Abstract:
A gas burner assembly for connection to a source of gas is provided. The gas burner assembly includes a burner body defining an opening therethrough and a generally circular outer periphery. The outer periphery includes a recess therein. The gas burner additionally includes a bracketing unit secured to the burner body and including a igniter holder and at least one igniter being concentric about a vertical axis and positioned within at least one of the recess and the igniter holder. The igniter includes an ignition element that is adjustably positioned to provide an optimal radial distance from the burner body, and wherein the gas burner assembly is configured to operatively accommodate a variety of igniter styles.

Description:
BACKGROUND OF THE DISCLOSURE 
       [0001]    The following disclosure relates generally to gas burners, and more particularly to ignition elements for igniting the fuel gas on the gas burners. The present disclosure finds particular application in accommodating a variety of ignition elements within a single family of burners. 
         [0002]    Traditionally gas burner cook tops include ignition devices that generate a spark to ignite a burner when applicable fuel valves are opened, delivering fuel to the burner. Increasingly, however, the spark ignition devices are being replaced by ceramic hot surface ignition devices to ignite burners more reliably. Rather than relying on a spark, the ceramic hot surface igniter includes an element that generates a sufficient amount of heat to ignite the gas supplied to the burner. The ceramic hot surface igniter is essentially a hot filament and, as opposed to a spark, makes no noise and can be left on constantly such that a user can re-light the flame should it extinguish. 
         [0003]    The different types of ignition devices used for gas burners depend primarily on customer preference, price point, and compatibility with existing burners. Each type of ignition device has a particular position in relation to a burner for optimal performance. Therefore, the optimal location of a hot surface ignition device may not be the same as that needed for a spark electrode, depending on the burner design and other design limitations. A traditional solution would be to use different brackets and supports for both a spark and hot surface igniter to secure each at their respective optimal positions. However, having to replace burner parts when changing ignition styles increases the number of parts to manage throughout the production and manufacturing chain, thereby increasing cost and complexity. 
         [0004]    Accordingly, there is a need for an ignition positioning system that can allow a burner assembly to accommodate each type of ignition device without the need for unique burner system parts. 
       SUMMARY OF THE DISCLOSURE 
       [0005]    A gas burner assembly for connection to a source of gas is provided. The gas burner assembly includes a burner body defining an opening therethrough and a generally circular outer periphery. The gas burner additionally includes a bracketing unit secured to the burner body and including an igniter holder and at least one igniter being concentric about a vertical axis and positioned within the igniter holder. The igniter comprises an ignition element that is adjustably positioned to provide an optimal radial distance from the burner body, and wherein the gas burner assembly is configured to operatively accommodate a variety of igniter styles. 
         [0006]    An ignition device for use with a gas burner assembly is provided. The igniter includes a generally cylindrical body substantially concentric about a vertical axis and an ignition element having an adjustable radial position in relation to the vertical axis. The radial position is dependent on an optimal gap distance from an associated gas burner. The ignition element preferably includes at least one of a spark wire and a silicon nitride hot surface. 
         [0007]    A method for constructing a gas burner assembly is provided. The method includes coupling a burner body to an injet bracket, the burner body defining an opening therethrough and a generally circular outer periphery. The method further includes detachably mounting an igniter to the burner body, the igniter being generally concentric about a vertical axis, and adjustably locating an ignition element in relation to the vertical axis to provide an optimal gap between the ignition element and the burner body, wherein the burner assembly is configured to accommodate at least two different ignition element styles. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]      FIG. 1  is a perspective view of an oven range. 
           [0009]      FIG. 2  is an exploded perspective view of a burner assembly. 
           [0010]      FIG. 3  is a perspective view of a burner assembly having a hot surface igniter. 
           [0011]      FIG. 4  is a perspective view of a burner assembly having a spark igniter. 
           [0012]      FIG. 5  is an exploded perspective view of a burner assembly in accordance with one aspect of the present disclosure. 
           [0013]      FIG. 6  is a side view of a hot surface igniter (top) and spark igniter (bottom) in accordance with one aspect of the present disclosure. 
           [0014]      FIG. 7  is a perspective view of a spark igniter (top) and hot surface igniter (bottom) in accordance with another aspect of the present disclosure; and 
           [0015]      FIG. 8  illustrates the gap differences between a hot surface igniter and a spark igniter in accordance with another aspect of the present disclosure. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0016]    While methods and apparatuses are herein described in the context of a gas-fired cooktop, as set forth more fully below, it is contemplated that the herein described methods and apparatuses may find utility in other applications, including, but not limited to, gas heater devices, gas ovens, gas kilns, gas-fired meat smoker devices, and gas barbecues. In addition, the principles and teachings set forth herein may find equal applicability to combustion burners for a variety of combustible fuels. The description hereinbelow is therefore set forth only by way of illustration rather than limitation. 
         [0017]      FIG. 1  illustrates an exemplary free standing gas range in which the herein described methods and apparatuses may be practiced. Range  10  includes an outer body or cabinet that incorporates a cooktop shown here as a generally rectangular cooktop  14 . An oven, not shown, is positioned below cooktop  14  and has a front-opening access door  16 . A range backsplash  18  extends upward of a rear edge  20  of cooktop  14  and contains various control selectors (not shown) for selecting operative features of heating elements for cooktop  14  and the oven. It is contemplated that the herein described methods and apparatuses is applicable, not only to cooktops which form the upper portion of a range, such as range  10 , but to other forms of cooktops as well, such as, but not limited to, free standing cooktops that are mounted to a kitchen counter. Therefore, gas range  10  is provided by way of illustration rather than limitation, and accordingly there is no intention to limit application of the herein described methods and apparatuses to any particular appliance or cooktop, such as range  10 , or cooktop  14 . 
         [0018]    Cooktop  14  includes, for example, four gas fueled burner assemblies  22  which are positioned in spaced apart pairs positioned adjacent each side of cooktop  14 . Each pair of burner assemblies  22  is preferably surrounded by a recessed area  24  of cooktop  14 . Recessed areas  24  are positioned below an upper surface  24  of cooktop  14  and serve to catch any spills from cooking utensils (not shown in  FIG. 1 ) being used with cooktop  14 . Each burner assembly  22  extends upwardly through an opening in recessed areas  24 , and a grate  28  is positioned over each burner  22 . Each grate  28  is positioned over each burner  22 . Each grate  28  includes a flat surface thereon for supporting cooking vessels and utensils over burner assemblies  22  for cooking of meal preparations placed therein. 
         [0019]    The construction and operation of the range heating elements, including cooktop gas burner assemblies  22 , are believed to be within the purview of those in the art without further discussion, and as details of the range heating elements are generally beyond the scope of the herein described methods and apparatuses, further description is therefore omitted. Further it is contemplated that the herein described methods and apparatuses may find utility in combination with other heat elements besides range gas burners  22 . 
         [0020]    While cooktop  14  includes two pairs of grates  28  positioned over two pairs of burner assemblies  22 , it is contemplated that greater or fewer number of grates could be employed with a greater or fewer number of burners without departing from the scope of the herein described methods and apparatuses. 
         [0021]      FIG. 2  is an exploded perspective view of an exemplary burner assembly that can be used with the gas range of  FIG. 1 . The burner assembly includes a burner body  32 , a solid base portion  34 , and a cylindrical sidewall  36  extending axially from the periphery of base portion  34 . A main gas conduit  38  having an entry area  40  and a burner throat region  42  is open to the exterior of burner body  32  and defines a passage that extends axially through the center of burner body  32  to provide fuel/air flow to the burner assembly  30 . As used herein, the term “gas” refers to a combustible gas or gaseous fuel-air mixture. 
         [0022]    Burner assembly  30  is mounted on a support surface  44 , such as cooktop  14 , of a gas cooking appliance such as a range or cooktop. A cap  46  is disposed over the top of the burner body  32 , defining therebetween an annular main fuel chamber  48  and annular diffuser region (not shown). A torodial-shaped upper portion  50  of burner body  32 , immediately bordering burner throat  42 , in combination with cap  46  defines the annular diffuser region therebetween. Cap  46  can be fixedly attached to the sidewall  36  or other designated attachment point or can simply rest on sidewall  36  for easy removal. Burner assembly  30  also includes at least one ignition element  52  (not shown in  FIG. 2 ) extending through an opening in base portion  34 . In the exemplary embodiment, the body of the ignition element  52  is preferably fabricated from a ceramic material, although other suitable materials are applicable and contemplated herein. 
         [0023]      FIGS. 3 and 4  illustrate two exemplary ignition elements, a hot surface igniter  54  ( FIG. 3 ) and a spark igniter  56  ( FIG. 4 ). The hot surface igniter  54  is preferably formed from a ceramic material and includes an ignition element  62 . The hot surface igniter  54  preferably includes a shield  58  around the ignition element  62  to protect the fragility of the elements contained therein. The ignition element  62  is preferably made from a material such as silicon carbide or nitride, and as electricity passes through the igniter, the ignition element will glow red hot. Preferably, the ignition element  62  comprises silicon nitride, as it is more durable and reduces the concern of fragility. The spark igniter  56  includes an electrode surrounded by an insulator, preferably ceramic, with a spark wire  60  associated with the electrode for creating a spark and igniting the gas released within the burner assembly  22 . 
         [0024]    The gas burner assemblies  22 , as shown in  FIGS. 3 and 4 , are generally circular with igniters  54 ,  56  disposed at a recessed portion  64  in the peripheral edge of a burner body  32 . The position of an ignition element  60 ,  62  within an igniter  54 ,  56 , in relation to the burner body  32  is critical for successful ignition. Each type of ignition element  60 ,  62  has a unique optimum distance, and often the optimal distances are different for hot surface igniters  54  and for spark igniters  56 . Accordingly, until now, it has been difficult if not impossible to assemble a single family of burners  22  that can accommodate a variety of the different ignition technologies, since unless the position of the igniter is adjusted each time, the gap between the burner  22  and the actual ignition element  60 ,  62  will not be optimized. Traditionally, the replacement of ignition devices is achieved by providing different burner brackets and/or burner bodies to accommodate each style of technology. Accordingly, the present disclosure provides a method and apparatus that enables a single set of burner assemblies  22  to accommodate a variety of ignition elements by varying the gaps between the different ignition elements  60 ,  62  and the burner bodies  32 , such that there is no need for additional mounting parts and/or different burner assemblies. Moreover, the present disclosure provides the ability to locate and index an igniter in a burner system such that 1) the cross section of the igniter at some point is asymmetrical, and 2) the radial distance of the axis of the igniter&#39;s ignition element (i.e. spark wire or silicon nitride hot surface) varies between the spark electrode style and the hot surface style. 
         [0025]    With reference to  FIG. 5 , an exemplary burner assembly  22  is provided that can accommodate various ignition technologies without requiring the replacement of the burner or bracket parts. The burner assembly  22  includes a burner body  32  and burner cap  46  positioned atop a cooktop  14 , similar to that provided in  FIG. 2  above. A main gas conduit  38  extends through a hole in the cooktop  14  to meet an injet bracket  59  disposed on the underside of the cooktop  14 . An ignition device  52  is generally positioned near the injet bracket  59 .  FIG. 5  shows the igniter  52  being disposed through a hole in the cooktop  14 , such that the top head  70  of the igniter  52  remains above the cooktop and an igniter stem  72  extends into a holder located on the injet bracket. In an alternative configuration, the igniter may be located within the burner body itself. 
         [0026]      FIGS. 6 and 7  show exemplary igniters having elongated, generally cylindrical bodies  68 , the bodies comprising top head portions  70  and stem portions  72 , extending downwardly therefrom. Generally, the top head portions have a generally greater diameter than the stem portions  72 . Each igniter style, hot surface  54  (top) and spark  56  (bottom) may include similarly formed bodies, such that each style is configured to mate with a burner body  32  and bracket  59 . The igniter stem  72  and top head  70  are generally concentric about a vertical axis A. When a traditional spark igniter  56  is mated with a burner assembly  22 , the spark wire  60  is typically optimally positioned such that it is generally aligned along the vertical axis A. However, if it is desired to replace the spark igniter  56  with a hot surface igniter  54 , it may be seen that the hot surface ignition element  62  has a different optimal gap distance than the spark wire  60 . Accordingly, to facilitate an optimal gap distance when replacing an igniter with that having a different style ignition element on a single family of gas burners, the position of the ignition element  60 ,  62  is shifted within a ceramic body  68  by moving the ignition element  60 ,  62  a particular distance offset from the vertical axis of the ignition top head  70  and stem  72 . 
         [0027]    Particularly referring to  FIG. 6 , an exemplary spark igniter (bottom) is illustrated, which generally includes a spark wire  60  through the ceramic body  68  that is centered about the vertical axis A of the igniter. The ignition element  70 ,  72  of the hot surface burner  54  (top), however, is offset from the igniter body&#39;s vertical axis, not centered about the axis as seen in the spark igniter  56 . The hot surface ignition element  62  may be offset from the axis in a location that provides the desired gap between the element  62  and the burner body  32 . Accordingly, although different gaps are optimal for the spark igniter  56  and hot surface igniter  54 , both types of technology may be used on the same burner assembly  22 , as shown in  FIG. 8 . 
         [0028]    The exemplary burner assemblies, shown in  FIG. 8 , include a hot surface igniter  54  (top), wherein the gap “x” between the hot surface ignition element  62  and the burner body  32  comprises a first distance. In essentially the same burner assembly  22 , a spark igniter  56  (bottom) is provided having a gap “y” between the spark ignition element and the burner body that comprises a second distance, which in the exemplary depiction of  FIGS. 6 and 7 , is less than the first distance x. Accordingly, the same burner assembly  22  can accommodate both the spark ignition technology and the hot surface technology without requiring a different cook top and/or bracketing configuration. Rather, the igniter may simply be replaced with an igniter adjusted for the optimal gap, thereby saving in costs and production steps. 
         [0029]    To properly locate and orient an ignition device  52  in relation to a burner body and ensure that an ignition element maintains its optimal gap, the ignition device may include a geometric key portion that ensures proper placement and eliminates potential rotation. Such a geometric key portion is achieved by several methods, such as by adding a flat surface amongst the cylindrical body  68 , adding a groove to the body  68 , or pressing the igniter on the bracket. The flat surface  66  provided on the body of the hot surface igniter  54  in  FIG. 7  allows the igniter to be positioned and oriented in such a way that that it will not rotate and will continuously maintain the optimized position of the igniter with respect to the burner. 
         [0030]    The disclosure has been described with reference to the preferred embodiments. Obviously, modifications and alterations will occur to others upon reading and understanding the preceding detailed description. It is intended that the disclosure be construed as including all such modifications and alterations.