Flexible Ignition Coil Extension for Confined Engine Access

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Solution Overview

Problem

The existing ignition coil assemblies for spark ignited internal combustion engines face difficulties in being easily removed or introduced into engine cylinder heads due to limited space, often requiring costly and complex extension designs to accommodate varying engine dimensions and deep well configurations.

Innovation Solution

An ignition coil assembly featuring an elongated and flexible extension body that can be bent up to 360°, made of a resilient material like rubber, which connects the spark plug receiving end and the ignition coil, allowing for adaptable length and easy handling in confined spaces, along with a detachable spark plug boot and adapter unit for heat protection and insulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If a rigid extension body is used to connect the ignition coil to the spark plug, then the structural stability is improved, but the ease of operation deteriorates due to difficulty in installation and removal in confined spaces

Engineering Contradiction:

Improvestructural stabilityVSAvoidease of installation and removal

Core Design Contradiction:

Stability of the object's compositionVSEase of operation

Solution Approach 1:

The extension body is made of flexible material (rubber or silicone rubber) that allows bending and deformation. This flexible extension body can be bent to navigate the narrow motor compartment space during installation and removal, while maintaining sufficient structural integrity to transmit mechanical forces and maintain electrical connections.

Inventive Principle:

Principle #30Flexible shells and thin films

2Reliability

If the extension body is made rigid to maintain structural integrity, then the reliability is improved, but the adaptability deteriorates due to inability to accommodate varying engine dimensions and deep well configurations

Engineering Contradiction:

Improvestructural integrityVSAvoidadaptability to engine configurations

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The extension body's physical state is changed from rigid to flexible, allowing it to adapt its shape and configuration. The flexible material enables the extension body to be bent to different angles and shapes to accommodate various engine dimensions and deep well configurations while maintaining structural integrity through the material's inherent strength and elasticity.

Inventive Principle:

Principle #35Parameter changes

3Adaptability or versatility

If a long extension body is used to reach deep combustion chambers, then the adaptability is improved, but the ease of operation deteriorates due to limited space in the motor compartment

Engineering Contradiction:

Improvereach to deep combustion chamberVSAvoidhandling in narrow space

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The flexible extension body can be bent and shaped to navigate around obstacles and fit through narrow openings in the motor compartment. Its flexibility allows it to be maneuvered into position even when the motor compartment space is limited, while still reaching deep combustion chambers through the use of adapters and proper routing.

Inventive Principle:

Principle #30Flexible shells and thin films

4Device complexity

If the ignition coil assembly is designed as a single integrated unit, then the device complexity is reduced, but the ease of repair deteriorates due to inability to service individual components

Engineering Contradiction:

Improveintegration of componentsVSAvoidserviceability of components

Core Design Contradiction:

Device complexityVSEase of repair

Solution Approach 1:

The ignition coil assembly is divided into separate serviceable components including the ignition coil, extension body, spark plug boot, and adapter unit. This segmentation allows individual components to be removed, inspected, and replaced independently, improving ease of repair while maintaining a relatively simple overall structure through modular design.

Inventive Principle:

Principle #1Segmentation

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 flexible extension body enables easy installation and removal of the ignition coil assembly in various engine types, preventing damage from heat and ensuring efficient high-voltage insulation, thus simplifying maintenance and reducing space constraints in narrow motor compartments.

Implementation Method 1

An ignition coil assembly (1) featuring an elongated and flexible extension body (6) that can be bent up to 360°, made of a resilient material like rubber

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

along with a detachable spark plug boot and adapter unit for heat protection and insulation

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 3

ensuring efficient high-voltage insulation

Methodology Applied

Scientific EffectElectrical insulation: Dielectric

Data Source

PatentUS10164410B2Spark plug extension

Publication Date: 2018.12.25 SEM AB

AI summary

The following invention relates to an ignition coil assembly for an ignition system comprising an ignition coil where said assembly has a main axis and is configured for insertion into and/or removal out of a well associated with an internal combustion engine, wherein the assembly comprises an elongated extension body made of flexible material, said extension body comprising an upper end portion and a lower end portion wherein the extension body is arranged to be transversally bendable in relation to the main axis so that the upper end portion and the lower end portion may assume an angle (α) in relation to each other.