Igniter Interference Fit Electrical Connection
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Solution Overview
Problem
Electrical igniters used in harsh environments, such as downhole applications, face reliability issues due to maintenance challenges in maintaining electrical connections, which can affect their operational integrity.
Innovation Solution
The igniter design employs an interference fit between the sleeve and leads to establish and maintain electrical communication, ensuring reliable current supply to the resistor, using crimping mechanisms to secure connections and prevent dislodgment, while also sealing the combustible medium.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional electrical connections are used in igniters, then the igniter can be assembled, but the electrical connections may fail in harsh environments, reducing reliability
Solution Approach 1:
The electrical connection is segmented into modular components (conductor, insulation layer, crimping features) that can be independently manufactured and assembled, allowing for specialized design of each component to optimize both reliability and ease of assembly
Solution Approach 2:
The conductor is pre-formed with specific geometric features (flared ends, crimping structures) before assembly, and the insulation layer is pre-applied to the conductor. This preliminary preparation ensures proper alignment and fit during final assembly, reducing assembly complexity while maintaining connection reliability
2Reliability
If interference fit is used to maintain electrical communication, then electrical connectivity is improved, but manufacturing precision requirements increase
Solution Approach 1:
The conductor's geometric parameters are specifically modified to create flared ends and crimping features that transform the interference fit from a tight-tolerance press-fit into a more forgiving deformation-based connection, maintaining electrical connectivity while reducing manufacturing precision requirements
Solution Approach 2:
The conductor is designed with different geometric properties at different locations: the body maintains standard dimensions, while the ends are flared and the surface is prepared for crimping. This localized variation in quality allows the interference fit to be achieved with lower overall tolerance while ensuring reliable electrical contact at the connection points
3Strength
If crimping mechanisms are used to secure connections, then connection strength is improved, but device complexity increases
Solution Approach 1:
The conductor's own material properties and geometric features (flared ends, ductility) enable it to be crimped directly into place without requiring external crimping tools or mechanisms. The conductor essentially crimps itself into the sleeve during assembly, achieving strong mechanical bonding while minimizing device complexity
Solution Approach 2:
The electrical conductor and mechanical fastening functions are merged into a single component. The same conductor that provides electrical connectivity also serves as the mechanical element that is crimped to secure the connection, eliminating the need for separate fasteners or complex assembly mechanisms
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 enhances the reliability and operational integrity of igniters by ensuring consistent electrical connectivity and preventing medium leakage, thereby maintaining effective ignition processes in harsh environments.
Implementation Method 1
electrical communication with the sleeve is maintained by interference fit between the sleeve and the at least one lead
Implementation Method 2
a resistor in operable communication with the combustible medium
Data Source
AI summary
An igniter includes, a sleeve receptive to combustible medium, a resistor in operable communication with the combustible medium, and at least one lead in electrical communication with the resistor and the sleeve the electrical communication with the sleeve is maintained by interference fit between the sleeve and the at least one lead.