Spark Plug Connector With Segmented Structural Element
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Solution Overview
Problem
Spark plug connectors face significant stress from engine vibrations, leading to reduced lifespan due to their heavy weight and high material costs, while needing to maintain high insulation capabilities and structural integrity under extreme conditions.
Innovation Solution
A spark plug connector design featuring a connector body made of ceramic or plastic PTFE and a structural element with reinforcement fibers, such as polyphenylene sulfide with 30-40% glass fiber content, which reduces weight and enhances rigidity, guiding the ignition cable within a channel and secured with a flange or rubber grommet for protection and support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the spark plug connector is made entirely of PTFE to ensure high insulation capability, then the insulation performance is improved, but the weight increases and vulnerability to engine vibrations worsens
Solution Approach 1:
The connector is divided into two distinct parts: a PTFE insulator body for electrical insulation and a separate structural element for mechanical support. This segmentation allows each component to be optimized for its specific function without the compromises required by a monolithic design.
Solution Approach 2:
The connector combines PTFE material with a structural element made of different material properties, creating a composite structure that leverages the high dielectric strength of PTFE while gaining the vibration resistance and structural integrity of the complementary material.
2Reliability
If the spark plug connector is made entirely of PTFE to ensure high insulation capability, then the insulation performance is improved, but the cost increases
Solution Approach 1:
By dividing the connector into functional segments, the expensive PTFE material is used only where absolutely necessary for insulation, while less costly materials are used for structural support, thereby reducing overall material costs.
Solution Approach 2:
The PTFE material is applied locally only to the insulator body where insulation is critical, rather than throughout the entire connector structure, optimizing material usage and reducing cost.
3Strength
If the spark plug connector has heavy weight to maintain structural integrity, then the structural strength is improved, but the vulnerability to engine vibrations increases
Solution Approach 1:
The separation of insulator and structural element allows the structural element to be specifically designed for vibration resistance through appropriate material selection and geometric optimization, independent of the insulation requirements.
Solution Approach 2:
The composite structure combines materials with complementary properties, where the structural element is specifically chosen for its vibration resistance characteristics while the PTFE provides insulation.
4Adaptability or versatility
If the spark plug connector uses long shaft length to reach deep spark plug recesses, then the adaptability is improved, but the stress from vibrations increases
Solution Approach 1:
The long shaft is segmented into a PTFE insulating portion and a separate structural element, allowing the structural element to be optimized for mechanical strength and vibration resistance over the extended length required for deep recess accommodation.
Data Source
AI summary
A spark plug connector (1) including a connector body (21) formed as an insulator having a spark plug high voltage contact (35) for producing a connection to and with a spark plug (6). The connector body (21) has a connection point (23) for receiving, mounting and/or connection of a spark plug connector (1) extending structural element (22). The structural element (22) is arranged at the junction (23) in such a manner such that the structural element (22) lengthens the connector body (21) on the side remote from the spark plug high voltage contact. The ignition cable (3) is held or guided along the length of the structural element (22) and the material of the structural element has a higher rigidity and strength and/or a lower density with at the same time less material than the material of the connector body (21).