Gas Appliance Knob Mounting Bracket for Alignment Precision
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Solution Overview
Problem
Existing methods for aligning knobs on gas cooking appliances during manufacture are either costly, increase assembly complexity, or have limitations in achieving precise alignment, leading to potential misalignment issues.
Innovation Solution
A system using a bracket with complementary protrusions and legs that mate with a cutout in the console to secure the knob to the valve, ensuring accurate alignment through a secure fastening mechanism, allowing for precise positioning of the knob relative to the bezel and valve.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If tight tolerances are used for appliance structure during manufacture, then alignment precision is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The patent introduces a bracket as an intermediary component between the knob and the valve stem. The bracket includes alignment features such as a slot or guide that automatically positions the knob relative to the valve stem during assembly, eliminating the need for tight tolerances on the valve stem itself. This mediator component absorbs the alignment function, allowing simpler manufacturing of the primary components.
Solution Approach 2:
The bracket is designed with self-aligning features where the alignment geometry (such as a slot, ridge, or guide feature) automatically positions the knob correctly as it is installed on the valve stem. The alignment occurs through the natural insertion motion without requiring external alignment tools or complex adjustment procedures, making the system self-aligning during assembly.
2Manufacturing precision
If manual repositioning of valve stems is performed, then alignment precision is improved, but assembly time and labor cost increase
Solution Approach 1:
The bracket is pre-configured with alignment features during manufacturing that automatically guide the knob into the correct position when installed. The alignment geometry (slot, guide ridge, or positioning feature) is built into the bracket beforehand, so that during final assembly, the knob simply snaps or slides into place with automatic alignment, eliminating the need for manual repositioning of the valve stem during assembly.
3Adaptability or versatility
If flexible tubing is used for valves, then adaptability is improved, but alignment precision and structural integrity worsen
Solution Approach 1:
The system is segmented into distinct functional components: the rigid bracket provides structural support and alignment, while the flexible element (if present) is isolated to specific sections where flexibility is needed. The bracket's rigid alignment features maintain precision, while any flexible tubing or components are confined to areas where adaptability is required, such as gas supply lines, without compromising the alignment of the control interface.
4Manufacturing precision
If expensive machined guides and alignment aids are employed, then alignment precision is improved, but manufacturing cost increases
Solution Approach 1:
The patent uses simple, inexpensive bracket components with basic alignment features (such as molded-in slots, simple guide ridges, or basic positioning tabs) rather than expensive precision-machined alignment aids. These simple alignment features are sufficient for achieving the required alignment precision and can be manufactured using low-cost processes such as stamping, molding, or simple machining, making the system economical while maintaining functionality.
Data Source
AI summary
A gas cooking appliance includes a valve and a first pipe configured to transport gas to the valve. The appliance also includes a burner and a second pipe configured to transport gas from the valve to the burner. The appliance further includes a console and a knob. The console includes a cutout having an edge defining a shape of the cutout, and the knob includes a handle and a bezel. The knob is configured to control a state of the valve. The bezel has a rear face and a protrusion extending rearward from the rear face through the cutout, the protrusion contacting the edge of the cutout. The appliance additionally includes a bracket coupling the knob to the valve. The bracket includes a leg mating with the protrusion.