Burner Hatch Baffle for Uniform Fuel Distribution

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Solution Overview

Problem

Conventional burner access hatches fail to evenly distribute fuel sources into combustion chambers, leading to incomplete combustion, reduced efficiency, and noise due to harmonic effects, which can cause damage and reliability issues in furnace systems.

Innovation Solution

A cover plate hatch with a baffle area designed to direct fluid fuel sources into the combustion chamber, featuring a body with a curved surface and connection points for structural support, and a removable hatch lid that reduces air volume and noise by promoting even fuel distribution.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a conventional burner access hatch is used, then the structure is simple, but the fuel source is not evenly distributed into the combustion chamber

Engineering Contradiction:
Improvefuel distribution uniformityVSAvoidhatch structure complexity
Core Design Contradiction:
Manufacturing precisionVSDevice complexity

Solution Approach 1:

The hatch lid body is segmented into multiple functional zones: a baffle area with curved surfaces for flow direction, an upper portion with connection points for structural support, and a lower portion for volume reduction. This segmentation allows each zone to perform its specific function optimally, achieving uniform fuel distribution through the baffle area while maintaining structural integrity through distributed connection points.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The baffle area incorporates curved surfaces that guide the fuel source flow in a smooth, distributed manner into the combustion chamber. The curvature of these surfaces creates favorable flow patterns that prevent localized concentration of fuel, ensuring even distribution across the combustion chamber inlet while managing the complexity through geometric design rather than mechanical complexity.

Inventive Principle:
Principle #14Spheroidality (Curvature)

2Reliability

If a conventional burner access hatch is used, then the manufacturing process is simple, but incomplete combustion occurs leading to potential leaks

Engineering Contradiction:
Improvecombustion completenessVSAvoidhatch manufacturing difficulty
Core Design Contradiction:
ReliabilityVSEase of manufacture

Solution Approach 1:

Different regions of the hatch lid are given different geometric qualities to optimize local functions. The baffle area has curved surfaces specifically designed for flow distribution, while the upper portion has connection points for structural support, and the lower portion is indented for volume reduction. This local differentiation ensures complete combustion through proper flow management without requiring complex manufacturing processes across the entire structure.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The geometry parameters of the hatch lid are optimized to achieve complete combustion. The curved surfaces in the baffle area have specific radius and curvature parameters that control fuel flow distribution. The connection points have defined spacing and structural parameters. These parameter optimizations ensure reliable combustion while maintaining manufacturability through precise geometric definition rather than complex assembly.

Inventive Principle:
Principle #35Parameter changes

3Reliability

If a conventional burner access hatch is used, then the design is simple, but hotspots are created reducing furnace system reliability

Engineering Contradiction:
Improvefurnace system reliabilityVSAvoidhatch design complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The hatch lid is divided into functional segments that control fuel flow distribution. The baffle area with curved surfaces segments the fuel flow into multiple streams, preventing concentration in single locations that would create hotspots. The upper portion with distributed connection points segments the structural support, and the lower portion segments the volume. This segmentation approach eliminates hotspots through flow distribution while keeping the design manageable through functional zoning.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The curved surfaces in the baffle area create smooth flow transitions that distribute fuel evenly across the combustion chamber inlet. The curvature geometry prevents flow concentration and associated hotspot formation. This geometric approach to reliability avoids the need for complex active control systems or multiple moving parts, achieving reliable operation through passive flow management.

Inventive Principle:
Principle #14Spheroidality (Curvature)

4Object-affected harmful factors

If a conventional burner access hatch is used, then the structure is simple, but excessive air volume creates noise due to harmonic effects

Engineering Contradiction:
Improvenoise reductionVSAvoidhatch structure complexity
Core Design Contradiction:
Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The lower portion of the hatch lid body includes indentations that extract or remove excess air volume from the combustion chamber space. By creating recesses in the lower portion, the design reduces the overall air volume that could participate in harmonic oscillations and generate noise. This extraction approach reduces noise harmful effects without requiring additional noise control components or complex structures.

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The indentations in the lower portion that reduce air volume also serve as structural features that can enhance fuel flow management. The volume reduction benefits noise reduction by minimizing excess air for harmonic effects, while the same geometric features can be designed to work with the baffle area for optimal fuel distribution. This converts a potential design addition into a multi-functional feature that addresses both noise and combustion efficiency.

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

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 improves the reliability and efficiency of furnace systems by stabilizing the flame, reducing hotspots, and minimizing noise-producing harmonic effects, while allowing for easier maintenance and access to internal components.

Implementation Method 1

The body forms a baffle area designed to direct a fluid fuel source into the combustion chamber

Methodology Applied
Scientific EffectFluid flow direction:

Implementation Method 2

The baffle area includes at least one curved surface... designed to distribute a fuel source evenly into a combustion chamber

Methodology Applied
Scientific EffectFlow distribution:

Implementation Method 3

the hatch lid is designed to reduce an air volume between the hatch lid and the combustion chamber

Methodology Applied
Scientific EffectVolume reduction:

Implementation Method 4

The excess space can cause noise due to harmonic effects... minimize noise-producing harmonic effects

Methodology Applied
Scientific EffectHarmonic effects: Resonance

Data Source

PatentUS20240263778A1Burner access hatch
Publication Date: 2024.08.08 WEIL MCLAIN
  • US20240263778A1 patent drawing
  • US20240263778A1 patent drawing
  • US20240263778A1 patent drawing

AI summary

A cover plate assembly for use with a furnace system is provided. The cover plate assembly includes a plate, a central opening formed within the plate, a hatch lid positioned at least partially within the central opening and the hatch lid having a body with a baffle area. The cover plate assembly further includes an inlet structure designed to direct a fluid fuel source towards the central opening. The baffle area is positioned towards the inlet structure forming a fluid pathway between the inlet structure and the baffle area. In some instances, the hatch lid is removable such that internal components of the furnace system can be accessed without having to remove the entire cover plate assembly. Also, the cover plate assembly provided herein is designed to distribute a fuel source evenly into a combustion chamber and reduce noise-producing harmonic effects in the furnace system.