Angled Cross-Tube Exhaust for Low-Back-Pressure Flue Merging
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Solution Overview
Problem
Existing heating systems face challenges with back pressure when merging flue flows and require separate components for condensate drainage, leading to increased costs and complexity in installation.
Innovation Solution
A modular exhaust system featuring a cross tube with a condensate drainage aperture and a vertically connected tube, where the cross tube's axis is angled to reduce back pressure and prevent inadvertent condensate escape, allowing for efficient merging of flue flows and integrated condensate drainage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If stainless steel exhausts are modified with apertures for condensate drainage, then condensate drainage function is added, but the exhaust structure becomes more complex and installation becomes more difficult
Solution Approach 1:
The patent combines the condensate drainage aperture and the exhaust aperture into a single integrated exhaust component. The condensate drainage aperture is positioned at the bottom of the exhaust while the exhaust aperture is at the top, allowing both functions to be performed by a single piece rather than requiring separate components for exhaust and condensate drainage.
Solution Approach 2:
The exhaust component is designed to perform multiple functions simultaneously: it serves as both the exhaust gas outlet and the condensate drainage outlet. This multi-functional design eliminates the need for separate condensate drainage components and simplifies the overall exhaust system structure.
2Adaptability or versatility
If two flue flows are merged at right angles using a stainless steel tee, then another flue flow can be combined, but back pressure increases significantly
Solution Approach 1:
The patent uses an asymmetric elbow design where the second heat exchanger is positioned at a specific angle (e.g., 45 degrees) relative to the first heat exchanger, rather than at a right angle. This asymmetric angular arrangement allows flue flows to merge more smoothly, reducing turbulence and back pressure compared to traditional right-angle configurations.
Solution Approach 2:
The patent employs curved transition sections in the exhaust piping to facilitate smooth merging of flue flows. Instead of sharp angular joints, curved pathways guide the flue gases from different directions into a unified flow path, minimizing flow separation and reducing back pressure.
3Reliability
If multiple separate components are used for exhaust and condensate drainage, then each function can be optimized independently, but fabrication costs increase
Solution Approach 1:
The patent integrates multiple functions into a single exhaust component that includes both the exhaust aperture and the condensate drainage aperture. This consolidation reduces the number of separate parts that need to be fabricated, assembled, and sealed, thereby lowering fabrication costs while maintaining functional reliability.
4Productivity
If condensate drainage aperture is disposed at lower portion of horizontal tube, then condensate can be drained effectively, but inadvertent escape of condensate may occur
Solution Approach 1:
The patent positions the condensate drainage aperture at a specific location on the exhaust component - at the bottom surface but with controlled dimensions and orientation. This localized design allows condensate to drain effectively under normal operation while the aperture geometry and positioning prevent condensate from escaping inadvertently during system operation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The modular exhaust system minimizes back pressure and simplifies installation by integrating condensate drainage, reducing the need for multiple components and enhancing the efficiency of flue flow merging.
Implementation Method 1
the central axis of the cross tube is not disposed perpendicularly with respect to the central axis of the vertical tube such that a flue flow from a second heat exchanger is facilitated through the vertical tube of the first modular exhaust, reducing back pressure in the flue flow from the first heat exchanger
Implementation Method 2
a condensate drainage exit aperture disposed on a bottom portion of the cross tube, wherein the condensate drainage exit aperture is configured for draining condensate from the first heat exchanger
Data Source
AI summary
A modular exhaust configured for exhausting a flue flow of a heat exchanger, the modular exhaust including a cross tube including an inlet end, an exit end and a central axis, wherein the cross tube configured for receiving the flue flow at the inlet end and channeling the flue flow to the exit end; a condensate drainage exit aperture disposed on a bottom portion of the cross tube, the condensate drainage exit aperture configured for draining condensate from the first heat exchanger; and a vertical tube including a central axis, a top end and a bottom end, the cross tube configured to be connected at the exit end of the cross tube to a portion of the vertical tube disposed between the top end and the bottom end, the central axis of the cross tube is not disposed perpendicularly with respect to the central axis of the vertical tube.