Electrical Connector With Cutting Element For Ignition Coil
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Solution Overview
Problem
Existing electrical connectors for magnetic ignition coils in internal combustion engines face issues with reliable connections due to thin wire dimensions, potential wire breaking, and the need for special tools, which complicates the connection process and increases production costs.
Innovation Solution
A conductive contact element with flexible walls and a cutting element, combined with a flexible sleeve that moves to create an electric connection by cutting into the insulating material without requiring special tools, ensuring a reliable and compact design with low production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering is used to create connection to ignition coil wire, then reliable electrical connection is achieved, but wire breaking occurs and special tools are required
Solution Approach 1:
The patent replaces the thermal soldering process with a mechanical crimping system. The connector uses a crimping element that mechanically deforms to create electrical contact with the wire, eliminating the need for soldering tools and thermal processes while maintaining connection reliability.
Solution Approach 2:
The connector is designed to be self-installing through a simple push-in motion. The crimping element automatically deforms upon insertion to create the electrical connection, eliminating the need for special tools or complex installation procedures.
2Length of moving object
If wire thickness is reduced to approximately 0.046 mm, then connector dimensions are reduced, but wire breaking and lack of electric contact occur
Solution Approach 1:
The patent employs a flexible crimping element with a specific geometric design that distributes mechanical stress evenly across the thin wire. This flexible structure adapts to the wire's dimensions without causing damage, maintaining wire integrity while ensuring reliable electrical contact.
Solution Approach 2:
The connector design incorporates specific dimensional parameters and material properties that are optimized for thin wires of approximately 0.046 mm thickness. The crimping force, contact surface area, and material hardness are carefully controlled to match the wire's mechanical properties, preventing breakage while ensuring electrical contact.
3Ease of manufacture
If connector structure is simplified to reduce production costs, then manufacturing cost decreases, but connection reliability under mechanical stress and high temperature may be compromised
Solution Approach 1:
The connector is manufactured as a single integrated piece using uniform material composition throughout. This homogeneous structure eliminates weak points that could arise from assembly joints or material transitions, ensuring consistent performance under mechanical stress and thermal conditions while simplifying the manufacturing process.
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 simple, intuitive, and reliable connection that withstands mechanical stress and high temperatures, ensuring effective electrical contact without damaging the wire, while being easy to install and cost-effective to produce.
Implementation Method 1
at least one cutting element being situated on at least one of said flexible walls on the inner surface thereof which faces towards the support element, said cutting element being situated so as to cut into said insulating material covering of said wire
Implementation Method 2
said at least one cutting element of at least one of said flexible walls remains at a distance from said wire wound around said support element, said flexible sleeve being situated above said contact element
Data Source
Figure 1
Figure 2~3
Figure 4A~4B
AI summary
There is described herein an electrical connector (C) for connection to a magnetic ignition coil (B) for an internal combustion engine. The coil (B) comprises a wire (W) which has an insulating material covering and which is wound on a support element (E). The electrical connector (C) comprises a contact element (1) made of conductive material which can be coupled to the support element (E) on which the wire (W) is wound. The contact element (1) has two flexible walls (2), facing one another and outwardly divergent and adapted to come into contact with the support element (E). A cutting element (3) is situated on at least one of the flexible walls (2) on the inner surface (S) thereof which faces towards the support element (E), and is adapted for cutting into the insulating material covering of the wire (W). The connector (C) further comprises a flexible sleeve (5) which can be mounted above and around the contact element (1) to retain the contact element (1) on the support element (E). The flexible sleeve (5) is situated above the contact element (E) and is movable with respect to the contact element (1), after the contact element (1) has been fitted over the support element (E), into a final operative position in which the flexible sleeve (5) pushes the flexible walls (2) of the contact element (1) towards an inwardly inclined position in which said cutting element (3) cuts into the insulating material covering and comes into electric contact with the wire (W).