Inshot Burner Flame Retainer Insert Design
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Solution Overview
Problem
Conventional inshot burner designs for gas furnaces suffer from ignition issues, flame instability, noise, and reduced combustion efficiency due to inadequate flame anchoring and increased potential for flashback, especially in smaller furnaces with shorter burner and flame retention inserts.
Innovation Solution
A burner insert with a cylindrical body having a central passage and circumferentially disposed openings, featuring fins within the passage and rib members in each opening, which creates turbulence and increases the surface perimeter, stabilizing the flame and reducing flashback by enhancing air-fuel mixing and anchoring the combustion process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the velocity of the primary air/gas flow from the insert is greater than the flame speed, then the flame may lift off from the burner insert, but this contributes to noise and reduces flame stability
Solution Approach 1:
The burner insert is divided into multiple functional zones with different opening sizes: a central passage for primary air/gas flow and multiple peripheral openings for secondary air. This segmentation allows different regions to control different aspects of flame behavior, preventing lift-off while maintaining stability.
Solution Approach 2:
The burner insert acts as an intermediary device between the high-velocity air/gas flow and the flame. It modifies the flow characteristics through its structured openings and fins, creating a transition zone that anchors the flame and prevents lift-off without excessive noise.
2Speed
If the velocity of the air/gas mixture is too slow when compared to the flame speed, then the flame may flashback, but this can cause overheating and reduce burner life expectancy
Solution Approach 1:
Different regions of the burner insert have different flow characteristics. The central passage provides high-velocity flow to prevent flashback, while the peripheral openings provide controlled secondary air flow. This local differentiation allows the system to operate at optimal speeds throughout, preventing both lift-off and flashback.
Solution Approach 2:
The burner insert changes the flow parameters by creating turbulence through its fin structures and opening arrangements. This turbulence mixes air and gas more effectively, increasing the velocity of the combustion products while maintaining flame stability, thus preventing flashback without overheating the burner.
3Length of moving object
If the burner and flame retention inserts are made shorter for smaller furnaces, then the device adapts to compact spaces, but combustion efficiency decreases due to reduced mixing length
Solution Approach 1:
The burner insert uses radial dimension (circumferential openings and fins) to compensate for the reduced axial length. By creating turbulence and increasing mixing in the radial direction, the design achieves effective combustion within a compact overall length, maintaining efficiency in smaller furnaces.
Solution Approach 2:
The fin structures within the burner insert create turbulence and vibrational mixing of the air/gas stream. This mechanical mixing action occurs over a shorter distance, allowing efficient combustion in compact burners while maintaining the mixing effectiveness that would otherwise require a longer burner length.
4Reliability
If conventional flame retention inserts are used, then flame stability improves, but they do not adequately address flashback and reduce mixing efficiency
Solution Approach 1:
The burner insert merges multiple functions into a single component: it provides flame retention, creates turbulence for mixing, controls air/gas flow velocities, and prevents both lift-off and flashback. This integrated design achieves flame stability while improving combustion efficiency, overcoming the limitations of conventional separate components.
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
The burner insert improves flame stability, reduces noise, and enhances combustion efficiency by increasing air-fuel mixing and anchoring the flame, while minimizing the risk of flashback, even in smaller furnace designs.
Implementation Method 1
A plurality of fins are coupled to the wall and arranged within the central passage... which creates turbulence and increases the surface perimeter
Implementation Method 2
the combustion process is anchored to the retention insert... stabilizing the flame and reducing flashback by enhancing air-fuel mixing and anchoring the combustion process
Implementation Method 3
A plurality of rib members are provided, wherein one of the plurality of rib members is disposed within each of the plurality of openings... increasing the surface perimeter
Data Source
AI summary
A burner insert for use with a burner is provided. The burner insert includes a cylindrical body member having an inlet end and an outlet end. The cylindrical body includes a central passage and a plurality of openings disposed about the central passage. One or more fins are axially disposed within the central passage. A plurality of rib members are coupled to the body, each of the plurality of rib members axially disposed within one of the plurality of openings.