Ignition Device Segmented Circuits Volume Reduction
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Solution Overview
Problem
Existing ignition devices for explosive charges face challenges in reducing their construction volume while maintaining high discharge currents and voltages, leading to increased size and production costs.
Innovation Solution
The ignition device is designed with two thin metal layers separated by an electrically insulating plastic layer, featuring a first ignition circuit with an ignition bridge and energy storage devices connected in series, allowing for a compact design that reduces space requirements and production costs without increasing supply voltage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional ignition device designs are used, then the required discharge currents and voltages can be achieved, but the construction volume and production costs increase
Solution Approach 1:
The ignition device is segmented into two separate ignition circuits (first and second ignition circuits) with distinct functions. The first circuit handles the initial ignition bridge vaporization, while the second circuit provides the high-voltage discharge for the load. This segmentation allows each circuit to be optimized independently, reducing overall volume while maintaining performance reliability.
Solution Approach 2:
The patent transitions from a planar layout to a three-dimensional stacked configuration with metal layers arranged in vertical tiers separated by insulating layers. This dimensional change allows compact integration of multiple circuits in a small footprint, achieving volume reduction without compromising the electrical performance required for high discharge currents and voltages.
2Volume of moving object
If the ignition device is compacted, then space requirements are reduced, but manufacturing complexity increases
Solution Approach 1:
The patent employs thin metal layers and thin insulating plastic layers stacked together to form the compact ignition device structure. This thin-film approach enables miniaturization while using standard deposition and lamination manufacturing techniques, keeping production processes relatively simple and costs manageable despite the compact form factor.
Solution Approach 2:
The device uses composite construction with alternating layers of conductive metal materials and insulating plastic materials. This composite structure achieves the required electrical isolation and conductivity in a compact package, and both material types can be manufactured using conventional techniques, balancing compactness with ease of manufacture.
3Power
If special spark gaps are used to maintain high discharge currents, then voltage requirements increase, but the device size increases
Solution Approach 1:
The ignition function is segmented into two separate circuits rather than using a single high-voltage spark gap. The first circuit vaporizes the ignition bridge to initiate the process, while the second circuit delivers the high-current discharge through a different mechanism (squib bridge), eliminating the need for a large special spark gap and reducing overall device size while maintaining required power output.
Solution Approach 2:
The patent replaces the traditional mechanical/electrical spark gap system with a chemical/thermal mechanism using squib bridges that vaporize to create conductive paths. This substitution allows high discharge currents to be achieved without requiring large voltage drops across spark gaps, thereby reducing device dimensions while maintaining power capability.
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 configuration achieves a significant reduction in size, production costs, and enhances long-term stability while maintaining high discharge currents and voltages, eliminating the need for special spark gaps.
Implementation Method 1
The squib bridge is configured to vaporize when the switch is closed
Implementation Method 2
the pressure generated, a part T of the plastic film K is thereby pressed upwards and punched out by the barrel B
Implementation Method 3
an ignition spark ZF is produced at the same time through the opening that part T of the plastic film has left behind
Implementation Method 4
an EFI ignition module that works according to this principle, with a plastic molding ultimately being ignited. An ignition bridge is provided in the ignition module
Data Source
Figure 1a~1b
Figure 1c
Figure 2a~2b
AI summary
The ignition device according to the invention reliably realizes a single transient switching process for high voltages (>1.5 kV) and high currents (>3 kA) in combination with minimal space requirements, maximum environmental resistance and simultaneously low costs by integrating the essential components on a flexible conductor system.