Spark Plug Coupler Flexible Coils Vibration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing spark plug couplers face issues with maintaining a secure and reliable electrical connection under varying conditions such as temperature changes and vibrations, often leading to degradation of the physical and electrical connection due to the rigidity of solid tabs and the potential for damage from thin, straight prongs used in prior devices.
Innovation Solution
A coupler formed from a single piece of electrically conductive wire, with coils defining cavities for both the power cable and spark plug terminal, providing a flexible and resilient connection through interference fits and frangible tangs for easy assembly and reduced risk of damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If solid tabs are used to connect the power cable and spark plug terminal, then the electrical connection is stable, but the connection degrades under temperature changes and vibrations
Solution Approach 1:
The patent replaces rigid solid tabs with flexible coil structures formed from wire. The coils can deform elastically under thermal expansion and vibrational stress, maintaining continuous electrical contact without degrading the connection. This flexibility allows the coupler to accommodate dimensional changes while preserving connection integrity.
Solution Approach 2:
The coupler transitions from a static rigid structure to a dynamic flexible structure. The wire coils can dynamically adjust their shape and position in response to external forces and thermal conditions, ensuring continuous reliable electrical connection throughout operating conditions.
2Ease of operation
If thin straight prongs are used for connection, then the assembly is simple, but there is potential for damage during installation
Solution Approach 1:
The flexible wire coils are more resistant to installation damage compared to thin straight prongs. The coiled structure distributes mechanical stress along the wire length rather than concentrating it at a single point, reducing the risk of breakage during assembly while maintaining ease of insertion.
Solution Approach 2:
The coil structure inherently provides mechanical cushioning against impact and stress during installation. The coiled configuration absorbs shock and distributes forces, protecting the connection points from damage before the actual electrical connection is established.
3Ease of manufacture
If rigid structures are used for the coupler body, then the manufacturing is straightforward, but the connection degrades under vibrations and temperature changes
Solution Approach 1:
The patent forms the coupler body and connecting elements as flexible wire coils rather than rigid cast or machined parts. This flexible construction maintains connection reliability under thermal and vibrational stress while remaining manufacturable through wire forming and coiling processes.
Solution Approach 2:
The invention changes the physical state and mechanical properties of the coupler material from rigid to flexible. By using wire with appropriate elasticity and forming it into coils, the coupler can dynamically respond to environmental conditions while maintaining electrical connection integrity.
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 flexible coils ensure a sturdy and reliable electrical connection under various conditions, including high temperatures and vibrations, while minimizing the risk of damage to the cable and boot during installation, thus maintaining efficient spark generation in internal combustion engines.
Implementation Method 1
A coupler for a spark plug includes a body formed from an electrically conductive material and including a first connecting portion defining a first cavity, and a second connecting portion defining a second cavity spaced from the first cavity
Implementation Method 2
The weakened portion may be defined by or include a notch or slot which provides a thinner or weaker portion of the wire at which the wire will break when sufficient force is applied
Data Source
AI summary
In at least some implementations, a coupler for a spark plug includes a body formed from an electrically conductive material and including a first connecting portion defining a first cavity, and a second connecting portion defining a second cavity spaced from the first cavity, and the body includes an intermediate portion physically and electrically coupling the first connection portion and the second connecting portion. In at least some implementations, the first connecting portion is formed from a wire coiled to define the first cavity within the coil. In at least some implementations, the second connecting portion is formed from a wire coiled to define the second cavity within the coil.