Patent Publication Number: US-9897326-B2

Title: Cooking appliance and burner device

Description:
CROSS-REFERENCE TO RELATED APPLICATION(S) 
     The present application claims priority under 35 U.S.C. 119 and 35 U.S.C. 365 to Korean Patent Application No. 10-2013-0163566, filed in Korea on Dec. 26, 2013, which is hereby incorporated by reference in its entirety. 
     BACKGROUND 
     1. Field 
     A cooking appliance and a burner device are disclosed herein. 
     2. Background 
     Cooking appliances are apparatus that heat food or other items to cook the food or other items. Cooktops of the cooking appliances heat food or other items using heat generated by gas combustion. 
     Such a cooking appliance may include a case, a top plate disposed on the case, and a burner device disposed in the case. The burner device may include a burner pot, a mixing tube unit or mixing tube, a combustion member, and a nozzle unit or nozzle. A mixed gas may be burned on the combustion member. 
     However, in the cooking appliance according to the related art, the mixed gas may not be completely burned in the combustion member, generating carbon monoxide due to the incomplete combustion of the mixed gas. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Embodiments will be described in detail with reference to the following drawings in which like reference numerals refer to like elements, and wherein: 
         FIG. 1  is a perspective view of a cooking appliance according to an embodiment; 
         FIG. 2  is a view illustrating a state in which a top plate is removed from the cooking appliance of  FIG. 1 ; 
         FIG. 3  is an exploded perspective view of a burner device according to an embodiment; 
         FIG. 4  is a side view of a burner frame according to an embodiment; 
         FIG. 5  is a perspective view of a catalyst device according to an embodiment; 
         FIG. 6  is an exploded perspective view of the catalyst device of  FIG. 4 ; and 
         FIG. 7  is a vertical cross-sectional view of the cooking appliance of  FIG. 1 . 
     
    
    
     DETAILED DESCRIPTION 
     Reference will now be made in detail to embodiments, examples of which are illustrated in the accompanying drawings. Where possible, like reference numerals have been used to indicate like elements, and repetitive disclosure has been omitted 
     In the following detailed description of embodiments, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration specific embodiments in which may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice, and it is understood that other embodiments may be utilized and that logical structural, mechanical, electrical, and chemical changes may be made without departing from the spirit or scope. To avoid detail not necessary to enable those skilled in the art to practice, the description may omit certain information known to those skilled in the art. The following detailed description is, therefore, not to be taken in a limiting sense. 
       FIG. 1  is a perspective view of a cooking appliance according to an embodiment.  FIG. 2  is a view illustrating a state in which a top plate is removed from the cooking appliance of  FIG. 1 . 
     Referring to  FIGS. 1 and 2 , a cooking appliance  1  according to an embodiment may include a case  10 , and a top plate  11  seated on the case  10 . The cooking appliance  1  may further include one or more burner device  20  accommodated in the case  10  to burn a mixed gas, in which air may be mixed with a gas, and a discharge part or discharge  12  to discharge the gas burned in the burner device  20 . The discharge part  12  may be seated on an upper rear end of the case  10 . 
     Although three burner devices  20  are disposed in the case  10  in  FIG. 2 , embodiments are not limited to the number of burner device  20 . The discharge part  12  may include a plurality of discharge holes  122  to discharge the combustion gas. 
     The cooking appliance  1  may further include gas supply tubes  14  and  16 , through which the gas to be supplied into the burner device  20  may flow, a gas valve  15  to adjust a flow rate of the gas supplied into the burner device  20 , a nozzle device or nozzle  30  to inject the gas into the burner device  20 , and a manipulation knob  13  to manipulate the gas valve  15 . The manipulation knob  13  may be disposed on a front surface of the case  10 . Each of the gas valve  15 , the nozzle device  30 , and the manipulation knob  13  may be provided in a same number as the burner device  20 . 
     The gas supply tubes  14  and  16  may include a common supply tube  14  connected to one or a first side of the gas valve  15 , and an individual supply tube  16  connected to the other or a second side of the gas valve  15  to supply the gas into the burner device  20 . 
     Hereinafter, the burner device will be described in detail. 
       FIG. 3  is an exploded perspective view of a burner device according to an embodiment.  FIG. 4  is a side view of a burner frame according to an embodiment.  FIG. 5  is a perspective view of a catalyst device according to an embodiment.  FIG. 6  is an exploded perspective view of the catalyst device of  FIG. 4 . 
     Referring to  FIGS. 3 to 6 , the burner device  20  according to an embodiment may include a burner pot  210 , into which a mixed gas may be introduced, a combustion member  230  seated on the burner pot  210  and heated by heat generated by combustion of the mixed gas, a burner frame  220  seated on the burner pot  210  to provide an exhaust passage for the combustion gas burned on the combustion member  230 , and a catalyst device  240  to convert carbon monoxide generated due to incomplete combustion of the mixed gas into carbon dioxide. The burner pot  210  may include a first pot  211 , and a second pot  212  disposed in an inner space of the first pot  211 . For example, the first pot  211  may have a cylindrical shape; however, embodiments are not limited thereto. 
     An inner space of the second pot  212  may be partitioned from a space between an outer surface of the second pot  212  and an inner surface of the first pot  211 . Thus, the mixed gas may be supplied into the first pot  211  or the second pot  212 , or may be supplied into each of the first and second pots  211  and  212  according to manipulation of the manipulation knob  13 . 
     A first mixing tube  217  may be connected to the first pot  211 , and a second mixing tube  218  may be connected to the second pot  211 . For example, the second pot  212  may have a cylindrical shape; however, embodiments are not limited thereto. 
     Air around the mixing tubs  217  and  218  may be introduced into the mixing tubes  217  and  218  while the gas is injected from the nozzle device  30  to each of the mixing tubes  217  and  218 . The gas and air may be primarily mixed with each other in the mixing tubes  217  and  218 , and then, may be secondarily mixed with each other in an inner space of each of the first and second pots  211  and  212 . 
     The second mixing tube  218  may be connected to the second pot  212  by passing through the first pot  211 . Alternatively, the first mixing tube  217  and the second mixing tube  218  may be integrated with the burner pot  210 . 
     A first seating part or seat  214 , on which the combustion member  230  may be seated, may be disposed above the burner pot  210 , that is, the first pot  211 . When the combustion member  230  is seated on the first seating part  214 , the combustion member  230  may cover the inner space of the first pot  211  and the inner space of the second pot  212  at the same time. Thus, the mixed gas of the first pot  211  and the mixed gas of the second pot  212  may be burned on the combustion member  230 . 
     Alternatively, the combustion member  230  may include a first combustion member that covers the first pot  211  and having a ring shape and a second combustion member that covers the second pot  212 . 
     A second seating part or seat  215 , on which the burner frame  220  may be seated, may be disposed above the burner pot  210 , that is, the first pot  211 . 
     The burner frame  220  may include a first frame  221  having a first height, and a second frame  222  having a second height greater than the first height. The second frame  222  may be disposed at a rear side of the first frame  221  with respect to a flow of the gas. That is, the combustion gas or carbon monoxide may flow into the first frame  221 , and then, may flow into the second frame  222 . 
     An ignition part or ignition  228  for the combustion of the mixed gas may be disposed on the first frame  221 . The ignition part  228  may be disposed above the combustion member  230 . An end of the ignition part  228  may vertically overlap the second pot  212  so that the mixed gas within the second pot  212  may be ignited first. 
     Thus, the mixed gas passing through the combustion member  230  may be ignited by the ignition part  228 , and thus, be burned to heat the combustion member  230 . Thereafter, the mixed gas may be burned on the combustion member  230 . 
     Also, in the combustion member  230 , a central portion (a portion corresponding to the second pot  212 ) may be heated first, and then, a remaining portion (a portion corresponding to the first pot  211 ) may be heated. The mixed gas of the first pot  211  may be burned by heat of the remaining portion of the combustion member  230 . 
     The first frame  221  may include a first bottom surface  221   a , and the second frame  222  may include a second bottom surface  222   b . The second bottom surface  222   b  may be lower than the first bottom surface  221   a . The first bottom surface  221   a  and the second bottom surface  222   a  may be connected to each other by an inclined surface  222   c . Thus, flow resistance when the gas of the first frame  221  flows into the second frame  222  may be minimized by the inclined surface  222   c.    
     A hole  223 , through which the combustion member  230  may pass, may be defined in the first frame  221 . That is, when the burner frame  220  is seated on the second seating part  215  in a state in which the combustion member  230  is seated on the first seating part  214  of the burner pot  210 , the combustion member  230  may pass through the hole  223 . 
     Alternatively, the combustion member  230  may not pass through the hole  223 , but rather, may contact a bottom surface of the first frame  221 . In this case, the gas burned by the combustion member may pass through the hole  223 . 
     The burner frame  220  may include a contact part or contact  227  to increase a contact area with a bottom surface of the top plate  11 . The contact part  227  may extend horizontally from an upper end of the burner frame  220 . As the contact part  227  may contact the bottom surface of the top plate  11 , a flow of the combustion gas between the top plate  11  and the burner frame  220  may be prevented. 
     The catalyst device  240  may be disposed on the second frame  222  of the burner frame  220 . The catalyst device  240  may include a catalyst body  250  having a plurality of holes  252 , through which the combustion gas and the carbon monoxide may pass, and a fixing part or portion  242  to fix the catalyst body  250  to the burner frame  220 . 
     To prevent the catalyst body  250  from being damaged by the heat of the combustion member  230 , the catalyst device  240  may be disposed on or at a position of the burner frame  220 , that is, adjacent to the discharge part  12 . Thus, a distance between the catalyst body  250  and the discharge part  12  may be less than a distance between the catalyst body  250  and the combustion member  230 . 
     Each of the plurality of holes  252  may have a circular shape, a polygonal shape, or a honeycomb shape; however, embodiments are not limited thereto. Further, the plurality of holes  252  may be horizontally or vertically defined in the catalyst body  250 . Alternatively, the plurality of holes  252  may be horizontally and vertically defined in the catalyst body  250 . Thus, as the catalyst body  250  has the plurality of holes  252 , a contact area with the carbon monoxide may increase. 
     Also, to increase the contact area with the carbon monoxide, the catalyst body  250  may have a same horizontal width as the second frame  222 . Further, the catalyst device  240  may have a same height as the second frame  222 . Thus, the catalyst device  240  may contact the bottom surface of the top plate  11  in a state in which the catalyst device  240  is disposed on the second frame  222 . 
     A carrier formed of a ceramic material may be coated with a catalyst to form the catalyst body  250 . The carrier may be coated with the catalyst by being immersed into a container containing the catalyst or by spraying the catalyst onto the carrier, for example. 
     The carbon monoxide generated by the incomplete combustion of the mixed gas may react with the catalyst as the following reaction formula, and thus, be converted into carbon dioxide.
 
2CO+O 2 →2CO 2  
 
     When the catalyst device  240  is disposed on the burner frame  220 , the catalyst device  240  may act as flow resistance. When the catalyst device  240  acts as the flow resistance, an amount of air introduced into the burner device  20  may be reduced, deteriorating combustion performance. 
     However, according to this embodiment, as the second frame  222  on which the catalyst device  240  may be disposed has a height greater than a height of the first frame  221  as described above, a second passage of the second frame  222  may have a cross-sectional area greater than a cross-sectional area of a first passage of the first frame  221 . Thus, the flow resistance due to the catalyst device  250  may be minimized to allow the air to be stably introduced into the burner device  20 . 
     The longer a time period for which the carbon monoxide contacts the catalyst body  250 , the more an amount of carbon monoxide discharged from the cooking appliance may decrease. 
     According to this embodiment, as the second frame  222  on which the catalyst device  240  may be disposed has a height greater than a height of the first frame  222 , a flow rate of the gas within the first frame  221  may be less than a flow rate of the gas within the second frame  222 . Thus, as the flow rate of the carbon monoxide in the second frame  222  is reduced, a flow rate of the carbon monoxide passing through the plurality of holes  252  of the catalyst body  250  may be reduced to increase a contact time between the catalyst and the carbon monoxide. Thus, an amount of carbon monoxide discharged outside of the cooking appliance  1  may be minimized. 
     To allow the carbon monoxide to react with oxygen using the catalyst, oxygen within the burner frame  220  may be sufficiently secured. 
     Thus, in this embodiment, at least one first inflow hole  224 , through which air containing oxygen may be introduced, may be defined in the second bottom surface  222   b  of the second frame  222  to supply the oxygen into the burner frame  220 . Alternatively, the at least one first inflow hole  224  may be defined in a side surface of the second frame  222 . 
     As the oxygen together with the carbon monoxide has to pass through the catalyst body  250 , the at least one first inflow hole  224  may be disposed at a front side of the catalyst device  240  with respect to the flow direction of the gas. That is, the at least one first inflow hole  224  may be defined upstream of the catalyst device  240  with respect to a flow direction of the gas within the second frame  222 . Thus, the carbon monoxide together with the oxygen passing through the at least one first inflow hole  224  may pass through the plurality of holes  252  of the catalyst body  250 , and the carbon monoxide may react with the oxygen in this process, and thus, be converted into carbon dioxide. 
     A plurality of the first inflow holes  224  may be defined in the second bottom surface  222   b  of the second frame  222  and be arranged to horizontally cross the flow direction of the gas. Thus, the oxygen may be uniformly introduced into the second frame  222 . 
     The fixing part  242  may include an upper body  243  seated on a top surface of the catalyst body  250 , and first and second extension parts or extensions  244  and  245  that, respectively, extend downward from both ends of the upper body  243 . Each of the first and second extension parts  244  and  245  may be vertically bent from the upper body  243 . The upper body  243  may contact a bottom surface of the top plate  11 . 
     The fixing part  242  may further include first and second lower bodies  246  and  247  that, respectively, extend horizontally from the first and second extension parts  244  and  245 . Each of the lower bodies  246  and  247  may be seated on the second bottom surface  222   b  of the second frame  220 . Alternatively, the lower body may extend from one of the first and second extension parts  244  and  245 . 
     At least one coupling hole  248 , to which a coupling member (not shown) may be coupled, may be defined in each of the lower bodies  246  and  247 . At least one coupling hole  226 , to which the coupling member may be coupled, may be defined in the second bottom surface  222   b  of the second frame  222 . 
     The catalyst body  250  may be inserted between the first and second extension parts  244  and  245 . Thus, when the lower bodies  246  and  247  are coupled to the second frame  222  by the coupling member, vertical movement of the catalyst body  250  may be prevented by the upper body  243 . Also, forward/backward or front/rear movement of the catalyst body  250  may be prevented by the first and second extension parts  244  and  245 . 
     A front/rear direction may represent a direction parallel to the flow direction of the gas within the burner frame  220 , and a left/right or lateral direction may represent a direction that horizontally crosses the flow direction of the gas. 
     The fixing part  242  may further include a contact part or contact  249  vertically bent from at least one of the first and second extension parts  244  and  245  to contact a side surface of the second frame  222 . The contact part  249  may be bent from the at least one of the first and second extension parts  244  and  245  to improve a strength of the fixing part  242 . The contact part  249  may contact the second frame  222  to prevent the carbon monoxide from flowing between the second frame  222  and the fixing part  242 . 
     Alternatively, the lower bodies  246  and  247  may be omitted, and a coupling hole, to which a coupling member to be coupled to the burner frame  220 , may be defined in the contact part  249 . 
       FIG. 7  is a vertical cross-sectional view of the cooking appliance of  FIG. 1 . Referring to  FIG. 7 , a fan  50  for an air flow may be disposed in the case  10 . An air inflow hole  102 , through which external air may be introduced, may be defined in a bottom or side surface of the case  10 . 
     Flow guides  104  and  105  to guide air introduced through the air inflow hole  102  to the burner frame  220  may be disposed within the case  10 . The flow guides  104  and  105  may include a first flow guide  104  that defines a first passage P, and a second flow guide  105  that communicates with the first flow guide  104  to define a second passage P 2 . 
     At least one second inflow hole  225 , through which the air may be introduced into the first passage P 1 , may be defined in the second bottom surface  222   b  of the second frame  222 . Thus, the air of the first passage P 1  may be introduced into the burner frame  220  through the at least one second inflow hole  225 , and the air of the second passage P 2  may be introduced into the burner frame  220  through the at least one first inflow hole  224 . 
     The at least one second inflow hole  225  may be defined at a rear side of the catalyst device  240  with respect to the flow of the gas within the burner frame  220 . Thus, the catalyst device  240  may be disposed on the second frame  222  between the first and second inflow holes  224  and  225 . 
     As an exhaust gas flowing into the burner frame  220  has a high temperature, when the high-temperature gas is discharged outside of the cooking appliance through the discharge part  12 , it may be dangerous for a user. However, according to this embodiment, as the gas passing through the catalyst device  240  may be mixed with the air introduced through the second inflow hole  225 , and then, the mixed gas may be cooled and discharged outside of the cooking appliance through the discharge part  12 , the danger to the user may be reduced. Also, the catalyst device  240  may be cooled by the air introduced through the second inflow hole  225 . 
     Hereinafter, an operation of the cooking appliance according to an embodiment will be described hereinbelow. 
     When the manipulation knob  13  is manipulated to operate the gas valve  15 , the mixed gas may be supplied into the burner pot  210 . Then, the fan  50  may rotate. The mixed gas supplied into the burner pot  210  may be ignited by the ignition part  228 , and thus, may be burned. Also, the combustion member  230  may be heated by heat generated by the combustion of the mixed gas. 
     Radiation energy of the combustion member  230  may include a frequency of at least visible light. Thus, operation of the cooling appliance may be recognized by the user through the visible light. Also, food may be heated by the combustion member  230 . Alternatively, the food may be heated by conduction heat of the top plate  11 . 
     The gas and carbon monoxide burned by the combustion member  230  may flow from the first frame  221  to the second frame  222  of the burner frame  220 . The carbon monoxide flowing into the second frame  222  may be converted into carbon dioxide, while the carbon monoxide together with the oxygen passing through the first inflow hole  224  may pass through the plurality of holes  252  of the catalyst body  250 . 
     The carbon dioxide and the combustion gas may be cooled by the air introduced through the at least one second inflow hole  225 , and then, may be discharged outside through the plurality of discharge holes  122  of the discharge part  12 . 
     Although the second frame has a height greater than a height of the first frame to reduce the flow rate of the gas within the second frame in this embodiment, the second frame may have a horizontal width (a passage width) of the second frame greater than a horizontal width (a passage width) of the first frame to reduce the flow rate of the gas within the second frame. 
     Embodiments disclosed herein provide a cooking appliance capable of minimizing discharge of carbon monoxide due to incomplete combustion and a burner device. 
     Embodiments disclosed herein further provide a cooking appliance that may include a case; a top plate seated on the case; and a burner device accommodated in the case. The burner device may include a burner pot to receive a gas and air a combustion member to burn a mixed gas of the gas and air within the burner pot; a burner frame seated on the burner pot to define an exhaust passage, through which the gas burned by the combustion member and carbon monoxide generated by incomplete combustion of the mixed gas may flow; and a catalyst device disposed in the exhaust passage, the catalyst device having a catalyst to allow the carbon monoxide to react with oxygen. The burner frame may include a first frame having a first passage cross-sectional area, and a second frame disposed at a rear side of the first frame with respect to a flow direction of the gas and having a second passage cross-sectional area greater than the first passage cross-sectional area, and the catalyst device may be disposed at the second frame. 
     Embodiments disclosed herein further provide a burner device that may include a burner pot to receive a gas and air; a combustion member to burn a mixed gas of the gas and air within the burner pot; a burner frame including a first frame seated on the burner pot, and a second frame that extends from the first frame; and a catalyst device disposed on the second frame. The catalyst device may have a catalyst to allow carbon monoxide generated while the mixed gas is burned to react with oxygen. The second frame may have at least one inflow hole to receive the oxygen in a front side of the catalyst device. 
     Although embodiments have been described with reference to a number of illustrative embodiments thereof, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the spirit and scope of the principles of this disclosure. More particularly, various variations and modifications are possible in the component parts and/or arrangements of the subject combination arrangement within the scope of the disclosure, the drawings and the appended claims. In addition to variations and modifications in the component parts and/or arrangements, alternative uses will also be apparent to those skilled in the art. 
     Any reference in this specification to “one embodiment,” “an embodiment,” “example embodiment,” etc., means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the invention. The appearances of such phrases in various places in the specification are not necessarily all referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with any embodiment, it is submitted that it is within the purview of one skilled in the art to effect such feature, structure, or characteristic in connection with other ones of the embodiments. 
     Although embodiments have been described with reference to a number of illustrative embodiments thereof, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the spirit and scope of the principles of this disclosure. More particularly, various variations and modifications are possible in the component parts and/or arrangements of the subject combination arrangement within the scope of the disclosure, the drawings and the appended claims. In addition to variations and modifications in the component parts and/or arrangements, alternative uses will also be apparent to those skilled in the art.