Condensing Heat Exchanger Composite Casing to Reduce Assembly Cost
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Solution Overview
Problem
Existing condensing heat exchangers have a complex structure with many parts, leading to high manufacturing and assembly costs, and require axial stress tie rods to prevent deformation, making them expensive and time-consuming to produce.
Innovation Solution
A condensing heat exchanger design featuring a tubular metal ferrule and composite plastic bottom, with fastening tabs and slots for secure assembly, eliminating tie rods and reducing parts while ensuring axial stress resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If retaining plates and axial mechanical restraint tie rods are added to prevent spacing movement of tube turns, then the tube spacing stability is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the retaining plate and tie rod functions into an integrated structure where the retaining plate itself provides axial mechanical restraint through its design features (such as engagement protrusions and recesses), eliminating the need for separate tie rods and reducing the total number of parts while maintaining tube spacing stability
Solution Approach 2:
The retaining plate is designed to perform multiple functions simultaneously: it retains the tube winding in place, provides axial mechanical restraint against spacing movement, and structurally connects to the casing. This multi-functionality reduces the need for additional specialized components
2Strength
If the casing is made of thick heat-resistant plastic material with good mechanical and thermal resistance, then the thermal insulation and mechanical strength are improved, but the manufacturing cost increases
Solution Approach 1:
The patent employs composite construction by combining metal (ferrule) and plastic materials in the casing structure. The metal ferrule provides the necessary mechanical strength and structural support, while the plastic material provides thermal insulation. This composite approach allows using thinner walls than solid thick plastic would require, reducing manufacturing cost while maintaining both strength and thermal resistance properties
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 redesigned exchanger reduces costs and simplifies assembly while maintaining structural integrity, achieving lower production expenses and efficient operation without deformation.
Implementation Method 1
at least one bundle of helically wound tubes made of a thermally conductive material and inside which water to be heated flows. This tube is itself disposed inside a casing and a burner is disposed axially inside said winding, so that the hot gases produced by the burner pass through the spaces between the adjacent turns and heat the water flowing in the tube
Implementation Method 2
a ferrule is disposed between the tube and the interior of the plastic casing, in order to ensure a heat shield function able to insulate the casing from the heat emitted by the flue gases
Data Source
AI summary
A condensation heat exchanger including at least one helically-coiled tube, inside which a fluid to be heated can circulate, a deflector, and a shell mounted inside which the tube, the shell having a gas-discharge sleeve having a bottom and a facade for feeding and/or producing a hot gas, inside the shell. The shell comprises a tubular metallic shroud closed at its two ends by a facade and a bottom, wherein the bottom is made of composite plastic, the rear edge of the shroud has a plurality of fastening tongues, the bottom has, at its periphery, a plurality of fastening slots arranged along at least part of its circumference, each fastening slot bordered longitudinally by a first longitudinal rib projecting outwardly, and wherein each fastening tongue is inserted into a fastening slot and folded twice around the first rib.