Single burn rate solid fuel heating appliance with managed airflow

Abstract

A single combustion chamber, single burn rate solid fuel combustion heating appliance (e.g., a wood stove) is provided. The heating appliance includes a firebox having a top and a side and a first secondary air manifold. The first secondary air manifold extends longitudinally within the firebox proximate the top and the side of the firebox. The first secondary air manifold has a plurality of air orifices configured to provide secondary air to a burn chamber of the heating appliance.

What is claimed is: 
     
         1 . A single combustion chamber, single burn rate solid fuel combustion heating appliance comprising:
 a firebox having a top and a side;   a first secondary air manifold extending longitudinally within the firebox, wherein the first secondary air manifold is positioned proximate the top and the side of the firebox.   
     
     
         2 . The solid fuel combustion heating appliance of  claim 1 , wherein the side is a first side and the firebox further comprises a second side opposite the first side, and wherein the solid fuel combustion heating appliance further comprises a second secondary air manifold extending longitudinally within the firebox, wherein the second secondary air manifold is positioned proximate the top and the second side of the firebox. 
     
     
         3 . The solid fuel combustion heating appliance of  claim 1 , wherein:
 the firebox has a front defined by a door having an upper half and a lower half, said door having at least one opening therethrough in the upper half of the door; and   the at least one opening is configured to receive primary combustion air from outside the solid fuel combustion appliance.   
     
     
         4 . The solid fuel combustion heating appliance of  claim 1 , wherein:
 the firebox has a front defined by a door having an upper half and a lower half, said door having at least one opening therethrough in the upper half of the door,   the at least one opening is configured to receive primary combustion air from outside the solid fuel combustion appliance;   the door further comprises primary air intake manifold attached to a firebox side of the door; and   the primary air intake manifold is configured to receive the primary combustion air from the outside of the solid fuel combustion appliance and provide the received primary combustion air to the lower half of the door.   
     
     
         5 . The solid fuel combustion heating appliance of  claim 1 , wherein:
 the firebox has a front defined by a door having an upper half and a lower half, said door having at least one opening therethrough in the upper half of the door; and   the at least one opening comprises a plurality of openings spaced laterally across the door such that primary air is intake and distribution into the firebox is substantially equalized laterally across the firebox.   
     
     
         6 . The solid fuel combustion heating appliance of  claim 1 , wherein:
 the firebox further comprises a bottom comprising a metal layer;   the heating appliance further comprises a secondary air baffle extending longitudinally below the bottom of the firebox of the heating appliance; and   the secondary air baffle is configured to direct secondary air from a front of the heating appliance to a rear of the heating appliance.   
     
     
         7 . The solid fuel combustion heating appliance of  claim 1 , wherein:
 the firebox further comprises a bottom;   the heating appliance further comprises a secondary air baffle extending longitudinally below the bottom of the firebox of the heating appliance;   the secondary air baffle is configured to direct secondary air from a front of the heating appliance to a rear of the heating appliance; and   wherein the secondary air baffle is a bottom heat shield of the solid fuel combustion heating appliance.   
     
     
         8 . The solid fuel combustion heating appliance of  claim 1 , wherein:
 the firebox further comprises a bottom;   the heating appliance further comprises a secondary air baffle extending longitudinally below the bottom of the firebox of the heating appliance;   the secondary air baffle is configured to direct secondary air from a front of the heating appliance to a rear of the heating appliance; and   the heating appliance further comprises a bottom heat shield below the secondary air baffle.   
     
     
         9 . The solid fuel combustion heating appliance of  claim 1 , wherein:
 the firebox further comprises a bottom comprising a metal layer and an insulating layer;   the heating appliance further comprises a secondary air baffle extending longitudinally below the bottom of the firebox of the heating appliance; and   the secondary air baffle is configured to direct secondary air from a front of the heating appliance to a rear of the heating appliance.   
     
     
         10 . The solid fuel combustion heating appliance of  claim 1 , wherein:
 the firebox further comprises a bottom;   the heating appliance further comprises a secondary air baffle extending longitudinally below the bottom of the firebox of the heating appliance;   the secondary air baffle is configured to direct secondary air from a front of the heating appliance to a rear of the heating appliance;   the bottom of the firebox and the secondary air baffle form a secondary air intake; and   the heating appliance further comprises a first secondary air tube in fluid communication with the secondary air intake and the first secondary air manifold.   
     
     
         11 . The solid fuel combustion heating appliance of  claim 1 , wherein:
 the firebox further comprises a bottom;   the heating appliance further comprises a secondary air baffle extending longitudinally below the bottom of the firebox of the heating appliance;   the secondary air baffle is configured to direct secondary air from a front of the heating appliance to a rear of the heating appliance;   the bottom of the firebox and the secondary air baffle form a secondary air intake;   the heating appliance further comprises a first secondary air tube in fluid communication with the secondary air intake and the first secondary air manifold;   the side is a first side;   the firebox further comprises a second side opposite the first side;   the solid fuel combustion heating appliance further comprises a second secondary air manifold extending longitudinally within the firebox;   the second secondary air manifold is positioned proximate the top and the second side of the firebox; and   the heating appliance further comprises a second secondary air tube in fluid communication with the secondary air intake and the second secondary air manifold.   
     
     
         12 . The solid fuel combustion heating appliance of  claim 1 , wherein:
 the firebox further comprises a bottom;   the heating appliance further comprises a secondary air baffle extending longitudinally below the bottom of the firebox of the heating appliance;   the secondary air baffle is configured to direct secondary air from a front of the heating appliance to a rear of the heating appliance;   the bottom of the firebox and the secondary air baffle form a secondary air intake;   the heating appliance further comprises a first secondary air tube in fluid communication with the secondary air intake and the first secondary air tube;   the side is a first side;   the firebox further comprises a second side opposite the first side;   the solid fuel combustion heating appliance further comprises a second secondary air manifold extending longitudinally within the firebox;   the second secondary air manifold is positioned proximate the top and the second side of the firebox;   the heating appliance further comprises a second secondary air tube in fluid communication with the secondary air intake and the second secondary air tube;   the first secondary air tube is integral with the first secondary air manifold; and   the second secondary air tube is integral with the second secondary air manifold.   
     
     
         13 . The solid fuel combustion heating appliance of  claim 1 , wherein:
 the firebox further comprises a bottom;   the heating appliance further comprises a secondary air baffle extending longitudinally below the bottom of the firebox of the heating appliance;   the secondary air baffle is configured to direct secondary air from a front of the heating appliance to a rear of the heating appliance;   the bottom of the firebox and the secondary air baffle form a secondary air intake;   the heating appliance further comprises a first secondary air tube in fluid communication with the secondary air intake and the first secondary air tube;   the side is a first side;   the firebox further comprises a second side opposite the first side;   the solid fuel combustion heating appliance further comprises a second secondary air manifold extending longitudinally within the firebox;   the second secondary air manifold is positioned proximate the top and the second side of the firebox;   the heating appliance further comprises a second secondary air tube in fluid communication with the secondary air intake and the second secondary air tube; and   the heating appliance further comprises a transverse secondary air manifold extending laterally between the first secondary air manifold and the second secondary air manifold proximate the front of the heating appliance.   
     
     
         14 . The solid fuel combustion heating appliance of  claim 1 , wherein:
 the firebox further comprises a bottom;   the heating appliance further comprises a secondary air baffle extending longitudinally below the bottom of the firebox of the heating appliance;   the secondary air baffle is configured to direct secondary air from a front of the heating appliance to a rear of the heating appliance;   the bottom of the firebox and the secondary air baffle form a secondary air intake;   the heating appliance further comprises a first secondary air tube in fluid communication with the secondary air intake and the first secondary air tube;   the side is a first side;   the firebox further comprises a second side opposite the first side;   the solid fuel combustion heating appliance further comprises a second secondary air manifold extending longitudinally within the firebox;   the second secondary air manifold is positioned proximate the top and the second side of the firebox;   the heating appliance further comprises a second secondary air tube in fluid communication with the secondary air intake and the second secondary air tube;   the heating appliance further comprises a transverse secondary air manifold extending laterally between the first secondary air manifold and the second secondary air manifold proximate the front of the heating appliance;   the first secondary air manifold has a plurality of secondary air orifices configured to direct secondary air toward the second side of the firebox;   the second secondary air manifold has a plurality of secondary air orifices configured to direct secondary air toward the first side of the firebox; and   the transverse secondary air manifold has a plurality of secondary air orifices configured to direct secondary air toward a rear of the heating appliance.   
     
     
         15 . The solid fuel combustion heating appliance of  claim 1 , wherein:
 the firebox further comprises a bottom;   the heating appliance further comprises a secondary air baffle extending longitudinally below the bottom of the firebox of the heating appliance;   the secondary air baffle is configured to direct secondary air from a front of the heating appliance to a rear of the heating appliance;   the bottom of the firebox and the secondary air baffle form a secondary air intake;   the heating appliance further comprises a first secondary air tube in fluid communication with the secondary air intake and the first secondary air tube;   the side is a first side;   the firebox further comprises a second side opposite the first side;   the solid fuel combustion heating appliance further comprises a second secondary air manifold extending longitudinally within the firebox;   the second secondary air manifold is positioned proximate the top and the second side of the firebox;   the heating appliance further comprises a second secondary air tube in fluid communication with the secondary air intake and the second secondary air tube;   the heating appliance further comprises a transverse secondary air manifold extending laterally between the first secondary air manifold and the second secondary air manifold proximate the front of the heating appliance;   the first secondary air tube has a plurality of secondary air orifices configured to direct secondary air toward the second side of the firebox;   the second secondary air tube has a plurality of secondary air orifices configured to direct secondary air toward the first side of the firebox; and   the transverse secondary air manifold has a plurality of secondary air orifices configured to direct secondary air toward a rear of the heating appliance; and   the first secondary air tube does not have any secondary air orifices such that the first secondary air tube is configured to conduct secondary air only from the secondary air intake into the first secondary air manifold; and   the second secondary air tube does not have any secondary air orifices such that the second secondary air tube is configured to conduct secondary air only from the secondary air intake into the secondary air manifold.   
     
     
         16 . The solid fuel combustion heating appliance of  claim 1 , wherein:
 the firebox further comprises a bottom;   the heating appliance further comprises a secondary air baffle extending longitudinally below the bottom of the firebox of the heating appliance;   the secondary air baffle is configured to direct secondary air from a front of the heating appliance to a rear of the heating appliance;   the bottom of the firebox and the secondary air baffle form a secondary air intake;   the side is a first side;   the firebox further comprises a second side opposite the first side;   the solid fuel combustion heating appliance further comprises a second secondary air manifold extending longitudinally within the firebox;   the second secondary air manifold is positioned proximate the top and the second side of the firebox;   the heating appliance further comprises a rear secondary air baffle; and   the rear secondary air baffle is configured to provide secondary combustion air from the secondary air intake to the first secondary air manifold and the second secondary air manifold.   
     
     
         17 . The solid fuel combustion heating appliance of  claim 1 , wherein:
 the firebox further comprises a bottom;   the heating appliance further comprises a secondary air baffle extending longitudinally below the bottom of the firebox of the heating appliance;   the secondary air baffle is configured to direct secondary air from a front of the heating appliance to a rear of the heating appliance;   the bottom of the firebox and the secondary air baffle form a secondary air intake;   the heating appliance further comprises a first secondary air tube in fluid communication with the secondary air intake and the first secondary air tube;   the side is a first side;   the firebox further comprises a second side opposite the first side;   the solid fuel combustion heating appliance further comprises a second secondary air manifold extending longitudinally within the firebox;   the second secondary air manifold is positioned proximate the top and the second side of the firebox;   the heating appliance further comprises a rear secondary air baffle;   the rear secondary air baffle is configured to provide secondary combustion air from the secondary air intake to the first secondary air manifold and the second secondary air manifold; and   the rear secondary air baffle forms a rear of the firebox.   
     
     
         18 . The solid fuel combustion heating appliance of  claim 1 , wherein:
 the firebox further comprises a bottom;   the heating appliance further comprises a secondary air baffle extending longitudinally below the bottom of the firebox of the heating appliance;   the secondary air baffle is configured to direct secondary air from a front of the heating appliance to a rear of the heating appliance;   the bottom of the firebox and the secondary air baffle form a secondary air intake;   the heating appliance further comprises a first secondary air tube in fluid communication with the secondary air intake and the first secondary air tube;   the side is a first side;   the firebox further comprises a second side opposite the first side;   the solid fuel combustion heating appliance further comprises a second secondary air manifold extending longitudinally within the firebox;   the second secondary air manifold is positioned proximate the top and the second side of the firebox;   the heating appliance further comprises an upper baffle extending between the first secondary air manifold and the second secondary air manifold; and   the upper baffle is configured to form an exhaust path between the upper baffle and a top of the heating appliance;   the heating appliance further comprises a flue extending from a top of the heating appliance proximate the rear of the heating appliance; and   the exhaust path conducts exhaust gases toward the flue from adjacent the front of the firebox and top of the firebox to the flue.   
     
     
         19 . The solid fuel combustion heating appliance of  claim 1 , wherein:
 the firebox further comprises a bottom;   the heating appliance further comprises a secondary air baffle extending longitudinally below the bottom of the firebox of the heating appliance;   the secondary air baffle is configured to direct secondary air from a front of the heating appliance to a rear of the heating appliance; the bottom of the firebox and the secondary air baffle form a secondary air intake;   the heating appliance further comprises a first secondary air tube in fluid communication with the secondary air intake and the first secondary air tube;   the side is a first side;   the firebox further comprises a second side opposite the first side;   the solid fuel combustion heating appliance further comprises a second secondary air manifold extending longitudinally within the firebox;   the second secondary air manifold is positioned proximate the top and the second side of the firebox;   the heating appliance further comprises an upper baffle extending between the first secondary air manifold and the second secondary air manifold; and   the upper baffle is configured to form an exhaust path between the upper baffle and a top of the heating appliance;   the heating appliance further comprises a flue extending from a top of the heating appliance proximate the rear of the heating appliance;   the exhaust path conducts exhaust gases toward the flue from adjacent the front of the firebox and top of the firebox to the flue;   the upper baffle is affixed to a top of the first secondary air manifold and a top of the second secondary air manifold.   
     
     
         20 . The solid fuel combustion heating appliance of  claim 1 , wherein:
 the firebox further comprises a bottom;   the heating appliance further comprises a secondary air baffle extending longitudinally below the bottom of the firebox of the heating appliance;   the secondary air baffle is configured to direct secondary air from a front of the heating appliance to a rear of the heating appliance;   the bottom of the firebox and the secondary air baffle form a secondary air intake;   the heating appliance further comprises a first secondary air tube in fluid communication with the secondary air intake and the first secondary air tube;   the side is a first side;   the firebox further comprises a second side opposite the first side;   the solid fuel combustion heating appliance further comprises a second secondary air manifold extending longitudinally within the firebox;   the second secondary air manifold is positioned proximate the top and the second side of the firebox;   the heating appliance further comprises an upper baffle extending between the first secondary air manifold and the second secondary air manifold; and   the upper baffle is configured to form an exhaust path between the upper baffle and a top of the heating appliance;   the heating appliance further comprises a flue extending from a top of the heating appliance proximate the rear of the heating appliance;   the exhaust path conducts exhaust gases toward the flue from adjacent the front of the firebox and top of the firebox to the flue;   the upper baffle is affixed to a top of the first secondary air manifold and a top of the second secondary air manifold.; and.   the heating appliance further comprises a ceramic insulation layer resting on a top surface of the upper baffle.