Heating element systems
New heating systems are provided that include a mating block element that reliably encases a resistive igniter element. Preferred igniter systems can prevent undesired moisture and other materials from contacting electrical lead portions of the igniter element.
1 . A ceramic igniter system comprising a ceramic igniter element and encasing block element that is affixed to and encases the igniter element.
2 . The igniter system of claim 1 wherein the igniter element contains a single electrical lead.
3 . The igniter system of claim 1 wherein the block element functions as an electrical ground.
4 . The igniter system of claim 2 wherein the block element functions as an electrical ground.
5 . The igniter system of claim 1 wherein the block element comprises ceramic portions.
6 . The igniter system of claim 1 wherein the block element comprises metal and ceramic portions.
7 . The igniter system of claim 1 wherein the block element proximal end is metal and the block element distal end comprises a ceramic portion.
8 . The igniter system of claim 1 wherein the igniter and block elements are affixed without a potting cement or hermetic sealant.
9 . The igniter system of claim 1 wherein the igniter and block element are configured for secure engagement of the elements.
10 . The igniter system of claim 1 wherein the igniter and block elements are affixed by metal brazing.
11 . A ceramic igniter system comprising:
a ceramic igniter element nested within a lead frame element;
a block element affixed to and encasing the igniter element.
12 . The igniter system of claim 11 wherein the igniter element contains a single electrical lead.
13 . The igniter system of claim 11 wherein the block element functions as an electrical ground.
14 . The igniter system of claim 11 wherein the lead frame and block elements are both affixed by a metal braze to the igniter element.
15 . A method for producing a ceramic igniter system comprising:
(a) providing an assembly comprising a lead frame element associated with a ceramic igniter element and a block element encasing the igniter element;
(b) thermally treating the assembly to affix the lead frame and block elements to the igniter element.
16 . The method of claim 15 wherein the thermal treatment fuses the lead frame and block elements to the igniter element through a braze material.
17 . The method of claim 15 wherein a single thermal treatment fuses both the lead frame element and the block element to the igniter element.
18 . A heating system comprising:
a heating appliance comprising a igniter system of claim 1 positioned therein to ignite fuel.
19 . The heating system of claim 18 wherein the appliance is a gas cook top or a gas grill.