Condensing Heat Exchanger for Gas Furnaces

Abstract

A condensing heat exchanger ( 100, 100 a ) is disclosed that includes a pair of opposing half shells ( 145, 145 a ) connected together. The half shells ( 145, 145 a ) define an inlet ( 111 ) at one end and at least one outlet ( 112, 113 ) at an opposing end of the heat exchanger. The pair of opposing half shells ( 145, 145 a ) also defines a central axis ( 133 ). Each half shell ( 145, 145 a ) includes a plurality of elongated angled beads ( 117, 117 a, 119 ) that extend inwardly towards the other half shell. The elongated angled beads ( 117, 117 a , 119 ) of each half shell ( 145, 145 a ) extend traversely across the central axis ( 133 ) at an angle θ with respect to the central axis ( 133 ). The beads of one half shell ( 145, 145 a ) also extend traversely across one or more beads of the other half shell. The half shells ( 145, 145 a ) form two side channels ( 121, 121 a , 122, 122 a ) for collecting condensate disposed opposite the plurality of elongated angled beads ( 117, 117 a, 119 ) from one another and between the inlet ( 111 ) and at least one outlet ( 112, 113 ).

1 . A condensing heat exchanger ( 100 ,  100   a ) comprising:
 a pair of opposing half shells ( 145 ,  145   a ) connected together, the half shells ( 145 ,  145   a ) defining an inlet ( 111 ) at one end and at least one outlet ( 112 ,  113 ) at an opposing end, the pair of opposing half shells ( 145 ,  145   a ) also defining a central axis ( 133 ),   each half shell ( 145 ,  145   a ) comprising a plurality of elongated angled beads ( 117 ,  119 ) that extend inwardly towards the other half shell ( 145 ,  145   a ), the elongated angled beads ( 117 ,  119 ) of each half shell ( 145 ,  145   a ) extending traversely across the central axis ( 133 ) at an angle θ with respect to the central axis ( 133 ), the beads ( 117 ,  119 ) of one half shell ( 145 ,  145   a ) extending traversely across one or more beads ( 117 ,  117   a ,  119 ) of the other half shell ( 145 ,  145   a ).   
     
     
         2 . The condensing heat exchanger ( 100 ,  100   a ) of  claim 1  wherein the half shells ( 145 ,  145   a ) form two side channels ( 121 ,  121   a ,  122 ,  122   a ) for collecting condensate disposed opposite the plurality of elongated angled beads ( 117 ,  117   a ,  119 ) from one another and between the inlet ( 111 ) and at least one outlet ( 112 ,  113 ). 
     
     
         3 . The condensing heat exchanger ( 100 ,  100   a ) of  claim 1  wherein each half shell ( 145 ,  145   a ) further comprises at least one perpendicular bead ( 141 ,  142 ) disposed in close proximity to the inlet ( 111 ). 
     
     
         4 . The condensing heat exchanger ( 100 ,  100   a ) of  claim 3  wherein the perpendicular beads ( 141 ,  142 ) of the half shells ( 145 ,  145   a ) are offset from one another. 
     
     
         5 . The condensing heat exchanger ( 100 ,  100   a ) of  claim 4  wherein each half shell ( 145 ,  145   a ) comprises from about two to about four perpendicular beads ( 141 ,  142 ) disposed in close proximity to the inlet ( 111 ). 
     
     
         6 . The condensing heat exchanger ( 100 ,  100   a ) of  claim 3  wherein the perpendicular beads ( 141 ,  142 ) do not extend across the central axis ( 133 ). 
     
     
         7 . The condensing heat exchanger ( 100 ,  100   a ) of  claim 1  wherein the elongated angled beads ( 117 ,  117   a ,  119 ) each comprise an elongated outer surface ( 138 ), the elongated outer surfaces ( 138 ) of at least some of the elongated angled beads ( 117 ,  117   a ,  119 ) being arced inwardly away from the opposing half shell ( 145 ,  145   a ) for increasing flow along the central axis ( 133 ). 
     
     
         8 . The condensing heat exchanger ( 100 ,  100   a ) of  claim 1  wherein the elongated angled beads ( 117 ,  117   a ,  119 ) each comprise two opposite ends ( 117 ′,  119 ′) with an elongated outer surface extending between the opposite ends ( 117 ′,  119 ′),
 the elongated outer surfaces ( 138 ) of at least some of the elongated angled beads ( 117 ,  117   a ,  119 ) being arced inwardly away from the opposing half shell ( 145 ,  145   a ) between the two opposite ends ( 117 ′,  119 ′) so the two opposite ends ( 117 ′,  119 ′) are disposed closer to the opposing half shell ( 145 ,  145   a ) than a remainder of the arced outer surface ( 138 ) extending between the two opposite ends ( 117 ′,  119 ′). 
 
     
     
         9 . The condensing heat exchanger ( 100 ,  100   a ) of  claim 1  wherein θ ranges from about 20° to about 70°. 
     
     
         10 . The condensing heat exchanger ( 100 ,  100   a ) of  claim 1  wherein θ is about 40°. 
     
     
         11 . The condensing heat exchanger ( 100 ,  100   a ) of  claim 1  wherein the inlet ( 111 ) is co-axial with the central axis ( 133 ) and the heat exchanger ( 100 ,  100   a ) comprises two outlets ( 112 ,  113 ) disposed opposite the central axis ( 133 ) from each other. 
     
     
         12 . The condensing heat exchanger ( 100 ,  100   a ) of  claim 1  wherein the elongated angled beads ( 117 ,  117   a ,  119 ) of one half shell ( 145 ,  145   a ) are disposed of perpendicularly to the elongated angled beads ( 117 ,  117   a ,  119 ) of the other half shell ( 145 ,  145   a ). 
     
     
         13 . A condensing heat exchanger ( 100 ,  100   a ) comprising:
 a pair of opposing half shells ( 145 ,  145   a ) connected together, the half shells ( 145 ,  145   a ) defining an inlet ( 111 ) at one end and at least one outlet ( 112 ,  113 ) at an opposing end, the pair of opposing half shells ( 145 ,  145   a ) also defining a central axis ( 133 ),   each half shell ( 145 ,  145   a ) comprising a plurality of elongated angled beads ( 117 ,  117   a ,  119 ) that extend inwardly towards the other half shell, the elongated angled beads ( 117 ,  117   a ,  119 ) of each half shell ( 145 ,  145   a ) extending traversely across the central axis ( 133 ) at an angle θ with respect to the central axis ( 133 ), the beads of one half shell ( 145 ,  145   a ) extending traversely across one or more beads ( 117 ,  117   a ,  119 ,  119   a ) of the other half shell ( 145 ,  145   a ),   the elongated angled beads ( 117 ,  117   a ,  119 ) each comprising an elongated outer surface ( 138 ), the elongated outer surfaces ( 138 ) of at least some of the elongated angled beads ( 117 ,  117   a ,  119 ) being arced inwardly away from the opposing half shell ( 145 ,  145   a ) for increasing flow along the central axis ( 133 ),   the half shells ( 145 ,  145   a ) forming two side channels ( 121 ,  121   a ,  122 ,  122   a ) for collecting condensate disposed opposite the plurality of elongated angled beads ( 117 ,  117   a ,  119 ) from one another and between the inlet ( 111 ) and at least one outlet ( 112 ,  113 ).   
     
     
         14 . The condensing heat exchanger ( 100 ,  100   a ) of  claim 13  wherein each half shell ( 145 ,  145   a ) further comprises at least one perpendicular bead ( 141 ,  142 ) disposed in close proximity to the inlet ( 111 ). 
     
     
         15 . The condensing heat exchanger ( 100 ,  100   a ) of  claim 14  wherein the perpendicular beads ( 141 ,  142 ) of the half shells ( 145 ,  145   a ) are offset from one another. 
     
     
         16 . The condensing heat exchanger ( 100 ,  100   a ) of  claim 13  wherein θ ranges from about 20° to about 70°. 
     
     
         17 . The condensing heat exchanger ( 100 ,  100   a ) of  claim 12  wherein the elongated angled beads ( 117 ,  117   a ,  119 ) of one half shell ( 145 ,  145   a ) are disposed of perpendicularly to the elongated angled beads ( 117 ,  117   a ,  119 ) of the other half shell ( 145 ,  145   a ). 
     
     
         18 . A method of reducing a size of a condensing heat exchanger ( 100 ,  100   a ) that comprises a pair of opposing half shells ( 145 ,  145   a ) connected together, the half shells ( 145 ,  145   a ) defining an inlet ( 111 ) at one end and at least one outlet ( 112 ,  113 ) at an opposing end, the pair of opposing half shells ( 145 ,  145   a ) also defining a central axis ( 133 ), the half shells ( 145 ,  145   a ) forming two side channels ( 121 ,  121   a ,  122 ,  122   a ) for collecting condensate disposed opposite the central core areas ( 120 ,  120   a ) of the two half shells ( 145 ,  145   a ), the method comprising:
 providing elongated angled beads ( 117 ,  117   a ,  119 ) in the opposing half shells ( 145 ,  145   a ) that extend across the central core areas ( 120 ,  120   a ) of the half shells ( 145 ,  145   a ) between the side channels ( 121 ,  121   a ,  122 ,  122   a ), the elongated angled beads ( 117 ,  117   a ,  119 ) of one half shell ( 145 ,  145   a ) extending traversely across the elongated angled beads ( 117 ,  117   a ,  119 ) of the other half shell ( 145 ,  145   a ).   
     
     
         19 . The method of  claim 18  further comprising increasing flow across central core areas ( 120 ) of the opposing half shells ( 145 ) by arcing an elongated outer surface of at least some of the elongated angled beads ( 117 ) inwardly away from the opposing half shell ( 145 ) to increase space between the elongated angled beads ( 117 ,  119 ) of the two opposing half shells ( 145 ) and for increasing flow along the central axis ( 133 ) of the condensing heat exchanger ( 100 ). 
     
     
         20 . The method of  claim 17  wherein the elongated angled beads ( 117 ,  117   a ,  119 ) of each half shell ( 145 ,  145   a ) extending traversely across the central axis ( 133 ) at an angle θ with respect to the central axis ( 133 ), and wherein θ ranges from about 20° to about 70°.