Spark Plug Insulator Through Hole Bending Prevention
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Solution Overview
Problem
The existing manufacturing methods for spark plug insulators face challenges in using small-diameter press pins, as they tend to bend due to resistance from the green powder, leading to non-straight through holes and increased manufacturing costs.
Innovation Solution
A method that involves arranging the press pin within the cavity before filling with green powder, using a blocking member to minimize resistance, and applying compression molding to form a compact with a straight through hole, allowing for easy extraction of the press pin and reducing bending.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a small-diameter press pin is used to manufacture insulators with smaller diameters, then the insulator diameter is reduced to save space, but the press pin bends due to resistance from green powder
Solution Approach 1:
The press pin is arranged within the cavity before the green powder is filled, allowing the pin to be positioned correctly before compression molding begins. This preliminary positioning prevents bending by ensuring the pin is stable and properly aligned before the resisting force of the green powder acts upon it during compression.
Solution Approach 2:
A blocking member is introduced as an intermediary element to block the opening of the cavity during compression molding. This blocking member minimizes the resistance that the green powder exerts on the press pin by controlling the compression process, thereby preventing pin bending while still allowing the formation of the through hole.
2Device complexity
If the press pin is arranged after powder filling, then the process sequence is simpler, but the press pin bends due to resistance from the green powder
Solution Approach 1:
The press pin is arranged within the cavity before the green powder is filled, allowing the pin to be positioned correctly before compression molding begins. This preliminary positioning prevents bending by ensuring the pin is stable and properly aligned before the resisting force of the green powder acts upon it during compression.
Solution Approach 2:
A blocking member is introduced as an intermediary element to block the opening of the cavity during compression molding. This blocking member minimizes the resistance that the green powder exerts on the press pin by controlling the compression process, thereby preventing pin bending while still allowing the formation of the through hole.
3Manufacturing precision
If the press pin moves a long distance during compression molding, then the through hole is formed more completely, but the press pin bends due to increased resistance
Solution Approach 1:
A blocking member is introduced as an intermediary element to block the opening of the cavity during compression molding. This blocking member minimizes the resistance that the green powder exerts on the press pin by controlling the compression process, thereby preventing pin bending while still allowing the formation of the through hole.
Solution Approach 2:
The compression molding parameters are optimized to achieve complete through hole formation while minimizing the distance the press pin needs to move. By adjusting compression force, speed, and duration, the process achieves effective through hole formation with reduced pin displacement, thereby maintaining pin rigidity and preventing bending.
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 approach enables the production of spark plug insulators with high yield and low manufacturing costs by preventing press pin bending and ensuring straight through holes, even with small diameters.
Implementation Method 1
as a compression molding step, the green powder within the cavity is pressed along with the press pin to obtain a compact
Implementation Method 2
the green powder within the cavity is pressed along with the press pin to obtain a compact
Implementation Method 3
the green insulator is sintered at a temperature of 1400°C to 1650°C. Thereby, a pinhole formed by the press pin becomes the through hole
Data Source
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AI summary
A method for manufacturing an insulator for a spark plug is provided. The method includes: a preparing step; a press pin arranging step; a powder filling step after the press pin arranging step; a cavity blocking step after the powder filling step; a compression molding step after the cavity blocking step; a die releasing step after the compression molding step; and a press pin removing step after the die releasing step.