Segmented Gas Burner Ports for High-Aspect-Ratio Cooktop Flames
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Solution Overview
Problem
Existing gas burner assemblies face challenges in manufacturing tall, narrow burner ports due to limitations in current manufacturing methods, such as die casting and forging, which lack the strength and wear properties to produce high aspect ratio burner ports effectively.
Innovation Solution
A gas burner assembly design featuring a lower and upper body with projections that define a boost burner chamber, allowing for the creation of tall, narrow burner ports that are easily manufactured and improve performance, by interposing second projections between first projections to form burner ports in fluid communication with the boost burner chamber.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If die casting or forging methods are used to manufacture burner heads, then the burner head can be produced with adequate strength and wear properties, but the ability to accommodate tall, narrow burner ports is limited due to thin-walled or fragile dies
Solution Approach 1:
The burner head is divided into multiple segments or components that can be manufactured separately using conventional die casting or forging methods, then assembled together. This segmentation allows each component to have adequate thickness for manufacturing while the assembled structure achieves the tall, narrow burner port configuration that would be impossible in a single piece
Solution Approach 2:
The design employs nested or interlocking components where smaller burner port structures are positioned within or between larger housing components. This nesting approach enables the creation of high aspect ratio ports by stacking or nesting multiple manufacturable elements rather than attempting to create the entire port structure in a single casting or forging operation
2Productivity
If tall, narrow burner ports are implemented to improve heat transfer efficiency, then burner performance and efficiency are enhanced, but conventional manufacturing methods cannot produce the required high aspect ratio ports
Solution Approach 1:
The solution transitions from attempting to create tall, narrow ports in a single horizontal casting/forging operation to stacking or assembling multiple components in the vertical dimension. This dimensional approach allows the burner ports to achieve high aspect ratios by combining multiple manufacturable elements stacked vertically, rather than requiring a single element of impossible geometry
3Reliability
If forced air supply is added to improve fuel-air mixture and burner stability, then burner efficiency and operation at higher outputs are improved, but the complexity of the burner assembly increases
Solution Approach 1:
The forced air system is designed to be self-regulating, where the burner assembly itself generates the suction or pressure differential needed to drive air through the system during operation. This self-service approach eliminates the need for external motors or complex control systems, adding the necessary air supply functionality while minimizing the increase in overall system 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 design enables the production of gas burner assemblies with improved heat transfer efficiency and stability, accommodating forced air for enhanced combustion performance while overcoming manufacturing limitations.
Implementation Method 1
Introducing a fan or another forced air supply into a gas burner assembly may improve the mixture of fuel and air for improved operation at higher outputs
Implementation Method 2
Normally aspirated gas burners rely on the energy available in the form of pressure from the fuel supplied to the gas burner to entrain air for combustion
Data Source
AI summary
A gas burner assembly for a cooktop appliance is provided including a lower body and an upper body positioned over the lower body to define a boost burner chamber. A first plurality of projections extends upward from the lower body and a second plurality of projections extends downward from the upper body. The second plurality of projections are interposed between the first plurality of projections to define a plurality of burner ports in fluid communication with the boost burner chamber. In this manner, burner ports are easily manufactured and define a larger height-to-width aspect ratio for improved burner performance.