Master Solenoid Shutoff Valve Layout for Gas Range Leak Reduction
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Solution Overview
Problem
Gas ranges with multiple connections are prone to methane gas leaks, exceeding permissible leak rates, and existing double solenoid valves are costly and inflexible, failing to meet safety standards.
Innovation Solution
A redundant safety shutoff valve system with a master solenoid valve positioned upstream of the gas regulator, coupled with smaller solenoids downstream, ensures a minimal leak rate and redundancy, using electronic control to manage gas flow and shut-off.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a standard four top burner gas range configuration is used, then the appliance provides complete cooking functionality, but the number of gas connections increases to up to 14, significantly increasing potential leak sources
Solution Approach 1:
The patent segments the gas control system by introducing a master solenoid valve that divides the gas flow into two separate controllable paths: one for oven/broil burners and another for top burners. This segmentation reduces the number of simultaneously open connections, as the master valve ensures that only one path can be active at a time, thereby reducing potential leak sources while maintaining full cooking functionality.
2Reliability
If double solenoid valves are used to provide redundant safety shutoff, then the leak rate is reduced, but the device size increases and installation flexibility is limited
Solution Approach 1:
The patent segments the redundant safety function into two separate single-solenoid valves positioned at different locations in the gas flow path. Instead of using one large double-solenoid valve, the system uses two smaller single-solenoid valves that can be installed in separate locations, reducing the volume requirement and improving installation flexibility while maintaining the same safety redundancy.
Solution Approach 2:
The patent transitions from a spatial arrangement where both solenoids must be in the same housing (double solenoid valve) to a distributed arrangement where solenoids are positioned at different locations in the gas flow path. This dimensional change from co-located to distributed positioning reduces the volume constraint while maintaining safety functionality.
3Reliability
If double solenoid valves are used throughout the range, then redundant safety shutoff is achieved, but the cost increases significantly due to additional components and electronics
Solution Approach 1:
The patent segments the safety redundancy requirement into two separate single-solenoid valves with individual controls, rather than requiring one expensive double-solenoid valve. This segmentation allows for simpler, less expensive components while achieving the same safety outcome, reducing manufacturing costs.
Solution Approach 2:
The patent uses two separate single-solenoid valves that replicate the safety shutoff function, rather than using one complex double-solenoid valve. This copying approach with simpler components reduces the overall cost while maintaining the redundant safety functionality.
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 configuration reduces off-position leak rates by up to 90% and provides flexibility and cost-effectiveness by using smaller solenoids, ensuring compliance with safety standards and reducing methane emissions.
Implementation Method 1
The first valve is an electrically controlled solenoid or other positive shutoff valve
Data Source
AI summary
A gas appliance, such as a gas range, is provided with a master shutoff valve, preferably as an electronic solenoid valve so that when in the “off” position, the leak rate may be cut up to 90% and to provide redundancy as it relates to ensuring the appliance is “off” when desired to be in an off configuration. The master shutoff valve may be controlled with an electronics module which assists in providing signals to position other valves and/or control or monitor ignition within the appliance.