Monolithic Fan Plate and Burner Door Assembly
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Solution Overview
Problem
Existing assemblies comprising a gas valve, fan, gas/air mixer, and burner door occupy excessive space due to separate components and lack efficient integration, particularly in the context of a monolithic element providing the fan plate housing and burner door.
Innovation Solution
The integration of a fan housing and fan motor with a monolithic element that also serves as the burner door, combined with a fan impeller housing part that includes grooves for a non-return valve, reduces space by defining a flow channel for the gas/air mixture and positioning the fan motor and impeller on opposite sides of the monolithic element, along with a bayonet connection between the fan impeller housing and gas/air mixer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate components are used for fan plate housing and burner door, then ease of manufacture and assembly are improved, but the overall assembly occupies excessive space
Solution Approach 1:
The fan plate housing and burner door are merged into a single monolithic element, reducing the number of separate components and minimizing the overall assembly space while maintaining ease of manufacture through integrated molding or casting processes
2Device complexity
If non-return valve is integrated into fan impeller housing part, then device complexity is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The non-return valve is integrated directly into the fan impeller housing part as a unified component, reducing device complexity by eliminating separate mounting operations and potential leakage points, while the manufacturing precision is managed through precision molding or machining of the integrated structure
Solution Approach 2:
The non-return valve is nested within the fan impeller housing part, with the valve frame and flap contained within the housing structure, reducing overall device complexity while maintaining functional separation through nested geometry
3Volume of moving object
If fan motor and impeller are positioned on opposite sides of monolithic element, then assembly space is minimized, but assembly and maintenance difficulty increases
Solution Approach 1:
The fan motor and impeller are positioned on opposite sides of the monolithic element along the axial dimension, minimizing the radial assembly space while maintaining ease of operation through straightforward axial access for assembly and maintenance operations
4Reliability
If integral seats are provided for gas valve and mixer during shipment, then reliability is improved, but device complexity increases
Solution Approach 1:
Integral seats for the gas valve and mixer are pre-formed on the monolithic element during manufacturing, ensuring proper alignment and secure positioning before shipment, thereby improving reliability while the seats are integrated into the existing housing structure without adding significant complexity
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 minimizes the overall assembly space, enhances integration of the non-return valve, and optimizes the assembly's structure during both operation and shipment by providing integral seats for the gas valve and mixer components.
Implementation Method 1
a fan motor (22) carrying a fan impeller (23)
Implementation Method 2
a valve frame (45) made from a relative rigid material and a valve flap (46) made from a relative elastic material
Implementation Method 3
The gas/air mixer is mounted to a support plate of the fan by a bayonet-connection
Data Source
Figure 1
Figure 2
Figure 3~5
AI summary
Assembly comprising a gas valve (10) for providing gas, a fan (11) for providing air, a gas/air mixer (12) for providing a gas/air mixture, and a burner door (13) for connecting the assembly to a gas burner; wherein the gas valve (10) comprises a gas valve housing (14) providing a gas inlet (15) through which the gas valve (10) is connectable to a gas pipe, and further providing a gas outlet (16) through which the gas valve (10) is connectable to the gas/air mixer (12); wherein the gas/air mixer (12) comprises a gas/air mixer housing (17) providing a gas inlet (18) through which the gas/air mixer (12) is connectable to the gas outlet (16) of the gas valve (10), providing an air inlet (20), and further providing an gas/air mixture outlet; wherein the fan (11) comprises a fan housing (21) and a fan motor (22) carrying a fan impeller (23), wherein the fan housing (21) comprises a fan plate housing part (24) carrying the fan motor (22) and a fan impeller housing part (25), and wherein the fan plate housing part (24) and the burner door (13) are commonly provided by one monolithic element (26).