Heat exchanger unit and method for manufacturing the same
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Solution Overview
Problem
Conventional water-heating devices, such as condensing boilers, face challenges with manufacturing complexity and high costs due to the use of plate-type heat exchangers, which also suffer from corrosion and inefficient thermal insulation, especially when condensate from combustion gases interacts with heat exchanger components.
Innovation Solution
A heat exchanger unit utilizing a fin-tube type heat exchange device with thermal insulation pipes to prevent condensate corrosion and reduce manufacturing costs, featuring a combustion chamber with integrated heat insulation pipes that thermally isolate the combustion chamber and a brazing method for assembly, ensuring efficient heat transfer and reduced assembly complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a plate type heat exchanger unit is used, then thermal efficiency is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent replaces expensive plate type heat exchangers with a more economical fin-tube type heat exchanger. While plate heat exchangers offer superior thermal efficiency, they are complex and costly to manufacture. The fin-tube design provides a cost-effective alternative that maintains adequate thermal performance while significantly simplifying the manufacturing process and reducing overall system cost.
Solution Approach 2:
The patent modifies the heat exchanger design by incorporating thermal insulation pipes around the fin-tube heat exchanger. This parameter change addresses the thermal efficiency limitation of fin-tube designs by adding insulation to reduce heat loss, thereby improving overall thermal performance without requiring the complex plate type construction.
2Loss of energy
If a plate type heat exchanger unit is used, then thermal efficiency is improved, but manufacturing cost increases
Solution Approach 1:
The patent substitutes expensive plate type heat exchangers with more affordable fin-tube heat exchangers. The fin-tube design uses simpler manufacturing processes and less expensive materials, significantly reducing manufacturing cost while maintaining functional adequacy. The thermal insulation pipes are added to compensate for the lower inherent thermal efficiency of the fin-tube design.
3Ease of manufacture
If thermal insulation is not adequately provided, then manufacturing cost is reduced, but corrosion from condensate increases
Solution Approach 1:
The patent introduces thermal insulation pipes as an intermediary protective layer around the fin-tube heat exchanger. These insulation pipes serve dual purposes: they provide thermal insulation to maintain thermal efficiency and create a protective barrier that prevents condensate from directly contacting the heat exchanger surfaces, thereby preventing corrosion without requiring expensive corrosion-resistant materials.
Solution Approach 2:
The patent uses relatively inexpensive thermal insulation pipes to provide both thermal insulation and corrosion protection. This approach is more economical than using expensive corrosion-resistant alloys or complex protective coating systems, achieving reliable corrosion protection through a simple, cost-effective insulation barrier.
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 proposed solution enhances thermal efficiency while minimizing corrosion and manufacturing costs by using fin-tube heat exchangers with thermal insulation pipes, ensuring effective heat transfer and improved durability in water-heating devices.
Implementation Method 1
a heat exchanger for a condensing boiler, the heat exchanger being located under the combustion chamber and including heat exchange pipes that receive heat generated by the combustion reaction and heat heating-water flowing through the heat exchange pipes
Implementation Method 2
a combustion chamber heat insulation pipe that is disposed adjacent to the combustion chamber and that receives the heating-water and allows the heating-water to flow therethrough to thermally insulate the combustion chamber
Data Source
AI summary
A heat exchanger unit according to the present disclosure includes a combustion chamber in which a flame caused by a combustion reaction is located, a heat exchanger for a condensing boiler, the heat exchanger being located under the combustion chamber and including heat exchange pipes that receive heat generated by the combustion reaction and heat heating-water flowing through the heat exchange pipes and a main case having the heat exchange pipes accommodated in an interior space thereof, and a combustion chamber heat insulation pipe that is disposed adjacent to the combustion chamber and that receives the heating-water and allows the heating-water to flow therethrough to thermally insulate the combustion chamber.