Notched Base Ring for Pressure Washer Heat Exchanger
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Solution Overview
Problem
Pressure washer heat exchangers operate inefficiently, leading to increased fuel consumption and emissions, as they struggle to maintain desired temperatures for effective cleaning, particularly when dealing with substances like grease, which requires heated water.
Innovation Solution
A blower and heat exchanger assembly featuring a notched base ring and a combustion chamber gasket that enhances air flow and structural support, allowing for improved heat transfer efficiency by forcing heated air through multiple flow passages and between coil pitches, reducing fuel usage and emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a solid base ring is used to provide structural support, then structural strength is improved, but air flow through the heat exchanger is restricted
Solution Approach 1:
The base ring is segmented by introducing notches that divide the continuous structure into sections. These notches create multiple air flow passages while the remaining portions of the base ring maintain structural support. The segmentation allows simultaneous achievement of both air flow requirements and structural strength requirements.
2Ease of manufacture
If the heat exchanger operates inefficiently, then manufacturing cost is reduced, but fuel consumption increases and emissions increase
Solution Approach 1:
The notched base ring segments the air flow path into multiple passages, increasing the total air flow volume through the heat exchanger. This improves heat transfer efficiency, which reduces fuel consumption and emissions while maintaining manufacturing simplicity through the straightforward notched design.
3Productivity
If air flow through the heat exchanger is increased, then heat transfer efficiency is improved, but structural support is reduced
Solution Approach 1:
The base ring is segmented by introducing notches that divide the continuous structure into sections. These notches create multiple air flow passages while the remaining portions of the base ring maintain structural support. The segmentation allows simultaneous achievement of both air flow requirements and structural strength requirements.
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 solution increases heat transfer efficiency by approximately 4%, reducing fuel consumption and emissions, while maintaining effective cleaning temperatures, thus enhancing the profitability and environmental impact of pressure washer operations.
Implementation Method 1
The notched base ring allows air to flow through the heat exchanger
Implementation Method 2
the same fuel is often used as part of an ignition system that creates a flame that heats air that is blown through a heat exchanger, which in turn, heats the water
Data Source
AI summary
The notched base ring comprises a base ring sheet body including a top portion, a bottom portion, a first end connecting the top portion to the bottom portion, and a second end connecting the bottom portion to the top portion. The top portion includes a plurality of attachment lugs and defines a plurality of notches, each notch being at least partially defined by two lugs disposed on opposite sides of the notch, the top portion also including an angled top edge that is disposed at each of the attachment lugs, and the bottom portion includes a bottom support edge.