HVAC Burner Box Airflow Diffuser for Compact Low-CO Combustion
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Solution Overview
Problem
Residential HVAC systems face challenges in compact installation due to increased space requirements with additional components, and existing burner designs struggle to achieve complete fuel combustion and minimize carbon monoxide production in cramped spaces.
Innovation Solution
A compact HVAC burner box design featuring a burner bank, manifold, and air director with a diffuser that directs airflow efficiently to ensure complete combustion, utilizing a shroud and air director configuration to maximize energy extraction while minimizing carbon monoxide production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If additional components (humidifiers, electronic air filters, UV sterilizers) are included in the HVAC assembly, then functionality and performance are improved, but the space required for installation increases
Solution Approach 1:
The patent combines the burner bank, manifold, and air director into a single integrated burner box assembly. This merging of components that were traditionally separate allows the HVAC system to maintain enhanced functionality while reducing the overall installation space required, as the components share common structural support and airflow pathways.
Solution Approach 2:
The burner box enclosure serves multiple functions simultaneously: it provides structural support for the burner bank and manifold, acts as an airflow distribution chamber, and serves as a mounting structure for the air director. This multi-functionality eliminates the need for separate housings or support structures, thereby reducing installation space.
2Volume of moving object
If the burner bank is oriented with the outlet end toward the first end of the enclosure, then space utilization is improved, but airflow distribution to the manifold may be compromised
Solution Approach 1:
The air director acts as an intermediary component between the airflow source and the manifold. It includes a diffuser with multiple openings that redirect and distribute airflow, ensuring that even with the compact burner bank orientation, adequate airflow reaches the manifold for proper combustion operation.
Solution Approach 2:
The diffuser within the air director uses multiple openings arranged in different directions to distribute airflow in three-dimensional space. This allows airflow to reach the manifold from various angles, compensating for the compact orientation of the burner bank and maintaining proper air-fuel mixing.
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 design achieves high energy extraction efficiency with minimal carbon monoxide production, facilitating installation in limited spaces and improving furnace performance by ensuring uniform airflow and mixing of gas and air within the burners.
Implementation Method 1
The diffuser includes a plurality of openings located therethrough. The diffuser is configured to direct a first portion of a received airstream through the openings and toward the burner bank.
Implementation Method 2
a burner bank, a manifold and an air director. The burner bank is oriented such that an outlet end of the burner bank is directed toward a first end of the enclosure.
Data Source
AI summary
An HVAC burner box includes a burner bank, a manifold and an air director located within an enclosure. The burner bank is oriented such that an outlet end of the burner bank is directed toward a first end of the enclosure. The manifold is located within the enclosure and adjacent an inlet end of the burner bank. The air director has a diffuser that is coupled to a side of the enclosure. The diffuser includes a plurality of openings located therethrough. The diffuser is configured to direct a first portion of a received airstream through the opening and toward the burner bank. The diffuser is further configured to send a second portion of the received airstream toward the manifold.