HIGH OUTPUT GAS BURNER AND RANGE

Abstract

Embodiments of the invention provide a gas burner comprising a first venturi configured to supply fuel in a substantially horizontal direction and a second venturi configured to also supply fuel along a substantially horizontal direction. A burner bottom may be coupled to the first venturi and the second venturi, and the burner bottom may be configured to direct fuel from the first venturi and second venturi into a burner base positioned above the burner bottom. The burner base may provide an inner annular chamber and an outer annular chamber separated by a dividing wall, and the inner annular chamber may be configured to receive and direct fuel from the first venturi assembly circumferentially about the burner base and the outer annular chamber may be configured to receive and direct fuel from the second venturi assembly circumferentially about the burner base. A burner cap may be coupled to the burner base to provide a fluidic seal between the inner annular chamber and outer annular chamber, and may be configured to produce flame bodies having radial and upward components.

Description

BACKGROUND

Several types of gas burners are used in household and commercial environments around the world. Common to nearly all gas burners is the use of air, a fuel source, and an ignition source to produce heat, which is then transferred towards a heating vessel containing an object to be cooked. Although there are many different variations of gas burner in existence, all gas burners can be categorized as either (1) open burners or (2) sealed burners.

Open burners offer a more direct heating in which an open flame comes up from the center of the burner and heats the pan with a more focused flame direction. An open burner is often supplemented with a circular vent around the burner components, which is configured to provide air towards the flames to produce full and consistent combustion of the gas and air mixture fed to the burner. The open design of the burner top allows additional air, called secondary air, to be drawn into the combustion area of the burner from above, thereby introducing additional oxygen into the combustion reaction. This allows open designs to achieve high heat outputs and efficiencies. While the increased heat outputs and efficiencies are advantageous, they also have significant drawbacks. The open design allows spillage from a container to fall into the flame or down into the range itself, which can cause flames within the range itself, undesirable odors of burnt foodstuffs, and significant issues with the operation of the burner itself. Moreover, these burners are generally very difficult to clean, as the foodstuffs may fall entirely below the burner and require a user to remove the entire burner during cleaning. These disadvantages have led open burners to be disfavored in residential applications.

Sealed burners, to the contrary, are favored in residential applications because they provide an easy-to-clean design. A seal between the burner and the surrounding range frame keeps spills contained to above the cooktop, which allows for a much more simplified cleaning and maintenance procedure. However, the sealed burner design greatly reduces the amount of secondary air available for the combustion process, and generally results in burners having lower maximum output capabilities. Additionally, sealed burners generally have flame ports located on the outer diameter of the burner head, and very large burner heads are typically required to achieve higher heating capacities. As the flames are directed outward, flame length on these burners must be much longer to heat the contents of a cooking vessel situated above the burner, and even less of the heat produced by sealed burners is effectively transferred to the cooking vessel. As a result, sealed burners typically only transfer about 40% or less of the energy they generate to the contents of a cooking vessel situated above the burner, resulting in substantial energy loss.

SUMMARY

A gas burner that can harness the cleanability and reliability of a traditional sealed burner that can produce a high BTU output at a high heat energy transfer efficiency is disclosed. The gas burner can comprise a first venturi and a second venturi. In some embodiments, both the first venturi and the second venturi are configured to supply fuel to the burner in a substantially horizontal direction. A burner bottom can be coupled to the first venturi and the second venturi. The burner bottom directs fuel from the first venturi along a first ramp upwardly and circumferentially in a first direction. The burner bottom also directs fuel from the second venturi along a second ramp upwardly and circumferentially in a second direction. A burner base can be positioned above the burner bottom and can be placed in fluid communication with the burner bottom. The burner bottom can provide an inner annular chamber and an outer annular chamber separated from one another by a dividing wall. The inner annular chamber receives and directs fuel from the first venturi assembly circumferentially about the burner base and the outer annular chamber receives and directs fuel from the second venturi assembly circumferentially about the burner base. A burner cap coupled to the burner base can provide a fluidic seal between the inner annular chamber and the outer annular chamber. The burner cap can distribute fuel from the inner annular chamber to a first plurality of ports positioned about the cap at a first radius and can distribute fuel from the outer annular chamber to a second plurality of ports positioned about the burner cap at a second radius larger than the first radius.

In some embodiments, the circumferential component of the first direction and the circumferential component of the second direction oppose one another. For example, the circumferential component of the first direction can be an approximately clockwise direction and the circumferential component of the second direction can be an approximately counterclockwise direction. In some embodiments, the circumferential component of the first direction and the circumferential component of the second direction are substantially concentric with one another.

In some embodiments, the burner base has a central cavity formed radially inward from the inner chamber. The burner cap can also include a bore extending through the burner cap that can be formed radially inward from the first plurality of ports. The bore can be positioned concentrically about the central cavity. In some embodiments, a gap may be formed between the burner base and the burner bottom that permits ambient air to flow underneath a portion of the burner base, into the central cavity of the burner base, and through the bore of the burner cap to feed the first plurality of ports with secondary air during combustion. In some embodiments, a gas flow rate of the first venturi is controlled by a first valve and a gas flow rate of the second venturi is controlled by a second valve, and the first valve and second valve can be controlled by a single controller.

In some embodiments, an ignition source is located within the central cavity of the burner base. The ignition source can provide a spark to light at least the first plurality of ports. In some embodiments, the burner cap includes a lighting port positioned radially inward from the first plurality of ports. The lighting port can direct fuel radially inward toward the ignition source.

In some embodiments, the burner cap comprises a plurality of ignition ports positioned radially between the first plurality of ports and the second plurality of ports. The ignition ports can be supplied with fuel from the inner annular chamber of the burner base. In some embodiments, the first plurality of ports and the second plurality of ports are configured to produce a turndown ratio of about 60:1, or greater. The first plurality of ports and the second plurality of ports can produce 30,000 BTU or greater when ignited. In some embodiments, the first plurality of ports and the second plurality of ports are configured to transfer about 60% or more of the heat produced to a cooking vessel positioned above the burner cap.

A sealed gas burner is also disclosed. The sealed gas burner can include a burner bottom receiving fuel and oxygen from a fuel source and an oxygen source. An annular burner base can be coupled to a portion of the burner bottom. The annular burner base can be placed in fluid communication with the fuel source and the oxygen source. The annular burner base can comprise an inner chamber and an outer chamber to selectively receive fuel and oxygen from the fuel source and the oxygen source. A burner cap can be coupled to the annular burner base. The burner cap can include a ring of simmering portions positioned above the inner chamber of the annular base and an outer ring of burner ports concentric with the ring of simmering ports and positioned above the outer chamber of the annular burner base. A plurality of simmering ports within the ring of simmering ports are angled to produce a flame body extending radially inward and upward from the burner cap and a plurality of burner ports within the outer ring of the burner ports are larger than the simmering ports and are angled to produce a flame body extending radially outward and upward from the burner cap.

In some embodiments, a plurality of radially aligned ignition ports are formed in the burner cap. The ignition ports extend outward from the ring of simmering ports towards the outer ring of burner ports. In some embodiments, the plurality of radially aligned ignition ports comprises at least one port angled to produce a flame body extending radially inward and upward from the burner cap and at least one port angled to produce a flame body extending radially outward and upward from the burner cap. In some embodiments, at least two pluralities of radially aligned ignition ports are formed in the burner cap, and the at least two pluralities of radially aligned ignition ports are spaced apart from one another evenly about the burner cap. In some embodiments, each port in the plurality of radially aligned ignition ports has a diameter approximately equal to the diameter of the simmering ports.

In some embodiments, the number of ports in the ring of simmering ports and the number of ports in the ring of burner ports is equal. The burner cap can also include at least one intermediate ring of burner ports positioned radially outward from and concentric with the ring of simmering ports. The at least one intermediate ring of burner ports can comprise ports defined by diameters larger than the diameters of the simmering ports. In some embodiments, the plurality of ports within the at least one intermediate ring of burner ports are angled to produce a flame body extending radially outward and upward from the burner cap. The burner cap can also comprise a second intermediate ring of burner ports positioned radially outward from and concentric with the first intermediate ring of burner ports and radially inward from the outer ring of burner ports. The second intermediate ring of burner ports can comprise ports defined by diameters larger than the diameters of the burner ports in the first intermediate ring of burner ports and smaller than the diameters of the burner ports in the outer ring of burner ports. In some embodiments, a plurality of radially aligned ignition ports are formed in the burner cap that extend outward from the at least one intermediate ring of burner ports. At least one port in the intermediate ring of burner ports is radially aligned with the plurality of radially aligned ignition ports. In some embodiments, the ring of simmering ports are capable of sustaining a heat output of about 500 BTU. In some embodiments, the ring of simmering ports and the outer ring of burner ports are together capable of sustaining a heat output of about 30,000 BTU.

In some embodiments, the burner cap comprises an annular shape with a convex top surface. The ring of simmering ports is positioned proximate a local minimum height of the convex top surface of the burner cap. In some embodiments, the burner comprises an ignition source coupled to an electrical power source. The ignition source is positioned within a central cavity of the burner base. In some embodiments, the burner cap comprises a lighting port positioned radially inward from the ring of simmering ports. The lighting port produces a flame body that extends radially inward and upward from the burner cap, towards the ignition source.

In some embodiments, the ignition source comprises a lower electrode and an upper electrode removably coupled to the lower electrode. The lower electrode can comprise a male connection and the upper electrode can comprise a female connection that receives a portion of the male connection. In some embodiments, the lower electrode is coupled to the burner bottom and the upper electrode is coupled to the annular burner base.

Some embodiments of the present disclosure are directed towards a gas burner. The gas burner comprises a burner base and a burner cap. The burner cap is positioned above the burner base, and the burner cap and burner base collectively define an inner annular chamber and an outer annular chamber. The burner cap comprises a first plurality of ports positioned above the inner annular chamber and a second plurality of ports positioned above the outer annular chamber. The gas burner can operate at a first heat output setting where the first plurality of ports are configured to output flames and at a second heat output setting about sixty times greater than the first heat output setting. The second heat output setting is produced when the first plurality of ports and the second plurality of ports simultaneously output flames.

Some embodiments of the present disclosure provide a range having a high output gas burner including any of the previously-mentioned features.

These and still other advantages of the invention will be apparent from the detailed description and drawings. What follows is merely a description of some preferred embodiments of the present invention. To assess the full scope of the invention, the claims should be looked to, as these preferred embodiments are not intended to be the only embodiments within the scope of the claims.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a gas burner according to one embodiment of the invention.

FIG. 2 is an exploded view of the gas burner of FIG. 1.

FIG. 3 is front view of the gas burner of FIG. 1.

FIG. 4 is a right side view of the gas burner of FIG. 1.

FIG. 5 is a rear view of the gas burner of FIG. 1.

FIG. 6 is a bottom view of the gas burner of FIG. 1.

FIG. 7 is a top view of the gas burner of FIG. 1.

FIG. 8 is a cross-sectional view of the gas burner of FIG. 1, taken along cut line 8-8 in FIG. 7.

FIG. 9A is a cross-sectional view of the gas burner of FIG. 1, taken along cut line 9A-9A in FIG. 7.

FIG. 9B is a top right perspective view of the cross-section taken along cut line 9A-9A in FIG. 7.

FIG. 9C is a top left perspective view of the cross-section taken along cut line 9A-9A in FIG. 7.

FIG. 10 is a cross-sectional view of the gas burner of FIG. 1, taken along cut line 10-10 in FIG. 7.

FIG. 11 is a cross-sectional view of the gas burner of FIG. 1, taken along cut line 11-11 in FIG. 7.

FIG. 12A is a perspective view of a burner stand present in the gas burner of FIG. 1.

FIG. 12B is a top view of the burner stand of FIG. 12A.

FIG. 13A is a perspective view of a gas inlet piece present in the gas burner of FIG. 1.

FIG. 13B is a top view of the gas inlet piece of FIG. 13A.

FIG. 13C is a bottom view of the gas inlet piece of FIG. 13A.

FIG. 13D is a front view of the gas inlet piece of FIG. 13D.

FIG. 14 is a perspective view of a gasket present in the gas burner of FIG. 1.

FIG. 15 is a perspective view of a plate present in the gas burner of FIG. 1.

FIG. 16A is a perspective view of a burner base present in the gas burner of FIG. 1.

FIG. 16B is a top view of the burner base of FIG. 16A.

FIG. 16C is a bottom view of the burner base of FIG. 16A.

FIG. 16D is a cross-sectional view of the burner base of FIG. 16A, taken along cut lines 16D-16D in FIG. 16B.

FIG. 16E is a cross-sectional view of the burner base of FIG. 16A, taken along cut lines 16E-16E in FIG. 16B.

FIG. 16F is a cross-sectional view of the burner base of FIG. 16A, taken along cut lines 16F-16F in FIG. 16B.

FIG. 17A is a perspective view of a burner cap present in the gas burner of FIG. 1.

FIG. 17B is a top view of the burner cap of FIG. 17A.

FIG. 17C is a cross-sectional view of the burner cap of FIG. 17A, taken along cut lines 17C-17C in FIG. 17B.

FIG. 17D is a cross-sectional view of the burner cap of FIG. 17A, taken along cut lines 17D-17D in FIG. 17B.

FIG. 17E is a cross-sectional view of the burner cap of FIG. 17A, taken along cut lines 17E-17E in FIG. 17B.

FIG. 18A is a top perspective view of an ignition source present in the gas burner of FIG. 1.

FIG. 18B is an exploded view of the ignition source of FIG. 18A.

Corresponding reference characters indicate corresponding parts throughout several views. Although the drawings represent embodiments of the present disclosure, the drawings are not necessarily to scale and certain features may be exaggerated in order to better illustrate and explain the embodiments of the present disclosure.

DETAILED DESCRIPTION

Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings.

The following discussion is presented to enable a person skilled in the art to make and use embodiments of the invention. Various modifications to the illustrated embodiments will be readily apparent to those skilled in the art, and the generic principles herein can be applied to other embodiments and applications without departing from embodiments of the invention. Thus, embodiments of the invention are not intended to be limited to embodiments shown, but are to be accorded the widest scope consistent with the principles and features disclosed herein. The following detailed description is to be read with reference to the figures, in which like elements in different figures have like reference numerals. The figures, which are not necessarily to scale, depict selected embodiments and are not intended to limit the scope of embodiments of the invention. Skilled artisans will recognize the examples provided herein have many useful alternatives and fall within the scope of embodiments of the invention.

FIG. 1 illustrates a gas burner 100 according to one embodiment of the present disclosure. As shown in the figure provided, the gas burner 100 may be a sealed burner having multiple flame ports that direct heat upwards toward a cooking vessel (not shown) positioned above the gas burner 100. In some embodiments, the gas burner 100 can produce a high energy output (30,000 or more BTU) at an extremely high energy transfer efficiency rate, as it may be capable of transferring 60% or more of the energy produced to the contents of a cooking vessel placed above the gas burner 100. The gas burner 100 may include several components discussed below that are easily positioned and mounted relative to one another quickly to allow efficient maintenance, cleaning, and inspection processes.

In some embodiments, the gas burner 100 has a burner cap 102, which has a plurality of ports configured to produce flames with flame bodies pointing generally in an upward direction, once ignited by ignition source 114. The burner cap 102 can mate with a burner base 104, which can supply the plurality of ports on the burner cap 102 with primary air and fuel. The burner base 104 can be divided into one or more distinct annular chambers, which may allow the gas burner 100 to output a simmering flame or a higher output flame, depending on input from a user. The burner base 104 can be mounted onto a burner bottom assembly 106. In some embodiments, the burner bottom assembly 106 rests partially above a top surface of a range top (not shown) that the gas burner 100 is mounted to. In some embodiments, the burner base 104 is mounted to the burner bottom assembly 106 to allow secondary air to enter between a gap between the burner bottom assembly 106 and the burner base 104.

The burner bottom assembly 106, burner base 104, and burner cap 102 may be fed with an air and fuel mixture, which can be supplied through one or more venturi assemblies coupled to the burner bottom assembly 106. In some embodiments, the first venturi assembly 108 supplies a primary air and fuel mixture into an annular inner chamber 116 of the gas burner 100, while the second venturi assembly 110 supplies a primary air and fuel mixture into an annular outer chamber 118 of the gas burner 100. The inner chamber 116 and outer chamber 118 can be separated by a dividing wall that prevents fluid travel between the inner chamber 116 and outer chamber 118 to provide a greater degree of control to the gas burner 100. In some embodiments, the first venturi assembly 108 and second venturi assembly 110 provide air and gas mixture in a substantially horizontal direction. The burner bottom assembly 106 can be coupled to burner stand 112, which can be then be used to mount the entire gas burner 100 to a range or other surface.

Referring now to FIG. 2, an exploded view of the gas burner 100 is provided. The gas burner 100 may include a burner stand 112, which may have a seat configured to receive the burner bottom assembly 106. The burner bottom assembly 106 can include a plate 140, a gasket 142, and a gas inlet piece 144 that together support burner base 104 and the burner cap 102. In some embodiments, the gas inlet piece 144 sits flush upon the seat of the burner stand 112. The gas inlet piece 144 can be coupled to the burner stand 112 in a number of ways, including the use of fasteners, rivets, adhesives, clamps, locating features (e.g. through holes and pins), for example. In some embodiments, the seat of the burner stand 112 serves as a locating feature for the gas inlet piece 144, so that the gas inlet piece 144 may not sit properly on the seat of the burner stand 112 unless it is in the proper angular and axial position relative to the burner stand 112.

Once the gas inlet piece 144 has been installed onto the seat of the burner stand 112, the gasket 142 may be installed onto a top surface of the gas inlet piece 144. In some embodiments, the gasket 142 includes a number of recesses and apertures that allow some features of the gas inlet piece 144 to extend through the gasket 142 when it is seated upon the top surface of the gas inlet piece 144. The recesses and apertures within the gasket 142 may be located so that the gasket 142 may only fit onto the top surface of the gas inlet piece 144 when it is properly aligned relative to the gas inlet piece 144.

After the gasket 142 is installed onto the top surface of the gas inlet piece 144, a plate 140 can be installed onto the gas inlet piece 144 and gasket 142 assembly. The plate 140 can be provided with a number of apertures and holes that can allow for portions of the gas inlet piece 144 to extend upwardly beyond a top surface of the plate 140 when the plate 140 is installed onto the gasket 142 and gas inlet piece 144 assembly. In some embodiments, the plate 140 may be coupled to the gas inlet piece 144 in a way that compresses the gasket 142. For example, fasteners, rivets, clamps, or adhesives, for example, may be used to provide adequate compressive loading to the gasket 142 positioned between the gas inlet piece 144 and the plate 140.

The first venturi assembly 108 and second venturi assembly 110 can then be coupled to the burner bottom assembly 106. The first venturi assembly 108 may have a fuel inlet 120, which can be coupled with a compressed fuel source (not shown), such as natural gas, propane, butane, liquefied petroleum gas, acetylene, or other suitable cooking fuels. Fuel may flow through the gas inlet 120 into a nozzle section (not shown) having a gradually decreasing cross-section, which causes the velocity of the fuel passing through the decreased cross-sectional area to create a lower pressure zone in this area. The fuel stream is placed in communication with an oxygen source, such as ambient air, compressed air, pressurized oxygen gas, or other oxygen-rich mixtures, and draws oxygen into the fuel stream to produce an approximately stoichiometric mixture of fuel and air ideal for combustion. Fuel-lean and fuel-rich mixtures may also be produced by the first venturi assembly 108, and in some embodiments, flow rate settings of the venturi assembly 108 may be adjusted to achieve either of these fuel concentrations. The low pressure of the fuel in the constricted section creates a pressure differential between the oxygen source and fuel that causes oxygen to be sucked into the constricted section of the venturi assembly 108, and into the fuel stream. The fuel and oxygen mixture then passes into a diffuser section 122, which provides a gradually increasing cross-sectional flow area. The increasing cross-sectional flow area causes the fuel and oxygen mixture to decrease in velocity and pressure to promote mixing between the two gases prior to being introduced into the inner chamber 116 of the burner base 104 through the burner bottom assembly 106. The diffuser section 122 can be provided with a flange 124 for mounting to a mounting face of the gas inlet piece 144. In some embodiments, a gasket 126 is incorporated between the flange 124 and mounting face of the gas inlet piece 144 to provide a leak-free seal between components. The flange 124 can be coupled to the gas inlet piece 144 using fasteners 128, for example, to provide leak-free compressive coupling between the components.

The second venturi assembly 110 may include similar components that can introduce fuel and oxygen into the outer chamber 118 of the burner base 104. As shown in FIGS. 1-8, both the first venturi assembly 108 and second venturi assembly 110 can supply a fuel and oxygen mixture into the burner base 104 at an approximately horizontal direction. A fuel inlet 130 may be provided, which can again be coupled to a fuel source. In some embodiments, the fuel inlet 120 of the first venturi assembly 108 and the fuel inlet 130 of the second venturi assembly 110 are coupled to a common fuel source that is configured to supply both the inner chamber 116 and outer chamber 118 of the burner base 104. Separate fuel sources may be utilized by each venturi assembly as well. The fuel may once again enter into a nozzle section and a constricted section, which draws oxygen from an oxygen source into the fuel stream to produce an approximately stoichiometric mixture of gas and air ideal for combustion. The amount of fuel in the mixture may be adjustable to achieve fuel-lean or fuel-rich mixtures as well. The oxygen and fuel then enter into a diffuser section 132, which provides an increasing cross-sectional flow area, and causes the fuel and oxygen mixture to decrease in velocity and pressure. The gas mixture then exits the diffuser section 132 into the gas inlet piece 144 of the burner bottom assembly 106. The diffuser section 132 may have a flange 134 configured to mount flat against a mounting face of the gas inlet piece 144. A gasket 136 may once again be used between the mounting face of the gas inlet piece 144 and the flange 134 of the diffuser section 132 to provide a substantially leak-free seal between the second venturi assembly 110 and the burner bottom assembly 106. Fasteners 138 for coupling the flange 134 to the gas inlet piece 144 can be used to ensure that the fuel-oxygen gas mixture is restricted from leaking outwardly outside the gas burner 100 components.

The first venturi assembly 108 may supply the inner chamber 116 with fuel and oxygen, while the second venturi assembly 110 may supply the outer chamber 118 with fuel and oxygen. Accordingly, these components can be sized to accommodate the volumes of these respective chambers, such that the first venturi assembly 108 is smaller than the second venturi assembly 110. In some embodiments, the fuel inlet 130 of the second venturi assembly 110 is chosen with a diameter much larger than the diameter of the fuel inlet 120 of the first venturi assembly 108, and can provide much higher fuel flow rates through the second venturi assembly 110 than can be produced by the first venturi assembly 108. For example, the fuel inlet 120 may be a size ¼″ NPT tube fitting configured to supply fuel at between about 0.5 and about 1.5 cubic feet per hour (cfh), while fuel inlet 130 may be a size ⅜″ NPT tube fitting configured to supply fuel at between about 2.5 and about 30 cfh. It should be appreciated that the sizes and types of fittings (i.e., thread types) provided are merely examples of some possible venturi assembly 108, 110 configurations, and that other sizes, fittings, and flow rates are both possible and are within the scope of the present disclosure. To accommodate the higher fuel flow rates, the diffuser section 132 may also be chosen to have a much larger diameter than the diffuser section 122 of the first venturi assembly 108.

With the burner bottom assembly 106 installed onto the burner stand 112 and the first venturi assembly 108 and second venturi assembly 110 coupled to the burner bottom assembly 106, the ignition source 114 can then be installed into the gas burner 100. In some embodiments, the ignition source 114 has a substantially cylindrical shape and is configured to extend through apertures in the plate 140, gasket 142, gas inlet piece 144, and burner stand 112. The ignition source 114 can then extend both below the gas inlet piece 144 and above the plate 140. In order to provide ignition to the gas burner 100, the ignition source 114 can be positioned proximate a lighting port 166 on the burner cap 102, shown in FIG. 9C.

In some embodiments, the ignition source 114 may include a spark plug or other sparking device to ignite gaseous fuel to promote combustion. The ignition source 114 can include a flame rectification sensor and system, and can operate to spark when a flame is not detected on the burner. The ignition source 114 can be placed in communication with a power source, which can be used to provide the necessary electricity to produce a spark. In some embodiments, the ignition source 114 can be placed in electrical communication with a control system, such as a control system utilized by a range. The range may then communicate to the ignition source 114 to provide a spark based upon input received by a user, such as a prompt to turn on the gas burner 100. As will be described in more detail below with reference to FIGS. 18A and 18B, the ignition source 114 can be a multiple piece assembly configured to further promote cleaning and maintenance of the gas burner 100.

With the ignition source 114 assembled to the burner bottom assembly 106, the burner base 104 can be installed into place. In some embodiments, the burner base has a number of locating features to mate with features of the gas inlet piece 144 that extend upward beyond the plate 140. The mating features may be arranged so that the burner base 104 can only sit properly on the burner bottom assembly 106 when it is positioned properly relative to the burner bottom assembly 106. Additionally, the mating features may restrict rotational movement of the burner base 104 once it is positioned properly into place above the burner bottom assembly 106. In some embodiments, the burner base 104 comprises one or more inlets that receive gas from the first venturi assembly 108 and the second venturi assembly 110. The burner base 104 can have a first aperture configured to allow the entry of gas from the first venturi assembly 108 into the inner chamber 116 and a second aperture configured to allow the entry of gas from the second venturi assembly 110 into the outer chamber 118 of the burner base. In some embodiments, the burner base 104 and gas inlet piece 144 form compressive, leak-free contact without the use of any additional coupling mechanisms. The burner base can then be lifted off of the burner bottom assembly 106 without the use of any additional tools. However, the burner base 104 can also be coupled to the gas inlet piece 144 using adhesives, fasteners, or rivets, for example.

With the burner base 104 assembled into place, the burner cap 102 can be positioned on top of the burner base 104. In some embodiments, the burner cap 102 and burner base 104 comprise a notch and tab mating system. The notch and tab mating system can ensure that the cap 102 will be properly positioned upon the burner base 104 during assembly, which aligns the lighting port(s) with the ignition assembly 114 and allows proper operation of the gas burner 100. The burner cap 102 can be provided with a shape that produces compressive, leak-free contact with the burner base 104, and may not require any additional coupling mechanisms. In other embodiments, the burner cap 102 can be rigidly or removably coupled to the burner base 104 using adhesives, for example.

With continued reference to FIG. 2 and further reference to FIGS. 3-5, the coupling of components in the gas burner 100 is shown. Once the gas inlet piece 144 is positioned on the seat of the burner stand 112, a plurality of stand mounting fasteners 148 can couple the gas inlet piece 144 to the burner stand 112. The stand mounting fasteners 148 may also comprise nuts (not shown), which can be threaded to compress the gas inlet piece 144 to the burner stand 112. Plate mounting fasteners 146 can be used to couple the plate 140 to the gas inlet piece 144. In some embodiments, the heads of plate mounting fasteners 146 sit flush on the top surface of the plate 140 and thread into holes in the gas inlet piece 144. In this orientation, the head of each plate mounting fastener 146 compresses the plate 140, gasket 142, and gas inlet piece 144 together.

With continued reference to FIGS. 2-6 and further reference to FIGS. 8 and 10, the secondary airflow mechanism of the gas burner 100 is shown. While the flame ports proximate the outer circumference of the burner cap 102 may be fed with additional oxygen from the ambient air surrounding the gas burner 100, the flame ports on the interior of the burner cap 102 surrounding the central cavity 156 may not be supplied with additional oxygen coming from above the burner cap 102. The flow of ambient air from above the burner may be blocked by a cooking vessel (not shown), and the flames supported by outer ports of the burner cap 102 may consume ambient air surrounding the gas burner 100 before the air can get to the interior ports surrounding the central cavity 156. To provide secondary air to these ports, the mating surfaces of the burner base 104 and gas inlet piece 144 can create a gap 158 between the bottom surface of the burner base 104 and the top surface of the plate 140. The gap 158 may be sufficient to serve as a secondary air passage 150, allowing ambient air to flow through the secondary air passage 150, underneath the burner base 104, and into central cavity 156, where it can then flow upward and supply the inner flame ports of the burner cap 102.

Referring now specifically to FIG. 4, one example of a locating mechanism between the burner base 104 and burner cap 102 is shown. In some embodiments, the burner base 104 has a tab 152 that extends upwardly from the burner base 104. The burner cap 102 includes a notch 154, which forms a tight clearance fit with the tab 152, so that the burner cap 102 and burner base 104 will always be positioned properly relative to one another during assembly of the burner 100.

With reference now to FIG. 6, the bottom of the gas burner 100 is shown. The first venturi assembly 108 and second venturi assembly 110 can provide gas into the burner bottom assembly 106 at an approximately horizontal direction. The first venturi assembly 108 and second venturi assembly 110 can also be configured to input gas at an approximately parallel orientation. As shown in the figures, the first venturi assembly 108 is configured to input the fuel and oxygen mixture into the burner bottom assembly 106 along an axis X-X. The second venturi assembly 110 may then introduce fuel and oxygen mixture into the burner bottom assembly 106 along an axis Y-Y, which may be approximately parallel to axis X-X.

Referring now to FIG. 7, the relationship between the burner cap 102, the burner base 104, and the burner bottom assembly 106 is shown. The burner cap 102 can be positioned over the burner base 104 and can support a flame pattern that produces a high efficiency heat transfer between the gas burner 100 and a cooking vessel positioned above the gas burner 100. The burner cap 102 includes a plurality of ports, which are formed as apertures extending through the burner cap 102. The ports may be designed to selectively allow oxygen and fuel mixture to exit the inner chamber 116 and outer chamber 118 of the burner base 104, which are positioned directly below the ports, where the fuel and oxygen can then be ignited to produce heat in a generally upward direction.

In some embodiments, the burner cap 102 includes multiple groups of ports that can produce different functionalities. For example, an inner ring of simmering ports 160 may be situated circumferentially around the central cavity 156 in the gas burner 100. The simmering ports 160 may be sized to produce a lower heat output setting. For example, simmering ports 160 may output about 500 BTU at their lowest setting, and up to about 1,500 BTU when they are operating at their highest setting. In some embodiments, the simmering ports 160 are positioned above only the inner chamber 116 of the burner base. The simmering ports 160 are then supplied only by fuel and oxygen mixture present in the inner chamber 116, which may be supplied exclusively by the first venturi assembly 108. Accordingly, the output of the simmering ports 160 may be controlled by controlling only the gas input of the first venturi assembly 108. The controller may be mechanical in nature, such as a manual gas valve. In other embodiments, a solenoid valve could be placed in electrical communication with a controller, and the controller can command the solenoid valve to produce different gas flow rates. Many different heat output settings may be produced by the simmering ports 160, as outputs of less than 500 BTU and greater than 1,500 BTU may be produced in various embodiments of the gas burner 100.

The rate at which oxygen and fuel are introduced into the first venturi assembly 108 and the second venturi assembly 110 may be varied, depending on the needs of a user. For example, if a user needs the gas burner 100 to provide a simmering flame, a much lower amount of fuel and air are necessary than when the gas burner 100 is operating at a maximum output. To avoid wasting fuel or overheating the contents of the cooking vessel above the gas burner 100, a controller (e.g., mechanical or electrical) may be used to restrict the flow of fuel and oxygen to only the first venturi assembly 108. The first venturi assembly 108 then provides fuel and oxygen to only the inner chamber 116 of the burner base 104 when a simmering flame is desired.

The burner cap 102 can have a plurality of burner ports 162, which are spaced about the burner cap 102 and configured to produce a larger heat output than the simmering ports 160. The burner ports 162 provide a larger diameter than the simmering ports, which allows more oxygen and fuel to flow through each port, where it can be combusted. The burner ports 162 can be positioned proximate the outer diameter of the burner cap 102. In some embodiments, the burner ports 162 are positioned in a plurality of concentric rings. Contrary to the simmering ports 160, the burner ports 162 can be positioned exclusively above the outer chamber 118, and can be supplied with fuel and oxygen exclusively by the second venturi assembly 110. Accordingly, the output of the burner ports 162 may be controlled by controlling only the gas input of the second venturi assembly 110.

Although the simmering ports 160 and the burner ports 162 may be fed by separate venturi assemblies, the gas burner 100 can be controlled by a single control device. For example, the first venturi assembly 108 and second venturi assembly 110 can be mechanically or electrically controlled by a single rotational device configured to rotate based upon input by a user. At a first position, the control device may correspond to a no-flow condition, where no fuel or oxygen is being supplied to the gas burner 100 by either the first venturi assembly 108 or the second venturi assembly 110. In this condition, the gas burner 100 would not produce any flame and would not output any significant amount of heat.

As the control device is rotated, the valve corresponding to the first venturi assembly 108 can be opened, and gas can be introduced into the inner chamber 116 of the burner base 104, where it can exit the simmering ports 160. To ignite the simmering ports 160, the burner cap 102 can have one or more lighting ports 166, which are positioned proximate to the ignition source 114. The one or more lighting ports 166 can supply gas at an angle, so that fuel and oxygen are directed through the burner cap 102 and above the ignition source 114 when fuel and oxygen are being supplied to the inner chamber 116 of the burner base 104. When the control device is turned to a position where gas is being supplied to the inner chamber 116 of the burner base 104, an electrical signal may be sent to the ignition source 114 that commands the ignition source 114 to produce a spark. The spark produced by the ignition source 114 ignites the fuel and oxygen mixture above the lighting port 166, producing a flame. In some embodiments, ignition may instead be generated by a hot surface ignition system (not shown) that includes a small localized heating mechanism. When the burner valve is actuated and calls for ignition, the hot surface ignition system creates heat in excess of the auto-ignition temperature of the air-fuel mixture used to operate the burner, and ignites the lighting port 166.

The ignition sequence and spacing of the simmering ports 160 ensures that a nearly constant flame will be produced by the gas burner 100 while the gas burner 100 is being supplied with fuel and oxygen. The flame present on the lighting port 166 can serve as an ignition source for the nearby simmering ports 160. In some embodiments, the simmering ports 160 are positioned in a grouping that allows adjacent ports to light one another. Accordingly, once the first simmering port 160 is lit by the lighting port 166, the remaining unlit simmering ports 160 ignite one by one outwardly away from the lighting port 166 until the entire simmering ring is ignited. In some embodiments, each simmering port 160 is configured to support its own, independent flame body. The tight grouping of the simmering ports 160 can also allow the simmering ports 160 to reignite and reproduce flames when spillage or other issues occur that temporarily extinguish a flame, as any adjacent flame may be used to ignite the fuel and oxygen mixture still exiting the nearby unlit port. In some embodiments, the gas burner 100 outputs about 500 BTU at its lowest setting.

The control device can be further rotated until a maximum simmering setting is reached. As the control device rotates, the valve associated with the first venturi assembly 108 continues to open, which in turn increases the flow rate of fuel and oxygen into the inner chamber 116 of the burner base 104. At the maximum simmering setting, the valve associated with the first venturi assembly 108 may be completely open, and the flow rate of oxygen and fuel into the inner chamber 116 of the burner base 104 may be at a maximum. In some embodiments, the simmering ports 160 produce about 1,500 BTU at the maximum simmering setting. As the control device is rotated from a minimum setting, the flow rate of gas continues to increase, so that multiple different simmering outputs can be achieved between the lowest and highest simmering settings of the gas burner 100. Outputs between about 500 BTU and about 1,500 BTU may be produced using intermediate settings on the control device. Some embodiments of the gas burner 100 produce minimum simmering outputs of less than about 500 BTU and maximum simmering outputs in excess of 1,500 BTU. For example, a gas burner 100 may have a simmering output range between about 400 BTU and about 3,000 BTU in some embodiments.

The control device can be further rotated beyond the maximum simmering setting to a minimum burn setting. The valve controlling fuel and oxygen flow of the second venturi assembly 110 can then be opened. In some embodiments, the position of the valve controlling the first venturi assembly 108 remains unchanged and the flow rate of fuel and oxygen into the inner chamber 116 of the burner base 104 remains at its maximum during this process. Accordingly, flames are still present on the simmering ports 160 when the second venturi assembly 110 begins supplying fuel and oxygen to the gas burner 100. Fuel and oxygen can be supplied to the outer chamber 118 of the burner base 104, which exits the burner ports 162. In order to ignite the burner ports 162, the burner cap 102 may comprise a plurality of ignition ports 164 that can transport the flames present on the simmering ports 160 to the burner ports 162. The ignition ports 164 can be positioned and angled relative to one another to allow each ignition port 164 in the sequence to act as an ignition source for adjacent ignition ports. The ignition ports 164 can be positioned over the inner chamber 116 of the burner base 104 and cn be supplied with fuel and oxygen exclusively by the first venturi assembly 108. In some embodiments, the proximity of the ignition ports 164 to the simmering ports 160 causes the simmering ports 160 to act as an ignition source for the ignition ports 164, and the ignition ports 164 are lit whenever the simmering ports 160 are lit. The outermost ignition port 164 in the plurality of ignition ports can be positioned proximate a burner port 162, where it may then serve as an ignition source for the burner ports 162. The burner ports 162 are positioned and angled relative to one another so that adjacent burner ports 162 then act as ignition sources for one another. Once one burner port 162 is lit, the remaining burner ports 162 can use the lit burner port 162 to ignite themselves.

In some embodiments, the burner cap 102 may include multiple sets of ignition ports 164 spaced about the burner cap 102. For example, the burner cap 102 may have three sets of ignition ports 164 to add redundancy into the ignition sequence. Three evenly spaced sets of ignition ports 164 can ensure that the burner ports 162 will be automatically ignited once gas begins to exit burner ports 162. Similarly, the plurality of ignition port sets 164 may allow for quick reignition of any burner ports 162 that may be extinguished due to some burner disturbance that may occur.

The control device may be rotated beyond the minimum burn setting towards a maximum burn setting, which opens the valve controlling the flow rate of gas through the second venturi assembly 110 further to increase the flow rate of fuel and oxygen into the outer chamber 118 of the burner base 104. Once again, the flow rate of gas through the first venturi assembly 108 may remain unchanged, and the simmering ports 160 and ignition ports 164 may remain lit. As more gas flows through the burner ports 162, the size and output of the flame bodies present on each burner port 162 increases. In some embodiments, the independent and separate flame bodies present on each burner port 162 begin to combine into a larger, higher power flame. In some embodiments, the gas burner 100 may can output about 30,000 BTU or more at its maximum setting. The heat output of the gas burner 100 may fluctuate as the gas burner 100 is toggled between a minimum burn setting and a maximum burn setting, and intermediate values between about 2,500 BTU and about 30,000 BTU can be achieved and maintained with high accuracy based upon the position of the control device. Accordingly, the gas burner 100 may produce a turndown ratio of about 60:1, with a minimum simmering setting of about 500 BTU and a maximum burn setting of about 30,000 BTU. The values provided are merely exemplary, and additional burn settings are possible. For example, some embodiments of gas burner 100 are configured to have a maximum burn setting of about 20,000 BTU, and can operate with a turndown ratio of about 40:1.

Referring now to FIGS. 9A-9C, the fuel and oxygen inlet mechanism is shown. When the gas burner 100 is in a simmer condition, fuel and oxygen are introduced into a first inlet chamber 170 of the gas inlet piece 144, along a ramp 172. In some embodiments, the ramp 172 provides a smoothly curving pathway for gas to be elevated up into the burner base 104 and directed circumferentially around the inner chamber 116, where it can be evenly distributed to the simmering ports 160, ignition ports 164, and the lighting port 166 to promote combustion. The ramp 172 may be provided with a semi-helical or arcuate shape with a smooth bottom that produces a laminar flow of fuel and oxygen into the inner chamber 116 of the burner base 104. In some embodiments, the ramp 172 imparts a substantially clockwise rotation of gas into the burner base 104.

When the gas burner 100 is in a burn condition, fuel and oxygen are additionally introduced into a second inlet chamber 174 of the gas inlet piece 144 along a second ramp 176. The ramp 176 may also provide a smoothly curving pathway for gas to be elevated up into the burner base 104, where it can then be distributed evenly about the burner ports 162 present above the outer chamber 118. The ramp 176 may also be provided with a semi-helical or arcuate shape with a smooth bottom that produces a laminar flow of fuel and oxygen into the outer chamber 118 of the burner base 104. In some embodiments, the ramp 176 imparts a substantially counterclockwise rotation of gas into the burner base 104, in a direction substantially opposing that of ramp 172.

Referring now to FIG. 11, a cross-section of the gas burner 100 is provided to demonstrate the shape of the ramp 176 and the direction in which gas enters into the gas burner 100 by way of the second venturi assembly 110. Fuel is first introduced through fuel inlet 130, through a constricted section to inject oxygen, and into the diffuser section 132 to mix. The fuel and oxygen mixture then passes into the second inlet chamber 174 of the gas inlet piece 144, where the gas is then directed by the ramp 176, which angles the gas upwards and inwards gradually until it reaches the outer chamber 118, where it can be distributed to the burner ports 162. The ramp 172 of the gas inlet piece 144 may operate in a similar manner to supply the simmering ports 160, ignition ports 164, and the lighting port 166 with fuel and oxygen.

Referring now to FIGS. 12A-12B with continued reference to FIG. 2, the burner stand 112 is shown. The burner stand 112 can have a burner seat 190, a plurality of legs 192, and a plurality of mounting tabs 194. In some embodiments, the burner seat 190, legs 192, and mounting tabs 194 are formed of a single sheet of steel or other corrosion resistant metal that is bent into the desired shape. The burner seat 190 can provide a flat surface designed to support the gas inlet piece 144, and may be shaped to support balanced contact with the underside of that piece. The legs 192 may extend away from the burner seat 190 to form angles of approximately 90° with the burner seat 190. Similarly, the mounting tabs 194 may extend away from the legs 192 to form angles of approximately 90° with the legs 192.

In order to receive the gas inlet piece 144, the burner seat 190 has a plurality of features designed to support components of the gas burner 100 assembly. In some embodiments, the burner seat 190 includes a first plate support 196 and a second plate support 198, which extend forward to support plate 140 of the burner bottom assembly 106. The burner seat 190 may have a first arcuate support section 200 that extends forward to form a slightly arcuate shape. The shape of the first arcuate support section 200 can be substantially concentric with the ramp 176 that supplies gas to the outer chamber 118 of the burner base 104. The shape of the first arcuate support section 200 may also function as a locating feature, as the bottom of the gas inlet piece 144 can include features that are chosen to mate with the shape of the first arcuate support section 200. Similarly, the burner seat 190 may have a second arcuate support section 202 that is approximately concentric with the ramp 172 that supplies gas to the inner chamber 116 of the burner base 104. The second arcuate support section 202 can mate with features of the gas inlet piece 144 to provide flat, compressive contact between the two components.

In some embodiments, a plurality of different apertures can be formed in the burner stand 112. An ignition assembly aperture 204 can be positioned proximate the first arcuate support section 200 and the second arcuate support section 202, and can receive a portion of the ignition source assembly 114. In some embodiments, the ignition assembly aperture 204 is a through hole that extends through the burner seat 190. The burner stand 112 may include additional apertures that allow other components of the gas burner 100 to be mounted to the burner stand 112. For example, a plurality of plate mounting apertures 206 may be spaced about the burner stand 112, and may receive fasteners 146 that compress the gas inlet piece 144, the gasket 142, and the plate 140 together. A plurality of stand mounting apertures 208 may be spaced apart the burner seat 190 to receive fasteners for securing the gas inlet piece 144 to the burner stand 112. In some embodiments, the one or more mounting tabs 194 are provided with range mounting apertures 210 that are configured to receive fasteners that can be used to mount the gas burner 100 to a stove-top assembly.

Referring now to FIGS. 13A-13D with continued reference to FIG. 2, the gas inlet piece 144 is shown in greater detail. The gas inlet piece 144 comprises a main support plate 220, which has a top surface 222, a bottom surface 224, and a cylindrical outer surface 226. In some embodiments, the top surface 222 of the gas inlet piece is substantially flat and is configured to receive a gasket 142, as discussed earlier.

In some embodiments, an outer chamber inlet 228 introduce gas into the outer chamber 118 of the burner base 104. The outer chamber inlet 228 extends upwardly away from the top surface 222 of the main support plate 220. The outer chamber inlet 228 can define a semi-annular shape having of a first wall 236, a second wall 238, an outer curved wall 230, and an inner curved wall 234. These walls may extend upwardly to form a flat surface 232 which can mate with the burner base 104. In some embodiments, the outer curved wall 230 and inner curved wall 234 are defined by substantially concentric radii. In some embodiments, the outer curved wall 230 and inner curved wall 234 are positioned substantially concentrically with the walls defining the perimeter of the outer chamber 118 of the burner base 104.

Similarly, the main support plate 220 may have an inner chamber inlet 244 to introduce gas into the inner chamber 116 of the burner base 104. The inner chamber inlet 244 can have a semi-annular shape defined by a first wall 252, second wall 254, outer curved wall 246, and inner curved wall 250. The walls may extend upwardly away from the top surface 222 to form a flat surface 248 that can mate with the burner base 104. In some embodiments, the outer curved wall 246 and inner curved wall 250 are defined by substantially concentric radii. The inner curved wall 250 and outer curved wall 246 can be positioned substantially concentrically with the walls defining the inner chamber 116 of the burner base 104.

Additional locating features 260 can be spaced about the main support plate 220 and can be provided to both locate and support the burner base 104 when it is being assembled. The locating features 260 may have an outer curved wall 262, an inner curved wall 266, and a flat surface 264 that mates with a surface of the burner base 104. In some embodiments, the outer curved wall 262 of the locating features 260 is defined by a radius approximately equivalent to the radius defining the outer curved wall 230 of the outer chamber inlet 228. In some embodiments, the outer curved surface 262 and inner curved surface 266 are substantially concentric with one another, and are substantially concentric with the radius defining the cylindrical outer surface 226 of the main support plate 220. In some embodiments, the flat surface 264 of the locating features, flat surface 232 of the outer chamber inlet 228, and flat surface 248 of the inner chamber inlet 244 are all approximately coplanar with one another.

The bottom surface 224 of the main support plate 220 can also have a plurality of mounting features that mate against the burner seat 190 of the burner stand. The inner chamber ramp 292 can extend arcuately away from the bottom surface 224 to follow the path of the ramp 272 that supplies gas to the inner chamber 116 of the burner base 104. Similarly, the outer chamber ramp 294 can extend arcuately away from the bottom surface 224 to follow the path of the ramp 276 that supplies gas to the outer chamber 118 of the burner base 104. In some embodiments, a mounting ring 296 extends away from the bottom surface 224 of the main support plate 220. The mounting ring 296 may be defined by an inner wall 300 and an outer wall 302 extending circumferentially about at least a portion of the bottom surface 224 of the main support plate 220. In some embodiments, the inner wall 300 and outer wall 302 are approximately concentric with one another and are approximately concentric with the cylindrical outer surface 226 of the main support plate 220. The mounting ring 296 may provide a flat mounting surface 298 that mates with the burner seat 190 of the burner stand 112. The mounting ring 296 may extend circumferentially about a portion of the bottom surface 224 of the main support plate 220. In some embodiments, a portion of the outer chamber ramp 294 extends away from the bottom surface 224 of the main support plate 220 further than the mounting ring 296, such that the mounting ring 296 has a discontinuity across the outer chamber ramp 294. To provide additional mounting support to the gas inlet piece 144, an interior mounting pad 304 may extend away from the bottom surface 224 of the main support plate 220. The interior mounting pad 304 may have a flat mounting surface 306 that engages a portion of the first arcuate section 202 and second arcuate section 204 of the burner stand 112, shown in FIGS. 12A-12B. In some embodiments, the flat mounting surface 306 of the interior mounting pad 304 and the flat mounting surface 298 of the mounting ring 296 are approximately coplanar with one another at a distance 308, so that they can all form flat, compressive contact with the burner seat 190 of the burner stand 112 when properly assembled.

To provide the gas burner 100 with fuel and oxygen, the gas inlet piece 144 can include multiple inlets. In some embodiments, the gas inlet piece 144 has a first air-gas inlet 280 that receives and directs fuel and oxygen into the inner chamber 116 of the burner base 104. Fuel and oxygen mixture is provided through the air-gas inlet 280, where it is smoothly directed along the concave ramp 172 in the first inlet chamber 170. A curved inlet wall 258 provides further definition to the travel path of the fuel and oxygen as it travels along the ramp 172, towards the smooth transition point 256 on the inner chamber inlet 244, where it then is introduced into the inner chamber 116 of the burner base 104. Similarly, the gas inlet piece 144 may include a second air-gas inlet 286 that receives and directs fuel and oxygen into the outer chamber 118 of the burner base. Fuel and oxygen mixture may be provided through the air-gas inlet 286, where it is smoothly directed along the concave ramp 176 in the second inlet chamber 174. The curved inlet wall 242 can further shape the flow path of the fuel and oxygen mixture as it travels upwards and circumferentially toward the smooth transition point 240, where the gas can be introduced into the outer chamber 118 of the burner base 104.

To ensure an adequate seal between the fuel and oxygen source and the gas burner 100, the gas inlet piece 144 may have a plurality of flat mounting faces to receive piping. In some embodiments, a mounting face 282 surrounds the first air-gas inlet 280, and receives a gasket 126 and/or the flange 124 of the first venturi assembly 108. The mounting face 282 may be provided with mounting holes 284, which can optionally be threaded. The flange 124 and gasket 126 may both be provided with through holes, so that a fastener 128 can be used to couple the flange 124 and the gasket 126 to the mounting face 282. The mounting face 282, gasket 126, and flange 124 can together form a leak-free compressive contact between the first venturi assembly 108 and the gas inlet piece 144. Similarly, a second mounting face 288 can surround the second air-gas inlet 286. The second mounting face 288 can also receive the flange 134 and/or the gasket 136 of the second venturi assembly 110. Mounting holes 290 may be provided to couple the flange 134, gasket 136, and second mounting face 288 to form leak-free compressive contact between the second venturi assembly 110 and the gas inlet piece 144.

A plurality of apertures can be formed through the main support plate 220 to couple the gas inlet piece 144 to other components in the gas burner 100 assembly. In some embodiments, an ignition assembly aperture 270 extends through the main support plate 220 and is receives the ignition source 114. In some embodiments, the ignition assembly aperture 270 is a counterbored hole that provides a mounting seat to the ignition source 114. Additionally, a plurality of plate mounting holes 272 can be positioned about the main support plate 220 of the gas inlet piece 144. Optionally, the plate mounting holes 272 can be threaded. In some embodiments, the plate mounting holes 272 are configured to receive fasteners 146 to couple the plate 140, gasket 142, and gas inlet piece 144 together. Additionally, a plurality of stand mounting holes 274 can be dispersed about the main support plate 220. The plurality of stand mounting holes 274 may be configured to receive fasteners that couple the gas inlet piece 144 to the burner stand 112. In some embodiments, the stand mounting holes 274 can be counterbored so that the heads of the fasteners 148 do not extend upwardly beyond the top surface 222 of the main support plate 220. The gasket 142 can then sit above the fasteners 148 during the assembly of the burner bottom assembly 106.

Referring now to FIG. 14 with continued reference to FIG. 2, the gasket 142 is shown in greater detail. The gasket 142 can have a top surface 320, a bottom surface 322, and a plurality of apertures to help properly position the gasket 142 on top of the top surface 222 of the gas inlet piece 144. In some embodiments, the gasket 142 has a chamber aperture 324, which is configured to receive both the outer chamber inlet 228 and the inner chamber inlet 244 of the gas inlet piece 144. Locating feature apertures 326 may also extend through the gasket 142, and can be similarly sized to form clearance fits about the locating features 260 on the gas inlet piece 144. In some embodiments, the bottom surface 322 of the gasket 142 will sit flat upon the top surface 222 of the gas inlet piece 144 when assembled. An ignition assembly aperture 328 and a plurality of plate mounting holes 330 may also extend through the gasket 142. The plate mounting holes 330 can receive fasteners 146 that compress the plate 140, gasket 142, and gas inlet piece 144 against one another. In some embodiments, the gasket comprises graphite or other temperature resistant flexible and compressible material(s).

Referring now to FIG. 15 with continued reference to FIG. 2, the plate 140 is shown in isolation. The plate 140 can have a stand mounting section 340, an angled section 342, and a gas inlet mounting section 344, each of which may be formed of a single stamped piece of aluminum, stainless steel, or other suitable cooktop material.

In some embodiments, the stand mounting section 340 indirectly engages the burner seat 190 of the burner stand 112. The outer diameter of the plate 140 can extend outwardly beyond at least a portion of the burner seat 190 to form a stand mounting surface 346. The stand mounting surface 346 can form compressive contact with a portion of the burner seat 190 and the first plate support arm 196 and second plate support arm 198, which help support the plate 140 when the gas burner 100 is fully assembled. In some embodiments, the stand mounting section 340 is configured to sit below a stove top (not shown). In other embodiments, the stand mounting section 340 may be positioned at least partially above a top surface of a range. The angled section 342 may extend gradually upwardly and inwardly away from the stand mounting section 340 towards the gas inlet mounting section 344. In some embodiments where the stand mounting section 340 is configured to sit below a stove top (e.g., it may be mounted to the underside of the stove top) and the angled section 342 may be configured to extend upwardly beyond the stove top to then allow the gas inlet mounting section 344 to be slightly elevated above the cooktop, where it forms an accessible platform-type surface that may serve as the bottom of the gas burner 100.

The plate 140 may have a number of apertures extending through at least the gas inlet mounting section 344, which may be used to both locate and couple the plate 140 to the gasket 142 and the gas inlet piece 144. In some embodiments, the gas inlet piece mounting section 344 has an inlet aperture 350, which may help locate the plate 140 properly relative to the gas inlet piece 144. In some embodiments, the perimeter of the inlet aperture 350 produces a clearance fit with the outer chamber inlet 228 and inner chamber inlet 244 of the gas inlet piece 144 when assembled. In some embodiments, the gas inlet mounting section 344 has a thickness that allows the outer chamber inlet 228 and inner chamber inlet 244 of the gas inlet piece 144 to protrude upwardly beyond the top surface of the gas inlet mounting section 344 when assembled. The outer chamber inlet 228 and inner chamber inlet 244 may then serve as locating features for the burner base 104. A gas inlet mounting surface 348 may compress against the gasket 142 and the top surface 222 of the gas inlet piece 144.

Additionally, the gas inlet mounting section 344 may include one or more locating feature apertures 352, which can at least partially receive the one or more locating features 260 present on the gas inlet piece 144. The locating feature apertures 352 can produce a clearance fit with the one or more locating features 260, which helps ensure the proper angular position of the plate 140 is found by a user during assembly of the burner bottom assembly 106. An ignition assembly aperture 354 can be formed as a through hole in the gas inlet mounting section 344 as well, which can accommodate the ignition source 114. A plurality of plate mounting holes 356 may be spread about the gas inlet mounting section 344 as well. The plurality of mounting plate holes 356 may receive plate mounting fasteners 146, which may then be passed through plate mounting holes 330 in the gasket 142, and threaded into the plate mounting holes 272 of the gas inlet piece 144.

Referring now to FIGS. 16A-16F with continued reference to FIG. 2, the burner base 104 is shown. The burner base 104 may be formed of cast aluminum or stainless steel, for example. As discussed previously, the burner base 104 can be divided into an inner chamber 116 and an outer chamber 118, and may selectively provide fuel and oxygen to ports situated above the burner base 104.

The burner base 104 can include an annular shape defined by an outer wall 360 that extends circumferentially around the burner base 104. At the top of the outer wall 360, a mounting surface 362 extends circumferentially about the entire burner base 104. In some embodiments, the mounting surface 362 mates with a surface of the burner cap 102 to create a leak-free seal. In some embodiments, the mounting surface 362 also has a tab 152 that extends upwardly along a portion of the mounting surface 362 to serve as a locating feature with the notch 154 of the burner cap 102. A ledge 364 may extend radially inward from the outer wall 360 to form an additional mating surface to receive a portion of the burner cap 102, so that a two-plane seal may be formed between the burner base 104 and the burner cap 102 along the outer perimeter of the gas burner 100.

The outer chamber 118 of the burner base can be formed of an outer chamber outer wall 366 extending downwardly from the ledge 364, an outer chamber inner wall 368 that forms part of a dividing wall 370, and an outer chamber base 382. The dividing wall 370 may also define an inner chamber outer wall 372 that serves as the outer perimeter of the inner chamber 116. The inner chamber 116 can be further defined by an inner chamber inner wall 374 and an inner chamber base 384. In some embodiments, the inner chamber base 384 and outer chamber base 382 are approximately coplanar with one another. At the upper end of the inner chamber inner wall 374, a mounting surface 376 is formed to mate with another surface of the burner cap 102. In some embodiments, a ledge 378 extends radially inwardly from the inner chamber inner wall 374 to provide a second mating surface for a portion of the burner cap 102. In some embodiments, the offset between the ledge 378 and the mounting surface 376 also serves as a locating feature to ensure that the burner cap 102 is positioned approximately concentrically with the burner base 104. A substantially cylindrical surface 380 may extend downward away from the ledge 378 to form a portion of the central cavity 156.

Referring specifically to FIG. 16D, the geometry of the burner base 104 is shown. In some embodiments, the outer chamber outer wall 366 extends away from the outer chamber base 382 to form an obtuse angle between about 91° and about 115°. Similarly, the outer chamber inner wall 368 may extend away from the outer chamber base 382 to form an angle of between about 80° and about 120° with the chamber base 382. Similarly, the inner chamber outer wall 372 may extend away from the inner chamber base 384 to form an obtuse angle between about 91° and about 115°, while the inner chamber inner wall 374 may extend away from the inner chamber base 384 to form an angle between about 80° and about 120°. Accordingly, both the inner chamber 116 and the outer chamber 118 can have cross sections that gradually expand away from the outer chamber base 382 and inner chamber base 384. The cylindrical surface 380 can also be provided with a slightly tapering upward cross-section, such that the central cavity 156 widens as it extends towards the burner cap 102 when the gas burner 100 is fully assembled. In some embodiments, the dividing wall 370 extends upwardly beyond the mounting surface 362 of the outer wall and the mounting surface 376 of the inner chamber inner wall 374. In some embodiments, the notch 152 extends upwardly beyond dividing wall 370. In some embodiments, ledge 364 and ledge 378 are approximately coplanar, while flat surfaces 362 and 376 are approximately coplanar as well.

In some embodiments, the inner chamber 116 and outer chamber 118 have apertures to place the burner base 104 into fluid communication with the burner bottom assembly 106 and the first venturi assembly 108 and second venturi assembly 110. An inner chamber inlet 386 can extend through the inner chamber base 384 to provide fluid communication with the gas inlet piece 144. In some embodiments, the inner chamber inlet 386 may sit above the inner chamber inlet 244 of the gas inlet piece 144 so that gas from the first venturi assembly 108 following the ramp 172 may then be introduced through the inner chamber inlet 386 and into the inner chamber 116 of the burner base 104. The gas following this path can then be distributed to ports in the burner cap 102 when the gas burner 100 is fully assembled. Similarly, an outer chamber inlet 388 may be formed in the outer chamber base 382. In some embodiments, the outer chamber inlet 388 sits above the outer chamber inlet 228 when the burner base 104 is coupled to the burner bottom assembly 106. Fuel and oxygen may then enter through the second venturi assembly 110 to the ramp 176, out the outer chamber inlet 228 at the smooth transition 240, through the outer chamber inlet 388, and into the outer chamber 118 of the burner base 104, where it may then be distributed to ports in the burner cap 102 above.

In some embodiments, the ledge 378 may have a substantially annular shape partially defined by the cylindrical surface 380. The ledge 378 may also provide a seat for the ignition source 114, and may have an ignition assembly aperture 390 to accommodate the ignition source 114. In some embodiments, the ignition source 114 may be provided with a flange with a diameter greater than the diameter of the ignition assembly aperture 390, so that the flange serves as a stopping feature and allows for the easy placement and assembly of the ignition source 114 into the burner base 104.

In some embodiments, the bottom of the burner base 104 comprises a locating surface 392. The locating surface 392 may extend downwardly beyond any other surfaces of the burner base 104, and can provide a raised lip that partially receives one or more locating features on the burner bottom assembly 106. In some embodiments, the locating surface 392 receives the outer chamber inlet 228 and the inner chamber inlet 244 of the gas inlet piece 144. The shape and positioning of the portion of the locating surface 392 configured to receive the outer chamber inlet 228 and the inner chamber inlet 244 may locate the burner base 104 above the burner bottom assembly 106. In some embodiments, the burner base 104 can only sit balanced upon the burner bottom assembly 106 when the burner base 104 is aligned properly relative to the gas inlet piece 144.

A mating surface 394 inwardly offset from the locating surface 392 can be present on the bottom of the burner base 104. The mating surface 394 can be provided with a substantially flat shape that is designed to form compressive, leak-free contact with the flat surface 232 of the outer chamber inlet 228 and the flat surface 248 of the inner chamber inlet 244. Additionally, the mating surface 394 can engage the flat surfaces 264 of the one or more locating features 260 extending upwardly from the main support plate 220 of the gas inlet piece 144. In some embodiments, the mating surface 394 extends circumferentially around a portion of the burner base 104, as well as radially inward towards the cylindrical surface 380 of the burner base 104. In some embodiments, the size of the offset between the mating surface 394 and the locating surface 392 is smaller than the distance that the flat surface 232 of the outer chamber inlet 228, the flat surface 248 of the inner chamber inlet 244, and the flat surfaces 264 of the one or more locating features 260 extends away from the top surface 222 of the main support plate 220 of the gas inlet piece 144. When the mating surface 394 is rested on the flat surfaces 232, 248, 264 of these components, a gap 158 is created between the locating surface 392 and the gas inlet mounting surface 348 of the plate 140 to supply secondary air through the secondary air passage 150 into the central cavity 156 of the gas burner 100.

Additional surfaces may be provided to the burner base 104 that help accommodate other features in the gas burner 100 assembly. For example, the bottom side of the burner base 104 may have a plurality of fastener recesses 396 to accommodate the heads of plate mounting fasteners 146 that may extend above the gas inlet mounting surface 348 of the plate 140. An ignition assembly recess 398 can be inwardly offset from the locating surface 392 and the mating surface 394 that allows the ignition source 114 to be fitted within the ignition assembly aperture 390. In some embodiments, a bottom surface 400 is also inwardly offset from the locating surface 392 and the mating surface 394. The bottom surface 400 can be positioned radially inward from the outer circumference of the locating surface 392, which extends about the entire bottom of the burner base 104.

To provide the necessary surface finish for the mating surface 394, the mating surface can be cast and then machined to the proper surface finish. Other manufacturing techniques are possible and may be used to produce the appropriate sealing function of the mating surface 394 as well. The other surfaces on the burner base 104 may be cast or otherwise machined to the appropriate size and surface finish. In some embodiments, the locating surface 392 and bottom surface 400 are cast surfaces, while the mating surface 394 is a machined surface.

Referring now to FIGS. 17A-17E with continued reference to FIG. 2, the burner cap 102 is shown. The burner cap 102 can have a radial outer surface 410 defined by radius R5, a top surface 412, and a bore 414 defined by radius R6 and configured to align concentrically with the cylindrical surface 380 of the burner base 104. The burner cap 102 may be formed of brass, aluminum, stainless steel, porcelain, or other suitable materials capable of withstanding high temperature while inhibiting rust and other contaminant buildup. As discussed previously, the burner cap 102 may include a notch 154 that receives the tab 152 of the burner base 104 to produce proper alignment of the burner cap 102 with the burner base 104.

In some embodiments, the burner cap 102 nests within a portion of the burner base 104. The burner cap may have an outer mating surface 422 and a ledge 424 that mate with the ledge 364 and the mounting surface 362 of the burner base 104. In some embodiments, the outer mating surface 422 of the burner cap 102 is partially received within a portion of burner base 104, and can be provided with a flat surface that compressively engages the ledge 364 of the burner base 104 to form a leak-free seal. The components can be sized to form a tight clearance fit with one another during assembly of the gas burner 100. Heat from the burner cap 102 may cause the burner cap to expand, and a temporary interference fit may be present between the burner cap 102 and the burner base 104, further improving the seal between components.

The burner cap 102 may also be provided with an inner mating surface 426 and a ledge 428, which can be coupled with the ledge 378 and mounting surface 376 of the burner base 104. The components may produce a tight clearance fit that produces substantially leak-free sealing between the burner base 104 and burner cap 102 when the gas burner 100 is fully assembled. In some embodiments, the coupling between the burner cap 102 and the burner base 104 may be through the use of fasteners or adhesives, for example. In some embodiments, the burner cap 102 is set onto the burner base 104 in the proper position, and the sizing and shaping of components in the gas burner 100 substantially restricts the movement of the burner cap 102 relative to the burner base 104 in every direction besides upward.

In some embodiments, the burner cap 102 includes a dividing wall 430 that may be used to divide the inner chamber 116 and outer chamber 118 of the burner base 104. The dividing wall 430 may prevent fuel and oxygen from passing between chambers during the operation of the gas burner 100. The dividing wall 430 may serve as an extension of dividing wall 370, and can form flat, metal-to-metal compressive contact with the dividing wall 370. In some embodiments, dividing wall 430 and dividing wall 370 collectively restrict fluid communication between the inner chamber 116 and the outer chamber 118 of the burner base 104, which may allow the gas burner 100 to have more accurate control.

The top surface 412 of the burner cap can be provided with a slight curvature, which can be defined by the radius R7. In some embodiments, the radius R7 is chosen to provide a curvature that may partially shield the simmering ports 160 from blowing air (e.g., from a fan or from wind) that may be directed towards the gas burner 100 from a substantially horizontal direction. For example, the top surface may arc from a local minimum height near the radial outer surface 410 of the burner cap to a local maximum height near the midpoint between the radial outer surface 410 and the bore 414, and finally to a second local minimum near the bore 414. The simmering ports 160 can be positioned proximate the bore 414 so that they are positioned below the local maximum height of the top surface 412, and may support flame bodies that originate below the local maximum height of the top surface 412. Accordingly, the local maximum of the top surface 412 may block or redirect blowing air upward away from the simmering ports 160, which may protect and preserve flame bodies present on the simmering ports 160.

The burner cap 102 can comprise a plurality of simmering ports 160, burner ports 162, and ignition ports 164. In some embodiments, the plurality of ports 160, 162, 164 can produce a flame pattern capable of outputting about 30,000 BTU or more and are able to transfer that heat to a cooking vessel at an efficiency of about 60% or more. To produce a flame with these characteristics, the flame port size, angle, location, and spacing can be carefully controlled. In some embodiments, the burner cap 102 has multiple of different port groups configured to produce and sustain a flame during the operation of the gas burner 100. For example, the burner cap may have a plurality of simmering ports 160 that output a lower energy flame pattern. The simmering ports may be positioned about radius R1, which can be concentric with the bore 414 of the burner cap 102. Each simmering port 160 can be spaced about the burner cap 102 at an angle θ1 with respect to the next simmering port 160. In some embodiments, θ1 may be between about 5° and about 20°. The simmering ports 160 can be spaced evenly about radius R1, or could be staggered or intermittently placed about radius R1 to produce an uneven flame. In some embodiments, θ1 is chosen to be uniform between all simmering ports 160, and can be small enough that each simmering port 160 can serve as an ignition source for each adjacent simmering port 160 when lit. Each of the simmering ports 160 may be provided with an angle α1 with respect to the horizontal reference plane, as shown in FIG. 17C. In some embodiments, α1 is chosen to be between about 45° and about 90°.

In addition to the simmering ports, the burner cap 102 may include a plurality of burner ports 162 spread about the burner cap 102. In some embodiments, the burner ports 162 are spread about the burner cap 102 in a plurality of concentric arrays. In some embodiments, a first plurality of intermediate ports 416 are spread about the burner cap 102 along radius R2, which may be approximately concentric with the bore 414 and the array of simmering ports 160. In some embodiments, each port in the first plurality of intermediate ports 416 is spaced apart from adjacent ports at an angle θ2. In some embodiments, θ2 may be between about 5° and about 30°. Once again, θ2 may be chosen to be small enough that each port 416 in the first plurality of intermediate ports may serve as an ignition source for each adjacent port 416, when lit. In some embodiments, each of the ports 416 in the first plurality of intermediate ports is chosen to have a diameter larger than the diameter of the simmering ports 160. Each of the ports 416 in the first plurality of intermediate ports 416 may be provided with an angle α2 with respect to the horizontal reference plane, as shown in FIG. 17D. In some embodiments, α2 is chosen to be between about 45° and about 90°.

A second plurality of intermediate ports 418 may also be dispersed about the burner cap 102 about radius R3. In some embodiments, the second plurality of intermediate ports 418 are spread about the burner cap 102 along radius R3, which may be approximately concentric with the bore 414 and the array of simmering ports 160 and may be larger than radii R2 and R1. In some embodiments, each port 418 in the second plurality of intermediate ports 418 is spaced apart from adjacent ports at an angle θ3. In some embodiments, θ3 may be between about 5° and about 30°. Once again, θ3 may be chosen to be small enough that each port 418 in the second plurality of intermediate ports may serve as an ignition source for each adjacent port 418, when lit. Additionally, the difference in size between R2 and R3 may be such that ports 416 from the first plurality of intermediate ports may act as ignition sources for adjacent ports 418 in the second plurality of ports. In some embodiments, each of the ports 418 in the second plurality of intermediate ports is chosen to have a diameter larger than the diameter of the ports 416 in the first plurality of intermediate ports. Each of the ports 418 in the second plurality of intermediate ports 418 may be provided with an angle α3 with respect to the horizontal reference plane, as shown in FIG. 17E. In some embodiments, α3 is chosen to be between about 30° and about 90°.

In addition to the intermediate ports, the burner cap may comprise an outer plurality of ports 420 positioned proximate the radial outer surface 410 of the burner cap 102. In some embodiments, outer ports 420 are positioned about radius R4, which may be concentric with radii R1, R2, and R3. In some embodiments, R4 may be chosen to be larger than R1, R2, and R3. Once again, the difference in size between R3 and R4 may be chosen such that ports 418 from the second plurality of intermediate ports may act as ignition sources to adjacent ports 420 in the outer plurality of ports. The outer ports 420 may be spaced about the burner cap 102 at an angle θ4 between ports 420. In some embodiments, θ4 is between about 5° and about 30°. The size of angle θ4 may again be chosen to allow adjacent ports 420 to act as ignition sources for each adjacent port 420 that may be unlit. In some embodiments, the diameter of outer ports 420 is chosen to be larger than the diameter of the simmering ports 160, the diameter of the ports 418 in the first plurality of intermediate ports, and the diameter of the ports 418 in the second plurality of intermediate ports. In some embodiments, each of the ports 420 in the outer plurality of ports is provided with an angle α4 with respect to the horizontal reference plane, as shown in FIG. 17C. In some embodiments, α4 is chosen to be between about 30° and about 90°.

To light the simmering ports 160, a lighting port 166 can be provided. The lighting port 166 can be positioned radially inward from a simmering port 160, and can direct fuel and oxygen from the inner chamber 116 of the burner base 104 towards the ignition source 114 of the gas burner 100. In order to direct the fuel and oxygen inward toward the ignition source, the lighting port 166 may be provided with an angle α5 with respect to the horizontal reference plane, as shown in FIG. 17C. In some embodiments, α5 is chosen to be between about 5° and about 85°. Angle α5 of the lighting port 166 and angle α1 of the adjacent simmering port 160 may be chosen to allow lighting port 166 to act as an ignition source for the adjacent simmering port 160, which may then be used to sequentially ignite the entire ring of simmering ports 160. The tab 152 and notch 154 locating mechanism between the burner base 104 and burner cap 102 can ensure that the lighting port 166 will be positioned proximate the ignition source 114 when the gas burner 100 is fully assembled.

The burner cap 102 may also comprise a plurality of ignition ports 164, which may be positioned about the burner cap 102 in locations that allow flames from the simmering ports 160 to be transferred to fuel and gas exiting the first plurality of intermediate ports 416. During ignition, the first plurality of intermediate ports 416 ignites, followed by the second plurality of intermediate ports 418, until finally the outer ports 420 become lit. In some embodiments, the ignition ports 164 have a plurality of differently sized and angled ports positioned in a straight line about the burner cap 102. For example, each plurality of ignition ports 164 may include two ports provided at angles α6 and α7 with respect to the horizontal reference plane, as shown in FIG. 17D. In some embodiments, α6 is chosen to be between about 60° and about 90°, and α7 is chosen to be between about 60° and about 90°. The ignition ports 164 may be positioned closely enough to the simmering ports 160 that the simmering ports 160 serve as ignition sources to the ignition ports. Similarly, the one ore more ignition ports 164 in each plurality may be positioned proximate to one another so each port may serve as an ignition source to the next ignition port 164 in the plurality. With at least one ignition port 164 positioned in close enough proximity to an intermediate port 416, 418, or 420, the outer ports 420 may be ignited without the use of an additional ignition source 114.

Referring now to FIGS. 18A and 18B with continued reference to FIG. 2, one embodiment of an ignition source 114 is shown in greater detail. The ignition source 114 may include an upper electrode 442 and a lower electrode 440, which may can collectively provide ignition to the gas burner 100. In some embodiments, the upper electrode 442 and lower electrode 440 are removably coupled to one another, and may be quickly and easily assembled and disassembled to promote faster and more comprehensive cleaning of the ignition source 114. Grease or other foodstuffs may accumulate on and around the ignition source 114 during gas burner 100 use, and cleaning may be periodically necessary. The two-piece assembly may allow a user to take the upper electrode 442 apart from the lower electrode 440 to clean (e.g., by scrubbing, washing, or otherwise) the ignition source 114 to ensure that no buildup prevents the ignition source 114 from being able to ignite the gas burner 100. Additionally, the two-piece design may promote a safer cleaning and maintenance process, both to the component and to a user. When the upper electrode 442 is uncoupled from the lower electrode 440, the upper electrode 442 is no longer in electrical communication with a power source, and therefore will not be able to shock a user during a cleaning process if a burner knob is accidentally bumped, rotated, or depressed. Additionally, the two-piece assembly may provide a more robust design that is less susceptible to cracking, which can prolong the life of the ignition source 114. Although the following description of a two-piece ignition source 114 is provided, other types of ignition sources 114 capable of producing a spark, flame, heat, or other ignition mechanism can also be used.

The lower electrode 440 may sit within the counterbored ignition assembly hole 270 formed within the gas inlet piece 144 of the burner bottom assembly 106. In some embodiments, the lower electrode 440 has a flange 444 extending outward from a body 446 that mates with the gas inlet piece 144. In some embodiments, the flange 444 is defined by a radius sized to form a clearance fit with the counterbored ignition assembly hole 270 and sit upon the counterbored surface within the counterbored ignition assembly hole 270, while the body 446 is defined by a radius sized to extend through the counterbored ignition assembly hole 270 through the gas inlet piece 144. An electrical connection 448 extends downward from the body, where it can be placed in electrical communication with a power source (not shown), such as a wall outlet or other electrical power source connected to a range. In some embodiments, the electrical connection 448 is also placed in communication with one or more controllers (not shown). The one or more controllers can be configured to selectively permit electricity to pass through to the electrical connection 448, based upon the user-inputted setting of the gas burner 100 or whether a flame is detected on the burner 100 when the burner 100 is receiving fuel and oxygen. When a spark is needed, a high voltage can be supplied to the ignition source, causing a spark upon the upper electrode 442. In some embodiments, the lower electrode 440 may include a male connection 450, which mates with a portion of the upper electrode 442 to place the lower electrode 440 in electrical communication with the upper electrode 442.

The upper electrode 442, as indicated previously, may have a female connection 452 that is formed as a cavity within a body 454 of the upper electrode 442. The female connection 452 may be lined with a conducting material, such as copper, titanium, graphite, brass, silver, or platinum, for example. In some embodiments, the female connection 452 is sized to accommodate the male connection 450 of the lower electrode 440 to form compressive, conductive contact with a portion of the male connection 450. Accordingly, electricity provided to the electrical connection 448 may be passed between the lower electrode 440 to the upper electrode 442, where it may eventually produce a spark, flame, or heat to ignite the lighting port(s) 166 and simmering ports 160 on the gas burner 100. In some embodiments, the connections will be reversed. For example, the lower electrode 440 can have a female connection, while the upper electrode 442 will have a male connection. Some embodiments of the gas burner 100 include ignition sources 114 with still different types of connection mechanisms, including terminal connections, soldered connections, and other suitable methods of placing two conducting materials into electrical communication with one another.

Similar to the lower electrode 440, the upper electrode 442 may sit securely within the gas burner 100. In some embodiments, the upper electrode 442 extends through the ignition assembly aperture 390 formed within the burner base 104. A flange 456 may extend outward from the body 454 to serve as a locating feature for the upper electrode 442. In some embodiments, the flange 456 rests upon the portion of the ledge 378 of the burner base 104 that extends inward around the ignition assembly aperture 390. The body 454 can extend upward beyond the flange 454, toward a top surface 458 which may be formed of a flame-resistant material, such as ceramic. In some embodiments, an ignition aperture 460 is formed within the top surface 458 that provides a spark, flame, or heat upward toward a lighting port 166 or simmering port 160 positioned nearby, where it may ignite gas exiting the ports 160, 166, and in turn light the gas burner 100.

In some embodiments, the ignition source 114 may also provide locating features that ensure the gas burner 100 is assembled properly. For example, the lower electrode 440 may be rigidly, adhesively, or otherwise coupled to the gas inlet piece 144 in a way that causes the lower electrode 440 to be assembled together with the burner bottom assembly 106, where it can be coupled to a power source and/or a controller. Similarly, the upper electrode 442 may be rigidly, adhesively, or otherwise coupled to the burner base 104. The male connection 450 of the lower electrode 440 can extend upwardly beyond the burner bottom assembly 106 so that the only orientation of the burner base 104 relative to the burner bottom assembly 106 that allows the burner base 104 to sit level above the burner bottom assembly 106 occurs when the male connection 450 of the lower electrode 440 and the female connection 452 of the upper electrode 442 are properly aligned. Improper alignment of components is further prevented because the gas burner 100 would require the male connection 450 of the lower electrode 440 to be aligned with the female connection 452 of the upper electrode 442 in order to produce a spark and operate the gas burner 100.

It will be appreciated by those skilled in the art that while the invention has been described above in connection with particular embodiments and examples, the invention is not necessarily so limited, and that numerous other embodiments, examples, uses, modifications and departures from the embodiments, examples and uses are intended to be encompassed by the claims attached hereto. The entire disclosure of each patent and publication cited herein is incorporated by reference, as if each such patent or publication were individually incorporated by reference herein. Various features and advantages of the invention are set forth in the following claims.

Claims

1. A gas burner comprising: a first venturi configured to supply fuel in a substantially horizontal direction;a second venturi configured to supply fuel in a substantially horizontal direction;a burner bottom coupled to the first venturi and the second venturi, the burner bottom being configured to direct fuel from the first venturi along a first ramp upwardly and circumferentially in a first direction and further configured to direct fuel from the second venturi along a second ramp upwardly and circumferentially in a second direction;a burner base positioned above the burner bottom and placed in fluid communication with the burner bottom, the burner base providing an inner annular chamber and an outer annular chamber separated by a dividing wall, the inner annular chamber being configured to receive and direct fuel from the first venturi assembly circumferentially about the burner base and the outer annular chamber being configured to receive and direct fuel from the second venturi assembly circumferentially about the burner base; anda burner cap coupled to the burner base to provide a fluidic seal between the inner annular chamber and outer annular chamber, the burner cap being configured to distribute fuel from the inner annular chamber to a first plurality of ports positioned about the burner cap at a first radius and configured to distribute fuel from the outer annular chamber to a second plurality of ports positioned about the burner cap at a second radius larger than the first radius.

2. The gas burner of claim 1, wherein a circumferential component of the first direction and a circumferential component of the second direction oppose one another.

3. The gas burner of claim 2, wherein the circumferential component of the first direction is an approximately clockwise direction and the circumferential component of the second direction is an approximately counterclockwise direction.

4. The gas burner of claim 2, wherein the circumferential component of the first direction and the circumferential component of the second direction are substantially concentric with one another.

5. The gas burner of claim 1, wherein the burner base comprises a central cavity formed radially inward from the inner annular chamber and the burner cap comprises a bore extending through the burner cap and formed radially inward from the first plurality of ports, and the bore is configured to be positioned concentrically about the central cavity.

6. The gas burner of claim 5, wherein a gap is formed between the burner base and the burner bottom that is configured to permit ambient air to flow underneath a portion of the burner base, into the central cavity of the burner base, and through the bore of the burner cap to feed the first plurality of ports with secondary air during combustion.

7. The gas burner of claim 1, further comprising an ignition source located within the central cavity of the burner base and configured to provide a spark to light at least the first plurality of ports.

8. The gas burner of claim 7, wherein the burner cap comprises a lighting port positioned radially inward from the first plurality of ports and configured to direct fuel radially inward towards the ignition source.

9. The gas burner of claim 1, wherein the burner cap comprises a plurality of ignition ports positioned radially between the first plurality of ports and the second plurality of ports and configured to be supplied with fuel from the inner annular chamber of the burner base.

10. The gas burner of claim 1, wherein a gas flow rate of the first venturi is controlled by a first valve and a gas flow rate of the second venturi is controlled by a second valve, and the first valve and second valve are configured to be controlled by a single controller.

11. The gas burner of claim 1, wherein the first plurality of ports and the second plurality of ports are configured to produce a turndown ratio of about 60:1 or greater.

12. The gas burner of claim 1, wherein the first plurality of ports and the second plurality of ports are configured to produce 30,000 BTU or greater when ignited.

13. The gas burner of claim 1, wherein the first plurality of ports and the second plurality of ports are configured to transfer about 60% or more of the heat produced to a cooking vessel positioned above the burner cap.

14. A sealed gas burner comprising: a burner bottom configured to receive fuel and oxygen from a fuel source and an oxygen source;an annular burner base coupled to a portion of the burner bottom and placed in fluid communication with the fuel source and the oxygen source, the annular burner base comprising an inner chamber and an outer chamber to selectively receive fuel and oxygen from the fuel source and the oxygen source; anda burner cap coupled to the annular burner base comprising a ring of simmering ports positioned above the inner chamber of the annular burner base and an outer ring of burner ports concentric with the ring of simmering ports and positioned above the outer chamber of the annular burner base;wherein a plurality of simmering ports within the ring of simmering ports are angled to produce a flame body extending radially inward and upward from the burner cap and a plurality of burner ports within the outer ring of burner ports are larger than the simmering ports and are angled to produce a flame body extending radially outward and upward from the burner cap.

15. The sealed gas burner of claim 14, wherein a plurality of radially aligned ignition ports are formed in the burner cap that extend outward from the ring of simmering ports towards the outer ring of burner ports.

16. The sealed gas burner of claim 15, wherein the plurality of radially aligned ignition ports comprises at least one port angled to produce a flame body extending radially inward and upward from the burner cap and at least one port angled to produce a flame body extending radially outward and upward from the burner cap.

16. The sealed gas burner of claim 15, wherein at least two pluralities of radially aligned ignition ports are formed in the burner cap, and the at least two pluralities of radially aligned ignition ports are spaced apart from one another evenly about the burner cap.

17. The sealed gas burner of claim 15, wherein the wherein each port in the plurality of radially aligned ignition ports has a diameter approximately equal to the diameter of the simmering ports.

18. The sealed gas burner of claim 14, wherein the number of ports in the ring of simmering ports and the number of ports in the ring of burner ports is equal.

19. The sealed gas burner of claim 14, wherein the burner cap comprises at least one intermediate ring of burner ports positioned radially outward from and concentric with the ring of simmering ports, the at least one intermediate ring of burner ports comprising ports defined by diameters larger than the diameters of the simmering ports.

20. The sealed gas burner of claim 19, wherein a plurality of ports within the at least one intermediate ring of burner ports are angled to produce a flame body extending radially outward and upward from the burner cap.

21. The sealed gas burner of claim 19, wherein the burner cap comprises a second intermediate ring of burner ports positioned radially outward from and concentric with the first intermediate ring of burner ports and radially inward from the outer ring of burner ports, the second intermediate ring of burner ports comprising ports defined by diameters larger than the diameters of the burner ports in the first intermediate ring of burner ports and smaller than the diameters of the burner ports in the outer ring of burner ports.

22. The sealed gas burner of claim 19, wherein a plurality of radially aligned ignition ports are formed in the burner cap that extend outward from the ring of simmering ports towards the at least one intermediate ring of burner ports, and at least one port in the intermediate ring of burner ports is radially aligned with the plurality of radially aligned ignition ports.

23. The sealed gas burner of claim 14, wherein the burner cap comprises an annular shape with a convex top surface, and the ring of simmering ports is positioned proximate a local minimum height of the convex top surface of the burner cap.

24. The sealed gas burner of claim 14, further comprising an ignition source coupled to an electrical power source, the ignition source being positioned within a central cavity of the burner base.

25. The sealed gas burner of claim 24, wherein the burner cap comprises a lighting port positioned radially inward from the ring of simmering ports and is configured to produce a flame body extending radially inward and upward from the burner cap, towards the ignition source.

26. The sealed gas burner of claim 24, wherein the ignition source comprises a lower electrode and an upper electrode removably coupled to the lower electrode.

27. The sealed gas burner of claim 26, wherein the lower electrode comprises a male connection and the upper electrode comprises a female connection configured to receive a portion of the male connection.

28. The sealed gas burner of claim 26, wherein the lower electrode is coupled to the burner bottom and the upper electrode is coupled to the annular burner base.

29. The sealed gas burner of claim 14, wherein the ring of simmering ports are capable of sustaining a heat output of about 500 BTU.

30. The sealed gas burner of claim 14, wherein the ring of simmering ports and the outer ring of burner ports are together capable of sustaining a heat output of about 30,000 BTU.

31. A gas burner comprising: a burner base; anda burner cap positioned above the burner base, the burner cap and burner base collectively defining an inner annular chamber and an outer annular chamber;wherein the burner cap comprises a first plurality of ports positioned above the inner annular chamber and a second plurality of ports positioned above the outer annular chamber, the gas burner being configured to operate at a first heat output setting where the first plurality of ports are configured to output flames and at a second heat output setting at least about sixty times greater than the first heat setting where the first plurality of ports and the second plurality of ports are configured to simultaneously output flames.