Exothermic Welding Igniter Using Electronic Starter

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Solution Overview

Problem

Conventional exothermic welding processes face challenges with low safety factors, complex operations, and high costs due to the instability and costliness of ignition agents, which hinder achieving continuous and stable high temperatures for igniting exothermic welding flux.

Innovation Solution

An exothermic welding apparatus utilizing an igniter with a heating wire and an electronic starter to supply power, providing a safety distance and reducing costs by eliminating the need for ignition agents, while increasing operation efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If ignition agent is used to ignite exothermic welding flux, then ignition can be achieved, but safety factor is reduced and cost increases

Engineering Contradiction:

Improvesafety factorVSAvoidcost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent removes the ignition agent from the system entirely, replacing it with an electronic starter that directly heats the heating wire. This extraction of the harmful ignition agent eliminates safety concerns and reduces costs associated with handling and storing unstable chemical substances.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the chemical ignition system with an electronic heating system. The electronic starter supplies electrical current to the heating wire, which generates heat through resistive heating to ignite the exothermic welding flux, eliminating the need for chemical ignition agents.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of operation

If ignition agent is used to ignite exothermic welding flux, then ignition can be achieved, but operation complexity increases

Engineering Contradiction:

Improveoperation complexityVSAvoidignition stability

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent replaces the complex chemical ignition process with a simple electronic heating process. The electronic starter provides controlled electrical current to the heating wire, which reliably generates heat to ignite the flux, eliminating the instability and complexity of chemical ignition agents.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The heating wire, once heated by the electronic starter, self-sustains the ignition process by generating sufficient heat to trigger the exothermic reaction of the welding flux, eliminating the need for continuous external ignition assistance.

Inventive Principle:

Principle #25Self-service

3Temperature

If conventional ignition method is used, then ignition can be achieved, but continuous stable high temperature cannot be maintained

Engineering Contradiction:

Improveignition temperature stabilityVSAvoidmanufacturing cost

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The patent replaces the unstable chemical ignition method with a controlled electrical heating system. The electronic starter provides stable electrical current to the heating wire, ensuring continuous and stable high temperature generation throughout the ignition process, eliminating the temperature fluctuations inherent in chemical ignition.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 apparatus safely and efficiently ignites exothermic welding flux, enhancing safety factors and reducing costs compared to prior art, with improved operation efficiency and a stable high-temperature ignition process.

Implementation Method 1

an igniter (30), including a heating wire (31), a first conductor wire (32) and a first connector (33), wherein the heating wire (31) is configured to ignite the exothermic welding flux (20) directly

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

an electronic starter (40), configured to cooperate with the first connector (33) and supply power to the first connector (33)

Methodology Applied

Scientific EffectElectrical energy conversion to thermal energy: Joule Heating

Data Source

PatentUS10758997B2Exothermic welding apparatus and exothermic welding method

Publication Date: 2020.09.01 SICHUAN SUNLIGHT INTELLIGENT ELECTRIC EQUIP CO LTD

AI summary

An exothermic welding apparatus and an exothermic welding method, belonging to the exothermic welding field are provided. The exothermic welding apparatus includes a mold, an igniter and an electronic starter, the mold has a holding space configured to accommodate an exothermic welding flux, the igniter includes a heating wire, a first conductor wire and a first connector, the heating wire is configured to ignite the exothermic welding flux directly, one end of the first conductor wire is electrically connected to the heating wire, the other end of the first conductor wire is electrically connected to the first connector, and the electronic starter cooperates with the first connector and is configured to supply power to the first connector. The exothermic welding apparatus can ignite an exothermic welding flux by supplying power with an electronic starter.