Gas Discharge Lamp Ignition Module with Integrated Ferrite and Ceramic Insulation
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Solution Overview
Problem
Existing gas discharge lamp ignition modules face challenges in achieving compact, reliable, and efficient designs that meet high electric strength and thermal management requirements, particularly in automotive applications, where environmental factors like temperature, vibration, and electromagnetic interference are significant.
Innovation Solution
A driving module with a high-temperature resistant plastic carrier that integrates an ignition transformer and a lamp socket with an embedded conducting track, along with additional electrical components, to ensure reliable high-voltage connections and efficient thermal management, while using ferrite materials for improved magnetic flux and shielding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the dimensions of functional groups (ballast and ignition unit) are reduced to achieve compact design, then the size of the ignition transformer must be minimized, but this makes it difficult to generate the necessary high ignition voltage (approx. 30 kV) while maintaining the required electric strength and insulation tracks
Solution Approach 1:
The patent employs a composite structure combining a plastic carrier with ceramic insulation elements. The ceramic material provides superior electrical insulation properties and high voltage resistance, while the plastic carrier offers mechanical support and compact integration. This composite approach enables the ignition transformer to achieve the necessary 30 kV ignition voltage generation within a reduced volume while maintaining adequate electric strength and insulation tracks.
2Reliability
If sufficiently large insulation tracks are provided in the ignition transformer area to guarantee reliable functioning under demanding ambient conditions (temperature range, environmental influences, vibration), then the overall size of the ignition module increases, but compact dimensions are necessary
Solution Approach 1:
The patent implements local quality enhancement by concentrating insulation resources at critical high-voltage points. Ceramic insulation elements are strategically positioned around the ignition transformer's high-voltage connections and secondary winding areas, providing localized high-voltage resistance where most needed. This allows the insulation tracks to be sufficiently large for reliability at critical points while keeping the overall module size compact, as non-critical areas use standard insulation.
3Reliability
If electronic components and ignition transformer are arranged on component part carriers with suitable plastic materials to provide insulation tracks and mechanical reliability, then the assembly complexity increases and accessibility of critical areas for welding/soldering is reduced, but reliable electric connections must be established
Solution Approach 1:
The patent merges the insulation function and mechanical support function into a single integrated plastic carrier structure. The carrier is molded with built-in insulation tracks and recesses that accommodate the ignition transformer and electronic components. Critical areas for welding and soldering are designed with accessible openings or recesses in the carrier that maintain insulation while allowing tool access. This integration reduces assembly complexity compared to separate insulation components and simplifies the manufacturing process.
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
The solution enables a compact, reliable, and efficient gas discharge lamp ignition system that withstands demanding automotive conditions, with improved electric strength, thermal management, and reduced material costs, suitable for use in vehicle headlights and other mobile applications.
Implementation Method 1
The necessary high ignition voltage is normally generated by means of an ignition transformer, which has supplied thereto a comparatively low primary voltage of approximately a few hundred volts from an associated electronic ballast and which then transforms this primary voltage to the high ignition voltage.
Implementation Method 2
using ferrite materials for improved magnetic flux and shielding
Data Source
AI summary
A driving module for a gas discharge lamp, in particular for headlights in vehicles, comprises a suitable lamp socket, a carrier for electrical components, and an ignition transformer, wherein the component part carrier is populated at least with electrical components of an ignition unit and moreover is designed for accommodating further electrical components that are required for a self-sustaining operation of the driving module. In addition, the lamp socket is made of a high temperature resistant plastic material and has an integrated high-voltage conducting track.