U.S. patent application number 12/632417 was filed with the patent office on 2011-06-09 for alternative ignition source system for an exothermic reaction mold device.
This patent application is currently assigned to CONTINENTAL INDUSTRIES, INC.. Invention is credited to David Lewis Lofton.
Application Number | 20110132966 12/632417 |
Document ID | / |
Family ID | 44022150 |
Filed Date | 2011-06-09 |
United States Patent
Application |
20110132966 |
Kind Code |
A1 |
Lofton; David Lewis |
June 9, 2011 |
ALTERNATIVE IGNITION SOURCE SYSTEM FOR AN EXOTHERMIC REACTION MOLD
DEVICE
Abstract
An alternative ignition source system for an exothermic reaction
mold device for welding conductors. The system includes a crucible
in a block with an open top so that the crucible receives an
exothermic weld material. The conductors to be welded
exothermically are placed in the weld cavity of the mold. A lid
covers the open top wherein the lid has a opening therethrough. An
electronic thermal igniter assembly has an ignition component
receivable through the opening in the lid so that the exothermic
weld material may be ignited either by the electronic thermal
igniter assembly or may be ignited by a spark.
Inventors: |
Lofton; David Lewis; (Tulsa,
OK) |
Assignee: |
CONTINENTAL INDUSTRIES,
INC.
Tulsa
OK
|
Family ID: |
44022150 |
Appl. No.: |
12/632417 |
Filed: |
December 7, 2009 |
Current U.S.
Class: |
228/18 ;
228/33 |
Current CPC
Class: |
B23K 23/00 20130101;
B23K 2101/38 20180801 |
Class at
Publication: |
228/18 ;
228/33 |
International
Class: |
B23K 37/06 20060101
B23K037/06 |
Claims
1. (canceled)
2. An alternative ignition source system for an exothermic reaction
mold device as set forth in claim 21 including a counter sunk
receptacle in said lid in communication with said opening in said
lid.
3. (canceled)
4. An alternative ignition source system for an exothermic reaction
mold device as set forth in claim 21 wherein said igniter body and
said igniter plug are wired to at least one battery and at least
one switch and wherein said at least one battery and said at least
one switch are remote from said igniter component and igniter
body.
5. An alternative ignition source system for an exothermic reaction
mold device as set forth in claim 4 including a battery life
voltage sensing indicator wherein said at least one battery, said
at least one switch and said battery life voltage sensing indicator
are contained in a housing.
6. (canceled)
7. (canceled)
8. An alternative ignition source system for an exothermic reaction
mold device as set forth in claim 21 wherein said igniter body is
an insulated printed circuit board with an opening spanned by a
metallic wire.
9. An alternative ignition source system for an exothermic reaction
mold device as set forth in claim 21 wherein said block is composed
of graphite.
10. An alternative ignition source system for an exothermic
reaction mold device as set forth in claim 23 wherein said counter
sunk receptacle in said lid receives starting powder and wherein
said mechanically generated spark is supplied by a flint
igniter.
11. An alternative ignition source system for an exothermic
reaction mold device as set forth in claim 21 including an exhaust
vent through a side of said lid in communication with said lid
opening.
12. An alternative ignition source system for an exothermic
reaction mold device as set forth in claim 11 wherein said lid
includes: a lower face completely covering said open top of said
block with the exception of an elongated slot therethrough; an
upper face with a circular opening therethrough, whereby an axis of
said circular opening passes through said slot; and a space between
said upper face and said lower face containing an exhaust vent
perpendicular to said elongated slot and in communication
therewith.
13. (canceled)
14. (canceled)
15. (canceled)
16. An alternative ignition source system for an exothermic
reaction mold device as set forth in claim 22 wherein said igniter
body includes an insulated printed circuit board.
17. An alternative ignition source system as set forth in claim 22
wherein said means to ignite said weld material in said crucible
with a mechanically generated spark includes a flint igniter.
18. An alternative ignition source system for an exothermic
reaction mold device as set forth in claim 22 including an exhaust
vent through a side of said lid in communication with said lid
opening.
19. An alternative ignition source system for an exothermic
reaction mold device as set forth in claim 22 wherein said lid
includes; a lower face completely covering said open top of said
block with the exception of a slot, an upper face with a circular
opening therethrough, whereby an axis of said circular opening
passes through said slot, and a space between said upper face and
said lower face containing an exhaust vent.
20. (canceled)
21. An alternative ignition source system for an exothermic
reaction mold device, which system comprises: a crucible in a block
with an open top so that said crucible receives an exothermic weld
material; a lid covering said open top wherein said lid has an
opening therethrough; an electronic thermal igniter assembly having
an igniter body removably retained in an igniter plug wherein said
body is receivable through said opening in said lid and wherein
said igniter plug rests against said lid and closes said lid
opening when said igniter body is received through said opening in
said lid so that said exothermic weld material is ignited by said
electronic thermal igniter assembly.
22. An alternative ignition source system for an exothermic
reaction mold device, which comprises: a crucible in a block with
an open top so that said crucible receives exothermic weld
material; a lid covering said open top wherein said lid has an
opening therethrough; means to ignite said exothermic weld material
within said crucible with an electronic thermal igniter assembly
having an ignition body receivable through said open top wherein
said electronic thermal igniter assembly includes an igniter plug,
at least one battery and at least one switch, wherein said igniter
plug rests against said lid and closes said lid opening when said
ignition body is received through said opening of said lid; and
means to alternatively ignite said weld material within said
crucible with a mechanically generated spark.
23. An alternative ignition source system for an exothermic
reaction mold device as set forth in claim 22 including a counter
sunk receptacle in said lid in communication with said opening in
said lid.
24. An alternative ignition source system for an exothermic
reaction mold device as set forth in claim 22 wherein said ignitor
body is removably retained in said igniter plug.
25. An alternative ignition source system for an exothermic
reaction mold device as set forth in claim 22 including a battery
life voltage sensing indicator wherein said at least one battery,
said at least one switch and said battery life voltage sensing
indicator are contained in a housing.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an alternative ignition
source system for an exothermic reaction weld mold device. In
particular, the present invention is directed to an exothermic
reaction weld mold device wherein alternate sources of ignition may
be chosen and utilized for initiating an exothermic reaction for
joining connectors.
[0003] 2. Prior Art
[0004] The use of exothermic reaction welding is known for joining
connectors to each other and also for joining other metal parts,
such as ground rods.
[0005] A reusable mold contains an internal crucible in which an
exothermic powder material is placed. When the exothermic powder
material is ignited, an exothermic reaction results in the
crucible. The powder liquefies and the molten material flows into a
weld cavity in the mold.
[0006] The exothermic reaction process is initiated by an ignition
which may occur from various sources. A spark or ignition gun,
sometimes referred to as a flint gun, is often used to start the
exothermic reaction which takes place extremely quickly once
ignited. One example of a mold ignited by a spark or flint gun is
shown in Assignee's U.S. Pat. No. 6,776,386 entitled LID FOR
EXOTHERMIC REACTION WELDING MOLD.
[0007] Alternatively, an electric ignition element having high
resistance may be used to start the exothermic weld reaction. An
electrical ignition system is advantageous in some cases since it
may be initiated from a greater distance away from the mold
itself.
[0008] Examples of prior exothermic molds that incorporate
electrical ignition include Brosnan et al. (U.S. Pat. No.
4,889,324) which disclose exothermic welding with an ignition
system having a pair of leads to connect to an ignition fuse or hot
wire.
[0009] Another example is shown in Harger et al. (U.S. Pat. No.
6,994,244) which discloses an exothermic welding assembly including
an electrical igniter which is embedded in the exothermic weld
material.
[0010] Assignee's U.S. Pat. No. 7,240,717 discloses an electrical
ignition source including an igniter element suspended above the
lid of the mold device outside of the crucible.
[0011] The exothermic reaction weld is often times made in the
field in remote locations and in all types of conditions.
Accordingly, it is desirable to have a choice of ignition sources.
Additionally, the weld may be made in confined spaces, such as an
open trench, wherein a ground wire is being installed or a cable is
being joined.
[0012] If electrical ignition tools are not present at the site, it
would be desirable to have an alternate source to ignite the
exothermic weld reaction. Alternatively, if spark ignition
materials are not available at the site, it would be desirable to
have an alternate source to initiate the exothermic reaction
welding.
[0013] Accordingly, it is a principal object and purpose of the
present invention to provide an alternate source exothermic
reaction weld mold device.
[0014] It is a further object and purpose of the present invention
to provide an exothermic reaction weld device that will accommodate
various types of ignition systems.
[0015] It is a further object and purpose of the present invention
to provide an exothermic weld device with multiple types of
ignition systems that will vent exhaust gases to the side.
[0016] It is a further object and purpose of the present invention
to provide an alternative ignition source system that may be used
with a wide variety of existing molds and mold designs.
SUMMARY OF THE INVENTION
[0017] The present invention is directed to an alternative ignition
source system for an exothermic reaction mold device.
[0018] Exothermic welding is used for joining conductors mainly
copper to copper, or copper to steel surfaces. The exothermic
reaction takes place in a mold which is often made up of a graphite
block and is able to withstand high exothermic temperature. A
crucible which is the most important part of the mold is where the
exothermic reaction takes place. A steel metal disk is placed in
the crucible followed by the weld metal which is often a mixture of
copper oxide and aluminum. Traditionally, starting powder is placed
on top of the lid and the reaction is ignited using a flint gun.
The weld metal is a mixture of copper oxide and aluminum which
produces copper and aluminum oxide after an exothermic reaction
takes place.
[0019] The present invention includes a mold block and two
alternate sources of ignition--an electronic thermal igniter
assembly and a mechanically generated spark igniter.
[0020] The mold block also includes a mold cavity below the
crucible which will receive molten material flowing from the
exothermic reaction taking place in the crucible through a
passageway.
[0021] A lid covers the open top of the mold block. The present
invention may be utilized with lids of various types. In one
preferred embodiment, the lid includes an upper top face with a
cylindrical opening extending through the lid. The lid also
includes a bottom or lower face opposed to the upper or top face.
The bottom face includes an opening therethrough. An exhaust vent
between the upper face and lower face of the lid forms a pocket in
communication with the cylindrical opening and opening of the
bottom face. The exhaust vent is vented through the side face of
the lid.
[0022] In one of the alternate sources of ignition, the electronic
thermal igniter assembly includes an extending ignition body which
is receivable into and through the cylindrical opening in the lid
and extends into the crucible until it is just above the level of
exothermic weld material. The ignition body is retained in a recess
in an igniter plug. When installed, the igniter plug will rest
against the top of the lid and close the opening in the lid when
the ignition body is received therethrough. The ignition body and
the igniter plug are, in turn, wired to a power source and a switch
or switches.
[0023] As an alternate ignition source, a mechanically generated
spark may be utilized. Exothermic weld material is inserted into
the crucible in the block and the lid is closed. A small portion of
starting powder is placed in the counter sunk receptacle in the top
of the lid. A spark may be mechanically generated by use of a flint
gun brought near the starting powder. The starting powder will
initially be ignited which will cause sparks to pass through the
cylindrical opening into the crucible causing the exothermic weld
material to be reduced.
[0024] In the case of either ignition source, the exhaust vents to
the side of the lid forms a vent for hot, escaping gases.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIG. 1 illustrates a perspective view of alternative
ignition source system for an exothermic reaction mold device
constructed in accordance with the present invention;
[0026] FIG. 2 illustrates a mold block of the present invention as
shown in FIG. 1;
[0027] FIG. 3 shows a top view of the invention shown in FIG. 1
utilizing an electronic thermal igniter assembly as an ignition
source;
[0028] FIG. 4 illustrates a side view of the invention shown in
FIG. 3;
[0029] FIG. 5 illustrates a sectional view taken along line 5-5 of
FIG. 3;
[0030] FIG. 6 illustrates a sectional view taken along line 6-6 of
FIG. 3; and
[0031] FIG. 7 illustrates a completed weld performed by use of the
present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0032] The embodiments discussed herein are merely illustrative of
specific manners in which to make and use the invention and are not
to be interpreted as limiting the scope of the instant
invention.
[0033] While the invention has been described with a certain degree
of particularity, it is to be noted that many modifications may be
made in the details of the invention's construction and the
arrangement of its components without departing from the spirit and
scope of this disclosure. It is understood that the invention is
not limited to the embodiments set forth herein for purposes of
exemplification.
[0034] Referring to the drawings in detail, FIG. 1 illustrates a
perspective view of an alternative ignition source system for an
exothermic reaction mold device 10 construction in accordance with
the present invention.
[0035] The invention includes a mold block 12 and two alternate
forms of ignition--an electronic thermal igniter assembly 14 (a
portion of which is visible in FIG. 1) and a mechanically generated
spark igniter 16.
[0036] FIG. 2 illustrates a perspective view of the mold block 12
apart from the other components with the mold block opened for ease
of viewing. The mold block which may be reused multiple times, and
may be composed of graphite, ceramic or other refractory
material.
[0037] Exothermic welding is used for joining conductors mainly
copper to copper, or copper to steel surfaces. The exothermic
reaction takes place in a mold which is made up of a graphite block
and is able to withstand high exothermic temperature. A crucible
which is the most important part of the mold is where the
exothermic reaction takes place. A steel metal disk is placed in
the crucible followed by the weld metal which is a mixture of
copper oxide and aluminum. Traditionally, starting powder is placed
on top of the lid and the reaction is ignited using a flint gun.
The weld metal is a mixture of copper oxide and aluminum which
produces copper and aluminum oxide after an exothermic reaction
takes place.
[0038] The present invention provides for alternative sources of
ignition of the exothermic weld reaction. FIGS. 3 through 6
illustrate the use of the electronic thermal igniter assembly 14 as
an ignition source.
[0039] One type of mold block 12 is illustrated in the present
embodiment although it will be understood that a wide variety of
molds may be used within the teachings of the present invention. A
first portion 20 of the mold device 12 joins with a second portion
22 of the mold device 12. When the portions 20 and 22 are joined
together as shown in FIG. 1, a crucible 24 is formed having an open
top 26 as seen in FIG. 2.
[0040] The base of the crucible 24 has a shoulder 28 to receive a
small metal disk 18 such as a steel metal disk (not shown in FIG.
2).
[0041] Clamps 30 retain the mold portions 20 and 22 so that they
may move between a closed position shown in FIG. 1 and an open
position shown in FIG. 2. Handles 32 extending from the clamps 30
may be utilized to move the clamps 30 and, in turn, move the mold
portions.
[0042] The mold block 12 also includes a mold cavity 34 below the
crucible 24 which will receive molten material flowing from the
exothermic reaction taking place in the crucible 24 through a
passageway 36.
[0043] A lid 40 covers the open top 26 of the mold block 12. The
lid 40 may be connected by a hinge or hinges to the mold block 12.
It will be understood that the present invention may be used with
lids of various types. In one preferred embodiment, the lid 40
includes an upper or top face with a cylindrical opening 38
extending through the lid 40. The lid also includes a bottom or
lower face opposed to the upper or top face. In the present
embodiment, the upper top face is parallel to the bottom face. The
bottom or lower face includes an opening 42 therethrough. The
opening 42 may be elliptical oval, or take other shapes. The
cylindrical opening 38 has an axis perpendicular to both the top
and the bottom faces and passes through the opening 42. Between the
top face and the bottom face of the lid 40 are a series of side
faces including a side face 44. An exhaust vent 46 between the
upper face and the lower face of the lid forms a pocket in
communication with the cylindrical opening 38 and the opening 42 of
the bottom face. The exhaust vent 46 is vented through the side
face 44 of the lid 40.
[0044] The cylindrical opening 38 also includes a counter sunk
receptacle 48 in the top face which is used to retain a portion of
starting powder when utilizing the mechanically generated spark
igniter as an ignition source.
[0045] The present invention employs alternative ignition sources
in order to initiate an exothermic reaction. A first ignition
source is a remotely activated electronic thermal igniter assembly
while a second, alternate ignition source is a mechanically
generated spark. FIG. 3 shows a top view, FIG. 4 illustrates a side
view, FIG. 5 illustrates a sectional view and FIG. 6 illustrates a
sectional view of the invention with the electronic thermal igniter
assembly employed.
[0046] The electronic thermal igniter assembly includes an
extending flat blade ignition body 50 which may be seen apart from
the mold block 12 in FIG. 1. The ignition body 50 includes a strip
or wire of two different metallic elements in contact with each
other. In one non-limiting example, the metallic elements are
palladium and aluminum. When an electrical charge is applied the
elements will alloy. The electronic ignition body 50 is receivable
into and through the cylindrical opening in the lid 40. When
installed, the ignition body 50 extends into the crucible 24 until
it is just above the level of exothermic weld material 52, as best
seen in FIGS. 5 and 6.
[0047] The ignition body 50 is not and should not be in contact
with the exothermic weld material as the ignition body works more
effectively when suspended above the weld metal. When ignition is
initiated, the sparks generated from the ignition body broadcast
more evenly over the weld material producing a more consistent and
even reaction of the weld material.
[0048] The ignition body 50 is inserted into a recess in the
igniter plug 54 and is replaceable each time an exothermic reaction
is desired. The ignition body 50 is retained in a recess in an
igniter plug 54. The igniter body 50 includes a printed circuit
board insulated on all sides with an ignition component 64 in the
form of a metallic wire soldered to the board to complete the
circuit. The ignition component 64 spans an opening in the ignition
body 50 and may be configured as a straight wire, as a loop or
another configuration.
[0049] Once installed, the igniter plug 54 will rest against the
top of the lid 40 and substantially closes the central opening in
the lid 40 when the ignition body 50 is received therethrough.
[0050] The ignition body 50 and the igniter plug 54 are wired via
wires 56 to a battery, to multiple batteries or to another power
source 58 and a switch or switches 60. In one non-limiting
configuration, an arming and an operation switch may be employed.
An optional battery life voltage sensing indicator 60 with a
voltage sensing circuit may be included.
[0051] The replaceable ignition body 50 is designed so that the
same size component is used for the smallest weld shot to the
largest weld shot.
[0052] The batteries 58 may be standard replacement alkaline
batteries and may be contained in a housing with the switch or
switches 60 in a portable, handheld device so that the exothermic
reaction is initiated remotely from the mold device 12.
[0053] In order to utilize the present invention, a cable, cables
or other components to be welded are positioned in the mold cavity
34 and a metal disk 18 is inserted into the crucible 24. Exothermic
weld material 52 is placed in the crucible and; optionally, a
portion of starting powder is sprinkled on top of the exothermic
reaction material. Thereafter, the lid 40 is closed covering the
open top. The ignition body 50 is then inserted through the
cylindrical opening 38 of the lid until the igniter body rest
against the top of the lid 40. Once the switch or switches 60 are
activated, electricity is delivered through the wires to a printed
circuit board in the igniter body and to the ignition body 50. In
one embodiment, a first arming switch and a second ignition switch
are used. The ignition body 50 will generate heat causing sparks or
discreet particles to fall onto the exothermic weld material and/or
starting powder causing the weld material 52 to turn into molten
liquid material. The igniter plug 54 blocks escaping gases from
venting out of the top of the lid. The metal disk 18 will be
melted, causing the molten material to flow through the passageway
36 into the mold cavity 34 forming an electrical connector in the
cavity.
[0054] Use of the electronic thermal igniter assembly provides an
easy and safe method of initiating an exothermic weld.
[0055] As an alternate ignition source, a mechanical spark may be
utilized. Once again, the connector or connectors are inserted into
the mold cavity 34, a metal disk 18 is placed in the mold block 12
and exothermic weld material 15 is inserted into the crucible in
the block. Thereafter, the lid 40 is closed. A portion of starting
powder is placed in the counter sunk receptacle in the top of the
lid 40. A spark may be mechanically generated by use of a flint gun
brought near the starting powder. The starting powder will
initially be ignited which will cause sparks to pass through the
cylindrical opening 38 into the crucible which will cause the
exothermic weld material to be reduced. The metal disk 18 will be
melted, causing the molten material to flow through the passageway
36 into the mold cavity.
[0056] FIG. 7 illustrates a completed connector 70 formed by the
present invention.
[0057] In the case of either of the ignition sources, the exhaust
vent through the side of the lid 40 forms a vent for hot, escaping
gases from the exothermic reaction.
[0058] Whereas, the present invention has been described in
relation to the drawings attached hereto, it should be understood
that other and further modifications, apart from those shown or
suggested herein, may be made within the spirit and scope of this
invention.
* * * * *