Condensing Gas Boiler Assembly With Integrated Fume and Hydraulic Closure
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Solution Overview
Problem
Existing condensation gas boilers are hindered by high production costs and large size, limiting market access due to complex assembly requirements and numerous parts.
Innovation Solution
The gas boiler integrates the fume evacuation and hydraulic assemblies to close the casing, reducing the number of parts and eliminating the need for additional spacing members, allowing for easier assembly and dismantling, and enabling a smaller design by using integrally made polymeric components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a separate cover and multiple conduit connections are used to close the casing, then the gas boiler can be assembled with standardized components, but the number of parts increases and assembly becomes more complex
Solution Approach 1:
The patent combines the cover function with the fume evacuation assembly and hydraulic assembly into a single integrated structure. The fume evacuation assembly includes a cover portion that closes the casing opening, while the hydraulic assembly integrates water circuit connections. This merging eliminates the need for separate covers and multiple discrete conduit connections, reducing the total number of parts while maintaining standardized manufacturing benefits.
Solution Approach 2:
The integrated assembly serves multiple functions simultaneously: the cover portion closes the casing, the fume evacuation assembly handles combustion fume removal, and the hydraulic assembly manages water circulation. This multi-functionality allows a single component to replace what would traditionally require several separate parts, simplifying the overall structure.
2Manufacturing precision
If multiple spacing members are used to maintain the annular gap between the helix and casing, then the helix can be properly positioned, but the number of parts increases and assembly time increases
Solution Approach 1:
The spacing function is merged into the integrated fume evacuation and hydraulic assembly. The cover portion and assembly structure inherently maintain the required annular gap between the helix and casing without requiring separate spacing members. This integration eliminates additional parts while ensuring proper helix positioning through the design of the integrated assembly itself.
3Ease of manufacture
If traditional separate components are used for fume evacuation and hydraulic assemblies, then each component can be manufactured independently, but the overall gas boiler size increases
Solution Approach 1:
The fume evacuation assembly and hydraulic assembly are merged into a single integrated unit that closes the casing. This integration allows the assemblies to share common structural elements and space, reducing the overall volume required compared to having separate components. The integrated design enables compact arrangement of fume evacuation channels and hydraulic circuits within the same structural envelope.
Data Source
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Figure 2
AI summary
A gas boiler, in particular a condensation gas boiler for producing hot water along a water circuit (C1l) has a gas combustion and premixing assembly (2) for producing thermal energy and combustion fumes; a heat exchanging assembly (3) having a casing (4) having an open end, and an elongated hollow member (5) wound, at least in part, in a helix (16) and defining a portion of the water circuit (C1) in said casing (4); a fume evacuation assembly (6) for evacuating the combustion fumes from the heat exchanging assembly (3); and a hydraulic assembly (7) for circulating the water in the water circuit (C1); wherein the casing (4) is clamped at the open end by the fume evacuation assembly (6) and the hydraulic assembly (7), which are so shaped so as to close the open end of the casing (4).