Woven Wire Mesh Burner Deck Tabs for Thermal Stress Management
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Solution Overview
Problem
Surface stabilized premix gas burners with woven wire mesh burner decks face early mechanical failure due to thermal expansion and shrinkage stresses, which existing technologies have not adequately addressed.
Innovation Solution
Incorporating tabs at the circumference of the woven wire mesh burner deck that are inserted through openings in a metal plate structure, allowing for movement without mechanical bonding, and using a groove structure to enhance thermal stress management, along with a convex burner deck shape and perforated plate segments for even gas distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the woven wire mesh burner deck is mechanically bonded to the metal plate structure, then structural stability is improved, but thermal expansion and shrinkage stresses cause early mechanical failure
Solution Approach 1:
The invention extracts the constraint mechanism by removing tabs from the burner deck and inserting them into openings in the metal plate structure, separating the burner deck from rigid mechanical bonding while maintaining positional stability through friction and geometry
Solution Approach 2:
The invention transforms the static rigid connection into a dynamic semi-rigid connection where tabs can rotate and move within openings, allowing the burner deck to adapt to thermal expansion and shrinkage while maintaining structural stability during operation
2Manufacturing precision
If the woven wire mesh burner deck is rigidly fixed to the metal plate structure, then positioning accuracy is improved, but thermal stress causes mechanical failure
Solution Approach 1:
The invention applies different connection characteristics at different locations: tabs at the circumference provide localized positioning and constraint, while the bulk of the burner deck remains free to expand and contract thermally, creating a hybrid connection that balances positioning accuracy with thermal stress resistance
3Strength
If mechanical bonding methods (welds or physical bonding) are used to attach the burner deck, then connection strength is improved, but thermal expansion compatibility deteriorates
Solution Approach 1:
The invention introduces tabs as intermediary elements between the burner deck and metal plate structure, which act as flexible mediators that can rotate and move to accommodate thermal expansion while maintaining connection strength through friction and geometric constraint rather than rigid bonding
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively withstands thermal expansion and shrinkage, leading to a longer lifetime of the burner deck by allowing movement and reducing the risk of mechanical failure and flame flashback.
Implementation Method 1
The woven wire mesh burner deck needs to be able to cope with the stresses induced by the thermal expansion associated with the high temperature when the burner is in use and by the shrinkage when the burner is not in use.
Implementation Method 2
an amount of movement of the woven wire mesh relative to the metal plate structure is possible when the woven wire mesh expands when warming up or shrinks when cooling down
Data Source
Figure 1~3
Figure 4~6
AI summary
A premix gas burner comprises a metal plate structure for mounting the premix gas burner in a heating appliance. The premix gas burner comprises a burner deck. The burner deck comprises a woven wire mesh on the outer surface of which premix gas is combusted after the premix gas has flown through the woven wire mesh. One or more than one opening is provided in the metal plate structure. The circumferential edge of the woven wire mesh comprises at least one tab. Each tab is inserted through an opening in the metal plate structure.