Production method of a burner assembly for gas cooker device

Abstract

The invention relates to a production method of a burner assembly comprising a metal lower body (20) in the form of a container provided with a gas inlet (14) and a cover (10) which is hermetically fitted to the lower body (20) rim part (29) on which there is a transfer channel (16) providing air gas mixture transmission to a flame distributor (30). The production method is comprising the steps of pre-fixing the cover (10) on a metal injection mold (40); injecting the lower body (20) into the mold in such a way to provide a junction line (1 ) along the cover (10) rim part (29); cooling the integrated lower body (20) and the cover (10) and the removal of the lower body (20) from the mold with the cover integrated.

Description

TECHNICAL FIELD

[0001] The present invention relates to a production method of a burner assembly used on gas cooker appliances and having a two-piece base, such as the one disclosed in WO 2005 / 073630 A1.BACKGROUND OF THE INVENTION

[0002] A burner assembly is mounted to the mounting holes on the burner plate in gas cooker appliances. The burner assembly mixes the ambient air with the flammable gas supplied from an injector through which a flammable gas is circulated by a gas pipe, and provides the heat energy required for the cooking process by burning it through a flame distributor in such a way to form a flame crown. Parts forming the burner assembly are generally produced by metal injection or casting. The gas burner bases, which consist of two parts, namely a lower body and an upper cover attached to it, lose some of their flatness during injection or during cooling. These faulty surface junctions that form during the joining of two metal parts may cause some gas leakage that occurs during the initial start-up of the combustor or when it reaches a high temperature, which is revealed only during quality control. If the user does not operate under appropriate standards, this gas may accumulate in the closed volume of the furnace or oven, causing the risk of reaching the flash point when conditions are met.

[0003] In order to prevent this problem in the current situation, the two parts were joined with a high temperature resistant carbon gasket to secure the sealing or the two parts were riveted at very different points. The solution of placing gaskets between the two parts, which is one of the known solutions, both slows down the production speed and brings additional costs due to the costliness of the high temperature resistant gaskets. The procedure of riveting the parts, which is the other solution, causes a certain amount of faulty joining process due to metal fatigue and post-expansion deformation.BRIEF DESCRIPTION OF THE INVENTION

[0004] The objective of the invention is to extend the gas tight life between the cover and the lower body in burner assemblies comprising a cover and a lower body.

[0005] In order to attain the aforementioned objectives, the invention relates to a burner assembly production method comprising a metal lower body in the form of a container provided with a gas inlet and a cover which is gas-tightly fitted to the lower body rim part on which there is a transfer channel providing air gas mixture transmission to a flame distributor. The production method comprises the process steps of pre-fixing the cover on a metal injection mold; injection of the lower body into the mold in such a way to provide a junction line along the rim part of the cover; cooling the integrated lower body and the cover and removing the lower body from the mold with the cover integrated. The integration of the lower body and the cover together by injection ensures the perfect gas tightness of the cover.

[0006] In a preferred embodiment of the invention, the material melting temperature of the cover is greater than the lower body melting temperature. In this way, during the lower body injection, the cover along the rim is heated along the junction line where the lower body comes into contact at a high temperature, preventing the corresponding part of the cover from melting and losing its form. The cover preferably has a flat plate structure. Thanks to the high melting temperature, a deformation of the flat plate structure is prevented that may cause bending or twisting due to melting or thermal stress.

[0007] In a preferred embodiment of the invention, the cover and the lower body comprise a metal, particularly aluminum alloy. Due to its high adhesion capability in the molten state, the aluminum alloy makes the integration possible directly with the adhesion of the rim part to the cover, without the need to apply another process in the junction line.

[0008] A burner assembly produced as described above, comprises a lower flange extending along the circumferential edge of the lower body and an upper flange which corresponds to the lower flange on the cover and aligned with the lower flange (22) on top of each other, between which a junction line is provided. The lower flange and the upper flange increase the sealing properties by providing a high radial junction line with planar surfaces that sit on each other. In addition, the extended lower and upper flange parts display fast cooling properties after injection and provide rapid cooling and integration in a way that increases the production speed in case the lower part is injected into the upper cover from the upper flange.

[0009] The gas inlet and the transfer channel are arranged essentially perpendicular to each other. Thus, a lower body and a cover structure suitable for a burner assembly comprising a horizontal or partially angled injector can be obtained. In an alternative embodiment, the gas inlet may be located at the bottom of the lower body. A suitable area can be created for the mounting of multiple injectors with one or more gas inlets.

[0010] The transfer channel is provided on the cover adjacent to the junction line. Thus, it is possible to quickly form the lower body by the transfer channel creating a cooling effect after the injection of the lower body onto the cover. The burner assembly comprises an inner channel coaxially provided with the transfer channel at the center of the cover and accessing the flame distributor in a manner that provides gas transmission. Multiple channels, that is, the transfer channel and the inner channel, can be connected together to a flame distributor having a multiple nested flame distribution for the wok burner assembly in such a way to supply air-gas mixture from the lower body.

[0011] The lower flange comprises a barrier extending circumferentially upward at its outer edge and delimiting a pool, and the upper flange is arranged in such a way that leans against the barrier from inside from a radial outer part thereof. The barrier helps the cover to wrap the cover not only in the radial direction with the junction line, but also axially. Thus, the sealing cross section is extended, for example forms an L-like structure.

[0012] The burner assembly comprises a tab extending radially outwardly on the outer part and a groove correspondingly wrapping the tab in the barrier. In this way, the contact surface of the barrier with the cover increases from the corner of the barrier and the cover is provided to be strongly integrated into the lower body after injection.

[0013] The junction line is in a circular strip structure. Thus, the sealing between the container-shaped lower body and the cover is provided circumferentially.BRIEF DESCRIPTION OF THE FIGURES

[0014] Figure 1 is the side sectional view of a representative embodiment of the burner assembly produced by means of the method of the invention, in a schematically shown injection mold. Figure 2 is an extended illustration of the flange part of the burner assembly shown in Figure 1. DETAILED DESCRIPTION OF THE INVENTION

[0015] In this detailed description, the development of the invention is described without any limitation and only with references to the examples for a better explanation of the subject.

[0016] In Figure 1, a representative embodiment of the burner assembly produced by means of the method of the invention is shown by taking a cross section in the integrated state after injection in a schematically given mold (40). The burner assembly comprises a lower body (20) in the form of a container covered in a gas-tight manner by a cover (10) and a flame distributor (30) placed on the cover (10). The lower body (20) is fixed on the burner plate (not shown) of a cooker with the cover (10). The cover (10) is in the form of a circular flat plate. The cover (10) is attached to the mold (40) in the form of an insert. The lower body (20) is injected on the cover (10) of similar metal material by injection of aluminum alloy and is connected in a way that defines a junction line (1) at the part where they come into contact with the cover (10). The alloy material of the cover (10) has been chosen to be higher than the alloy material of the lower body (20) in terms of melting temperature. An inner channel (18) in the form of a hole in the center of the cover (10) and a transfer channel (16) radially distanced therefrom are provided. The inner channel (18) and the transfer channel (16) are surrounded by forms in the form of chimneys that are extended outwards from an upper surface (14). The part close to the outer part (15) of the cover (10) circumferentially defines an upper flange (12). The upper flange (12) is an extension outward from the part that the transfer channel (16) separates.

[0017] The lower body (20) is formed under the cover (10). The lower body (20) comprises a hollow cylindrical container (24) with gas inlet (28) on its side and a lower part (26) surrounding it. The container (24) mixes the flammable gas supplied from the gas inlet (28) with the ambient air and transfers the mixture to the inner wall (23) and the transfer channel (16) with the channels provided at the lower part (26). The container (24) is in a hollow, closed-bottom, thin-walled cylindrical form.

[0018] In Figure 2, the part A provided in Figure 1 is shown as enlarged. The cover (10) is obtained by extending the upper flange (12) to form a barrier (25) in the form of an upward protrusion that limits the outer part (15) of the lower flange (22) in the form of a radial strip. An inward groove (21) is formed on the inner wall of the barrier (25), in such a way that forms a level with the lower corner (13) part. A tab (11) formed on the edge of the upper flange (12) near the lower corner of the outer part (15) is placed in the groove (21). The tab (11) is placed in the groove (21) to fit perfectly. The lower surface (17) of the upper flange (12) is planar. Similarly, the corresponding seating surface (27) of the lower body (20) placed on the lower surface (17) is also planar. The metal injection mold (40) supports the upper flange (12) internally with the help of a core (not shown) leaning against the inner wall (23), and the aluminum alloy injected into the lower surface (17) adheres to the seating surface (27) without melting the cover (10), and cools in such a way to form the lower flange (22). Once it is removed from the mold (40), the cover (10) is integrated with the lower body (20) and is combined with the flame distributor (30) to be used in the burner assembly.REFERENCE NUMBERS

[0019] 1Junction line20Lower body10Cover21Groove11Tab22Lower flange12Upper flange23Inner wall13Lower corner24Container14Upper surface25Barrier15Outer part26Lower part16Transfer channel27Seating surface17Lower surface28Gas inlet18Inner channel29Rim part30Flame distributor40Metal injection mold

Examples

Embodiment Construction

[0015]In this detailed description, the development of the invention is described without any limitation and only with references to the examples for a better explanation of the subject.

[0016]In Figure 1, a representative embodiment of the burner assembly produced by means of the method of the invention is shown by taking a cross section in the integrated state after injection in a schematically given mold (40). The burner assembly comprises a lower body (20) in the form of a container covered in a gas-tight manner by a cover (10) and a flame distributor (30) placed on the cover (10). The lower body (20) is fixed on the burner plate (not shown) of a cooker with the cover (10). The cover (10) is in the form of a circular flat plate. The cover (10) is attached to the mold (40) in the form of an insert. The lower body (20) is injected on the cover (10) of similar metal material by injection of aluminum alloy and is connected in a way that defines a junction line (1) at the part where t...

TECHNICAL FIELD

[0001] The present invention relates to a production method of a burner assembly used on gas cooker appliances and having a two-piece base, such as the one disclosed in WO 2005 / 073630 A1.BACKGROUND OF THE INVENTION

[0002] A burner assembly is mounted to the mounting holes on the burner plate in gas cooker appliances. The burner assembly mixes the ambient air with the flammable gas supplied from an injector through which a flammable gas is circulated by a gas pipe, and provides the heat energy required for the cooking process by burning it through a flame distributor in such a way to form a flame crown. Parts forming the burner assembly are generally produced by metal injection or casting. The gas burner bases, which consist of two parts, namely a lower body and an upper cover attached to it, lose some of their flatness during injection or during cooling. These faulty surface junctions that form during the joining of two metal parts may cause some gas leakage that occurs during the initial start-up of the combustor or when it reaches a high temperature, which is revealed only during quality control. If the user does not operate under appropriate standards, this gas may accumulate in the closed volume of the furnace or oven, causing the risk of reaching the flash point when conditions are met.

[0003] In order to prevent this problem in the current situation, the two parts were joined with a high temperature resistant carbon gasket to secure the sealing or the two parts were riveted at very different points. The solution of placing gaskets between the two parts, which is one of the known solutions, both slows down the production speed and brings additional costs due to the costliness of the high temperature resistant gaskets. The procedure of riveting the parts, which is the other solution, causes a certain amount of faulty joining process due to metal fatigue and post-expansion deformation.BRIEF DESCRIPTION OF THE INVENTION

[0004] The objective of the invention is to extend the gas tight life between the cover and the lower body in burner assemblies comprising a cover and a lower body.

[0005] In order to attain the aforementioned objectives, the invention relates to a burner assembly production method comprising a metal lower body in the form of a container provided with a gas inlet and a cover which is gas-tightly fitted to the lower body rim part on which there is a transfer channel providing air gas mixture transmission to a flame distributor. The production method comprises the process steps of pre-fixing the cover on a metal injection mold; injection of the lower body into the mold in such a way to provide a junction line along the rim part of the cover; cooling the integrated lower body and the cover and removing the lower body from the mold with the cover integrated. The integration of the lower body and the cover together by injection ensures the perfect gas tightness of the cover.

[0006] In a preferred embodiment of the invention, the material melting temperature of the cover is greater than the lower body melting temperature. In this way, during the lower body injection, the cover along the rim is heated along the junction line where the lower body comes into contact at a high temperature, preventing the corresponding part of the cover from melting and losing its form. The cover preferably has a flat plate structure. Thanks to the high melting temperature, a deformation of the flat plate structure is prevented that may cause bending or twisting due to melting or thermal stress.

[0007] In a preferred embodiment of the invention, the cover and the lower body comprise a metal, particularly aluminum alloy. Due to its high adhesion capability in the molten state, the aluminum alloy makes the integration possible directly with the adhesion of the rim part to the cover, without the need to apply another process in the junction line.

[0008] A burner assembly produced as described above, comprises a lower flange extending along the circumferential edge of the lower body and an upper flange which corresponds to the lower flange on the cover and aligned with the lower flange (22) on top of each other, between which a junction line is provided. The lower flange and the upper flange increase the sealing properties by providing a high radial junction line with planar surfaces that sit on each other. In addition, the extended lower and upper flange parts display fast cooling properties after injection and provide rapid cooling and integration in a way that increases the production speed in case the lower part is injected into the upper cover from the upper flange.

[0009] The gas inlet and the transfer channel are arranged essentially perpendicular to each other. Thus, a lower body and a cover structure suitable for a burner assembly comprising a horizontal or partially angled injector can be obtained. In an alternative embodiment, the gas inlet may be located at the bottom of the lower body. A suitable area can be created for the mounting of multiple injectors with one or more gas inlets.

[0010] The transfer channel is provided on the cover adjacent to the junction line. Thus, it is possible to quickly form the lower body by the transfer channel creating a cooling effect after the injection of the lower body onto the cover. The burner assembly comprises an inner channel coaxially provided with the transfer channel at the center of the cover and accessing the flame distributor in a manner that provides gas transmission. Multiple channels, that is, the transfer channel and the inner channel, can be connected together to a flame distributor having a multiple nested flame distribution for the wok burner assembly in such a way to supply air-gas mixture from the lower body.

[0011] The lower flange comprises a barrier extending circumferentially upward at its outer edge and delimiting a pool, and the upper flange is arranged in such a way that leans against the barrier from inside from a radial outer part thereof. The barrier helps the cover to wrap the cover not only in the radial direction with the junction line, but also axially. Thus, the sealing cross section is extended, for example forms an L-like structure.

[0012] The burner assembly comprises a tab extending radially outwardly on the outer part and a groove correspondingly wrapping the tab in the barrier. In this way, the contact surface of the barrier with the cover increases from the corner of the barrier and the cover is provided to be strongly integrated into the lower body after injection.

[0013] The junction line is in a circular strip structure. Thus, the sealing between the container-shaped lower body and the cover is provided circumferentially.BRIEF DESCRIPTION OF THE FIGURES

[0014] Figure 1 is the side sectional view of a representative embodiment of the burner assembly produced by means of the method of the invention, in a schematically shown injection mold. Figure 2 is an extended illustration of the flange part of the burner assembly shown in Figure 1. DETAILED DESCRIPTION OF THE INVENTION

[0015] In this detailed description, the development of the invention is described without any limitation and only with references to the examples for a better explanation of the subject.

[0016] In Figure 1, a representative embodiment of the burner assembly produced by means of the method of the invention is shown by taking a cross section in the integrated state after injection in a schematically given mold (40). The burner assembly comprises a lower body (20) in the form of a container covered in a gas-tight manner by a cover (10) and a flame distributor (30) placed on the cover (10). The lower body (20) is fixed on the burner plate (not shown) of a cooker with the cover (10). The cover (10) is in the form of a circular flat plate. The cover (10) is attached to the mold (40) in the form of an insert. The lower body (20) is injected on the cover (10) of similar metal material by injection of aluminum alloy and is connected in a way that defines a junction line (1) at the part where they come into contact with the cover (10). The alloy material of the cover (10) has been chosen to be higher than the alloy material of the lower body (20) in terms of melting temperature. An inner channel (18) in the form of a hole in the center of the cover (10) and a transfer channel (16) radially distanced therefrom are provided. The inner channel (18) and the transfer channel (16) are surrounded by forms in the form of chimneys that are extended outwards from an upper surface (14). The part close to the outer part (15) of the cover (10) circumferentially defines an upper flange (12). The upper flange (12) is an extension outward from the part that the transfer channel (16) separates.

[0017] The lower body (20) is formed under the cover (10). The lower body (20) comprises a hollow cylindrical container (24) with gas inlet (28) on its side and a lower part (26) surrounding it. The container (24) mixes the flammable gas supplied from the gas inlet (28) with the ambient air and transfers the mixture to the inner wall (23) and the transfer channel (16) with the channels provided at the lower part (26). The container (24) is in a hollow, closed-bottom, thin-walled cylindrical form.

[0018] In Figure 2, the part A provided in Figure 1 is shown as enlarged. The cover (10) is obtained by extending the upper flange (12) to form a barrier (25) in the form of an upward protrusion that limits the outer part (15) of the lower flange (22) in the form of a radial strip. An inward groove (21) is formed on the inner wall of the barrier (25), in such a way that forms a level with the lower corner (13) part. A tab (11) formed on the edge of the upper flange (12) near the lower corner of the outer part (15) is placed in the groove (21). The tab (11) is placed in the groove (21) to fit perfectly. The lower surface (17) of the upper flange (12) is planar. Similarly, the corresponding seating surface (27) of the lower body (20) placed on the lower surface (17) is also planar. The metal injection mold (40) supports the upper flange (12) internally with the help of a core (not shown) leaning against the inner wall (23), and the aluminum alloy injected into the lower surface (17) adheres to the seating surface (27) without melting the cover (10), and cools in such a way to form the lower flange (22). Once it is removed from the mold (40), the cover (10) is integrated with the lower body (20) and is combined with the flame distributor (30) to be used in the burner assembly.REFERENCE NUMBERS

[0019] 1Junction line20Lower body10Cover21Groove11Tab22Lower flange12Upper flange23Inner wall13Lower corner24Container14Upper surface25Barrier15Outer part26Lower part16Transfer channel27Seating surface17Lower surface28Gas inlet18Inner channel29Rim part30Flame distributor40Metal injection mold

Examples

Embodiment Construction

[0015]In this detailed description, the development of the invention is described without any limitation and only with references to the examples for a better explanation of the subject.

[0016]In Figure 1, a representative embodiment of the burner assembly produced by means of the method of the invention is shown by taking a cross section in the integrated state after injection in a schematically given mold (40). The burner assembly comprises a lower body (20) in the form of a container covered in a gas-tight manner by a cover (10) and a flame distributor (30) placed on the cover (10). The lower body (20) is fixed on the burner plate (not shown) of a cooker with the cover (10). The cover (10) is in the form of a circular flat plate. The cover (10) is attached to the mold (40) in the form of an insert. The lower body (20) is injected on the cover (10) of similar metal material by injection of aluminum alloy and is connected in a way that defines a junction line (1) at the part where t...

Claims

1. A production method of a burner assembly for a gas cooker device, the burner assembly comprising a metal lower body (20) in the form of a container provided with a gas inlet (14), formed under a cover (10) and the cover (10) which is hermetically fitted to a rim part (29) of the lower body (20) on which there is a transfer channel (16) providing air gas mixture transmission to a flame distributor (30), the method comprising the steps of pre-fixing the cover (10) on a metal injection mold (40); injecting the lower body (20) into the mold forming a gas-tight junction line (1) along the cover (10) where the rim part (29) come into contact with the cover (10); cooling the lower body (20) and the cover (10) integrated by injection and the removing the lower body (20) from the mold with the cover.

2. A burner assembly production method according to Claim 1, wherein the material melting temperature of the cover (10) is higher than the melting temperature of the lower body (20).

3. A production method of burner assembly according to any one of the preceding claims, wherein the cover (10) and the lower body (20) contain a metal, particularly aluminum alloy.

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