Reinforced Burner Electrode With Cavity-Strut Structure
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Solution Overview
Problem
Conventional burner electrodes in gas heating systems are prone to frequent replacement due to high thermal and mechanical stress, leading to increased costs and reduced reliability, as they are made of expensive high-temperature-resistant materials that wear out quickly from sparking and exposure to flames.
Innovation Solution
The burner electrode features a middle part with cavities and struts for structural stabilization, made from refractory material with a layered and sintered structure, reducing material usage while maintaining mechanical stability, and allowing for the separation and replacement of the electrode tip independently from the central part, which is designed with a lattice, framework, or bone structure for enhanced durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional burner electrodes are made from high-temperature-resistant material, then they can withstand thermal loads, but they wear out quickly due to sparking and exposure to flames, requiring frequent replacement
Solution Approach 1:
The electrode is divided into multiple sections with different structures: a solid electrode tip for sparking, a middle section with cavities for reduced material usage and thermal stress, and a shaft section. This segmentation allows each part to be optimized for its specific function while reducing overall material consumption and thermal stress on the refractory material.
Solution Approach 2:
Different sections of the electrode have different structural qualities - the tip is solid for effective sparking, the middle section has cavities for thermal stress reduction and material savings, and only critical areas use expensive refractory material. This local differentiation optimizes performance while reducing cost and improving durability.
2Temperature
If burner electrodes use expensive refractory material, then they resist high temperatures, but replacement costs increase and service interruption occurs
Solution Approach 1:
The middle section of the electrode incorporates cavities creating a porous or honeycomb-like structure. This reduces the amount of expensive refractory material needed while maintaining sufficient thermal resistance and structural integrity. The porous structure also reduces thermal stress and facilitates heat dissipation.
Solution Approach 2:
The electrode combines different material structures - solid refractory material at the tip for sparking, cavitied refractory material in the middle section for thermal management, and potentially different materials in the shaft section. This composite approach optimizes the balance between heat resistance and cost-effectiveness.
3Ease of operation
If the electrode tip is continuously exposed to sparking and flames, then it performs its ignition function, but it erodes rapidly and requires frequent replacement
Solution Approach 1:
The electrode is segmented into a consumable tip section and a durable middle/shaft section. The tip is designed to be replaced independently when worn, while the expensive refractory middle section with cavities is preserved. This allows replacement of only the worn tip rather than the entire electrode assembly.
Solution Approach 2:
The electrode tip is designed as a replaceable component that can be discarded when eroded, while the valuable middle section with cavities is recovered and reused. This extends the overall lifespan of the electrode assembly and reduces replacement costs.
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
This design extends the service life of the burner electrode, reduces replacement costs, and ensures reliable operation by minimizing the use of expensive refractory material while maintaining mechanical stability and resistance to environmental influences.
Implementation Method 1
the cavity-bearing section of the central part consists at least partially of material applied in layers and melted and/or sintered by targeted local heating
Implementation Method 2
serve to generate a spark at the start of each combustion process, which ignites a gas flame or detects the presence of a flame
Data Source
Figure 1a~1b
Figure 2
Figure 3
AI summary
The present invention relates to a burner electrode comprising a lower shaft section (1), a central section (2) adjoining the shaft section at one end, and an electrode tip (3) adjoining the other end of the central section, wherein at least the electrode tip (3) and at least one section (2b) of the central section (2) adjoining the electrode tip are made of a high-temperature-resistant material. To create a burner electrode with significantly improved durability while requiring as little of the relatively expensive refractory material as possible for its manufacture, the invention proposes that the central section has cavities (2d) at least along the section (2b) adjoining the electrode tip and is structurally stabilized in this section (2b) by partitions or struts between the cavities.