Ceramic Igniter Shield with Integrated Mounting Structure
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Solution Overview
Problem
Existing ceramic igniter systems lack robustness and manufacturing efficiency, with a need for enhanced protection against accidental damage and increased mechanical integrity while avoiding potential shock hazards and high production costs.
Innovation Solution
A ceramic igniter system comprising a shield element affixed to a mounting structure, which can be non-metallic, providing secure engagement with the igniter element and avoiding direct electrical contact with metal components to prevent shock hazards, while using high-temperature alloys for the shield and optimizing material usage for reduced costs and enhanced protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a shield element is added to protect the igniter element, then mechanical integrity and protection against damage are improved, but device complexity increases
Solution Approach 1:
The shield element and mounting structure are combined into a single integrated component. The shield element includes a mounting structure with engagement features that directly attach to the igniter element, eliminating the need for separate mounting brackets or fasteners. This merging reduces the number of parts while maintaining protective function and mechanical integrity.
Solution Approach 2:
The shield element serves multiple functions simultaneously: it protects the igniter element from physical damage, provides structural support, and includes integrated mounting features for attachment. The engagement features on the shield element allow it to function both as a protective barrier and as a mounting mechanism, reducing overall device complexity.
2Reliability
If a non-metallic mounting structure is used to electrically isolate the shield element, then safety against electrical shock is improved, but manufacturing precision requirements increase
Solution Approach 1:
A non-metallic mounting structure material acts as an intermediary between the shield element and any metal components. This intermediate material provides electrical isolation to prevent shock hazards while allowing mechanical engagement through molded features. The intermediary material bridges the gap between electrical safety requirements and mechanical mounting needs.
Solution Approach 2:
The mounting structure utilizes composite or non-metallic materials that combine electrical insulation properties with mechanical strength and engagement capabilities. These materials provide both the electrical isolation needed for safety and the structural features needed for precise manufacturing and assembly.
3Ease of manufacture
If direct attachment of the shield element to the igniter element is implemented, then ease of manufacture is improved, but protection against accidental damage may be compromised
Solution Approach 1:
The shield element is segmented into distinct functional zones: a protective encasement portion that surrounds the igniter element and engagement features that attach to the igniter. This segmentation allows the protective portion to be optimally designed for damage prevention while the engagement features facilitate easy manufacturing and attachment, with each segment optimized for its specific function.
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 solution provides a robust and cost-effective ceramic igniter system with enhanced protection against damage, improved manufacturing efficiency, and reduced risk of electrical shock, suitable for high-temperature applications in various fuel ignition scenarios.
Implementation Method 1
a highly resistive 'hot zone' at the igniter tip with one or more conductive 'cold zones' providing to the hot zone from the opposing igniter end
Data Source
AI summary
New igniter systems are provided that comprise a ceramic igniter element and an affixed encasing shield element. The shield element may be engaged or affixed to the igniter element in a variety of configurations, including by direct attachment to the igniter element or through another structure interposed between the igniter and shield elements. In preferred systems, a proximal end of an igniter element may be engaged in a mounting structure and a shield element that encases the igniter element is affixed to the mounting structure.