Chimney cap with replaceable or recyclable ceramic catalytic filter insert

Abstract

A chimney cap device for a flue opening. The device includes a tubular housing with an open lower end and an open upper end. A plurality of louver openings in a lower portion of the tubular housing draw air into the tubular housing. A removable top is attached to the open upper end of the tubular housing wherein the top includes a plurality of exit openings. A liner is provided within and attached to the tubular housing. A removable catalytic converter insert is supported within the liner to treat emissions from a gas fired appliance.

1 . A chimney cap device for a flue opening, which device comprises:
 a tubular housing with an open lower end and an open upper end;   a plurality of louver openings in a lower portion of said tubular housing to draw air into said tubular housing;   a removable top attached to said open upper end of said tubular housing wherein said top includes a plurality of exit openings;   a liner within and attached to said tubular housing; and   a removable filter insert within said tubular housing.   
   
   
       2 . A chimney cap device for a flue opening as set forth in  claim 1  including an inner frame and mounting assembly attached near said open lower end of the tubular housing having anchoring and leveling means to anchor said inner frame and mounting assembly. 
   
   
       3 . A chimney cap device for a flue opening as set forth in  claim 2  wherein said inner frame and mounting assembly includes receptacles and wherein said anchoring and leveling means includes a plurality of clips receivable in said receptacles. 
   
   
       4 . A chimney cap device for a flue opening as set forth in  claim 1  wherein said tubular housing is fabricated from flat sheet metal. 
   
   
       5 . A chimney cap device for a flue opening as set forth in  claim 4  wherein said louver openings are stamped into said flat sheet metal. 
   
   
       6 . A chimney cap device for a flue opening as set forth in  claim 1  wherein said tubular housing has a cross-section in a form chosen from the group consisting of an octagon, a hexagon, a square, a rectangle, or a circle. 
   
   
       7 . A chimney cap device for a flue opening as set forth in  claim 1  wherein said removable top is fastened to said tubular housing by fasteners. 
   
   
       8 . A chimney cap device for a flue opening as set forth in  claim 1  wherein said top includes a heat deflector to direct gases toward said exit openings. 
   
   
       9 . A chimney cap device for a flue opening as set forth in  claim 1  including a plurality of supports to uphold said filter insert. 
   
   
       10 . A chimney cap device for a flue opening as set forth in  claim 9  wherein said plurality of supports extend from said liner. 
   
   
       11 . A chimney cap device for a flue opening as set forth in  claim 1  wherein said filter insert is a catalytic converter. 
   
   
       12 . A chimney cap device for a flue opening as set forth in  claim 11  wherein said catalytic converter includes a core or substrate, a washcoat, and a catalyst. 
   
   
       13 . A chimney cap device for a flue opening as set forth in  claim 12  wherein said core or substrate is a ceramic honeycomb structure with gas flow passages. 
   
   
       14 . A chimney cap device for a flue opening as set forth in  claim 12  wherein said washcoat and catalyst are applied to said core or substrate. 
   
   
       15 . A chimney cap device for a flue opening as set forth in  claim 1  wherein said flue opening includes an upstanding flue pipe and wherein said tubular housing surrounds said flue pipe. 
   
   
       16 . A chimney cap device for a flue opening, which device comprises:
 a tubular housing fabricated from sheet metal with an open lower end and an open upper end;   a plurality of louver openings in a lower portion of the tubular housing to draw air into said tubular housing;   a removable top attached to said open upper end of said tubular housing wherein said top includes a plurality of exit openings;   a removable catalytic converter filter insert; and   a plurality of supports extending from said liner to hold said filter insert within said tubular housing.   
   
   
       17 . A chimney cap device for a flue opening as set forth in  claim 16  including an inner frame and mounting assembly attached near said open lower end of the tubular housing having anchoring and leveling means to anchor said inner frame and mounting assembly. 
   
   
       18 . A process to treat carbon monoxide and unburned hydrocarbon emissions generated from a gas fired appliance, which process comprises:
 passing exhaust gases from said gas fired appliance from a flue opening into a tubular housing of a chimney cap device;   permitting atmospheric air to pass through louver openings in a lower portion of said tubular housing into the tubular housing;   permitting said exhaust gases and said atmospheric air in said tubular housing to pass into and through a filter insert supported within said tubular housing;   treating emissions within said exhaust gases with said filter insert;   permitting gases passing through said filter insert to be received in a removable top; and   permitting passage of gases from said removable top through a plurality of exit openings in said removable top.   
   
   
       19 . A process to treat emissions as set forth in  claim 18  wherein said step of treating emissions includes promoting oxidation with a catalytic converter.