Diode Accommodation Core for Starter Engine Solenoid
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Solution Overview
Problem
Current methods for installing suppressor diodes in starter engine solenoids are complex, costly, and can damage components due to the need for welding and crimping, which are difficult to execute within the limited space and often result in suboptimal contact quality, leading to electrical pulse issues.
Innovation Solution
A diode accommodation core with a structural body featuring opposite contact sides with accommodation guides that support and expose diode terminals for pressure contact, eliminating the need for welding and crimping, and utilizing a flexible insulating material to ensure secure and isolated terminal positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding and crimping methods are used to install diode terminals, then secure electrical connection is achieved, but the complexity of the manufacturing process increases and component damage risk increases
Solution Approach 1:
The patent replaces the mechanical welding and crimping processes with a pressure-based electrical contact system. The diode terminals are positioned to make direct pressure contact with the solenoid's electrical contacts through the flexible insulating material, eliminating the need for complex thermal and mechanical joining processes while maintaining reliable electrical connection.
Solution Approach 2:
The flexible insulating material serves as an intermediary element that transmits pressure from the solenoid structure to the diode terminals, ensuring secure electrical contact without requiring welding or crimping. This intermediary approach simplifies the manufacturing process while maintaining connection reliability.
2Reliability
If welding and crimping processes are used, then terminal positioning is secured, but the installation time and manufacturing cost increase
Solution Approach 1:
The diode terminals are pre-positioned within the flexible insulating material structure, which is then installed as a complete assembly. This preliminary positioning eliminates the need for time-consuming welding and crimping operations during final assembly, reducing installation time while maintaining terminal positioning stability through the flexible material's pressure contact mechanism.
3Reliability
If welding and crimping are performed in limited space, then electrical connection is achieved, but the risk of damaging existing solenoid structures increases
Solution Approach 1:
The patent eliminates the harmful thermal and mechanical effects of welding and crimping by using a pressure-based contact system. The flexible insulating material applies distributed pressure to establish electrical contact without generating localized heat or concentrated mechanical stress that could damage the solenoid's existing structures.
Solution Approach 2:
The patent changes the physical state and properties of the insulating material to be flexible, allowing it to conform to the limited space within the solenoid and apply appropriate pressure for electrical contact without rigid mechanical force that could cause structural damage.
4Reliability
If additional structural elements are added for diode installation, then secure mounting is achieved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The flexible insulating material serves multiple functions simultaneously: it provides electrical insulation, mechanical support for diode terminal positioning, and pressure transmission for electrical contact. This multi-functionality eliminates the need for separate structural elements for each function, reducing overall device complexity while maintaining mounting security.
Solution Approach 2:
The patent merges the insulation, support, and contact functions into a single flexible insulating material component, eliminating the need for separate brackets, weldments, and mounting structures. This consolidation reduces structural complexity and manufacturing cost while achieving secure diode mounting.
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 solution simplifies the installation process, reduces manufacturing costs, and ensures proper terminal positioning without damaging existing solenoid structures, effectively mitigating electrical pulse issues by maintaining secure and isolated electrical connections.
Implementation Method 1
the solenoid receives an electrical signal through the engine driving terminal thereof, which is also called 'borne #50' in order to trigger the coils of said solenoid and, thus, generate a magnetic field that pulls the solenoid armature
Implementation Method 2
at the time the electrical signal at said borne #50 was stopped, electrical pulses were generated due to the inductance properties of the solenoid's coils
Implementation Method 3
the starter engine manufacturers began to install a voltage suppressor diode with the solenoid, particularly in a parallel connection with the coils, in order to limit said electrical pulses
Data Source
Figure 1~2C
Figure 3~4B
Figure 5A~5C
AI summary
The present invention relates to a diode accommodation core, especially developed for use in solenoids ofstarter engines commonly used in automotive vehicles, being understood by technicial, constructive and functional characteristics totally innovative and capable of obtaining a simple, practical and highly efficient solution regarding installation and accommodation of the diodes in these solenoids without thereby affect the structural configuration of the diodes or the structures of starter engines. More specifically, the diode accommodation core object of the present invention is comprised of a structural body (1 ) having opening (2) for the accommodation of body (4) of diode (D), and two contact sides (3a, 3b) opposite each other, wherein each side is provided with accommodation guide (5', 5") of the respective terminals (6', 6") of said diode (D), which has a surface portion (8) in which at least one of said terminals (6', 6") is supported and at least partially exposed regarding the surface of the corresponding contact side (3a, 3b) of structural body (1 ), in order to promote electrical contact with at least one adjacent component by pressure.