Condensation heat exchanger
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Solution Overview
Problem
Condensation heat exchangers have a high number of parts, leading to increased manufacturing costs and complexity, with axial stress tie rods required to prevent deformation, making them expensive and difficult to assemble.
Innovation Solution
A condensation heat exchanger design featuring a tubular metal shroud with a composite plastic bottom, utilizing fixing tabs and slots with double-folded tongues to secure the ferrule, eliminating tie rods and reducing parts while ensuring axial constraint of the helically wound tube.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If retaining plates and axial mechanical tensioning straps are used to limit axial movement of tube coils, then axial movement is prevented, but the number of parts increases and manufacturing cost increases
Solution Approach 1:
The patent combines the functions of retaining plates and axial mechanical tensioning straps into the casing structure itself. The casing includes axial constraint elements integrated into its walls that directly engage with the tube coils, eliminating the need for separate retaining plates and tensioning straps. This merging reduces the number of parts while maintaining axial movement prevention.
2Strength
If the casing is made of thick material to withstand hot gases and ensure tube compression, then mechanical strength and thermal resistance are improved, but manufacturing cost increases
Solution Approach 1:
The patent applies local quality by using thick material only in specific areas of the casing where mechanical strength and thermal resistance are critical (such as areas contacting hot gases and supporting tube compression), while using thinner material in other areas where full thickness is not required. This localized approach reduces overall material consumption and manufacturing cost while maintaining necessary performance.
Solution Approach 2:
The patent employs composite materials in the casing construction, combining materials with different properties to achieve both mechanical strength and thermal resistance. The casing may include layers or sections with different material compositions optimized for specific functions, reducing the need for uniformly thick expensive materials throughout the entire structure.
3Reliability
If many parts are used in the heat exchanger design, then functional requirements are met, but assembly time increases and manufacturing becomes more expensive
Solution Approach 1:
The patent merges multiple functional components into fewer integrated parts. The casing is designed to simultaneously provide structural support, thermal insulation, axial constraint, and gas flow pathways, eliminating the need for separate components for each function. This reduces the total number of parts and simplifies assembly procedures.
Solution Approach 2:
The patent implements multi-functionality in the casing design, where a single component performs multiple functions. The casing structure serves as both the containment vessel, the thermal barrier, the axial constraint mechanism, and the gas distribution system, reducing the number of parts needed while meeting all functional requirements.
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 reduces the overall number of parts, lowers manufacturing costs, and prevents deformation of the envelope, while ensuring effective axial stress management and thermal performance.
Implementation Method 1
at least one tube bundle, wound in a helix, made of a thermally good conductor material, and through which water to be heated circulates
Implementation Method 2
a ferrule is placed between the tube and the inside of the plastic casing, in order to provide a thermal shield function, capable of insulating the casing from the heat emitted by the burnt gases
Data Source
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AI summary
The present invention relates to a condensation heat exchanger comprising at least one helically-coiled tube, inside which a fluid to be heated can circulate, a deflector, and a shell inside which said tube is mounted, this shell being provided with a gas-discharge sleeve, with a bottom and with a façade that supports means for feeding and/or for producing a hot gas, inside the shell. This exchanger is noteworthy in that said shell comprises: a tubular metallic shroud closed at its two ends by a façade and by a bottom, in that the bottom is made of composite plastic, in that the rear edge of the shroud has a plurality of fastening tongues, in that the bottom has, at its periphery, a plurality of fastening slots arranged along at least part of its circumference, each fastening slot being bordered longitudinally by a first longitudinal rib that projects outwardly, and in that each fastening tongue is inserted into a fastening slot and folded twice around said first rib.