Specification
FORM-2
THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENTS RULES 2003
Complete Specification
(See section 10; rule 13)
NOISE SUPPRESSOR SPARK PLUG CAP
CHHEDA VIJAY JAGDISH
an Indian National
of 14, Hadapsar Industrial Estate, Pune 411 013,
Maharashtra, India
THE FOLLOWING SPECIFICATION PARTICULARLY DESCRIBES THE INVENTION AND THE MANNER IN WHICH IT IS TO BE PERFORMED.
FIELD OF INVENTION
The subject invention relates to an ignition apparatus in an automobile, particularly a two wheeler. The subject invention particularly relates to a noise suppressor spark plug cap for a spark-ignited internal combustion engine.
BACKGROUND OF THE INVENTION
A spark plug is a device that extends into the combustion chamber of an internal combustion engine and produces a spark to ignite a mixture of air and fuel. A typical induction ignition system of an internal combustion engine produces a rapid voltage rise in a secondary winding of an ignition coil which is electrically connected to a center electrode of a spark plug. Spark plug and other such ignition devices used in internal combustion engines are thus subjected to high temperature environments produced in the combustion chambers. Such high temperature environment has a damaging effect on the different components of the spark plug and eventually causing diminishing performance of the spark plug. There are various ways in which the spark plug is negatively affected. One way in which the spark plug performance is negatively affected involves the conductance of the center wire assembly and the other is corrosion or breakdown of materials or other phenomena accelerated by extreme heat and intense vibrations. This factor affects the conduction characteristic of the components, thus altering the intensity of the ignition pulse and ultimately the spark delivered to the combustion chamber. If the voltage applied at the secondary winding is too high, a gap between the center electrode and a ground electrode will ionize
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and a spark discharge will occur therein. In the absence of some means of suppression in the ignition circuit, this initial spark discharge will be followed by relatively high frequency, oscillatory spark discharges. These discharges are the source of EMI which causes interference in electronic equipment which is sensitive to the frequency of the discharge and also causes noise due to oscillatory vibration. Ignition EMI is a nuisance and in extreme cases can cause performance and safety related malfunctions. Electromagnetic emission is the phenomenon by which electromagnetic energy emanates from the source. The extent to which equipment is resistant to electromagnetic interference without malfunctioning (degradation of performance) or damage is termed as Electromagnetic immunity (EMI). Electromagnetic compatibility (EMC) is the study of the unintentional generation, propagation and reception of electromagnetic energy with reference to the unwanted effects or electromagnetic interference that such energy may induce. The goal of this study is the correct operation, in an electromagnetic environment, of different equipment which uses electromagnetic phenomena, and the avoidance of any interference effects. Electromagnetic interference is the degradation of the performance of equipment, transmission channel or system, caused by an electromagnetic emission. This is the result of EMC being unsatisfactory. Electromagnetic interference is the main source of noise generation in the ignition system. A basic noise suppression filter includes the following two components -
1) A capacitor installed between the signal line and ground line. As the frequency becomes higher, the impedance of the capacitor becomes lower. Thus the noise is forced to go through the bypass capacitors to ground.
2) An inductor coil or the resistive wound wire installed in series with the signal line. As the frequency increases, the impedance of the inductor
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increases which prevents noise from flowing into the signal line. Lack of filter grounding simplifies installation of inductor filters.
The levels of EMI emitted by a spark ignition system engine can be controlled or suppressed in many ways. Commonly, EMI suppression of the ignition system itself is accomplished by the use of resistive spark plugs, resistive ignition leads, and inductive components in a secondary high voltage ignition circuit. The use of resistive noise suppression devices along with spark plugs is well known. A common type of resistor/suppressor spark plug used for the suppression of EMI contains an internal resistor element placed within the ceramic insulator between the upper terminal stud and the lower center electrode.
Several devices and systems for EMI noise suppression have been disclosed in the prior arts.
U.S. Patent No. 2,323,399 issued July 6, 1943, comprises a hood-like housing, having an outer conducting rubber material and an inner layer formed of soft insulating rubber material, which is to shield the EMI. The hood like structure of the housing is pulled over the spark plug base while the other opening of the housing is pulled over the lead wire end. The lead wire end abuts against the terminal of the spark plug. A drawback of this invention is that the housing made up of insulating inner lining does not effectively shield the EMI. Further the rubber being soft material, does not provide a robust protection to the spark plug and the lead wire. Again since the lead wire is made to abut against the spark plug, hence the connection is affected due to heat and vibration which the elements are subjected to during operational condition.
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U.S. Patent No. 3,686,607 issued August 22, 1972, uses a high frequency radiation suppression shield which is positioned around a moulding, housing a radiation suppression resistor positioned between adjacent ends of a spark plug lead wire and a spark plug. A moulding metal screen is supported from a cylinder and is adapted to fit over the base of a spark plug by means of a connecting strip between the cylinder and the screen. Such structure has the disadvantage of being a separable article subject to being lost. Further, the high frequency shield disclosed in this patent is exposed and therefore subject to damage. Also, the grounding of the high frequency shield in this structure is through the connecting strip and the hexagonal cylinder into the base of the spark plug, and since the cylinder is a slip-fit on the spark plug base, the ground connection for the shield is not always satisfactory. U.S. Patent No. 3,881,051, issued April 29, 1975, comprises a shield which houses an insulating boot, a spark plug, a lead wire and a resistor. The resistor is connected at one axial end to the spark plug electrode through a sleeve and the other end of the resistor is connected to the lead wire by a connector. The drawback of this invention is that the resistor, which is a sensitive element, is connected directly to the spark plug electrode. Thus, the heat and the vibration generated in the spark plug is transmitted directly to the resistor, which reduces the operational life of the resistor. In case of malfunctioning of the resistor, the spark plug and the lead wire also needs to be replaced, since the resistor, the spark plug and the lead wire connector is assembled in the same shield.
U.S. Patent No. 3,965,879, issued June 29, 1976, uses a two piece tubular L shaped shield provided with a pivotal joint to permit opening of the two shield members. A flexible coil in the form of a coiled spring is placed over
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a portion of the high tension lead immediately adjacent to the spark plug connection and extends from beneath the shield as an extension thereof. A disadvantage of this invention is the use of a two piece housing which renders the housing to be easily damaged due to vibration. Further the construction of this invention is complex. Again, another disadvantage of this invention is that it is not effective in suppressing EMI.
U.S. Patent No. 6, 724, 289, issued April 20, 2004, disclose a pencil coil type ignition apparatus that includes an electrically conductive cup configured to engage and surround the high voltage terminal, thereby suppressing the electromagnetic field concentration at the high voltage terminal. Further, it uses a predetermined amount or volume of the insulating resin, which has a certain cost. It would be desirable to reduce this cost. U.S. Publication No. 2005/0093414, published May 5, 2005, illustrates use of an intermediate connecting pin lodged in the central passage of the insulator, generally midway between a center electrode at the lower end of the insulator and a terminal post at the upper end of the insulator. The contact pin fits within the central passage and includes a threaded lower portion, which is embedded in the conductive glass seal above the center electrode. The glass seal may have several distinctive layers to provide desirable electrical characteristics such as suppression of high frequency interference. Such a structure has the disadvantage of gasses being trapped in the smooth piston-like fit of the connecting pin within the central passage during assembly, thereby creating gas bubble inclusions within the glass seal which degrade electrical performance during use.
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U.S. Patent No. 7,228,853 Bl, issued June 12, 2007, has a housing which comprises an outer layer of electrically conducting material, an intermediate layer of electrically insulating material and an inner lining of an insulating resin. The housing includes a conductive cup, a resistor and a spring. One of the resistor caps is electrically engaged with the conductive cup which is connected to the lead wire. The other resistor cap is made smaller than the first cap such that it forms a shoulder to fit the spring. The other end of the spring is made to fit the spark plug. The housing also includes two magnets, a primary winding and a secondary winding. Thus, in the case of malfunctioning of any of the parts, the entire assembly is required to be replaced. The spring being directly connected to the spark plug, is subject to high temperature and vibrations which has a damaging effect on the spring and also on the resistor. Another disadvantage arises due to the special design of the resistor which is expensive. Yet another drawback of the design is that the complex assembly of the housing involves several layers.
U.S. Patent No. 2007/0293064 Al issued December 20, 2007, uses an ignition wire end and a spark plug receiving end which are housed in a spark plug boot having an elbow. The spark plug boot is made up of 3 layers — an inner layer of PBT material, an intermediate layer of rubber and an outer casing of steel. The wire end includes a wire receiving portion and a resistive element portion. The resistive element is located in between the wire end and the spark plug receiving end. The resistive element is connected to the spark plug receiving cap, either directly or by means of an intermediate element. A disadvantage of this design is the use of an intermediate element. Incase of dislocation of the intermediate element the electrical contact is hampered. One major drawback of this design is the use of the multi-layered
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housing. Such housing besides increasing the cost of manufacturing also makes the manufacturing process complex and time consuming.
Accordingly, there is a need for an improved noise suppression device for ignition apparatus in internal combustion engine that minimizes or eliminates one or more of the shortcomings as set forth above.
OBJECT OF THE INVENTION
It is an object of the instant invention is to provide a noise suppression spark plug cap for a spark plug which eliminates the disadvantages of the prior art caps.
It is yet another object of the instant invention to provide superior electrical contact between the various parts.
Another object of the present invention is to provide for effective noise suppression due to EMI.
A further an object of the present invention is to reduce the cost incurred in assembling.
Still another object of the present invention is to provide a device which is simple to manufacture.
Again another object of the present invention is to develop a robust device. It is still another object of the present invention to provide a device which is not affected by moisture.
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Another object of the present invention is to provide a device which is cost effective.
Further an object of the present invention is to provide a long lasting device. Still another object of the present invention to provide a device which is compact.
SUMMARY OF THE INVENTION
In accordance with the present invention there is provided a noise suppressor spark plug cap which typically comprises:
a) an L-shaped shaped hollow housing having a long and a short arm of synthetic polymeric material;
b) a metallic cable connector element having a body, with a bayonet screw and a flat contact section extending from either side of the body;
c) an assembly of a resistor having contact caps at both ends and a
spring, located in the longer arm, with one resistor cap end in intimate contact with the flat contact section of said cable connector element; and
d) a spark plug connector element defined by a hollow body for
accommodating the non-sparking end of the spark plug, said
body being partially embedded in the longer arm of the housing
and the said body further having a flat surface at the operative
inner end adapted to biasedly abut the free end of the said spring.
Typically, the housing is of PBT material.
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Preferably, both the arms of the housing are funnel shaped, with a relatively broad cross-section and a sleeve section.
Typically, the area of cross-section in the sleeve of the shorter arm is smaller than the cross-sectional area of the body of the cable connector element but larger than the flat contact section of the cable connector element.
Typically, the area of cross-section in the sleeve of the longer arm is smaller than the cross-sectional area in the middle of the body of the spark plug connector element but larger than the flat closed end section of the spark plug connector element.
Typically, the cable connector element is of nickel coated brass. Preferably at least a portion of the body of the cable connector is roughened, typically by diamond knurling.
Typically, the body of the cable connector element is partially embedded in the sleeve of the shorter arm of said housing.
Typically, the resistor caps are flat and the flat surface of the flat contact section is dimensioned so as to enable complete contact with one of the cap end surfaces.
Typically, the spring is a stepped helically wound spring having two sections, a large diameter section for force fitting of one of the resistor caps
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and a small diameter section for contact with the closed end of the flat end surface of the spark plug connector element.
Preferably, the resistor and the spring assembly diameter is smaller than the sleeve of the longer arm.
Typically, in accordance with the present invention the spark plug connector element has a hollow body, open at one end and closed at the other end.
Preferably, the body of the spark plug connector element has a plurality of stepped sections.
Typically, the spark plug connector element is of nickel coated brass.
Typically, the body of the spark plug connector element is partially embedded in the sleeve of the longer arm of said housing.
Typically, a lock spring is provided in the spark plug connector element to firmly fit the spark plug thereto.
Preferably, said lock spring provided in the spark plug connector element partly resides in the hollow of the spark plug connector element.
Typically, the noise suppressor spark plug cap is hermetically sealed at the longer arm and the shorter arm of said housing, while ensuring efficient spring contact.
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In accordance with another aspect of the invention, there is provided a method of manufacturing a noise suppressor cap comprising the following steps:
a. mounting the housing on a turn table jig or job holder;
b. heating the cable connector element to 300°C;
c. inserting the heated cable connector element, using an appropriate
tool, in the annular space of the shorter arm of the housing such
that the flat section of the flat contact section is perpendicular to
the axis of the longer arm of the housing;
d. holding the cable connector element in position till part of the
body of the cable connector element is firmly embedded in the
sleeve of the shorter arm of the housing;
e. assembling the resistor with the spring such that one of the resistor
caps is force fitted in the large diameter section of the stepped
helically wound spring and the other cap is kept free;
f. inserting the resistor and spring assembly, using an appropriate
tool, in the sleeve of the longer arm of the housing so that the free
resistor cap is in electrical contact with the flat surface of the flat
contact element of the cable connector element;
g. heating the spark plug connector element to 300°C;
h. inserting the heated spark plug connector element, using an appropriate tool, in the annular space of the sleeve of the longer arm of the housing such that the flat end section of the spark plug connector element biasedly abut against the free end of the spring; and
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i. holding the spark plug connector element in said position till part of the body of the spark plug connector element is firmly embedded in the sleeve of the longer arm of the housing.
BRIEF DESCRIPTION OF THE FIGURES
Other aspects of the invention will become apparent by consideration of the accompanying drawing and their description stated below, which is merely illustrative of a preferred embodiment of the invention and does not limit in any way the nature and scope of the invention.
Figure 1 shows the top view of the noise suppression spark plug cap;
Figure 2 shows the side view of the noise suppression spark plug cap;
Figure 3 shows the bottom views of the noise suppression spark plug cap;
Figure 4 shows the elevation of the noise suppression spark plug cap;
Figure 5 shows the section A-A of figure 1 of the noise suppression spark
plug cap;
Figure 6 shows the elevation of the housing of the noise suppression spark
plug cap of the figure 1 to figure 5;
Figure 7 shows the section X-X of the figure 6 of the housing of the noise
suppression spark plug cap of the figure 1 to figure 5;
Figure 8 shows the side view of the cable connector element of the noise
suppression spark plug cap of the figure 1 to figure 5;
Figure 9 shows the perspective view of the cable connector element of the
noise suppression spark plug cap of the figure 1 to figure 5;
Figure 10 shows the resistor element of the noise suppression spark plug cap
of the figure 1 to figure 5;
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Figure 11 shows the stepped helically wound spring of the noise suppression
spark plug cap of the figure 1 to figure 5;
Figure 12 shows the partially sectioned view of the spark plug connector
element of the noise suppression spark plug cap of the figure 1 to figure 5;
Figure 13 shows the section Y-Y of figure 12 of the spark plug connector
element (54) of the noise suppression spark plug cap of the figure 1 to figure
5;
Figure 14 shows the enlarged view of the lock spring of the noise
suppression spark plug cap of the figure 1 to figure 5;
Figure 15 shows the assembling of the cable connector element in the
housing shown in figure 7 of the noise suppression spark plug cap of the
figure 1 to figure 5;
Figure 16 shows the assembling of the resistor and the spring of the noise
suppression spark plug cap of the figure 1 to figure 5;
Figure 17 shows the assembling of the resistor and spring assembly in the
housing shown in figure 7 of the noise suppression spark plug cap of the
figure 1 to figure 5; and
Figure 18 shows the assembling of the spark plug connector element in the
housing shown in figure 7 of the noise suppression spark plug cap of the
figure 1 to figure 5.
DETAILED DESCRIPTION
Referring to the accompanied drawings, a noise suppressor spark plug cap, in accordance with this invention is generally indicated by the reference numeral 100 and is particularly shown in figure 1 to figure 5 of the drawing. The cap (100) helps in suppressing the electromagnetic Interference that is radiated and conducted in automotive vehicles, particularly two wheelers.
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Figure 1 illustrates the top view of the noise suppression spark plug cap. Figure 2 shows the side view of the noise suppression spark plug cap shown in figure 1. Figure 3 shows the bottom views of the noise suppression spark plug cap shown in figure 1. Figure 4 shows the elevation of the noise suppression spark plug cap shown in figure 1. Figure 5 illustrates the section A-A of the noise suppression spark plug cap (100) shown in figure 1. The noise suppression spark plug cap (100) as particularly shown in figure 5 consists of the following elements:
Housing Element(lO)
Cable Connector Element (26)
Resistor Element (40)
Stepped Helically Wound Spring (48)
Spark Plug Connector Element (54)
The noise suppression spark plug cap (100) includes a housing element (10). Figure 6 shows the top view of the housing (10). Figure 7 shows the cut section along line X-X of the housing (10) in figure 6. The housing element (10), which is pre-moulded, is made up of glass filled Polybutylene terephthalate (PBT) material. PBT is a polymer that is used as an insulator. PBT is resistant to solvents, shrinks very little during forming, is mechanically strong, heat-resistant up to 200°C with glass-fiber reinforcement and can be treated with flame retardants to make it noncombustible.
The housing (10) has an annular space and is L-shaped having a longer arm (12) and a shorter arm (14). The annular space of both the arms is typically
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funnel shaped and the outer circumference of both the arms is typically bell shaped. The annular space of the longer arm;(12) has 2 sections— a broad section (16) and a sleeve (20). The broad section (16) has an open mouth (13). Section (16) has an inner diameter (Dl) and the section (20) has an inner diameter (D2). The inner diameter D2 of the section (20) of the longer arm (12) is less than the inner diameter (Dl) of the section (16) of the longer arm (12), that is, D2
Documents
Application Documents
| # |
Name |
Date |
| 1 |
2699-MUMNP-2012-CORRESPONDENCE(10-12-2012).pdf |
2012-12-10 |
| 1 |
279-MUM-2009- AFR.pdf |
2022-10-07 |
| 2 |
abstract1.jpg |
2018-08-10 |
| 2 |
279-MUM-2009-AbandonedLetter.pdf |
2018-12-05 |
| 3 |
279-mum-2009-form 3.pdf |
2018-08-10 |
| 4 |
279-mum-2009-form 26.pdf |
2018-08-10 |
| 4 |
279-mum-2009-abstract.pdf |
2018-08-10 |
| 5 |
279-MUM-2009-FORM 26(6-2-2013).pdf |
2018-08-10 |
| 6 |
279-MUM-2009-FORM 26(4-2-2013).pdf |
2018-08-10 |
| 6 |
279-mum-2009-claims.pdf |
2018-08-10 |
| 7 |
279-mum-2009-form 2.pdf |
2018-08-10 |
| 7 |
279-MUM-2009-CORRESPONDENCE(4-2-2013).pdf |
2018-08-10 |
| 8 |
279-mum-2009-correspondence.pdf |
2018-08-10 |
| 9 |
279-mum-2009-form 2(title page).pdf |
2018-08-10 |
| 10 |
279-mum-2009-description(complete).pdf |
2018-08-10 |
| 10 |
279-MUM-2009-FORM 18(4-2-2013).pdf |
2018-08-10 |
| 11 |
279-mum-2009-drawing.pdf |
2018-08-10 |
| 11 |
279-MUM-2009-FORM 13(6-2-2013).pdf |
2018-08-10 |
| 12 |
279-MUM-2009-FER.pdf |
2018-08-10 |
| 12 |
279-mum-2009-form 1.pdf |
2018-08-10 |
| 13 |
279-MUM-2009-FER.pdf |
2018-08-10 |
| 13 |
279-mum-2009-form 1.pdf |
2018-08-10 |
| 14 |
279-mum-2009-drawing.pdf |
2018-08-10 |
| 14 |
279-MUM-2009-FORM 13(6-2-2013).pdf |
2018-08-10 |
| 15 |
279-mum-2009-description(complete).pdf |
2018-08-10 |
| 15 |
279-MUM-2009-FORM 18(4-2-2013).pdf |
2018-08-10 |
| 16 |
279-mum-2009-form 2(title page).pdf |
2018-08-10 |
| 17 |
279-mum-2009-correspondence.pdf |
2018-08-10 |
| 18 |
279-mum-2009-form 2.pdf |
2018-08-10 |
| 18 |
279-MUM-2009-CORRESPONDENCE(4-2-2013).pdf |
2018-08-10 |
| 19 |
279-MUM-2009-FORM 26(4-2-2013).pdf |
2018-08-10 |
| 19 |
279-mum-2009-claims.pdf |
2018-08-10 |
| 20 |
279-MUM-2009-FORM 26(6-2-2013).pdf |
2018-08-10 |
| 21 |
279-mum-2009-form 26.pdf |
2018-08-10 |
| 21 |
279-mum-2009-abstract.pdf |
2018-08-10 |
| 22 |
279-mum-2009-form 3.pdf |
2018-08-10 |
| 23 |
abstract1.jpg |
2018-08-10 |
| 23 |
279-MUM-2009-AbandonedLetter.pdf |
2018-12-05 |
| 24 |
2699-MUMNP-2012-CORRESPONDENCE(10-12-2012).pdf |
2012-12-10 |
| 24 |
279-MUM-2009- AFR.pdf |
2022-10-07 |
Search Strategy
| 1 |
279mum2009_(searchstrategy)_15-05-2018.pdf |
| 1 |
PatSeersearch_28-11-2017.pdf |
| 2 |
279mum2009_(searchstrategy)_15-05-2018.pdf |
| 2 |
PatSeersearch_28-11-2017.pdf |