Spark Ignition Engine Head Cover Plug Cap Mounting
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Solution Overview
Problem
Conventional spark ignition engines with ignition-coil-integrated plug caps require a dedicated plug cap attachment flange and gasket, increasing assembly costs and man-hours due to the need for additional components and complex mounting procedures.
Innovation Solution
Forming cylindrical parts on the head cover to support plug caps, eliminating the need for a separate plug cap attachment flange and gasket by using press-fitted pipe materials and incorporating a fixing unit with a female screw part on the valve operating mechanism housing part to secure the ignition-coil-integrated plug caps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a dedicated plug cap attachment flange and gasket are used to support ignition-coil-integrated plug caps, then the plug caps can be securely mounted, but the number of components increases and assembly complexity increases
Solution Approach 1:
The patent combines the plug cap attachment flange and gasket functions into the head cover itself. The head cover is designed with integrated attachment structures including cylindrical parts for supporting plug caps and fixing units with female screw parts, eliminating the need for separate attachment flange and gasket components while maintaining secure mounting reliability
Solution Approach 2:
The head cover is designed to perform multiple functions: it covers the valve operating mechanism housing part, provides structural support, and integrates the plug cap attachment functionality through built-in cylindrical parts and fixing units. This multi-functional design eliminates the need for dedicated attachment components
2Reliability
If a dedicated plug cap attachment flange and gasket are used, then secure mounting is achieved, but assembly time increases
Solution Approach 1:
By integrating the attachment flange and gasket functions into the head cover, the number of assembly steps is reduced. The plug caps can be directly mounted to the head cover using the integrated fixing units, eliminating the separate assembly operations required for attachment flange and gasket installation
Solution Approach 2:
The head cover is pre-designed with integrated attachment structures including cylindrical parts and fixing units during the head cover manufacturing process. This preliminary integration of mounting features eliminates the need for separate attachment component installation during final assembly
3Ease of operation
If deep plug holes are formed in the cylinder head for spark plugs, then proper spark plug installation is enabled, but manufacturing cost increases due to cutting work
Solution Approach 1:
The patent introduces cylindrical parts as intermediary structures formed on the head cover. These cylindrical parts serve as intermediate mounting structures that support the plug caps, replacing the need for deep cutting operations in the cylinder head while maintaining the capability for proper spark plug and ignition coil assembly
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 approach reduces assembly costs and man-hours by eliminating unnecessary components and simplifying the assembly process, while also minimizing unnecessary thickness and cutting work costs associated with deep hole formation.
Implementation Method 1
the pipe material is inserted in the mounting hole part by press-fitting
Data Source
AI summary
A cylindrical part capable of supporting an ignition-coil-integrated plug cap is formed on a head cover so as to correspond to a plug hole of a cylinder head. The cylindrical part is formed by fitting and fixing a pipe material to a mounting hole part formed in the head cover, the mounting hole part facing the plug hole.