Corona Igniter Forward Assembly Design
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Solution Overview
Problem
The reverse-assembly method of corona igniters, which requires the insulator to be inserted into the shell from the combustion chamber, leads to operational and manufacturing compromises such as difficulty in retaining the insulator without putting it in tension, and limits the ability to achieve optimal electrical performance.
Innovation Solution
A corona igniter design where the conductive inner diameter is less than the insulator outer diameter adjacent the insulator nose region, allowing for forward-assembly and maintaining exceptional electrical performance while avoiding the issues associated with reverse-assembled igniters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the insulator outer diameter is increased to improve electrical performance, then the insulator cannot be assembled into the shell using conventional forward-assembly methods
Solution Approach 1:
The patent inverts the conventional assembly sequence by performing reverse-assembly, where the insulator is inserted into the shell from the combustion chamber end rather than from the opposite end. This allows the insulator outer diameter to be larger than the shell inner diameter at the assembly end, enabling optimal electrical performance while maintaining manufacturability through the inverted assembly approach
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 forward-assembly method enables the corona igniter to achieve exceptional electrical performance without the tension-related issues of reverse-assembled designs, ensuring reliable operation and improved assembly processes.
Implementation Method 1
a central electrode formed of an electrically conductive material for receiving a high radio frequency voltage and emitting an radio frequency electric field
Implementation Method 2
The electric field causes a portion of a mixture of fuel and air in the combustion chamber to ionize and begin dielectric breakdown
Implementation Method 3
facilitating combustion of the fuel-air mixture... corona discharge occurs, also referred to as a non-thermal plasma
Data Source
Figure 1
Figure 1A
Figure 2
AI summary
A corona igniter (20) comprises a central electrode (22) surrounded by an insulator (26), which is surrounded by a conductive component. The conductive component includes a shell (34) and an intermediate part (36) both formed of an electrically conductive material. The intermediate part (36) is disposed between said insulator outer surface and said shell inner surface and between said insulator upper end and said insulator lower shoulder.