Claims
- 1. A ceramic igniter element comprising one or more electrical connections to the igniter element, the electrical connections having thereon a hermetic sealant material.
- 2. The igniter element of claim 1 wherein the hermetic sealant composition comprises a cermoplastic material.
- 3. The igniter element of claim 1 or 2 wherein the igniter comprises an electrically conductive portion; one or more electrical connections affixed to the conductive portion; and a hot zone in connection with and having greater resisitivity than the conductive portion.
- 4. The igniter element of any one of claims 1 through 3 wherein the hermetic sealant material is stable to exposure to a temperature of about 400° C. for at least five minutes.
- 5. The igniter element of any one of claims 1 through 4 wherein the hermetic sealant material is a substantially inorganic composition.
- 6. The igniter element of any one of claims 1 through 5 wherein the hermetic sealant material comprises Si.
- 7. The igniter element of any one of claims 1 through 6 wherein the hermetic sealant material comprises mica.
- 8. The igniter element of any one of claims 1 through 7 wherein a lead frame is attached to each of the one or more electrical connections.
- 9. The igniter element of claim 8 wherein the hermetic sealant material covers the one or more connections and lead frames thereof.
- 10. The igniter element of any one of claims 1 through 9 wherein the hermetic sealant material is applied by insert molding.
- 11. The igniter element of any one of claims 1 through 10 wherein the hermetic sealant material coating has a thickness of less than about 3 mm.
- 12. The igniter element of any one of claims 1 through 10 wherein wherein the hermetic sealant material coating has a thickness of less than about 2 mm.
- 13. The igniter element of any one of claims 1 through 12 wherein the hermetic sealant material is overcoated with a sealant composition distinct from the hermetic material.
- 14. The igniter element of any one of claims 1 through 12 wherein the hermetic sealant material is coated over a sealant composition distinct from the hermetic material.
- 15. The igniter element of claim 13 or 14 wherein the distinct sealant composition has a moisture and/or oxygen permeability greater than that of the hermetic sealant material.
- 16. The igniter element of any one of claims 13 through 15 wherein the distinct sealant composition is resistant to degradation upon exposure to a temperature of at least about 400° C. for more than 30 seconds.
- 17. The igniter element of any one of claims 13 through 16 wherein the distinct sealant composition is a potting cement.
- 18. The igniter element of any one of claims 13 through 17 wherein the distinct sealant composition comprises an epoxy material.
- 19. The igniter element of claim 3 wherein an electrically non-conductive heat sink material contacts the hot zone.
- 20. The igniter element of claim 19 wherein the heat sink material is disposed between conductive portions.
- 21. The igniter element of claim 20 wherein each of the electrically conductive portions extends in the same direction from the hot zone to define a pair of legs, and the electrically non-conductive heat sink material is disposed between the legs.
- 22. The igniter element of claim 3 wherein the ratio of the room temperature resistivity of the hot zone is at least about 1.5 times the room temperature resistivity of the cold zone portions.
- 23. An igniter device comprising an igniter of any one of claims 1 through 22 and a distinct operational element.
- 24. The igniter device of claim 23 wherein the distinct element is a sensor element.
- 25. The igniter device of claim 23 or 24 wherein an integral structure comprises the igniter and distinct element.
- 26. The igniter device of claim 25 wherein the integral structure is formed predoiminately from a hermetic sealant composition.
- 27. An igniter device comprising an igniter element of any one of claims 1 through 22 that is adapted to mate with a sizing element.
- 28. The igniter device of claim 27 wherein the igniter element is threaded, bracketed or grooved for mating with the sizing element.
- 29. The igniter device of claim 27 or 28 the sizing element is an oval block element.
- 30. An igniter device comprising an igniter element of any one of claims 1 through 22 that is adapted to receive an electrical connection.
- 31. The igniter device of claim 30 wherein the igniter comprises a housing that releasably secures the electrical connection.
- 32. The igniter device of claim 31 wherein the housing is formed at least in part from a hermetic sealant material.
- 33. A method of igniting gaseous fuel, comprising:
applying an electric current across an igniter of any one of claims 1 through 32.
- 34. A method for forming a ceramic igniter, comprising:
providing a sintered ceramic igniter element comprising one or more electrical connections to the igniter element; applying a hermetic sealant material to the igniter element.
- 35. The method of claim 34 wherein the hermetic sealant material is a cermoplastic material.
- 36. The method of claim 34 or 35 wherein the hermetic sealant material covers the electrical connections.
- 37. The method of any one of claims 34 through 36 wherein the hermetic sealant material is applied by insert molding.
- 38. The method of any one of claims 34 through 37 wherein the hermetic sealant material is applied to the igniter without use of a separate housing block.
- 39. The method of any one of claims 34 through 38 wherein the igniter comprises an electrically conductive portion; one or more electrical connections affixed to the conductive portion; and a hot zone in connection with and having greater resisitivity than the conductive portion.
- 40. The method of any one of claims 34 through 39 wherein the hermetic sealant material is stable to exposure to a temperature of about 800° C. for at least five minutes.
- 41. The method of any one of claims 34 through 40 wherein the hermetic sealant material is a substantially inorganic composition.
- 42. The method of any one of claims 34 through 41 wherein the hermetic sealant material comprises Si.
- 43. The method of any one of claims 34 through 42 wherein the hermetic sealant material comprises mica.
- 44. The method of any one of claims 34 through 43 wherein a lead frame is attached to each of the one or more electrical connections.
- 45. The method of claim 44 wherein the hermetic sealant material covers the one or more connections and lead frames thereof.
- 46. The method of any one of claims 34 through 45 wherein the hermetic sealant material is applied by injection molding.
- 47. The method of any one of claims 34 through 45 wherein the hermetic sealant material is applied by compression molding.
- 48. The method of any one of claims 34 through 45 wherein the hermetic sealant material is applied by transfer molding.
- 49. The method of any one of claims 34 through 48 wherein the hermetic sealant material composition coating has a thickness of less than about 3 mm.
Parent Case Info
[0001] The present application claims the benefit of U.S. provisional application No. 60/313,113, filed Aug. 18, 2001, which is incorporated herein by reference in its entirety.
Provisional Applications (1)
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Number |
Date |
Country |
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60313113 |
Aug 2001 |
US |