Coaxial Twin Spark Plug Using Standard Insulators
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Solution Overview
Problem
Dual gap spark plugs with asymmetrical insulators increase manufacturing complexity and cost, making them less desirable.
Innovation Solution
A spark plug design featuring two independent spark gaps with coaxially aligned electrodes and insulators, using a cylindrical electrode assembly and a center wire assembly to form axially spaced spark gaps, allowing for the use of standard-shaped insulators and reducing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If dual gap spark plugs use asymmetrical insulators to achieve two independent spark gaps, then ignition functionality is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent applies asymmetry in reverse - it uses a symmetrical, standard-shaped insulator to achieve the dual spark gap function, avoiding the need for custom asymmetrical insulator designs. The asymmetry is achieved through the electrode configuration rather than the insulator shape itself.
Solution Approach 2:
The patent divides the spark plug into distinct functional segments: the standard insulator, the cylindrical electrode assembly, and the center wire assembly. This segmentation allows each component to be manufactured independently using standard processes, reducing overall manufacturing complexity.
2Reliability
If dual gap spark plugs use asymmetrical insulators to achieve two independent spark gaps, then ignition functionality is improved, but manufacturing cost increases
Solution Approach 1:
The standard-shaped insulator serves multiple functions: it provides electrical insulation, structural support, and a standardized interface for installation. By using a universal insulator design rather than a custom asymmetrical one, manufacturing costs are reduced while maintaining dual spark gap functionality.
Solution Approach 2:
The patent uses a standard-shaped insulator that can be mass-produced using existing molds and processes, rather than requiring new custom tooling for asymmetrical insulators. This copying of standard designs significantly reduces manufacturing costs.
3Reliability
If dual gap spark plugs use asymmetrical insulators, then two independent spark gaps are achieved, but standard-shaped insulator usage is prevented
Solution Approach 1:
Instead of making the insulator asymmetrical to achieve dual spark gaps, the patent inverts the approach by keeping the insulator symmetrical and standard-shaped, and achieving the dual gap function through the electrode configuration. This allows standard insulators to be used while maintaining the desired functionality.
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
This design simplifies the manufacturing process and reduces costs while maintaining the functionality of dual gap spark plugs by using standard insulators and ensuring independent spark gaps for efficient ignition.
Implementation Method 1
The center wire assembly is responsible for delivering a high voltage ignition pulse from an ignition wire to a single spark gap
Implementation Method 2
a spark plug having two independent spark gaps formed between two coaxial electrodes
Data Source
AI summary
A spark plug having a pair of independent spark gaps includes a shell, inner and outer insulators, a cylindrical electrode assembly, a center wire assembly, and a pair of ground electrodes. The cylindrical electrode assembly is generally located between the two insulators and delivers a first high voltage ignition pulse to a first spark gap. The center wire assembly is located in an axial bore of the inner insulator and delivers a second high voltage ignition pulse to a second spark gap. The two insulators and two electrode assemblies are all coaxially aligned within the shell so that both insulators can be rotationally symmetrical. The first spark gap is radially oriented while the second spark gap is axially oriented, and the first and second spark gaps are located at different axial positions and can fire independently of one another. A method of assembling the spark plug is also disclosed.