Glow Plug Inner Pole Embossing for Reliable Electrical Connection
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Solution Overview
Problem
The existing methods for producing glow plugs with improved mechanical and electrical connections are time-consuming, particularly due to the need for knurling, which is labor-intensive and can be affected by oxide layers on the inner pole extension, limiting extraction and twisting parameters and electrical contact quality.
Innovation Solution
An embossed structure with grooves or elevations is created on the inner pole of the glow plug using opposing stamps with flat or rounded end faces, allowing for a mechanically robust and efficient electrical connection without the need for extensive knurling, enabling better contact by breaking up oxide layers and enhancing mechanical meshing during crimping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If knurling is cut into the inner pole extension to improve mechanical and electrical connection, then extraction and twisting parameters are significantly improved, but production time increases
Solution Approach 1:
The patent replaces the mechanical cutting process (knurling) with an embossing process using stamps. The stamps create the necessary surface structure through pressure and deformation rather than material removal, significantly reducing production time while achieving the same mechanical interlocking and electrical contact improvement
Solution Approach 2:
The patent changes the manufacturing parameter from cutting (material removal) to embossing (plastic deformation). By using stamps with specific geometric patterns pressed onto the inner pole extension, the surface structure is created through controlled deformation, maintaining the functional benefits while reducing process time
2Ease of manufacture
If a plain round rod is used for the inner pole extension to simplify production, then manufacturing is easier, but extraction and twisting parameters are limited
Solution Approach 1:
The embossed structure is created in advance on the inner pole extension before final assembly. The stamps pre-form the mechanical interlocking pattern on the surface, ensuring that when the connector is crimped, the mechanical meshing occurs immediately without requiring additional processing steps
3Ease of manufacture
If oxide layer is present on the inner pole extension to reduce manufacturing complexity, then production is simpler, but contact resistance increases
Solution Approach 1:
The embossing process is performed while the oxide layer is still present on the inner pole extension surface. The stamping action mechanically breaks up and removes the oxide layer during the forming process itself, creating a fresh, low-resistance contact surface without requiring separate oxide removal steps
Solution Approach 2:
The oxide layer, which would normally be harmful to electrical contact, is converted into a beneficial element. The embossing process uses the oxide layer as a sacrificial material that is mechanically broken up during stamping, revealing the clean metal underneath and ensuring good electrical contact without adding extra processing steps
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 method reduces production time and improves mechanical and electrical connection efficiency by creating a cost-effective embossed structure that ensures reliable contact and handling, even with partial embossing on the inner pole circumference, facilitating easier assembly and operation.
Implementation Method 1
two opposite facing stamps which are pressed against the inner pole. The end face of these stamps comprises elevations and/or depressions for embossing the desired structure
Implementation Method 2
any oxide layer present is broken up during the embossing, therefore also enabling a good electrical contact to be produced
Implementation Method 3
a mechanical meshing is obtained between the connector sleeve and the inner pole, or inner pole extension
Data Source
AI summary
A glow plug is described, having a body, a glow pin which protrudes from a first end of the body, and an inner pole which protrudes from a second end of the body and is electrically connected to the glow pin. A section of the inner pole that protrudes out of the body has an embossed structure for improving the mechanical and electrical connection to a plug connector. A method for producing a glow plug is also disclosed.