Single-Piece Gas Burner Cup Casting for Axial Venturi Mixers
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Solution Overview
Problem
The existing methods for manufacturing gas burners with a mixer having an axial Venturi effect are complex, expensive, and difficult to implement, especially when aiming for a single-piece construction that can deliver high thermal power.
Innovation Solution
A method involving casting or die-casting a gas burner cup with a tubular tapered mixer using a removable core that includes a cantilevered portion to create the Venturi effect, allowing for a single-piece, cost-effective, and mechanically robust burner production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a mixer with axial Venturi effect is manufactured by assembling multiple metal parts through welding and chip removal machining, then the structural robustness and mechanical strength are improved, but the manufacturing complexity and cost increase significantly
Solution Approach 1:
The patent merges the mixer with axial Venturi effect into the cup structure by integrating it during the die-casting process. The core is inserted into the mould before casting, allowing the mixer to be formed as an integral part of the cup in a single operation, eliminating the need for separate manufacturing and assembly of multiple metal parts through welding and machining
Solution Approach 2:
The core is preliminarily positioned and fixed within the mould before the die-casting process begins. This preliminary arrangement ensures that the mixer with axial Venturi effect is correctly formed during casting, avoiding the need for subsequent complex machining and welding operations to achieve the desired robust structure
2Strength
If a mixer with axial Venturi effect is manufactured by assembling multiple metal parts, then the structural integrity is improved, but the manufacturing time and production cost increase
Solution Approach 1:
The mixer is combined with the cup in a single die-casting operation using a core inserted into the mould. This integration eliminates multiple manufacturing steps including separate casting, welding, and machining operations, significantly reducing manufacturing time while maintaining structural integrity
Solution Approach 2:
The core is preliminarily installed in the mould before casting to pre-form the mixer structure. This preliminary action allows the mixer to be created during the casting process itself, avoiding time-consuming post-casting operations and reducing overall production time
3Strength
If a single-piece cup with mixer is manufactured through complex chip removal machining, then the structural robustness is improved, but the manufacturing cost and difficulty increase
Solution Approach 1:
The core is preliminarily positioned and fixed in the mould before die-casting to pre-form the mixer with axial Venturi effect. This preliminary action creates the desired structure during casting, eliminating the need for difficult and expensive chip removal machining operations while maintaining structural robustness
Solution Approach 2:
The patent replaces complex mechanical machining operations with a die-casting process that uses a core to directly form the mixer structure. This substitution of manufacturing methodology simplifies production, reduces cost, and maintains structural integrity by forming the robust mixer shape during casting rather than through difficult machining
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 and reduces the manufacturing time and cost of gas burners while ensuring a robust structure capable of delivering high thermal power, by using a core to shape the Venturi effect within the cup during casting or die-casting.
Implementation Method 1
The cup is made in a single piece by casting or die-casting in an apposite mould
Implementation Method 2
The cup is made in a single piece by casting or die-casting in an apposite mould
Implementation Method 3
a cup which is provided with at least one tubular tapered part of a mixer with axial Venturi effect
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
Method for manufacturing a gas burner of the type comprising a cup, provided with at least one tubular tapered part of a mixer with axial Venturi effect, and shaped to couple with a burner head provided with at least one flame-spreader, wherein said cup is made in a single piece by casting or die-casting in an apposite mould. Such a method comprises, in sequence, the following steps: a) arranging a mould with at least two shells, for casting or die-casting the afore said cup; b) arranging at least one core which could be removably inserted into the respective mould, which has at least one jutting portion shaped with at least one tubular tapered part of the strickle of the afore said mixer with axial Venturi effect; c) inserting such a core into the mould and closing the afore said at least two mould shells so that the afore said at least one jutting portion of the core is retained, at least partially, at a distance from the opposite inner walls of the closed mould; the core and the mould being shaped so that at least one ending part of such a core replaces, at least partially, part of the perimetrical area of the cup defined by the mould; d) pouring or pressure-injecting molten metal material into the closed mould; e) opening the mould, drawing out the afore said core and then removing the die formed cup after the metal material is solidified; f) applying at least one closing plug to the side hole (or side holes) of the die formed cup which corresponds/ correspond to the ending part of the core which replaced part of the perimetrical area of the cup in the mould.