Water Heater Combustion Chamber Temperature Shutoff
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Solution Overview
Problem
Gas-fired water heaters with flame traps are prone to inefficiencies and increased CO emissions due to clogged ports, which can lead to elevated combustion chamber temperatures and potential ignitions from accidental fuel spills.
Innovation Solution
A combustion chamber temperature sensing system that includes a movable sensor and switch to automatically shut off fuel to the burner when an abnormal temperature is detected, preventing inefficient combustion and potential ignitions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If flame traps with ports are used to contain ignitions from fuel spills, then ignition confinement is improved, but the ports may become clogged with lint, dust, oil or other elements
Solution Approach 1:
The patent removes the problematic ports from the flame trap design. Instead of having ports that can become clogged, the invention uses a solid flame trap barrier that contains ignitions without requiring open passages. This extraction of the clog-prone component resolves the contradiction between ignition confinement and combustion efficiency.
Solution Approach 2:
The patent introduces a temperature sensing system as an intermediary monitoring device. The sensor detects abnormal temperature rises caused by clogged flame traps or inefficient combustion and triggers a response to prevent harmful effects. This intermediary monitoring mechanism addresses the reliability issue without compromising the ignition confinement function.
2Ease of manufacture
If ports in flame traps become clogged, then combustion efficiency deteriorates and CO emissions increase, but the structure remains simple
Solution Approach 1:
The patent implements a feedback mechanism through the temperature sensing system. The sensor continuously monitors combustion chamber temperature and provides feedback to the control system. When abnormal temperatures indicate clogging or inefficient combustion, the system responds by shutting off the gas supply, preventing CO emissions while maintaining the simple flame trap structure.
3Reliability
If a temperature sensing system is added to detect abnormal combustion, then safety is improved, but device complexity increases
Solution Approach 1:
The patent monitors temperature as a key parameter to detect abnormal combustion conditions. By focusing on this single critical parameter rather than multiple sensors, the system achieves improved safety with minimal added complexity. The temperature change serves as an early indicator of problems such as clogged flame traps or inefficient 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 effectively prevents inefficient combustion and reduces CO emissions by automatically terminating fuel supply to the burner when an abnormal temperature is sensed, enhancing safety and operational efficiency.
Implementation Method 1
a sensor disposed within the barrel portion and adapted to operate from a concave to convex position upon reaching a predetermined temperature
Data Source
AI summary
A combustion chamber is disposed below the water container of a water heater and formed at least partially by a shell. A burner disposed within the combustion chamber and a fuel supply line is connected to the burner. A valve associated with the fuel supply line. A combustion chamber sensor is disposed within the combustion chamber and adapted to sense a rise in temperature indicative of an abnormality in the combustion chamber. A circuit connected to the sensor and the valve such that the circuit triggers the valve to shut off fuel to the burner in response to a sensed temperature by the sensor.