Engine Plug Hole Cover Structure with Integrated Rain Shield
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Solution Overview
Problem
The conventional cover structure for plug holes in engine cylinder heads is costly due to the need for multiple types of plug caps and complex manufacturing, as it requires a rain cover and projection portions that vary with plug hole depth, leading to increased production complexity and costs.
Innovation Solution
A cover structure comprising a detachable plug cap with an outer cover and a seal member on the cylinder head cover, featuring projection portions and convex portions that form a maze-like structure to prevent water entry, with features like water discharging cut portions and cable routing to improve assemblability and prevent water vaporization and pressure issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rain cover is fitted to the opening of the plug hole with a projection portion, then rainwater entry is restrained, but the number of plug cap types increases and manufacturing complexity increases
Solution Approach 1:
The plug cap is designed with an integrated rain cover and projection portion that can be universally applied to plug holes of different depths. The projection portion extends from the rain cover to press against the cylinder head cover, creating a standardized structure that eliminates the need for multiple plug cap variants while maintaining effective water shielding across different engine models.
2Reliability
If a projection portion is formed at the outer circumferential edge of the plug hole opening, then rainwater entry is restrained, but manufacturing the cylinder head cover becomes difficult
Solution Approach 1:
The water shielding function is segmented between the plug cap's projection portion and the cylinder head cover. Instead of forming complex projection portions directly on the cylinder head cover, the projection is integrated into the removable plug cap, simplifying the cylinder head cover manufacturing process while maintaining the same water shielding effect through the plug cap's projection pressing against the cover.
3Reliability
If multiple types of plug caps are prepared according to plug hole depth, then proper fit is achieved, but production cost increases
Solution Approach 1:
The plug cap design incorporates a projection portion with adjustable or variable effective length that can accommodate different plug hole depths. This parameter variation within a single standardized design allows the same plug cap type to fit multiple plug hole depths, reducing inventory requirements while maintaining proper fit and sealing across different engine models.
Data Source
AI summary
A cover structure of a plug hole provided to a cylinder head cover of an engine includes: a plug cap detachably attached to the plug hole; an outer cover covering at least an upper side of the plug cap; and a seal member provided on an upper face of the cylinder head cover and surrounding a periphery of the plug hole. In the cover structure, the outer cover has a projection portion projected toward the cylinder head cover, and the seal member is pressed to the upper face of the cylinder head cover by the projection portion.