EP1780737B1 - Ignition Coil - Google Patents

Ignition Coil Download PDF

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Publication number
EP1780737B1
EP1780737B1 EP06270043A EP06270043A EP1780737B1 EP 1780737 B1 EP1780737 B1 EP 1780737B1 EP 06270043 A EP06270043 A EP 06270043A EP 06270043 A EP06270043 A EP 06270043A EP 1780737 B1 EP1780737 B1 EP 1780737B1
Authority
EP
European Patent Office
Prior art keywords
primary
coil
support spool
ignition coil
resilient
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Active
Application number
EP06270043A
Other languages
German (de)
French (fr)
Other versions
EP1780737A1 (en
Inventor
Corina Moga
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Delphi Technologies Inc
Original Assignee
Delphi Technologies Inc
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Filing date
Publication date
Application filed by Delphi Technologies Inc filed Critical Delphi Technologies Inc
Publication of EP1780737A1 publication Critical patent/EP1780737A1/en
Application granted granted Critical
Publication of EP1780737B1 publication Critical patent/EP1780737B1/en
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Anticipated expiration legal-status Critical

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02P—IGNITION, OTHER THAN COMPRESSION IGNITION, FOR INTERNAL-COMBUSTION ENGINES; TESTING OF IGNITION TIMING IN COMPRESSION-IGNITION ENGINES
    • F02P13/00—Sparking plugs structurally combined with other parts of internal-combustion engines
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F38/00—Adaptations of transformers or inductances for specific applications or functions
    • H01F38/12—Ignition, e.g. for IC engines
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01T—SPARK GAPS; OVERVOLTAGE ARRESTERS USING SPARK GAPS; SPARKING PLUGS; CORONA DEVICES; GENERATING IONS TO BE INTRODUCED INTO NON-ENCLOSED GASES
    • H01T13/00—Sparking plugs
    • H01T13/40—Sparking plugs structurally combined with other devices
    • H01T13/44—Sparking plugs structurally combined with other devices with transformers, e.g. for high-frequency ignition
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02P—IGNITION, OTHER THAN COMPRESSION IGNITION, FOR INTERNAL-COMBUSTION ENGINES; TESTING OF IGNITION TIMING IN COMPRESSION-IGNITION ENGINES
    • F02P3/00—Other installations
    • F02P3/02—Other installations having inductive energy storage, e.g. arrangements of induction coils
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F38/00—Adaptations of transformers or inductances for specific applications or functions
    • H01F38/12—Ignition, e.g. for IC engines
    • H01F2038/122—Ignition, e.g. for IC engines with rod-shaped core
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/32—Insulating of coils, windings, or parts thereof
    • H01F27/323—Insulation between winding turns, between winding layers
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/32—Insulating of coils, windings, or parts thereof
    • H01F27/327—Encapsulating or impregnating

Definitions

  • the present invention relates to ignition coils, particularly, but not exclusively, ignition coils which are directly attached to the spark plugs of internal combustion engines.
  • Independent ignition coils are commonly mounted directly to the spark plugs of an internal combustion engine.
  • Such coils typically include co-axially arranged secondary and primary coils which are wound around respective support spools. Each coil is typically attached to the support spool by way of a resin which holds them in place during assembly and operation.
  • Pencil-type coils are normally mounted very close to the engine combustion chambers and are therefore subjected to a continual heating/cooling cycle throughout their operational lifetime.
  • the variation in the thermal expansion properties of the co-axially arranged materials in the ignition coil can cause stresses and strains within the coil which result in components breaking over time. This produces reliability problems.
  • an ignition coil comprising:
  • the resilient thermal expansion de-coupling means is provided between the first coil and first support spool.
  • the resilient thermal expansion de-coupling means is provided between the second coil and second support spool.
  • the resilient thermal expansion de-coupling means comprises a resilient sheath buffer capable of expanding and contracting in a radial direction i.e. normal to the co-axis. More preferably, the resilient sheath buffer is also capable of movement in an axial direction. Preferably, said movement in the axial direction is a result of relative axial movement between the primary coil and primary support spool.
  • the material comprising the resilient thermal expansion de-coupling means comprises a material having a Young's Modulus in the region of 10 to 100Mpa at approximately 170°C and typically has a wall thickness in the region of 0.1 to 0.5 mm.
  • the resilient sheath buffer is provided with a radial protrusion adjacent at least one end of the resilient sheath buffer such that resilient axial movement of the primary coil relative to the primary support spool is possible.
  • the primary support spool comprises a tubular synthetic member around which the resilient thermal expansion de-coupling means and primary coil may be arranged.
  • the secondary support spool comprises a tubular synthetic member around which the secondary coil may be wound.
  • a shrink tube is provided around the core member.
  • An ignition coil unit 10 comprises an ignition circuit case 12 which houses the coil circuitry (not shown), a core housing 14 and a boot 16 which allows connection to a spark plug (not shown).
  • co-axial layers within the core housing 14 comprise a core member 18, shrink tube 37, epoxy resin layer 20, secondary support spool 22, secondary coil 24, epoxy insulation layer 26, primary support spool 28, resilient thermal expansion de-coupling buffer 30, primary coil 32 and casing 34.
  • An outer protective sheath 36 ( Fig. 3 ) is also provided around the mid-section of ignition coil 10.
  • the core member 18 is typically formed from an elongate silicon steel member.
  • the secondary support spool 22 is typically a tube formed from a synthetic resin and houses the core member 18 therein via a shrink tube 37 and a layer of epoxy resin 20. In addition to its securing properties, the layer of resin 20 also provides electrical insulation between the core member 18 and the outer coils 24, 32.
  • Secondary coil 24 is formed from a wire wound around the secondary support spool 22 thousands of times. In the present embodiment the wire has approximately 1500 turns.
  • the epoxy insulation layer 26 and shrink tube 37 act as electrical insulators between the primary and secondary coils.
  • Primary support spool 28 is positioned around the epoxy insulation layer 26 and may be held to some extent thereby.
  • the primary support spool 28 is similar in construction to the secondary support spool 22 with appropriate dimensional modifications; however, a lip L also projects radially outward from the outer circumference of the primary support 28. This lip L allows secure abutment against a shoulder 35 of the casing 34 and provides a gap A between the shoulder 35 and the coil 32 / buffer 30 as discussed subsequently.
  • the resilient thermal expansion de-coupling buffer 30 comprises any material (such as silicon rubber) which is capable of withstanding the heating conditions of the surrounding environment and which is capable of expanding and contracting to accommodate the differential expansion and contraction of the components surrounding it.
  • the buffer may typically comprise a sleeve having a wall thickness of between 0.1mm and 0.5mm and a Young's Modulus of 10 to 100 MPa at 170°C.
  • a radially extending protrusion P is provided around the lower circumference of the buffer 30 as shown in Fig. 3 . This sits against the upper surface of lip L and resiliently supports coil 32 as discussed subsequently.
  • Primary coil 32 is formed by a wire wound around the buffer 30 and primary support spool 28 many hundreds of times. In the present embodiment, the wire is provided with approximately 200 turns. Primary coil 32 typically has a lower co-efficient of thermal expansion than the rest of the components in the ignition coil 10 and the effects of this will be discussed subsequently.
  • each of the co-axial layers described will expand in the axial direction (Ax in Fig. 3 ) and radial direction (Ra in Fig. 3 ) according to their respective co-efficient of thermal expansion.
  • the primary wire may be regarded as a composite material since it comprises copper wire combined with an epoxy. This results in a composite material which has a co-efficient of thermal expansion that is significantly less than that of the other layers.
  • the buffer 30 is able to accommodate these differences in expansion of the layers by radially expanding or contracting as required.
  • the protrusion P of the buffer in conjunction with the support provided by lip L allows resilient relative axial movement between the primary coil 32 and primary spool 28 to occur.
  • Such a protrusion P may be provided at either or both of the high voltage and low voltage ends of the ignition coil 10.
  • the expansion and compression of the buffer 30 therefore allows stresses between the primary coil 32 and primary support 28 (which would otherwise occur during heating and cooling of the ignition coil 10) to be alleviated. This de-coupling of stresses increases the longevity and reliability of the ignition coil 10.
  • the embodiment described only has a buffer 30 between the primary coil 32 and the primary support spool 28 it would be possible to have a buffer between the secondary coil and the secondary support if desired. In addition, it would be possible to arrange the primary coil inside of the secondary coil.

Landscapes

  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Ignition Installations For Internal Combustion Engines (AREA)

Abstract

This invention relates to an ignition coil for the engine of a vehicle. The ignition coil comprises a core member (18) having a number of layers wrapped around it. The formation of these layers from the core member outward comprises a secondary support spool (22), a secondary coil (24), a primary support spool (28) and a primary coil (32). Resilient thermal expansion de-coupling means (30) is provided between at least one of the primary and secondary coils (32, 24) and its or their corresponding support spool or spools (28, 22). The thermal expansion de-coupling means (30) allows each layer to expand and contract substantially independently of one another. This reduces the stress exerted on each layer as it is heated/cooled which increases the overall lifetime of the ignition coil.

Description

  • The present invention relates to ignition coils, particularly, but not exclusively, ignition coils which are directly attached to the spark plugs of internal combustion engines.
  • Independent ignition coils (also known as "pencil-type coils") are commonly mounted directly to the spark plugs of an internal combustion engine. Such coils typically include co-axially arranged secondary and primary coils which are wound around respective support spools. Each coil is typically attached to the support spool by way of a resin which holds them in place during assembly and operation.
  • Pencil-type coils are normally mounted very close to the engine combustion chambers and are therefore subjected to a continual heating/cooling cycle throughout their operational lifetime. The variation in the thermal expansion properties of the co-axially arranged materials in the ignition coil can cause stresses and strains within the coil which result in components breaking over time. This produces reliability problems.
  • One type of ignition coil having improved resistance to stresses and strains is described in United States Patent Publication No. 2003/0122645 A1 .
  • According to the present invention there is provided an ignition coil comprising:
    • a core member;
    • a secondary support spool around the core member;
    • a secondary coil around the secondary support spool; a primary support spool around the secondary coil; and
    • a primary coil around the primary support spool, wherein resilient thermal expansion de-coupling means comprising a resilient sheath buffer capable of expanding and contracting in a radial direction is provided between the primary support spool and the primary coil characterised in that the resilient sheath buffer is provided with a radially outwardly extending protrusion adjacent the primary coil in order to allow resilient axial movement of the primary coil relative to the primary support spool.
  • Preferably, the resilient thermal expansion de-coupling means is provided between the first coil and first support spool. Optionally, the resilient thermal expansion de-coupling means is provided between the second coil and second support spool.
  • Preferably, the resilient thermal expansion de-coupling means comprises a resilient sheath buffer capable of expanding and contracting in a radial direction i.e. normal to the co-axis. More preferably, the resilient sheath buffer is also capable of movement in an axial direction. Preferably, said movement in the axial direction is a result of relative axial movement between the primary coil and primary support spool.
  • Typically, the material comprising the resilient thermal expansion de-coupling means comprises a material having a Young's Modulus in the region of 10 to 100Mpa at approximately 170°C and typically has a wall thickness in the region of 0.1 to 0.5 mm.
  • Preferably, the resilient sheath buffer is provided with a radial protrusion adjacent at least one end of the resilient sheath buffer such that resilient axial movement of the primary coil relative to the primary support spool is possible.
  • Typically, the primary support spool comprises a tubular synthetic member around which the resilient thermal expansion de-coupling means and primary coil may be arranged.
  • Typically, the secondary support spool comprises a tubular synthetic member around which the secondary coil may be wound.
  • Preferably, a shrink tube is provided around the core member.
  • Embodiments of the present invention will now be described, with reference to the following figures, in which:-
    • Fig. 1 is a isometric partial cut-away view of an ignition coil according to the present invention;
    • Fig. 2 is a cross section of the co-axial layers of the apparatus of Fig. 1 taken along the view A-A;
    • Fig. 3 is a more detailed view of the lower portion of the ignition coil shown in Fig. 1; and
    • Fig. 4 is a isometric view showing a section of the co-axial layers shown in Fig. 2.
  • An ignition coil unit 10 comprises an ignition circuit case 12 which houses the coil circuitry (not shown), a core housing 14 and a boot 16 which allows connection to a spark plug (not shown).
  • Referring to Fig. 2, co-axial layers within the core housing 14 comprise a core member 18, shrink tube 37, epoxy resin layer 20, secondary support spool 22, secondary coil 24, epoxy insulation layer 26, primary support spool 28, resilient thermal expansion de-coupling buffer 30, primary coil 32 and casing 34. An outer protective sheath 36 (Fig. 3) is also provided around the mid-section of ignition coil 10.
  • The core member 18 is typically formed from an elongate silicon steel member.
  • The secondary support spool 22 is typically a tube formed from a synthetic resin and houses the core member 18 therein via a shrink tube 37 and a layer of epoxy resin 20. In addition to its securing properties, the layer of resin 20 also provides electrical insulation between the core member 18 and the outer coils 24, 32.
  • Secondary coil 24 is formed from a wire wound around the secondary support spool 22 thousands of times. In the present embodiment the wire has approximately 1500 turns.
  • The epoxy insulation layer 26 and shrink tube 37 act as electrical insulators between the primary and secondary coils.
  • Primary support spool 28 is positioned around the epoxy insulation layer 26 and may be held to some extent thereby. The primary support spool 28 is similar in construction to the secondary support spool 22 with appropriate dimensional modifications; however, a lip L also projects radially outward from the outer circumference of the primary support 28. This lip L allows secure abutment against a shoulder 35 of the casing 34 and provides a gap A between the shoulder 35 and the coil 32 / buffer 30 as discussed subsequently.
  • The resilient thermal expansion de-coupling buffer 30 comprises any material (such as silicon rubber) which is capable of withstanding the heating conditions of the surrounding environment and which is capable of expanding and contracting to accommodate the differential expansion and contraction of the components surrounding it. In this regard, the buffer may typically comprise a sleeve having a wall thickness of between 0.1mm and 0.5mm and a Young's Modulus of 10 to 100 MPa at 170°C.
  • A radially extending protrusion P is provided around the lower circumference of the buffer 30 as shown in Fig. 3. This sits against the upper surface of lip L and resiliently supports coil 32 as discussed subsequently.
  • Primary coil 32 is formed by a wire wound around the buffer 30 and primary support spool 28 many hundreds of times. In the present embodiment, the wire is provided with approximately 200 turns. Primary coil 32 typically has a lower co-efficient of thermal expansion than the rest of the components in the ignition coil 10 and the effects of this will be discussed subsequently.
  • In use, as the ignition coil 10 heats up from an initial cold state, each of the co-axial layers described will expand in the axial direction (Ax in Fig. 3) and radial direction (Ra in Fig. 3) according to their respective co-efficient of thermal expansion. The primary wire may be regarded as a composite material since it comprises copper wire combined with an epoxy. This results in a composite material which has a co-efficient of thermal expansion that is significantly less than that of the other layers. However, the buffer 30 is able to accommodate these differences in expansion of the layers by radially expanding or contracting as required. In addition, the protrusion P of the buffer in conjunction with the support provided by lip L allows resilient relative axial movement between the primary coil 32 and primary spool 28 to occur. Such a protrusion P may be provided at either or both of the high voltage and low voltage ends of the ignition coil 10.
  • The expansion and compression of the buffer 30 therefore allows stresses between the primary coil 32 and primary support 28 (which would otherwise occur during heating and cooling of the ignition coil 10) to be alleviated. This de-coupling of stresses increases the longevity and reliability of the ignition coil 10.
  • Modifications and improvement may be made to the foregoing, for example:-
  • Although, the embodiment described only has a buffer 30 between the primary coil 32 and the primary support spool 28 it would be possible to have a buffer between the secondary coil and the secondary support if desired. In addition, it would be possible to arrange the primary coil inside of the secondary coil.

Claims (7)

  1. An ignition coil comprising:-
    a core member (18);
    a secondary support spool (22) around the core member (18);
    a secondary coil (24) around the secondary support spool (22);
    a primary support spool (28) around the secondary coil (24); and
    a primary coil (32) around the primary support spool (28), wherein resilient thermal expansion de-coupling means (30) comprising a resilient sheath buffer (30) capable of expanding and contracting in a radial direction is provided between the primary support spool (28) and the primary coil (32) characterised in that the resilient sheath buffer (30) is provided with a radially outwardly extending protrusion (P) adjacent the primary coil (32) in order to allow resilient axial movement of the primary coil (32) relative to the primary support spool (28).
  2. An ignition coil according to claim 1, wherein the resilient sheath buffer (30) is also capable of movement in an axial direction where said movement in the axial direction is a result of relative axial movement between the primary coil (32) and primary support spool (28).
  3. An ignition coil according to any preceding claim, wherein the material comprising the resilient thermal expansion de-coupling means (30) comprises a material having a Young's Modulus in the region of 10 to 100Mpa at approximately 170°C.
  4. An ignition coil according to claim 3, wherein the material comprising the resilient thermal expansion de-coupling means (30) further has a wall thickness in the region of 0.1 to 0.5 mm.
  5. An ignition coil according to any preceding claim, wherein the primary support spool (28) comprises a tubular synthetic member around which the resilient thermal expansion de-coupling means (30) and primary coil (32) are arranged.
  6. An ignition coil according to any preceding claim, wherein the secondary support spool (22) comprises a tubular synthetic member around which the secondary coil (24) is wound.
  7. An ignition coil according to any preceding claim, wherein a shrink tube (37) is provided around the core member (18).
EP06270043A 2005-10-28 2006-05-04 Ignition Coil Active EP1780737B1 (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GBGB0522000.9A GB0522000D0 (en) 2005-10-28 2005-10-28 Ignition coil

Publications (2)

Publication Number Publication Date
EP1780737A1 EP1780737A1 (en) 2007-05-02
EP1780737B1 true EP1780737B1 (en) 2009-01-07

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EP06270043A Active EP1780737B1 (en) 2005-10-28 2006-05-04 Ignition Coil

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EP (1) EP1780737B1 (en)
AT (1) ATE420447T1 (en)
DE (1) DE602006004675D1 (en)
GB (1) GB0522000D0 (en)

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB201014107D0 (en) * 2010-08-24 2010-10-06 Rolls Royce Plc An electromagnetic device

Family Cites Families (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH09289122A (en) * 1996-04-19 1997-11-04 Matsushita Electric Ind Co Ltd Ignition coil device for internal combustion engine
ES2275785T3 (en) * 1997-02-14 2007-06-16 Denso Corporation IGNITION COIL OF THE BAR TYPE THAT HAS AN IMPROVED STRUCTURE TO AVOID FISURES OR ELECTRIC SHOCK.
JP3727764B2 (en) * 1997-09-30 2005-12-14 株式会社日立製作所 Ignition coil device for engine and method for manufacturing the same
JP4206666B2 (en) * 1999-06-09 2009-01-14 株式会社日立製作所 Ignition coil for internal combustion engine
JP4032700B2 (en) * 2001-10-30 2008-01-16 株式会社デンソー Ignition coil
EP1589546A1 (en) * 2004-04-22 2005-10-26 Federal-Mogul Ignition Srl Ignition coil having improved thermal stress resistance

Also Published As

Publication number Publication date
DE602006004675D1 (en) 2009-02-26
ATE420447T1 (en) 2009-01-15
GB0522000D0 (en) 2005-12-07
EP1780737A1 (en) 2007-05-02

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