Spiral Boiler Heat Exchanger Tubes With Nested End Portions
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Solution Overview
Problem
Existing heat exchangers for boilers face challenges in achieving efficient operation, compact dimensions, and flexible production due to the need for extensive heat-exchange surfaces, complex tube assembly configurations, and the requirement for additional spacers, which complicates construction and reduces efficiency.
Innovation Solution
The development of a heat exchanger tube with a substantially plane spiral design featuring transverse depressions to accommodate end portions, allowing for compact stacking and efficient heat transfer without the need for internal manifold connections, enabling flexible assembly and reduced production complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If tubes are stacked with end portions superimposed on the spiral, then modular structure is achieved, but wide gaps must be provided between tubes reducing heat exchange efficiency
Solution Approach 1:
The end portion of the tube is nested within transverse depressions formed in the spiral turns of adjacent tubes. This nesting arrangement allows tubes to be stacked closely together without requiring wide gaps, thereby maintaining heat exchange efficiency while preserving the modular structure benefit.
2Stability of the object's composition
If additional spacer components are provided to maintain tube distance, then tube positioning is ensured, but device complexity and construction difficulty increase
Solution Approach 1:
The tube structure includes self-contained transverse depressions formed directly in the spiral turns that automatically receive and position the end portions of adjacent tubes. This self-positioning mechanism eliminates the need for separate spacer components, reducing device complexity while ensuring proper tube positioning and spacing.
3Ease of operation
If manifold extends axially within the tube assembly, then connection is achieved, but construction is complicated and gas burner operation is adversely affected
Solution Approach 1:
The manifold is extracted from the axial interior space of the tube assembly and repositioned to connect to the outer ends of the tubes. This extraction removes the obstruction from the gas burner's operational space, simplifying construction and eliminating adverse effects on burner performance while maintaining connection functionality.
4Adaptability or versatility
If tubes are made with different shapes for series connection, then connection flexibility is achieved, but production complexity increases
Solution Approach 1:
All tubes are manufactured with the same homogeneous spiral shape and dimensions, differing only in the number of turns. This standardization greatly simplifies production processes while maintaining connection flexibility, as tubes can be easily connected in series or parallel configurations without requiring custom-shaped components.
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
This solution results in a compact, efficient, and modular heat exchanger with consistent tube height, facilitating easy assembly and varying thermal powers, while maintaining heat transfer efficiency and simplifying production processes.
Implementation Method 1
The function of a heat exchanger is to transfer thermal energy between two fluids. For example, in the case of domestic gas boilers, the function of the heat exchanger is to heat water circulating inside it, starting from the hot fumes that result from the combustion produced via a burner.
Implementation Method 2
heat exchangers for condensation boilers also exploit the latent heat of condensation contained in the combustion fumes
Implementation Method 3
heat exchangers for condensation boilers also exploit the latent heat of condensation contained in the combustion fumes
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A heat exchanger for a heating device, such as a boiler, comprises a tube assembly (10), which includes a plurality of tubes (1) arranged in a juxtaposed configuration, and at least one first manifold member (11) on the outside of the tube assembly (10). Each tube (1) is wound in a spiral having a plurality of substantially co-planar turns (2a, 2b, 2c), amongst which at least one inner turn (2a) and at least one further turn (2b, 2c) around the inner turn (2a), the at least one further turn (2b, 2c) comprising at least one outer turn (2b) of the spiral. At least one first tube (1), or each tube, of the plurality of tubes has a first end portion (3), which extends starting from the inner turn (2a) towards the outside of the corresponding spiral, with at least one part (30) of the first end portion (3) that is superimposed on the at least one further turn (2b, 2c) in a position corresponding to a major face of the spiral, for connection to the at least one first manifold member (11). The at least one first tube (1), or each tube, of the plurality of tubes, has at least one transverse depression (6) defined in the at least one further turn (2b, 2c), or in each further turn, in which a corresponding part (30) of the first end portion (3) is at least partially received.