Igniter Support Segmentation for Gas Generator Manufacturing
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Solution Overview
Problem
The manufacturing of igniter supports for gas generators is complex and expensive due to the use of single-piece complex turned metal parts, which complicates the assembly and increases 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 by using chipless forming and injection molding, respectively, and enabling a positive coupling that aligns and secures the components without the need for initial interconnection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a one-piece complex turned metal part is used for the igniter support, then the structural integrity and electrical conductivity are ensured, but the manufacturing complexity and cost increase significantly
Solution Approach 1:
The igniter support is divided into two separate holder elements (first holder element and second holder element) that can be manufactured independently and then assembled together. This segmentation allows each element to be produced using simpler, more cost-effective processes while maintaining the overall structural integrity of the igniter support assembly.
2Reliability
If a one-piece complex turned metal part is used for the igniter support, then the structural integrity is ensured, but the manufacturing cost increases due to turning and milling operations
Solution Approach 1:
The igniter support is divided into two separate holder elements (first holder element and second holder element) that can be manufactured independently and then assembled together. This segmentation allows each element to be produced using simpler, more cost-effective processes while maintaining the overall structural integrity of the igniter support assembly.
3Ease of manufacture
If a two-part assembly with different materials is used, then the manufacturing cost and complexity are reduced, but the alignment and coupling precision must be ensured
Solution Approach 1:
The first holder element and second holder element are designed to be nested within each other, with the second holder element positioned inside or alongside the first holder element. This nesting arrangement provides inherent alignment guidance and ensures precise relative positioning of the two elements during assembly, eliminating the need for complex alignment procedures.
4Weight of moving object
If a two-part assembly with different materials is used, then the weight is reduced, but the electrical conductivity may be compromised
Solution Approach 1:
The igniter support utilizes a composite structure combining two different materials (first material and second material) in the two holder elements. This composite material approach allows optimization of each element's material properties - one material can provide electrical conductivity where needed while the other provides weight reduction, achieving both goals simultaneously through material selection and strategic placement.
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. Both holder elements (30, 32) can be positively coupled to each other. Further, a subassembly (16), a gas generator (10) and a method for manufacturing a gas generator (10) are described.