Patent Publication Number: US-10767857-B2

Title: Gas burner

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a continuation of U.S. patent application Ser. No. 15/395,557 (now U.S. Pat No. 10,393,371), filed on Dec. 30, 2016, entitled GAS BURNER, the entire disclosure of which is hereby incorporated by reference. 
    
    
     BACKGROUND 
     The present device generally relates to a gas burner unit, and particularly a gas burner unit that provides multiple configurations using a plurality of burners and multiple valve control assemblies to accommodate various cooking apparatuses. 
     SUMMARY 
     In at least one aspect, an appliance includes a burner unit having first and second sets of burner assemblies, wherein the second set of burner assemblies surrounds the first set of burner assemblies. First and second valves are fluidly coupled to the first set of burner assemblies. A first valve control assembly is configured to control the first and second valves of the first set of burner assemblies between open and closed positions. Third and fourth valves are fluidly coupled to the second set of burner assemblies. A second valve control assembly is configured to control the third and fourth valves of the second set of burner assemblies between open and closed positions. 
     In at least another aspect, a burner unit has a central body with a flame crown disposed thereon. An outer body is disposed around the central body, and includes inner and outer flame crowns disposed on opposite sides thereof. First and second lobes extend outwardly from the outer body, wherein the first and second lobes each include a flame crown disposed thereon. A first valve is fluidly coupled to the flame crown of the central body portion by a first supply line. A second valve is fluidly coupled to the inner flame crown of the outer body portion by a second supply line. A third valve is fluidly coupled to the outer flame crown of the outer body portion by a third supply line. A fourth valve is fluidly coupled to the flame crown of the first lobe and fluidly coupled to the flame crown of the second lobe. 
     In at least another aspect, a burner unit has first and second burner assemblies supplied with a gas mixture via first and second valves, respectively. A first valve control assembly controls the first and second valves between open and closed positions. Third and fourth burner assemblies are supplied with a gas mixture via third and fourth valves, respectively. A second valve control assembly controls the third and fourth valves between open and closed positions. The first and second valve control assemblies are separate assemblies that cooperate to simultaneously provide a gas mixture to the first, second, third and fourth burner assemblies in respective high power settings of the first and second valve control assemblies. 
     These and other features, advantages, and objects of the present device will be further understood and appreciated by those skilled in the art upon studying the following specification, claims, and appended drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In the drawings: 
         FIG. 1  is a top plan view of a burner unit according to one embodiment; 
         FIG. 2  is a top plan view of the burner unit of  FIG. 1  showing multiple flames disposed around a plurality of flame crowns; 
         FIG. 3  is a top plan view of the burner unit of  FIG. 2  showing first and second valve control assemblies; 
         FIGS. 4A-4E  are top plan views of the burner unit of  FIG. 1  in different power configurations; 
         FIG. 5  is a top perspective view of the burner unit of  FIG. 2 ; 
         FIG. 6A  is a top plan view of a first valve control assembly; and 
         FIG. 6B  is a top plan view of a first valve control assembly. 
     
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS 
     For purposes of description herein the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the device as oriented in  FIG. 1 . However, it is to be understood that the device may assume various alternative orientations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise. 
     Referring to the embodiment illustrated in  FIG. 1 , reference numeral  10  generally designates a burner unit having a plurality of flame crowns disposed thereon. Specifically, the burner unit  10  includes a central body  12  having a cylindrical shape with an outer perimeter  14 . A flame crown  16  is disposed along the outer perimeter  14  of the central body  12  and defines an innermost and first flame crown of the burner unit  10 . The flame crown  16  is comprised of and defined by a plurality of burner holes  18  which are spaced-apart along the outer perimeter  14  of the central body  12  in a substantially even distribution. The burner holes of the present concept are identified throughout this disclosure using reference numeral  18  and generally comprise the apertures through which flames are emitted when a gas mixture of a particular flame crown is ignited. Together, the central body  12  and the flame crown  16  define a first burner assembly  20  of the burner unit  10 . The flame crown  16  of the first burner assembly  20  is shown as a circular flame crown and is contemplated to have a diameter of about 15-25 mm as defined between the head portions of arrows A 1  and A 2 . It is contemplated that the flame crown  16  of the first burner assembly  20  can be used to provide a simmer feature for delicate cooking techniques where limited and precise temperature control is desired. It is contemplated that the flame crown  16  of the first burner assembly  20  alone is capable of generating approximately 500-1,200 BTUs ( FIG. 3 ). 
     As further shown in  FIG. 1 , the burner unit  10  includes an outer body  30  in the form of a ring  32  having an inner perimeter  34  and an outer perimeter  36  with a connecting portion  38  disposed therebetween. As shown in  FIG. 1 , the outer body  30  is disposed around the central body  12  in a concentric manner, such that the central body  12  is nested within the ring  32  of the outer body  30 . With the outer body  30  surrounding the central body  12 , a spacing  22  exists between the outer body  30  and the central body  12 . A plurality of braces  24  interconnects the outer body  30  and the central body  12 . In use, the spacing  22  provides necessary airflow to the burner unit  10  to ensure proper ignition and burning. A flame crown  40  is disposed along the inner perimeter  34  of the outer body  30 , defining an inner flame crown for the outer body  30  and a second flame crown of the burner unit  10 . A flame crown  42  is disposed along the outer perimeter  32  of the outer body  30 , defining an outer flame crown for the outer body  30  and a third flame crown of the burner unit  10 . Much like the first flame crown  16 , the flame crowns  40 ,  42  are comprised of and defined by a plurality of burner holes  18  which are spaced-apart along the inner and outer perimeters  34 ,  36  of the outer body  30  in a substantially even distribution. In the present concept, it is contemplated that the first flame crown  16  and the second flame crown  40  are controlled by a dual valve assembly, as further described below. Together, the outer body  30  and the second flame crown  40  define a second burner assembly  50  of the burner unit  10 . Further, the outer body  30  and the third flame crown  42  define a third burner assembly  52  of the burner unit  10 . The second and third flame crowns  40 ,  42  of the second and third burner assemblies  50 ,  52  are shown as a circular flame crowns and are contemplated to have diameters of about 45-55 mm and 90-110 mm as defined between the head portions of arrows B 1 , B 2  and C 1 , C 2 , respectively. It is contemplated that the flame crown  40  of the second burner assembly  50  can be used to provide an auxiliary feature for delicate cooking techniques, such as chocolate melting ( FIG. 2 ), where limited and precise temperature control is desired. It is contemplated that the flame crown  40  of the second burner assembly  50  alone is capable of generating approximately 1,200-2,800 BTUs ( FIG. 3 ). 
     It is further contemplated that the flame crown  42  of the third burner assembly  52  can be used to provide a power flame feature ( FIG. 2 ) for less delicate cooking techniques, such as boiling water, wherein maximum heat is desired. It is contemplated that the flame crown  42  of the third burner assembly  52  alone is capable of generating approximately 1,200-2,800 BTUs ( FIG. 3 ). 
     With further reference to  FIG. 1 , the flame crowns  16 ,  40  and  42  are concentric with one another, wherein the flame crowns  16 ,  40  and  42  generally share a common center. While the flame crowns  16 ,  40  and  42  are shown as ring-shaped annular flame crowns in  FIG. 1 , other shapes are contemplated for use with the present concept, such that the present concept is not limited to the exemplary embodiment shown in  FIG. 1 . 
     With further reference to  FIG. 1 , the outer body  30  includes first and second lobes  60 ,  62  extending outwardly therefrom. Specifically, in  FIG. 1 , the first and second lobes  60 ,  62  extend outwardly from the outer perimeter  36  of the outer body  30 . The first and second lobes  60 ,  62  include end portions  64 A,  64 B, respectively, and outer perimeters  66 A,  66 B, respectively. The first and second lobes  60 ,  62  further include flame crowns  68 A,  68 B disposed along the outer perimeters  66 A,  66 B, respectively. Much like the flame crowns  16 ,  40  and  42  described above, the flame crowns  68 A,  68 B are comprised of and defined by a plurality of burner holes  18  which are spaced-apart along the outer perimeters  66 A,  66 B of the first and second lobes  60 ,  62  in a substantially even distribution. From the end portions  64 A,  64 B, with the central body  12  and outer body  30  disposed in between, the first and second lobes  60 ,  62  generally span a distance of approximately 100-210 mm as indicated between head portions of arrows D 1  and D 2 . In this way, the first and second lobes  60 ,  62  provide a wide distribution area well-suited for use with a large cooking vessel, such as a stock pot or griddle pan ( FIG. 2 ). The flame crowns  68 A,  68 B of the first and second lobes  60 ,  62  cooperate to define a fourth burner assembly as indicated by reference numerals  70 A and  70 B with respect to the separated flame crowns  68 A,  68 B of the first and second lobes  60 ,  62 . It is contemplated that the flame crowns  68 A,  68 B of the fourth burner assembly  70 A,  70 B are each capable of generating approximately 1,200-4000 BTUs ( FIG. 3 ). It is further contemplated that the fourth burner assembly  70 A,  70 B can be a continuous unit which surrounds the first, second and third burner assemblies  20 ,  50  and  52  in assembly. 
     Referring now to  FIG. 2 , the burner unit  10  is contemplated to include first and second valve assemblies  100 ,  110 . The first valve assembly  100  includes first and second valves  102 ,  104 , while the second valve assembly  110  includes third and fourth valves  112 ,  114 . In this way, the first and second valve assemblies  100 ,  110  are dual valve assemblies, each having two valves. The valves  102 ,  104 ,  112 ,  114  are operable between open and closed positions (and a variety of intermediate positions therebetween) for controlling a gas and air mixture supplied to specific flame crowns of the burner unit  10  to which the valves are fluidly coupled. The term “fluidly coupled”, as used herein, means that a valve is coupled to a flame crown along a gas supply line to that flame crown. The first valve assembly  100  is controlled by a first valve control assembly VCA 1  for opening and closing the first and second valves  102 ,  104 , and the second valve assembly  110  is controlled by a second valve control assembly VCA 2  for opening and closing the third and fourth valves  112 ,  114 . The first and second valve control assemblies VCA 1 , VCA 2  are further described below with reference to  FIGS. 6A and 6B . 
     As further shown in  FIG. 2 , the first valve assembly  100  is configured to control the simmer flame option and the melt flame option of the burner unit  10  at flame crowns  16  and  40  respectively. Specifically, the first valve  102  of the first valve assembly  100  controls a gas mixture supply provided to the first burner assembly  20  at flame crown  16  via supply line  106 . The second valve  104  of the first valve assembly  100  controls a gas mixture supply provided to the second burner assembly  50  at flame crown  40  via supply line  108 . In this way, the first valve assembly  100  controls a first set of burner assemblies BA 1 , wherein the first set of burner assemblies BA 1  includes the first burner assembly  20  and the second burner assembly  50  along with the respective flame crowns  16 ,  40 . 
     As further shown in  FIG. 2 , the second valve assembly  110  is configured to control the power flame option and the griddle flame option of the burner unit  10  at flame crowns  42  and  68 A,  68 B, respectively. Specifically, the third valve  112  of the second valve assembly  110  controls a gas mixture supply provided to the third burner assembly  52  at flame crown  42  via supply line  116 . The fourth valve  114  of the second valve assembly  110  controls a gas mixture supply provided to the fourth burner assembly  70 A,  70 B at flame crowns  68 A,  68 B via supply line  118 . In this way, the second valve assembly  110  controls a second set of burner assemblies BA 2 , wherein the second set of burner assemblies BA 2  includes the third burner assembly  52  and the fourth burner assembly  70 A,  70 B along with the respective flame crowns  42 ,  68 A and  68 B. 
     Referring now to  FIG. 3 , the first valve assembly  100  is shown controlling the first set of burner assemblies BA 1 , which includes the first burner assembly  20  and the second burner assembly  50  along with the respective flame crowns  16 ,  40 . The second valve assembly  110  is shown controlling the second set of burner assemblies BA 2 , which includes the third burner assembly  52  and the fourth burner assembly  70 A,  70 B along with the respective flame crowns  42 ,  68 A and  68 B. Thus, the first valve assembly  100  controls a range of BTUs for the first set of burner assemblies BA 1  that is contemplated to cover approximately 500-4,000 BTUs. The low end 500 BTU setting is provided by the first flame crown  16  of the first burner assembly  20  when operating alone on a low power setting. The high end 4,000 BTU setting is provided by the first flame crown  16  of the first burner assembly  20  and the second flame crown  40  of the second burner assembly  50  when operating together at high power settings. 
     With further reference to  FIG. 3 , the second valve assembly  110  is shown controlling the second set of burner assemblies BA 2 , thus, the second valve assembly  110  controls a range of BTUs for the second set of burner assemblies BA 2  that is contemplated to cover approximately 1,200-16,000 BTUs. The low end 1,200 BTU setting is provided by the third flame crown  42  of the third burner assembly  52  when operating alone on a low power setting. The high end 16,000 BTU setting is provided by the third flame crown  42  of the third burner assembly  52  and the fourth flame crown  68 A,  68 B of the fourth burner assembly  70 A,  70 B when operating together at high power settings. 
     Referring now to  FIG. 4A , the burner unit  10  is shown in a first power setting PS 1 , wherein a range of approximately 500-1,200 BTUs is provided by the first flame crown  16  of the first burner assembly  20  operating alone. In  FIG. 4B , the burner unit  10  is shown in a second power setting PS 2 , wherein a range of approximately 1,700-4,000 BTUs is provided by the first flame crown  16  of the first burner assembly  20  and the second flame crown  40  of the second burner assembly  50  operating together. Thus, the first set of burner assemblies BA 1  is shown operating in an “all-on” configuration at second power setting PS 2 . 
     Referring now to  FIG. 4C , the burner unit  10  is shown in a third power setting PS 3 , wherein a range of approximately 1,200-8,000 BTUs is provided by the third flame crown  42  of the third burner assembly  52  operating alone. In  FIG. 4D , the burner unit  10  is shown in a fourth power setting PS 4 , wherein a range of approximately 3,600-16,000 BTUs is provided by the third flame crown  42  of the third burner assembly  52  and the fourth flame crown  68 A,  68 B of the fourth burner assembly  70 A,  70 B operating together. Thus, the second set of burner assemblies BA 2  is shown operating in an “all-on” configuration at fourth power setting PS 4 . 
     Referring now to  FIG. 4E , the burner unit  10  is shown in a fifth power setting PS 5 , wherein a range of approximately 5,300-20,000 BTUs is provided by the first, second, third and fourth flame crowns  16 ,  40 ,  42 , and  68 A,  68 B of the first, second, third and fourth burner assemblies  20 ,  50 ,  52  and  70 A,  70 B operating together. Thus, in the fourth power setting PS 4  shown in  FIG. 4E , both the first and second sets of burner assemblies BA 1 , BA 2  are shown operating in “all-on” configurations. The fifth power setting PS 5  is also shown in the burner unit  10  of  FIG. 5 . In the fifth power setting PS 5 , it is contemplated that the first and second valve assemblies  100 ,  110  have all valves  102 ,  104 ,  112  and  114  open to supply gas for combustion at the flame crowns  16 ,  40 ,  42 , and  68 A,  68 B of the first, second, third and fourth burner assemblies  20 ,  50 ,  52  and  70 A,  70 B. 
     Referring now to  FIGS. 6A and 6B , the first and second valve control assemblies VCA 1 , VCA 2  are shown on the form knobs  120 ,  122  contemplated to be disposed on an outer surface of a cooking appliance in which the burner unit  10  is disposed. The knobs  120 ,  122  are contemplated to be rotatable knobs that are configured to control the first and second valve assemblies  100 ,  110  ( FIGS. 2 and 3 ), which are dual valve assemblies which have first and second valves  102 ,  104  and third and fourth valves  112 ,  114 , respectively. As noted above, with reference to  FIG. 2 , the first and second valve control assemblies VCA 1 , VCA 2  is operably coupled to the first and second valve assemblies  100 ,  110  for controlling the same. The coupling of the first and second valve control assemblies VCA 1 , VCA 2  to the first and second valve assemblies  100 ,  110  is contemplated to be achieved using mechanical or electrical means known in the art for selectively opening and closing valves using a knob-like control. It is further contemplated that the first and second valve control assemblies VCA 1 , VCA 2  can be substantially electronic assemblies having digital displays and electronic buttons. In the description below, the first and second valve control assemblies VCA 1  and VCA 2  will be described as having “positions” to which the knobs  120 ,  122  can be rotated for initiating various power settings of the burner unit  12 . It is contemplated that the first and second valve control assemblies VCA 1  and VCA 2  can be operated by means other than a rotatable knob for initiating the power settings of the present concept, such that term “position” is interchangeable with a configuration for a non-mechanical control assembly. 
     With further reference to  FIGS. 6A and 6B , the knobs  120 ,  122  each include handle portions  124  having indicators  126  used to indicate a position to which the knobs  120 ,  122  are rotated. Each knob  120 ,  122  is shown in  FIGS. 6A, 6B  in an OFF position. With specific reference to  FIG. 6A , the knob  120  of the first valve control assembly VCA 1  includes a starting position  120 A which is contemplated to light a specific burner assembly, and/or a pilot light feature. After ignition at the starting position  120 A, the knob  120  is rotatable to a first position P 1  which is contemplated to be a high simmering power setting which opens the first valve  102  of the first valve assembly  100  and ignites the first flame crown  16  of the first burner assembly  20 . The first flame crown of the  16  of the first burner assembly  20  operates alone from the first position P 1  to a second position P 2  (a low simmering power setting) at a range of about 500-1,200 BTUs for a first power setting PS 1  as shown in  FIG. 4A . Movement of the knob  120  to the first position P 1 , opens the first valve  102  of the first valve assembly  100  for supplying a gas mixture to the first burner assembly  20 . Movement of the knob  120  from the first position P 1  to the second position P 2 , partially closes the first valve  102  of the first valve assembly  100 . From the second position P 2 , the knob  120  is rotatable to a third position P 3  which is contemplated to open the first and second valves  102  and  104  of the first valve assembly  100  to simultaneously light the flame crown  16  of the first burner assembly  20  and the flame crown  40  of the second burner assembly  50 . The first and second flame crowns  16 ,  40  of the first set of burner assemblies BA 1  operate from the third position P 3  (a high auxiliary power setting) to a fourth position P 4  (a low auxiliary power setting) at a range of about 1,700-4,000 BTUs to define the second power setting PS 2  as shown in  FIG. 4B . 
     With specific reference to  FIG. 6B , the knob  122  of the first valve control assembly VCA 2  includes a starting position  122 A which is contemplated to light a specific burner assembly, and/or a pilot light feature. After ignition at the starting position  122 A, the knob  122  is rotatable to a first position P 1  which is contemplated to be a high semi-rapid heat power setting which opens the third valve  112  of the second valve assembly  110  and ignites the third flame crown  42  of the third burner assembly  52 . The third flame crown  42  of the third burner assembly  52  operates alone from the first position P 1  to a second position P 2  (a low semi-rapid heat power setting) at a range of about 1,200-8,000 BTUs for a third power setting PS 3  as shown in  FIG. 4C . Movement of the knob  122  to the first position P 1 , opens the third valve  112  of the second valve assembly  110  for supplying a gas mixture to the third burner assembly  52 . Movement of the knob  122  from the first position P 1  to the second position P 2 , partially closes the third valve  112  of the second valve assembly  110 . From the second position P 2 , the knob  122  is rotatable to a third position P 3  which is contemplated to open the third and fourth valves  112  and  114  of the second valve assembly  110  to simultaneously light the flame crown of the  42  of the third burner assembly  52  and the flame crown  68 A,  68 B of the fourth burner assembly  70 A,  70 B. The third and fourth flame crowns  52  and  68 A,  68 B of the second set of burner assemblies BA 2  operate from the third position P 3  (a high rapid heat power setting) to a fourth position P 4  (a low rapid heat power setting) at a range of about 3,600-16,000 BTUs to define the fourth power setting PS 4  as shown in  FIG. 4D . 
     As noted above, the burner unit  10  of the present concept includes dual controls VCA 1  and VCA 2  for controlling dual valve assemblies  100 ,  110  on a single burner unit. The first and second valve control assemblies VCA 1  and VCA 2  can be used separately, as described above, or they can be used together to provide an ultra-rapid heat setting which correlates to power setting PS 5  shown in  FIG. 4E . For using first and second valve control assemblies VCA 1  and VCA 2  together, the first valve control assembly VCA 1  will have the knob  120  disposed at the third position P 3  which is contemplated to open the first and second valves  102  and  104  of the first valve assembly  100  to simultaneously light the flame crown of the  16  of the first burner assembly  20  and the flame crown  40  of the second burner assembly  50 . The second valve control assembly VCA 2  will have the knob  122  disposed at the third position P 3  as well, which is contemplated to open the third and fourth valves  112  and  114  of the second valve assembly  110  to simultaneously light the flame crown  42  of the third burner assembly  52  and the flame crown  68 A,  68 B of the fourth burner assembly  70 A,  70 B. In this way, the burner unit  10  has all four flame crowns  16 ,  40 ,  42  and  68 A,  68 B lit for generating BTUs in a range of about 5,300-20,000 BTUs as the first and second knobs  120 ,  122  move between the third positions P 3  and the fourth positions P 4 . Thus, the dual control features of the burner unit  10  provide for a highly configurable burner unit to provide the precise configuration needed for a particular cooking or food preparation procedure. 
     It will be understood by one having ordinary skill in the art that construction of the described device and other components is not limited to any specific material. Other exemplary embodiments of the device disclosed herein may be formed from a wide variety of materials, unless described otherwise herein. 
     For purposes of this disclosure, the term “coupled” (in all of its forms, couple, coupling, coupled, etc.) generally means the joining of two components (electrical or mechanical) directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two components (electrical or mechanical) and any additional intermediate members being integrally formed as a single unitary body with one another or with the two components. Such joining may be permanent in nature or may be removable or releasable in nature unless otherwise stated. 
     It is also important to note that the construction and arrangement of the elements of the device as shown in the exemplary embodiments is illustrative only. Although only a few embodiments of the present innovations have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements shown as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and/or members or connector or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied. It should be noted that the elements and/or assemblies of the system may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of colors, textures, and combinations. Accordingly, all such modifications are intended to be included within the scope of the present innovations. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the desired and other exemplary embodiments without departing from the spirit of the present innovations. 
     It will be understood that any described processes or steps within described processes may be combined with other disclosed processes or steps to form structures within the scope of the present device. The exemplary structures and processes disclosed herein are for illustrative purposes and are not to be construed as limiting. 
     It is also to be understood that variations and modifications can be made on the aforementioned structures and methods without departing from the concepts of the present device, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise. 
     The above description is considered that of the illustrated embodiments only. Modifications of the device will occur to those skilled in the art and to those who make or use the device. Therefore, it is understood that the embodiments shown in the drawings and described above is merely for illustrative purposes and not intended to limit the scope of the device, which is defined by the following claims as interpreted according to the principles of patent law, including the Doctrine of Equivalents.