Gas Cooktop Knob Mounting with Bracket-Mediated Alignment
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Solution Overview
Problem
Existing methods for aligning knobs on gas cooking appliances during manufacture are either costly, require additional assembly steps, or risk damage to valve stems, and do not ensure precise alignment.
Innovation Solution
A system using a spider bracket with protrusions and a cutout in the console to secure the knob to the valve, ensuring accurate alignment by complementary shapes and fasteners, which maintains the valve stem's precise position.
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 in the valve stem positioning while ensuring precise alignment.
Solution Approach 2:
The alignment features built into the bracket enable the assembly process to self-align components without requiring external alignment aids or complex positioning mechanisms. The bracket's geometry automatically guides the knob into proper alignment with the valve stem during installation.
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 serves as a mediator that pre-establishes the correct alignment geometry between the knob and valve stem. During assembly, the operator simply attaches the knob to the bracket, which automatically maintains proper alignment without requiring manual measurement or adjustment of the valve stem position.
Solution Approach 2:
The bracket is pre-configured with alignment features during manufacturing, so that when the knob is assembled to the valve stem through the bracket, the alignment is already established. This preliminary preparation eliminates the need for time-consuming manual repositioning during final assembly.
3Adaptability or versatility
If flexible tubing is used in connection with valves, then alignment flexibility is improved, but connection reliability deteriorates
Solution Approach 1:
The rigid bracket with built-in alignment features acts as an intermediary structure that provides both alignment flexibility through its design geometry and connection reliability through secure mechanical attachment points. The bracket's slot or guide features allow for adjustable positioning while maintaining stable, reliable connections.
4Manufacturing precision
If machined guides and alignment aids are employed, then alignment precision is improved, but manufacturing cost increases
Solution Approach 1:
The patent combines the alignment aid function directly into the bracket structure itself, rather than using separate machined guides or alignment fixtures. The bracket's integrated slot or guide features provide alignment functionality as part of the standard component, eliminating the need for additional expensive alignment hardware.
Solution Approach 2:
The bracket serves as an economical intermediary component that incorporates alignment features directly into its design. This approach provides precise alignment capability through simple geometric features in the bracket rather than requiring costly external alignment mechanisms.
Data Source
Figure 1A
Figure 1B
Figure 2A~2B
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.