Starter Solenoid Diode Retention Using Toroidal Space
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Solution Overview
Problem
Conventional starter motor solenoids require non-standard diode leads due to space constraints, increasing production costs and lead times.
Innovation Solution
The solenoid design incorporates a toroidal space with diode holders that allow standard diode leads to be used, with diodes positioned within the holders and connected to a conductive stop member, enabling secure retention and electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If suppressor diodes are physically retained adjacent to the spools within pockets of a spacer between two solenoid coils, then the diodes can be retained in a compact space, but non-standard diode leads with non-conventional lengths must be used which drive up lead times and production costs
Solution Approach 1:
The patent positions the diode holders in the toroidal space (a three-dimensional space surrounding the coil) rather than in a two-dimensional plane within the spacer pocket. This spatial reconfiguration allows standard lead-length diodes to reach the connection points without requiring non-conventional lead lengths, thereby reducing production costs and lead times while maintaining compact retention.
Solution Approach 2:
The patent introduces a conductive stop member as an intermediary element that facilitates the electrical connection between the diode and the solenoid circuit. The stop member serves as a mediator that enables standard diodes to connect properly without requiring custom lead lengths, thus resolving the contradiction between compact retention and ease of manufacture.
2Reliability
If suppressor diodes are retained within pockets of a spacer between two solenoid coils, then the diodes are securely retained, but the arrangement requires diodes with non-conventional lead lengths which increases production complexity
Solution Approach 1:
By moving the diode holders into the toroidal space and using a conductive stop member for connection, the patent maintains secure diode retention while simplifying the production process. Standard diodes can be used without custom lead bending or special positioning, reducing production complexity while preserving retention security.
Solution Approach 2:
The conductive stop member serves multiple functions: it provides structural support, enables electrical connection, and facilitates diode retention. This multi-functional element allows standard diodes to be used universally without requiring custom modifications, thereby reducing device complexity while maintaining reliable retention.
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 design enables the use of standard diodes, reducing production costs and lead times by allowing for easier integration and connection of diodes within the solenoid.
Implementation Method 1
The solenoid includes a coil that is energized by a battery upon the closing of an ignition switch. When the solenoid coil is energized, a plunger moves in a linear direction
Implementation Method 2
The suppressor diode is a diode that is connected in parallel with the coil and configured to eliminate or reduce sudden voltage spikes that may be experienced across the coil's inductive load when the current to the coil is suddenly reduced or interrupted
Data Source
AI summary
A solenoid for a motor vehicle starter includes at least one coil wound on at least one spool, the at least one coil defines a toroidal space encircling the at least one coil. A stop member is positioned adjacent to the at least one spool. A diode holder is positioned in the toroidal space defined by the at least one coil, and a diode is positioned in the diode holder. The diode includes a cylindrical body, a first lead extending from a first end of the cylindrical body, and a second lead extending from a second end of the cylindrical body. The cylindrical body of the diode is retained by the diode holder within the toroidal space, and the first lead of the diode extends out of the toroidal space and is electrically connected to the stop member.