Ignition Switch Assembly Uniform Contact Design
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Solution Overview
Problem
Existing ignition switches for gas appliances face issues with inaccurate ignition due to manufacturing variations, contamination, and excessive torque, leading to reduced longevity and increased production costs, as well as vulnerability to liquid spills.
Innovation Solution
The ignition switch assembly features uniformly sized and shaped contacts that are angled and include a flexible beam, secured within a cover, with a camming protuberance to ensure accurate engagement and disengagement, and an open drain path to prevent liquid contact, reducing manufacturing complexity and improving durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If contacts are bent at the tip to create edge-to-surface contact for cleaning contamination, then contamination cleaning is improved, but manufacturing precision deteriorates due to variation in contact engagement
Solution Approach 1:
The patent converts the harmful effect of contamination into a beneficial self-cleaning mechanism by designing the contact geometry so that the natural engagement motion creates a scraping action that removes contamination from the contact surfaces, eliminating the need for separate cleaning mechanisms
Solution Approach 2:
The patent changes the geometric parameters of the contacts by angling them relative to each other instead of keeping them parallel, which fundamentally alters the engagement motion from a sliding action to a scraping action that effectively removes contamination while maintaining consistent electrical connection
2Reliability
If ignition switch exerts high torque during engagement, then reliable contact engagement is improved, but ease of operation deteriorates due to undesirable feel when turning control knob
Solution Approach 1:
The patent introduces dynamic elements to the contact engagement mechanism, allowing the contacts to flex and the hub to rotate through a controlled range of motion, which distributes the engagement force over time and reduces peak torque requirements while maintaining reliable contact
Solution Approach 2:
The patent adds a rotational dimension to the engagement mechanism through the hub, transforming a linear push engagement into a rotational engagement that provides mechanical advantage and reduces the force required at the control knob while ensuring reliable contact engagement
3Ease of manufacture
If contacts are mounted parallel to each other, then ease of manufacture is improved, but reliability deteriorates due to inaccurate ignition from contamination and oxidation
Solution Approach 1:
The patent introduces asymmetry in the contact arrangement by angling the contacts relative to each other rather than mounting them parallel, which creates a scraping action during engagement that removes contamination and oxidation, thereby improving ignition reliability while maintaining manufacturing simplicity
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 design enhances ignition accuracy, reduces manufacturing costs, and increases the longevity of the ignition switches while preventing liquid-induced failures, providing a more reliable and efficient ignition mechanism.
Implementation Method 1
The hub may include a camming protuberance configured to urge the portion of the first ignition contact into the second ignition contact
Implementation Method 2
The cover may also include an upstanding rim surrounding a portion of the hub. The upstanding rim is configured to direct liquid away from the hub
Data Source
AI summary
An ignition switch assembly is configured to be operatively connected to a gas valve. The ignition switch assembly may include a first ignition contact and a second ignition contact. The first and second ignition contacts may be sized and shaped the same. A hub may be configured to be rotated within the ignition switch assembly. A rotation of the hub in a first direction causes a portion of the first ignition contact to engage the second ignition contact. Further rotation of the hub in the first direction or rotation of the hub in a second direction that is opposite from the first direction causes the portion of the first ignition contact to disengage from the second ignition contact.