Ribbed Metal Fabric Combustion Membrane for Flame Stability
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Solution Overview
Problem
Existing gas burners face issues such as localized flame detachment, overheating, uneven temperature distribution, and poor thermal insulation, leading to combustion noise, structural damage, and uncontrollable flame phenomena, particularly in premixed or partially premixed burners.
Innovation Solution
A combustion membrane for gas burners featuring a fabric structure made of interlaced metal threads with uniform porosity and surface structuring, supported by a perforated sheet metal layer, to enhance flame uniformity and thermal insulation while reducing weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If accessory structures (inserts or diaphragms) are added to locally bias inert masses and fluid dynamic conditions, then combustion stability is improved, but device complexity increases and operating range is limited
Solution Approach 1:
The invention merges the stabilizing function previously requiring separate accessory structures into the combustion membrane itself. The membrane integrates both the gas distribution function and the flame stabilization function through its porous structure and geometric configuration, eliminating the need for additional inserts or diaphragms.
Solution Approach 2:
The combustion membrane performs multiple functions simultaneously: it distributes gas uniformly, stabilizes the flame, provides thermal insulation, and defines the combustion surface. This multi-functional design replaces what previously required multiple separate components, broadening the operating range while maintaining combustion stability.
2Weight of moving object
If metal fabric structure is made lighter, then weight is reduced, but thermal insulation capacity may be compromised
Solution Approach 1:
The invention applies local quality by creating variations in the fabric structure at the micrometer scale. The porous structure has different properties at different locations within the fabric, with voids and solid material distributed to provide both lightness and thermal insulation. The geometric parameters (thread diameter, spacing, porosity) are optimized locally to achieve the desired balance between weight and thermal performance.
Solution Approach 2:
The combustion membrane utilizes a porous metal fabric structure where the voids provide thermal insulation by reducing heat conduction paths. The porous structure allows the membrane to be lighter while maintaining thermal insulation capacity, as the air trapped in the pores acts as an insulating medium.
3Productivity
If fabric porosity and surface structuring are made non-uniform with sharply circumscribed areas, then combustion optimization is achieved, but manufacturing precision requirements increase
Solution Approach 1:
The invention introduces dynamic characteristics into the fabric structure through geometric parameters that can be adjusted during operation or manufacturing. The porous structure allows for controlled variations in gas flow and flame behavior, achieving combustion optimization without requiring extremely precise static fabric construction. The dynamic interaction between gas flow, flame, and porous structure provides robustness against manufacturing tolerances.
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 achieves improved flame uniformity, enhanced thermal insulation, and reduced risk of overheating, thereby minimizing combustion noise and structural damage, while maintaining efficient operation across a wider range of conditions.
Implementation Method 1
the fabric forms an interlacement of metal threads... to enhance flame uniformity and thermal insulation
Implementation Method 2
The heat generated by the combustion is conveyed by the hot combustion gases (convection) and by heat radiation to a heat exchanger for heating a fluid
Implementation Method 3
The heat generated by the combustion is conveyed by the hot combustion gases (convection) and by heat radiation to a heat exchanger
Data Source
Figure 1~3A
Figure 4
Figure 5
AI summary
A combustion membrane (14) for a gas burner (2) comprises a fabric (21) having two opposite fabric surfaces (19, 20) which form a combustion surface (19) exposed on the outer side (17) and an inner surface (20) facing an inner side (18), respectively, wherein the fabric (21) forms an interlacement of metal threads (22) comprising warp threads and weft threads transverse with respect to the warp threads, wherein: both fabric surfaces (19, 20) form high-relief ribs (23) formed by a main float thread (25), respectively, extending straddling exactly three underlying transverse threads, and wherein a side thread bridge (25'), extending straddling exactly one underlying transverse thread, is formed on both longitudinal sides of each main float thread (25), so that the main float thread (25) and the two side thread bridges (25') delimit a cross thread configuration (25") formed by mutually parallel threads.