High temperature flame quenching gas burner

Abstract

The present invention is a gas burner having a mixture plenum that receives gas and air. A port plenum is positioned above the mixture plenum. The port plenum comprises a plurality of ports for combustion of the gas air mixture. A quenching plate is positioned between the mixture plenum and the port plenum to separate the mixture plenum from the port plenum. The quenching plate comprises a plurality of apertures. The gas air mixture flows through the plurality of apertures and from the mixture plenum to the port plenum. The construction and arrangement of the mixture plenum, the port plenum, the quenching plate and the quenching plate apertures retard back flow and auto ignition, and provide cooling to the quenching plate for quenching a flame in the event of back flow from the port plenum toward the mixture plenum.

What is claimed: 
     
         1 . A grill having a flame quenching high temperature gas burner, comprising:
 a port plenum positioned within a combustion zone of the gas burner, the port plenum comprising a plurality of ports constructed and arranged to discharge a gas air mixture from the port plenum for combustion in the combustion zone, wherein in use, the temperature of the port plenum is above an auto ignition temperature of the gas air mixture;   a mixture plenum, wherein in use, the temperature of the mixture plenum is below the auto ignition temperature of the gas air mixture in the port plenum;   a quenching plate positioned between and separating the mixture plenum from the port plenum, the quenching plate comprising a plurality of apertures, wherein the apertures are sufficiently small to change the molecular carriers of the gas air mixture, and in combination with the burner construct, quench a flame retrogressing from the port plenum to the mixture plenum.   
     
     
         2 . A grill having a flame quenching high temperature gas burner as described in  claim 1 , wherein the quenching plate comprises a wire mesh screen disposed within a plate, and the wire mesh screen is surrounded by a material forming the plate. 
     
     
         3 . A grill having a flame quenching high temperature gas burner as described in  claim 1 , wherein the quenching plate comprises a plurality of wire mesh screens disposed within a plate, and wherein each wire screen of the plurality of wire mesh screens is surrounded by a material forming the plate. 
     
     
         4 . A grill having a flame quenching high temperature gas burner as described in  claim 1 , wherein the quenching plate comprises a wire mesh screen disposed within a metal plate, and the wire mesh screen is surrounded by metal forming the metal plate. 
     
     
         5 . A grill having a flame quenching high temperature gas burner as described in  claim 1 , wherein the quenching plate comprises a plurality of wire mesh screens disposed within a metal plate, and wherein each wire mesh screen of the plurality of wire mesh screens is surrounded by metal forming the metal plate. 
     
     
         6 . A grill having a flame quenching high temperature gas burner as described in  claim 1 , wherein the gas burner is naturally aspirated, and the gas burner comprises a source that supplies primary air to the mixture plenum and a source that supplies secondary air to the combustion zone. 
     
     
         7 . A grill having a flame quenching high temperature gas burner as described in  claim 1 , wherein an infrared emitter is positioned above the port plenum and above the combustion zone to receive heat from the burner and emit infrared radiation. 
     
     
         8 . A grill having a flame quenching high temperature gas burner as described in  claim 1 , wherein the combustion zone is defined by sidewalls, a bottom, and an infrared emitter positioned above the port plenum and above the combustion zone. 
     
     
         9 . A grill having a flame quenching high temperature gas burner as described in  claim 1 , wherein in use, the temperature in the port plenum is 500 degrees Fahrenheit or more than the temperature in the mixture plenum. 
     
     
         10 . A grill having a flame quenching high temperature gas burner as described in  claim 1 , wherein the port plenum has a volume that is 15% to 35% of the mixture plenum. 
     
     
         11 . A grill having a flame quenching high temperature gas burner as described in  claim 1 , wherein the individual apertures of the quenching plate are not larger than 0.050 inches. 
     
     
         12 . A grill having a flame quenching high temperature gas burner as described in  claim 1 , wherein the individual apertures of the quenching plate are not larger than 0.025 inches. 
     
     
         13 . A grill having a flame quenching high temperature gas burner as described in  claim 1 , wherein the quenching plate is in thermal communication with the mixture plenum and the quenching plate is cooled by the mixture plenum. 
     
     
         14 . A grill having a flame quenching high temperature gas burner as described in  claim 1 , wherein the mixture plenum is positioned outside the combustion zone of the gas burner, wherein the port plenum and the combustion zone are constructed and arranged so that heat is conducted from the combustion zone to an interior of the port plenum and wherein the mixture plenum is constructed and arranged so that heat is conducted from the mixture plenum into outside air. 
     
     
         15 . A grill having a flame quenching high temperature gas burner as described in  claim 1 , wherein the quenching plate is connected to a housing of the grill and is in thermal communication with the housing of the grill. 
     
     
         16 . A grill having a flame quenching high temperature gas burner as described in  claim 1 , wherein the quenching plate comprises a wire mesh screen disposed within a plate, and the wire mesh screen is surrounded by a material forming the plate, and the wire mesh screen occupies no more than one third (⅓) of the surface area of the quenching plate. 
     
     
         17 . A grill having a flame quenching high temperature gas burner as described in  claim 1 , wherein the plurality of apertures occupy no more than one third (⅓) of the surface area of the quenching plate. 
     
     
         18 . A grill having a flame quenching high temperature gas burner as described in  claim 1 , wherein a housing of the grill comprises an enclosed combustion zone defined by sidewalls, a bottom, and an infrared emitter positioned above the port plenum and above the combustion zone. 
     
     
         19 . A grill having a flame quenching high temperature gas burner as described in  claim 1 , wherein a plurality of ports in the port plenum are equal to or greater than 0.10 inches in diameter. 
     
     
         20 . A grill having a flame quenching high temperature gas burner as described in  claim 1 , wherein a plurality of ports in the port plenum are equal to or greater than 0.15 inches in diameter.