Gas Generator Igniter Assembly for Airtight Pin Insulation
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Solution Overview
Problem
Existing igniters for gas generators face challenges in achieving mechanical stability and airtightness while maintaining cost-effective production, with complex and expensive manufacturing processes for traditional designs and difficulties in ensuring mechanical strength and tightness in plastic-based alternatives.
Innovation Solution
An igniter design featuring a pole body composed of a metal retaining ring and a plastic insulating ring, connected through an embossing process that deforms the retaining ring to securely join the components without play, providing a mechanically stable and airtight passage for the connection pin, and a separate fastening section for additional structural support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional GTMS headers with glass mass are used, then electrical insulation and mechanical stability are achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent changes the material parameter from glass mass to plastic compound, and changes the joining method parameter from cooling/fixing to embossing/deformation. This substitution maintains the insulating and stabilizing functions while dramatically simplifying the manufacturing process and reducing costs.
Solution Approach 2:
The patent replaces the complex thermal-mechanical system of cooling liquid glass mass and fixing pins with a simpler mechanical embossing system that deforms the plastic compound to secure components. This substitution eliminates the need for temperature control and complex fixing mechanisms.
2Ease of manufacture
If plastic compound overmolding is used, then manufacturing cost decreases, but mechanical strength and tightness become difficult to ensure
Solution Approach 1:
The patent applies preliminary embossing to the plastic compound before final assembly, pre-compressing and pre-shaping the material to ensure optimal mechanical strength and tightness. This preliminary action prepares the plastic to securely hold the connection pins and maintain sealing integrity.
Solution Approach 2:
The embossing process creates curved, deformed regions in the plastic compound that conform to the shapes of the connection pins and retaining ring. This curvature allows the plastic to wrap around and securely hold the components, enhancing mechanical strength and tightness through form-fitting deformation.
3Ease of manufacture
If connection pins are secured in plastic without embossing, then manufacturing is simpler, but mechanical stability and airtightness are compromised
Solution Approach 1:
The embossing step is introduced as a preliminary action that pre-compresses and pre-shapes the plastic compound around the connection pins and retaining ring. This preliminary deformation ensures that the final assembly achieves the necessary mechanical stability and airtightness without requiring complex subsequent operations.
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 design enables the production of a cost-effective, mechanically stable, and well-sealed igniter with simplified manufacturing, ensuring reliable operation and reduced production costs by using a metal retaining ring and plastic insulating ring connected via embossing, which provides a secure and airtight connection for the connection pin.
Implementation Method 1
the retaining ring, insulating ring and at least one connection pin are embossed in an embossing step in which the retaining ring, insulating ring and connection pin are firmly connected to one another without play by deforming at least the retaining ring
Data Source
Figure 1a~1b
Figure 2~3
Figure 4~5
AI summary
An igniter for a gas generator comprises a pole body (14) having at least one connection pin (16, 18), a retaining ring (20) and an insulation ring (22), wherein the insulation ring (22) spaces apart the at least one connection pin (16, 18) from the retaining ring (20) and electrically insulates it relative to same. The retaining ring (20) consists of a metal and the insulation ring (22) consists of a plastic. In order to produce an igniter (10) for a gas generator at least one connection pin (16, 18), a retaining ring (20) and an insulation ring (22) are provided, the connection pin (16, 18), the insulation ring (22) and the retaining ring (20) are fitted inside one another in such a way that the connection pin (16, 18) is surrounded by the insulation ring (22) and the insulation ring (22) is surrounded by the retaining ring (20), and the retaining ring (20), the insulation ring (22) and the connection pin (16, 18) are compressed in a compression step, in which at least the retaining ring (20) is deformed and the retaining ring (20), the insulation ring (22) and the connection pin (16, 18) are connected to one another securely and without play.