Spark plug coupler

Patent metadata

Field	Value
Publication number	US-11233378-B2
Application number	US-201816766434-A
Country	US
Kind code	B2
Filing date	Nov 30, 2018
Priority date	Dec 1, 2017
Publication date	Jan 25, 2022
Grant date	Jan 25, 2022

Abstract

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.

First claim

What is claimed is:

1. A coupler for a spark plug, comprising:
a body formed from an electrically conductive material and including a first connecting portion defining a first cavity, and the body includes a second connecting portion defining a second cavity spaced from the first cavity, and the body including an intermediate portion physically and electrically coupling the first connection portion and the second connecting portion, wherein the first connecting portion is formed from a wire coiled to define the first cavity within the coil, and wherein an end of the wire is adjacent to or defines part of the coil that defines the first cavity and the end of the wire is defined in a tang that extends outwardly relative to the coil that defines the first cavity.

2. The coupler of claim 1 wherein the second connecting portion is formed from a wire coiled to define the second cavity within the coil.

3. The coupler of claim 1 wherein the second connecting portion is formed from a wire coiled to define the second cavity within the coil, and wherein the same wire defines both the first and second connecting portions.

4. The coupler of claim 3 wherein the intermediate portion is also defined by the wire that defines both the first and second connecting portions.

5. The coupler of claim 1 wherein the tang extends radially outwardly beyond the coil that defines the first cavity.

6. The coupler of claim 1 wherein the tang is defined in a frangible portion of the wire that is defined by or includes a weakened portion of the wire.

7. The coupler of claim 6 wherein the weakened portion is defined by or includes a notch or slot.

8. The coupler of claim 6 wherein the weakened portion is provided in a surface of the wire that faces inwardly toward a centerline of the coil that defines the first cavity.

9. The coupler of claim 6 wherein the weakened portion of the wire is located in a portion of the wire that is not radially outward of the coil that defines the first cavity or that extends radially outwardly of the coil that defines the first cavity by 1 mm or less.

10. The coupler of claim 1 wherein a second end of the wire is adjacent to or defines part of the coil that defines the second cavity.

11. The coupler of claim 10 wherein the second end of the wire is not located radially outwardly of the coil that defines the second cavity or the second end of the wire is located radially outwardly of the coil that defines the second cavity by 1 mm or less.

12. An assembly, comprising:
a coupler 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 an intermediate portion physically and electrically coupling the first connection portion and the second connecting portion;
a power supply cable having an electrically conductive core and an insulator surrounding the core, wherein a portion of the cable, including part of the insulator and part of the core, is received within the first cavity with a portion of the core engaged with the first connecting portion and received between an exterior of the insulator and the first connecting portion; and
a spark plug having a terminal wherein the terminal is received at least partially within and engaged by the second connecting portion.

13. The assembly of claim 12 wherein the first connecting portion is formed from a wire having a first coil that defines the first cavity, and the second connecting portion is formed from a second coil of wire that defines the second cavity, and wherein the same wire defines both the first and second coils.

14. The assembly of claim 13 wherein one or both of the first coil and second coil are defined by loops of wire that may move relative to each other so that the coupler is flexible.

15. The assembly of claim 12 wherein the intermediate portion is also defined by the wire that defines both the first and second connecting portions.

16. An assembly, comprising:
a coupler 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 an intermediate portion physically and electrically coupling the first connection portion and the second connecting portion;
a power supply cable having an electrically conductive core wherein the cable is partially-received within the first cavity with the core engaged with the first connecting portion; and
a spark plug having a terminal wherein the terminal is received at least partially within and engaged by the second connecting portion, wherein the first connecting portion is formed from a wire having a first coil that defines the first cavity, and the second connecting portion is formed from a second coil of wire that defines the second cavity, and wherein the same wire defines both the first and second coils, wherein an end of the wire is adjacent to or defines part of the coil that defines the first cavity and the end of the wire is defined in a tang that extends outwardly relative to the coil that defines the first cavity.

17. The assembly of claim 16 wherein the tang extends radially outwardly beyond the coil that defines the first cavity.

18. The assembly of claim 16 wherein the tang is defined in a frangible portion of the wire that is defined by or includes a weakened portion of the wire, and wherein the weakened portion is defined by or includes a notch or slot.

19. The assembly of claim 18 wherein the weakened portion is provided in a surface of the wire that faces inwardly toward a centerline of the coil that defines the first cavity.

20. The assembly of claim 18 wherein the weakened portion of the wire is located in a portion of the wire that is not radially outward of the coil that defines the first cavity or that extends radially outwardly of the coil that defines the first cavity by 1 mm or less.

21. The assembly of claim 16 wherein a second end of the wire is adjacent to or defines part of the coil that defines the second cavity and the second end of the wire is not located radially outwardly of the coil that defines the second cavity or the second end of the wire is located radially outwardly of the coil that defines the second cavity by 1 mm or less.

Assignees

• Walbro Llc

Inventors

• Healy Cyrus M
• King Eric L

Classifications

• F02P13/00

  Sparking plugs structurally combined with other parts of internal-combustion engines ({connection of ignition coil to spark plug connector F02P3/02;} with fuel injectors F02M57/06 {; spark plug connector per se H01T13/04 – H01T13/06; predominant aspects of sparking plug, see H01T13/40 – H01T13/44}) · CPC title

• H01R4/14

  by wrapping · CPC title

• H01T13/04 Primary

  Means providing electrical connection to sparking plugs · CPC title

• H01R24/20

  Coupling parts carrying sockets, clips or analogous contacts and secured only to wire or cable · CPC title

• H01T13/20

  characterised by features of the electrodes or insulation · CPC title