Offset Burner Tube Layout for Uniform Coolant Heater Performance
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Solution Overview
Problem
Existing heater systems for recreational vehicles and boats are inefficient due to the need for multiple heaters and pumps, uneven coolant heating, and the requirement for additional components like remotely located heat exchangers, which increase cost and complexity.
Innovation Solution
A compact heater system with a burner tube offset within the coolant tank, integrating the burner, exhaust manifold, expansion tank, pump, and heat exchanger within a single casing, allowing for efficient coolant circulation and even heating, and incorporating a level switch to prevent dry running and air introduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the burner tube is located in the center of the coolant tank, then the heater can be compact, but the coolant heating becomes uneven with zones at different temperatures
Solution Approach 1:
The burner tube is positioned asymmetrically within the coolant tank, specifically offset from the center toward one side. This asymmetric positioning creates a more effective thermal gradient that promotes natural convection currents throughout the coolant, ensuring more uniform heating across the entire tank volume while maintaining a compact heater design.
2Adaptability or versatility
If the exhaust manifold extends beyond the coolant tank end, then it can accommodate both up and down exhaust configurations, but it requires more space within the coolant tank
Solution Approach 1:
The exhaust manifold is designed to extend along the longitudinal axis of the coolant tank rather than protruding radially beyond the tank end. This dimensional reorientation allows the manifold to accommodate both upward and downward exhaust configurations while containing its volume within the existing coolant tank footprint, eliminating the need for additional tank space.
3Productivity
If multiple heaters and pumps are used to assist significant fluid movement, then adequate thermal energy is supplied, but the system complexity and component count increase
Solution Approach 1:
The heater integrates the burner assembly, heat exchanger, and fluid circulation pump into a single unified unit. This consolidation combines multiple previously separate components into one integrated system that delivers adequate thermal energy and fluid circulation performance while significantly reducing overall system complexity and component count.
4Reliability
If the level switch terminates heater operation when coolant is low, then the heater is protected, but the expansion tank may be empty and the pump runs dry introducing air into the system
Solution Approach 1:
The level switch is positioned to terminate heater operation at a higher coolant level threshold, before the expansion tank becomes completely empty. This preliminary action prevents the pump from running dry and introducing air into the system, while still providing adequate protection against low coolant conditions. The expansion tank maintains sufficient reserve coolant to prevent pump cavitation.
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 compact design reduces space requirements, enhances coolant temperature uniformity, minimizes component count, and prevents air introduction, leading to a more efficient and cost-effective heating solution for both potable water and space heating applications.
Implementation Method 1
a burner (102) having a burner tube (103), the burner tube being positioned within a coolant tank (111) and adapted to heat the coolant in the tank
Implementation Method 2
the burner tube being positioned within a coolant tank (111) and adapted to heat the coolant in the tank
Implementation Method 3
said heat exchanger being one of a plurality of heat exchangers arranged in parallel and adapted to exchange heat between the coolant and water
Implementation Method 4
a pump (132) adapted to pump the coolant from the coolant tank (111) through the heat exchanger (112) and back to the coolant tank
Implementation Method 5
The convection current enhances the distribution of the heated coolant within the coolant tank
Data Source
AI summary
A coolant heater having a coolant tank and a burner tube within the coolant tank is used for marine and motor coach installations. The burner tube is offset sidewise from the center line of the coolant tank to allow an exhaust manifold to be positioned within the coolant tank and beside the burner tube which allows a predictable coolant movement to more evenly distribute the heat throughout the coolant. An exhaust manifold is positioned within the coolant tank in the space obtained by the burner tube offset which allows an “up” or “down” exhaust duct configuration depending on the heater installation. An expansion tank connected to the coolant tank has a level switch located within the expansion tank and a pump is operably connected to the expansion tank and to the level switch. The pump terminates operation when the level switch indicates low coolant in the expansion tank.