Gas Ignition Transformer With Split Ring Core for Flux Efficiency
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Solution Overview
Problem
Current electronic gas lighting devices for household appliances, such as cooking ranges, face challenges of low electric efficiency, high cost, and large size due to the design of their transformers, which are not easily adaptable for improved performance without increasing complexity and cost.
Innovation Solution
The design features a ring-shaped ferrite core with two half rings arranged coaxially, allowing for efficient magnetic flux concatenation and reduced material usage, with a cup-shaped body and pre-mounted parts for easy assembly, including a primary and secondary winding structure embedded in electrically insulating resin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a straight bar ferrite core is used in the transformer, then the assembly is simple, but magnetic flux disperses from the ends resulting in low electric efficiency
Solution Approach 1:
The ferrite core is divided into two separate half-rings that are positioned facing each other. This segmentation allows the core to be assembled around the primary winding more easily while maintaining a closed magnetic circuit that prevents flux dispersion, thereby improving electric efficiency without excessive complexity
Solution Approach 2:
The ferrite core uses curved half-rings instead of straight bars. The curved geometry of the half-rings allows them to form a circular or annular magnetic path when assembled, which efficiently contains the magnetic flux and prevents dispersion, significantly improving electric efficiency
2Reliability
If more electric material is used in the windings to improve performance, then the required performance levels are achieved, but the cost and size of the device increase
Solution Approach 1:
The invention converts the potential harm of magnetic flux dispersion into benefit by using curved half-ring ferrite cores that actively contain and direct the magnetic flux. This improves the effectiveness of the existing winding material, achieving required performance levels without increasing the amount of electric material used, thus avoiding increased cost and size
3Loss of energy
If a C-shaped ferrite core is used to reduce magnetic flux dispersion, then electric efficiency improves, but the assembly becomes extremely complex and costly
Solution Approach 1:
Instead of using a complex C-shaped core, the invention segments the core into two simple half-rings. These half-rings can be independently manufactured and then easily assembled by positioning them facing each other around the primary winding, dramatically simplifying the manufacturing and assembly process while maintaining the flux-containing benefits of a closed magnetic circuit
Solution Approach 2:
The curved half-ring geometry provides the necessary magnetic flux containment similar to a C-shaped core, but with the added advantage of modular assembly. The curved shape efficiently directs magnetic flux while the separation into two halves makes the overall assembly much simpler and less costly than a monolithic C-shaped core
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
This configuration significantly enhances electric efficiency from less than 15% to over 50%, reduces device size, and simplifies assembly, while maintaining cost-effectiveness and compatibility with existing assembly systems.
Implementation Method 1
a transformer housed in the body and in turn comprising a primary winding wound around and carried by a ferromagnetic material core, a carrying element formed by an electrically insulating material and designed to contain the primary winding therein, and a secondary winding consisting of a plurality of coils externally carried by the carrying element, electrically insulated from the primary winding and essentially coaxial with the latter
Data Source
Figure 1~2
Figure 3~4
AI summary
A gas lighting device (1) including: a body (3) formed by an electrically insulating material carrying a plurality of high-voltage outputs (4) for the connection of spark generating means; a transformer (10) accommodated in the body and including a primary winding (11) wound around and carried by a ferromagnetic material core (12), a carrying element (14) formed by an electrically insulating material and designed to contain the primary winding (11) therein, and a secondary winding (15) consisting of a plurality of coils (16) externally carried by the carrying element (14), electrically insulated from the primary winding and essentially coaxial with the latter; the core (12) is ring-shaped on a plane parallel to an axis (A) of the windings (11; 15) and consists of two half rings (20,21) reciprocally coupled and arranged facing and closely adjacent to each other in the direction of the axis of the windings; a first circumferential portion (22) of the ring-shaped core, formed by one or both of the half rings, is accommodated inside the carrying element (14) so as to be surrounded by the windings (11;15), while a second circumferential portion (24) of the core is formed parallel to the first and radially on the outside of the windings so as not to be surrounded by the same.