Carrier Corporation

Consolidated Industries Corp.

Paul M Haydock

Larry D Rieke

Stephen Leon Pulley

Nitu Gupta

Ninev Karl Zia

Robert C Swilik, Jr

Sivakumar Gopalnarayanan

Scott A Beck

William J Roy

Hall Virgil

Rex R Mills

John A Wade

Asad M Sardar

Gerald K Gable

Pratap Kumar Dvs

Mathew S Vargo

Stephen R Carlisle

Michael E Kirkpatrick

Heng-Yi Lai

James J Mitchum

Robert A Lang, Ii

A furnace with a baffle assembly including at least one horizontal gap, and a heating, ventilation, and/or air conditioning (HVAC) system incorporating the same are provided. The furnace includes a furnace heat exchanger, a baffle assembly, and a fan. The baffle assembly is disposed adjacent to the furnace heat exchanger. The fan is in airflow communication with the furnace heat exchanger. The baffle assembly may include a first side and a second side. Each of the first side and the second side may respectively include a first section and a second section. A horizontal gap may be disposed between the first section and the second section (e.g., on either or both of the first side and the second side). The horizontal gap(s) may increase the efficiency of the furnace and/or the HVAC system.

Heat exchanger baffle assembly with horizontal gap

A plate fin for a heat exchanger is provided including a base plate having a plurality of holes formed therein. The plate fin also includes a plurality of generally annular collars. Each collar is positioned substantially coaxially within one of the plurality of holes. The plurality of first collars is substantially less than the plurality of holes such that a portion of the plurality of holes does not have a collar arranged therein.

Condensing heat exchanger fins with enhanced airflow

A coupling to connect a primary heat exchanger to a condensing heat exchanger of a furnace includes a coupling box extending between a primary heat exchanger and a condensing heat exchanger. The coupling box defines a flow path for flue gas between a primary heat exchanger outlet and a condensing heat exchanger inlet. A tube sheet is located at a distance from the tube sheet in the coupling box. The liner and the tube sheet define an insulating liner space therebetween reducing condensation on the liner.

Furnace heat exchanger coupling

An attachment between a heat exchanger and a cell panel of a furnace includes a cell panel including a plurality of cell panel openings and a heat exchanger having a plurality of cells. Each cell has a cell outlet insertable into a cell panel opening of the plurality of cell panel openings. A compressible gasket is insertable between the cell panel openings and the cell outlets and securable therein when the heat exchanger is secured to the cell panel. A crimping tool for securing a heat exchanger cell outlet to a cell panel of a furnace includes a male portion including a split die having two die halves and a die expander configured to separate the two die halves to engage an inner surface of the cell outlet. A female portion applies a force to the cell outlet to crimp the cell outlet to the cell panel.

Furnace heat exchanger attachment

A compact furnace heat exchanger for a gas furnace is disclosed. The compact furnace heat exchanger may include a first pass having an inlet end, a second pass in fluid communication with the first pass through a first return bend, and a third pass having an outlet end and in fluid communication with the second pass through a second return bend. The third pass may further include a plurality of irregularities for optimizing performance of the compact furnace heat exchanger and the associated gas furnace.

Primary heat exchanger design for condensing gas furnace

In a residential furnace having a layered insulation material on the inner walls of the heat exchanger compartment, the inner aluminum foil layer has a plurality of holes formed therein in order to allow for the outer layer to absorb the sound within the heat exchanger compartment and thereby reduce the noise emanating from the furnace. Both the density and size of the holes are optimized to maximize the sound absorption performance over the particular frequency ranges that are characteristic of the furnace.

Use of thermal insulation for noise abatement

A media filter cabinet for a gas furnace is sized to accept a high-efficiency media filter while being easily adaptable to accept a standard size filter. A perforated duct flange on one side of the cabinet permits ease of installation since the flange can be bent at 90 or 180 degrees along the perforations, or removed, depending on the type of duct the cabinet is installed with. The cabinet is adapted to fit a standard filter by using a removable bracket and a wire to retain the standard filter within the cabinet. With the removal of a front door and a back side of the cabinet, the cabinet collapses to diminish its shipping size. In one embodiment, the cabinet is in kit form which is easily assembled.

Media filter cabinet for gas furnace

A heating apparatus for delivering heated air to an enclosure comprising a casing with at least two compartments separated by a panel. A burner with an arcuate profile is located within a first compartment of the casing for burning a combustible fuel-air mixture delivered thereto and producing products of combustion. A heat exchanger is located within a second compartment of the casing and has an opposed inlet and outlet. The inlet is in fluid communication with the burner through an aperture in the panel. The heat exchanger receives the products of combustion. A blower is located within the casing for directing a flow of air across the heat exchanger into the enclosure. Through the heat exchanger heat is transferred from the products of combustion to the air. An exhaust system is in fluid communication with the outlet and includes a vent for exhausting the products of combustion from the casing. The vent is contained within the casing.

Curved inshot burner and method for vent-within-casing furnace

A heat exchanger manifold (44) is provided which includes a plurality of manifold inlet openings (58) including sealant means such as grommet means (62) which receive the tube outlets (40c) of the condensing section (34) of a heat exchanger (28). The heat exchanger manifold (44) is made of a corrosion-resistant material such as a polymer such as one sold under the trademark LEXAN.TM. and the grommets (62) are preferably made of a resilient, corrosionresistant polymer such as rubber, e.g., a nitrile rubber. The condensing tubes (38a, 38b, 38c) are slanted to facilitate drainage of the condensate into the heat exchanger manifold (44) and a flue gas outlet (64) and a condensate drain (49) are provided to discharge, respectively, flue gas and condensate from the heat exchanger manifold (44). The condensing tubes (38a, 38b, 38c) are connected to the primary heating section (30) of the heat exchanger (28) through swaged joints (37).

Forced air condensing furnace and heat exchanger manifold therefor

Masonry chimney adapter

An abatement member for inhibiting formation of oxides of nitrogen in a gas-fired furnace by controlling peak flame temperatures and residence times at the peak flame temperatures is described. The combustion system has at least one heat exchanger conduit having a flow path therethrough and at least one gas burner for burning fuel to produce a combustion flame. The abatement member has a porous refractory body portion having at least one section which is disposed transversely to the direction of flow of gases through the conduit. In one embodiment, the abatement member is a metallic screen having a serpentine shape and positioned within the fire tube. The combustion flame is directed toward and into the inlet of a fire tube and through the screen whereby the screen absorbs thermal energy from the combustion flame at a rate which limits peak flame temperatures to levels which inhibit formation of oxides of nitrogen.

Growing community of inventors

Zionsville, IN, United States of America

Paul M Haydock