WO2015003078A1

WO2015003078A1 - Automatic ignition module

Info

Publication number: WO2015003078A1
Application number: PCT/US2014/045290
Authority: WO
Inventors: Flavio Luis CARTAPATTI
Original assignee: Illinois Tool Works
Priority date: 2013-07-04
Filing date: 2014-07-02
Publication date: 2015-01-08
Also published as: BR102013017223A2

Abstract

The present invention relates to an automatic ignition module for actuating gas burners, preferably used in gas cooking appliances or heating systems in general, comprising 5 technical and functional innovations especially developed to promote simplification and a reduction in costs in the processes of manufacture and assembly of these components, and also to make it possible to increase levels of safety and quality in connection with the protection and precision nature of the electrical and electronic components provided in this type of item. More particularly, the automatic ignition module 10 according to the present invention is constituted by a base body (10) that has at least two interlinked cavities (11, 11') for accommodating its electrical and electronic components and it further comprises a protective cover (20) formed by at least two regions (21, 21') for covering, respectively, the two cavities (11, 11'), the region (21) being partially open and provided with capsules (22) for accommodating the high-tension terminals (T), and said 15 region (21') is closed to substantially cover the cavity (11') and the board (PCB).

Description

AUTOMATIC IGNITION MODULE

Field of the invention

The present invention relates to a device for actuating burners used in cooking appliances and heating equipment in general that are normally supplied with a source of fuel and need sparks/flashes in order to promote actuation.

More particularly, the present invention relates to an automatic ignition module for actuating gas burners, comprising technical and functional innovations especially developed to promote simplification and a reduction in costs in the processes of manufacture and assembly of these components, and also to make it possible to increase the levels of safety and quality in connection with the protection and precision nature of the electrical and electronic components provided in this type of item.

Bases of the invention

According to the prior art, practically all cooking appliances and heating equipment nowadays comprise a component known as an ignition module, the purpose of which is to accommodate electrical and electronic elements responsible for generating sparks flashes close to the burners and consequently to light the flames in order for the equipment to function.

In this context, as is familiar to persons skilled in the art, these ignition modules are constituted by a printed circuit board (PCB) on which a number of electrical and electronic components and elements are arranged, such as resistors, capacitors, diodes and SIDACs. These components often require a particular degree of care in terms of handling and installation, but principally by virtue of the dimensions of these components, which are small and fragile.

Furthermore, said ignition modules are composed of energizing coils responsible for generating energy and consequently providing the sparks and flashes in the vicinity of the burner. These coils are arranged inside the structural body of the ignition module and are encased in a resin, the purpose of which is to protect the coils against moisture and to prevent high-tension leakage between them.

In figures 1 A and 1 B it is possible to see a model known in the prior art of an ignition module for cooking equipment in general, said model being formed by a structural body 1 that forms a receptacle 2 where the printed circuit board (PCB), the energizing coils (B) and the respective high-tension electrical terminals (T) are accommodated.

In accordance with the models known in the prior art, it is noted that said receptacle 2 is responsible for accommodating all the electrical and electronic components of the ignition module. Furthermore, as may be seen in figures 1A and 1B, said high-tension electrical terminals (T) are arranged on the side opposite the open side of the body 1 , where said electrical and electronic components are accommodated and installed. As stated, after proper positioning and installation of the electrical and electronic components inside the receptacle 2, resin, which is usually epoxy- or polyurethane-based, with or without mineral filler, is applied and completely fills said receptacle, covering literally all the components installed therein. In accordance with the ignition module models that are known in the prior art, said high-tension terminals (T) are arranged, normally, in the lower portion of the body 1 , and each one of them is positioned within a respective capsule (C).

As must be appreciated by persons skilled in the art, the positioning of said high- tension terminals (T) together with their corresponding capsule (C) requires a degree of precision and adjustment so as to eliminate risks of the resin escaping via any space or clearance between the high-tension terminal (T) and the body 1. This is because, as it is possible to see from figures 1A and 1B, if said resin is spilled and fills the receptacle 2, owing to the action of gravity and the low viscosity of the resin the latter is able easily to run through small voids or clearances precisely where there is contact between the terminal (T) and the body 1 , this location normally being a small slot of dimensions corresponding to the size of the terminal (T). Thus, should this small slot be larger than that planned at the design stage, there is a risk that the resin will be able to escape during the curing stage.

Thus, although they have worked up to the present time, it can be seen that these ignition module models could be improved, particularly in terms of the process for their manufacture and assembly, and principally in terms of the costs of raw material, simplification and precision in the arrangement of the high-tension electrical terminals (T) together with the structural body of the ignition module.

One specific point of these prior-art ignition modules that could be improved is connected with the amount of resin used to fully cover the open side of the body 1 after due positioning and installation of all the electrical and electronic components inside the receptacle 2. This is because this excess consumption of resin represents a considerable cost in the production of these ignition modules, and may be as much as almost 10% of the total cost. It should be pointed out that, with possible filling of only part of the ignition module with said resin, such as the region where the printed circuit board (PCB) is installed, it is possible to obtain a degree of economy of material, but there is an obvious fragility in terms of the absence of protection against moisture.

A further point that could be improved relates to the risks of said resin escaping via the contact regions of the high-tension electrical terminals (T). This is because, as stated previously, during the manufacturing process these modules are maintained in a standby location for approximately twenty-four hours in order for the resin to cure and, owing to positioning and the action of gravity, there is a risk that the resin will flow and escape from the receptacle via any clearances or spaces in the location where said terminals (T) are arranged, i.e. there is a risk of there being resin inside the capsules (C), which may compromise proper functioning of these ignition modules.

Also known in the prior art is an automatic ignition module with high-tension terminals positioned on the same side as that where the resin is poured and, thus, it has been possible to reduce the risks of resin escaping during the curing stage. However, for this type of embodiment, it has been necessary to develop and to apply an individual component in order to form each capsule of said high-tension terminals (T), i.e., for each high-tension terminal, the manufacturer needed individually to align and to position a capsule, which has a direct adverse effect on ignition-module production lines.

Thus, on the basis of the aforesaid, it may be seen that the ignition modules commonly used to actuate ovens, stoves, gas burners and boilers have a technical and functional configuration that could be improved, principally in terms of a simplification of production lines and also a reduction in costs of raw material and principally improvement of levels of precision and safety when arranging and positioning the high-tension electrical terminals.

Objectives of the invention

It is therefore an objective of the present invention to provide an ignition module for use in cooking equipment, gas heaters and boilers, comprising technical and functional characteristics especially developed in order to improve and, optionally, correct certain limitations in ignition devices known in the prior art.

More preferably, the objective of the present invention is to propose an ignition module for actuating cooking equipment and heating systems in general that is capable of considerably simplifying the processes of manufacture and assembly of these devices, but principally reducing expenditure in terms of raw material.

In addition, a further objective of the present invention is to provide an ignition module used in cooking equipment and heating systems in general that has technical aspects capable of eliminating risks of leakage deriving from possible poor positioning of the high-tension terminals together with the structural body of the module. Thus, it is likewise an objective of the ignition module that is the subject of the present invention to provide means that eliminate the undesirable drawbacks and risks of contamination of resin over the exposed portions of the terminals or inside the capsules protecting the terminals.

In sum, and more objectively, the present invention aims to provide an ignition module for cooking equipment and heating systems in general comprising a protective cover responsible for providing benefits relating to the process of manufacture, such as simplification of assembly lines and the costs involved, and also technical and functional advantages connected with protection and safety in the positioning and arrangement of the high-tension terminals. Summary of the invention

Thus, with a view to achieving the abovementioned objectives and technical effects, the present invention relates to an automatic ignition module that is formed from at least two interlinked cavities, the first cavity being designed to accommodate the high-tension electrical terminals connected to the energizing coils and the other cavity being intended for the installation of the printed circuit board with its electrical and electronic components. The ignition module according to the present invention additionally comprises a protective cover formed by at least two regions for covering, respectively, said cavities, the first region being partially open and provided with capsules for suitable positioning and accommodation of the high-tension terminals and the second being closed to substantially cover the cavity and, preferably, the board with the electrical and electronic components.

According to a preferred embodiment of the present invention, the ignition module comprises, in said first region of the protective cover, a portion, particularly over the cavity accommodating the terminals and the coils, that is partially open, forming at least one opening for the introduction of resin.

In addition, according to a further embodiment of the present invention, said capsules for accommodating the terminals project downward, in the direction toward the inside of the first cavity of the base body, and said capsules are provided with at least one slot through which said high-tension terminal is passed.

Another preferably advantageous embodiment of the present invention involves said high-tension terminals being arranged so as to fit tightly with said slots provided at the free ends of said capsules.

Moreover, according to the present invention, said base body of the automatic ignition module comprises a peripheral wall with an edge constituted by a difference in level that engages with a difference in level of corresponding format and position in said protective cover. This configuration is preferably applied in the region where the printed circuit board (PCB) is located, and it has the principal purpose of protecting said board against moisture during use of the cooking equipment and heating systems.

According to possible embodiments of the present invention, the base body and the protective cover are provided with means for promoting the fastening and locking together of the base body and protective cover, there preferably being tabs with slots that interact with strategically positioned projections for guaranteeing locking between the components.

Also, according to a further embodiment of the invention, said region of the protective cover that covers said set of coils comprises an inner edge that is lowered in relation to the upper edge of the capsules, assuring that there will be no overflow of resins to the inside of the capsules, but it principally promotes a means for assisting the anchoring and fastening of the protective cover by means of the interaction with the resin on these edges. Brief description of the drawings

The characteristics, advantages and technical effects of the present invention, as setforth above, will be better understood by a person skilled in the art on the basis of the following detailed description, that is given merely by way of non-limiting illustration, of preferred embodiments, and with reference to the appended schematic figures, in which figure 1A shows a perspective view of a prior-art ignition module without the resin, making it possible to identify the electrical and electronic components inside the receptacle; figure 1B shows a perspective view of the prior-art ignition module illustrated in figure 1A, from the side opposite the receptacle for accommodating the electrical and electronic components;

figure 2 shows a perspective view of the base body of the ignition module;

figure 3 shows a view similar to that illustrated in figure 2, but showing all the electrical and electronic components of the ignition module according to the present invention;

figure 4 shows an upper perspective view of the protective cover of the ignition module that is the subject of the present invention;

figure 5 shows a lower perspective view of the protective cover of the ignition module that is the subject of the present invention;

figure 6 shows an upper perspective view of the ignition module of the present invention, in the assembled state but without the resin;

figure 7 shows a view similar to that of figure 6, but said ignition module is in the finished state, i.e. with said resin applied over the predetermined region;

figure 8 shows a view in longitudinal section of the automatic ignition module according to the present invention and in accordance with the indication A-A of figure 6; figure 9 shows a view in cross section of the automatic ignition module according to the present invention and in accordance with the indication B-B of figure 6;

figure 10 shows a partial view, in section, of the automatic ignition module that is the subject of the present invention; and

figure 11 shows a further partial view, in section, of the automatic ignition module according to the present invention.

Detailed description of the invention

In accordance with the abovementioned schematic figures, a number of preferred and possible illustrative embodiments of the present invention will be described in more detail below, but it should be clarified that this is a merely non-limiting illustrative description, since the present ignition module for cooking equipment and heating systems in general may comprise different details and structural and dimensional aspects without thereby departing from the scope of protection thereof.

In addition, it is pointed out that certain references indicating the characteristics of the present invention will not be fully reproduced in all the figures mentioned above, given that the reproduction of all the references in all the figures could adversely affect the interpretation and proper definition of the scope of protection in question.

In accordance with figures 2 to 7, it may be seen that the automatic ignition module that is the subject of the present invention comprises a base body 10 formed by at least two cavities 11 , 11' that are interlinked in some way, within which are arranged, respectively, the high-tension electrical terminals (T) interconnected with the energizing coils (B) and the printed circuit board (PCB) with its electrical and electronic components.

Said ignition module according to the present invention further comprises a protective cover 20 formed by at least two regions 21 , 21' for covering the corresponding at least two cavities 11 , 11', the region 21 being partially open and provided with capsules 22 for accommodating the high-tension terminals (T), and said region 21' being closed to substantially cover the cavity 11', promoting adequate protection of the board (PCB).

According to a preferred embodiment of the present invention, said region 21 of the protective cover 20 is partially open, forming an opening for the introduction of the resin (R) inside the cavity 11 after actual assembly and installation of all the components of the ignition module.

Furthermore, as may be seen, said capsules 22 project downward and such that their lower end is provided with merely one slot 23 through which the high-tension terminal (T) passes. As may be appreciated by persons skilled in the art, after assembly and coupling of said protective cover 20 on the base body 10, said terminals are duly positioned inside their respective capsule 22 and, owing to that configuration, together with the action of gravity, any risks of leakage of resin (R) are eliminated and consequently any waste of said material is avoided. Figures 9 and 10 show this tightly fitting relationship between the high- tension terminal (T) and the protective cover 20, particularly in the region of the slot 23 provided at the free end of each capsule 22.

As far as the use of the resin is concerned, especially in connection with the amount applied, attention is drawn to the fact that, owing to the assembly configuration of the base body 10 together with the protective cover 20, the need for the application of resin (R) in the cavity 11' is eliminated, i.e. it is no longer necessary to apply resin on the printed circuit board (PCB) and consequently a substantial reduction in the costs involved in the manufacture of the ignition modules according to the present invention is achieved.

In addition, according to a preferably advantageous embodiment of the invention in question, the base body 10 has a peripheral wall with an edge constituted by a difference in level 13, such as an inner step, and the protective cover 20 has a difference in level 24 with a format corresponding to the difference in level 13 in order to allow precise engagement between the two components, as illustrated in figure 8. This arrangement guarantees, moreover, secure sealing of the cavity 11' against moisture and the penetration of liquids that may possibly and/or accidentally be spilled during the use of the cooking appliances or of the heating systems where the ignition module is installed.

Additionally, as is better illustrated in figures 10 and 11 , in an alternative embodiment of the present invention said base body 10 comprises a wall 16 separating the two cavities 11 and 11', which eliminates any risks of the resin (R) flowing or penetrating the cavity 11' where the printed circuit board (PCB) is accommodated.

According to one embodiment of the present invention, the protective cover 20 comprises tabs 25 for promoting engagement and locking together with the outer surface of the wall of the base body 10, where projections 14 are provided, positioned in locations corresponding to said tabs 25. In accordance with an alternative embodiment, as must be appreciated by persons skilled in the art, said tabs 25 may be arranged on the base body 10 and said projections 14 positioned in the protective cover 20. In a further alternative configuration, it is possible to interchange such elements between the base body 10 and the protective cover 20, i.e. either may comprise tabs 25 and projections 14 provided they are strategically combined to ensure the fastening of the cover 20 on the base body 10.

Logically, despite being preferred embodiments, principally because they eliminate complementary fastening means such as screws and/or other elements, the scope of protection of the patent in question should not be restricted by virtue of the manner in which the protective cover 20 is fastened onto the base body 10. Thus, as must be appreciated by persons skilled in the art, this fastening may easily be effected with the use of any widely known means for fastening two components, for example screws, rivets, glue, adhesive, simple press-engagement, etc.

In addition, according to a further particularly advantageous embodiment of the automatic ignition module that is the subject of the present invention, said region 21 of the protective cover 20, especially in the partially open surface thereof, comprises an inner edge 26 that is lowered in relation to the upper edge of the capsules 22. As well as representing a structural reinforcement of the protective cover 20, these inner edges 26 are responsible for assisting correct and secure anchoring and fastening of said protective cover on the base body 10. This is because, by means of this configuration, it is guaranteed that, during the assembly process, and principally in the stage of filling the cavity 11 with the resin (R), this resin is applied until it overflows said edges 26 and, upon drying, the resin locks the protective cover.

Lastly, it should be made clear that, despite the appended figures illustrating embodiments that include 6 high-tension terminals (T), this number may vary in accordance with the technical and functional specifications required by the cooking appliance or by the heating system, and may include more or fewer electrical connection terminals. Therefore, it is not the number and type of actual connection but the subject matter as defined in the appended claims that should be understood as limiting the scope of protection.

Therefore, all the aforesaid being taken into consideration, it is important to point out that the present description has as sole aim that of describing, in an illustrative manner, preferred embodiments of the switch device for an ignition system according to the invention in question. Thus, as persons skilled in the art will well understand, there is a number of possible structural combinations, variations and modifications in terms of elements that perform the same function substantially in the same way in order to achieve the same results, and these should be included within the scope of protection defined by the appended claims.

Claims

1. An automatic ignition module formed by a base body (10) that has at least two interlinked cavities (11 , 11'), the high-tension electrical terminals (T) interconnected with the energizing coils (B) being arranged in the first cavity (11), and the printed circuit board (PCB), with its electrical and electronic components, being installed in the other cavity (11'), the ignition module being CHARACTERIZED in that it comprises a protective cover (20) formed by at least two regions (21 , 21') for covering, respectively, the two cavities (11 , 11'), the region (21) being partially open and provided with capsules (22) for accommodating the high- tension terminals (T), and said region (21') is closed to substantially cover the cavity (11') and the board (PCB).

2. The automatic ignition module as claimed in claim 1 , CHARACTERIZED in that said region (21) of the protective cover (20) is partially open, forming at least one opening for the introduction of resin (R).

3. The automatic ignition module as claimed in claim 1 , CHARACTERIZED in that said capsules (22) project downward, in the direction toward the inside of the cavity (11) of the body (10), and comprise at least one slot (23) through which the high-tension terminal (T) is passed.

4. The automatic ignition module as claimed in claim 3, CHARACTERIZED in that said high-tension terminal (T) is arranged so as to fit tightly with said slot (23).

5. The automatic ignition module as claimed in claim 1 , CHARACTERIZED in that said base body (10) comprises a peripheral wall with an edge constituted by a difference in level (13), and said protective cover (20) has a difference in level (24) with a format corresponding to the difference in level (13) in order to provide precise engagement between the two components.

6. The automatic ignition module as claimed in claim 5, CHARACTERIZED in that the difference in level (13) of the base body (10), and also the difference in level (24) of the protective cover (20) are preferentially applied in the region of the cavity (11').

7. The automatic ignition module as claimed in claim 1 , CHARACTERIZED in that said protective cover (20) comprises tabs (25) interacting with the base body (10) via respective projections (14) positioned in locations corresponding to said tabs (25).

8. The automatic ignition module as claimed in claim 1 , CHARACTERIZED in that said protective cover (20) comprises projections (14) and said base body has duly projected tabs (25) in locations corresponding to said projections (14).

9. The automatic ignition module as claimed in claim 1 , CHARACTERIZED in that said protective cover (20) and said base body (10) comprise projections (14) and tabs (25) strategically combined to ensure the fastening of the cover (20) on the base body (10).

10. The automatic ignition module as claimed in claim 1 , CHARACTERIZED in that said region (21) of said protective cover (20) comprises an inner edge (26) that is lowered in relation to the upper edge of the capsules (22). (Necessary to clarify certain doubts in this respect).

11. The automatic ignition module as claimed in claim 1 , CHARACTERIZED in that said base body (10) comprises a wall (16) separating the two cavities (11 , 11').