MICRO BURNER APPARATUS AND ASSOCIATED METHOD

Description

FIELD

This disclosure relates generally to a method for testing a combustion reaction and, more particularly, to a micro burner utilized for testing a combustion reaction.

BACKGROUND

Industries, including the aerospace sector, are exploring alternative gases as fuel options instead of traditional carbon-based fuels. Hydrogen is a prominent fuel candidate due to its potential environmental benefits. However, the use of hydrogen poses safety challenges, primarily due to its broad flammability range. Preventing appreciable amounts of hydrogen gas from mixing with air is critical, as such a mixture can ignite, leading to fires. Unlike hydrocarbon flames, hydrogen fires are difficult to detect as they primarily radiate in the ultraviolet spectrum, which could potentially allow a leak to go undetected. Despite the recognized risks, the specific dangers associated with hydrogen leaks are not fully understood. Comprehensive tests to determine a leak rate at which hydrogen gas might ignite when exposed to air, and how such leaks could potentially damage nearby infrastructure, are lacking. Currently testing for small or variable leak rates for alternative gases is difficult as typical fire testing rigs are designed to create and test the largest foreseeable fire rather than testing for small leaks.

SUMMARY

The subject matter of the present application has been developed in response to the present state of the art, and in particular, in response to the problems of and needs created by, or not yet fully solved by, existing method for testing a combustion reaction and associated apparatuses and systems. Generally, the subject matter of the present application has been developed to provide a micro burner apparatus and associated method that overcomes at least some of the above-discussed shortcomings of prior art techniques.

Disclosed herein is a micro burner including a leak plate having a testing aperture that is configured to simulate a microleak of a gaseous fuel into a combustion environment, containing a reaction gas, to test a combustion reaction between the reaction gas and the gaseous fuel within the combustion environment. The micro burner also includes a gas supply line couplable to the leak plate and, when coupled, configured to supply the gaseous fuel through the testing aperture and into the combustion environment. The micro burner further includes an ignition source configured to initiate the combustion reaction between the reaction gas and the gaseous fuel within the combustion environment. The preceding subject matter of this paragraph characterizes example 1 of the present disclosure.

The combustion environment is a combustion chamber that includes a housing defining an internal chamber configured to contain the reaction gas and further contain the combustion reaction between the reaction gas and the gaseous fuel and a leak-plate opening within the housing. The leak plate is removably attachable to the leak-plate opening to close the leak-plate opening and seal the internal chamber of the combustion chamber. When the leak plate is attached to the leak-plate opening and when the gas supply line is coupled to the leak plate, the gas supply line is configured to supply the gaseous fuel through the testing aperture and into the internal chamber. The preceding subject matter of this paragraph characterizes example 2 of the present disclosure, wherein example 2 also includes the subject matter according to example 1, above.

The combustion chamber includes at least one visualization window configured to allow exterior observation of the combustion reaction within the internal chamber. The preceding subject matter of this paragraph characterizes example 3 of the present disclosure, wherein example 3 also includes the subject matter according to any of examples 1-2, above.

The combustion environment is an open-air environment. The preceding subject matter of this paragraph characterizes example 4 of the present disclosure, wherein example 4 also includes the subject matter according to example 1, above.

The testing aperture of the leak plate is one of a pin hole or a slot. The preceding subject matter of this paragraph characterizes example 5 of the present disclosure, wherein example 5 also includes the subject matter according to any of examples 1-4, above.

The testing aperture of the leak plate has an area of less than or equal to 32 mm². The preceding subject matter of this paragraph characterizes example 6 of the present disclosure, wherein example 6 also includes the subject matter according to any of examples 1-5, above.

The gas supply line is configured to regulate a flow rate of the gaseous fuel through the testing aperture of the leak plate so that the flow rate is less than or equal to one mmol/s. The preceding subject matter of this paragraph characterizes example 7 of the present disclosure, wherein example 7 also includes the subject matter according to any of examples 1 -6, above.

The micro burner includes a second leak plate having a second testing aperture. The leak plate and the second leak plate are interchangeable, such that the gas supply line is individually couplable to a selected one of the leak plate or the second leak plate. A size of the testing aperture of the leak plate is different than a size of the second testing aperture of the second leak plate. The preceding subject matter of this paragraph characterizes example 8 of the present disclosure, wherein example 8 also includes the subject matter according to any of examples 1-7, above.

The leak plate includes a receiver plate having an exterior surface and an interior surface, opposite of the exterior surface. The leak plate also includes a leak insert having the testing aperture and configured to be selectively attached to the interior surface of the receiver plate. The gas supply line is couplable to the exterior surface of the receiver plate to supply the gaseous fuel through the testing aperture of the leak insert. The preceding subject matter of this paragraph characterizes example 9 of the present disclosure, wherein example 9 also includes the subject matter according to any of examples 1-8, above.

The leak insert includes a slot-insert receiver having a recessed portion with a first slot surface and a slot aperture extending from the recessed portion through a width of the slot-insert receiver. The leak insert also includes a second slot surface and is sized to be fitted within the recessed portion of the slot-insert receiver, such that the testing aperture is defined between the first slot surface of the slot-insert receiver and the second slot surface of the slot insert. The preceding subject matter of this paragraph characterizes example 10 of the present disclosure, wherein example 10 also includes the subject matter according to example 9, above.

The leak insert includes a receiver-mating surface and a supply surface, opposite of the receiver-mating surface. The supply surface of the leak insert has a non-planar surface. The preceding subject matter of this paragraph characterizes example 11 of the present disclosure, wherein example 11 also includes the subject matter according to example 9, above.

The micro burner includes at least one thermocouple within the combustion environment configured to measure a temperature of the combustion reaction. The preceding subject matter of this paragraph characterizes example 12 of the present disclosure, wherein example 12 also includes the subject matter according to any of examples 1-11, above.

The micro burner includes at least one sensor coupled to the combustion chamber configured to measure a combustion characteristic of the combustion reaction. The at least one sensor includes at least one of a pressure sensor, an optical sensor, a gas sensor, or a heat sensor. The preceding subject matter of this paragraph characterizes example 13 of the present disclosure, wherein example 13 also includes the subject matter according to any of examples 1-12, above.

The gaseous fuel is hydrogen gas. The preceding subject matter of this paragraph characterizes example 14 of the present disclosure, wherein example 14 also includes the subject matter according to any of examples 1-13, above.

Further disclosed herein is a leak plate for a micro burner including a receiver plate having an exterior surface and an interior surface, opposite of the exterior surface. The leak plate also includes a leak insert having a testing aperture that is configured simulate a microleak of a gaseous fuel into a combustion environment. The leak insert is removeable attachable to the interior surface of the receiver plate. When the leak insert is attached to the interior surface of the receiver plate, a gas supply line is couplable to the exterior surface of the receiver plate to supply a gaseous fuel through the testing aperture and into the combustion environment to test a combustion reaction between a reaction gas and the gaseous fuel. The preceding subject matter of this paragraph characterizes example 15 of the present disclosure.

The testing aperture is one of a pin hole or a slot. The preceding subject matter of this paragraph characterizes example 16 of the present disclosure, wherein example 16 also includes the subject matter according to example 15, above.

The leak plate includes a second leak insert having a second testing aperture configured to simulate a microleak of the gaseous fuel into the combustion environment. The second leak insert is removably attachable to the interior surface of the receiver plate. The leak insert and the second leak insert are interchangeable, such that a selected one of the leak insert or the second leak insert is individually attachable to the interior surface of the receiver plate to test a corresponding combustion reaction between the reaction gas and the gaseous fuel. A size of the testing aperture of the leak insert is different than a size of the second testing aperture of the second leak insert. The preceding subject matter of this paragraph characterizes example 17 of the present disclosure, wherein example 17 also includes the subject matter according to any of examples 15-16, above.

Further disclosed herein is a method of testing a combustion reaction within a micro burner. The method includes supplying a gaseous fuel through a testing aperture of the leak plate and into a combustion environment. The testing aperture is configured to simulate a microleak of the gaseous fuel into the combustion environment. The method also includes activating an ignition source to initiate the combustion reaction between the reaction gas and the gaseous fuel within the combustion environment. The method further includes monitoring the combustion reaction within the combustion reaction. The preceding subject matter of this paragraph characterizes example 18 of the present disclosure.

After the combustion reaction is complete, the method includes detaching a gas supply line from the leak plate, where the gas supply line is configured to supply the gaseous fuel. The method includes selectively attaching a second leak plate to the gas supply line to supply the gaseous fuel through a second testing aperture of the second leak plate and into the combustion environment. The second testing aperture configured to simulate a microleak of the gaseous fuel into the combustion environment and a size of the second testing aperture of the second leak plate is different than a size of the testing aperture of the leak plate. The method also includes activating the ignition source to initiate a subsequent combustion reaction between the reaction gas and the gaseous fuel within the combustion environment and monitoring the subsequent combustion reaction within the combustion environment. The preceding subject matter of this paragraph characterizes example 19 of the present disclosure, wherein example 19 also includes the subject matter according to example 18, above.

After the combustion reaction is complete, the method includes removing a leak insert, having a testing aperture, from a receiver plate of the leak plate and selectively attaching a second leak insert having a second testing aperture to the receiver plate of the leak plate. A size of the second testing aperture of the second leak insert is different than a size of the testing aperture of the leak insert. The method also includes supplying the gaseous fuel through the second testing aperture of the leak insert of the leak plate and into the combustion environment. The second testing configured to simulate a microleak of the gaseous fuel into the combustion environment. The method further includes activating the ignition source to initiate a subsequent combustion reaction between the reaction gas and the gaseous fuel within the combustion environment and monitoring the subsequent combustion reaction within the combustion environment. The preceding subject matter of this paragraph characterizes example 20 of the present disclosure, wherein example 20 also includes the subject matter according to any of examples 18-19, above.

The described features, structures, advantages, and/or characteristics of the subject matter of the present disclosure may be combined in any suitable manner in one or more examples, including embodiments and/or implementations. In the following description, numerous specific details are provided to impart a thorough understanding of examples of the subject matter of the present disclosure. One skilled in the relevant art will recognize that the subject matter of the present disclosure may be practiced without one or more of the specific features, details, components, materials, and/or methods of a particular example, embodiment, or implementation. In other instances, additional features and advantages may be recognized in certain examples, embodiments, and/or implementations that may not be present in all examples, embodiments, or implementations. Further, in some instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the subject matter of the present disclosure. The features and advantages of the subject matter of the present disclosure will become more fully apparent from the following description and appended claims, or may be learned by the practice of the subject matter as set forth hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

In order that the advantages of the subject matter may be more readily understood, a more particular description of the subject matter briefly described above will be rendered by reference to specific examples that are illustrated in the appended drawings. Understanding that these drawings depict only typical examples of the subject matter, they are not therefore to be considered to be limiting of its scope. The subject matter will be described and explained with additional specificity and detail through the use of the drawings, in which:

FIG. 1 is a schematic perspective view of a micro burner and a combustion chamber, according to one or more examples of the present disclosure;

FIG. 2 is a schematic perspective view of a leak plate of a micro burner, according to one or more examples of the present disclosure;

FIG. 3A is a schematic perspective view of a leak insert that is selectively attachable to a leak plate, with a pin hole testing aperture, according to one or more examples of the present disclosure;

FIG. 3B is a schematic cross-sectional view of the leak insert, such as FIG. 3A along line 3B, or FIG. 3C along line 3B, according to one or more examples of the present disclosure;

FIG. 3C is a schematic perspective view of another example of a leak insert that is selectively attachable to a leak plate, with a slot testing aperture, according to one or more examples of the present disclosure;

FIG. 4A is a schematic perspective view of another example of a leak insert that is selectively attachable to a leak plate, having a slot-insert receiver and a slot insert, according to one or more examples of the present disclosure;

FIG. 4B is a schematic front view of the leak insert of FIG. 4A, with the slot insert separate from a recessed portion of the slot-insert receiver, according to one or more examples of the present disclosure;

FIG. 4C is a schematic cross-sectional view of the leak insert of FIG. 4A along line 4C, with the slot insert within the recessed portion of the slot-insert receiver, according to one or more examples of the present disclosure; and

FIG. 5 is a schematic flow view of a method of testing a combustion reaction within a micro burner, according to one or more examples of the present disclosure.

DETAILED DESCRIPTION

Reference throughout this specification to “one example,” “an example,” or similar language means that a particular feature, structure, or characteristic described in connection with the example is included in at least one example of the subject matter of the present disclosure. Appearances of the phrases “in one example,” “in an example,” and similar language throughout this specification may, but do not necessarily, all refer to the same example. Similarly, the use of the term “implementation” means an implementation having a particular feature, structure, or characteristic described in connection with one or more examples of the subject matter of the present disclosure, however, absent an express correlation to indicate otherwise, an implementation may be associated with one or more examples.

Disclosed herein are examples of a micro burner utilized for testing a combustion reaction, including the response of materials and structures to the combustion reaction, and associated methods. The following provides some features of at least some examples of the micro burner and associated methods. The micro burner is designed for test a combustion reaction between a reaction gas, such as air, and a gaseous fuel, like hydrogen or methane. The purpose of these tests is to observe the combustion reaction itself and assess its effects, including the damage caused by the combustion reaction, such as flames, to various structures and materials. For example, the impacts on surrounding structures and materials may include burning, melting, and other forms of degradation. Additionally, measurements of the combustion reaction, such as flame length are recorded to understand the overall impact and response of surrounding structures to the combustion exposure. Specifically, the micro burner is utilized to simulate microleaks, which can occur from punctures in equipment containing the gaseous fuel, such as refueling equipment or transportation tanks. As used herein, a microleak is a small, unintended escape or seepage of gas or liquid from a system, typically through tiny punctures or gaps in equipment. These leaks are usually characterized by their extremely small size, which makes them challenging to detect and measure but potentially hazardous due to the flammable nature of the escaped gases. Accordingly, the micro burner includes a leak plate with a testing aperture that allows the gaseous fuel to pass through the testing aperture into a combustion environment, simulating a microleak.

In some examples, the micro burner features multiple leak plates that are interchangeable, enabling the simulation of microleaks of various sizes, typically extremely small, within the combustion environment. These interchangeable leak plates provide control over the size and shape of the microleaks, allowing for a wide range of microleak sizes and shapes, enabling comprehensive and flexible testing. By using these interchangeable leak plates and igniting the resulting gaseous fuel-reaction gas mixture, such as a hydrogen-air mixture, the micro burner can be used to assess differences in the resulting combustion reaction and its effects. This testing, using the micro burner, can aid in understanding gaseous fuel leak hazards, developing effective safety protocols for gaseous and cryogenic liquid fuel storage, and ultimately reducing the risk of accidents in fuel-powered systems.

Referring to FIG. 1, a micro burner 100 for testing a combustion reaction is shown. The micro burners 100 is configured to be used within a combustion environment 101. The combustion environment 101 is a controlled setting in which the combustion reaction can occur. As such, the combustion environment 101 includes the necessary elements to facilitate the combustion reaction, including the presence of a reaction gas. The combustion environment 101 can be enclosed, such as within a combustion chamber 102, or in an open environment (i.e., open-air environment). Moreover, the combustion environment 101 is designed to allow the observation of combustion reactions and their effects on surrounding materials and structures.

In some examples, as shown in FIG. 1, the combustion environment 101 includes a combustion chamber 102 that is designed to facilitate and contain the combustion reaction. As shown, the combustion chamber 102 has a shape that is generally round but may be other shapes including rectangular or cylindrically shaped, based on testing needs of the combustion reaction. The combustion chamber 102 is made from any of various materials that can withstand the extreme conditions produced during a combustion reaction. For examples, the combustion chamber 102 may be made of stainless steel or alloys designed for high-heat applications. Moreover, the combustion chamber 102 is a robust structure, designed to withstand high thermal loads without undergoing deformation or failure. The combustion chamber 102 includes a housing 105 defining an internal chamber 106 that is designed to be airtight when a leak plate is attached, as explained below, ensuring that no gases escape and that the combustion environment remains controlled. The housing 105 includes a leak-plate opening 104 configured to accommodate a leak plate 108 of the micro burner 100. The leak-plate opening 104 is an aperture in the housing 105 of the combustion chamber 102 that exposes the internal chamber 106 to the exterior of the combustion chamber 102. The leak-plate opening 104 is sized and shaped to fit the leak plate 108, such that when the leak plate 108 is coupled to the leak-plate opening 104, the combustion chamber 102 is closed and creates an airtight environment for the combustion reaction. Moreover, the leak-plate opening 104 may include sealing mechanisms, such as gaskets or O-rings, to ensure the airtight seal and prevent any leakage.

In other examples, the combustion environment 101 is an open-air environment, allowing the micro burner 100 to be used outside of a combustion chamber 102. An open-air environment allows for the testing of the effects of the combustion reaction on parts that may not fit within the internal chamber 106 of the combustion chamber 102. Appropriate safety measures can be implemented to safety conduct testing using the micro burner 100 in an open-air lab setup.

The combustion environment 101 contains a reaction gas and is configured to contain the combustion reaction between the reaction gas and a gaseous fuel. As used herein, the reaction gas is a gaseous substance that participates in a chemical reaction, often serving as an oxidizing agent for the reaction. In some examples, the reaction gas is air, which provides the necessary oxygen to facilitate combustion. Additionally, the gaseous fuel is a gaseous substance that can produce energy in a combustion reaction with the reaction gas. In some examples, the gaseous fuel originates from cryogenic liquids, as fuel systems may store a fuel as a cryogenic liquid. The gaseous fuel is introduced into the combustion environment 101 to test whether, and at what amount, it will react with the reaction gas (e.g., air). Examples of gaseous fuels include hydrogen gas, methane gas, and natural gas. In some examples, the micro burner 100 may be used to test a combustion reaction between hydrogen gas and air, as hydrogen gas is considered to be a more sustainable fuel option than carbon-based fuels, and would likely be mixed with air if a leak were to occur. In other examples, the micro burner 100 may be used to test a combustion reaction between natural gas and air.

The micro burner 100 includes a leak plate 108, a gas supply line 112 couplable to the leak plate 108, and an ignition source 114. The leak plate 108 includes a testing aperture 110 which serves as the conduit through which the gaseous fuel is introduced into the combustion environment 101. In other words, the testing aperture 110 allows for the controlled introduction of the gaseous fuel into the combustion environment 101, to simulate a microleak of the gaseous fuel. The testing aperture 110 is in fluid communication with the gaseous fuel, such that the gaseous fuel is introduced through the testing aperture 110 into the combustion environment 101. The leak plate 108 includes a supply side 118, which is couplable to the gas supply line 112, and a testing side 120, opposite of the supply side 118, which includes the testing aperture 110 for introducing the gaseous fuel into the combustion environment 101. In some examples, the leak plate 108 is a multi-component assembly and includes a leak insert 122 and a receiver plate 116, as explained below in reference to FIG. 2. In other examples, the leak plate 108 is a singular unit with the testing aperture 110 integrated directly within the leak plate 108.

When the combustion environment 101 is a combustion chamber 102, as in FIG. 1, the leak plate 108 is removably attachable to the combustion chamber 102. Specifically, the leak plate 108 is attachable to the leak-plate opening 104 within the housing 105. When the leak plate 108 is attached, the testing side 120 of the leak plate 108 forms a portion of the internal chamber 106 of the combustion chamber 102, such that the gaseous fuel is introduced into the internal chamber 106 through the testing aperture 110. Moreover, the supply side 118 of the leak plate 108 forms a portion of an outer surface of the combustion chamber 102. Accordingly, when the leak plate 108 is attached to the combustion chamber 102, the combustion chamber 102 provides a controlled and contained environment for the combustion reaction.

The gas supply line 112 is couplable to the supply side 118 of the leak plate 108. When the gas supply line 112 is coupled to the leak plate 108, the gas supply line 112 supplies the gaseous fuel through the testing aperture 110 and into the combustion environment 101. The gas supply line 112 includes any of various devices, such as valves and piping equipment to deliver the gaseous fuel from a storage container, which contains the gaseous fuel or aa precursor, such as a cryogenic liquid, to the leak plate 108. In some examples, the gas supply line 112 includes valves for regulating pressure and/or flow rate of the gaseous fuel, allowing control over testing conditions for accurate results. Alternatively, or additionally, the size of the testing aperture 110 is used to regulate the flow rate of the gaseous fuel. For example, the gas supply line 112 may regulate the flow rate of the gaseous fuel through the testing aperture 110 so that the flow rate is less than or equal to 1 mmol/s. In other examples, the flow rate of the gaseous fuel through the testing aperture 110 is between and inclusive of, 0.1 mmol/s and 5 mmol/s, such as between, and inclusive of 0.1 mmol/s and 1 mmol/s in creation examples, and such as between, and inclusive of 0.1 mmol/s and 0.5 mmol/s in another example. The gas supply line 112 may be compatible with various types of gaseous fuels, allowing the micro burner 100 to be used for testing different gaseous fuels.

The ignition source 114 is within the combustion environment 101 and configured to initiate the combustion reaction between the reaction gas and the gaseous fuel within the combustion environment 101. That is, the ignition source 114 provides the spark or high-energy discharge required to ignite the gas mixture. For example, the ignition source 114 may consist of electrodes connected to an ignition coil connected to a spark plug, which generates the necessary spark to ignite the gas mixture. Alternatively, the ignition source 114 could use a torch to provide the required ignition. When the combustion environment 101 is the combustion chamber 102, the ignition source 114 may be located at any location on the combustion chamber 102 provided the ignition source 114 is in operative communication with the internal chamber 106 to ignite the combustion reaction.

In some examples, at least one sensor 109 is within the combustion environment 101 and is configured to measure a combustion characteristic of the combustion reaction and its effects on surrounding materials. Combustion characteristics may include pressure, temperature, gas concentration, light emission, etc. The at least one sensor 109 may include any of various sensors including a pressure sensor, an optical sensor, a gas sensor, or a heat sensor. In some cases, multiple sensors 109 are utilized to measure different combustion characteristics simultaneously. For example, an optical sensor, which may be a camera, can detect light emissions from the combustion reaction. This may include measuring the intensity and wavelength of the emitted light, which can provide insights into the reaction's efficiency and completeness. A camera may also capture visual data for further analysis of the flame characteristics and behavior. Additionally, an optical sensor can include a photodetector or a planar laser induced fluorescence (PLIF) system to visualize the reactant and product distribution. Moreover, a gas sensor may be used to measure the concentration of specific gases within the combustion environment 101. This includes detecting unburned fuel, combustion by-products, or oxygen levels, which are useful for evaluating the combustion process's efficiency and safety. Furthermore, pressure and heat sensors can measure the physical impacts of the combustion reaction on materials within the combustion environment 101, providing data on structural integrity and thermal damage.

In some examples, the at least one sensor 109 may be at least one thermocouple. The at least one thermocouple is within the combustion environment 101, which in certain examples, is the internal chamber 106 of the combustion chamber 102. The thermocouple is configured to measures a temperature of the combustion reaction. That is, the at least one thermocouple aids in assessing the thermal characteristics of the combustion reaction. When used in conjunction with additional equipment, such as a heat flux sensor, a thermocouple can also help calculate heat flux, providing detailed insights into the rate of heat energy transfer.

Referring specifically to FIG. 1, in certain examples where the combustion environment 101 is a combustion chamber 102, the combustion chamber 102 may include at least one visualization window 107. The visualization window 107 is configured to allow exterior observation of the combustion reaction within the internal chamber 106. In other words, the combustion reaction can be monitored from outside the combustion chamber 102, providing a view of the combustion reaction without interfering with the internal environment. Accordingly, the visualization window 107 is made from a high-temperature resistant material that is transparent or translucent. For example, a heat-resistant glass, such as borosilicate glass or fused silica, that can withstand the conditions inside the internal chamber 106 while providing visibility for observation, allowing monitoring of the combustion reaction in real-time without compromising the integrity of the combustion chamber 102. The two visualization windows shown in FIG. 1, are shown in exploded view for illustrative reasons only, allowing the internal chamber 106 to be visible. In practice, the visualization windows would be attached to the combustion chamber 102 ensuring an airtight seal between the visualization window 107 and the combustion chamber 102.

Shown in FIG. 2 is one example of the leak plate 108 of the micro burner 100. The leak plate 108 includes the testing aperture 110, which is depicted in a central location but may be positioned at any location on the leak plate 108. In some examples, not shown, the leak plate 108 is a singular unit with the testing aperture 110 integrated directly within the leak plate 108. In other examples, the leak plate 108 is a multi-component assembly and includes a leak insert 122 and a receiver plate 116. The leak insert 122 includes the testing aperture 110 and is selectively attachable to the interior surface 121 of the receiver plate 116, where the interior surface 121 forms a portion of the supply side 118 of the leak plate 108, when the leak insert 122 is attached. An exterior surface 119 of the receiver plate 116 defines the supply side 118 of the leak plate 108, such that the gas supply line 112 is couplable to the exterior surface 119 of the receiver plate 116 to supply the gaseous fuel through the testing aperture 110 of the leak insert 122. Moreover, the leak insert 122 has a plurality of receiver-attachment couplings 136 that are attachable to a corresponding one of a plurality of leak-attachment couplings 138 of the receiver plate 116, to attach the leak insert 122 to the receiver plate 116. The receiver plate 116 includes a fuel inlet port 129 that is couplable to the gas supply line 112, allowing the gaseous fuel to be introduced through the fuel inlet port 129 of the receiver plate 116 and to the testing aperture 110 of the leak insert 122.

When the leak insert 122 is attached to the receiver plate 116, a seal is formed between the two components, ensuring that the gaseous fuel is effectively directed through the testing aperture 110 without any unintended leakage. The seal can utilize any of various sealing mechanisms, such as an O-ring, rubber gasket, copper gasket, or other suitable materials, to ensure a secure and air-tight connection between the leak insert 122 and the receiver plate 116. In certain examples, the seal mechanism uses an O-ring 130 within an O-ring slot 128 of the receiver plate 116.

When the combustion environment 101 is a combustion chamber 102, the receiver plate 116 may include a plurality of chamber-attachment couplings 140 that allow the receiver plate 116 to be securely attached to the combustion chamber 102. The secure attachment forms a seal between the receiver plate 116 of the combustion chamber 102, ensuring that the internal chamber 106 is properly sealed for the combustion reaction. The chamber-attachment couplings 140 may include any of a variety of couplings, such as screws, bolts, clamps, or simply openings that allow for the insertion of such fasteners.

In some examples, the micro burner 100 includes a plurality of leak plates, such that each one of the leak plates 108 is interchangeable with others of the plurality of leak plates where each one of the plurality of leak plates has a different sized testing aperture. Each one of the plurality of leak plates is individually couplable to the gas supply line 112, such that the selected one of the plurality of leak plates is coupled to the gas supply line 112 to setup the micro burner 100. The interchangeability of the leak plates 108 allows for varying the test conditions (e.g., size and shape of testing aperture) without the need for multiple micro burners. By removing and replacing the leak plate 108 on the micro burner 100, testing can simulate differently sized microleak scenarios to observe the differently sized microleaks under consistent testing conditions. In some examples, the leak plate 108 is interchangeable with another leak plate 108, such that the entirely of the leak plate 108 is replaced with another leak plate. For example, a first leak plate is interchangeable with a second leak plate, where a size of the testing aperture 110 of the first leak plate and a size of the testing aperture 110 of the second leak plate are different. In other examples, when using a leak plate having a multi-component assembly as shown in FIG. 2, rather than replacing the entire leak plate 108, only the leak insert 122 is interchangeable with other leak inserts 122, such that the receiver plate 116 is reused with each leak insert 122.

The testing aperture 110 may be any of a various of shapes and sizes. In some examples, an area of the testing aperture 110 is less than or equal to 5 mm². In other examples, the area is between 0.01 mm² to 32 mm², such as between, and inclusive of 0.1 mm² to 10 mm²in some examples, and between, and inclusive of 0.1 mm² to 5 mm² in other examples. The differing sizes and shapes allow of the simulation of various leak scenarios, providing flexibility in testing different conditions. That is, each testing aperture 110 of the interchangeable leak plates, or in interchangeable leak inserts, is designed to simulate a distinct microleak, ensuring that the micro burner 100 can be used to test a wide range of leak scenarios. For example, as shown in FIGS. 3A and 3C, in certain examples, the testing aperture 110 of the leak insert 122 may be a pin hole 124 or a slot 126.

Referring to FIG. 3A and 3B, the pin hole 124 of the leak insert 122 is a small hole with a diameter that extends through a width WI of the leak insert 122. Specifically, the testing aperture 110 extends from a receiver-mating surface 132 to a supply surface 134 of the leak insert 122. It is noted that the pin hole 124 and the leak insert 122 are not necessarily to scale. For example, in the illustrated renderings, the size of the pin hole 124 is large relative to the size of the leak insert 122 for better clarity in showing and describing the invention. In some examples, the diameter of the pin hole 124 is between, and inclusive of, 0.001 inches to 0.25 inches, such as between, and inclusive of 0.002 inches and 0.1 inches in one example and between, and inclusive of 0.005 inches and 0.05 inches in other examples. For example, a plurality of leak inserts may have a corresponding pin hole 124 with diameters of 0.002 inches, 0.008 inches, 0.015 inches, 0.040 inches, 0.080 inches, 0.1 inches, 0.25 inches, etc.

As shown in FIG. 3C, the testing aperture 110 of the leak insert 122 is a slot 126. The slot 126 is an elongated opening with a width and length that extends through the width WI of the leak insert 122. The slot 126 allows for a different type of microleak simulation compared to the pin hole 124, as the elongated shape can simulate a crack or larger gap, rather than a small puncture. The slot 126 extends from the receiver-mating surface 132 to the supply surface 134 of the leak insert 122. Similar to the pin hole 124, the dimensions of the slot 126 are not necessarily to scale, as the size of the slot 126 is exaggerated relative to the size of the leak insert 122 for better clarity. In some examples, the area of the slot is less than or equal to 32 mm². Accordingly, in some examples, a width of the slot 126 is between, and inclusive of, 0.001 inches to 0.1 inches, such as between, and inclusive of 0.002 inches and 0.25 inches in one example and a length of the slot 126 is between, and inclusive of, 2 to 50 times the width of the slot, ensuring that the total area of the slot 126 remains less than 32 mm². Additionally, in some examples, the supply surface 134 of the leak insert 122 has a non-planar surface, allowing for testing the effect of three-dimensional curvature on the combustion reaction. The non-planar surface can potentially introduce complex flow dynamics of the gaseous fuel into the combustion environment 101, closely simulating real-world conditions. This may help in understanding how variations in surface geometry affect combustion efficiency, flame propagation, and heat transfer.

Referring to FIG. 4A-4C, another example of a leak insert 122 having a slot 126 is shown. The leak insert 122 is configured to be selectively attached to the receiver plate 116, as shown in FIG. 2. The leak insert 122 is a two-piece assembly and includes a slot-insert receiver 142 and a slot insert 144, shown in an exploded view in FIG. 4A, and separately in FIG. 4B. Specifically, the slot-insert receiver 142 has a recessed portion 146 into which the slot insert 144 is sized to fit within. When the slot insert 144 is fitted within the recessed portion 146, the slot 126 is defined between a first slot surface 148 of the slot-insert receiver 142 and the second slot surface 152 of the slot insert 144. By changing out the slot insert 144, and reusing the slot-insert receiver 142, the size of the slot 126 can be adjusted. In other words, both the receiver plate 116 and the slot-insert receiver 142 of the leak insert 122 are reused from test to test, and only the slot insert 144 is interchanged to adjust the size of the slot 126 for different testing parameters. That is, each slot insert 144 has a different size, resulting in varying spacing between the first slot surface 148 of the slot-insert receiver 142 and the second slot surface 152 of the slot insert 144 for each slot insert 144. This allows for flexible testing by replacing the slot insert 144 to vary the slot size, without the need to replace the entire assembly. The slot insert 144 includes a plurality of slot-insert couplings 154 that are attachable to a corresponding one of a plurality of slot-receiver couplings 156 of the slot-insert receiver 142, to attach the slot insert 144 to the slot-insert receiver 142.

The slot-insert receiver 142 includes a slot aperture 150 that extends from the recessed portion 146 through the remainder of a width W2 of the slot-insert receiver 142. As shown in FIG. 4C, the slot aperture 150 is in fluid communication with the slot 126, such that the gaseous fuel can enter into the slot aperture 150 and through the slot 126. That is, the gaseous fuel flows from the receiver-mating surface 132 of the leak insert 122 through the supply surface 134 of the leak insert 122.

Referring to FIG. 5, according to some examples, a method 300 of testing a combustion reaction within a micro burner 100 is shown. The method 300 includes the step of (block 302) supplying a gaseous fuel through a testing aperture 110 of a leak plate 108 into the combustion environment 101. Specifically, a gas supply line 112 is connected to the fuel inlet port 129 of the leak plate 108 to provide the gaseous fuel, through the testing aperture 110 of the leak plate 108, and into the combustion environment 101. The gas supply line 112 may include valves and flow control mechanisms to regulate the flow rate and pressure of the gaseous fuel.

The method 300 also includes the step of (block 304) activating an ignition source 114 to initiate the combustion reaction between a reaction gas and the gaseous fuel within the combustion environment 101. The ignition source 114 is in operative communication with the combustion environment 101 such that the ignition source 114 is configured to provide the spark to initiate the combustion reaction between the gas mixture.

The method 300 further includes the step of (block 306) monitoring the combustion reaction within the combustion environment 101. The combustion reaction may be visually monitored. Additionally, or alternatively, the combustion reaction may be monitored using at least one sensor 109 to measure combustion characteristics of the combustion reaction. Sensors may include pressure sensors, optical sensors (e.g., camera), gas sensors, and heat sensors (e.g., thermocouples). Data may be collected in real-time from the at least one sensor during the combustion reaction and provide information such as pressure changes, temperatures fluctuations, gas concentrations, and light emissions. A camera may be used to visually monitor the combustion reaction, allowing for observation of flame characteristics, reaction stability, and any anomalies that may occur. Additionally, when the combustion environment 101 is a combustion chamber 102, the combustion chamber 102 may include visualization windows 107 to allow for exterior observation of the combustion reaction.

In examples where the combustion environment 101 is a combustion chamber 102, the method may include the step of removably attaching the leak plate 108 to a combustion chamber 102. The leak plate 108 is attached to a leak-plate opening 104 to seal an internal chamber 106 of the combustion chamber 102. The leak plate 108 may be attached to the combustion chamber 102 using chamber-attachment couplings 140, which may include various types of couplings such as screws, clamps, and other fastening mechanisms. The seal between the leak plate 108 and the combustion chamber 102 is airtight, ensuring that the combustion reaction is contained within the internal chamber 106.

In some examples, the leak plate 108 of the micro burner 100 is interchangeable with other leak plates 108, each leak plate having a corresponding and different testing aperture. That is, the micro burner 100 may be used for testing with leak plates 108 having differently sized testing apertures 110. Specifically, after any combustion reaction within the combustion environment 101 is complete, the leak plate 108 can be removed from the combustion chamber 102, and replaced with a second leak plate. The second leak plate has a testing aperture 110 that is differently sized than the testing aperture of the leak plate 108, allowing for tests to be conducted under varying testing size conditions. Interchangeable leak plates provide flexibility in testing different scenarios and obtaining a wide range of data. Specifically, the gas supply line 112 can be attached to the second leak plate and the ignition source activated to initiate a subsequent combustion reaction between the reaction gas and the gaseous fuel, introduced into the combustion environment 101 through the testing aperture 110 of the second leak plate.

Alternatively, in some examples, the leak plate 108 is a multi-component assembly having a receiver plate 116 and a leak insert 122. The receiver plate 116 is selectively attached to the gas supply line 112 during a combustion reaction to supply the gaseous fuel into the combustion environment 101. After a combustion reaction within the combustion environment 101 is complete, the leak insert 122 can be removed from the receiver plate 116 can and replaced with a second leak insert 122 having a testing aperture 110 that is differently sized.

That is, the receiver plate 116 can be reused with different leak inserts to allow for tests to be conducted under varying testing size conditions. The receiver plate 116, with the second leak insert, can then be attached to the gas supply line and the ignition source activated to initiate a subsequent combustion reaction between the reaction gas and the gaseous fuel, introduced into the combustion environment 101 through the testing aperture 110 of the second leak insert 122.

In the above description, certain terms may be used such as “up,” “down,” “upper,” “lower,” “horizontal,” “vertical,” “left,” “right,” “over,” “under” and the like. These terms are used, where applicable, to provide some clarity of description when dealing with relative relationships. But, these terms are not intended to imply absolute relationships, positions, and/or orientations. For example, with respect to an object, an “upper” surface can become a “lower” surface simply by turning the object over. Nevertheless, it is still the same object. Further, the terms “including,” “comprising,” “having,” and variations thereof mean “including but not limited to” unless expressly specified otherwise. An enumerated listing of items does not imply that any or all of the items are mutually exclusive and/or mutually inclusive, unless expressly specified otherwise. The terms “a,” “an,” and “the” also refer to “one or more” unless expressly specified otherwise. Further, the term “plurality” can be defined as “at least two.”

Additionally, instances in this specification where one element is “coupled” to another element can include direct and indirect coupling. Direct coupling can be defined as one element coupled to and in some contact with another element. Indirect coupling can be defined as coupling between two elements not in direct contact with each other, but having one or more additional elements between the coupled elements. Further, as used herein, securing one element to another element can include direct securing and indirect securing. Additionally, as used herein, “adjacent” does not necessarily denote contact. For example, one element can be adjacent another element without being in contact with that element.

As used herein, the phrase “at least one of”, when used with a list of items, means different combinations of one or more of the listed items may be used and only one of the items in the list may be needed. The item may be a particular object, thing, or category. In other words, “at least one of” means any combination of items or number of items may be used from the list, but not all of the items in the list may be required. For example, “at least one of item A, item B, and item C” may mean item A; item A and item B; item B; item A, item B, and item C; or item B and item C. In some cases, “at least one of item A, item B, and item C” may mean, for example, without limitation, two of item A, one of item B, and ten of item C; four of item B and seven of item C; or some other suitable combination.

Unless otherwise indicated, the terms “first,” “second,” etc. are used herein merely as labels, and are not intended to impose ordinal, positional, or hierarchical requirements on the items to which these terms refer. Moreover, reference to, e.g., a “second” item does not require or preclude the existence of, e.g., a “first” or lower-numbered item, and/or, e.g., a “third” or higher-numbered item.

As used herein, a system, apparatus, structure, article, element, component, or hardware “configured to” perform a specified function is indeed capable of performing the specified function without any alteration, rather than merely having potential to perform the specified function after further modification. In other words, the system, apparatus, structure, article, element, component, or hardware “configured to” perform a specified function is specifically selected, created, implemented, utilized, programmed, and/or designed for the purpose of performing the specified function. As used herein, “configured to” denotes existing characteristics of a system, apparatus, structure, article, element, component, or hardware which enable the system, apparatus, structure, article, element, component, or hardware to perform the specified function without further modification. For purposes of this disclosure, a system, apparatus, structure, article, element, component, or hardware described as being “configured to” perform a particular function may additionally or alternatively be described as being “adapted to” and/or as being “operative to” perform that function.

The term “about” or “substantially” in some embodiments, is defined to mean within +/−5% of a given value, however in additional embodiments any disclosure of “about” may be further narrowed and claimed to mean within +/−4% of a given value, within +/−3% of a given value, within +/−2% of a given value, within +/−1% of a given value, or the exact given value. Further, when at least two values of a variable are disclosed, such disclosure is specifically intended to include the range between the two values regardless of whether they are disclosed with respect to separate embodiments or examples, and specifically intended to include the range of at least the smaller of the two values and/or no more than the larger of the two values. Additionally, when at least three values of a variable are disclosed, such disclosure is specifically intended to include the range between any two of the values regardless of whether they are disclosed with respect to separate embodiments or examples, and specifically intended to include the range of at least the A value and/or no more than the B value, where A may be any of the disclosed values other than the largest disclosed value, and B may be any of the disclosed values other than the smallest disclosed value.

The schematic flow chart diagrams included herein are generally set forth as logical flow chart diagrams. As such, the depicted order and labeled steps are indicative of one example of the presented method. Other steps and methods may be conceived that are equivalent in function, logic, or effect to one or more steps, or portions thereof, of the illustrated method. Additionally, the format and symbols employed are provided to explain the logical steps of the method and are understood not to limit the scope of the method. Although various arrow types and line types may be employed in the flow chart diagrams, they are understood not to limit the scope of the corresponding method. Indeed, some arrows or other connectors may be used to indicate only the logical flow of the method. For instance, an arrow may indicate a waiting or monitoring period of unspecified duration between enumerated steps of the depicted method.

Additionally, the order in which a particular method occurs may or may not strictly adhere to the order of the corresponding steps shown.

The present subject matter may be embodied in other specific forms without departing from its spirit or essential characteristics. The described examples are to be considered in all respects only as illustrative and not restrictive. All changes which come within the meaning and range of equivalency of the examples herein are to be embraced within their scope.