Extension Spark Plug Merging Components for Deep Bore Installation
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Solution Overview
Problem
Existing spark plug designs with multiple pieces are complex, leading to assembly challenges, reduced reliability, and logistical issues, particularly in applications where access is limited, such as in internal combustion engines.
Innovation Solution
A simplified extension-type spark plug design featuring an installation conduit, contact button, electrode extension, ground plate, insulator sleeve, and upper and lower insulators, with a gasket and threaded components for secure assembly, reducing the number of components and enhancing reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple separate pieces are used to create an extension spark plug, then the spark plug can be installed in deep bore applications, but the assembly complexity increases and reliability decreases
Solution Approach 1:
The patent combines multiple separate components (conduit, insulator, electrode, gasket, contact button) into a single pre-assembled unit. This merging eliminates the need for field assembly while maintaining the extension functionality for deep bore installations, directly resolving the contradiction between installation capability and assembly complexity
Solution Approach 2:
The spark plug components are pre-assembled and pre-sealed in the factory before shipment. The conduit is pre-installed with the insulator, electrode, gasket, and contact button in the correct positions and secured together. This preliminary action ensures that the complex assembly is completed under controlled manufacturing conditions rather than in the field, reducing complexity and improving reliability
2Adaptability or versatility
If multiple separate pieces are used to create an extension spark plug, then the spark plug can be installed in deep bore applications, but field assembly is required which reduces reliability
Solution Approach 1:
By merging all critical components into a single pre-assembled unit with factory-sealed connections, the patent eliminates field assembly operations that could introduce errors or compromise seals. The pre-assembled design ensures proper torque distribution and sealing integrity are achieved during manufacturing, not during installation, thereby improving reliability
Solution Approach 2:
All assembly operations including threading, sealing, and electrical connections are performed preliminarily in the factory environment where quality control can be ensured. The pre-assembled unit arrives at the installation site ready for direct installation, eliminating field assembly variables that reduce reliability
3Adaptability or versatility
If accessory pieces are used to extend spark plug reach, then deep bore installations are enabled, but training complexity and logistical issues increase
Solution Approach 1:
The patent merges the extension conduit and all necessary components into a single integrated spark plug unit, eliminating the need for technicians to handle multiple separate accessory pieces. This single-unit design simplifies inventory management, reduces training requirements, and streamlines the installation process while maintaining deep bore installation capability
Data Source
AI summary
An extension-type spark plug (10) is disclosed for igniting the air-fuel mixture in an internal combustion engine. The spark plug (10) includes an installation conduit (12), a contact button (34), an electrode extension (20), a firing electrode (60), a ground plate (66), a sleeve insulator (22), an upper insulator (90) and a lower insulator (50). The electrode extension (20) is axially aligned with and in communication with the firing electrode (60). The ground plate (66) is proximate the firing electrode (60) to define a spark gap between the firing electrode (60) and a first end of the ground plate (66). The sleeve insulator (22) surrounds the electrode extension (20). The upper insulator (90) surrounds an upper portion of the electrode extension (20) and is in contact with the sleeve insulator (22). The lower insulator (50) surrounds the lower portion of the electrode extension (20) and is in contact with the sleeve insulator (22).