Addressable Ignition Circuit for Scalable, Reliable Detonators

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Solution Overview

Problem

Existing detonators used in oilfield and mining operations are difficult to scale in production due to their fragility and small, intricate components, making them challenging to handle and inspect, which affects reliability and durability in harsh conditions.

Innovation Solution

A detonator initiator device incorporating a thyristor with a standoff voltage of >50V AC/DC, a high-power resistor, and a thermally conductive substrate, mounted on a standard FR4 circuit board, and a thermally conductive substrate, allowing for large current flow and reliable detonation, with optional RFID technology for inventory and tracking.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional nichrome heating element detonators are used, then detonation function is achieved, but manufacturing scalability and reliability deteriorate due to fragility and difficulty in handling small components

Engineering Contradiction:

Improvedetonator reliabilityVSAvoidmanufacturing scalability

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces the traditional mechanical nichrome heating element assembly with an electronic ignition circuit board containing a thyristor, resistors, and capacitors. This substitution eliminates the need for fragile manual assembly of small components while maintaining the detonation function, thereby improving both reliability and manufacturing scalability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention changes the electrical parameters of the ignition system by using a thyristor with standoff voltage >50V AC/DC and specific resistor values (50Ω or greater) to control current flow. This parameter optimization ensures reliable detonation while enabling standardized production processes.

Inventive Principle:

Principle #35Parameter changes

2Power

If small nichrome heating element is used, then detonation capability is achieved, but inspection and handling difficulty increases

Engineering Contradiction:

Improveignition power outputVSAvoidinspection difficulty

Core Design Contradiction:

PowerVSDifficulty of detecting and measuring

Solution Approach 1:

The patent transitions from a one-dimensional wire-based heating element to a two-dimensional circuit board layout. This dimensional change allows the ignition components to be visually inspected and handled as a complete assembly rather than individual tiny components, significantly reducing inspection difficulty while maintaining ignition power through the thyristor circuit design.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Reliability

If resistors are added for safety, then current flow restriction is achieved, but device complexity increases

Engineering Contradiction:

ImprovesafetyVSAvoidcircuit complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the safety resistor function with the ignition circuit board assembly, integrating multiple components (thyristor, resistors, capacitors) into a single standardized unit. This merging reduces overall device complexity compared to assembling separate components, while maintaining safety through the inherent current-limiting properties of the circuit design.

Inventive Principle:

Principle #5Merging (Combining)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution enables robust detonation with high reliability, scalability, and operational dependability, suitable for high-volume production, and includes RFID for inventory management and tracking, enhancing operational safety and efficiency.

Implementation Method 1

incorporates a thyristor which has a standoff voltage of >50V AC/DC, allows for large current flow

Methodology Applied

Scientific EffectVoltage breakdown:

Implementation Method 2

The nichrome heating element 100 typically has a resistance of less than 1Ω. The resistors 104a and 104b add safety to the nichrome heating element by restricting current flow

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 3

incorporates a high-power resistor for ignition and a thermally conductive substrate allowing for operation at high temperatures

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS12422237B2Addressable ignition stage for enabling a detonator/ignitor

Publication Date: 2025.09.23 PARASRAM RYAN

AI summary

The present invention is directed toward an addressable ignition stage which produces an output sufficient to detonate a secondary explosive, generally. The present invention comprises addressability and ignition functions that may be used together or separately to incorporate a high-power resistor with a thermally conductive substrate allowing for operation at high temperatures for ignition. The ignition stage is amendable to high volume production, exhibits a high degree of reliability, robustness and operational dependability for use alone or configurable into existing technology.