Combustion Membrane Rib Structure for Uniform Gas Burner Flames
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Solution Overview
Problem
Existing combustion membranes in gas burners suffer from issues such as localized flame detachment, overheating, uneven temperature distribution, and mechanical failures due to thread tension differences, leading to noise, structural damage, and inefficient thermal insulation.
Innovation Solution
A combustion membrane made of a fabric with alternating high-relief ribs and low-relief sags, formed by zigzag patterns of warp and weft threads, which uniform thread lengths and reduce mechanical anisotropy, supported by a perforated sheet metal layer, to enhance flame uniformity and thermal insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If reliefs and depressions are created in the combustion membrane to provide volume and thickness, then thermal insulation and flame uniformity are improved, but uneven consumption of metal threads occurs causing breakages and machine stoppages
Solution Approach 1:
The fabric structure is segmented into distinct relief and depression zones created by alternating float patterns of warp and weft threads. This segmentation allows different regions to serve different functions: reliefs provide thermal insulation and flame distribution, while depressions allow gas passage and reduce material concentration, preventing hot spots and thread overheating
Solution Approach 2:
Different regions of the fabric are given different properties through the relief-depression pattern. The reliefs have higher thermal mass and insulation properties, while the depressions have lower material density and better gas flow characteristics. This local differentiation optimizes both thermal performance and thread stress distribution
2Manufacturing precision
If reliefs and depressions are created in the combustion membrane, then flame uniformity is improved, but manufacturing complexity increases due to uneven thread tension and breakages
Solution Approach 1:
The fabric uses periodic repetition of float patterns at regular intervals in both warp and weft directions. This periodic structure creates the desired relief-depression pattern while maintaining consistent thread tension cycles that are manageable by standard loom mechanisms, reducing manufacturing complexity compared to aperiodic or random patterns
Solution Approach 2:
The relief structures are formed with curved, rounded profiles rather than sharp angular transitions. This curvature distributes stress more evenly across the metal threads during weaving and operation, preventing concentration of tension at sharp corners that would cause breakages and simplify the weaving process
3Reliability
If accessory structures like inserts or diaphragms are added to bias fluid dynamic conditions, then combustion stability is improved, but device complexity and cost increase
Solution Approach 1:
The fabric structure performs multiple functions simultaneously: it distributes gas flow, provides thermal insulation, supports the combustion process, and stabilizes flame attachment. This multi-functionality eliminates the need for separate accessory structures like inserts or diaphragms that would otherwise be required to achieve these same effects
Solution Approach 2:
The combustion membrane integrates several previously separate components into a single fabric structure. The relief patterns combine the functions of flow distributors, thermal insulation layers, and flame stabilizers that were traditionally implemented as separate accessory structures, simplifying the overall burner design
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 reduces thread breaks, optimizes weaving, and achieves uniform flame distribution and improved thermal insulation, minimizing noise and structural damage while extending the burner's operational lifespan.
Implementation Method 1
a fabric (21) forming an interlacement of metal threads (22) comprising warp threads and weft threads transverse with respect to the warp threads
Implementation Method 2
The heat generated by the combustion is conveyed by the hot combustion gases (convection) and by heat radiation to a heat exchanger
Implementation Method 3
The heat generated by the combustion is conveyed by the hot combustion gases (convection) and by heat radiation to a heat exchanger
Implementation Method 4
said fabric (21) being supported by a support layer (32), in particular made of a perforated sheet metal
Data Source
AI summary
A combustion membrane (14) for a gas burner (2) comprises a fabric (21) having two opposite fabric surfaces (19, 20) which form a combustion surface (19) exposed on the outer side (17) and an inner surface (20) facing an inner side (18), respectively, wherein the fabric (21) forms an interlacement of metal threads (22) comprising warp threads and weft threads transverse with respect to the warp threads, wherein both fabric surfaces (19, 20) form high-relief ribs (23) alternating with low-relief sags (24), and the ribs (23) comprise:weft ribs (25) formed by weft threads and extending in the weft direction (26) arranged in weft rib sequences (2′) aligned along weft directions (26) substantially straight and parallel to one another, andwarp ribs (27) formed by warp threads and extending in the warp direction (28) and arranged in zigzag warp rib sequences (27′), wherein all the warp threads participate in the formation of said warp ribs (27) in an alternating and repetitive manner along the extension thereof in the warp direction (28).