CONDENSING BOILER

• US 20180031276A1
• Filed: 07/26/2017
• Published: 02/01/2018
• Est. Priority Date: 07/28/2016
• Status: Active Grant

• Current Assignee: Bkbd Limited
• Original Assignee: Brendan Kemp Boiler Design Limited
• Inventors: Kemp, Brendan
• Granted Patent: US 10,760,820 B2
• Time in Patent Office: Days
• CPC Class Codes: F24H 1/181 Construction of the tank
• CPC Class Codes: F24H 1/406 the tubes forming a membrane wall
• CPC Class Codes: F24H 1/43 helically or spirally coiled
• CPC Class Codes: F24H 1/445 with integrated flue gas condenser
• CPC Class Codes: F24H 8/00 Fluid heaters characterised by means for extracting latent heat from flue gases by means of condensation
• CPC Class Codes: F24H 9/001 Guiding means
• CPC Class Codes: F24H 9/45 for preventing galvanic corrosion, e.g. cathodic or electrolytic means
• CPC Class Codes: F28D 7/026 the conduits of only one medium being helically coiled and formed by bent members, e.g. plates, the coils having a cylindrical configuration
• CPC Class Codes: Y02B 30/00 Energy efficient heating, ventilation or air conditioning [HVAC]

Abstract

The invention provides a condensing boiler 100 including a heat exchanger 160, the heat exchanger including at least one fluid flow cassette 162a, 162b, 163a, 163b, 164a, 164b, each cassette comprising first 181 and second 182 sheets, wherein at least the first sheet has corrugations 185, 186, 187 along a length of the sheet so as to form a number of grooves extending across a width of the sheet, wherein the second sheet is attached against the first sheet so as to enclose the grooves to form a number of fluid flow passageways 193 extending across a width of the cassette in between the first and second sheets, and wherein the cassette is substantially curved across its width such that the fluid flow passageways are substantially curved along their length. The invention also provides a method of manufacturing a heat exchanger or condensing boiler.

Claims

1. A condensing boiler including a heat exchanger, the heat exchanger comprising:

at least one fluid flow cassette, each cassette including,

first and second sheets,

wherein at least the first sheet has corrugations along a length of the sheet so as to form a number of grooves extending across a width of the sheet,

wherein the second sheet is attached against the first sheet so as to enclose the grooves to form a number of fluid flow passageways extending across a width of the cassette in between the first and second sheets, and

wherein the cassette is substantially curved across its width such that the fluid flow passageways are substantially curved along their length.

2. The condensing boiler as claimed in claim 1, wherein the cassette is curved with a constant radius of curvature so as to form part of a curved side of a cylinder.

3. The condensing boiler as claimed in claim 2, wherein the width of the cassette corresponds to approximately half the circumference of the curved cylinder side.

4. The condensing boiler as claimed in claim 3, wherein the width of the cassette corresponds to between 100% and 80% of half the circumference of the curved cylinder side.

5. The condensing boiler of claim 1, wherein the second sheet of the cassette also has corrugations along a length of the second sheet so as to form a number of grooves extending across a width of the second sheet.

6. The condensing boiler of claim 5, wherein the second sheet of the cassette is attached against the first sheet so that the adjacent corrugations of the first and second sheets substantially correspond, such that the formed fluid flow passageways extending across the width of the cassette in between the first and second sheets are defined by corrugations of both the first and second sheets.

7. The condensing boiler of claim 6, wherein the adjacent corrugations of the first and second sheets are substantially mirror images of each other along the length of the corrugations, such that the cross-sections of the formed fluid flow passageways are symmetrical.

8. The condensing boiler of claim 1, wherein the corrugations each comprise a cross-section with a substantially flat portion at a second level, the second level being offset from a first, non-corrugated level of the sheet.

9. The condensing boiler as claimed in claim 8, wherein the cross-section of each corrugation also comprises two further straight sides extending from the flat portion to the first level of the sheet, such that the cross-section is in the shape of a trapezium.

10. The condensing boiler of claim 8, wherein, in between the corrugations, the cross-sections of the sheets are substantially flat.

11. The condensing boiler of claim 1, wherein the first and/or second sheets are metallic, preferably comprising stainless steel.

12. The condensing boiler of claim 1, wherein the heat exchanger comprises a plurality of such cassettes and a number of fluid flow connectors connecting a fluid flow passageway in a first cassette to a fluid flow passageway in a second cassette.

13. The condensing boiler as claimed in claim 12, wherein the fluid flow connectors are arranged to reverse the flow of the fluid such that the fluid is able to flow out of the first cassette in one direction, through a fluid flow connector and then flow into the second cassette in substantially the opposite direction.

14. The condensing boiler of claim 1, wherein the boiler is substantially in the form of a cylinder and comprises 3 such cassettes stacked adjacent a first side of the cylinder and 3 such cassettes stacked adjacent a second opposite side of the cylinder.

15. A method of manufacturing a heat exchanger or condensing boiler, the method comprising the following steps:

providing a first sheet with corrugations along its length so as to form a number of grooves extending across a width of the sheet, and

attaching a second sheet against the first sheet so as to form a cassette and to enclose the grooves to form a number of fluid flow passageways extending across a width of the cassette in between the first and second sheets, wherein the cassette is substantially curved across its width such that the fluid flow passageways are substantially curved along their length.