Integrated Manifold for Hydrogen Gas Boiler Safety
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Solution Overview
Problem
Current gas boilers are not suitable for combustion of hydrogen due to safety risks and require expensive modifications, and existing solutions increase the size and risk of malfunction by adding components like Venturi mixers and flashback suppressors.
Innovation Solution
A compact, one-piece hollow frame structure manifold with a mixer located downstream the blower, integrating a mixer and suppressor to efficiently mix and distribute air/gas mixture, reducing mechanical connections and potential leakages, and ensuring safe operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a Venturi mixer and flashback suppressor are added to the conduit, then the mixing efficiency and safety are improved, but the size of the connection system increases and the risk of malfunctioning increases
Solution Approach 1:
The patent combines the mixer and flashback suppressor into a single integrated component that is directly incorporated into the manifold structure. This merging eliminates the need for separate Venturi mixer and flashback suppressor components, thereby reducing the overall number of parts while maintaining both mixing efficiency and safety functions.
Solution Approach 2:
The manifold is designed to perform multiple functions simultaneously: it distributes air and gas, mixes the gases through integrated mixer elements, and prevents flashback through built-in suppressor features. This multi-functionality reduces the need for additional specialized components in the connection system.
2Productivity
If the mixer is located upstream the blower, then the mixing occurs earlier in the system, but the risk of unexpected ignition increases due to friction or sparks from mechanical parts
Solution Approach 1:
The mixer is positioned downstream of the blower, allowing air to be pressurized and delivered to the mixing zone before gas introduction. This preliminary action of air delivery before mixing eliminates the need for early mixing upstream of the blower, thereby avoiding ignition risks from mechanical friction or sparks while still achieving efficient mixing.
3Adaptability or versatility
If multiple structural components are used in the connecting system, then the system can be more flexible in design, but the number of mechanical connections increases and the risk of gas leakages increases
Solution Approach 1:
The mixer and suppressor are merged into the manifold as a single integrated structure, eliminating multiple separate components and their associated mechanical connections. This reduction in connections directly lowers the potential points of gas leakage while maintaining design effectiveness.
Solution Approach 2:
The manifold is designed with distinct functional zones (air inlet, gas inlet, mixing chamber, outlet) that are integrated into a single piece, allowing each function to be clearly defined without requiring separate components. This segmentation within integration maintains design clarity while minimizing connections.
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 manifold provides a safe, efficient, and cost-effective solution for hydrogen combustion by minimizing structural components, reducing ignition risks, and ensuring homogeneous mixing before the burner, thus enhancing safety and ease of maintenance.
Implementation Method 1
the manifold comprises a mixer for allowing the mixing of the fuel gas and air at a mixer outlet
Implementation Method 2
the mixing between fuel gas and air usually occurs in the blower
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3B
AI summary
Manifold (1) for a combustion appliance (2), in particular for a gas boiler, for distributing an air/gas mixture to a burner (3) of said combustion appliance (2), the manifold (1) having a one-piece hollow frame structure (4) comprising a first inlet section (6) for receiving fuel gas through a first inlet opening (5), a second inlet section (7) for receiving air through a second inlet opening (10), the second inlet section (7) being located upstream the first inlet section (6), and an outlet section (8) for releasing the air/gas mixture to the burner (3) through an outlet opening (9), the outlet section (7) being located downstream the first inlet section (6) and the second inlet section (7), wherein the manifold (1) comprises a mixer (11) for allowing the mixing of the fuel gas and air at a mixer outlet (12).