Bent Ignition Coil Rigid Intermediate Member Insertion
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Solution Overview
Problem
The installation and maintenance of bent ignition coil devices in internal combustion engines are hindered by low workability due to the tilted center axis of the ignition plug relative to the high voltage terminal, leading to difficulties in inserting the plug into the plug hole, especially in engines with limited opening, and potential deformation of the plug boot.
Innovation Solution
An ignition coil device with a rigid intermediate member that connects the high voltage terminal to the ignition plug, featuring a boot base and a boot leading end with a tilt at the bend position, allowing direct insertion force application and improved insertion properties, while maintaining electrical and mechanical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the ignition coil is bent to accommodate the tilted plug center axis, then the device can be installed in engines with complicated and downsized structures, but the insertion property deteriorates and the plug boot may deform
Solution Approach 1:
The ignition coil device is divided into distinct segments: a rigid upper portion (case, transformer structure, high voltage terminal) and a flexible lower portion (plug boot). This segmentation allows the upper portion to maintain its rigid bent configuration for adaptability while the flexible plug boot absorbs insertion forces without deformation
Solution Approach 2:
The plug boot material properties are optimized to provide flexibility in the insertion direction while maintaining rigidity in other directions. The bend position is strategically located to change the structural parameters of force distribution, allowing the boot to flex during insertion while maintaining its bent shape for installation adaptability
2Adaptability or versatility
If the center axis of the ignition plug is tilted with respect to the high voltage terminal, then the device can fit complicated and downsized engine structures, but the workability for inserting the plug into the plug hole deteriorates
Solution Approach 1:
The flexible plug boot acts as an intermediary element between the rigid high voltage terminal and the ignition plug. It mediates the mismatch between the tilted center axes by providing a flexible connection that can accommodate angular misalignment during insertion while maintaining electrical connectivity
Solution Approach 2:
The plug boot transitions from a static rigid structure to a dynamic flexible structure that can adapt its shape during insertion. The boot's flexibility allows it to dynamically adjust to the tilted angle between the high voltage terminal and plug hole, improving workability while maintaining the bent configuration for structural adaptability
Data Source
AI summary
In an ignition coil device mainly mounted in an internal combustion engine, the installation can be improved even in an ignition coil having a bent leading end. The ignition coil device of a bent type includes a case having a transformer structure with a primary coil and a secondary coil therein; a high voltage tower including a high voltage terminal that transmits a high voltage developed in the secondary coil to a lower portion of the case; and a plug boot that electrically and mechanically connects the high voltage terminal, the high voltage tower to an ignition plug, includes a boot base close to the high voltage tower and a boot leading end close to the ignition plug in which a center axis of the high voltage tower and a center axis of the boot leading end are tilted, wherein a bend position is set in the vicinity of an intersection point of the center axis of the high voltage tower and the center axis of the boot leading end, and a rigid intermediate member including a connection relay member that electrically connects the high voltage terminal and the ignition plug is provided, and the rigid intermediate member extends from the boot base to the bend position.