Woven Mesh Premix Gas Burner Mounting for Thermal Expansion
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Solution Overview
Problem
Surface stabilized premix gas burners with woven wire mesh burner decks face early mechanical failure due to inadequate handling of thermal expansion and shrinkage stresses, leading to reduced lifetime.
Innovation Solution
The design incorporates a metal mounting plate with a central opening and a woven wire mesh burner deck featuring a circumferential edge with tabs that fit into notches, allowing for play and movement to accommodate thermal expansion and shrinkage, thereby enhancing the burner's durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the woven wire mesh burner deck is rigidly fixed to the mounting plate, then the mounting structure is simple and stable, but the burner deck cannot withstand thermal expansion and shrinkage stresses, leading to early mechanical failure
Solution Approach 1:
The mounting structure transitions from a rigid fixed connection to a dynamic connection that allows controlled movement. The tabs on the burner deck engage with slots in the mounting plate, enabling the burner deck to expand and contract thermally while remaining mechanically supported. This dynamic connection resolves the contradiction by providing both stability and thermal movement capability.
Solution Approach 2:
The mounting structure accommodates changes in physical parameters (thermal expansion and contraction) by designing a mechanism that allows dimensional changes in the burner deck. The slot-based engagement system permits the burner deck to change dimensions with temperature while maintaining structural integrity, thus improving reliability without excessive complexity.
2Reliability
If the woven wire mesh burner deck is allowed to move freely, then thermal expansion and shrinkage are accommodated, but the burner deck becomes unstable and may detach from the mounting plate
Solution Approach 1:
The mounting structure is segmented into multiple engagement points (multiple tabs engaged with slots). This segmentation provides distributed support that maintains stability while allowing controlled movement. The burner deck is divided into functional zones: areas engaged with slots for controlled movement and areas fixed to the mounting plate for stability.
Solution Approach 2:
The slot-based engagement system acts as an intermediary mechanism between the burner deck and mounting plate. It mediates between the need for stability and the need for thermal movement, providing a controlled interface that allows expansion while preventing detachment. The slots serve as intermediaries that guide and limit the movement of tabs.
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 effectively withstands thermal stresses, resulting in a longer lifetime for the premix gas burner by allowing movement of the woven wire mesh during temperature changes, preventing early mechanical failure.
Implementation Method 1
The woven wire mesh burner deck needs to be able to cope with the stresses induced by the thermal expansion associated with the high temperature when the burner is in use and by the shrinkage when the burner is not in use
Data Source
AI summary
A premix gas burner (100) comprises a metal mounting plate (102) for mounting the premix gas burner in a heating appliance; a metal plate structure (104) and a burner deck (106). The burner deck comprises a woven wire mesh on the outer surface of which premix gas is combusted after the premix gas has flown through the woven wire mesh. The woven wire mesh comprises a circumferential edge (108). The circumferential edge comprises a plurality of tabs (110). The mounting plate comprises a central opening. The burner deck is inserted through the central opening. The metal mounting plate or the metal plate structure comprises at least one ridge (112). The at least one ridge comprises at least one notch (114). Each of the tabs is positioned in a notch. The metal mounting plate and the metal plate structure are in contact with each other at the top of the ridge, such that the open side of the at least one notch is covered; and such that the tabs are held in between the metal mounting plate and the metal plate structure with play being present of the tabs relative to the metal mounting plate and relative to the metal plate structure.