Connector Plug Protective Tube with Predetermined Bending Points
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Solution Overview
Problem
The production of connector plugs with either straight or curved protective tubes is expensive, necessitating a cost-effective solution that can be easily bent for different engine geometric conditions without compromising protection.
Innovation Solution
A connector plug with a protective tube featuring predetermined bending points, such as recesses in reinforcement ribs, allowing for easy bending into straight or curved configurations while maintaining mechanical robustness and electrical insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If connector plugs are produced with straight or curved protective tubes to meet different engine geometric conditions, then the adaptability to different engine configurations is improved, but the manufacturing cost increases
Solution Approach 1:
The protective tube is designed with variable bending stiffness along its length, creating predetermined bending points where the stiffness is reduced. This allows a single straight protective tube design to be adapted into different configurations (straight, curved at 45 degrees, curved at 90 degrees) by bending at these predetermined points, eliminating the need to manufacture separate curved and straight tube variants and thereby reducing manufacturing costs while maintaining adaptability
Solution Approach 2:
The protective tube is segmented into regions with different structural characteristics - reinforcement ribs in certain areas provide structural integrity, while predetermined bending points with reduced stiffness allow controlled deformation. This segmentation enables the tube to maintain robustness where needed while allowing easy bending at specific locations to achieve different engine configurations
2Reliability
If curved protective tubes are manufactured to fit specific engine geometries, then the fit and protection for specific applications is improved, but the production complexity and cost increase
Solution Approach 1:
The protective tube transitions from a static, pre-formed curved shape to a dynamic structure that can be bent and configured on-demand. The predetermined bending points enable the tube to be adapted to different engine geometries during installation without requiring complex pre-manufacturing processes for each specific curve configuration, thereby reducing production complexity while maintaining reliable protection
3Strength
If the protective tube is made mechanically robust to prevent damage, then the protection function is improved, but the ability to bend the tube easily deteriorates
Solution Approach 1:
The protective tube features non-uniform structural properties: reinforcement ribs are placed in areas requiring high mechanical strength and protection, while predetermined bending points have reduced bending stiffness to facilitate easy bending. This local differentiation of structural quality allows the tube to be mechanically robust where needed while remaining easily bendable at specific locations, resolving the contradiction between strength and ease of operation
Data Source
AI summary
A connector plug is described for connecting an ignition coil to a spark plug, comprising an electrical conductor, which has a first end for contacting the ignition coil and a second end for contacting the spark plug, and a protective tube, which surrounds the electrical conductor. In accordance with this disclosure it is proposed that the protective tube has a predetermined bending point with a reduced bending stiffness.