Flat Oven Burner Assembly for Even Flame and Thin-Sheet Strength
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Solution Overview
Problem
Existing flat burners for ovens and grills face challenges in manufacturing efficiency, assembly complexity, and uneven flame distribution due to large size and material waste, with issues related to fastening and positioning of components like thermocouples and igniters.
Innovation Solution
A flat burner design featuring a reflecting shield with fastening tabs and a venturi tube integrated into the burner body, allowing for thinner metal sheets and improved gas-air mixture distribution, along with automatic positioning of thermocouples and igniters through integrated mountings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional flat burner design with two half shells is used, then integrated pilot burner is achieved, but manufacturing complexity and assembly time increase
Solution Approach 1:
The burner is divided into two half-shells that are assembled together, with the reflecting shield as a separate pre-assembled unit. This segmentation allows parallel manufacturing of components and simplifies final assembly by reducing the number of separate fastening operations needed.
Solution Approach 2:
The reflecting shield is pre-assembled with its fastening tabs attached to the burner body before the final assembly with the second half-shell. This preliminary action optimizes the assembly sequence and reduces on-site fastening operations.
2Strength
If thicker metal sheets are used for burner construction, then strength and stability are improved, but material waste and manufacturing cost increase
Solution Approach 1:
The burner combines thin metal sheets with strategically placed stiffening elements and contacting areas that form structural ribs. This composite approach maintains strength while minimizing material usage, as the stiffening features provide structural integrity without requiring uniformly thick material throughout.
Solution Approach 2:
Instead of using uniformly thick metal sheets, the design implements localized stiffening through contacting areas and fastening tabs only where structurally necessary. This allows thin material to be used in non-critical areas while maintaining strength at critical load-bearing points.
3Ease of operation
If larger burner size is used, then component positioning is easier, but overall device size and material consumption increase
Solution Approach 1:
The reflecting shield and its fastening tabs are pre-assembled as a unit before final installation. This preliminary assembly establishes precise component positioning in advance, eliminating the need for large tolerances or extensive on-site adjustment, thereby allowing compact overall dimensions.
Solution Approach 2:
The fastening tabs are designed to automatically position and secure the reflecting shield when bent against the burner wall. This self-positioning mechanism eliminates the need for additional positioning fixtures or large adjustment clearances, enabling compact design while maintaining ease of assembly.
4Ease of manufacture
If conventional gas distribution without inner walls is used, then manufacturing is simpler, but flame distribution becomes uneven
Solution Approach 1:
The burner incorporates localized inner walls or modulating structures at specific positions within the combustion chamber. These localized features are strategically placed to control gas flow and achieve uniform flame distribution only where needed, without requiring complete internal wall structures that would complicate manufacturing.
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 enhances manufacturing efficiency, reduces material waste, and achieves a more even flame distribution while simplifying assembly and positioning of components, allowing for thinner, stronger burner construction.
Implementation Method 1
a venturi tube integrated into the burner body
Implementation Method 2
a reflecting shield that can be secured to one of the two upper or lower walls of said flat body
Data Source
Figure 1
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AI summary
The invention relates to an oven or grill burner composed of a flat body delimiting an inner chamber and having fastening protrusions, characterized in that fastening members are composed of at least a tab made of one piece with flat body wall or walls. In addition to have the fastening tab as one piece, the burner has mountings fastening the thermocouple and/or igniter and/or the venturi tube supplying air and gas mixture also of one piece therewith. The burner is shaped such to increase the even distribution to outlet holes of gas and it has such constructive characteristics allowing to reduce the thickness of the metal sheet for making it without compromising the burner strength.