Ignition Resistor Segmentation for Precise Material Placement
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Solution Overview
Problem
Conventional surface mount ignition resistors face challenges in accurately placing ignition material due to the narrow channel design, leading to ignition failure or poor ignition effects.
Innovation Solution
An ignition resistor design featuring an insulation substrate with a filling portion that includes a hole aligning with and exposing the ignition portion, allowing for precise placement of ignition material, along with a conductive layer structure for electrical connection, enhancing the reliability and quality of the ignition process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a narrow channel is designed in the surface mount ignition resistor, then the ignition function is achieved through fusion and spark, but the ignition material cannot be placed accurately leading to ignition failure
Solution Approach 1:
The ignition resistor is divided into distinct functional regions: a body portion containing the narrow channel for spark generation, and a cap portion with a through-hole for ignition material placement. This segmentation allows the narrow channel to maintain its ignition function while the through-hole provides accurate material placement capability.
Solution Approach 2:
The cap portion acts as an intermediary structure that bridges the narrow channel and the external environment. The through-hole in the cap portion serves as a mediator that enables precise ignition material placement without directly interfering with the narrow channel's ignition function, thus resolving the contradiction between maintaining narrow channel integrity and achieving accurate material placement.
2Ease of operation
If the narrow channel is small to achieve ignition function, then spark generation is enabled, but it becomes difficult to place ignition material accurately on the narrow channel
Solution Approach 1:
The solution transitions from a two-dimensional placement problem on the narrow channel surface to a three-dimensional solution by introducing a vertical through-hole in the cap portion. This dimensional change allows ignition material to be placed through the hole from above, bypassing the size constraints of the narrow channel and significantly improving ease of operation.
3Reliability
If ignition material is placed on the narrow channel, then ignition function is achieved, but location deviation occurs resulting in poor ignition effect
Solution Approach 1:
The cap portion with the pre-formed through-hole is prepared in advance as part of the ignition resistor structure. This preliminary preparation of the placement pathway ensures that ignition material can be accurately guided to the intended location, preventing location deviation and ensuring reliable ignition effect.
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
Ensures accurate disposition of ignition material, thereby improving the ignition effect and reliability of the ignition resistor.
Implementation Method 1
A conventional electric ignition device generates arc discharge mainly by applying high voltage between two electrodes to emit spark
Implementation Method 2
a narrow channel of low resistance is designed, such that the narrow channel is fused and sparks when digital voltage passes through the narrow channel in a short time
Data Source
AI summary
An ignition resistor includes an ignition structure, an insulation substrate, a carrying base, and first and second conductor layers. The ignition structure includes an ignition portion, and first and second electrode portions respectively connected to two opposite ends of the ignition portion. The insulation substrate is disposed on the ignition structure and includes a filling portion including a hole exposing the ignition portion and configured to accommodate an ignition material, and a sidewall surrounding the hole. The carrying base is disposed under the ignition structure. The carrying base includes first and second electrodes respectively corresponding to the first and second electrode portions. The first and second electrodes and the ignition structure are located on two opposite sides of the carrying base. The first and second conductive layers electrically connect the first electrode portion and the first electrode, and the second electrode portion and the second electrode respectively.