Plasma Torch Ignition Wand for Safe Contamination-Free Starting
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Solution Overview
Problem
Existing methods for starting a plasma in plasma torches are manual, hazardous, and lead to contamination, as they require an operator to introduce a material into the torch to spark ignition.
Innovation Solution
A device comprising an elongate, hollow wand member with apertures and an elongate wire member positioned within the wand, which is used to automatically start a plasma by being placed in operable communication with a power source, such as a microwave generator, within the plasma torch.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual material introduction is used for plasma ignition, then plasma can be started, but operator safety is compromised and material contamination occurs
Solution Approach 1:
The patent introduces a remote plasma ignition system where a dielectric rod with metal wire extends into the plasma torch through a sealed feedthrough. This intermediary structure allows electrical connection to initiate plasma without requiring manual material insertion, thereby maintaining operator safety while preventing contamination of the plasma environment.
Solution Approach 2:
The manual mechanical process of inserting material into the plasma torch is replaced with an automated electrical ignition system. The dielectric rod with embedded metal wire provides a controlled electrical pathway to initiate plasma remotely, substituting the hazardous mechanical insertion with a safe electrical activation method.
2Object-affected harmful factors
If automatic plasma starting is implemented, then operator safety improves, but device complexity increases
Solution Approach 1:
The dielectric rod serves multiple functions: it provides electrical insulation, supports the metal wire for plasma ignition, and maintains a sealed connection to the plasma chamber. This multi-functional design achieves automatic plasma starting without requiring separate complex mechanisms for each function, thereby limiting the increase in device complexity.
3Reliability
If material is introduced for plasma spark, then plasma ignition is achieved, but process contamination occurs
Solution Approach 1:
The sealed feedthrough with dielectric rod acts as an intermediary that isolates the external environment from the plasma chamber interior. This allows electrical ignition to occur without introducing external materials that could contaminate the process, maintaining both ignition reliability and process purity.
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 safe and contamination-free automatic ignition of plasma, allowing for stable and continuous operation of the plasma torch, thereby improving operational safety and reducing material contamination.
Implementation Method 1
the power source comprises a microwave generator, and wherein a length of the wire member comprises 1⁄4 of a wavelength or longer of a microwave generated by the microwave generator
Data Source
AI summary
Some embodiments herein are directed to devices and methods for automatically starting a plasma utilizing a wand. In some embodiments, the wand may be used to start a plasma in a plasma torch such as, for example, a microwave plasma torch or an induction plasma torch, as discussed below. The wand may comprise an elongate, hollow wand member comprising a closed distal end, a proximal end, and one or more apertures extending from a hollow interior of the wand member to an exterior surface of the wand member; and an elongate wire member positioned within the hollow interior of the wand member and extending along at least a portion of a length of the wand member, wherein the wire member is configured to be placed in operable communication through the aperture with a power source, such that the power source can be activated to in turn start the plasma within the plasma torch. The plasma torches discussed herein may be used in various applications including, for example, high volume synthesis of advanced materials such as nano-materials, micro-powders, coatings, alloy compositions for additive manufacturing.