Condensing Boiler Flat-Gap Channel for Uniform Heat Transfer
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Solution Overview
Problem
Existing boilers face challenges in achieving efficient heat transfer and are prone to calcification and thermal stresses, which affect their performance and longevity.
Innovation Solution
The boiler features a flow guide configured as a flat gap channel that fully encloses the chamber, allowing for even heat distribution and reduced thermal stresses, with supporting elements to maintain stability, and includes a secondary channel for enhanced condensation and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the chamber is cooled by flow guides arranged below the chamber with crossing ribs or grooves, then heat transfer from exhaust gas to water takes place, but thermal stresses on the material increase and calcification risk arises
Solution Approach 1:
The invention transitions from a conventional flow guide arrangement (below the chamber) to a peripheral flow guide arrangement that fully encloses the chamber periphery. This dimensional change allows heat transfer to occur uniformly around the entire chamber circumference rather than concentrated in specific areas, distributing thermal stresses and preventing calcification while maintaining efficient heat transfer from exhaust gas to water.
Solution Approach 2:
The flow guide is designed with locally adapted features including supporting elements (nubs) at specific locations to prevent plate element deformation, and a peripheral arrangement that provides localized cooling zones where needed. This local quality approach ensures uniform heat distribution and reduces thermal stresses without compromising overall heat transfer efficiency.
2Temperature
If multiple plate elements are arranged in a sandwich-like manner to form the chamber, then heat transfer surface area increases, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The invention merges the flow guide function with the chamber structure by integrating the flow guide into the peripheral arrangement of plate elements. This combination eliminates the need for separate complex flow guide components arranged below the chamber, while maintaining the sandwich-like plate element configuration for enhanced heat transfer surface area. The integrated design simplifies manufacturing while preserving thermal efficiency.
3Reliability
If the chamber is fully enclosed by a flow guide designed as a flat gap channel, then heat transfer becomes more uniform and thermal stresses are reduced, but the channel length increases relative to channel height
Solution Approach 1:
The invention adopts a peripheral flat gap channel arrangement that encloses the chamber around its circumference, transforming the conventional below-chamber flow guide into a surrounding structure. This dimensional reconfiguration allows the channel to wrap around the chamber, achieving uniform heat distribution and reduced thermal stresses while managing the length-to-height ratio through the peripheral geometry rather than extending linearly in one direction.
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
This design enhances heat transfer efficiency, reduces calcification risks, and allows for the creation of a compact, high-efficiency condensing boiler with improved condensation rates and cost-effectiveness.
Implementation Method 1
heat transfer from the hot exhaust gas into the water which flows around the body from which the plate element is formed takes place
Implementation Method 2
the hot exhaust air thus flows out of the chamber into the flow guides provided with crossing ribs or grooves
Implementation Method 3
thermal stresses during entry into the flat gap channel are minimised via an even distribution in peripheral direction
Implementation Method 4
In order to be able to operate the boiler according to the invention as a condensing boiler
Data Source
AI summary
A boiler includes a chamber designed to receive and conduct hot exhaust gases, the chamber being enclosed by two plate elements which have an angled design and are arranged relative to one another in a sandwich-like manner, and the chamber being connected to a flow guide that is designed between the plate elements and used to cool the hot exhaust gases. The flow guide is designed in the form of a flat gap channel which fully encloses the periphery of the chamber.