Reverse combustion type combustion apparatus
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Solution Overview
Problem
The assembly of reverse combustion type combustion apparatuses with synthetic resin exhaust boxes is challenging due to their non-flat bottom design, which prevents self-standing assembly, leading to potential damage and increased assembly time and cost.
Innovation Solution
A synthetic resin exhaust box with an integrally formed leg portion that allows it to stand upright, enabling convenient assembly of heat exchangers and combustion components without risking damage and reducing assembly area and time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the bottom portion of the exhaust box is formed as a concave shape with inclined surfaces to enhance condensed water drainage, then drainage performance is improved, but the exhaust box cannot stand up by itself during assembly
Solution Approach 1:
The exhaust box is segmented into functional zones: the concave bottom portion for water collection and drainage, and the cylindrical upper portion that provides structural stability and self-standing capability during assembly. This segmentation allows each zone to optimize its specific function without compromising the other.
Solution Approach 2:
Different portions of the exhaust box have different geometries optimized for their specific functions: the bottom portion has a concave shape with inclined surfaces for effective condensed water drainage, while the upper portion maintains a cylindrical shape that provides structural integrity and enables the exhaust box to stand upright independently during assembly operations.
2Ease of manufacture
If the exhaust box is made from synthetic resin material to reduce cost and enable complex shaping, then manufacturing cost is reduced, but assembly becomes difficult without temporary stands
Solution Approach 1:
The exhaust box design segments the structure into a stable cylindrical upper portion and a functional concave bottom portion, allowing the synthetic resin material to achieve both cost-effectiveness and assembly-friendly geometry without requiring temporary stands or complex assembly fixtures.
Solution Approach 2:
The exhaust box is designed to stand up by itself during assembly through its cylindrical upper portion geometry, eliminating the need for external temporary stands or support fixtures. This self-service capability simplifies the assembly process and reduces additional manufacturing costs despite using synthetic resin material.
3Strength
If the exhaust box is made from metal with excellent strength, then structural strength is improved, but the bottom surface must be flat which reduces condensed water drainage performance
Solution Approach 1:
The exhaust box applies local quality by providing structural strength through the cylindrical upper portion while the concave bottom portion with inclined surfaces optimizes condensed water drainage. This localized functional differentiation resolves the contradiction between strength and drainage performance.
Solution Approach 2:
The exhaust box uses composite construction combining the structural advantages of metal-like cylindrical geometry for strength with the drainage advantages of concave shaped surfaces, all manufactured from synthetic resin material that provides both strength and drainage capability simultaneously.
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
Enables efficient and damage-free assembly of the combustion apparatus with a compact assembly process, reducing manufacturing and handling costs while ensuring reliable drainage of condensed water.
Implementation Method 1
condensed water generated in the heat exchanger from the combustion exhaust gases drips down into the exhaust box
Implementation Method 2
the bottom portion of the exhaust box is formed, not in a flat shape, but in a concave shape composed of a plurality of inclined surfaces
Data Source
AI summary
A reverse combustion type combustion apparatus (1) includes a combustion section (2) that combusts fuel in a downward direction, heat exchangers (4, 5) disposed under the combustion section (2), and an exhaust box (6) disposed under the heat exchangers (4, 5). The exhaust box (6) is a molded product made from a synthetic resin material; the exhaust box (6) includes an opening portion (30) for introduction of combustion exhaust gases generated by an upper portion, a fixing portion (33) for fixing the heat exchanger (5), and an inclined bottom portion (35) that collects condensed water generated by the heat exchanger (5); and, at the lower end portion of the exhaust box (6), at least three legs (40) are integrally formed and make the exhaust box (6) stand up by itself.