Twisted Metal-Yarn Combustion Membrane for Flame Stability
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Solution Overview
Problem
Existing gas burners face issues such as localized or extensive flame detachment, overheating, uneven temperature distribution, and poor thermal insulation, leading to high combustion noise, reduced burner resistance, and structural damage, which conventional noise reduction accessories fail to adequately address across a wide operating range.
Innovation Solution
A combustion membrane for gas burners featuring a fabric or mesh of interlaced metal threads with twisted fibers, having protruding ends and a specific weight and diameter, providing enhanced thermal insulation and gas permeability, and a ribbed surface structure for improved gas distribution and flame stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional combustion membranes are used, then gas flow is permitted, but thermal insulation is insufficient leading to overheating
Solution Approach 1:
The combustion membrane employs a composite structure consisting of a metal fabric base layer combined with a ceramic coating layer. This composite material provides both mechanical strength from the metal fabric and superior thermal insulation properties from the ceramic coating, thereby reducing the combustion membrane temperature while maintaining structural reliability under high temperature conditions.
Solution Approach 2:
The metal fabric used in the combustion membrane features a porous structure with controlled porosity. This porous configuration allows adequate gas flow permeability while the interstices between fibers provide thermal insulation pathways, reducing heat transfer through the membrane and preventing overheating.
2Power
If gas flow rate is increased to enhance heating power, then combustion intensity increases, but flame detachment occurs
Solution Approach 1:
The ceramic coating is applied non-uniformly on the metal fabric, with varying thickness and composition in different regions. This local quality variation creates zones with different flame anchoring characteristics, allowing the flame to remain stable across a wider range of gas flow rates by providing localized attachment points even at higher velocities.
Solution Approach 2:
The ceramic coating structure is pre-configured on the combustion membrane surface to create favorable flow conditions before combustion occurs. The textured surface and porous structure preliminarily condition the gas flow and flame front interaction, preventing flame detachment before it can occur during operation.
3Loss of energy
If metal fabric thickness is increased to improve thermal insulation, then thermal protection improves, but gas permeability decreases
Solution Approach 1:
The composite structure of metal fabric with ceramic coating allows achieving effective thermal insulation without substantially increasing the gas flow resistance. The ceramic layer provides the thermal barrier function while the metal fabric maintains open porosity for gas permeability, thus decoupling the thermal insulation function from the gas flow function.
Solution Approach 2:
The ceramic coating thickness is optimized locally rather than uniformly throughout. In regions where thermal insulation is most critical, the coating is thicker, while in regions requiring higher gas flow, the coating is thinner or more porous, thereby balancing thermal protection and gas permeability requirements.
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 enhances thermal insulation, reduces the risk of flame detachment, and improves gas flow distribution, resulting in quieter, more durable, and efficient burner operation.
Implementation Method 1
achieve a desired thermal insulation effect of the combustion membrane and thermal protection of portions of the burner upstream of the combustion membrane
Implementation Method 2
achieve a better distribution of the gas permeability of the combustion membrane
Data Source
AI summary
A combustion membrane (14) for a gas burner (2) comprises a fabric or mesh (21) of interlaced metal threads (22), having two opposite interlacing surfaces (19, 20) which form a combustion surface (19) and an inner surface (20) of the fabric/mesh (21), respectively, wherein the metal threads (22) are formed by twisted metal fibers (22) to form a yarn and:the individual metal fibers (22) are shorter than the yarn (22) formed therefrom, and free ends (22″) of the metal fibers (22) protrude divergently from the yarn (22) along its longitudinal extension and make the yarn (22) hairy, andthe metal thread (22) is a yarn (22) of mass per length in the range from 0.8 g/m to 1.4 g/m.