantial free movement
so as to
facilitate connection with first end 14a. It may be necessary to loosen or
adjust supports or
hangers or straps restraining the cut interior end 58. Then, RTV silicone
sealant may be
applied to the cut interior end 58 of section 56 of intake conduit 50
connected to the
exterior air source. After applying the sealant, cut interior end 58 may be
inserted into first
end 14a. This placement of cut interior end may be a delicate maneuver and may
require a
gentle insertion. For example, it may be necessary to support section 52 of
the intake
conduit 50 directly connected to the sealed combustion condensing appliance
while
inserting cut end 58 of intake conduit 50 into first end 14a. Once sections
52, 56 of
conduit 50 have been inserted into device 10 and the sealant has cured, device
10 may be
in operational connection with the conduit system of the sealed combustion
condensing
appliance.
[Para 50] Adjustment of Device 10
[Para 51] Once device 10 has been operationally connected to intake conduit
50 of a
sealed combustion condensing appliance, flapper 20 may be adjusted for use in
a particular
operation of the sealed combustion condensing appliance. A first step in
adjusting flapper
20 for proper operation is to test the flapper when conduit 50 is not blocked
(i.e., in normal
working condition). This step includes threadingly engaging threads of
adjustment screw
22 and threads of adjuster hole 30, and rotating adjustment screw 22 through
adjuster hole
30 until screw 22 is flush (or nearly flush) with flapper 20. Adjustment screw
22 may be
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inserted into adjuster hole 30 from front side 40 of flapper 20. Screw 22 may
also be a
self-tapping screw. When screw 22 has been completely inserted into adjuster
hole 30, the
sealed combustion condensing appliance should be turned on (or may be already
running)
and flapper 20 should be (or may be) in a slightly open position. If flapper
20 is in a closed
position, the inserted screw 22 should be removed and a lighter screw should
be inserted.
If flapper 20 is in a slightly open position, unscrew the screw 22 (or rotate
the screw 22 in a
loosening direction) one rotation (for instance, or a fraction of a rotation
if desired) at a
time until flapper 20 is in a closed position. Screw 22 may be rotated in a
gentle or
cautious manner while repeatedly checking or monitoring the position of
flapper 20 after
each revolution, or part of a revolution, of screw 22. Multiple revolutions
may also be used
to make greater calibration changes. Once flapper 20 has been adjusted to a
closed
position, device 10 has been properly adjusted. In such calibrated state,
slight changes in
the pressure of the conduit may cause flapper 20 to rotate. If screw 22 is
completely
unscrewed without flapper 20 automatically positioning itself in a closed
position, unscrew
screw 22 and use a heavier screw. These steps may be repeated until a screw of
an
appropriate weight is found. The steps may be repeated until the appropriate
depth or
positioning of the screw is calibrated. Recalibration may be needed from time-
to-time or in
the event there are changes to the appliance such that the air pressures are
altered.
[Para 52] Alternatively, or in addition to the above, a step in adjusting
flapper 20 for
operation may include threadingly engaging threads of adjustment screw 22 and
threads of
adjuster hole 30, and rotating adjustment screw 22 through adjuster hole 30
until screw 22
is flush (or nearly flush) with flapper 20. A self-tapping screw may
alternatively be used.
Adjustment screw 22 may be inserted into adjuster hole 30 from front side 40
of flapper 20.
Then plug an exterior end of the section of the intake conduit connected to an
exterior air
source. The exterior end may be plugged by placing a plug, cap, tight-fitting
cloth or other
object over or in the exterior end. The object covering the exterior end may
be any object
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connected in any manner that will not allow the object to be sucked into the
conduit
through the exterior end. The screwing of screw 22 and blocking of conduit 50
may be
performed in any order without the order having a significant affect on the
adjustment.
During these steps, the sealed combustion condensing appliance may be turned
off. After
these steps have been completed, power to the sealed combustion condensing
appliance
may be restored. The sealed combustion condensing appliance may be allowed to
start-up
as it would under normal operations. When conduit 50 is completely blocked,
flapper 20
should be in an open position. Flapper 20 may be in an open position any time
it is not in a
closed position, but flapper 20 may be in a completely open position when
apron
shoulder(s) 34c is/are in contact with external portion 24a of mount 24, or
when it has
rotated about axle 26 to a position between eighty-five (85) and eight-nine
(89) degrees
with respect to a closed position of flapper 20 or axis A (i.e., if axis B is
substantially
perpendicular to axis A). In alternative aspects flapper 20 may rotate at
different degrees
with respect to a closed position.
[Para 53] After properly adjusting flapper 20, the object plugging an
exterior end of the
intake conduit 50 may be removed. Once the object is removed, flapper 20 may
be
inspected to make sure flapper 20 is closed. When there is no object or other
obstruction
interfering with the exterior air intake conduit 50, an indicator on neck 36
of flapper 20
may be viewed indicating the sealed combustion condensing appliance and its
exterior air
intake conduit is operating properly. Further, flapper 20 may now be in a
closed position or
a slightly open position and flapper 20 may be substantially preventing air
flow through
mount opening 32.
[Para 54] The start-up of the sealed combustion condensing appliance may be
accomplished by any method, which includes, but is not limited to, setting a
thermostat to
initiate start-up of the sealed combustion condensing appliance. Further, once
a first set
up step has been accomplished, a step may be to test the initial adjustment by
performing
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the other test. That is, if flapper 20 was initially adjusted with a conduit
50 unblocked, test
flapper 20 adjustment with a blocked conduit 50 and vice versa.
[Para 55] As the sealed combustion condensing appliance begins its
operations, flapper
20 may be automatically adjusted to an open or closed position due to pressure
levels in
conduit 50 or other considerations. Flapper 20 may rotate to any number of
positions.
Flapper 20 may be considered to be in an open position when air is flowing
through mount
opening 32. Flapper 20 may be considered to be in a closed position when both
apron 34
and apron riser 38 are in contact with mount 24. When flapper 20 is in a
closed position,
air may be substantially blocked from passing through mount opening 32. With
section 56
of intake conduit 50 blocked, as the sealed combustion condensing appliance
starts up and
is operating, flapper 20 may be in a completely open position. As mentioned
above, flapper
20 may be in a completely open position when it has rotated about axle 26
nearly eight-
nine (89) degrees with respect to a closed position of flapper 20 or axis A,
or apron
shoulder 34c contacts exterior portion 24a of mount 24. In alternative
aspects, flapper 20
may be in a completely open position at different angles of rotation. When
flapper 20 is in
a completely open position, a user may be able to view colored covered portion
38a as an
indication that section 56 of intake conduit 50 is at least partially
obstructed or is not
taking-in a required amount of exterior air.
[Para 56] In operation, when an obstruction is present within intake pipe
50 or when air
intake is otherwise minimized, apron 34 will automatically rotate in the
direction of arrow A
(See Fig. 8). The amount of rotation will depend upon the intensity of the
pressure change
caused by reduction of air flow and/or the degree of calibration due to the
adjustment of
adjust screw 22 which impacts the balance of flapper 20. In turn, apron riser
38 will rotate
in the direction of arrow B, thus exposing or opening mount opening 32 to
allow air to be
introduced into the air intake tube of the appliance. The indicator placed
upon covered
portion 38a will then be generally visible, which indicates that exterior air-
flow intake has
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been altered (reduced) and that air from the immediate surroundings of the
appliance is
being drawn into the intake tube of the appliance (e.g., air from the area
within a basement
will be drawn into the appliance). When the obstruction is removed from pipe
50 or altered
so that additional or normal air flow is restored to intake pipe 50, apron
riser 38 will rotate
in a direction opposite arrow B to thereby close or reduce the opening of
mount opening 32
(which stops or reduces introduction of air from the immediate surroundings of
the
appliance).
[Para 57] Such automatic adjustment to the air-flow intake will allow the
appliance to
continue operation. For instance, with some models, an appliance will
automatically shut-
off if the air intake is reduced to a particular level. Some appliances will
attempt to restart
or self-start periodically; however, if sufficient airflow is not restored by
the time of the
automatic re-start, the applicance will fail to operate or restart. Applicant
believes that
maintaing a sufficient level of air intake to the apparatus will enhance
efficiency of the
device. With a more constant supply of intake air, the burner or flame will
operate at a
more efficient rate. When flapper 20 rotates to an open position, air enters
through mount
opening upper portion 33a (See Figure 10). Note that when flapper 20 rotates
to an open
position, air may also enter mount opening lower portion 33 via passage behind
apron 34.
Finally, if the flapper 20 is in an open position when a back-fire or other
pressure is
released from the appliance, apron riser 38 of flapper 20 will be immediately
forced to a
closed position to prevent unwanted backfire or backdraft air from exiting
mount opening
32 into the immediate area surrounding the appliance.
[Para 58] The terms and descriptions used herein are set forth by way of
illustration only
and are not meant as limitations. Those skilled in the art will recognize that
many
variations are possible within the spirit and scope of the invention as
defined in the
following claims, and their equivalents, in which all terms are to be
understood in their
broadest possible sense unless otherwise specifically indicated.
