Spark Plug Boot Remnant Removal Tool Design
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Solution Overview
Problem
Existing tools are ineffective in removing remnant pieces of spark plug boots that break off during removal, especially in hard-to-access locations due to limited clearance and adhesion, causing difficulties in engaging the hex shoulder for unscrewing.
Innovation Solution
A simple tool with a stiff long shaft and a tip, configured to slip into position adjacent the remnant piece and dig into it upon partial rotation, allowing for easy extraction from deep recesses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If existing tools are used to remove remnant pieces of spark plug boots, then the removal process becomes complex requiring multiple elements, but the tool cannot effectively access deep recesses with limited clearance
Solution Approach 1:
The tool is divided into distinct functional segments: a long shaft for reaching deep recesses, a tip for engaging the remnant piece, and a handle for operation. This segmentation allows each part to be optimized for its specific function while maintaining overall simplicity
Solution Approach 2:
The invention extracts only the essential elements needed for the specific task of removing remnant pieces from deep recesses, eliminating unnecessary components. The tool consists of merely three parts (shaft, tip, handle) compared to existing tools requiring four or more elements
2Device complexity
If a simple one-element tool is used, then the device complexity is reduced, but the tool lacks the capability to dig into and remove remnant pieces effectively
Solution Approach 1:
The tip of the shaft is given special local quality with a protruding portion designed to dig into the remnant piece. This localized feature provides the necessary gripping capability without complicating the overall simple one-element structure
Solution Approach 2:
The tip features an asymmetric protruding portion that is specifically shaped to engage with the remnant piece geometry. This asymmetric design allows the tip to dig into and grip the remnant effectively, compensating for the simplicity of the single-element construction
3Productivity
If the boot is removed quickly without special tools, then the process is fast, but the boot tears and leaves remnant pieces on the spark plug
Solution Approach 1:
The tool enables preliminary engagement with the remnant piece before full removal. The protruding tip digs into the remnant first, securing it, then the shaft is pulled to extract the entire remnant in one motion, preventing tearing
Solution Approach 2:
The tool acts as an intermediary between the user and the remnant piece, providing mechanical advantage and proper engagement. The long shaft transmits force from the handle to the tip, enabling controlled removal that prevents tearing while maintaining efficiency
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
Enables efficient removal of remnant spark plug boot pieces without requiring multiple elements, providing easy access and intuitive use, even in tight spaces.
Implementation Method 1
a protruding portion for digging into or slipping under the remnant piece upon the partial rotation of the shaft and for pulling the remnant piece
Data Source
AI summary
A tool facilitates removing a remnant piece of rubber/insulating material on a spark plug located in a deep engine recess, where the piece is a remnant portion (e.g., a ring portion) of an insulating boot from a conductor assembly formerly attached to a top of the spark plug, but where the remnant portion tore away upon removal of the boot. The tool includes a long shaft, a handle, and a tip configured to slip between or under the remnant piece and the spark plug, where it can be partially rotated to slip under or bite into the piece to forcibly pull the piece out of the recess. The tip includes a sharp corner and a chamfered corner adapted to physically dig into (or slip under) the remnant piece upon the partial rotation of the shaft. A related method is also disclosed. The tool can be a strip of 3/16″× 1/32″ steel, such as an oil dipstick.