An alternative-fuel gas orifice, a gas furnace configured to employ the same and a method of designing a gas orifice. In one embodiment, the gas orifice includes: (1) a body having an aperture extending therethrough and including: (1a) a metering neck having a cross-sectional area such that a given flow rate of a gas is established when the gas is delivered to the gas orifice at a given alternative-fuel delivery pressure and (1b) a diffuser having a cross-sectional area larger than the cross-sectional area of the metering neck and a length such that the gas achieves a substantially laminar flow before exiting the diffuser.

A header box (3) includes a header (10) and a cover (11) having a longitudinal extent dimension and at least one flange (8) crimped in-between the header (10) and the cover (11). The header (10) has a ductility different from that of the flange (8). At the flange (8), a longitudinal portion (18) of the header (10) and/or of the flange (8) is rolled in such a way that the flange (8) is trapped between the header (10) and the cover (11). Additionally, a heat exchanger includes such a box.

A method of manufacturing a box header for an air-cooled heat exchanger. The method includes the steps of boring at least one hole into at least one end of an elongated slab of metal. Material from the slab is milled out adjacent to the at least one hole to form an elongated internal chamber in the slab having at least one open end. An inlet nozzle opening is machined into the elongated chamber and an outlet nozzle opening is machined into the elongated chamber. A plurality of tube holes and a plurality of plug holes are drilled and tapped in the elongated slab into the internal chamber. An end block is welded to the at least one open end in order to form a closed internal chamber.

A method for manufacturing a heat exchanger structure includes additively forming a top layer of a header after disposing a corrugated core within the header to retain the corrugated core within the header. Additively forming the top layer can include filling the corrugated core with powder until a suitable layer of powder overlays the corrugated core and the header and sintering the powder to form the top layer of the header.

A condensation trap comprising an inlet chamber, a vent chamber and an outlet chamber. The inlet chamber is configured to receive condensate fluid through an external opening therein. The vent chamber is in fluid communication with the inlet chamber via a first passageway that includes an internal opening of the inlet chamber. The internal opening is located substantially at an opposite end of the vent chamber as the external opening. The outlet chamber is in fluid communication with the vent chamber via a second passageway that includes an internal opening in a sidewall of the vent chamber and an interior opening in an end of the outlet chamber. The outlet chamber is configured to transmit the condensate fluid through an exterior opening located at an opposite end of the outlet chamber. A vent volume portion is greater than a total volume of an internal space of the inlet chamber.

A method for manufacturing a heat exchanger structure includes additively forming a top layer of a header after disposing a corrugated core within the header to retain the corrugated core within the header. Additively forming the top layer can include filling the corrugated core with powder until a suitable layer of powder overlays the corrugated core and the header and sintering the powder to form the top layer of the header.

A method of custom manufacturing a flame arrestor includes providing a housing having an interior surface and an exterior surface where the exterior surface of the housing is shaped to fit within a fluid passageway. The method includes forming, using an additive manufacturing technique, a three-dimensional lattice structure by depositing a first material onto the interior surface of the housing in a predetermined pattern. The lattice structure includes a plurality of connected lattice members forming channels extending from a first end to a second end of the three-dimensional lattice structure. An element of a second material is provided adjacent to the three-dimensional lattice structure. The second material is different than the first material and the element is configured to draw heat away from fluid flowing through the plurality of channels.

A boiler (100) for a machine for preparing beverages, intended to heat a liquid pressurized to at least 8 bars, so that the heated liquid can brew a product, with the boiler including: a body (1) having an outer wall (2) covered with a screen-printed resistance (14) and an inner wall (3); the inner wall (3) of the body (1) having a longitudinal wall (4) which has a circular cross-section, as well as a bottom wall (5); an inner element (30) having an outer face (35) for defining, together with the longitudinal wall (4), at least a portion of heating chamber (102); a liquid inlet (10) and outlet (12); a support (20) so configured as to cooperate with the body (1) so as to form, together with the longitudinal wall (4) and the bottom wall (5), a sealed enclosure (101) including the heating chamber (102).

A flame cell of a flame arrestor may include a body of a first material having a first end, a second end, and a plurality of channels formed in the body and extending from the first end to the second end of the body. The flame cell may also include an element of a second material coupled to the body, the second material being different from the first material. The element may be configured to draw heat away from fluid flowing through the plurality of channels.

A furnace heat exchanger assembly includes first and second heat exchanger halves. The first heat exchanger half includes a first half of an exhaust channel and an inner joint flange half at an end thereof. The second heat exchanger half includes a second half of the exhaust channel and an outer joint flange half at an end thereof having first and second capturing tabs. The first and second heat exchanger halves are coupled together such that the first and second capturing tabs substantially overlap the inner joint flange half to form a joint flange.