Patent application title:

Systems and Methods for Combustion Tube Assemblies for Water Heaters

Publication number:

US20250198654A1

Publication date:
Application number:

18/975,598

Filed date:

2024-12-10

Smart Summary: A water heater has a special part called a combustion tube assembly. This assembly has a tube with one end open and the other end closed, plus an opening for exhaust gas to escape. Inside the tube, fuel burns to create gas that needs to exit. There’s also a neck portion near the exhaust opening that helps with the design. Additionally, a diverter is included to guide the exhaust gas out of the tube efficiently and can be secured in place with the neck portion. 🚀 TL;DR

Abstract:

A combustion tube assembly of a water heater is disclosed. The combustion tube assembly includes a combustion tube having an open end, a closed end, and an outflow opening located between the open end and the closed end. A cavity of the combustion tube provides a chamber for combustion of a water heater fuel that produces an exhaust gas. The outflow opening provides an outlet for the exhaust gas to exit the combustion tube. The combustion tube includes a neck portion on a wall of the combustion tube. The neck portion may be disposed in proximity to the outflow opening. The combustion tube assembly may further include a diverter disposed in the cavity. The diverter may be configured to divert the exhaust gas to the outflow opening. The diverter may be configured to engage with the neck portion to secure the diverter in the combustion tube.

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Classification:

F24H9/0026 »  CPC main

Details for water heaters; Guiding means in combustion gas channels

F24H1/186 »  CPC further

Water heaters, e.g. boilers, continuous-flow heaters or water-storage heaters; Water-storage heaters using fluid fuel

F24H1/206 »  CPC further

Water heaters, e.g. boilers, continuous-flow heaters or water-storage heaters; Water-storage heaters with immersed heating elements, e.g. electric elements or furnace tubes with furnace tubes with submerged combustion chamber

F24H9/00 IPC

Details

F24H1/18 IPC

Water heaters, e.g. boilers, continuous-flow heaters or water-storage heaters Water-storage heaters

F24H1/20 IPC

Water heaters, e.g. boilers, continuous-flow heaters or water-storage heaters; Water-storage heaters with immersed heating elements, e.g. electric elements or furnace tubes

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority to and the benefit of U.S. provisional application No. 63/611,345, filed Dec. 18, 2023, which is hereby incorporated by reference herein in its entirety.

FIELD

The present disclosure relates to water heaters and more specifically to combustion tube assemblies for water heaters.

BACKGROUND

Water heaters are generally used to provide a supply of heated water in a variety of applications, including residential, commercial, and industrial applications. Typical down-fired water heaters use fuels, such as natural gas, propane or oil, to heat water contained in a water tank of such water heaters.

In many down-fired water heaters, a combustion chamber and a heat exchanger are positioned in a water tank of the water heater. The heat exchanger may be fluidly connected to the combustion chamber such that an exhaust gas generated in the combustion chamber flows down to an inlet of the heat exchanger and flows through the heat exchanger to heat the water in the water tank. The hot exhaust gas typically flows down unobstructed through the combustion chamber to the inlet of the heat exchanger. The exhaust gas that enters the heat exchanger from the combustion chamber cools down as it flows through the heat exchanger. Although some heat exchange may occur from hot exhaust gas to the water in the tank through the combustion chamber, the heat exchanger serves as the primary component for the exchange of heat from the hot exhaust gas to the water.

The cross-section of the heat exchanger tube is typically smaller than the cross-section of the combustion chamber tube, which may result in increased thermal stress at the transition between the combustion chamber tube and the heat exchanger tube due to an increased pressure drop. In this manner, one or more diverters or baffles may be disposed about the transition between the combustion chamber tube and the heat exchanger tube to reduce the pressure drop and thermal stress thereabout.

BRIEF DESCRIPTION OF THE DRAWINGS

The detailed description is set forth with reference to the accompanying drawings. The use of the same reference numerals may indicate similar or identical items. Various embodiments may utilize elements and/or components other than those illustrated in the drawings, and some elements and/or components may not be present in various embodiments. Elements and/or components in the figures are not necessarily drawn to scale. Throughout this disclosure, depending on the context, singular and plural terminology may be used interchangeably.

FIG. 1 depicts a cross-sectional view of a water heater in accordance with one or more embodiments of the present disclosure.

FIG. 2 illustrates a front view of a heat exchanger assembly of a water heater in accordance with one or more embodiments of the present disclosure.

FIG. 3 illustrates a cross-sectional view of a combustion tube of a water heater in accordance with one or more embodiments of the present disclosure.

FIG. 4 illustrates a cross-sectional view of a heat exchanger assembly of a water heater in accordance with one or more embodiments of the present disclosure.

FIG. 5 illustrates a top view of a heat exchanger assembly of a water heater in accordance with one or more embodiments of the present disclosure.

FIG. 6 depicts a flow diagram of a method to position a diverter in a combustion tube in accordance with one or more embodiments of the present disclosure.

DETAILED DESCRIPTION

The present disclosure is directed to combustion tube assemblies of water heaters, such as down-fired water heaters or the like. The combustion tube assembly may include a combustion tube and a diverter. In some instances, the combustion tube may be positioned vertically within the water heater. In this manner, the combustion tube may include an open end (at a top end of the tube) and a closed end (at a bottom end of the tube). The combustion tube may also include a cavity in an interior portion of the combustion tube that forms a chamber for combustion of a fuel, such as natural gas, propane, or oil. Any suitable fuel may be used herein. The combustion tube may further include an outflow opening between the top end and the bottom end of the combustion tube. The outflow opening may be configured to provide an outlet for exhaust gases resulting from the combustion of the fuel to exit the combustion tube. The outflow opening may be in fluid communication with a heat exchanger coil or the like. In some instances, a diameter of the combustion tube may be greater than a diameter of the heat exchanger coil. In this manner, the diverter may be used to provide a transition between the exhaust gasses flowing from the combustion tube to the heat exchanger coil through the outflow opening in order to reduce a pressure drop between the combustion tube and the heat exchanger coil, which may reduce the thermal stresses about the outflow opening.

In some instances, the combustion tube may include a neck portion (or a roll form) in proximity to the outflow opening. In certain embodiments, the outflow opening may be disposed between the neck portion and the bottom end of the combustion tube. In this manner, the neck portion may be disposed above the outflow opening when the combustion tube is positioned vertically within the water heater. In some instances, the neck portion may be a portion that is curved inwards towards the interior portion of the combustion tube such that a diameter of the neck portion may be less than a diameter of other portions of the combustion tube. A thickness of the neck portion may be less than a length of the combustion tube, and the neck portion may cover an entire circumference of the combustion tube.

In certain embodiments, the diverter may include a wider section and a narrow section. The wider section and the narrow section may form a funnel shaped structure. The diverter may be positioned in the cavity of the combustion tube such that the diverter engages with the neck portion to secure the diverter in the combustion tube. Specifically, the wider section may be configured to engage with the neck portion such that the diverter hangs in the combustion tube without contacting the bottom end of the combustion tube and without using any external support. Thus, the wider portion contacts the combustion tube (via the neck portion), and the narrow portion does not contact the combustion tube. That is, the outer walls of the narrow portion may be spaced apart from the inner walls of the combustion tube.

The present disclosure discloses a combustion tube assembly that facilitates proper positioning (or orientation) of the diverter in the combustion tube. In addition, the present disclosure facilitates easy manufacturing (as any welding or external support structure is not required to position the diverter in the combustion tube) and ensures sealing such that there is no leakage from the edges of the diverter (and all the exhaust gases pass through the diverter and move towards the outflow opening).

Although certain examples of the disclosed technology are explained in detail herein, it is to be understood that other examples, embodiments, and implementations of the disclosed technology are contemplated. Accordingly, it is not intended that the disclosed technology is limited in its scope to the details of construction and arrangement of components expressly set forth in the following description or illustrated in the drawings. The disclosed technology can be implemented in a variety of examples and can be practiced or carried out in various ways. In particular, the presently disclosed subject matter is described in the context of being a system and method for positioning a diverter within a combustion chamber of a water heater. The present disclosure, however, is not so limited, and can be applicable in other contexts. Accordingly, when the present disclosure is described in the context of being a system and method for positioning a diverter within a combustion chamber of a water heater, it will be understood that other implementations can take the place of those referred to.

Although the term “water” is used throughout this specification, it is to be understood that other fluids may take the place of the term “water” as used herein. Therefore, although described as a system and method to increase heat transfer through a combustion chamber of a water heater, it is to be understood that the system and method described herein can apply to fluids other than water. Further, it is also to be understood that the term “water” can replace the term “fluid” as used herein unless the context clearly dictates otherwise.

Turning now to the drawings, FIG. 1 depicts a cross-sectional view of a water heater 100 in accordance with one or more embodiments of the present disclosure. In some embodiments, the water heater 100 includes a water tank 102, a top cover assembly 104, and a shell/housing 106 positioned on the outside of the water tank 102. The water heater 100 also includes a combustion system 108 at the top end of the water heater 100. In an exemplary aspect, the combustion system 108 may include a down-fired burner, where a hot exhaust gas produced by the combustion system 108 is pushed downward in a combustion tube assembly 110 by a blower of the combustion system 108. The hot exhaust gas that flows down in the combustion tube assembly 110 enters a heat exchanger 112 that transfers heat from the hot exhaust gas to water 116 that is contained/stored in the water tank 102. In some aspects, the heat exchanger 112 may be a hollow coil attached to the combustion tube assembly 110.

In some embodiments, the water heater 100 includes a water inlet that may be disposed, for example, closer to a bottom end 114 of the water heater 100. The water heater 100 may also include a top water outlet through the top cover assembly 104. In some embodiments, the water heater 100 may have a water inlet and a water outlet on the same side or end (e.g., top end) of the water heater 100 or different sides or ends of the water heater 100. In some embodiments, the water heater may also have other inlets or outlets (e.g., exhaust gas and condensate outlets) as can be readily understood by those of ordinary skill in the art with the benefit of this disclosure.

The combustion tube assembly 110 may be installed in the water tank 102. In certain embodiments, the combustion tube assembly 110 may include a combustion tube (shown as combustion tube 302 in FIG. 3) and a diverter structure (“diverter,” shown as 402 in FIG. 4) that diverts the hot exhaust gas in the combustion tube. The structural details of the combustion tube and the diverter are described below in conjunction with FIGS. 2-5. The diverter may be configured to provide a specific path for the flow of hot exhaust gas in the combustion tube, which may reduce the pressure drop and thermal stress about the transition between the combustion tube and the heat exchanger coil (e.g., outlet of the combustion tube and inlet of the heat exchanger).

During operations of the water heater 100, unheated water enters the water tank 102 through a water inlet of the water tank 102, and fuel may be ignited by the combustion system 108, for example, inside the combustion tube assembly 110, where the resulting hot exhaust gas is pushed down the combustion tube assembly 110, for example, by a blower of the combustion system 108. The unheated water that enters the water tank 102 is heated by hot exhaust gas flowing in the combustion tube assembly 110 and the heat exchanger 112. To illustrate, some of the heat from the hot exhaust gas is transferred to the water in the water tank 102 through the combustion tube assembly 110, and some of the heat from the hot exhaust gas is transferred through the heat exchanger 112 to the water in the water tank 102. The resulting heated water exits the water tank 102 through the water outlet in the water tank 102 and the water heater 100. The hot exhaust gas that enters the heat exchanger 112 from the combustion tube assembly 110 cools down after flowing through the heat exchanger 112 and generally exits the heat exchanger 112 at a much lower temperature and may exit the water heater 100 through a hot gas outlet, for example, at the bottom of the water heater 100.

FIG. 2 illustrates a front view of a heat exchanger assembly of a water heater (e.g., the water heater 100) in accordance with one or more embodiments of the present disclosure. The heat exchanger assembly may be installed in the water tank 102 and may include a combustion tube assembly 202 and a heat exchanger 204. The combustion tube assembly 202 may be same as the combustion tube assembly 110 of FIG. 1, and the heat exchanger 204 may be same as the heat exchanger 112 of FIG. 1. FIG. 2 is explained in conjunction with FIGS. 3-5. FIG. 3 illustrates a cross-sectional view of a combustion tube 302 of the combustion tube assembly 202, FIG. 4 illustrates a cross-sectional view of a heat exchanger assembly including the combustion tube assembly 202 and the heat exchanger 204, and FIG. 5 illustrates a top view of the heat exchanger assembly of FIG. 4.

In certain embodiments, the combustion tube 302 may be a cylindrical tube having a top end 304a and a bottom end 304b. The top end 304a may be disposed in proximity to the combustion system 108, and the bottom end 304b may be disposed away from the combustion system 108. In some aspects, the top end 304a may be open and the bottom end 304b may be closed (e.g., by a cover structure).

In some instances, the combustion tube 302 may include a cavity in an interior portion of the combustion tube 302 that provides a chamber for combustion of a fuel such as natural gas, propane, oil, etc. In some aspects, a portion of the cavity which is in proximity to the top end 304a is configured to form the chamber for the combustion. The combustion tube 302 may further include an outflow opening 306 located between the top end 304a and the bottom end 304b. In certain embodiments, the outflow opening 306 may be located in proximity to the bottom end 304b, as shown in FIG. 3. Stated another way, in some instances, a distance between the outflow opening 306 and the bottom end 304b may be less than a distance between the outflow opening 306 and the top end 304a. The outflow opening 306 provides an outlet for the hot exhaust gas to exit the combustion tube 302. For example, hot exhaust gas resulting from the combustion of fuel proximal to the top end 304a may flow down towards the bottom end 304b and may exit through the outflow opening 306.

Specifically, the outflow opening 306 is configured to provide an outlet for the exhaust gas to flow from the combustion tube 302 into the heat exchanger 204 (or the hollow coil). In some aspects, the heat exchanger 204 may be attached to the combustion tube 302 at the outflow opening 306, which enables the heat exchanger 204 to receive the exhaust gas from the combustion tube 302 via the outflow opening 306. In an exemplary aspect, the heat exchanger 204 may be welded or attached to the combustion tube 302 by other means as can be readily contemplated by those of ordinary skill in the art with the benefit of this disclosure. The heat exchanger 204 may be a hollow coil that includes an inflow opening that is aligned with the outflow opening 306. In some aspects, the heat exchanger 204 may be a cylindrical hollow coil which may have a diameter equivalent to a diameter of the outflow opening 306 (which may be circular in shape). In some instances, the diameters of the heat exchanger 204 and the outflow opening 306 may be in a range of 1 to 2 inches.

During operation, the exhaust gas in the heat exchanger 204 transfers heat to the water 116 in the water tank 102 as the exhaust gas flows through the heat exchanger 204. The exhaust gas leaves the heat exchanger 204 through an exhaust outlet 206. Because the exhaust gas transfers heat to the water 116 through the heat exchanger 204 as it flows through the heat exchanger 204, the exhaust gas has a lower temperature at the exhaust outlet 206 than at the outflow opening 306.

In some embodiments, the heat exchanger 204 may be made from a suitable material as can be readily contemplated by those of ordinary skill in the art with the benefit of this disclosure. For example, the heat exchanger 204 may be made from steel or another material using methods, such as bending, etc., known by those of ordinary skill in the art with the benefit of this disclosure. In an exemplary aspect, the combustion tube 302 may be made of a material similar to the material of the heat exchanger 204.

In some embodiments, the heat exchanger 204 may have fewer windings than shown in FIG. 2, without departing from the scope of this disclosure. In some alternative embodiments, the heat exchanger 204 may have a different shape than shown without departing from the scope of this disclosure. In some embodiments, the heat exchanger 204 may be attached to the combustion tube 302 at a different location than shown without departing from the scope of this disclosure. In some embodiments, the relative heights of the combustion tube 302 and the heat exchanger 204 may be different than shown without departing from the scope of this disclosure.

In some aspects, the combustion tube 302 may include a neck portion 208 (or a roll form), for example, on a wall of the combustion tube 302. In some instances, the neck portion 208 may be disposed in proximity to the outflow opening 306. In further aspects, the neck portion 208 may be disposed on the entire circumference of the combustion tube 302. In other aspects, the neck portion 208 may be disposed about a partial circumference of the combustion tube 302. In addition, the neck portion 208 may be disposed along a lateral axis of the combustion tube 302 (or perpendicular to a longitudinal axis of the combustion tube 302). The neck portion 208 may be disposed on a portion of a length of the combustion tube 302. For example, the combustion tube 302 may have a length “L1” (which may be in a range of 25 to 35 inches) and the neck portion 208 may have a length “L2” (which may be in a range of 0.75 to 1.8 inches). The length “L1” may be considerably greater than the length “L2”. In some embodiments, the lengths “L1” and “L2” may be different from the lengths mentioned above, without departing from the scope of this disclosure.

In some aspects, the neck portion 208 may have an indentation that may be curved inwards towards the interior portion of the combustion tube 302 such that a diameter “D2” of the neck portion 208 may be less than a diameter “D1” of the combustion tube 302, as shown in FIG. 3. Stated another way, in the neck portion 208, the wall of the combustion tube 302 may be bent (or pressed) inwards towards the interior portion of the combustion tube 302 over the entire circumference of the combustion tube 302. In an exemplary aspect, “D1” may be in a range of 4 to 6 inches, and “D2” may be in a range of 3 to 5 inches. In some embodiments, the diameters “D1” and “D2” may be different from the diameters mentioned above without departing from the scope of this disclosure.

In some aspects, the neck portion 208 may be located above the outflow opening 306. Stated another way, the outflow opening 306 may be disposed between the neck portion 208 and the bottom end 304b. For example, the neck portion 208 may be located at a first distance “L3” from the bottom end 304b and the outflow opening 306 may be located at a second distance “L4” from the bottom end 304b, where the first distance “L3” is greater than the second distance “L4”. In an exemplary aspect, “L3” may be in a range of 6 to 10 inches and “L4” may be in a range of 4 to 8 inches. In some aspects, the neck portion 208 may be formed via a roll-forming technique. In some embodiments, the distances “L3” and “L4” may be different from the lengths mentioned above without departing from the scope of this disclosure.

The combustion tube assembly 202 may further include a hollow diverter structure 402 (or diverter 402, shown in FIG. 4). The diverter 402 may be shaped as a funnel and may include a first section 404a (a diverter top portion) and a second section 404b (a diverter bottom portion). The first section 404a may be the wider section of the funnel and the second section 404b may be the narrow section of the funnel. Stated another way, a diameter of the first section 404a may be greater than a diameter of the second section 404b. In an exemplary aspect, the diameter of the second section 404b may be in a range of 40-75% of the diameter of the first section 404a. Further, a length of the second section 404b may be greater than a length of the first section 404a. In some instances, the diameter of the outlet of the diverter 402 (e.g., the second section 404b) may be substantially similar to the diameter of the windings of the heat exchanger. In other instances, the diameter of the outlet of the diverter 402 (e.g., the second section 404b) may be 1 to 20 percent larger or smaller than the diameter of the windings of the heat exchanger.

In some aspects, the first section 404a may have a tapered diameter, which linearly decreases from a top end (or a first proximal end 406a) of the first section 404a to a bottom end (or a first distal end 406b) of the first section 404a (which connects to a top end or a second proximal end 408a of the second section 404b). In some instances, the second section 404b may be substantially linear. As described above, the first section 404a and the second section 404b may collectively form a funnel-shaped structure. The diverter 402 may have an open end at the top and an open end at the bottom to enable exhaust gas flow movement through the diverter 402. Specifically, the top and bottom ends (i.e., the first proximal and distal ends 406a, 406b) of the first section 404a and the top and bottom ends (i.e., the second proximal and distal ends 408a, 408b) of the second section 404b may be open, so that gas (e.g., exhaust gas) may flow through the interior portion of the diverter 402. During operation, the exhaust gas may enter the diverter 402 from the first proximal end 406a and may exit the diverter 402 from the second distal end 408b.

In some aspects, the diverter 402 may be positioned in the cavity of the combustion tube 302 and may be disposed concentric with the combustion tube 302. In some aspects, a diameter of the first proximal end 406a may be substantially equivalent to an inner diameter of the combustion tube 302. In certain embodiments, the diverter 402 may be positioned in proximity to the outflow opening 306. The diverter 402 may be configured to divert or “route” the exhaust gas to the outflow opening 306. Specifically, the exhaust gas may enter the diverter 402 from the first proximal end 406a, pass through the first and second sections 404a, 404b, exit the second distal end 408b, and then is routed/diverted towards the outflow opening 306 by reflecting off the bottom end 304b of the combustion tube 302 (that may be disposed in proximity to the second distal end 408b). Stated another way, the exhaust gas may enter the diverter 402 and flow towards the bottom end 304b and then is routed away from the bottom end 304b (after reflecting from the bottom end 304b) to exit the combustion tube 302 via the outflow opening.

In some aspects, the diverter 402 may be configured to engage, push against, or lock with the neck portion 208 to secure the diverter 402 in the combustion tube 302. For example, the first section 404a (i.e., the wider section) may engage with the neck portion 208 to secure the diverter 402 in the combustion tube 302. A user may insert the diverter 402 in the top end 304a of the combustion tube 302, with the second section 404b downward, and as the diverter 402 “slides” in the combustion tube 302, the first proximal end 406a of the first section 404a (which has a diameter substantially equivalent to the inner diameter of the combustion tube 302, and hence a diameter greater than the diameter of the neck portion 208) may lock against the neck portion 208 to secure the diverter 402 and prevent the diverter 402 from further sliding down the length of the combustion tube 302. For example, in some instances, the pressure of the exhaust gas flow pushing down on the first section 404a may assist in locking and/or maintaining the first section 404a against the neck 208. For example, relative pressures (e.g., P1 at 404a, P2 at 404b, P3 at 304b, and p4 at 306) may be such that the first section 404a is maintained against the neck 208. In some aspects, the diverter 402 may engage with the neck portion 208 such that the neck portion 208 acts as a positive stop for the diverter 402 and the diverter 402 may hang inside the combustion tube 302 (using the neck portion 208) without contacting the bottom end 304b of the combustion tube 302 (and without using any external support). Stated another way, when the diverter 402 engages with the neck portion 208, a predefined gap “G” may exist between the second distal end 408b of the diverter 402 and the bottom end 304b. The gap “G” may enable the exhaust gas to exit from the second distal end 408b and reflect from the bottom end 304b to finally get routed towards the outflow opening 306.

In some aspects, the first section 404a (e.g., the wider section) contacts/engages with the combustion tube 302 via the neck portion 208, and the second section 404b (e.g., the narrow section) does not contact the walls or the bottom end 304b of the combustion tube 302. The first section 404a may engage with the neck portion 208 such that all the exhaust gas, which moves from the combustion system 108 into the combustion tube 302, travels or passes into the diverter 402, and there is no leakage from the edges of the first section 404a. When the exhaust gas enters inside the first section 404a, the exhaust gas flows into the second section 404b and exits the second section 404b via the predefined gap “G.” When the exhaust gas exits the second section 404b, the exhaust gas flows towards the outflow opening 306 (e.g., via an exterior side portion of the second section 404b) and then move to the heat exchanger 204 (that is connected with the outflow opening 306, as described above).

As described above, the first section 404a (or the wider section) includes the first proximal end 406a and the first distal end 406b. The first proximal end 406a may be configured to receive the exhaust gas and the first distal end 406b may be configured to output the exhaust gas towards the second section 404b (or the narrow section). Further, as described above, the second section 404b may include the second proximal end 408a and the second distal end 408b. The second proximal end 408a may be attached to the first distal end 406b. The second distal end 408b may be disposed at a predefined distance (e.g., 0.2 to 1 inch) from the bottom end 304b such that the predefined gap “G” may exist between the second distal end and the bottom end 304b. The second proximal end may be configured to receive the exhaust gas from the first distal end. The second distal end may be configured to output the exhaust gas towards the outflow opening 306, in the manner described above.

In some embodiments, the combustion tube 302 and the diverter 402 may be made from a material that is suitable for use in a water heater as can be readily understood by those of ordinary skill in the art with the benefit of this disclosure. For example, the combustion tube may be made from steel. As another example, the diverter 402 may be made from stainless steel or Inconel in a manner known by those of ordinary skill in the art with the benefit of this disclosure. In some embodiments, the diverter structure 402 may be shorter or longer relative to the combustion tube 302 than shown in FIG. 4. In some alternative embodiments, the combustion tube 302 and/or the diverter 402 may have a different shape than shown without departing from the scope of this disclosure.

FIG. 6 depicts a flow diagram of a method 600 to position the diverter 402 in the combustion tube 302 in accordance with one or more embodiments of the present disclosure. FIG. 6 may be described with continued reference to prior figures, including FIGS. 1-5. The following process is exemplary and not confined to the steps described hereafter. Moreover, alternative embodiments may include more or less steps than are shown or described herein and may include these steps in a different order than the order described in the following example embodiments.

The method 600 starts at step 602. At step 604, the method 600 may include providing a combustion tube (e.g., the combustion tube 302). The combustion tube 302 may include the neck portion 208 (or roll form), as described above. At step 606, the method 600 may include providing a diverter (e.g., diverter 402). The diverter 402 may be a funnel shaped structure, as described above. At step 608, the method 600 may include positioning the diverter 402 in the combustion tube 302. Specifically, the diverter 402 may be inserted in the combustion tube 302 from a top end of the combustion tube 302. When the diverter 402 is inserted in the combustion tube 302, the diverter 402 may engage with the neck portion 208 and may be secured in the combustion tube 302. Specifically, the diverter 402 may hang in the combustion tube 302 such that a predefined gap may exist between a bottom end (i.e., the second distal end 408b) of the diverter 402 and the bottom end 304b of the combustion tube 302, as described above.

The method 600 stops at step 610.

In the above disclosure, reference has been made to the accompanying drawings, which form a part hereof, which illustrate specific implementations in which the present disclosure may be practiced. It is understood that other implementations may be utilized, and structural changes may be made without departing from the scope of the present disclosure. References in the specification to “one embodiment,” “an embodiment,” “an example embodiment,” etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a feature, structure, or characteristic is described in connection with an embodiment, one skilled in the art will recognize such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described.

It should also be understood that the word “example” as used herein is intended to be non-exclusionary and non-limiting in nature. More particularly, the word “example” as used herein indicates one among several examples, and it should be understood that no undue emphasis or preference is being directed to the particular example being described.

With regard to the processes, systems, methods, heuristics, etc. described herein, it should be understood that, although the steps of such processes, etc. have been described as occurring according to a certain ordered sequence, such processes could be practiced with the described steps performed in an order other than the order described herein. It further should be understood that certain steps could be performed simultaneously, that other steps could be added, or that certain steps described herein could be omitted. In other words, the descriptions of processes herein are provided for the purpose of illustrating various embodiments and should in no way be construed so as to limit the claims.

Accordingly, it is to be understood that the above description is intended to be illustrative and not restrictive. Many embodiments and applications other than the examples provided would be apparent upon reading the above description. The scope should be determined, not with reference to the above description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. It is anticipated and intended that future developments will occur in the technologies discussed herein, and that the disclosed systems and methods will be incorporated into such future embodiments. In sum, it should be understood that the application is capable of modification and variation.

All terms used in the claims are intended to be given their ordinary meanings as understood by those knowledgeable in the technologies described herein unless an explicit indication to the contrary is made herein. In particular, use of the singular articles such as “a,” “the,” “said,” etc., should be read to recite one or more of the indicated elements unless a claim recites an explicit limitation to the contrary. Conditional language, such as, among others, “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments could include, while other embodiments may not include, certain features, elements, and/or steps. Thus, such conditional language is not generally intended to imply that features, elements, and/or steps are in any way required for one or more embodiments.

Claims

That which is claimed is:

1. A combustion tube assembly of a water heater, the combustion tube assembly comprising:

a combustion tube having an open end, a closed end, and an outflow opening located between the open end and the closed end, wherein the outflow opening provides an outlet for an exhaust gas to exit the combustion tube, wherein the combustion tube comprises a neck portion, and wherein the neck portion is disposed in proximity to the outflow opening; and

a diverter disposed in the combustion tube, wherein the diverter is configured to divert the exhaust gas to the outflow opening, and wherein the diverter is configured to engage with the neck portion to secure the diverter in the combustion tube.

2. The combustion tube assembly of claim 1, wherein the neck portion is disposed about an entire circumference of the combustion tube.

3. The combustion tube assembly of claim 1, wherein the neck portion is disposed about a portion of a circumference of the combustion tube.

4. The combustion tube assembly of claim 1, wherein the neck portion is disposed perpendicular to a longitudinal axis of the combustion tube.

5. The combustion tube assembly of claim 1, wherein the neck portion is disposed at a first distance from the closed end, wherein the outflow opening is disposed at a second distance from the closed end, and wherein the first distance is greater than the second distance.

6. The combustion tube assembly of claim 1, wherein the diverter comprises a narrow section and a wider section, and wherein the narrow section and the wider section form a funnel shaped structure.

7. The combustion tube assembly of claim 6, wherein the wider section engages with the neck portion.

8. The combustion tube assembly of claim 6, wherein the narrow section does not contact the combustion tube.

9. The combustion tube assembly of claim 6, wherein the wider section comprises a first proximal end and a first distal end, wherein the first proximal end is configured to receive the exhaust gas and the first distal end is configured to output the exhaust gas.

10. The combustion tube assembly of claim 9, wherein the narrow section comprises a second proximal end and a second distal end, wherein the second proximal end is attached to first distal end, and wherein the second distal end is disposed at a predefined distance from the closed end of the combustion tube such that a gap exists between the closed end and the diverter.

11. The combustion tube assembly of claim 10, wherein the narrow section is configured to receive the exhaust gas via the first distal end and output the exhaust gas towards the closed end via the second distal end such that the exhaust gas flows from the second distal end to the outflow opening.

12. A heat exchanger assembly of a water heater, the heat exchanger assembly comprising:

a combustion tube having an open end, a closed end, and an outflow opening located between the open end and the closed end, wherein a cavity of the combustion tube provides a chamber for combustion of a water heater fuel that produces an exhaust gas, wherein the outflow opening provides an outlet for the exhaust gas to exit the combustion tube, wherein the combustion tube comprises a neck portion on a wall of the combustion tube, and wherein the neck portion is disposed in proximity to the outflow opening;

a diverter disposed in the cavity of the combustion tube, wherein the diverter is configured to divert the exhaust gas to the outflow opening, and wherein the diverter is configured to engage with the neck portion to secure the diverter in the combustion tube; and

a hollow coil attached to the combustion tube, wherein the outflow opening provides an outlet for the exhaust gas to flow from the combustion tube into the hollow coil.

13. The heat exchanger assembly of claim 12, wherein the neck portion is disposed about an entire circumference of the combustion tube.

14. The heat exchanger assembly of claim 12, wherein the neck portion is disposed about a portion of a circumference of the combustion tube.

15. The heat exchanger assembly of claim 12, wherein the neck portion is disposed perpendicular to a longitudinal axis of the combustion tube.

16. The heat exchanger assembly of claim 12, wherein the neck portion is disposed at a first distance from the closed end, wherein the outflow opening is disposed at a second distance from the closed end, and wherein the first distance is greater than the second distance.

17. The heat exchanger assembly of claim 12, wherein the diverter comprises a narrow section and a wider section, and wherein the narrow section and the wider section form a funnel shaped structure.

18. The heat exchanger assembly of claim 17, wherein the wider section engages with the neck portion, and the narrow section does not contact the combustion tube.

19. A combustion tube comprising:

an open end;

a closed end;

an outflow opening located between the open end and the closed end, wherein the outflow opening provides an outlet for exhaust gas to exit the combustion tube; and

a neck portion on a wall of the combustion tube, wherein the neck portion is disposed in proximity to the outflow opening.

20. The combustion tube of claim 19, wherein the neck portion is configured to engage with a diverter disposed in the combustion tube to secure the diverter in the combustion tube.

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