Programmable Exothermic Reaction Ignition for Remote Mold Welding
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Solution Overview
Problem
Current exothermic reaction molds pose hazards due to the need for users to be in close proximity during ignition, and remote ignition systems have limited reach, making it difficult to safely ignite exothermic reactions, especially in inaccessible locations.
Innovation Solution
A programmable exothermic reaction controller unit with input/output control circuitry, processing circuitry for user-programmable parameters, and an output connector for connecting to an ignitor cable, allowing users to set a time delay and safely initiate the exothermic reaction from a distance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a disposable ignitor with a short cable is used, then the ignition system is simple and reliable, but the user cannot be at a safe distance from the exothermic reaction
Solution Approach 1:
The patent transitions from a one-dimensional constraint (cable length) to a three-dimensional solution by using wireless communication (radio frequency signals) to transmit ignition commands. This eliminates the physical cable constraint entirely, allowing the user to be at any safe distance from the exothermic reaction while maintaining reliable communication with the ignitor.
Solution Approach 2:
The patent replaces the mechanical/electrical connection (physical cable) with an electromagnetic field-based communication system (wireless radio frequency signals). This substitution eliminates the need for a physical cable while maintaining the ability to transmit ignition commands, thereby resolving the contradiction between cable length and user safety distance.
2Object-affected harmful factors
If a longer cable is used to increase safe distance, then user safety improves, but the system complexity and signal reliability deteriorate
Solution Approach 1:
The patent replaces the mechanical cable system with an electronic wireless communication system using standard radio frequency protocols. This substitution reduces overall system complexity by eliminating physical cable management while leveraging well-established wireless technology for reliable signal transmission over distance.
Solution Approach 2:
The patent employs a microcontroller unit that can perform multiple functions: receiving wireless commands, controlling the ignitor, and providing user feedback through display and buttons. This multi-functional approach consolidates what would otherwise require separate components, reducing system complexity while enabling remote operation.
3Adaptability or versatility
If a longer cable is used to reach inaccessible locations, then accessibility improves, but signal attenuation and reliability worsen
Solution Approach 1:
The patent replaces the electrical signal transmission through a long cable with wireless radio frequency signal transmission. This eliminates signal attenuation issues associated with long cables, as wireless signals can be transmitted over distances without degradation, maintaining ignition reliability while reaching inaccessible locations.
Solution Approach 2:
The patent moves from constrained linear transmission (cable) to omnidirectional wireless transmission, allowing the ignition signal to reach the mold from any direction and distance within the wireless communication range, thereby improving adaptability to inaccessible locations without compromising reliability.
4Device complexity
If manual ignition with ignition powder is used, then no remote control system is needed, but the user must be in close proximity to the reaction creating safety hazards
Solution Approach 1:
The patent replaces the manual chemical ignition process (ignition powder requiring direct handling) with an electronic ignition system controlled via wireless communication. This substitution allows the user to initiate the exothermic reaction from a safe distance, eliminating direct exposure to sparks, flames and hot gasses while maintaining a relatively simple ignition mechanism.
Solution Approach 2:
The patent introduces a wireless communication system as an intermediary between the user and the ignition process. This intermediary allows the user to remotely control the ignitor without being physically present at the reaction site, thereby eliminating safety hazards while keeping the ignition mechanism itself simple and reliable.
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
Enables safe and controlled ignition of exothermic reactions at various distances, reducing user exposure to hazards and allowing for welding in hard-to-reach locations by providing a programmable and user-friendly remote ignition system.
Implementation Method 1
The distal end 27 of ignitor 24 includes the ignition material which may include a strip of wire of two different metallic elements in contact with each other. For example, the metallic elements may be palladium and aluminum.
Implementation Method 2
When the exothermic powder 16 ignites, an exothermic reaction is created in the crucible 12. The exothermic reaction liquefies the exothermic powder 16 and the disc of material 40 which then flow down from the crucible into the mold portion 14 holding the parts to be joined.
Data Source
AI summary
A programmable exothermic reaction controller includes input/output control circuitry for inputting and outputting information to/from the controller, processing circuitry including user programmable parameters, wherein the parameters are programmable using the input/output control circuitry and an output connector connectable to an ignitor cable.