Membrane Igniter Structure With Thermal Isolation for Fast Low-Power Ignition
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Solution Overview
Problem
Conventional gas appliance igniters are power-hungry, fragile, slow to reach ignition temperature, and prone to degradation and contamination, with unreliable resistance versus temperature characteristics.
Innovation Solution
A membrane-based ignition device with thermally isolated heating elements and a cavity to reduce power consumption and enhance robustness, featuring microscale resistors and a non-electrically conductive high-temperature material for rapid temperature attainment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional silicon carbide or silicon nitride hot surface igniters are used, then ignition function is achieved, but power consumption is high and time to reach ignition temperature is long
Solution Approach 1:
The heating element is divided into multiple segments or zones along its length, allowing different portions to be heated to different temperatures or at different rates. This segmentation enables more efficient heat distribution and faster overall heating, reducing both power consumption and time to reach ignition temperature.
Solution Approach 2:
The patent modifies the physical and electrical parameters of the heating element, including its geometry, material composition, and electrical resistance characteristics. By optimizing these parameters, the heating element achieves faster heat-up time with reduced power consumption compared to conventional igniters.
2Reliability
If heating elements are exposed to the environment for ignition function, then ignition is achieved, but degradation and contamination occur leading to accelerated failure
Solution Approach 1:
A protective coating or encapsulation layer is introduced as an intermediary between the heating element and the environment. This layer protects the heating element from contamination and degradation while still allowing heat transfer to occur, thereby improving reliability without compromising ignition function.
Solution Approach 2:
The heating element is enclosed in a sealed chamber filled with an inert atmosphere that prevents oxidation and contamination. This protective environment significantly reduces degradation and extends the operational life of the heating element.
3Strength
If conventional igniters are subjected to impacts during cleaning and maintenance, then routine maintenance is performed, but the igniter breaks due to fragility
Solution Approach 1:
The heating element is encased in a flexible or resilient protective shell that can absorb impact forces during cleaning and maintenance operations. This shell protects the fragile heating element from breakage while allowing the igniter to remain accessible for maintenance.
Solution Approach 2:
A protective coating or cushioning layer is applied to the heating element before it is installed in the igniter. This pre-applied protection reduces the element's susceptibility to impact damage during routine cleaning and maintenance activities.
4Loss of time
If high voltage is supplied to heating elements for rapid ignition, then ignition temperature is reached faster, but premature failure of heating elements occurs
Solution Approach 1:
The voltage supplied to the heating element is made dynamic rather than static. The system adjusts the voltage level based on real-time feedback about the heating element's temperature and condition, allowing rapid heating when needed while preventing excessive voltage that would cause premature failure.
Solution Approach 2:
A feedback control system monitors the heating element's temperature and adjusts the supplied voltage accordingly. This feedback mechanism enables the system to achieve rapid ignition when required while automatically reducing voltage to prevent premature failure, optimizing both speed and reliability.
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 significantly reduces power and voltage requirements, achieves rapid ignition, and enhances reliability by minimizing exposure to environmental degradation, resulting in a more robust and efficient ignition process.
Implementation Method 1
patterning a plurality of resistors on a membrane to form heating elements
Implementation Method 2
thermally isolating the heating elements from an external environment via a cavity disposed adjacent to the heating elements
Data Source
AI summary
A method of manufacturing an ignition device is provided. The method includes patterning a plurality of resistors on a membrane to form heating elements and thermally isolating the heating elements from an external environment via a cavity disposed adjacent to the heating elements.