burner

The burner's eccentric inlet opening design addresses condensate leakage issues by enhancing the hydraulic barrier, ensuring reliable operation and preventing damage in boilers and industrial applications.

EP4678978A1Pending Publication Date: 2026-01-14BECKETT THERMAL SOLUTIONS SRL
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Patent Information

Application Number
EP2025188008
Authority / Receiving Office
EP · EP
Patent Type
Applications
Current Assignee / Owner
Priority Date
2024-07-12
Filing Date
2025-07-08
Publication Date
2026-01-14

AI Technical Summary

Technical Problem

Existing gas burners suffer from condensate leakage under abnormal operating conditions due to a low hydraulic head at the inlet opening, leading to malfunctions and damage in boilers and industrial applications.

Method used

The burner design features an eccentric inlet opening with a greater vertical distance from the lower edge than the upper edge, positioned transversely or orthogonally to the longitudinal axis, creating a higher barrier against condensate overflow.

Benefits of technology

This configuration effectively prevents condensate leakage, ensuring reliable operation and minimizing damage to connected systems.

✦ Generated by Eureka AI based on patent content.

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Abstract

A gas burner (1) with a support wall (2) forming an inlet opening (5) in communication with an internal space (13) of the burner (1), a diffuser wall (6) connected to the support wall (2) and forming a perforation (10), a closing wall (9) connected to the diffuser wall (6) on a side of the burner (1) opposite the support wall (2), wherein the diffuser wall (6) is a tubular, generally cylindrical wall, developed around a longitudinal axis (15) of the burner (1), and the support wall (2) is oriented transversely to the longitudinal axis (15), wherein the inlet opening (5) is eccentric with respect to the diffuser wall (6) and the burner (1) is mountable in a main use position in which the longitudinal axis (15) extends horizontally and in which: - a lower edge (16) of the inlet opening (5) has a first minimum vertical distance (16') from a lower end (16") of the support wall (2), and - an upper edge (17) of the inlet opening (5) has a second minimum vertical distance (17') from an upper end (17") of the support wall (2), wherein the first minimum vertical distance (16') is greater than the second minimum vertical distance (17').
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Description

[0001] The present invention relates to a gas burner for boilers and / or for industrial applications, for example a burner for a 24 kW boiler, with Qmax = 24.7 kW for heating domestic water and Qmin = 4.9 kW for the domestic heating circuit.

[0002] Gas burners 1 ( figures 1 and 2), for example tubular or cylindrical, of the type comprising: a support wall 2 connectable to a combustion chamber 3 of the boiler 4 or of the industrial application, the support wall 2 having an inlet opening 5 for the introduction of a mixture of fuel and oxidizing gas inside the burner 1, a tubular diffuser wall 6 and having a first end 7 connected to the support wall 2 in flow communication with the inlet opening 5, a second end 8 closed by a closing wall 9, and a perforation 10 for the passage of the gas mixture from inside the burner 1 to an external side of the diffuser wall 6 where combustion takes place.

[0003] Under particular or abnormal operating conditions or under regulatory test conditions, which provide for a closure or obstruction of the combustion condensate evacuation, the non-evacuated condensate causes the burner to shut down, and with the premixed (premix) burners of the prior art, an unwanted leakage of condensate from the round inlet opening of the burner support wall may occur. Condensate leakage can occur with certain air-gas mixture manifold configurations and also depends, for example, on the position of the flame detection sensor, as well as on the geometry of the burner support wall.

[0004] The leakage of condensate can cause malfunctions or damage to the application (for example to the boiler) to which the burner is connected.

[0005] As can be seen in figures 1 and 2, which represent a state of the art, the inlet opening 5 of the support wall 2 of the burner 1 defines, due to its wide circular geometry, a hydraulic head 11 (in other words: a hydraulic overflow level with respect to a lower point of the combustion chamber) undesirably low (in some burner examples, the overflow level, measured from a lower point of the diffuser wall 6, is less than 18.7 mm), which is why the condensate accumulated under abnormal operating conditions can easily overflow and escape from the burner 1 and from the combustion chamber through the inlet opening 5 in the opposite direction to the flow of the gas and air mixture.

[0006] The purpose of the present invention is therefore to make available a gas burner of the type described above or similar, having characteristics such as to prevent or reduce as much as possible the risk of condensate leakage observed in the prior art.

[0007] The objective is achieved by means of a burner according to claim 1. Advantageous and preferred embodiments are the subject of the dependent claims.

[0008] According to one aspect of the invention, a gas burner for a boiler and / or for industrial applications, for example, a burner for a boiler with a nominal power in the range from 18 kW to 36 kW, for example from 18 kW to 28 kW, e.g. 24kW, with maximum power Qmax in the range from 18 kW to 28kW, for example 24.7 kW, for domestic water heating and with minimum power Qmin in the range from 4kW to 6kW, for example 4.9 kW, for the domestic heating circuit, includes: a support wall connectable to a combustion chamber of the boiler or industrial application, said support wall forming an inlet opening in communication with an internal space of the burner for the introduction of a gas mixture into the internal space, a diffuser wall connected to the support wall and which delimits the internal space and forms a perforation for the passage of the gas mixture from the internal space to an external side of the diffuser wall where combustion takes place, a closing wall connected to the diffuser wall on a side opposite the support wall, wherein the diffuser wall is a tubular, generally cylindrical, or circular cylindrical wall developed around a longitudinal axis of the burner, and the support wall (although not necessarily planar) is oriented transversely or orthogonal to the longitudinal axis, wherein the inlet opening is eccentric with respect to the diffuser wall and the burner is positionable or mountable in a main use position (not necessarily the only use position) in which the longitudinal axis extends horizontally and: a lower edge of the inlet opening has a first minimum vertical distance from a lower end of the support wall, and an upper edge of the inlet opening has a second minimum vertical distance from an upper end of the support wall, wherein the first minimum vertical distance is greater than the second minimum vertical distance.

[0009] This geometric configuration allows the air and gas mixture to be fed into the burner (as is already the case in the prior art) and, at the same time, provides a higher barrier against the overflow of condensate from inside the burner - and from the combustion chamber - to the outside.

[0010] To better understand the invention and appreciate its advantages, some non-limiting exemplary embodiments will be described below, with reference to the figures, in which: figure 1 is a sectional view according to a vertical section plane, of a burner mounted to an application, for example a combustion chamber with a heat exchanger of a boiler, in which a combustion and condensate fumes exhaust duct is visible, and in which an overflow level is indicated with respect to a bottom level of the combustion chamber, figure 2 is a sectional view according to the vertical section plane II - II in figure 1, of the burner in figure 1, with indication of the overflow level with respect to the bottom level of the combustion chamber, figure 3 is a view similar to the view of figure 1, but of a burner according to an embodiment of the invention, in which a significantly higher overflow level is indicated than in figure 1, figure 4 is a sectional view according to the vertical section plane IV - IV in figure 3, of the burner in figure 3, with indication of the overflow level with respect to the bottom level of the combustion chamber, figure 5. 1 is a perspective view of a gas burner (premix) according to an embodiment of the invention, figure 5. 2 is a sectional view of the burner in figure 5.1, figure 5. 3 is an exploded view of the burner in figure 5.1, figure 5. 4 is a front view of the burner support wall in figure 5.1, figure 6. 1 is a perspective view of a gas burner (premix) according to a further embodiment of the invention, figure 6. 2 is a sectional view of the burner in figure 6.1, figure 6. 3 is an exploded view of the burner in figure 6.1, figure 6. 4 is a front view of the burner support wall in figure 6.1, figure 7 shows a comparison of the difference between the overflow level of the support wall with the burner inlet opening according to the invention (left side) and the overflow level of a burner of the prior art (right side). Description of the burner 1

[0011] With reference to Figures 2.1 to 6.4, a burner 1 comprises: a support wall 2 connectable to a combustion chamber 3 of a boiler 4 or of the industrial application, said support wall 2 forming an inlet opening 5 in communication with an internal space 13 of the burner 1 for the introduction of a gas mixture 12 into the internal space 13, a diffuser wall 6 connected to the support wall 2 and which delimits the internal space 13 and forms a perforation 10 for the passage of the gas mixture 12 from the internal space 13 to an external side 14 of the diffuser wall 6 where combustion takes place, a closing wall 9 connected with the diffuser wall 6 on a distal side of the burner 1 opposite the support wall 2, wherein the diffuser wall 6 is a tubular, generally cylindrical, or circular cylindrical wall, developed around a longitudinal (geometric) axis 15 of the burner 1, and the support wall 2 (although not necessarily planar) is oriented transversely or orthogonally to the longitudinal axis 15, wherein the inlet opening 5 is eccentric with respect to the diffuser wall 6 and the burner 1 can be positioned or mounted in a main position of use (not necessarily the only position of use) in which the longitudinal axis 15 extends horizontally and: a lower edge 16 of the inlet opening 5 has a first minimum vertical distance 16' from a lower end 16" of the support wall 2, and an upper edge 17 of the inlet opening 5 has a second minimum vertical distance 17' from an upper end 17" of the support wall 2, wherein the first minimum vertical distance 16" is greater than the second minimum vertical distance 17".

[0012] This geometric configuration allows the air and gas mixture 12 to be fed into the interior 13 of the burner 1 (as already occurs in the prior art) and, at the same time, provides a higher barrier against the overflow of condensate from the inside of the burner - and from the combustion chamber - towards the outside.Detailed description of the support wall 2 and the inlet opening 5

[0013] According to one embodiment, in the main position of use, the inlet opening 5 is delimited above and laterally by the upper edge 17, and below by the lower edge 16.

[0014] The lower edge 16 is preferably straight and (always in the main position of use) horizontal so as to be parallel to a level of possible condensate accumulated in the burner 1.

[0015] According to one embodiment, the upper edge 17 has an arched shape, preferably an arc of a circle, even more preferably an arc of a circle concentric with respect to the diffuser wall 6. This allows for a maximization of the passage area of the inlet opening 5 at the same height as the lower edge 16.

[0016] According to one embodiment, the lower edge 16, and therefore the entire inlet opening 5 (always in the main position of use), is formed above a lower third of the entire diffuser height 20 of the diffuser wall 6 at its first end 7 (in the sense that the support wall 2 is impermeable from the lower end 16" for / up to at least one third of the diffuser height 20), preferably above half of the entire diffuser height 20 of the diffuser wall 6 at its first end 7 (in the sense that the support wall 2 is impermeable from the lower end 16" for / up to at least half of the diffuser height 20), even more advantageously the lower edge 16, and therefore the entire inlet opening 5 (always in the main position of use), is formed above 55% of the diffuser height 20 ( Figures 5. 4, 6. 4).

[0017] According to one embodiment, the support wall 2 is made of sheet metal, e.g. steel, and preferably in the shape of a circular disk, possibly with one or more circular steps 21 that engage the diffuser wall 6 and / or the distributor wall 18.

[0018] According to one embodiment, the support wall 2 forms one or more shape references 22, for example recesses, which facilitate a correct positioning and assembly of the burner 1 in the main use position and, preferably, prevent (due to space violation), an assembly of the burner 1 in unplanned and rotated positions with respect to the main use position around the longitudinal axis 15.Detailed description of the diffuser wall 6 and the perforation 10

[0019] According to one embodiment, the diffuser wall 6 is made of sheet metal, e.g. steel, and is preferably circular cylindrical.

[0020] According to one embodiment, the perforation 10 comprises one or more equal or different perforation patterns, wherein each of the perforation patterns a repetitive hole pattern in the perimeter direction, preferably along at least 80% or 90% of the perimeter or along the entire perimeter of the diffuser wall 6.

[0021] Preferably, each of the perforation patterns forms a repetitive hole pattern also in the longitudinal direction of the diffuser wall 6.

[0022] According to one embodiment, the diffuser wall 6 forms a proximal end portion 6' without perforation to which the support wall 2 is connected, as well as a distal end portion 6" without perforation to which the closing wall 9 is connected.Detailed description of the distributor wall 18

[0023] The burner 1 may be without an additional distribution wall upstream (referring to the flow direction of the fuel gas 12) of the diffuser wall 6 ( Figure 6. 2, 6. 3).

[0024] Alternatively ( Figures 5. 2, 5. 3), the burner 1 may also comprise a tubular distributor wall 18, preferably cylindrical or circular cylindrical, arranged in the internal space 13 and connected with the support wall 2 in flow communication with the inlet opening 5 and closed on the opposite side of the support wall 2, for example by means of the same closing wall 9.

[0025] The distributor wall 18 forms a further perforation 19 for the distribution of the gas mixture 12 from an inner side of the distributor wall 18 towards the diffuser wall 6.

[0026] According to one embodiment, the distributor wall 18 is made of sheet metal, e.g. steel, and is preferably circular cylindrical.

[0027] Obviously, a person skilled in the art, in order to meet contingent and specific needs, may make further modifications and variations to the burner according to the present invention, all of which are contained within the scope of protection of the invention, as defined by the following claims.Numerical references

[0028] burner 1 support wall 2 combustion chamber 3 boiler 4 inlet opening 5 diffuser wall 6 proximal end portion 6' distal end portion 6" first end 7 second end 8 closing wall 9 perforation 10 hydraulic head 11 combustible gas 12 internal space 13 outer side 14 longitudinal axis 15 lower edge 16 first minimum vertical distance 16' lower end 16" upper edge 17 second minimum vertical distance 17' upper end 17" distributor wall 18 further perforation 19 diffuser height 20 circular step 21 shape reference 22

Examples

Embodiment Construction

[0011]With reference to Figures 2.1 to 6.4, a burner 1 comprises:

a support wall 2 connectable to a combustion chamber 3 of a boiler 4 or of the industrial application, said support wall 2 forming an inlet opening 5 in communication with an internal space 13 of the burner 1 for the introduction of a gas mixture 12 into the internal space 13, a diffuser wall 6 connected to the support wall 2 and which delimits the internal space 13 and forms a perforation 10 for the passage of the gas mixture 12 from the internal space 13 to an external side 14 of the diffuser wall 6 where combustion takes place, a closing wall 9 connected with the diffuser wall 6 on a distal side of the burner 1 opposite the support wall 2,

wherein the diffuser wall 6 is a tubular, generally cylindrical, or circular cylindrical wall, developed around a longitudinal (geometric) axis 15 of the burner 1, and the support wall 2 (although not necessarily planar) is oriented transversely or orthogonally to the longitudin...

Claims

1. Gas burner (1), comprising: - a support wall (2) connectable to a combustion chamber (3) of an application (4), said support wall (2) forming an inlet opening (5) in communication with an internal space (13) of the burner (1) for the introduction of a gas mixture (12) into the internal space (13), - a diffuser wall (6) connected to the support wall (2) and delimiting the internal space (13) and forming a perforation (10) for the passage of the gas mixture (12) from the internal space (13) to an external side (14) of the diffuser wall (6) where combustion takes place, - a closing wall (9) connected to the diffuser wall (6) on a side of the burner (1) opposite the support wall (2), wherein the diffuser wall (6) is a tubular, generally cylindrical, or circular cylindrical wall, developed around a longitudinal axis (15) of the burner (1), and the support wall (2) is oriented transversely or orthogonally to the longitudinal axis (15), wherein the inlet opening (5) is eccentric with respect to the diffuser wall (6) and the burner (1) is positionable or mountable in a main use position (figures 3, 4) in which the longitudinal axis (15) extends horizontally and in which: - a lower edge (16) of the inlet opening (5) has a first minimum vertical distance (16') from a lower end (16") of the support wall (2), and - an upper edge (17) of the inlet opening (5) has a second minimum vertical distance (17') from an upper end (17") of the support wall (2), wherein the first minimum vertical distance (16") is greater than the second minimum vertical distance (17").

2. Burner (1) according to claim 1, wherein in the main position of use, the inlet opening (5) is delimited above and laterally by the upper edge (17), and below by the lower edge (16), wherein the lower edge (16) is straight and horizontal, in the main position of use, so as to be arranged parallel to a level of possible accumulation of condensate in the burner (1).

3. Burner (1) according to claim 1 or 2, in which the upper edge (17) has an arched shape, or a circular arc, or a concentric circular arc with respect to the diffuser wall (6).

4. Burner (1) according to one of the preceding claims, wherein in the main position of use, the diffuser (6) has a diffuser height (20) measurable as the vertical height or diameter of the diffuser wall (6) at its first end (7), wherein the lower edge (16), and therefore the entire inlet opening (5), are formed above a lower third of the entire diffuser height (20) and the support wall (2) is impermeable from the lower end (16") for at least one third of the diffuser height (20).

5. Burner (1) according to claim 4, in which the lower edge (16), and therefore the entire inlet opening (5), are formed above half of the entire diffuser height (20) and the support wall (2) is impermeable from the lower end (16") up to at least half of the diffuser height (20).

6. Burner (1) according to claim 4, in which the lower edge (16), and therefore the entire inlet opening (5), are formed above 55% of the diffuser height (20).

7. Burner (1) according to one of the preceding claims, in which the support wall (2) is made of sheet metal and forms one or more steps (21) that engage the diffuser wall (6) or a distributor wall (18) of the burner (1).

8. Assembly of an application (4) with a combustion chamber (3) and the burner (1) according to any one of the preceding claims, in which the support wall (2) forms at least one shape reference (22) suitable to engage a corresponding reference formation of the application (4), in which the shape reference (22) facilitates a positioning and assembly of the burner (1) to the application (4) in the main use position and prevents, by means of space violation, an assembly of the burner (1) in unplanned positions, rotated with respect to the main use position, around the longitudinal axis (15).

9. Assembly of an application (4) with a combustion chamber (3) and the burner (1) according to any of the claims from 1 to 7, in which the burner (1) is mounted to the application (4) in the main use position.

Citation Information

Patent Citations

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