Premix Burner Manifold Cooling for Heat Exchanger Inlet Hot Spots
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Solution Overview
Problem
In warm air furnaces, heat tends to collect at the inlet of heat exchangers due to differences in flame shape between inshot and premix burners, leading to inefficient heat distribution.
Innovation Solution
A pre-mix burner manifold system that allows air to flow over its external surface through slots in a housing, mixing with fuel within the manifold, and is attached to a burner and heat exchanger, effectively cooling the heat exchanger inlet by drawing combustion air over it and adjusting orifice sizes for optimal fuel-air mixture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If premix burners are used in warm air furnaces, then fuel-air mixing is improved, but heat accumulates at the inlet of the heat exchanger causing inefficient heat distribution
Solution Approach 1:
The patent extracts the harmful heat accumulation from the heat exchanger inlet area by introducing a dedicated cooling air flow path. Cool air is drawn from the furnace plenum and directed through a channel that passes over the external surface of the manifold, carrying heat away from the heat exchanger inlet and preventing inefficient heat distribution.
Solution Approach 2:
The patent introduces cool air from the furnace plenum as an intermediary substance to transfer heat away from the heat exchanger inlet. This intermediary air flow acts as a heat carrier, absorbing excess heat from the manifold surface and transporting it to a more appropriate location in the furnace, thereby resolving the heat accumulation problem.
2Temperature
If air flow is directed over the manifold surface to cool the heat exchanger inlet, then heat distribution is improved, but the manifold temperature decreases potentially affecting combustion performance
Solution Approach 1:
The patent applies local quality by directing the cooling air flow specifically over the external surface of the manifold where heat accumulation occurs, rather than cooling the entire combustion system. The cooling channels are positioned to target only the areas requiring temperature reduction, allowing the combustion chamber and burner components to maintain their optimal temperatures for reliable combustion performance.
Solution Approach 2:
The patent segments the thermal management of the burner system by separating the cooling function from the combustion function. The cooling air flow is channeled through specific pathways that expose only the manifold exterior to cooling, while the interior combustion components remain thermally isolated and maintain temperatures suitable for reliable combustion.
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 system efficiently cools the front of the heat exchanger by pulling combustion air over the inlet area, reducing heat accumulation and improving heat distribution by adjusting the air-fuel mixture, thereby enhancing the performance of the burner system.
Implementation Method 1
air to be drawn through slots in the housing to flow over an external surface of the manifold. The flow of air may maintain a temperature of the manifold lower than a temperature that the manifold might have without the flow.
Implementation Method 2
The manifold may be attached to a burner and heat exchanger. air which mixes with fuel 59 to result in a mixture 62 inside of manifold 56
Implementation Method 3
A valve 52 may control a fuel 59 coming in from a source to apparatus 51. The mixture can become richer as the air warms up with heat from the burner.
Data Source
AI summary
A system having a pre-mix burner manifold in a housing that may permit air to be drawn through slots in the housing to flow over an external surface of the manifold. The flow of air may maintain a temperature of the manifold lower than a temperature that the manifold might have without the flow. The manifold may be attached to a burner and heat exchanger.