Improvements in or relating to a burner module and an integrated gas burner

Abstract

A burner module that can be used in combusting an air/fluid fuel flow is described. The burner module may be incorporated in an appliance. The burner module comprises a burner face comprising catalytic material for combusting the air/fluid fuel flow and a perforated screen having a plurality of micro-perforations where the perforated screen is positioned upline to the burner face to increase combustion; an integrated gas burner for connection to a pressurised fluid fuel flow where the integrated gas burner comprises a burner module and a gas train. The gas train comprises (a) an ejector for entraining air with the fluid fuel flow; and (b) a diffusor for converting the air/fluid fuel flow kinetic energy into pressure and for performing flow expansion.

1 . A burner module for use in combusting an air/fluid fuel flow wherein the burner module comprises a burner face comprising catalytic material for combusting the air/fluid fuel flow and a perforated screen having a plurality of micro-perforations and the perforated screen is positioned upline to the burner face to increase combustion, wherein the perforated screen is formed from a material having a thermal conductivity adapted to reduce thermal bridging from the burner face and reflect incident heat radiation in a direction substantially perpendicular to the burner face. 
     
     
         2 . A burner module as defined in  claim 1  wherein the module is configured to cooperate with a gas train to deliver air/fluid fuel from at least one ejector. 
     
     
         3 . A burner module as defined in  claim 2  wherein the at least one ejector is closely coupled to the burner face via the gas train such that minimum axial space is required in use and positioned to provide a radial diffusion and mixture distribution to the burner face. 
     
     
         4 . A burner module as defined in  claim 3  wherein the burner is a radiant flameless burner configured to permit a minimal clearance between the burner face and a culinary vessel while ensuring maximum combustion of fuel during use. 
     
     
         5 . A burner module as defined in  claim 3  comprising a step positioned at an inlet to a radial diffuser configured to promote formation of a stable toroidal vortex to improve diffuser efficiency. 
     
     
         6 . A burner module as defined in any one of the preceding claims which comprises at least two perforated screens upline of the burner face wherein the perforated screens comprise a throttling perforated screen and a homogenisation perforated screen wherein the perforations on the throttling perforated screen are selected to provide a predetermined degree of aeration of the air/fuel mixture; and the perforations on the throttling perforated screen are arranged to provide a flattened velocity profile of the air/fluid fuel flow perpendicular to the throttling perforated screen to provide uniform combustion. 
     
     
         7 . A burner module as defined in  claim 6  wherein the homogenisation perforated screen is positioned upline and adjacent to the burner face and the throttling perforated screen is positioned upline of the homogenisation perforated screen 
     
     
         8 . A burner module as defined in  claim 6  or  claim 7  which is a radiant burner module comprising two perforated screens wherein the throttling perforated screen is configured to provide a fully-aerated air/fuel mixture. 
     
     
         9 . A burner module as defined in any one of  claims 6  to  8  wherein the degree of aeration of the air/fuel mixture provided by the throttling perforated screen is 12-24 parts of air entrained with each part of fuel gas by weight. 
     
     
         10 . A burner module as defined in any one of the preceding claims wherein the plurality of perforations of the one or more perforated screens are shaped to increase spill resistance and/or noise attenuation. 
     
     
         11 . A burner module as defined in  claim 10  wherein the perforations comprise an area of at least 15% of the perforated screen surface area. 
     
     
         12 . A burner module as defined in any one of the preceding claims wherein the perforations have a cusp. 
     
     
         13 . A burner module as defined in any one of the preceding claims wherein the perforated screen comprises a foil material or a metallic foil. 
     
     
         14 . A burner module as defined in any one of the preceding claims wherein the perforated screen is polished to reduce heat transfer to the gas train and consequent generation of temperatures at a surface confining the flow of air/fuel mixture which are high enough to initiate light-back. 
     
     
         15 . A burner module as defined in any one of the preceding claims wherein the perforated screen is shaped to provide one or more supports for the burner face. 
     
     
         16 . A burner module as defined in  claim 15  wherein the one or more perforated screen supports have a pointed shape to minimise thermal bridging. 
     
     
         17 . A burner module as defined in any one of the preceding claims wherein the perforated screen has one or more ribs to provide axial stiffness. 
     
     
         18 . A burner module as defined in any one of the preceding claims which comprises a crimp ring for attaching the burner module to a gas train. 
     
     
         19 . A burner module as defined in  claim 18  wherein the crimp ring is dimensioned to provide a radial space to allow the burner module to thermally expand and contract freely in use. 
     
     
         20 . A burner module as defined in  claim 18  wherein the crimp ring comprises an axial spacer for providing axial separation between the burner face and perforated screen wherein the axial spacer has an axial length which is dimensioned to reduce risk of light back. 
     
     
         21 . A burner module as hereinbefore described and/or illustrated with reference to the Figures of the accompanying drawings. 
     
     
         22 . An integrated gas burner for connection to a pressurised fluid fuel flow wherein the integrated gas burner comprises a burner module as defined in any one of  claims 1  to  21  and the gas train wherein the gas train comprises:
 a. an ejector for entraining air with the fluid fuel flow; and 
 b. a diffusor for converting the air/fluid fuel flow kinetic energy into pressure and for performing flow expansion. 
 
     
     
         23 . An integrated burner as defined in  claim 20  wherein the integrated burner is a compact integrated burner having a folded gas train. 
     
     
         24 . An integrated burner as defined in  claim 23  wherein the gas train comprises a co-annular folded gas train. 
     
     
         25 . An integrated burner as defined in  claim 23  wherein the folded gas train has a reduced axial length. 
     
     
         26 . An integrated burner as defined in any one of  claims 22  to  25  which comprises an additional perforated screen having a plurality of micro-perforations; preferably the perforated screen is as defined in any one of  claims 2  to  17 . 
     
     
         27 . An integrated burner substantially as hereinbefore described and/or illustrated with reference to one or more of the Figures of the accompanying drawings. 
     
     
         28 . An appliance comprising an integrated burner as defined in any one of  claims 22  to  27 ; preferably the appliance is:
 a) a chafing dish heater comprising two nesting metal vessels and one or more integrated burner; 
 b) a space heater comprising a reflective surface, one or more integrated burners and a pressurised fuel source; preferably the space heater additionally comprises a support, an electrical igniter and/or a handle for positioning of the reflective surface; or 
 c) a stove comprising an integrated burner, a pressurised fuel supply, a pot support, a pot and a burner shield; preferably the pot is shaped such that the other components can fit inside it for storage. 
 
     
     
         29 . An appliance substantially as hereinbefore described and/or illustrated with reference to one or more of the Figures of the accompanying drawings.