Gas Burner Head Segmentation for Flame Stability and Cost Reduction
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Solution Overview
Problem
Existing gas burner designs require high-temperature-resistant materials for both the upper and lower parts of the burner head to prevent flame lifting, making them costly and inefficient in terms of material usage.
Innovation Solution
The annular gap is designed as a groove within the upper part of the burner head, allowing the holding flame to only contact the upper part, which is made of a high-temperature-resistant material, while the lower part can be made of a less expensive, lower-temperature-resistant material like an aluminum alloy, with multiple bores ensuring even gas-air mixture distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the annular gap is formed by a defined gap between the lower part and upper part of the burner head, then the holding flame can prevent gas flames from lifting off, but both parts must be made of high-temperature-resistant material increasing cost
Solution Approach 1:
The burner head is divided into an upper part and a lower part, with the annular gap formed only in the upper part. This segmentation allows the holding flame to be contained in the upper part only, exposing the lower part to significantly lower temperatures, thereby enabling the use of cheaper, lower-temperature-resistant materials for the lower part while maintaining flame stability through the holding flame in the upper part.
Solution Approach 2:
Different parts of the burner head are assigned different material properties based on their thermal exposure. The upper part, which is in contact with the holding flame, is made of high-temperature-resistant material, while the lower part, which does not contact the holding flame, can be made of less expensive, lower-temperature-resistant material. This local differentiation optimizes both performance and cost.
2Reliability
If the annular gap is formed by a defined gap between parts, then the holding flame can be maintained, but manufacturing complexity increases due to precise gap requirements
Solution Approach 1:
The annular gap is extracted from the inter-part space and repositioned entirely within the upper part of the burner head as a groove. This extraction eliminates the need for precise gap control between parts and instead requires only a single groove feature to be machined in the upper part, simplifying manufacturing while maintaining the holding flame function.
Solution Approach 2:
The annular gap is transformed from a radial gap between two parts into a groove feature within the upper part's structure. This dimensional repositioning moves the gap from an inter-component space to an intracomponent feature, eliminating the need for precise assembly gap control and reducing manufacturing complexity.
3Manufacturing precision
If multiple bores are provided for gas supply to the annular gap, then even gas-air mixture distribution is ensured, but manufacturing complexity increases
Solution Approach 1:
The multiple bores in the upper part serve dual functions: they supply the gas-air mixture to the annular gap for the holding flame and simultaneously act as ignition sources for the gas outlet openings. This multi-functionality justifies the increased number of bores by delivering multiple benefits from a single structural feature set.
Solution Approach 2:
The gas outlet openings utilize the gas supply bores to ignite the gas-air mixture directly at the opening. The bores serve the self-service function of both supplying gas to the holding flame and providing ignition for the main gas flow, eliminating the need for separate ignition mechanisms.
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 effectively prevents flame lifting while reducing material costs by allowing the use of less expensive materials for the lower part of the burner head without compromising heat resistance or flame stability.
Implementation Method 1
The holding flame prevents the gas flames from lifting off the gas outlet openings, in that the holding flames ignite the gas exiting from the gas outlet openings directly at the gas outlet opening
Implementation Method 2
The gas mixing chamber inside the burner head, between the upper part of the burner head and the lower part of the burner head, is designed in such a way that the gas and primary air are mixed as well as possible
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The range has a gas mixing cavity that is installed between a lower component (1) and an upper component (2). The upper component is equipped with a gas outlet on an outer circumferential surface. The gas outlet is connected with the gas mixing cavity. An annular clearance unit is formed below the gas outlet. The annular clearance unit is connected with the gas mixing cavity through multiple holes, where the annular clearance unit is equipped with a groove formed in the upper component.