Ignition Coil Plug Boot Thin Wall Flex
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Solution Overview
Problem
Existing ignition coil apparatuses for internal combustion engines with bent plug holes require numerous components and complex molding processes, leading to high production costs and potential insertability issues.
Innovation Solution
An ignition coil apparatus featuring a high voltage tower with a cylindrical, electrically insulating and flexible plug boot, including a thin wall part and optional guard portions or sliding guard members, allowing easy insertion into bent plug holes with a simple and cost-effective design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a bendable coil spring and multiple metal fittings are arranged in the plug boot to enable bending, then the insertability into bent plug holes is improved, but the number of component parts increases and production cost becomes high
Solution Approach 1:
The plug boot is designed with a thin wall part that provides flexibility and bendability, eliminating the need for coil springs and multiple metal fittings. The thin-walled structure can naturally deform to accommodate bent plug holes while maintaining electrical insulation and structural integrity.
Solution Approach 2:
The wall thickness of the plug boot is reduced in the bending region to create a thin wall part. This parameter change enables the plug boot to flex and adapt to bent plug holes without requiring additional mechanical components for bending.
2Ease of operation
If the intermediate portion of the plug boot is molded with a bent shape, then insertability into bent plug holes is improved, but molding processing becomes difficult
Solution Approach 1:
Instead of molding the entire plug boot with a bent shape, only a localized thin wall part is created at the bending region. This allows the plug boot to flex during insertion while keeping the rest of the structure simple and easy to mold.
Solution Approach 2:
The plug boot is designed to dynamically adapt its shape during insertion by flexing at the thin wall part, rather than being pre-formed with a fixed bent shape. This dynamic flexibility achieves insertability while simplifying the molding process.
3Ease of operation
If the plug boot wall thickness is reduced to enable bending, then flexibility and insertability are improved, but mechanical strength may be compromised
Solution Approach 1:
The thin-walled plug boot is designed to flex at the thin wall part while maintaining sufficient mechanical strength through proper material selection and wall thickness optimization. The thin wall provides flexibility for bending without compromising overall structural integrity.
Solution Approach 2:
The plug boot may utilize composite material structures or reinforced thin-walled designs that provide both flexibility for bending and sufficient mechanical strength to withstand installation and operational forces.
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 solution enables cost-effective production and maintains insertability without impairing the plug boot's ability to be inserted into bent plug holes, ensuring reliable and efficient operation.
Implementation Method 1
an electrically insulating and flexible plug boot... The plug boot has a thin wall part of a thin thickness formed at a location facing in opposition to a bent portion of the plug hole
Implementation Method 2
a flexible and cylindrical cap that has one end fitted over the high voltage tower, and the other end fitted over the sleeve spaced from a tip end surface of the high voltage tower with a gap therebetween. The gap faces in opposition to a bent portion of the plug hole
Data Source
AI summary
An ignition coil apparatus for an internal combustion engine can be produced at low cost with a simple structure, and can be inserted into a bent plug hole without impairing insertability thereof. The apparatus is provided with a high voltage tower (2b) that holds a high voltage terminal (8) in its interior, and a cylindrical plug boot (10) that has electrical insulation and flexibility and is attached at its one end to the high voltage tower (2b). The plug boot 10 is installed on a main body of the internal combustion engine by being inserted into the bent plug hole. The plug boot (10) has a thin wall part (10a) of a thin thickness formed at a location facing in opposition to a bent portion of the plug hole.