Gas supply module for burner with beaded gas supply tube

Abstract

A gas supply module that includes an orifice element; a gas supply tube having an inlet end, an outlet end threaded to receive the orifice element, and an outer diameter; and a beaded element having an outermost dimension at least one and a half times larger than the outer diameter of the gas supply tube, wherein the beaded element is formed directly from the outlet end of the gas supply tube. The gas supply module further includes a support bracket comprising at least one mounting flange, an inlet surface, an outlet surface, and a support hole, wherein the gas supply tube is routed through the support hole; and a fastening element is configured to secure the beaded element to the support bracket. The beaded element may be formed directly from the gas supply tube and may further comprise various shapes, including circular and non-circular shapes.

We claim: 
     
         1 . A method of assembling a gas module, the gas module comprising:
 an orifice element;   a gas supply tube having an inlet end adapted to receive a gas supply, an outlet end threaded to receive the orifice element, and an outer diameter;   a beaded element formed directly from the outlet end of the gas supply tube and having a substantially non-circular shape with an outermost dimension at least one and a half times larger than the outer diameter of the gas supply tube;   a support bracket comprising at least one mounting flange, an inlet surface, an outlet surface, and a support hole, wherein the gas supply tube is routed through the support hole; and   a fastening element configured to secure the beaded element and the gas supply tube to the support bracket, wherein the fastening element comprises a fixation bracket coupled to the inlet surface of the support bracket and the beaded element; and   wherein the fixation bracket comprises a recessed feature configured to receive the beaded element and having a plurality of alignment tabs adapted to align the gas supply tube relative to the support bracket and a pair of opposing fixation flanges adapted to affix the fixation bracket to the support bracket;   the method comprising the steps:   forming the beaded element having a substantially non-circular shape directly from the outlet end of the gas supply tube, wherein the forming step comprises a mechanical force applied against the gas supply tube;   routing the gas supply tube through the support hole of the support bracket such that the beaded element is received by the support hole;   aligning the gas supply tube relative to the support bracket; and   securing the beaded element of the gas supply tube to the support bracket.   
     
     
         2 . The method of  claim 1 , wherein the non-circular shape comprises a circularly-shaped portion and a substantially straight-edged portion. 
     
     
         3 . The method of  claim 1 , comprising the step coupling a lock washer to the gas supply tube at a location in proximity to an outlet surface of the support bracket. 
     
     
         4 . The method of  claim 1 , wherein the recessed feature has a substantially non-circular shape for receiving the beaded element. 
     
     
         5 . The method of  claim 4 , wherein the substantially non-circular shape has a circularly-shaped portion and a substantially straight-edged portion. 
     
     
         6 . The method of  claim 1 , wherein the recessed feature has a substantially circular shape for receiving the beaded element. 
     
     
         7 . A method of assembling a gas module adapted for use with a cooktop burner, the method comprising the steps:
 forming a beaded element having a substantially non-circular shape directly from an outlet end of a gas supply tube, wherein the forming step comprises a mechanical force applied against the gas supply tube;   routing the gas supply tube through a support hole of a support bracket such that the beaded element is received by the support hole;   aligning the gas supply tube relative to the support bracket; and   coupling a fixation bracket to an inlet surface of the support bracket and to the beaded element of the gas supply tube.   
     
     
         8 . The method of  claim 7 , wherein the non-circular shape comprises a circularly-shaped portion and a substantially straight-edged portion. 
     
     
         9 . The method of  claim 7 , further comprising a step coupling a lock washer to the gas supply tube at a location in proximity to an outlet surface of the support bracket. 
     
     
         10 . The method of  claim 7 , wherein the gas module further comprises an orifice element. 
     
     
         11 . The method of  claim 7 , wherein the fixation bracket further comprises a recessed feature configured to receive the beaded element. 
     
     
         12 . The method of  claim 11 , wherein the fixation bracket further comprises a pair of opposing fixation flanges adapted to affix the fixation bracket to the support bracket. 
     
     
         13 . The method of  claim 11 , wherein the fixation bracket further comprises a plurality of alignment tabs adapted to align the gas supply tube relative to the support bracket. 
     
     
         14 . The method of  claim 11 , wherein the recessed feature is circularly-shaped. 
     
     
         15 . The method of  claim 11 , wherein the recessed feature has a non-circular shape. 
     
     
         16 . A method of assembling a gas module adapted for use with a cooktop burner assembly, the method comprising the steps:
 providing a gas supply tube having an inlet end adapted to receive a gas supply, an outlet end threaded to receive an orifice element, and an outer diameter;   forming a beaded element having a substantially non-circular shape directly from the outlet end of the gas supply tube, wherein the forming step comprises a mechanical force applied against the gas supply tube;   providing a support bracket comprising at least one mounting flange, an inlet surface, an outlet surface, and a support hole;   routing the gas supply tube through the support hole of the support bracket such that the beaded element is received by the support hole;   providing a fastening element configured to secure the beaded element and the gas supply tube to the support bracket wherein the fastening element comprises a fixation bracket, a recessed feature configured to receive the beaded element, and a plurality of alignment tabs adapted to align the gas supply tube relative to the support bracket, and a pair of opposing fixation flanges adapted to affix the fixation bracket to the support bracket;   aligning the gas supply tube relative to the support bracket;   coupling the fixation bracket to the inlet surface of the support bracket and the beaded element; and   securing the beaded element of the gas supply tube to the support bracket.   
     
     
         17 . The method of  claim 16 , further comprising a step coupling a lock washer to the gas supply tube at a location in proximity to an outlet surface of the support bracket. 
     
     
         18 . The method of  claim 16 , wherein the recessed feature has a substantially non-circular shape for receiving the beaded element. 
     
     
         19 . The method of  claim 18 , wherein the substantially non-circular shape has a circularly-shaped portion and a substantially straight-edged portion. 
     
     
         20 . The method of  claim 16 , further comprising the step of providing an orifice element and the step of assembling the orifice element to the gas supply tube.