PPS Insulating Housing for High-Temperature Ignition Terminals
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Solution Overview
Problem
Conventional insulating materials in ignition cables for internal combustion engines, such as PTFE, PPA, and silicone rubber, are expensive, prone to deformation or failure at high temperatures, and incompatible with certain chemicals, leading to mechanical and dielectric failures.
Innovation Solution
An ignition terminal with an insulating housing made of polyphenylene sulfide (PPS), which is cost-effective, maintains structural integrity and dielectric properties at high temperatures, and is compatible with steam and petroleum-based materials, replacing multiple insulating components with a single over-molded part.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If PTFE is used for insulating housing, then insulation performance is improved, but cost increases and deformation occurs at high temperatures
Solution Approach 1:
The patent changes the material parameter from PTFE to PPS (polyphenylene sulfide), which has a higher melting point and maintains dimensional stability at temperatures above 450°F, eliminating the gelatinous deformation issue while preserving dielectric properties
Solution Approach 2:
The patent employs a composite structure with PPS as the base material and incorporates fiberglass reinforcement to enhance mechanical strength and thermal resistance, creating a material system that outperforms pure PTFE at high temperatures
2Reliability
If multiple insulating components are used, then insulation reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent consolidates multiple separate insulating components (inner insulator, outer insulator, sealing elements) into a single integrated PPS insulating housing that performs all insulation and sealing functions simultaneously, reducing assembly steps and potential failure points
Solution Approach 2:
The PPS insulating housing serves multiple functions: electrical insulation, high-temperature resistance, chemical compatibility, and mechanical sealing, replacing what previously required multiple specialized components made from different materials
3Ease of manufacture
If conventional insulating materials are used, then ease of manufacture is improved, but compatibility with chemicals and high temperatures deteriorates
Solution Approach 1:
The patent selects PPS material with specific chemical resistance properties that are compatible with steam and petroleum-based materials used in engine environments, while maintaining processability through injection molding techniques
Data Source
AI summary
An ignition terminal built for connection to a spark plug or igniter includes an insulating housing composed of polyphenylene sulfide extending outward from conductive structures within the ignition terminal. The ignition terminal may be an extender that is used to move a point of connection of an ignition cable to the spark plug or igniter outward, so that such a connection can be easily made, or the ignition terminal may be at an end of the ignition cable itself that is directly connected to the spark plug or igniter.