Abstract: New igniter systems are provided that comprise a ceramic igniter element and an affixed encasing shield element. The shield element may be engaged or affixed to the igniter element in a variety of configurations, including by direct attachment to the igniter element or through another structure interposed between the igniter and shield elements. In preferred systems, a proximal end of an igniter element may be engaged in a mounting structure and a shield element that encases the igniter element is affixed to the mounting structure.

Abstract: 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.

Abstract: Resistive igniter systems are provided that comprise a metal substrate with an associated resistive igniter element in electrical connection through braze applied to the metal substrate. Igniter systems of the invention can enable significantly simplified manufacturing as well as notably higher yield production of more robust igniters. In preferred systems, the braze material is applied to the metal substrate prior to adjoining the igniter and metal substrate, which can enable application of a relatively precise amount of braze in a defined area of the metal substrate.

Abstract: Robust ceramic igniters are provided that include an improved sealing system which can significantly enhance operational life of the igniter. Preferred igniters comprise a conductive cold zone and hot zone with higher resisitivity. A hermetic sealant material covers one or more electrical connections on the of each cold zone, thus shielding the electrical connections from environmental exposure, and thereby avoiding igniter failure resulting from electrical shorts and/or undesired oxidation.

Abstract: An igniter for use in industrial and domestic gas burning appliances is disclosed. One embodiment of the igniter includes an igniter element disposed on the longitudinal axis of a tubular shield. The shield includes at least one open slot formed therethrough for providing a passageway through which gas and air can flow, thereby forming one or more open spiral patterns in the tubular shield. Another embodiment of the igniter includes an igniter element disposed on the longitudinal axis of a spiral coil. Still another embodiment of the igniter includes an igniter element disposed on the longitudinal axis of a ceramic, cylindrical sleeve. The sleeve includes at least one hole formed therethrough for optimally exposing the igniter element to a gas flow. The tubular shield, the spiral coil, and the ceramic sleeve protect the igniter element from accidental damage or breakage, and allow an optimal flow of gas and air to the igniter element, thereby facilitating subsequent ignition of the gas.

Abstract: Robust ceramic igniters are provided that include an improved sealing system which can significantly enhance operational life of the igniter. Preferred igniters comprise a conductive cold zone and hot zone with higher resisitivity. A hermetic sealant material covers one or more electrical connections on the of each cold zone, thus shielding the electrical connections from environmental exposure, and thereby avoiding igniter failure resulting from electrical shorts and/or undesired oxidation.

Abstract: Ceramic igniters are provided that comprise two cold zones with an interposed hot zone, the hot zone having an electrical path length of from 0.51 cm to about 2 cm. Igniters of the invention can effectively diffuse power density throughout the igniter hot zone region, without producing isolated temperature gradients which can lead to premature igniter degradation and failure. The invention also provides new methods for forming ceramic igniters.