US-20260126173-A1 - BUSHING FOR A BURNER TO REDUCE COMBUSTION BYPRODUCTS AND OIL DRIPPING

US20260126173A1US 20260126173 A1US20260126173 A1US 20260126173A1US-20260126173-A1

Abstract

A combustion head assembly for a burner that reduces combustion byproduct and oil pooling on a flame ring stabilizer or air diffuser element during normal operational cycling. The polymeric bushing directs away or prevents a non-combusted fuel in the fuel line interior portion from the nozzle end after a combustion cycle, and is fabricated from a polymeric material having thermal/electrical insulating properties, which is resistant to decomposition, dissolution, or breakdown when exposed to No. 2 fuel oil, biodiesel fuel oil, such as fluoropolymers, including PTFE (Teflon), fluorinated ethylene propylene (FEP), perfluoroalkoxy (PFA), ethylene-based fluoropolymers (ETFE/ECTFE), and/or polyvinylidene fluoride (PVDF), polyether ether ketones (PEEK), polyphenylene sulfide (PPS), and/or fluoroelastomers (FKM), or acrylonitrile butadiene styrene (ABS). The polymeric bushing is situated within a fuel line interior portion behind a nozzle element, having a channel or bore extending from end to end and in fluid communication with the nozzle element opening.

Inventors

James L. Jones

Assignees

COWLES OPERATING COMPANY

Dates

Publication Date: 20260507
Application Date: 20250930

Claims (16)

1 . A combustion head assembly for a burner, comprising: a fuel line having a nozzle end and an interior portion; a nozzle element for coupling engagement with the nozzle end, the nozzle element including an opening; a flame ring stabilizer or air diffuser element proximate the nozzle end and in airflow communication with the burner via an air tube; at least one electrode for the ignition of a fuel egressing the nozzle element; and a polymeric bushing situated within the fuel line interior portion behind said nozzle element, the polymeric bushing comprising a channel or bore extending from end to end and in fluid communication with said nozzle element opening; wherein said polymeric bushing deters and reduces thermal transfer of heat energy through the fuel line, thereby reducing or eliminating accumulation of oil and combustion byproducts on said flame ring stabilizer and/or air diffuser element, and/or reducing or eliminating oil pooling within said air tube.
2 . The combustion head assembly of claim 1 , wherein the polymeric bushing directs away and/or prevents an un-combusted fuel in the fuel line interior portion from the nozzle end after a combustion cycle.
3 . The combustion head assembly of claim 1 wherein said polymeric bushing comprises a polymeric material having thermal/electrical insulating properties, which is resistant to decomposition, dissolution, or breakdown when exposed to No. 2 fuel oil, biodiesel fuel oil, and/or combinations thereof.
4 . The combustion head assembly of claim 1 wherein said polymeric bushing comprises fluoropolymers, including PTFE (Teflon), fluorinated ethylene propylene (FEP), perfluoroalkoxy (PFA), ethylene-based fluoropolymers (ETFE/ECTFE), and/or polyvinylidene fluoride (PVDF).
5 . The combustion head assembly of claim 1 wherein said polymeric bushing comprises polyether ether ketones (PEEK), polyphenylene sulfide (PPS), and/or fluoroelastomers (FKM).
6 . The combustion head assembly of claim 1 wherein said polymeric bushing comprises acrylonitrile butadiene styrene (ABS).
7 . The combustion head assembly of claim 1 wherein said combustion head assembly is incorporated within a burner system, wherein said burner system comprises: a burner housing including an air tube and an outlet; said combustion head assembly disposed within the burner air tube; a motor in communication with a fan; an ignitor in communication with the combustion head assembly at least one electrode; a controller in communication with the motor and the ignitor; and a fuel line member for the delivery of a fuel to the combustion head assembly.
8 . The combustion head assembly of claim 1 wherein said polymeric bushing fits within and engages the fuel line interior portion in a clearance or transition fit.
9 . The combustion head assembly of claim 1 wherein said polymeric bushing includes one or a plurality of slots extending within an end of said polymeric bushing or any portion thereof.
10 . The combustion head assembly of claim 9 wherein said plurality of slots forms a peripherally slotted surface of said polymeric bushing.
11 . The combustion head assembly of claim 1 wherein said polymeric bushing includes an end having a crenellation-like design, including a plurality of merlons and embrasures to further prevent fuel clogging and facilitating fuel transfer to a side of the fuel line.
12 . A burner system comprising: a burner housing including an air tube and an outlet; a combustion head assembly disposed within the burner air tube, said combustion head assembly including: a fuel line having a nozzle end and an interior portion; a nozzle element for coupling engagement with the nozzle end, the nozzle element including an opening; a flame ring stabilizer or air diffuser element proximate the nozzle end and in airflow communication with said air tube; at least one electrode for the ignition of a fuel egressing the nozzle element; and a polymeric bushing situated within the fuel line interior portion behind said nozzle element, the polymeric bushing comprising a channel or bore extending from end to end and in fluid communication with said nozzle element opening; wherein said polymeric bushing deters and reduces thermal transfer of heat energy through the fuel line, thereby reducing or eliminating accumulation of oil and combustion byproducts on said flame ring stabilizer or air diffuser element, and reducing or eliminating oil pooling within said air tube; a motor in communication with a fan; an ignitor in communication with the combustion head assembly at least one electrode; a controller in communication with the motor and the ignitor; and a fuel line member for the delivery of the fuel to the combustion head assembly.
13 . The burner system of claim 12 wherein said polymeric bushing comprises a polymeric material having thermal/electrical insulating properties, which is resistant to decomposition, dissolution, or breakdown when exposed to No. 2 fuel oil, biodiesel fuel oil, and/or combinations thereof.
14 . The burner system of claim 12 wherein said polymeric bushing comprises fluoropolymers, including PTFE (Teflon), fluorinated ethylene propylene (FEP), perfluoroalkoxy (PFA), ethylene-based fluoropolymers (ETFE/ECTFE), and/or polyvinylidene fluoride (PVDF).
15 . The burner system of claim 12 wherein said polymeric bushing comprises polyether ether ketones (PEEK), polyphenylene sulfide (PPS), and/or fluoroelastomers (FKM).
16 . The burner system of claim 12 wherein said polymeric bushing comprises acrylonitrile butadiene styrene (ABS).

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to commercial and residential petrodiesel fuel burners, and more particularly, to petrodiesel fuel burners using biodiesel fuels and biodiesel blended fuels. 2. Description of Related Art Presently, millions of homes in the US are heated using petrodiesel fuel products such as No. 2 fuel oil. Heating systems utilizing this fuel source typically include petrodiesel fuel burners (“burners”) mounted on boilers, furnaces, and water heaters. During operation, a fuel is ignited within the burner of the appliance for the production of heat energy for the distribution into the apparatus (e.g., water heater) or living spaces by way of ductwork and/or piping within the home. To combat the environmental concerns associated with petrodiesel, the residential and commercial oil heating industry has begun the implementation of biodiesel fuels, which often consist of long-chain fatty acid esters derived from plants and animals (“biofuel”). Advantageously, biodiesel fuel is compatible within existing petrodiesel fuel burners without modification if the biodiesel fuel is blended with petrodiesel fuel. Biodiesel blends of up to B20 (80% No. 2 fuel oil mixed with 20% biodiesel fuel) are now readily available. The oil heating industry plans to continue increasing the blend levels—with the ultimate goal of reaching B100 (100% biodiesel fuel). Renewable diesel may also be implemented as an alternative fuel. Notably, renewable diesel and biodiesel are not the same type of fuel. Renewable diesel, previously known as green diesel, is a hydrocarbon produced most often by hydrotreating and also via gasification, pyrolysis, and other biochemical and thermochemical technologies. In contrast, biodiesel is a mono-alkyl ester produced via transesterification. It is possible that a blended form of renewable diesel and biofuel may be considered for implementation in a burner. Biofuel is most commonly manufactured from soybeans or recycled restaurant grease, and other plant and animal fat, in lieu of petroleum. When heating a home, it produces less sulfur dioxide, hydrocarbons, and air toxins, making it a cleaner heating solution. It is renewable, sustainable, and provides for lower emissions. Biofuel up to B20 and beyond generally do not require equipment changes or settings. Moreover, according to the National Oilheat Research Alliance (“NORA”), the use of biodiesel fuel reduces greenhouse gas emissions by 50% to 85% compared to petroleum diesel. Blends over B20 may require some minor burner upgrades or setting changes, where the costs of such changes are comparatively low with respect to the alternative appliance replacement normally required to resolve combustion byproduct mitigation. While many modern burners are designed to manage lower biofuel blends, using higher blends or pure biodiesel (B100) may require more timely system inspections by a professional to ensure compatibility and address potential issues like filter clogging from system gunk, carbon deposits, and/or rubber seal degradation. A long-standing issue of burners using No. 2 fuel oil relates to oil drips and combustion byproduct build-up on the combustion head assembly and within the air tube following burner run cycles, and onto the flame ring burner stabilizer (air diffuser). It has been known in the industry that such oil drips can accumulate over time, forming deposits of combustion byproducts on the flame ring burner stabilizer. Oil drips from the nozzle have been a source of carbon build-up and combustion byproducts. If not properly maintained, the accumulation can inhibit proper combustion within the burner which can result in burner malfunction. It has been found that biodiesel blends can be particularly problematic with this issue, as deposits are able to accumulate more immediately than burners using pure No. 2 fuel oil. Generally, it is recommended to service burners and the associated appliances annually. This service interval is a critical aspect to the acceptance of biofuel within the industry, as most oil dealers are not staffed to conduct burner service multiple times a year. While one way to address this issue is to run a post purge cycle (keeping the burner fan on at the end of a burner run cycle), there are limits to how long a post purge cycle can run, as it pushes latent heat to the housing exterior that would otherwise stay within the building's envelope. Thus, a need exists in the art to develop an apparatus to stop or minimize the accumulation of combustion by-products on the components of the burner, including the retention ring assembly, air tube, air diffuser, and combustion head. There further exists a need to extend the service life of a burner that utilizes biofuel, such that the normal service interval for burners utilizing No. 2 oil can be adapted for burners using biofuel. SUMMARY OF THE INVENTION Bearing in mind the problems and deficiencies of the prior ar