Furnace heat exchanger

Claim 2

A furnace heat exchanger comprising a pair of joined generally planar surfaces having a serpentine passage shaped therebetween, the passage including: an inlet; an outlet; a burner path connected to the inlet and extending in a first direction; a transition leg connected to the burner path and altering the serpentine passage to a second direction substantially perpendicular to the first direction; a first oblique path connected to the transition leg and extending in a third direction toward the burner path, where the third direction is oblique to the first direction and to the second direction; a second oblique path connected to the first oblique path and extending in a fourth direction away from the burner path where the fourth direction is generally parallel to the third direction; a third oblique path connected to the second oblique path and generally extending in said third direction; a fourth oblique path connected to the third oblique path and generally extending in said fourth direction; an outlet leg connected between the fourth oblique path and the outlet; and wherein the serpentine passage has a cross-section which gradually changes from an elliptical shape at the burner path to a rectangular shape at the end of the first oblique path.

Claim 3

A furnace heat exchanger comprising a pair of joined generally planar surfaces having a serpentine passage shaped therebetween, the passage including: an inlet; an outlet; a burner path connected to the inlet and extending in a first direction; a transition leg connected to the burner path and altering the serpentine passage to a second direction substantially perpendicular to the first direction; a first oblique path connected to the transition leg and extending in a third direction toward the burner path, where the third direction is oblique to the first direction and to the second direction; a second oblique path connected to the first oblique path and extending in a fourth direction away from the burner path where the fourth direction is generally parallel to the third direction; a third oblique path connected to the second oblique path and generally extending in said third direction; a fourth oblique path connected to the third oblique path and generally extending in said fourth direction; an outlet leg connected between the fourth oblique path and the outlet; and wherein the serpentine passage has a cross-section which gradually changes from an elliptical shape at the burner path to a rectangular shape at the end of the first oblique path.

Claim 4

A furnace heat exchanger comprising a pair of joined generally planar surfaces having a serpentine passage shaped therebetween, the passage including: an inlet; an outlet; a burner path connected to the inlet and extending in a first direction; a transition leg connected to the burner path and altering the serpentine passage to a second direction substantially perpendicular to the first direction; a first oblique path connected to the transition leg and extending in a third direction toward the burner path, where the third direction is oblique to the first direction and to the second direction and where the third direction is at an angle relative to the first direction of between 50 and 70 degrees; a second oblique path connected to the first oblique path and extending in a fourth direction away from the burner path where the fourth direction is generally parallel to the third direction; a third oblique path connected to the second oblique path and generally extending in said third direction; a fourth oblique path connected to the third oblique path and generally extending in said fourth direction; and an outlet leg connected between the fourth oblique path and the outlet.

Claim 5

A furnace heat exchanger comprising a pair of joined generally planar surfaces having a serpentine passage shaped therebetween, the passage including: an inlet; an outlet; a burner path connected to the inlet and extending in a first direction; a transition leg connected to the burner path and altering the serpentine passage to a second direction substantially perpendicular to the first direction; a first oblique path connected to the transition leg and extending in a third direction toward the burner path, where the third direction is oblique to the first direction and to the second direction and where the third direction is at an angle relative to the first direction of between 50 and 70 degrees; a second oblique path connected to the first oblique path and extending in a fourth direction away from the burner path where the fourth direction is generally parallel to the third direction; a third oblique path connected to the second oblique path and generally extending in said third direction; a fourth oblique path connected to the third oblique path and generally extending in said fourth direction; and an outlet leg connected between the fourth oblique path and the outlet.

Claim 6

The heat exchanger of claim 3 wherein the angle of the third direction relative to the first direction is approximately 60 degrees.

Claim 7

The heat exchanger of claim 4 wherein the outlet leg is generally parallel to the burner path.

Claim 8

The heat exchanger of claim 3 wherein the burner path and the transition leg are elliptical in cross-section.

Claim 9

The heat exchanger of claim 6 wherein the burner path is linear.

Claim 10

The heat exchanger of claim 7 wherein the burner path includes a flare at the inlet, and the transition leg is shaped as a curved elbow.

Claim 11

The heat exchanger of claim 3 wherein the pair of planar surfaces are integral on one side.

Claim 12

The heat exchanger of claim 9 wherein the integral side is cut away at one corner.

Claim 13

The heat exchanger of claim 3 wherein the pair of planar surfaces are joined by at least one clinch hole fastener.

Claim 14

The heat exchanger of claim 3 wherein the serpentine passage gradually decreases in cross-sectional width and area as the passage moves away from an inlet end of the burner path.

Claim 15

The heat exchanger of claim 3 wherein the first, second, third and fourth oblique path each include a linear portion which has a generally hexalinear cross-section.

Claim 16

A furnace heat exchanger comprising a pair of joined generally planar surfaces having a serpentine passage shaped therebetween, the passage including: an inlet; an outlet; a burner path connected to the inlet and extending in a first direction; a transition leg connected to the burner path and altering the serpentine passage to a second direction substantially perpendicular to the first direction; a first oblique path connected to the transition leg and extending in a third direction toward the burner path, where the third direction is oblique to the first direction and to the second direction; a second oblique path connected to the first oblique path and extending in a fourth direction away from the burner path where the fourth direction is generally parallel to the third direction; a third oblique path connected to the second oblique path and generally extending in said third direction; a fourth oblique path connected to the third oblique path and generally extending in said fourth direction; and an outlet leg connected between the fourth oblique path and the outlet wherein the serpentine passage has a cross-section which gradually changes from an elliptical shape at the burner path to a hexalinear shape at the end of the first oblique path.

Claim 17

A furnace heat exchanger comprising a pair of joined generally planar surfaces having a serpentine passage shaped therebetween, the passage including: an inlet; an outlet; a burner path connected to the inlet and extending in a first direction; a transition leg connected to the burner path and altering the serpentine passage to a second direction substantially perpendicular to the first direction; a first oblique path connected to the transition leg and extending in a third direction toward the burner path, where the third direction is oblique to the first direction and to the second direction; a second oblique path connected to the first oblique path and extending in a fourth direction away from the burner path where the fourth direction is generally parallel to the third direction; a third oblique path connected to the second oblique path and generally extending in said third direction; a fourth oblique path connected to the third oblique path and generally extending in said fourth direction; and an outlet leg connected between the fourth oblique path and the outlet wherein the serpentine passage has a cross-section which gradually changes from an elliptical shape at the burner path to a hexalinear shape at the end of the first oblique path.

Claim 18

The heat exchanger of claim 3 wherein the oblique paths are separated by narrow peninsulas.

Claim 19

A serpentine path from an inlet of a furnace heat exchanger to an outlet of a furnace heat exchanger comprising: a burner path connected to an inlet and linearly running in a first direction; a transition leg connected to the burner leg and turning the serpentine path from the first direction to a second direction which is substantially perpendicular to the first direction; a first turn connected to the transition leg and turning the serpentine path from the second direction to a third direction which is oblique to the second direction; a first oblique leg connected to the first run and extending in the third direction toward the burner path; a second turn connected to the first oblique leg and turning the serpentine path approximately 180°; a second oblique leg connected to the second turn and extending in a fourth direction which is substantially parallel to the third direction; a third turn connected to the second oblique leg and turning the serpentine path approximately 180°; a third oblique leg connected to the third turn and extending in said third direction; a fourth turn connected to said third oblique leg and turning the serpentine path approximately 180°; a fourth oblique leg connected to said fourth turn and extending in said fourth direction; an outlet turn connected to said fourth oblique leg and turning the serpentine path in a fifth direction which is opposite to and parallel with said first direction; and an outlet passage extending in said fifth direction wherein the third direction is at an angle relative to the first direction of between 50 and 70 degrees.

Claim 20

A serpentine path from an inlet of a furnace heat exchanger to an outlet of a furnace heat exchanger comprising: a burner path connected to an inlet and linearly running in a first direction; a transition leg connected to the burner leg and turning the serpentine path from the first direction to a second direction which is substantially perpendicular to the first direction; a first turn connected to the transition leg and turning the serpentine path from the second direction to a third direction which is oblique to the second direction; a first oblique leg connected to the first run and extending in the third direction toward the burner path; a second turn connected to the first oblique leg and turning the serpentine path approximately 180°; a second oblique leg connected to the second turn and extending in a fourth direction which is substantially parallel to the third direction; a third turn connected to the second oblique leg and turning the serpentine path approximately 180°; a third oblique leg connected to the third turn and extending in said third direction; a fourth turn connected to said third oblique leg and turning the serpentine path approximately 180°; a fourth oblique leg connected to said fourth turn and extending in said fourth direction; an outlet turn connected to said fourth oblique leg and turning the serpentine path in a fifth direction which is opposite to and parallel with said first direction; and an outlet passage extending in said fifth direction wherein the third direction is at an angle relative to the first direction of between 50 and 70 degrees.