Liquid Glass Bonding for Boiler Spark Plug Fastening
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Solution Overview
Problem
Existing methods for fastening ignition spark plugs in boilers are prone to mechanical stress, leading to ceramic breakage and inadequate sealing, and require complex assembly processes with multiple materials and testing steps, which are costly and inefficient, especially in complex systems with multiple components.
Innovation Solution
The use of a glass material in a liquid or semi-liquid phase for mechanical and chemical adhesion to fasten and seal the spark plug and inspection window to a supporting plate, which solidifies to provide enhanced mechanical strength and sealing, reducing the risk of ceramic breakage and simplifying the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If fastening rings or resins are used to bind the ceramic insulating body to the metal plate, then the spark plug is fastened to the supporting plate, but the mechanical forces can cause the spark plug to move from its operating position or generate localized pressure peaks that cause the ceramic insulator to be broken
Solution Approach 1:
The patent changes the physical state of the binding material from solid (fastening rings, resins) to liquid (binding composition) during application, allowing it to flow and conform to the ceramic surface without concentrating mechanical stress. The liquid composition penetrates micro-pores and adheres uniformly, then solidifies to provide strong bonding without the localized pressure peaks that cause ceramic breakage in rigid fastening methods.
Solution Approach 2:
The patent replaces mechanical fastening systems (fastening rings requiring compression, riveting) with a chemical-physical bonding system. The binding composition uses adhesion and cohesion forces rather than mechanical compression, eliminating the need for high radial compression forces that deform fastening rings and create stress concentrations on the ceramic body.
2Reliability
If higher tolerances are provided to avoid the risk of breaking, then the risk of ceramic breakage is reduced, but the ring, by being deformed, does not perfectly adhere to the walls failing in its sealing function, or not guaranteeing a suitable fastening
Solution Approach 1:
The patent uses the liquid state of the binding composition to adapt to dimensional variations. The liquid flows to fill gaps and conform to the actual geometry of the ceramic and supporting plate, eliminating the need for tight tolerances. After solidification, it provides both mechanical strength and perfect sealing contact, achieving both reliability and manufacturing precision simultaneously.
Solution Approach 2:
The binding composition is applied in a liquid state that can penetrate into the porous structure of the ceramic insulator. This penetration creates strong mechanical interlocking and chemical adhesion within the ceramic's micro-pores, ensuring perfect adherence and sealing function regardless of dimensional tolerances. The porous absorption of the liquid binder creates a bond that is both strong and密封 (sealing).
3Reliability
If different methods and different steps are used for assembling rod/ceramic body, window/supporting plate, and ceramic body/supporting plate, then each component is fastened securely, but the assembly process becomes very complicated and requires high accuracy
Solution Approach 1:
The patent merges multiple separate fastening operations into a single integrated process. The binding composition is applied once and simultaneously fastens the rod to the ceramic body, the ceramic body to the supporting plate, and seals all interfaces. This single-step chemical-physical bonding process replaces multiple mechanical fastening steps, dramatically simplifying the assembly process while maintaining secure fastening of all components.
Solution Approach 2:
The binding composition serves multiple functions simultaneously: it acts as an adhesive for the rod-ceramic interface, as a sealant for preventing condensate and fume leakage, and as a mechanical fastener providing thrust and torsional resistance. This multi-functional material eliminates the need for separate components for each function, reducing assembly complexity while ensuring reliable fastening.
4Reliability
If known fastening methods are used, then the spark plug is secured to the supporting plate, but additional costs are incurred due to the need of dielectric strength tests, pressure tightness tests and tests for mechanical strength against removal
Solution Approach 1:
The liquid binding composition creates a bond that inherently provides both mechanical strength and electrical insulation. The chemical-physical bonding mechanism produces a unified structure where the binder integrates with both ceramic and metal surfaces, creating a bond that naturally resists mechanical removal forces and maintains dielectric strength, eliminating the need for separate verification tests.
Solution Approach 2:
The binding composition is designed as a simple, cost-effective material that provides sufficient performance without requiring expensive verification testing. The material itself is relatively inexpensive and the application process is simple, making the overall fastening system economical and eliminating the need for costly dielectric strength tests, pressure tightness tests, and mechanical strength tests that are required for traditional fastening methods.
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 approach significantly reduces the risk of ceramic breakage, enhances mechanical strength and sealing, and simplifies the assembly process, saving time and costs by eliminating the need for multiple materials and testing steps, while maintaining stability across thermal cycles.
Implementation Method 1
a glass material which is brought in the liquid or semi-liquid phase beforehand such to adhere mechanically and/or by chemical/physical adhesion to the outer surface of the tubular body of the spark plug and to the inner surface of the insertion hole
Implementation Method 2
a glass material which is brought in the liquid or semi-liquid phase beforehand such to adhere mechanically and/or by chemical/physical adhesion to the outer surface of the tubular body of the spark plug
Implementation Method 3
a glass material which is brought in the liquid or semi-liquid phase beforehand such to adhere mechanically and/or by chemical/physical adhesion to the outer surface of the tubular body of the spark plug and to the inner surface of the insertion hole and subsequently it is brought to the solid phase
Data Source
Figure 1a~1b
Figure 2
Figure 3~4
AI summary
System for fastening ignition spark plugs (2) of boilers or the like, comprising a supporting plate (1), which supporting plate (1) has at least one insertion hole (11) intended for the insertion of a spark plug (2) and/or of an inspection window (6), which spark plug (2) comprises an outer ceramic tubular body (21), inside which a detection and/or ignition rod (22) is housed which projects at least from one head end of said ceramic tubular body (21). Said insertion hole (11) having such dimensions that said spark plug (2), in the inserted condition, forms a gap region between the outer surface of the tubular body (21) of the spark plug (2) and the inner surface of the insertion hole (11), at least in said gap region there being provided means (4) for fastening and sealing said spark plug (2) to said supporting plate (1). Said fastening and sealing means (4) are composed of glass material (4) which is brought in the liquid or semi-liquid phase beforehand such to adhere mechanically and/or by chemical/physical adhesion to the outer surface of said tubular body (21) of the spark plug (2) and to the inner surface of said insertion hole (11) and subsequently it is brought to the solid phase.