Note: Descriptions are shown in the official language in which they were submitted.
2()038~9
BACKGROUND OF THE INVENTION
Field of the Invention
A pulse combustor having a combined mixing and
ignition chamber in communication with a combustion
chamber having combustion chamber branches. A plurality
of exhaust tubes extend from the combustion chamber to
an exhaust manifold. A process for pulse combustion in
a horizontal pulse combustor having a fuel inlet valve,
an air inlet valve, a combustion chamber, and a
plurality of downstream combustion chamber branches each
having a plurality of downstream exhaust tubes.
Description of the Prior Art
Pulsing combustion devices and processes are
generally known to the art. Putnam et al., U.S. Patent
4,314,444, discloses a two-stage apparatus for burning a
fuel and a combustion-sustaining gas. A portion of fuel
is burned in a first stage having pulse combustors. The
remaining fuel is burned in a second combustion stage
with gas that is aspirated using backflow through an
aerodynamic valve inlet. The '444 patent discloses a
valveless pulse combustor in which the flow of gas in
one direction is stronger than the flow of the gas in an
opposite direction. The '444 patent teaches a plurality
of pulse combustors wherein each pulse combustor has
only one combustion chamber and only one outlet conduit.
The second combustion stage has one combustion chamber
with a multiplicity of exhaust tubes. The '444 patent
teaches a vertical arra~gement for the heating
apparatus.
Kitchen, U.S. Patent 4,241,723, discloses a
pulse combustion heater having a combustion chamber and
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at least one exhaust pipe forming a resonant system with
a chamber. The combustion chamber is in the form of a
one-piece bronze casting having an internal cavity which
is generally of flattened spherical shape.
Whitacre, U.S. Patent 3,554,182, teaches a
liquid heater, especially adapted for liquid submerged
uses, for example for heating a swimming pool. The
combustion generated i8 of the pulse type and the
combustion chamber in which the fuel-air mixture is
ignited has a body of material of high radiating
potential, such as ceramic, which is heated in the
combustion chamber and which radiates heat to the
enclosing heat-conducting walls of the chamber in
contact with the liquid to be heated.
Severyanin, Russian Patent 826,137, discloses
a pulsating combustion unit having an ignition chamber
connected to an exhaust chamber through`two resonance
pipes. One of the resonance pipes has a length which
exceeds the length of the other resonance pipe by 3
times to increase combustion efficlency. Combustion
product~ reach the exhaust chamber in an anti-phase thus
reducing sound radiation.
Davis, U.S. Patent 4,637,792, describes a
pulsing combustion device having a combustion chamber
and a floating valve member mounted in reciprocal
relation in the wall of the combustion chamber where
reciprocation of the floating valve closes and opens
communication through ports between the supply of a
combustlble mixture and the combustlon chamber. The
'792 patent teaches a single elongated combustion
chamber burner shell which defines a combustion chamber.
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Davis, U.S. Patent 4,651,712, teaches a pulsing
combustion device having a combustion chamber with an
inlet for a combustible mixture and an unvalved outlet
open to the atmosphere for combu~tion gases. The '712
patent describes an elongated combustion chamber shell
or burner shell which defines a combustion chamber. The
combustible mixture is ignited and burned in a single
combustion chamber.
Adams, U.S. Patent 4,465,024, and Adams, U.S.
Patent 4,545,329, teach a water heater having a water
tank with a water inlet, a water outlet, and an opening
in the side wall of the tank. The combustion chamber
assembly has a submergible portion which is adapted to
fit within the opening in the tank side wall. The
submergible combustion chamber portion comprises a
single cylindrical elongated member having an open end
and an opposite closed end. A plurality of curved fire
tubes are joined to and extend from the closed end of
the combustion chamber to a single flue. The ~dams
patents disclose power combustion systems where fuel and
air are force fed to the point where combustion occurs.
Cook, U.S. Patent 4,257,355, teaches a cold
water inlet tube located in a horizontal position
adjacent the bottom of a commercial water heater. The
water heater has a tank formed of a cylindrical shell
which is enclosed by a lower head and an upper head. A
plurality of vertical flues are disposed inside the tank
and extend from the end of the combustion chamber to a
single flue. .The system operates with a natural draft
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venting system and not a pulse combustion system.
Asakawa, V.S. Patent 3,665,153, teaches an
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apparatus and method for heating water to generate steam
or provide hot water. A burner is positioned in a
combustion chamber having heat exchanger pipes passing
from one end of the combustion chamber to a chimney.
The combustion system operates with a natural draft
venting system, not an acoustically tuned pulse
combustion system.
Lovekin, U.S. Patent 1,170,834, teaches a
thermostatic valve mechanism which supplies gas to a
burner of a heater. Fig. 1 of the '834 patent shows a
! single corrugated combustion chamber with a flue exiting
from one end.
SUMMARY OF THE INVENTION
It is one object of this invention to provide
a process for pulse combustion in a horizontal pulse
combustor having a fuel inlet valve, an air inlet valve,
a mixing chamber in communication with a combustion
chamber, and a plurality of downstream combustion
chamber branches, each in communication with a plurality
of dnwnstream exhaust tubes.
It is another object of this invention to
provide a process for pulse combustion in which
combustion product gases flow through downwardly sloping
exhaust tubes to prevent condensate build-up.
It is another ob~ect of this invention to
provide a process for pu~se combustion in a pulse
combustor having an air inlet flapper valve and a fuel
inlet flapper valve.
It is another ob;ect of this invention to
provide a pulse combustor having a combustion chamber
which properly aspirates and does not create excessive
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noise levels.
It is another object of this invention to
provide a pulse ~ombustor that is easy to manufacture
and requires no special machining, dies, molds or the
like. ~-
It is another object of this invention to
provide a pulse combustor having a single cavity
combustion chamber which splits first into a plurality
of combustion chamber branches, further into a plurality
of exhaust tubes and thus has greater surface area for
increased heat transfer.
It is another object of this invention to
provide a pulse combustor which has a single mixing and
ignition chamber.
It is yet another object of this invention to ~ -
provide a pulse combustor having a single combustion
chamber which splits into a plurality of combustion
chamber branches each having a cross-sectional area less
-than the cross-sectional area of the single combustion
chamber.
In a preferred embodiment of this invention, a
process for pulse combustion occurs in a pulse
combustor, operating in a horizontal position relative
to ground, having an air inlet flapper valve, a fuel
inlet flapper valve, a mixing chamber in communication
with a aombustion chamber, and a plurality of downstream
combustion chamber branches in which each is in
communication with a plurality of downstream exhaust
.
tubes. The process includes the steps of introducing
air through the air inlet flapper valve into a mixing
chamber and introducing fuel through the fuel inlet
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flapper valve, also into the mixing chamber. The fuel
and air form a combustible fuel/air mixture within the
combustion chamber. The fuel which is introduced into
the mixing chamber preferably is gaseous. The fuel/air
mixture is ignited to produce combustion within the
combustion chamber. Combustion product gases are then
exhausted through the combustion chamber branches and
further exhausted through the exhaust tubes. The
combustion product gases can be further exhausted from
the exhaust tubes into an exhaust manifold.
In one embodiment according to this invention,
the mixing and ignition chamber is positioned downstream
from the air inlet flapper valve and the fuel inlet
flapper valve and is positioned upstream from the
combustion chamber. Thus, flashback cannot proceed
through either the air or fuel line and neither contains
a combustible mixture.
In a preferred embodiment according to this
invention, the combustion product gases flow through
downwardly sloping exhaust tubes. SUch configuration
permits fluid flow through the exhaust tubes without
condensation build-up.
In one embodiment of this invention, the pulse
combustor has an exterior surface which is surrounded by
a fluid, preferably water. Heat generated from
combustion is transferred through the exterior surface
of the pulse combustor to the fluid. ln one embodiment,
the exterior surface of the pulse combustor is at least
partially corrugated for increased heat transfer~
increased relative to the heat transfer of a similar
- pulse combustor without corrugated walls. The heat
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transfer from the exterior surface to the surrounding
- fluid can also be relatively increased by having at
least one fin secured to the exterior surface of the
pulse combustor.
Each exhaust tube has a cross-sectional area
less than the cross-sectional area of each combustion
chamber branch. In one embodiment, a summation of
cross~sectional areas of each exhaust tube is less than
a summation of cross-sectional areas of each combustion ~-
chamber branch. In another embodiment, a summation of
cross-sectional areas of each combustion chamber branch
is less than the cross-sectional area of the combustion
chamber.
In another preferred embodiment of this
invention, a pulse combustor apparatus has a combined
mixing and ignition chamber in communication with a fuel
inlet tube and an air inlet tube. The fuel inlet tube
and air inlet tube inject fuel and air, respectively, to
form a combustible fuel/air mixture in the combined
mixing and ignition chamber. The combined mixing and
ignition chamber has an ignition source located within i
the mixing and ignition chamber for igniting the
fuel/air mixture.
The pulse combustor also has a combustion
chamber in communication with the mixing and ignition
chamber. The combustion system has a single combustion
chamber which first splits into a plurality of
downstream combustion chamber branches, then each
downstream combustion chamber b~anch further splits into
at least one, preferably a plurality oP exhaust tubes. :
The combustion chamber branches of the combustion
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~- chamber have a slot between the combustion chamber
branches. At least one reinforcing strut is secured to
the wall of the combustion chamber branches within the
slot between the combustion chamber branches.
At least one exhaust tube has a chamber end
sealably secured to and in communication with the wall
of the combustion chamber. Each exhaust tube has an
- exhaust manifold end sealably secured to and in
communication with an exhaust manifold.
The fuel inlet tube is sealably secured to the
wall of the mixing and ignition chamber and is in
communication with a mixing and ignition chamber.
Likewise, the air inlet tube is sealably secured to the
wall of the mixing and ignition chamber and is in
communication with the mixing and ignition chamber.
Each combustion chamber branch has a cross-sectional
area less than the cross-sectional area of the main
combustion chamber. Each exhaust tube has a cross-
sectional area less than the cross-sectional area of the
combustion chamber branch with which the exhaust tube is
in communication.
According to one embodiment of this invention,
the main combustion chamber and its combustion chamber
branches have corrugated sides for increased heat
transfer. In another embodiment of this invention, the
main combustion chamber and its combustion chamber
branches have at least one fin secured to and extending
from at least one side of the combustion chamber,
lncluding its combustion chamber branches, Eor increased
heat transfer.
~RIEF DESCRIPTION OF THE DRAWINGS
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Fig. 1 shows a top view of a pulse combustor
having a main combustion chamber with two combustion
chamber branches and a plurality of exhaust tubes
according to one embodiment of this invention, Fig. 1
does not show the exhaust manifold of the pulse
combustor;
Fig. 2 shows a cross-sectional view along line
2-2 of a submerged pulse combustor as shown in Fig. 1;
Fig. 3 shows a cross-sectional view along iine
3-3 of a pulse combustor as shown in Fig. 1;
Fig. 4 shows an end view of a pulse combustor -~
having a main combustion chamber with four combustion
chamber branches and two slots according to one
embodiment of this invention:
Fig. 5 shows a perspective view of a pulse
combustor having a main combustion chamber with four
combustion chamber branches and two slots according to
one embodiment of this invention: and
Fig. 6 shows a perspective view of a pulse
combustor with the main combustion chamber and four
combustion chamber branches having corrugated sides
according to one embodiment of this invention.
DESCRIPTION OF_rHE PREFER~ED EMBODIMENTS
Pulse combustion is an acoustically controlled
oscillating combustion where sinusoidal pressure waves
are generated in a combustion chamber. After initial
ignition, combustion will continue without further
ignition from an ignition source such as a spark plug or ,
the like. The frequency of oscillation within the -
combustion chamber is mainly a function of the
combustion chamber volume, the total cross-sectional
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area of the exhaust tubes, the length of the exhaust
tubes and the speed of sound.
One major advantage of this invention is the
greatly enhanced heat transfer as compared with the heat
transfer achieved in a conventional combustor. In a
combustor according to this invention, a major portion
of heat is transferred through the walls of the
combustion chamber, thus a configuration having
increased surface area without a proportional increase
in the volume of the combustion chamber provides greater
heat transfer.
In a preferred embodiment of this invention, a
process for pulse combustion occurs within pulse
combustor 10 as shown in Figs. l, 2 and 3. The process
preferably occurs within an embodiment of pulse
combustor 10 having fuel inlet valve means, air inlet
valve means, combustion chamber 15, and a plurality of
downstream combustion chamber branches 16. Bach
combustion chamber branch 16 is in communication with a
plurality of downstream exhaust tubes 20.
The pulse combustion process begins with
introducing air through the air inlet valve means into
mixing and ignition chamber 13. In a preferred
embodiment, the air inlet valve means comprises at least
one air inlet flapper valve 17 positioned upstream from
and in communication with mixing and ignition chamber
13, as shown in Fig. l.
Fuel is introduced through the fuel inlet
valve means into mixing and ignition chamber 13, as
shown in Fig. 1. In a preferred embodiment of this ;
invention, the fuel inlet valve means comprises at least -
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one fuel inlet flapper valve 19 positioned upstream from
and in communication with mixing and ignition chamber
13. In one preferred embodiment of this invention, the
fuel is a gaseous fuel suitable for combustion within
the combustion zone.
It is apparent that the air inlet valve means
and/or the fuel inlet valve means may comprise other
known valves suitable for pulse combustion. In
particular, a suitable flapper check valve for either
the air or fuel is described in applicant's U.S. Patent
No. 4,856,558, issued August 15, 1989.
The fuel and air introduced into the mixing
chamber combine to form a combustible fuel/air mixture
within the mixing zone. The fuel/air mixture is then
ignited to produce combustion within combustion chamber
15. Combustion product gases are then exhausted through
combustion chamber branches 16 and then further
exhausted through exhaust tubes 20.
In one preferred embodiment of this invention,
the mixing zone includes the volume of mixing and
ignition chamber 13 which is located upstream from
combustion chamber 15. It is apparent that combustion
may occur in mixing and ignition chamber 13 and continue
in combustion chamber 15.
The combustion product gases are preferably
exhausted through downwardly sloping exhaust tubes 20. ~; ;
Such downward slope of each exhaust tube 20, as shown in
Figs. 2 and 3, prevents build~up of condensate within -
B each exhaust tube 20. In another embodlment of this
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invention, the process further includes the step of
exhausting the combustion product gases into exhaust
manifold 21 which is positioned downstream from exhaust
tubes 20.
In a preferred embodiment according to this
invention, pulse combustor 10 including exhaust tubes 20
and exhaust manifold 22 are submerged within a fluid,
preferably water, as shown in Fig. 2 by liquid level 29.
Heat transfer from pulse combustor 10 to the surrounding
fluid can be increased by pulse combustor 10 having at
least a portion of the exterior surface of combustion
chamber 15 and/or combustion chamber branches 16 with
corrugations 30, as shown in Fig. 6. The heat transfer
can also be increased by having at least one fin secured
to the exterior surface of combustion chamber 15 and/or .
combustion chamber branch 16.
To accommodate proper fluid flow conditions : .
throughout pulse combustor 10, one preferred embodiment :
of this invention lncludes each exhaust tube 20 having a ~.
cross-sectional area less than the cross-sectional area
of each combustion chamber branch 16. In another
preferred embodiment, the summation of the cross-
sectional areas of each exhaust tube 20 within each
t combustion chamber branch is less than the of cross-
sectional area of each combustion chamber branch 16. In .
another preferred embodiment, the summation of cross-
sectional areas of each combustion chamber branch 16 is
less than the cross-sectional area of combustion chamber
15. . :':
In a preferred embodiment of the apparatus of ~.
this invention as shown in Figs. 1, 2 and 3, pulse
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combustor 10 has fuel inlet tube 11 and air inlet tube
12 sealably secured to mixinq and ignition chamber wall
33 and in communication with mixing and ignition chamber
13 as defined by mixing and ignition chamber wall 33.
It is apparent that fuel inlet tube 11 and air inlet
tube 12 can be sealably secured to mixing and ignition
chamber wall 33 by a welded connection, a screwed
connection, by having fuel inlet tube 11 and air inlet
tube 12 as channels within a block in lieu of tubes, or
the like. Fuel inlet tube 11 injects fuel and air inlet
tube 12 injects combustion air into mixing and ignition
chamber 13 forming a combustible fuel/air mixture within
mixing and ignition chamber 13.
An ignition source is located within mixing
and ignition chamber 13 for igniting the fuel/air
mixture within mixing and ignition chamber 13. It is
apparent that ignitor 18 can be a spark plug, glow plug
or other ignition source known to the art. Once
combustion occurs from an initial ignition source, pulse
combustor 10 will operate and combustion will continue
without further ignition from the initial ignition
source, such as the spark plug, glow plug or the like.
Main combustion chamber 15 as defined by main
combustion chamber wall 35 is in communication with
mixing and ignition chamber 13. In a preferred
embodiment of this invention, main combustion chamber 15
has transition plate 14 sealably secured to one end of ~;
main combustion chamber wall 35. Transition plate 14
has a through hole in communication with mixing and
ignition chamber 13. It is apparent that mixing and
ignition chamber wall 33 can secure to either transition
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plate 14 or combustion chamber wall 35 by a welded
connection, a screwed connection, by having mixing and
` ignition chamber wall 33 and main combustion chamber
wall 35 one molded piece, or the like.
; As shown in Fig. 1, main combustion chamber 15
splits into a plurality of downstream combustion chamber
` branches 16 as defined by combustion chamber branch
walls 36. A plurality of exhaust tubes 20 are attached
to main combustion chamber wall 35 and/or combustion
chamber branch wall 36 along a longitudinal axis of main
combustion chamber 15. Figs. 1 and 3 show main
combustion chamber 15 having two combustion chamber
branches 16 and several exhaust tubes 20. Figs. 4, 5, 6
and 7 show main combustion chamber 15 having four
combustion chamber branches 16. It is apparent that
main combustion chamber 15 can split into two or more
downstream combustion chamber branches 16. Such
branching arrangement provides ~ncreased heat transfer
by providing more surface area and increased contact of
the combustion gases with the inside surfaces of the
heat exchanger.
Combustion chamber branches 16 have "U" shaped
slot 23 located between combustion chamber branches 16
of main combustion chamber 15. In a preferred
embodiment of this invention, at least one reinforcing
strut 25 span~ slot 23 and is secured between combustion
chamber branch walls 36. Reinforcing strut 25 provides
rigid support for combustion chamber branch walls 36.
In a preferred embodiment of this invention,
combustion chamber branches 16 of main combustion
chamber 15 have end plates 24 sealably secured to
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combustion chamber branch walls 36. It is apparent thatcombustion chamber branches 16 can be sealed by having
combustion chamber walls 36 welded together, by having
one molded piece, by being connected to another chamber
or tube, or the like.
Depending upon the specific design of pulse
combustor 10, combustion can be completed either in main
combustion chamber 15 or combustion can continue in main :
combustion chamber 15 and carry into combustion chamber
branches 16 for completion of combustion. Whether
complete combustion occurs in main combustion chamber 15
or carries into combustion chamber branches 16 depends
upon the total volume and configuration of main .
combuRtion chamber 15 and combustion chamber branches
16. The location of complete combustion also depends
upon the flame speed, reaction time, and the number,
spacing and size of exhaust tubes 20. In a preferred ..
embodiment of this invention, complete combustion occurs ;:
within main combustion chamber 15 and does not carry : .
into combustion chamber branches 16.
As shown in Figs. 1, 2 and 3, each exhaust :.
tube 20 has a chamber end sealably secured to and in
communication with main combustion chamber wall 35 ..
and/or combustion chamber branch wall 36. Each exhaust :
tube 20 also has an exhaust manifold end sealably
secured to and in communication with exhaust manifold 21
as shown in Fig. 2. In one embodiment of this
invention, a plurality of exhaust tubes 20 are sealably
secured to main combustion chamber wall 35 and
combustion chamber branch walls 36 along a longitudinal
axis of main combustion chamber 15 and along the
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longitudinal axis of combustion chamber branches 16.
Such longitudinal arrangement provides increased heat
transfer by providing more surface area for heat
exchange. It is apparent that exhaust tubes 20 can be
sealably secured to main combustion chamber wall 35
; and/or combustion chamber branch walls 36 and exhaust
manifold 21 by using welded connections, screwed
connections, channel means ~r the like.
In a preferred embodiment of this invention,
exhaust tubes 20 have a downwardly sloped and staggered
configuration as shown in Figs. 2 and 3. It is apparent
that exhaust tubes 20 can have other tortuous shaped
configurations. However, staggered exhaust tubes 20
provide a convenient configuration for attaching a
plurality of exhaust tubes 20 to main combustion chamber
wall 35 and/or combustion chamber branch walls 36.
Downwardly sloped exhaust tubes 20 prevent water or
condensation from the flue gas from collecting in
exhaust tubes 20. With the downwardly sloped
configuration, any condensate can drain into exhaust
manifold 21 from which such condensation can be easily
removed. Condensation will collect either during
initial start-up of a relatively cold pulse combustor 10
or when pulse combustor 10 acts as a condensing unit and
achieves very high thermal efficiencies.
Each combustion chamber branch 16 has a cross-
sectional area less than the cross-sectional area of
main combustion chamber 15. Each exhaust tube 20 has a
cross-sectional area less than the cross-sectional area
of the combustion chamber branch 16 to which the exhaust
tube 20 is in communication. Exhaust tubes 20 can be
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secured to main combustion chamber wall 35 and/or
combustion chamber branch walls 36 at a location where
combustion is nearly complete, preferably exhaust tubes
20 are secured to combustion chamber branch walls 36 so
that the combustion gases flow through combustion
chamber branches 16 providing heat transfer to
combustion chamber branch walls 36 rather than flowing
primarily through the path of least resistance which
would be those exhaust tubes 20 secured to main
combustion chamber wall 35. In one embodiment of this
invention, main combustion chamber wall 35 and
combustion chamber branch wall 36 are corrugated and
thus provide greater surface area for increased heat
transfer. Fiqs. 6 and 7 show main combustion chamber
wall 35 and combustion chamber branch walls 36 having
corrugations. It is apparent that main combustion
chamber wall 35 and/or combustion chamber branch wall 36
can have fins or other heat transfer means secured to
the walls for increased heat transfer.
Figs. 4, 5 and 6 show main combustion chamber
15 having four combustion chamber branches 16. As shown
in Fig. 4, a plurality of exhaust tubes 20 have a
downwardly sloped and curved configuration extending
between main combustion chamber 15 and exhaust manifold
21. It is apparent that pulse combustor 10, including
exhaust tubes ~0, can fit within shell 28, or the like,
as shown in Figs. 2 and 3. Fig. 2 shows pulse combustor
10 operating as a steam boiler where pulse combustor 10,
exhaust tubes 20 and exhaust manifold 22 are submerged
within shell 28. Liquid level 29 indicates the water
level or other liquid level within shell 28.
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Several design considerations exist for a
pulse combustor according to this invention. Main
combustion chamber 15 must have the proper size for a
prescribed fuel/air mixture input range. An oversized
main combustion chamber 15 may lack proper aspiration
capabilities. An undersized main combustion chamber 15
may generate excessive noise levels which are difficult
and costly to attenuate. Main combustion chamber 15
must have enough surface area to provide proper heat
transfer and main combustion chamber wall 35 and/or
combustion chamber branch walls 36 must have enough
surface area for easy and proper attachment of exhaust
tubes 20. As the cross-sectional area of combustion
cllamber branches 16 decreases, velocity of the hot
combustion products increases thus improving heat
transfer. Reinforcement struts 25 provide rigid support
for combustion chamber branch walls 36 and also reduce
the vibration of the sheet metal surfaces of combustion
chamber branch walls 36.
For a combustor having a given total volume of
the combustion chamber and any associated combustion
chamber branches, pulse combustor lO according to this
invention will have greater overall heat transfer and
thus greater heat transfer per unit of surface area than
a conventional single combustion chamber pulse combustor
having the same total volume.
While in the foregoing specification this
invention has been described in relation to certain
preferred embodiments thereof, and many details have ~
been set forth for purpose of illustration, it will be -
apparent to those skilled in the art that the invention ~
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is susceptible to additional embodiments and that
certain of the details described herein can be varied
considerably without departing from the basic principles
. of the invention.
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