Igniter Support Segmentation for Gas Generator Manufacturing
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Solution Overview
Problem
The existing igniter supports for gas generators are complex and expensive to manufacture due to their one-piece metal design, which complicates the electric connection and increases production costs.
Innovation Solution
The igniter support is designed as a two-part assembly, with one part made from metal and the other from plastic, allowing for a simpler and cost-effective manufacturing process. The metal part is used for electrical conductivity and connection to the gas generator housing, while the plastic part reduces weight and manufacturing complexity, with sawtooth profiles ensuring a positive and torsion-resistant coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the igniter support is made as a one-piece complex turned part from metal, then electrical conductivity and structural strength are ensured, but manufacturing complexity and cost increase significantly
Solution Approach 1:
The igniter support is divided into two separate holder elements: a first holder element made from metal for electrical conductivity and a second holder element made from plastic for structural support. These elements are positively coupled to each other, allowing each to be manufactured using simpler, more cost-effective processes while maintaining the required electrical and mechanical properties.
Solution Approach 2:
The igniter support combines metal and plastic materials in a composite structure. The metal first holder element provides electrical conductivity for ground contacts, while the plastic second holder element provides structural support. This composite approach allows optimization of each material for its specific function, reducing overall manufacturing complexity and cost.
2Strength
If the igniter support is made as a one-piece complex turned part from metal, then structural strength is ensured, but manufacturing cost increases due to turning and milling operations
Solution Approach 1:
The igniter support is segmented into two holder elements that can be manufactured separately using simpler processes. The metal first holder element can be produced with fewer complex operations, while the plastic second holder element can be manufactured using injection molding or similar cost-effective methods, thereby reducing overall manufacturing cost while maintaining structural integrity through their positive coupling.
3Reliability
If the igniter support is made entirely from metal, then electrical conductivity is ensured, but weight increases
Solution Approach 1:
The igniter support uses a composite structure where the metal first holder element provides electrical conductivity for ground contacts, while the plastic second holder element provides structural support with lower weight. This composite approach maintains the necessary electrical properties while reducing overall weight compared to an all-metal construction.
Data Source
AI summary
The invention describes an igniter support (22) for an igniter unit (20) of a gas generator (10), comprising a first holder element (30) made from a first material and a second holder element (32) made from a second material different from the first material. The two holder elements (30, 32) can be positively coupled to each other, especially can be at least partially positively nested. Further, a subassembly (16), a gas generator (10) as well as a method for manufacturing a gas generator (10) are described.