Condensing Heat Exchanger Layout Without a Separate Gas Collector
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Solution Overview
Problem
High efficiency hot air heating appliances have complex and costly assemblies due to separate primary and secondary heat exchangers connected by an expensive stainless steel collector, making optimization and production difficult.
Innovation Solution
The collector is integrated into the heat exchanger elements, allowing for simultaneous construction of primary and secondary sections, reducing the need for additional components and simplifying assembly, with modular design enabling flexible adjustment of segments and elements for optimized efficiency and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If separate primary and secondary heat exchangers are connected by a stainless steel collector, then the heat exchanger can achieve high efficiency through condensing water vapour, but the assembly becomes complex and costly
Solution Approach 1:
The patent merges the collector and secondary heat exchanger into a single integrated component. The collector serves dual functions: distributing combustion gases to multiple secondary elements and acting as the secondary heat exchanger itself. This eliminates the need for separate collectors and reduces the number of connection points, thereby simplifying assembly while maintaining high efficiency through water vapour condensing.
2Adaptability or versatility
If separate primary and secondary heat exchangers are connected by a collector, then the heat exchanger can function with distinct primary and secondary sections, but the manufacturing and assembly become difficult to optimise
Solution Approach 1:
The collector and secondary heat exchanger are manufactured as a single integrated component, eliminating the need for separate manufacturing processes and assembly steps. This integration simplifies production while maintaining the functional distinction between primary and secondary sections, allowing for easier optimization of the overall heat exchanger design.
Solution Approach 2:
The heat exchanger is divided into modular segments, each containing a primary element and associated secondary elements. This segmentation allows for flexible configuration and easy manufacturing of standardized modules that can be assembled in different quantities to meet specific heating requirements, thereby optimizing both production and functionality.
3Ease of operation
If a collector is used to distribute flue gases, then the gas flow can be distributed to secondary elements, but an additional expensive component is required
Solution Approach 1:
The collector is designed to perform multiple functions: it distributes combustion gases to multiple secondary elements and simultaneously acts as a secondary heat exchanger where water vapour condenses. This multi-functionality eliminates the need for separate collector and secondary heat exchanger components, reducing material costs while maintaining effective gas flow distribution.
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 approach results in a simpler, cost-effective, and highly efficient heat exchanger with reduced risk of gas leaks and increased strength, capable of higher efficiency than traditional models while allowing for customizable configurations.
Implementation Method 1
heat transfer occurs from the combustion gases to the airflow
Implementation Method 2
the combustion gases are guided through one or more elements that each form a flow channel with an inlet and outlet for these gases, while the airflow to be heated is guided along the outside of these elements
Implementation Method 3
the combustion gases are further cooled by the airflow in order to allow the water vapour in the combustion gases to condense, whereby, as is known, energy is released with which the airflow can be heated
Data Source
AI summary
Heat exchanger for a high efficiency hot air heating appliance (1), with at least one segment (5) and with a primary section (14) and, viewed in the flow direction (A), followed by a secondary condensing section (15), whereby the segment (5) consists of at least one primary element (16) and at least two secondary condensing elements (19), that form part of the secondary condensing section (15) of the segment (5), and the inputs (20) of each of them are connected in parallel to the output (18) of the primary element (16) in such a way that the gas flow coming from the primary element (16) is divided over the secondary condensing elements (19) connected to it.