Bent Spark Plug Connector Design for Deep Well Engines
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Solution Overview
Problem
Current spark plug connectors for complex and compact engines with non-straight spark plug wells are costly, complex, and require additional space for external handles to ensure proper assembly and electrical connection.
Innovation Solution
A compact spark plug electrical connector featuring a bent tubular boot with an internal conductive rod and springs, along with flat plates, that matches the angle of the spark plug well, ensuring a secure and efficient electrical connection without external handles, using a soft silicone boot and smooth conductive elements to prevent damage during assembly and operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an external handle is added to ensure proper assembly of the soft boot onto the spark plug terminal, then the electrical connection reliability is improved, but the device complexity and cost increase
Solution Approach 1:
The connector is designed to assemble itself without external handles. The soft boot's elasticity and the retaining means work together to automatically secure the boot onto the spark plug terminal when inserted, eliminating the need for external assembly aids and reducing device complexity while maintaining connection reliability
Solution Approach 2:
The connector is divided into distinct functional segments: the soft boot for insulation and flexibility, the retaining means for secure attachment, and the electrically conductive means for electrical connection. This segmentation allows each component to perform its specific function efficiently without requiring complex integration or external assembly tools
2Adaptability or versatility
If a metallic coil spring is placed inside the boot to enable bending accommodation, then the adaptability to bent wells is improved, but the device complexity and space requirements increase
Solution Approach 1:
The boot is made of soft, flexible material that can bend to accommodate the angled well configuration. This flexible shell approach eliminates the need for rigid metallic coil springs while maintaining the ability to adapt to bent well geometries, thereby reducing device complexity and space requirements
Solution Approach 2:
The boot material properties are selected to provide appropriate flexibility and elastic recovery, allowing it to bend to the required angle and maintain electrical connection. By changing the material parameters (softness, elasticity) rather than adding mechanical spring components, the design achieves adaptability with simpler construction
3Adaptability or versatility
If the connector is designed to bend to accommodate the bent well, then the adaptability to complex engine designs is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The flexible boot material naturally conforms to the bent well angle through elastic deformation rather than requiring precisely manufactured rigid bends. This approach tolerates variations in well angle while maintaining functional performance, significantly reducing manufacturing precision requirements compared to rigid bent structures
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a simpler, cheaper, and more compact connector design that maintains electrical integrity and prevents damage, ensuring reliable spark plug connections in complex engine configurations without the need for external handles.
Implementation Method 1
an electrically insulating tubular boot
Implementation Method 2
made of soft material such as silicone
Implementation Method 3
an electrically conductive means connecting the coil to the spark plug
Implementation Method 4
comprises a first spring connected to the spark plug and a second spring connected to the ignition coil
Data Source
Figure 1
Figure 2
AI summary
Spark Plug Electrical Connector for connecting an ignition coil to a spark plug especially for use with an engine in which a spark plug is located within a deep and bent well while the ignition coil is outside the well, the connector comprising an electrically insulating tubular boot inside of which is an electrically conductive means connecting the coil to the spark plug. To accommodate the bent well the electrically conductive means is bent accordingly and serves as a strengthening member extending from the spark plug end to the coil end.