ULTRA-LOW NOx BURNER

Abstract

A burner for use with an igniter for firing a flame into a heat-exchanger includes a body having a sidewall that defines an interior chamber. A first opening in the body receives a pre-mixed mixture of air and fuel. A second opening in the body is in fluid communication with the first opening. A distributor is connected to the body and closes the second opening. The distributor includes a first portion and at least one curved second portion provided on the first portion. Each second portion includes a plurality of first perforations in fluid communication with the first opening in the body. The first perforations of one second portion are positioned adjacent to the igniter such that ignition of the pre-mix mixture flowing through the first perforations results in a flame through the second portion. A flange extends around the first portion and includes second perforations.

1 . A burner for use with an igniter for firing a flame into a heat-exchanger comprising:
 a body having a sidewall that defines an interior chamber;   a first opening in the body for receiving a pre-mixed mixture of air and fuel;   a second opening in the body in fluid communication with the first opening; and   a distributor connected to the body and closing the second opening, the distributor comprising:
 a first portion; 
 at least one curved second portion provided on the first portion, each second portion including a plurality of first perforations in fluid communication with the first opening in the body, wherein the first perforations of one second portion are positioned adjacent to the igniter such that ignition of the pre-mix mixture flowing through the first perforations results in a flame through the second portion; and 
 a flange extending around the first portion and including second perforations. 
   
     
     
         2 . The burner of  claim 1  further comprising at least one baffle positioned within the interior chamber for directing the pre-mixed mixture to the at least one second portion, the baffle being tapered and including a base and legs extending outwardly from the base. 
     
     
         3 . The burner of  claim 2 , wherein each leg of the baffle includes at least one opening for reducing noise during operation of the burner. 
     
     
         4 . The burner of  claim 2 , wherein the baffle extends an entire width of the interior chamber. 
     
     
         5 . The burner of  claim 1 , wherein the second perforations extend entirely around the first portion. 
     
     
         6 . The burner of  claim 1 , wherein the second perforations are arranged in multiple rows. 
     
     
         7 . The burner of  claim 1 , wherein the flange is secured to a flange on the body for connecting the distributor to the body. 
     
     
         8 . The burner of  claim 1 , wherein the distributor and body are separated by a gap for receiving the pre-mixed mixture to cool the distributor. 
     
     
         9 . The burner of  claim 1 , further comprising a mesh burner surface including a planar portion, curved portions extending from the planar portion, and a flange portion extending around the planar portion. 
     
     
         10 . A furnace including the heat exchanger and burner of  claim 1 . 
     
     
         11 . A device for mixing air and fuel for a burner, comprising:
 a mixing wheel including circumferentially arranged openings for receiving air;   a nozzle connected to the mixing wheel and including a longitudinal passage for receiving fuel, radial openings extending from the longitudinal passage and upstream of the mixing wheel for delivering the fuel upstream of the mixing wheel; and   a restrictor plate positioned upstream of the nozzle and including circumferentially arranged openings for helping to mix the air and fuel for delivery to the burner.   
     
     
         12 . The mixing device of  claim 11 , wherein the openings in the mixing wheel are wedge-shaped. 
     
     
         13 . The mixing device of  claim 11 , wherein the openings in the restrictor plate are circular. 
     
     
         14 . A furnace including the mixing device of  claim 11 . 
     
     
         15 . The mixing device of  claim 11 , further comprising:
 a gas valve;   a tube extending from the gas valve to the mixing wheel;   an adaptor connected to an end of the tube; and   a gas flow regulation device threadably engaged with the adaptor and the gas valve to form a fluid-tight seal between the tube, the adaptor, the gas flow regulation device, and the gas valve.