Integrated Plastic Gas Burner Assembly for Corrosion Resistance
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Solution Overview
Problem
The mass production of gas cooking appliances is hindered by the complexity and cost of assembling numerous components, with existing materials like pressure-cast aluminium being prone to corrosion and having a limited lifespan, leading to increased production costs and difficulties in maintenance.
Innovation Solution
Integrating key components such as the supporting frame, burner bodies, gas rail, and connection pipes into a single piece using thermosetting or thermoplastic materials through injection moulding, reducing the number of parts and simplifying the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional materials like pressure-cast aluminium are used for burner components, then the appliance can be manufactured using conventional processes, but the material is prone to corrosion by cleaning agents and has a limited lifespan
Solution Approach 1:
The patent changes the material parameter from traditional pressure-cast aluminium to thermoplastic materials through injection moulding. This material substitution eliminates corrosion susceptibility while extending component lifespan, and the injection moulding process provides manufacturing efficiency comparable to conventional methods.
Solution Approach 2:
The patent employs composite construction by integrating multiple functional components (burner body, gas distribution channels, structural elements) into a single thermoplastic piece through injection moulding. This composite approach combines durability, corrosion resistance, and manufacturing efficiency in one integrated component.
2Ease of operation
If numerous individual components are assembled to form the gas cooking appliance, then functional requirements can be met, but the assembly process becomes time-consuming and complex
Solution Approach 1:
The patent merges multiple separate components (burner body, gas distribution channels, structural supports) into a single integrated thermoplastic component manufactured by injection moulding. This consolidation dramatically reduces the number of parts to assemble while maintaining all necessary functions, thereby simplifying the assembly process.
Solution Approach 2:
The integrated thermoplastic component performs multiple functions simultaneously: structural support, gas distribution, and burner housing. This multi-functionality eliminates the need for separate components for each function, reducing assembly complexity while maintaining operational capabilities.
3Reliability
If die casting processes are used to produce burner components, then safe and long-lasting parts can be manufactured, but the tooling has limited duration and energy consumption is high
Solution Approach 1:
The patent changes the manufacturing process parameter from die casting to injection moulding of thermoplastic materials. This substitution maintains component durability and safety while significantly reducing energy consumption and eliminating tooling duration limitations, as injection moulding uses reusable steel dies with extended service life.
Data Source
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AI summary
A gas cooking appliance (1) comprises a support frame (2), at least one burner (3) rigidly connected to said support frame, and a gas feeding circuit (4) to feed gas to the burner, wherein at least one of the following components of the gas cooking appliance is made of a thermosetting or thermoplastic material: • at least one burner body, being part of said at least one burner; • a spark plug body, being part of said at least one burner; •at least one gas connection pipe, being part of said gas feeding circuit, to feed gas to said at least one burner; • a gas rail, being part of said gas feeding circuit, connected to said at least one gas connection pipe; •a connection member, being part of said gas feeding circuit, for connecting the gas rail to an external feeding pipe; and • at least part of the support frame.