Gas Fired Radiant Emitter Coating Sintering
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Solution Overview
Problem
Existing methods for manufacturing gas fired radiant emitters with high emissivity coatings require a separate curing and sintering process in an oven, which is costly, labor-intensive, and energy-consuming.
Innovation Solution
A method involving a porous ceramic burner deck with a wet coating layer comprising ceramic and metallic particles, where the sintering and curing process is achieved by operating the gas fired radiant emitter, eliminating the need for an oven by using combustible gas to transform the coating layer into a firmly adhering, high emissivity layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate oven sintering process is used to cure the coating layer, then the coating adheres firmly to the burner surface, but the manufacturing complexity and energy consumption increase
Solution Approach 1:
The patent combines the coating application and sintering operations into a single integrated process. The coating slurry is applied directly to the burner surface and sintered in-place within the burner assembly itself, eliminating the need for a separate oven treatment step. This merging of operations reduces manufacturing complexity while maintaining coating adhesion quality.
Solution Approach 2:
The burner assembly serves its own coating sintering function by providing the necessary heating capability within its own structure. The burner can be ignited and used to sinter the coating material directly on its surface, making the system self-sufficient and eliminating dependence on external oven equipment.
2Reliability
If a separate oven sintering process is used to cure the coating layer, then the coating adheres firmly to the burner surface, but the energy consumption and cost increase
Solution Approach 1:
The patent combines the coating application and sintering operations into a single integrated process. The coating slurry is applied directly to the burner surface and sintered in-place within the burner assembly itself, eliminating the need for a separate oven treatment step. This merging of operations reduces manufacturing complexity while maintaining coating adhesion quality.
Solution Approach 2:
The burner assembly serves its own coating sintering function by providing the necessary heating capability within its own structure. The burner can be ignited and used to sinter the coating material directly on its surface, making the system self-sufficient and eliminating dependence on external oven equipment.
3Reliability
If a separate oven sintering process is used to cure the coating layer, then the coating adheres firmly to the burner surface, but the manufacturing time and labor requirements increase
Solution Approach 1:
The patent combines the coating application and sintering operations into a single integrated process. The coating slurry is applied directly to the burner surface and sintered in-place within the burner assembly itself, eliminating the need for a separate oven treatment step. This merging of operations reduces manufacturing complexity while maintaining coating adhesion quality.
Solution Approach 2:
The burner assembly serves its own coating sintering function by providing the necessary heating capability within its own structure. The burner can be ignited and used to sinter the coating material directly on its surface, making the system self-sufficient and eliminating dependence on external oven equipment.
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 method simplifies the sintering process, reduces energy consumption, and results in a strong, high emissivity coating that enhances the performance of the gas fired radiant emitter, achieving emissivity 30% to 100% higher than uncoated surfaces.
Implementation Method 1
supplying combustible gas to it and igniting the combustible gas after it has flown through the porous ceramic burner deck, whereby the uncured and/or unsintered coating layer is transformed into a sintered and/or cured coating layer
Implementation Method 2
the uncured and/or unsintered coating layer is transformed into a sintered and/or cured coating layer adhering to the porous ceramic burner deck
Data Source
Figure 1
AI summary
The invention relates to a method for manufacturinga gas fired radiant emitter with increased emissivity. The method comprises the steps of - providing a porous ceramic burner deck, e.g. a perforated ceramic burner deck, - applying a wet coating layer on the porous ceramic burner deck, wherein the wet coating layer comprises ceramic particles and/or metallic particles that will form a coating layer with increased emissivity compared to the porous ceramic burner deck without the coating layer, - sintering and/or curing the coating layer, whereby the sintering and/or curing is performed by operating the gas fired radiant emitter in which the porous ceramic burner deck is mounted, via supplying combustible gas to the radiant emitter and igniting the combustible gas after it has flown through the porous ceramic burner deck, whereby the uncured and/or unsintered coating layer is transformed into a sintered and/or cured coating layer adhering to the porous ceramic burner deck via sintered and/or cured bonds.