A hybrid condensate trap for a boiler

Abstract

A condensate trap for capturing and releasing condensate; the trap comprising a main body, a condensate inlet, a condensate outlet and a syphoning mechanism; wherein, the main body is coupled between the condensate inlet and condensate outlet; the main body comprises a chamber configured to collect condensate; the syphon mechanism is located within the chamber; wherein, the syphon mechanism comprises of a syphon outlet pipe, syphon inlet and air intake; the syphon inlet is located at the distal end of the syphon outlet pipe; the condensate outlet is coupled to the proximal end of the syphon outlet pipe; whereby, the syphon outlet pipe is configured to form an asymmetric U-bend comprising a first and second bend; the first bend has a higher summit than the second bend; and the first and second bends are configured such that condensate is syphoned to the summit of the first bend first.

Description

A HYBRID CONDENSATE TRAP FORA BOILERFIELD OF THE INVENTION

[0001] The present invention relates to a hybrid condensate trap for a boiler. More especially, the invention relates to a hybrid trap to capture, neutralise and release condensation from a condensate pipe of a heating system once the trap is filled to a pre-defined level, through a syphon mechanism.BACKGROUND TO THE INVENTION

[0002] Condensing boilers form part of the state of the art of heating systems. Condensing boilers improve heat production efficiency by re-capturing heat formerly expelled in flue gasses. Specifically, condensing boilers comprise heat exchanges wherein hot flue gasses transfer stored thermal energy to a ‘primary circuit’.

[0003] Condensing boilers combust fuels such as, but not limited to, natural gas, off-gasses, liquified petroleum gas, naphtha, fuel oils or biogas. Condensing boiler fuels comprise sulphur, nitrogen and carbon compounds.

[0004] As a product of combustion, flue gases comprise sulphur dioxide (SO2), sulphur trioxide (SO3) carbon dioxide (CO2) and nitric oxides (NO and NO2). Another product of combustion is water vapour. The water, sulphur oxides and nitric oxides react to form sulphuric acid (H2SO4) and nitric acid (HNO3), respectively. The acids condense, as condensate solution, at their respective dew points, as thermal energy is transferred from the flue gasses to the heat exchange.

[0005] Subsequently, the condensate temperature cools, the solution further dissolves gaseous CO2.Dissolved CO2 also reacts with the condensed water to form carbonic acid (H2CO3). Therefore, flue condensate has a pH between 3 and 5 and exhibits acidic corrosive characteristics.

[0006] The condensate corrodes metallic plumbing, lime mortar, concrete and clay drainage pipes;consequently, condensing boilers require frequent maintenance to prevent a shortening of the boiler’s lifespan. Furthermore, if untreated, released boiler condensate is hazardous to both the local environment and individuals in the immediate vicinity.

[0007] To reduce the hazards and risks, state of the art condensing boilers comprise a condensate neutraliser.

[0008] By way of example, but not limited to, condensate neutralisers are coupled between the condensate pipe of the boiler and the condensate outlet pipe. Condensate neutralisers comprise of a single chamber of which is filled with an alkaline material such as, but not limited to, calcite (CaCO3).

[0009] Condensate enters the condensate neutraliser from the condensate pipe. The condensate percolates through the single chamber and reacts with the alkaline material forming a neutralised condensate comprised of solubilised neutral salts and water. The neutralised condensate exits the condensate neutraliser via the condensate outlet pipe and is directed to an outdoor drainage system or soakaway.

[0010] A domestic condensing boiler produces approximately 2 Lof condensate per hour of operation. Post neutralisation, condensate drainage via the condensate outlet pipe slows to a drip. Portions of the condensate outlet located outdoors are at risk of blockages. More specifically, during cold weather, condensate may progressively freeze in layers until the condensate outlet pipe is fully occluded.

[0011] To reduce the risk of freezing of the condensate outlet pipe, state of the art condensing boilers comprise a condensate trap.

[0012] By way of example, but not limited to, condensate traps are coupled between the condensate neutraliser and the condensate outlet pipe. Condensate traps comprise a chamber to collect neutralised condensate and a syphon to flush the collected condensate via the condensate outlet. The chamber and syphon are configured to flush the collected condensate in predetermined volumes. The predetermined volumes are configured to reduce the risk of condensate freezing in the outdoor portion of a condensate outlet pipe by reducing the presence of a condensate drip.

[0013] To reduce the space occupied by both the condensate neutraliser and condensate trap, state of the art condensate traps are configured to hold the alkaline material in the condensate collection chamber. This hybrid design neutralises the condensate as it is collected prior to the flushing action by the condensate trap syphon.

[0014] The Applicant submits that the state of the art condensate traps and hybrid condensate traps do not sufficiently reduce the risk of condensate outlet pipe occlusion by freezing.

[0015] Specifically, the Applicant submits that following a flush of condensate by the syphon, a trickle of condensate persists in the condensate outlet pipe. During prolonged cold periods, the trickle of condensate is sufficient to form a full occlusion of the condensate pipe.

[0016] More specifically, the Applicant submits that condensate traps make use of syphons which increase drag at the summit of the syphon. Said drag reduces the velocity of syphoned condensate and therefore allows residual condensate to remain trapped in the syphon post-flushing.

[0017] Additionally still, the Applicant submits that condensate traps make use of syphons which either are too narrow to flush a large volume of condensate rapidly, or comprise a diameter too large to provide a fast-start-self-starting flush. Said small volumes or low velocity flushes allows residual condensate to remain trapped in the syphon post-flushing.

[0018] The Applicant further submits that the alkaline material located in the condensate collection chamber of hybrid condensate traps introduces drag to the syphoned condensate during flushing. Specifically, the Applicant submits that alkaline material in communication with collected condensate introduces turbulence and drag on condensate passing through the condensate collection chamber to the syphon. Therefore, the presence of alkaline material in the condensate collection chamber reduces the velocity of syphoned condensate and consequently increases the presence of residual condensate in the syphon and condensate outlet pipe.

[0019] Therefore, residual condensate trickles from state of the art syphons post-flushing and consequently a risk of condensate outlet pipe occlusion by freezing still exists.

[0020] The present invention seeks to significantly reduce the risk of condensate pipe occlusion, via freezing, by providing a hybrid condensate trap with an enhanced self-starting-fast-flushing syphon mechanism. Specifically, the present invention provides a syphon with a stepped syphon inlet for enhanced self-starting-fast-flushing, reduced drag at the respective syphon summit and a hybrid condensate trap devoid of alkaline material associated turbulence and drag.STATEMENT OF THE INVENTION

[0021] A condensate trap for capturing and releasing condensate; the trap comprising a main body, a condensate inlet, a condensate outlet and a syphoning mechanism; wherein, the main body is coupled between the condensate inlet and condensate outlet; the main body comprises a chamber configured to collect condensate; the syphon mechanism is located within the chamber; wherein, the syphon mechanism comprises of a syphon outlet pipe, syphon inlet and air intake. The syphon inlet is located at the distal end of the syphon outlet pipe. The condensate outlet is coupled to the proximal end of the syphon outlet pipe; whereby, the syphon outlet pipe is configured to form an asymmetric U-bend comprising a first and second bend; the first bend has a higher summit than the second bend; and the first and second bends are configured such that condensate is syphoned to the summit of the first bend first. The asymmetric U-bend is advantageous as it is configured to accelerate the velocity of syphoning condensate; therefore, the enhanced syphoning effect reduces residual condensate being trapped within the syphon after flushing.

[0022] In a further embodiment, the condensate trap comprises a condensate neutralising cartridge. The use of a condensate neutralising cartridge isolates the enclosed alkaline material from the collected condensate and therefore reduces turbulence and drag, with respect to condensate, during a syphoning flush.

[0023] Moreover, in an alternative embodiment the chamber is configured to reversibly receive the condensate neutralising cartridge. This is advantageous as it allows for the condensate neutralising cartridge to be replaced routinely; thereby ensuring the efficacy of the alkaline material held therein.

[0024] In a preferred embodiment, the condensate neutralising cartridge has a hollow frustrum base and hollow cylinder top. Adventurously, the frustum base is configured to reduce the effective capacity of the upper portion of the chamber, thereby when the collected condensate is in communication with the frustrum base, the rate at which the condensate level rises within the chamber is increased and a faststart syphoning effect is achieved.

[0025] In an alternative embodiment, the condensate neutralising cartridge comprises one or more channels, configured to allow neutralised condensate to pass into the chamber. The channels ensure that the condensate percolates through, and is neutralised by, the alkaline material held therein.

[0026] In a preferred embodiment, the condensate neutralising cartridge is configured with a complimentary recessed profile to accommodate the syphon mechanism. Consequently, in comparison to the upper portion of the chamber, the lower portion of the chamber has an increased effective capacity. The reduced effective capacity of the upper portion increases the rate the condensate will rise with respect to the total volume captured in the chamber. Therefore, as captured condensate rises to a level equal to, or greater than, the level defined by the base of the tapered neutralising cartridge, the condensate level increases more rapidly.

[0027] In a further embodiment, the frustrum portion of the condensate neutralising cartridge is configured to position the condensate neutralising cartridge lower than the summit of the first bend of the syphon outlet pipe. This is advantageous, as the condensed configuration allows for a reduced size condensate trap. Furthermore, the condensed configuration reduces the respective ratios of the upper and lower portions of the chamber and therefore increases the frequency of syphon flushing.

[0028] In another embodiment, the air intake and syphon are located substantially centrally in the base of the chamber and orientated to extend vertically upward therefrom. This reduces the width of the condensate trap and therefore allows the condensate trap to be located in a greater number of places.

[0029] In a further embodiment, the air intake projects further than the summit of the syphon outlet pipe with respect to the base of the chamber. This is advantageous as it reduces the risk of collected condensate flowing through the air intake before reaching the syphon outlet pipe.

[0030] Preferably, the air intake comprises an angled top portion, configured to prevent condensate dripping into the air intake from the condensate inlet. This is advantageous as it prevents condensate apparent from the condensate inlet and boiler dripping into the air intake.

[0031] In a preferred embodiment, the air intake is configured to act as an emergency overflow pipe. This is advantageous in the circumstance the syphon outlet pipe becomes blocked, as the air intake prevents backflow of both condensate and neutralised condensate into the boiler.

[0032] In another embodiment, a proximal end of the air intake is coupled to the condensate outlet, configured such that an air channel is formed between the condensate outlet and chamber. This coupling permits air pressure equalisation within the chamber, in particular to accommodate air pressure changes occurring during a syphoning flush.

[0033] In another embodiment, the proximal end of the air intake and a proximal end of the syphon outlet pipe are located within the syphon outlet and configured such that condensate expelled from the syphon outlet pipe is not drawn up the air intake. This is advantageous as this configuration prevents condensate expelled from the syphon outlet pipe from being drawn up the air intake during pressure equalisation of the chamber.

[0034] In a preferred embodiment, the proximal end of the air intake terminates at a location higher in the condensate outlet than that of the terminus of the proximal end of the outlet pipe.

[0035] In another embodiment, the syphon inlet is orientated such that an orifice of the syphon inlet is substantially parallel to the base of the chamber. In this orientation, the siphon inlet forms a sealed interface with collected condensate, such that the siphoningflush terminates only when the condensate level falls to a predetermined level.

[0036] In a preferred embodiment, the orifice of the syphon inlet is configured to have a proximity to the base of the chamber, such that, at least 90% of the collected condensate is syphoned. By siphoning the majority of the collected condensate, the flush is more effective and less likely to leave residual condensate in the condensate outlet.

[0037] In an alternative embodiment, the syphon inlet is configured to have a decreasing stepped diameter.The stepped configuration of the syphon inlet is designed to allow a fast start to the syphon mechanism.

[0038] Preferably, the syphon inlet is stepped from approximately 22 mm to 15 mm, to 10 mm.

[0039] In a preferred embodiment, the syphon inlet and condensate outlet have a larger cross-section than that of the syphon outlet pipe. The syphon outlet pipe therefore serves as a constriction. The constriction reduces fluid pressure within the syphon outlet pipe, thereby generating a venturi effect between the chamber, the syphon outlet pipe and the condensate outlet. This increases suction and draws condensate from the chamber through the syphon outlet pipe at an increased velocity.

[0040] Preferably, the condensate trap comprises a removable lid configured to be reversible fastenable to the main body. The removable lid therefore allows maintenance of the syphon mechanism and replacement of the condensate neutralising cartridge periodically.

[0041] Preferably, the removable lid comprises a rubber gasket. The rubber gasket is configured to provide an airtight and watertight seal at the interface between the main bod and the removable lid. The seal created prevent flue gasses and un-treated condensate from leaving the hybrid condensate trap.

[0042] Preferably, the main body is formed of a fire-resistant material.

[0043] Preferably, the main body is textured to ensure easy handling when wet.

[0044] In one embodiment, the condensate trap is integral to a boiler.

[0045] In an alternative embodiment, the condensate trap is configured to be retrofittable to a boiler. BRIEF DESCRIPTION OF DRAWINGS

[0046] A preferred embodiment of the invention will now be described by way of example only and with reference to the figures, in which:

[0047] Figure 1 is a schematic illustration of a state of the art condensate trap system;

[0048] Figure 2 is a schematic illustration of a hybrid condensate trap in accordance with the invention.

[0049] Figure 3 is a schematics illustration showing the process of installing the condensate trap.DETAILED DESCRIPTION OF THE INVENTION

[0050] A condensate trap 2 is shown in figure 1 represents the state of the art. The trap 2 comprises a main body 4 forming an internal chamber 6 to collect condensate produced from a boiler 8 (see figure 3).

[0051] One end of the trap 2 has a removable lid 10 connectable to the main body 4 using a screw thread or other known connection means.

[0052] The lid 10 has an inlet 12, a condensate pipe 40 is coupled to the inlet 12 using an inlet compression nut and washer assembly (not shown).

[0053] The first section of the condensate pipe 40 is coupled between the boiler 8 and inlet 12.

[0054] Similarly, the other end of the trap 2 has a condensate outlet 18 that connects to a condensate outlet pipe 50, using a removable clip 20.

[0055] The condensate outlet pipe 50 has a diameter of 21.5 mm and leads to a drainage system.

[0056] Once coupled between the condensate inlet 40 and outlet pipe 50, a side wall of the trap 2 can be connected to a wall using a sliding clip 22 securable to a wall clip bracket 24.

[0057] A flushing mechanism is located within the chamber 6 to flush condensate through the condensate outlet 18 into the condensate outlet pipe 50 and to the drainage system.

[0058] The flushing mechanism follows Pascal’s principle of communicating vessels. The structure and mechanism principally being similar to that of a Pythagorean cup.

[0059] The flushing mechanism primarily comprises a syphon air intake pipe 26 and a syphon outlet pipe 28.

[0060] The air intake pipe 26 is 10mm diameter and extends from the condensate outlet 18 to the top of the trap 2. The air intake pipe 26 comprises a substantially angled top portion 30.

[0061] The air intake pipe 26 is configured to allow air into the chamber 6 for pressure equalisation during syphoning.

[0062] The syphon outlet pipe 28 is formed with an inverted U-bend 32. The syphon outlet pipe 28 also typically has a diameter of 10mm. The syphon outlet pipe 28 has a syphon inlet 34 within the chamber 6 near to its base. The syphon outlet pipe 28 extends upwardly from the position of the syphon inlet 34, within the chamber 6, before reaching a U-bend 32 and extending downwardly to the condensate outlet 18.

[0063] The air intake pipe 26 extends higher than the summit of the U-bend 32 of the syphon outlet pipe 28, such that the air intake pipe 26 is protected from condensate, held in the chamber 6, flowing therethrough.

[0064] The syphon is configured to flush the chamber 6 when the volume of condensate collected is such that the U-bend 32 of the syphon outlet pipe 28 is submerged. Specifically, gravity creates a syphon effect through the outlet pipe 28, causing the majority of the volume of condensate of the chamber 6 to be emptied through the condensate outlet 18 when the U-bend 32 of the syphon outlet pipe 28 first becomes submerged .

[0065] The syphon inlet 34 of the syphon outlet pipe 28 has a larger cross-section than the syphon outlet pipe 28, of 22mm.

[0066] By virtue of the syphon inlet 34 and condensate outlet 18 having a larger cross-section than the syphon outlet pipe 28, the syphon outlet pipe serves as a constriction. The constriction is configured to cause a reduction in fluid pressure within the syphon outlet pipe 28 and thus a venturi effect between the chamber 6, the syphon outlet pipe 28 and condensate outlet 18 is created. This effectively provides an increased suction effect, drawing the condensate of the chamber 6 through the syphon outlet pipe 28 at an increased velocity.

[0067] The ratio of the diameter of the syphon inlet 34 and the syphon outlet pipe 28 is approximately 2:1 or greater.

[0068] The chamber 6 contains an alkaline compound (not shown) through which acidic condensate is neutralised. Therefore, the trap 2, exemplifies a hybrid condensate trap, whereby the condensate is buffered at a neutral pH to prevent corrosion of plumbing infrastructure, contamination to the local environment and caustic health hazards.

[0069] The lid 10 is removable from the main body 4 to gain access to the chamber 6 to replace orclean the syphon or replace the alkaline compound.

[0070] Figure 2 illustrates one non-limiting embodiment of a system and apparatus of a hybrid condensate trap 60 in accordance with the invention. Where technical features of the trap 60 are equivalent to technical features highlighted in the state of the art trap 2 the same reference signs have been used.

[0071] The hybrid condensate trap 60 comprises of a main body 4, a condensate inlet 12, a removable lid 10, a chamber 6, a condensate outlet 18, a tapered neutralising cartridge 42 and a syphon mechanism 62.

[0072] The condensate inlet pipe 40 and condensate outlet pipe 50 have an approximate diameter of 21.5 mm. The hybrid condensate trap 60 is coupled between the condensate inlet pipe 40 and condensate outlet pipe 50. The hybrid condensate trap 60 is fastened to the condensate inlet pipe 40 at the condensate inlet 12 via an inlet compression nut and washer system 44. The hybrid condensate trap 60 is fastened to the condensate outlet pipe 50 at the condensate outlet 18 via an outlet compression nut and washer system 52. The hybrid condensate trap 60 may be affixed to an adjacent wall by a mounting clip 22. By way of example, but not limited to, the hybrid condensate trap 60 may be an integral component of a boiler 8 or a retrofitted device coupled to an existing boiler 8.

[0073] The removable lid 10 comprises the condensate inlet 12. The removable lid 10 is reversibly fastenable to the main body 4. Byway of example, but not limited to, the removable lid may be fastenable to the main body 4 by a thread or any other suitable fastening means. The removable lid 10 comprises a rubber gasket 54. The rubber gasket 54 is configured to provide an airtight and watertight seal at the interface between the main body 4 and removable lid 10. Specifically, the rubber gasket is configured to prevent flue gasses and un-treated condensate from leaving the hybrid condensate trap 60.

[0074] The main body 4 is formed of fire-resistant material to allow for fitting external to the boiler. The main body 4 is textured to ensure easy handling when wet. The main body 4 comprises a chamber 6. The chamber 6 is configured to collect up to 0.87 L of neutralised condensate. The chamber 6 reversibly receives the tapered neutralising cartridge 42.

[0075] The chamber 6 further comprises a syphon mechanism 62. The syphon mechanism 62 is formed of a syphon inlet 34, a syphon outlet pipe 28, and an air intake pipe 26.

[0076] The syphon inlet 34 is located at a distal end of the syphon outlet pipe 28. The syphon outlet pipe 28 is located substantially centrally in the chamber 6. The syphon outlet pipe 28 couples the syphon inlet 34 to the condensate outlet 18. The condensate outlet 18 is located at a proximal end 64 of the syphon outlet pipe 28. The condensate outlet 18 is located substantially centrally in the base of the chamber 6 and orientated to extend substantially vertically downwardly therefrom.

[0077] The air intake 26 is located substantially centrally in the base of the chamber 6 and orientated to extend substantially vertically upwardly therefrom, such that the air intake 26 projects though and above the tapered neutralising cartridge 42. The air intake 26 has an approximate diameter of 10 mm. The air intake pipe 26 extends higher than the summit of the syphon outlet pipe 28, such that the air intake pipe 26 is protected from condensate flowing therethrough. The air intake pipe 26 comprises a substantially angled top portion (not shown) configured to prevent condensate dripping from the condensate pipe 40 into the air intake 26. However, in the circumstance that the syphon 62 becomes blocked, the air intake 26 is configured to act as an emergency overflow pipe.

[0078] The air intake 26 is coupled to the condensate outlet 18, at a proximal end 62, such that air in the condensate outlet 18 may be drawn into the chamber 6, via the air intake 26. The coupling of the air intake 26, the condensate outlet 18 and chamber 6 is configured to ensure the air pressure in the chamber 6 is equal to the air pressure of the condensate outlet 18. The orifice, at a distal end (not shown) of the air intake 26 has a proximity to the underside of the removable lid 10 configured to allow for sufficient flow of air to equalise the pressure between the chamber 6 and the condensate outlet 18.

[0079] The proximal end 62 of the air intake 26 and the proximal end 64 of the syphon outlet pipe 28 are configured such that condensate expelled from the syphon outlet pipe 28 is not drawn up the air intake 26 during pressure equalisation of the chamber 6. In the preferred embodiment, the proximal end 62 of the intake 26 terminates higher in the condensate outlet 18 than that of the proximal end 64 of the syphon outlet pipe 28. The configuration of the respective proximal end 62 of the air intake 26 and proximal end 64 of the syphon outlet pipe 28 therefore increases air pressure re-equalisation and therefore, increases the rate of syphoning.

[0080] The syphon inlet 34 is located substantially towards the bottom of the chamber 6. The syphon inlet 34 is orientated such that the orifice of the syphon inlet 34 is substantially parallel to the base of the chamber 6. The orifice of the syphon inlet 34 has a proximity to the base of the chamber 6 configured to allow the syphon to drain the majority of collected condensate in the chamber 6, byway of example 0.8 Lof condensate of a 0.87 L capacity chamber 6. The syphon inlet 34 is configured to provide a decreasing stepped diameter, whereby the orifice of the syphon inlet 34 is wider in diameter than the syphon outlet pipe 28. By way of example the diameter of the syphon inlet 34 is stepped from 22 mm to 15 mm and then 10 mm; wherein 10 mm is equal to the diameter of the syphon outlet pipe 28.

[0081] Concordant to the hybrid trap 2, the syphon inlet 34 and condensate outlet 18, of the hybrid condensate trap 60, have a larger diameter than the syphon outlet pipe 28. The syphon outlet pipe 28 therefore serves as a constriction. The constriction is configured to cause a reduction in fluid pressure within the syphon outlet pipe 28 and therefore a venturi effect between the chamber 6, the syphon outlet pipe 28 and condensate outlet 18 is created. This effectively provides an increased suction effect, drawing the condensate of the chamber 6 through the syphon outlet pipe 28 at an increased velocity.

[0082] The syphon 62 of the trap 60 comprises an asymmetric U-bend 32; wherein, the U-bend 32 comprises a first bend 48 and second bend 46. The first bend 48 has a higher summit than the second bend 46; whereby, the syphon 62 is configured to draw syphoned condensate to the summit of the first bend 48 first. The second bend 46 is configured to accelerate the velocity by reducing drag of the syphoned condensate. Therefore, the asymmetric U-bend 32 of the syphon 62 provides an enhanced syphoning effect over the state of the art and reduces the risk of residual condensate being trapped within the syphon after flushing.

[0083] The syphon 62 is configured to flush a large volume of neutralised condensate from the chamber 6, in a rapid manner, when the volume of condensate collected is such that the first bend 48 of the syphon 62 is submerged. Specifically, gravity creates a syphon effect through the syphon outlet pipe 28, causing the majority of the volume of condensate of the chamber 6 to be emptied through the condensate outlet 18 when the first bend 48 of the syphon 62 first becomes submerged. Furthermore, the stepped configuration of the syphon inlet 34 is designed to allow a fast start to the syphon mechanism. Furthermore still, the combination of the syphon inlet 34 stepped configuration and the asymmetric syphon U-bend 32 are configured to allow a fast-start-self-starting flush of a large volume of neutralised condensate.

[0084] The tapered neutralising cartridge 42 is configured in a hybrid form comprising a of a hollow frustum base 66 and hollow cylinder top 68. The base 66 of the tapered neutralising cartridge 42 comprises one or more channels (not shown) configured to allow neutralised condensate to pass into the chamber 6. The tapered neutralising cartridge 42 is orientated such that the hollow cylinder top 68 is substantially located at the interface between the main body 4 and removable lid 10. The narrowest portion is of the tapered neutralising cartridge 42 base 68 is located at a distal end with respect the interface between the main body 4 and removable lid 10. The tapered neutralising cartridge 42 is configured with a complimentary recessed profile to accommodate a projecting syphon mechanism 62 and air intake pipe 26.

[0085] The tapered neutralising cartridge 42 is configured to hold alkaline material such that gravity concentrates the alkaline material at the channels at the base 66. This ensures that the condensate percolates through, and is neutralised by, the alkaline material held therewith.

[0086] The frustum portion and complementary recessed profile of the tapered neutralising cartridge 42 are configured to position the tapered neutralising cartridge 42 lower than the summit of the first bend 48 of the syphon 62. Consequently, in comparison to state of the art hybrid traps, the upper portion of the chamber 6, has a reduced effective capacity. The reduced effective capacity of the upper portion of the chamber 6 varies the rate of condensate rise with respect to total volume captured in the chamber 6. Therefore, as the captured condensate rises to a level equal to, or greater than, the level defined by the base 66 of the tapered neutralising cartridge 42 the condensate level increases more rapidly. Thus, incomparison to state of the art hybrid traps, the invention as claimed achieves a larger neutralised condensate volume flush with a fast-start-self-starting flush.

[0087] The combination of a stepped syphon inlet 34, asymmetrical U-bend 32, absence of alkaline material at the base of the chamber 6, configuration of the proximal end 62 of the air intake 26 and proximal end 64 of the syphon outlet pipe 28 and reduction of the effective capacity of the upper portion of chamber 6 interact to provide an enhanced, fast-start-self-starting, high volume, flushing mechanism of the hybrid condensate trap 60. Therefore, the risk of residual condensate trickling / dripping in the condensate outlet 50 is reduced. Consequently, in comparison to the state of the art the risk of the condensate outlet 50 becoming occluded by freezing is reduced.

[0088] Additionally, the combination of the removable lid 10 and tapered neutralising cartridge allow for simplified access to the syphon mechanism 62 and replenishment of the alkaline material. The tapered neutralising cartridge is configured to be replaced at each boiler service.

[0089] Figure 3 is a schematic illustration of the method of installation of the hybrid condensate traps 2 and 60. Initially the condensate pipe is segmented into a condensate inlet pipe 40 and condensate outlet pipe 50. In segmenting a gap 36 is formed, suitable to couple the hybrid condensate traps 2 and 60 therebetween. The bracket 24 is secured to the internal side of the neighbouring wall using a drill and screws or other common attachment mechanism.

[0090] The hybrid condensate traps 2 or 60 are then placed in the gap 36 and the condensate inlet pipe 40 of the condensate pipe is secured over through its condensate inlet 12 using a fastening means such as, but not limited to, an inlet compression nut and washer system 44. At the same time, the condensate outlet pipe 50 of the condensate pipe is secured to the condensate outlet 18 using a fastening means such as, but not limited to, a removable clip 20 or an outlet compression nut and washer system 52.

[0091] The condensate outlet pipe 50 is configured to extend through a wall to the outdoors wherein the neutralised condensate is drained.

[0092] It will be appreciated that the forgoing is merely exemplary of a hybrid condensate trap in accordance with the invention and that modifications can readily be made thereto without departing from the true scope of the invention as set out in the appended claims.

Claims

CLAIMS1. A condensate trap for capturing and releasing condensate; the trap comprising a main body, a condensate inlet, a condensate outlet and a syphoning mechanism; wherein, the main body is coupled between the condensate inlet and condensate outlet; the main body comprises a chamber configured to collect condensate; the syphon mechanism is located within the chamber; wherein, the syphon mechanism comprises of a syphon outlet pipe, syphon inlet and air intake; the syphon inlet is located at the distal end of the syphon outlet pipe; the condensate outlet is coupled to the proximal end of the syphon outlet pipe; whereby, the syphon outlet pipe is configured to form an asymmetric U-bend comprising a first and second bend; the first bend has a higher summit than the second bend; and the first and second bends are configured such that condensate is syphoned to the summit of the first bend first.

2. A condensate trap in accordance with claim 1 , wherein the condensate trap comprises a condensate neutralising cartridge.

3. A condensate trap in accordance with claim 2, wherein the chamber is configured to reversibly receive the condensate neutralising cartridge.

4. A condensate trap in accordance with claims 2 or 3, wherein the condensate neutralising cartridge has a hollow frustrum base and hollow cylinder top.

5. A condensate trap in accordance with claims 2 to 4, wherein the condensate neutralising cartridge comprises one or more channels, configured to allow neutralised condensate to pass into the chamber.

6. A condensate trap in accordance with claims 2 to 5, wherein the condensate neutralising cartridge is configured with a complimentary recessed profile to accommodate the syphon mechanism.

7. A condensate trap in accordance with claims 2 to 6, wherein the frustrum portion, of the condensate neutralising cartridge is configured to position the condensate neutralising cartridge lower than the summit of the first bend of the syphon outlet pipe.

8. A condensate trap in accordance with claims 1 to 7, wherein the air intake and syphon are located substantially centrally in the base of the chamber and orientated to extend vertically upward therefrom.

9. A condensate trap in accordance with claims 1 to 8, wherein the air intake projects further than the summit of the syphon outlet pipe with respect to the base of the chamber.

10. A condensate trap in accordance with claims 1 to 9, wherein the air intake comprises an angled top portion, configured to prevent condensate dripping into the air intake from the condensate inlet.

11. A condensate trap in accordance with claims 1 to 10, wherein the air intake is configured to act as an emergency overflow pipe.

12. A condensate trap in accordance with claims 1 to 11, wherein a proximal end of the air intake is coupled to the condensate outlet, configured such that an air channel is formed between the condensate outlet and chamber.

13. A condensate trap in accordance with claims 1 to 12, wherein the proximal end of the air intake and a proximal end of the syphon outlet pipe are located within the syphon outlet and configured such that condensate expelled from the syphon outlet pipe is not drawn up the air intake.

14. A condensate trap in accordance with claims 1 to 13, wherein the proximal end of the air intake terminates ata location higher in the condensate outlet than thatof the terminus of the proximal end of the outlet pipe.

15. A condensate trap in accordance with claims 1 to 14, wherein the syphon inlet is orientated such that an orifice of the syphon inlet is substantially parallel to the base of the chamber.

16. A condensate trap in accordance with claims 1 to 15, wherein the orifice of the syphon inlet is configured to have a proximity to the base of the chamber, such that, at least 90 % the collected condensate is syphoned.

17. A condensate trap in accordance with claims 1 to 16, wherein the syphon inlet is configured to have a decreasing stepped diameter.

18. A condensate trap in accordance with claim 17, wherein the syphon inlet is stepped from approximately 22 mm to 15 mm, to 10 mm.

19. A condensate trap in accordance with claims 1 to 18, wherein the syphon inlet and condensate outlet have a larger cross-section than that of the syphon outlet pipe.

20. A condensate trap in accordance with claims 1 to 19, wherein the condensate trap comprises a removable lid configured to be reversible fastenable to the main body.

21. A condensate trap in accordance with claim 20, wherein the removable lid comprises a rubber gasket.

22. A condensate trap in accordance with any preceding claims, wherein the main body is formed of a fire-resistant material.

23. A condensate trap in accordance with any preceding claims, wherein the main body is textured to ensure easy handling when wet.

24. A condensate trap in accordance with any preceding claims, wherein the condensate trap is integral to a boiler.

25. A condensate trap in accordance with claims 1 to 23, wherein the condensate trap is configured to be retrofittable to a boiler.

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