Flexible Ignitor Assembly for Bent Engine Bore Configurations
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Solution Overview
Problem
Existing ignitors for air/fuel mixtures in automotive applications are limited by their inability to accommodate non-straight or partially obstructed ignitor openings, restricting design flexibility and space utilization in engine cylinder heads.
Innovation Solution
A flexible ignitor assembly with a non-metal tube allowing pivotal movement between the upper inductor subassembly and the lower firing end subassembly, enabling the assembly to fit in bent or multi-axis ignitor holes, and a method involving a ceramic insulator, metal housing, and a spring-biased electrical connector for efficient space utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a straight ignitor assembly is used, then the structure is simple and easy to manufacture, but it cannot accommodate non-straight or partially obstructed ignitor openings
Solution Approach 1:
The ignitor assembly is divided into two separate subassemblies: an upper inductor subassembly and a lower firing end subassembly. These subassemblies are connected by a flexible non-metal tube, allowing each segment to be positioned independently to accommodate complex bore configurations while maintaining overall functionality.
Solution Approach 2:
The non-metal tube connecting the two subassemblies is designed with flexibility to allow relative pivotal movement between the upper inductor subassembly and the lower firing end subassembly. This dynamic capability enables the ignitor assembly to adapt to non-straight and partially obstructed ignitor openings in the cylinder head.
2Adaptability or versatility
If a flexible ignitor assembly with pivotal movement capability is used, then adaptability to complex bore configurations is improved, but device complexity increases
Solution Approach 1:
The electrical connector is extracted from the rigid housing structure and positioned within the flexible non-metal tube. This allows the electrical connector to move independently with the flexible tube, maintaining electrical contact while accommodating pivotal movements between subassemblies.
Solution Approach 2:
A flexible non-metal tube is used to connect the upper inductor subassembly and the lower firing end subassembly. This flexible tube replaces rigid structural elements, enabling pivotal movement and adaptation to complex bore configurations while maintaining the structural integrity and electrical connectivity of the assembly.
3Volume of moving object
If space-efficient complex bore configurations are used in cylinder head, then engine size and weight are reduced, but manufacturing precision requirements increase
Solution Approach 1:
The flexible non-metal tube and pivotal movement capability of the ignitor assembly compensate for variations in bore configuration and positioning tolerances. This dynamic adaptation allows the use of complex, space-efficient bore configurations in the cylinder head without requiring extremely tight manufacturing precision.
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 ignitor assembly allows for efficient use of space in engine cylinder heads, reducing the size, weight, and cost of the engine by accommodating complex bore configurations without compromising functionality.
Implementation Method 1
the lower electrical connector being axially biased relative to the tubular housing by a spring member
Data Source
Figure 1~1A
Figure 2
Figure 3
AI summary
An ignitor assembly constructed in accordance with one aspect of the invention has an upper inductor subassembly coupled to a lower firing end subassembly for relative pivot movement between the subassemblies. The upper inductor subassembly includes a tubular housing with inductor windings received therein with an upper electrical connector adjacent an upper end of the housing and a lower electrical connector adjacent a lower end of the housing. The lower firing end subassembly includes a ceramic insulator and a metal housing surrounding at least a portion of the ceramic insulator. The ceramic insulator has an electrical terminal extending from a terminal end and an electrode extending from a firing end. A flexible tube couples the upper inductor subassembly to the lower firing end subassembly and maintains the electrical terminal of the lower firing end subassembly in electrical contact with the lower electrical connector of the upper at a pivot joint.