Abstract:
A fireworks igniter system and method for safely igniting fuse-type fireworks including a handheld igniter module and a remote control module. An igniter head at the proximal end of the igniter module includes a heater element and fuse clamp slide which receives and biasingly molds the fuse against the heater element. A microprocessor in the igniter module includes an infrared receiver and an igniter module actuator. The remote control module includes an infrared emitter and a remote control module actuator, the infrared emitter emitting a coded IR signal in response to activation of the actuator. The IR signal is sensed by the infrared receiver to activate the igniter module actuator and deliver electric current to the heater element sufficient to ignite the fuse.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     Not applicable 
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not applicable 
     INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC 
     Not applicable 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates generally to the field of fireworks and pyrotechnic igniters, and more particularly to a remotely controlled fireworks igniter for use with consumer-type fireworks. 
     2. Description of Related Art 
     Although consumer-type fireworks have been severely regulated and, with respect to those that are legal in most states, have been substantially reduced in explosive and pyrotechnic capacities, nonetheless, legal fireworks which are currently available and illegal fireworks which carry substantially greater charges of explosive material, can be quite dangerous. Particularly with respect to young and adult children, many injuries to the eyes and hands, particularly fingers occur during each yearly fireworks seasons particularly prior to Fourth of July celebrations. 
     Many of these consumer-type fireworks have very short fuses and are difficult to hand launch a safe distance away. Moreover, all fuses have their own burn rate and erratic and rapid fuse burn can lead to unpleasant surprises and fireworks ignition before anticipated. A number of devices and apparatus have been developed and patented which are intended to substantially enhance the safety factor in setting off fireworks, particularly those for both commercial and consumer use. 
     Bailey et al. teach remotely controlled igniters for use with consumer class fireworks in U.S. Pat. No. 6,874,424 and U.S. Patent Application Publication 2006/0207467. A fireworks holder with remote control firing system is disclosed by Tang in U.S. Patent Application Publication 2003/0070572. U.S. Pat. No. 5,691,500 to Mancini discloses a remotely-actuated fireworks launcher. Neahr teaches an electric firework igniter in U.S. Pat. No. 1,445,904. A fuse igniter is taught by Frye in U.S. Pat. No. 2,003,483. U.S. Pat. No. 7,688,566 to Zhang discloses an electric firing device for fireworks. U.S. Pat. No. 4,862,802 to Streifer et al. discloses a method for initiating pyrotechnic ignitions in the proper sequence. 
     The present invention discloses a very safe fireworks igniter system which, when used properly as taught, ensures fuse ignition at a safe distance and manner of ignition. 
     The foregoing examples of the related art and limitations related therewith are intended to be illustrative and not exclusive. Other limitations of the related art will become apparent to those skilled in the art upon a reading of the specification and a study of the drawings. 
     BRIEF SUMMARY OF THE INVENTION 
     This invention is directed to a fireworks igniter system and method for safely igniting fuse-type fireworks including a handheld igniter module and a remote control module. An igniter head at the proximal end of the igniter module includes a heater element and fuse clamp slide which receives and biasingly molds the fuse against the heater element. A microprocessor in the igniter module includes an infrared receiver and an igniter module actuator. The remote control module includes an infrared emitter and a remote control module actuator, the infrared emitter emitting a coded IR signal in response to activation of the actuator. The IR signal is sensed by the infrared receiver to activate the igniter module actuator and deliver electric current to the heater element sufficient to ignite the fuse. 
     The following embodiments and aspects thereof are described and illustrated in conjunction with systems, tools and methods which are meant to be exemplary and illustrative and not limiting in scope. In various embodiments one or more of the above-described problems have been reduced or eliminated while other embodiments are directed to other improvements. In addition to the exemplary aspects and embodiments described above, further aspects and embodiments will become apparent by reference to the drawings and by study of the following descriptions. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S) 
         FIG. 1  is a perspective view of the igniter module  1  and the remote control module  2  of the system of this disclosure. 
         FIG. 2  is an end elevation view of the igniter module  1 . 
         FIG. 3  is a front elevation view of  FIG. 1 . 
         FIG. 4  is a side elevation view of  FIG. 3 . 
         FIG. 5  is an end elevation view of the remote control module  2 . 
         FIG. 6  is a bottom plan view of  FIG. 5 . 
         FIG. 7  is another end elevation view of  FIG. 6 . 
         FIG. 8  is a side elevation view of  FIG. 6 . 
         FIG. 9  is a top plan view of  FIG. 5 . 
         FIG. 10  is a perspective view of a method of using the remote control module  2  to ignite a fuse of a bottle rocket. 
         FIG. 11  is a simplified top plan view of  FIG. 10 . 
         FIG. 12  is an enlarged view of area  12  in  FIG. 13 . 
         FIG. 13  is a section view in the direction of arrows  13 - 13  in  FIG. 11 . 
         FIG. 14  is a reduced sized view of  FIG. 3 . 
         FIG. 15  is a section view in the direction of arrows  15 - 15  in  FIG. 14 . 
         FIG. 16  is a reduced size view of  FIG. 4 . 
         FIG. 17  is a section view in the direction of arrows  17 - 17  in  FIG. 16 . 
         FIG. 18  is an exploded perspective view of the igniter module  1  and fuse retainer and igniter head  3 . 
         FIG. 19  is another perspective view of  FIG. 18 . 
         FIG. 20  is an exploded perspective view of the remote control module  2 . 
         FIG. 21  is a reduced size view of  FIG. 3 . 
         FIG. 22  is an enlarged view of area  22  in  FIG. 21 . 
         FIG. 23  is an electronic schematic view of the control system of the invention. 
         FIG. 24  is an electronic circuit diagram of the microprocessor  64  of the igniter module  1 . 
         FIG. 25  is an electronic circuit diagram of the remote control module  2 . 
     
    
    
     Exemplary embodiments are illustrated in reference figures of the drawings. It is intended that the embodiments and figures disclosed herein are to be considered to be illustrative rather than limiting. 
     DETAILED DESCRIPTION OF THE INVENTION 
     
         
           1  igniter module 
           2  remote control module 
           3  fuse retainer and igniter head 
           4  main housing 
           6  battery cover 
           8  igniter housing 
           10  fuse clamp slide 
           11  clamp slide aperture 
           12  clamp actuator surface 
           14  switch manual actuator 
           16  switch on actuator 
           18  label 
           20  support rod aperture 
           22  thermo insulator sleeve 
           24  heater element 
           26  clamp plate 
           28  clamp plate aperture 
           30  adhesive gland 
           32  thermo insulator aperture 
           34  debris channel 
           36  clamp spring 
           38  spring retainer 
           39  rear spring cavity wall 
           40  forward stop contact 
           42  forward stop 
           44  reverse stop tab 
           46  reverse stop contact 
           48  heater support 
           50  bifurcated contact 
           52  printed wiring board 
           54  infrared receivers 
           56  heater support screw 
           58  lithium battery 
           59  battery retainer 
           60  AA alkaline batteries 
           62  heater relay 
           64  microprocessor 
           66  battery spring clip 
           68  printed wiring board retainer screw 
           70  fuse 
           72  battery cover latch 
           74  battery cover latch aperture 
           76  bottle 
           78  bottle rocket 
           80  support slot 
           82  igniter housing support guide 
           84  infrared light emitting diode 
           86  remote bottom cover 
           88  remote top cover 
           90  switch actuator 
           92  switch guard 
           94  lanyard aperture 
           96  bottom retainer screw 
           98  remote printed wiring board 
           99  retainer screw 
           100  remote active light 
           102  light aperture 
           103  infrared light emitting diode driver 
           104  microcircuit 
           106  remote switch 
           108  igniter housing retainer detent 
           110  main housing retainer slot 
           112  rear door latch 
           114  on switch 
           115  manual switch 
           116  support rod 
           118  ground 
       
    
     Referring to  FIG. 1 , the fireworks igniter system includes an igniter module  1  and an remote control module  2 . The remote control module  2  may activate the igniter module  1  by a coded infrared signal which ignites a firework fuse at a range of the infrared signal of approximately 30 feet. Igniter module  1  contains a fuse retainer system  3  to clamp fuse securely against the ignition element. 
     Referring to  FIGS. 2 ,  3 ,  4 ,  14 ,  15 ,  16 ,  17 ,  18 , &amp;  19 , the igniter module  1  includes a main housing retainer slot  110 , battery cover  6 , and igniter housing  8 . The battery cover  6  provides a mounting for a printed wiring board  52 , AA alkaline batteries  60 , switch manual actuator  14 , switch on actuator  16 , battery spring clip  66 , igniter housing  8  and label  18 . The proximal end of battery cover  6  is retained in the main housing  4  by a battery cover latch  72  detent engaging battery cover latch aperture  74  on main housing  4 . The distal end of battery cover  6  is retained by a rear door latch  112  on main housing  4 . Igniter housing  8  is retained on main housing  4  by an igniter housing retainer detent  108  engaging main housing retainer slot  110  on main housing  4 . 
     Referring to  FIGS. 15 ,  17 ,  18  and  19 , printed wiring board  52  provides a mounting and electrical connection of two infrared receivers  54 , lithium battery  58 , heater relay  62 , microprocessor  64  and various electrical support components. The infrared receivers  54  are mounted facing 180° apart to provide a 360° infrared signal receiving coverage. Printed wiring board  52  is retained in main housing  4  by printed wiring board retainer screw  68 . 
     The main housing  4  and battery cover  6  are made from a standard temperature-grade plastic. Igniter housing  8  is made from a standard temperature-grade plastic that is infrared-transparent and visible-light translucent. The fuse clamp slide  10  is made from high temperature grade plastic due to the proximity of burning fuses. The main housing  4  and battery cover  6  are made photoluminescent by the addition of photoluminescent materials in the plastic formulation for enhanced visibility at night when fireworks are ignited. 
     Still referring to  FIGS. 12 ,  15 ,  17 ,  18 , &amp;  19 , the fuse retainer and igniter system  3  may include a thermo insulator  22  attached to igniter housing  8 , clamp plate  26  attached to fuse clamp slide  10 , and heater element  24 . The thermo insulator  22  is made from a high-temperature alumina ceramic material that prevents melting or burning of the plastic igniter housing  8  when heater element  24  is energized. The thermo insulator  22  is attached to igniter housing  8  by an adhesive filled gland  30 . 
     The heater element  24  is made from size 28 American Wiring Gauge nichrome wire formulated from 60% nickel, 16% chromium and 24% iron. Current flow provided by two AA alkaline batteries  60  raises the temperature of the heater element  24  to approximately 975° K. The heater element  24  is contained within a thermo insulator sleeve  22  and is electrically connected to and supported by opposing heater supports  48  fabricated from brass and being affixed to igniter housing  8  by means of heater support screws  56 . 
     To secure a fuse, clamp plate  26  is held in an open position by being slid across the inner surface of thermo insulator sleeve  22  by pushing the fuse clamp slide  10  in the direction of arrow A in  FIG. 12 . The clamp plate  26  is made from a high-temperature alumina ceramic material due to the proximity of burning fuses. Clamp slide  10  is retained in aperture  11  in igniter housing  8  which allows clamp slide  10  to have lateral freedom of motion through igniter housing  8 . Clamp slide  10  is retained laterally by forward stop  42  on its distal end and reverse stop tab  44  on the proximal end. These make contact with forward stop contact  40  and reverse stop contact  46  on igniter housing  8 . Clamp spring  36  creates a bias by means of spring retainer  38  on igniter housing  8  and rear spring cavity wall  39  in clamp slide  10 . This bias is translated to clamp plate  26 . 
     An electrical connection is made between the heater element  24  and printed wiring board  52  by means of bifurcated contact  50  on heater support  48  connecting to contacts integral to printed wiring board  52 . This connects heater relay  62  on printed wiring board  52  in series with two AA alkaline batteries  60  which are connected in series by a conductive battery spring clip  66  held by main housing  4 . 
     Referring to  FIGS. 1 ,  5 ,  6 ,  7 ,  8 ,  9 ,  20 , &amp;  25 , remote control module  2  includes remote bottom cover  86 , remote top cover  88 , switch actuator  90  and remote printed wiring board  98 . Retainer screws  99  secure remote printed wiring board  98  to remote top cover  88 . Bottom retainer screw  96  secures remote bottom cover  86  to remote top cover  88 . Switch actuator  90  is captured by remote top cover  88  and has freedom of motion to activate remote switch  106  on remote printed wiring board  98 . A lithium battery  58 , mechanically held and electrically connected to remote printed wiring board  98  by battery retainer  59 , powers the circuit. A lanyard aperture  94  is an integral molded feature of remote bottom cover  86 . 
     When remote switch  106  is activated, microcircuit  104  drives infrared light emitting diode  84  with a unique coded signal that is transmitted to igniter module  1 . Remote active light  100  illuminates through lamp aperture  102  in remote top cover  88  to confirm to the user that a remote transmission has been sent. To prevent accidental activation of remote control module  2 , switch guard  92 , an integral part of remote top cover  88 , and positioned at a higher elevation than switch actuator  90 , prevents depression and activation. 
     Referring to  FIG. 10 , one typical use of this device is there shown wherein the user desires to ignite a bottle rocket  78  from a remote location, typically up to 30 feet away. The user places the bottle rocket  78  in bottle  76  and attaches fuse  70  to the igniter module  1 . Due to low fuse retention in some fireworks, the weight of the igniter module  1  is supported by support rod  116  which is pressed into ground  118  and, referring to  FIGS. 3 ,  21 , &amp;  22 , is inserted into support rod aperture  20  and locked into vertical alignment by twisting the oblong support rod  116  in the oblong support rod aperture  20  in igniter module  1 . This twisting action deforms support rod  116  and causes a friction lock with the support rod aperture  20  as required for vertical positioning anywhere along the longitudinal axis of support rod  116 . Fireworks that have high fuse retention allow igniter module  1  to be dangled freely in the air supported only by the fuse. 
     As best seen in  FIG. 12 , to retain fuse  70  in igniter module  1 , thumb pressure is exerted on the clamp actuator surface  12  on clamp slide  10  in the direction of arrow A to align the cylindrical surfaces of thermo insulator aperture  32  and clamp plate aperture  28  of clamp plate  26 . Fuse  70  is properly positioned when protruding through insulator aperture  32 , clamp plate aperture  28  and into debris channel  34  which extends to one end of the clamp slide  16 . As pressure is released from clamp actuator surface  12 , the clamp spring  36  biases clamp plate aperture  28  edge against fuse  70 . This creates a friction lock to retain fuse  70 . After fuse ignition, fuse debris may be cleared from the debris channel  34  by gravity and a shake of the igniter module  1 . 
     Referring to  FIGS. 3 ,  19 ,  23 ,  24 , pushing switch  14  on actuator  16  in main housing  4  activates switch  114  on printed wiring board  52 . Microprocessor  64  is activated and accepts inputs from infrared receivers  54  or manual switch  115 . When remote control module  2  is activated and a valid infrared code is detected and sent to microprocessor  64 , heater relay  62  is activated to close the circuit path between the AA alkaline batteries  60  and heater element  24 . Current flow raises temperature in heater element  24  sufficiently to light the fuse  70  of a firework. 
     A timer function of microprocessor  64  limits the time the heater element  24  is active to reliably light the fuse  70 . This heater element timer  24  prevents overheating of thermo insulator sleeve  22  and melting or burning of plastic igniter housing  8 . The timer also increases battery life of AA alkaline batteries  60 . At the same time heater element  24  is active, the microprocessor  64  disables the inputs from the infrared receivers  54 . After the heater element  24  is inactive, the microprocessor  64  continues to disable infrared receivers  54  input based in an internal time delay until the heater element  24  cools down. The microprocessor  64  disables the heater element  24  through the active and cool-down stages to avoid close proximity infrared energy from the heater element  24  reactivating the highly sensitive infrared receivers  54 . A manual switch  115 , activated by switch manual actuator  14 , overrides the IR control link to allow firework ignition without using remote control module  2 . After fuse  70  ignition, the ash from the fuse that was captured in the fuse clamp slide  10  is expelled through the debris channel  34 . 
     While a number of exemplary aspects and embodiments have been discussed above, those of skill in the art will recognize certain modifications, permutations and additions and subcombinations thereof. It is therefore intended that the following appended claims and claims hereinafter introduced are interpreted to include all such modifications, permutations, additions and subcombinations that are within their true spirit and scope.