Method of assembling pilot burner assembly
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Solution Overview
Problem
Existing pilot burner assemblies for gas-fired appliances are complex to assemble, costly due to multiple discrete components, and suffer from unreliable spark gaps and power efficiency losses due to suboptimal thermocouples.
Innovation Solution
A pilot burner assembly featuring a unitary pilot guard with a mounting bracket and a thermo-electric device that simplifies assembly through retention elements and optimizes spark gap reliability with an angled sparking tip, and enhances power efficiency by matching internal resistance with the controller's load resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple discrete components are used to connect the burner tube assembly to the gas supply line and mount the pilot burner assembly, then the connection can be achieved, but the assembly becomes timely and complicated
Solution Approach 1:
The patent combines multiple discrete components (burner tube assembly, mounting brackets, connection elements) into a single integrated pilot burner assembly. The burner tube assembly includes integrated mounting brackets and connection elements that allow the entire assembly to be installed as one unit, eliminating the need for multiple separate connection steps and reducing assembly complexity while maintaining reliable connections.
2Reliability
If a pilot hood is included as a separate component from the burner tube assembly, then the pilot burner assembly can be constructed, but the material cost and assembly time increase
Solution Approach 1:
The pilot hood is integrated directly onto the burner tube assembly as a single unified component. The burner tube assembly includes the hood formed as part of its structure, eliminating the need for separate hood components and reducing the total number of parts while maintaining all necessary pilot burner functions.
3Manufacturing precision
If the spark gap is adjusted by bending the igniter toward or away from the igniting component, then the desired spark gap can be obtained, but the process becomes difficult, time-consuming, and costly
Solution Approach 1:
The igniter is pre-positioned and pre-adjusted during manufacturing to achieve the correct spark gap distance from the igniting component. This preliminary positioning ensures that the spark gap is already optimized when the pilot burner assembly is installed, eliminating the need for difficult and time-consuming field adjustments by bending the igniter.
4Reliability
If thermocouples are not optimized for the system, then the pilot burner assembly can operate, but power efficiency losses occur
Solution Approach 1:
The thermocouple is optimized by selecting specific material compositions and geometric parameters (such as diameter, length, and positioning) that maximize its electrical output for a given pilot flame size. These parameter optimizations ensure the thermocouple generates sufficient voltage to reliably operate the gas valve control system while minimizing energy losses, thereby improving overall power efficiency.
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 solution enables quick and simple assembly, improves spark gap reliability, and enhances power efficiency by reducing the need for manual adjustments and optimizing energy conversion.
Implementation Method 1
a thermo-electric device configured to convert thermal energy into electrical energy
Data Source
AI summary
A method of assembling a pilot burner assembly for use with a gas fired appliance includes inserting a retention element of a gas supply line through a slot defined by a retaining ledge of a second bracket plate, rotating an outlet orifice of the gas supply line such that the second retention element engages the retaining ledge, and inserting a pilot guard through first and second pilot guard apertures defined by respective first and second bracket plates such that a retention element of the pilot guard cooperatively engages the retention element of the gas supply line to maintain a connection between the pilot guard and the gas supply line.