EP2052394A2 - Method for producing a coil, in particular an ignition coil for a motor vehicle - Google Patents

Method for producing a coil, in particular an ignition coil for a motor vehicle

Info

Publication number
EP2052394A2
EP2052394A2 EP07788167A EP07788167A EP2052394A2 EP 2052394 A2 EP2052394 A2 EP 2052394A2 EP 07788167 A EP07788167 A EP 07788167A EP 07788167 A EP07788167 A EP 07788167A EP 2052394 A2 EP2052394 A2 EP 2052394A2
Authority
EP
European Patent Office
Prior art keywords
winding
coil
mandrel
primary winding
housing
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.)
Granted
Application number
EP07788167A
Other languages
German (de)
French (fr)
Other versions
EP2052394B1 (en
Inventor
Alfred Glatz
Konstantin Lindenthal
Thomas Pawlak
Axel Keib
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.)
Robert Bosch GmbH
Original Assignee
Robert Bosch GmbH
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Robert Bosch GmbH filed Critical Robert Bosch GmbH
Publication of EP2052394A2 publication Critical patent/EP2052394A2/en
Application granted granted Critical
Publication of EP2052394B1 publication Critical patent/EP2052394B1/en
Expired - Fee Related legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F38/00Adaptations of transformers or inductances for specific applications or functions
    • H01F38/12Ignition, e.g. for IC engines
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/28Coils; Windings; Conductive connections
    • H01F27/30Fastening or clamping coils, windings, or parts thereof together; Fastening or mounting coils or windings on core, casing, or other support
    • H01F27/306Fastening or mounting coils or windings on core, casing or other support
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F5/00Coils
    • H01F5/02Coils wound on non-magnetic supports, e.g. formers
    • H01F2005/025Coils wound on non-magnetic supports, e.g. formers wound on coaxial arrangement of two or more formers
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F38/00Adaptations of transformers or inductances for specific applications or functions
    • H01F38/12Ignition, e.g. for IC engines
    • H01F2038/122Ignition, e.g. for IC engines with rod-shaped core
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00Metal working
    • Y10T29/49Method of mechanical manufacture
    • Y10T29/49002Electrical device making
    • Y10T29/4902Electromagnet, transformer or inductor
    • Y10T29/49071Electromagnet, transformer or inductor by winding or coiling
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00Metal working
    • Y10T29/49Method of mechanical manufacture
    • Y10T29/49002Electrical device making
    • Y10T29/4902Electromagnet, transformer or inductor
    • Y10T29/49073Electromagnet, transformer or inductor by assembling coil and core
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00Metal working
    • Y10T29/53Means to assemble or disassemble
    • Y10T29/5313Means to assemble electrical device

Definitions

  • the invention relates to a method for producing a coil, in particular an ignition coil for a motor vehicle.
  • a coil which has an elongated coil housing.
  • several, pre-assembled modules or components are used. These components include u.a. a rod-shaped magnetic core which is concentrically surrounded by a secondary coil body having a secondary winding and by a primary coil body having a primary winding.
  • the coil housing is filled with an insulating resin.
  • Such an ignition coil is inserted into the cylinder head of the engine in a corresponding receiving bore and contacted with the spark plug of the internal combustion engine.
  • the receiving bore for the ignition coil is limited in diameter. This contradicts the requirement to provide the highest possible ignition energy for the spark plug, as this would require a maximum in terms of installation space in the diameter of the ignition coil.
  • the primary wire for a primary winding is wound in a first step on a mandrel, which also serves as an inner part for an injection molding tool.
  • the primary winding together with mandrel is then encapsulated with a plastic, wherein the plastic simultaneously forms the outer housing of the pencil ignition coil.
  • the known primary winding is thus in terms of their radial extent a very favorable education possible because of a separate, the diameter the rod ignition coil enlarging primary coil body and is dispensed with an additional outer housing.
  • the inventive method for producing a coil, in particular an ignition coil for a motor vehicle with the features of claim 1 has the advantage that it enables a simple and inexpensive production by reducing the space by dispensing with a separate primary coil body.
  • connection ring which is connected in advance with the ends of the primary winding and together with the winding mandrel in the housing Coil is inserted.
  • the winding mandrel In order to allow a particularly good transfer or stripping of the primary winding in the housing of the coil, it is provided in a further advantageous embodiment to provide an additional stripping element that holds the primary winding or fixed when the winding mandrel is pulled out of the housing of the coil.
  • an additional stripping element instead of a stripping element, it is also conceivable to provide the winding mandrel with a variable diameter, such that for pulling out of the winding mandrel, the diameter of the winding mandrel is reduced so that the adhesion or bond between the winding mandrel and the primary winding when pulling out the winding mandrel from the housing will be annulled.
  • Figure 2 shows a longitudinal section through a first mandrel with wound on the winding mandrel primary winding
  • Figures 3 and 4 are cross-sections through a second mandrel during different working positions.
  • the bar coil 10 shown in Figure 1 is used in particular as an ignition coil in internal combustion engines of motor vehicles, and is provided for direct contacting with a spark plug, not shown, which in turn is used together with the rod coil 10 in a shaft in the cylinder head of the internal combustion engine.
  • the rod coil 10 includes in coaxial arrangement to a longitudinal axis 12 in a housing 13 made of plastic in a central position an elongated cylindrical core 14, which is also referred to as the I-core.
  • the core 14 is made of layered magnetizable material and is part of an open magnetic circuit.
  • a secondary coil body 18 Concentrically around the core 14, a secondary coil body 18 is arranged with a high-voltage secondary winding 19.
  • the secondary winding 19 is surrounded by a primary winding 20.
  • the primary winding 20 is surrounded with a small radial distance from a cylindrical portion 22 of the housing 13, which has a winding 19, 20 adapted longitudinal extent.
  • the section 22 of the housing 13 in turn is enveloped without radial play by a longitudinally slotted sleeve-shaped return plate 23, which forms the outer shell in this area of the bar coil 10.
  • the return plate 23 serves as Inference element of the magnetic circuit of the bar coil 10 of the leadership of the magnetic field and is also referred to as the outer core.
  • metallic connector 27 are arranged, via which the primary winding 20 of the bar coil 10 is supplied with low voltage.
  • the second end portion 26 includes a metallic ferrule 28 connected to the secondary winding 19, through which the high voltage of the bar coil 10 is dissipated to the spark plug (not shown).
  • a connection ring 30 is provided, on the one hand with the
  • the interior of the housing 13 is preferably filled with an insulating resin 33, which also fills in particular the radial gap between the primary winding 20 and the opposite secondary winding 19.
  • the winding mandrel 35 has a cylindrical or preferably slightly conical shape, at least in the region provided for the primary winding 20.
  • the length of the mandrel 35 is dimensioned so that at least the primary winding 20 and the ring 29 and the connecting ring 30 find space on it. It should be the
  • Inner diameter of the ring 29 and the connecting ring 30 to be matched to the outer diameter of the winding mandrel 35 that a slight stripping of the ring 29 and the connecting ring 30 in the axial direction of the winding mandrel 35 is possible.
  • the ring 29 and the connecting ring 30 are positioned at a corresponding distance from each other on the winding mandrel 35, whereupon subsequently the wire of the primary winding 30 in at least one layer between the ring 29 and the connecting ring 30 is wound onto the winding mandrel 35.
  • winding mandrel 35 relative to a (not shown) wire dispenser rotatable and displaceable in the axial direction, or preferably characterized in that with fixed winding mandrel 35, the wire dispensing device rotates about the mandrel 35 and at the same time in the axial direction the winding mandrel 35 moves.
  • the wire ends 36, 37 of the primary winding 20 are electrically contacted with the connection ring 30, for example, welded.
  • the wire of the primary winding 20 may be formed as a so-called baked enamel wire.
  • the baked enamel layer of the primary winding 20 is activated by a corresponding heat treatment, so that thereafter the primary winding 20 is formed as a compact, solid unit.
  • the mandrel 35 is inserted together with the primary winding 20 in the housing 13 until the primary winding 20 is located at the intended position in the housing 13 ( Figure T).
  • Figure T For stripping the primary winding 20 in the housing 13 of the winding mandrel 35 and the ring 29 then cooperates with a tubular stripping element 38 in the exemplary embodiment, which upon removal of the winding mandrel 35 from the
  • the winding mandrel 35 to facilitate the stripping operation of the primary winding 20 of the winding mandrel 35 is slightly conical, such that the diameter of the winding mandrel 35 is reduced viewed in the direction of the connection ring 30.
  • the intermediate layer 40 consists for example of a possibly coated paper or plastic film layer, which may be perforated if necessary.
  • the intermediate layer 40 is here applied to the winding mandrel 35 before winding the primary winding 20 onto the winding mandrel 35 first, and then stripped together with the primary winding 20 in the housing 13.
  • FIGS. 3 and 4 a modified winding mandrel 35a is shown in FIGS. 3 and 4.
  • the mandrel 35a is characterized in that it is variable in diameter. In the example shown, this is realized by movable in the direction of the double arrows 41 segments 42, but of course other embodiments are conceivable. For winding up the primary winding 20 or the
  • Interlayer 40 in this case has the winding mandrel 35a according to the figure 3 its largest diameter.
  • the diameter of the winding mandrel 35a is reduced as shown in FIG 4, so that the adhesion of the intermediate layer 40 and the primary winding 20 is lifted to the winding mandrel 35a.
  • the stripping element 38 can be dispensed with in the case of the modified winding mandrel 35a.

Landscapes

  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Ignition Installations For Internal Combustion Engines (AREA)
  • Manufacture Of Motors, Generators (AREA)

Abstract

The invention describes a method for producing a coil (10), in particular an ignition coil for a motor vehicle, in which a primary coil (20) is wound around a mandrel (35; 35a). The mandrel (35; 35a) is then inserted into a housing (13) of the coil (10), after which the mandrel (35; 35a) is removed from the housing (13), with the primary coil (20) remaining in the housing (13). Finally, additional components of the coil (10), in particular a secondary coil body (18) holding a secondary coil (19), are inserted into the housing (13) in such a way that the secondary coil (19) is concentrically arranged within the primary coil (20), dispensing with the need for a separate primary coil body. According to the invention, the method makes it possible to create a coil (10) with a smaller diameter.

Description

Titel title
Verfahren zum Herstellen einer Spule, insbesondere einer Zündspule für ein KraftfahrzeugMethod for producing a coil, in particular an ignition coil for a motor vehicle
Stand der TechnikState of the art
Die Erfindung betrifft ein Verfahren zum Herstellen einer Spule, insbesondere einer Zündspule für ein Kraftfahrzeug. Aus dem DE 200 12 401 Ul ist eine Spule bekannt, welche ein längliches Spulengehäuse aufweist. In das Spulengehäuse sind mehrere, vorab montierte Baugruppen bzw. Bauteile eingesetzt. Zu diesen Bauteilen gehört u.a. ein stabförmiger Magnetkern, der konzentrisch von einem Sekundärspulenkörper mit einer Sekundärwicklung sowie von einem Primärspulenkörper mit einer Primärwicklung umgeben ist. Nach der Montage bzw. dem Einsetzen der Bauteile und Baugruppen in das Spulengehäuse wird das Spulengehäuse mit einem Isolierharz befüllt. Eine derartige Zündspule ist in den Zylinderkopf des Motors in eine entsprechende Aufnahmebohrung eingesetzt und mit der Zündkerze des Verbrennungsmotors kontaktiert. Da der Bauraum im Zylinderkopf des Verbrennungsmotors begrenzt ist, ist auch die Aufnahmebohrung für die Zündspule im Durchmesser limitiert. Dem widerspricht die Forderung, eine möglichst hohe Zündenergie für die Zündkerze bereitzustellen, da dies bezüglich des Bauraums eine auch im Durchmesser möglichst große Zündspule erfordern würde.The invention relates to a method for producing a coil, in particular an ignition coil for a motor vehicle. From DE 200 12 401 Ul a coil is known, which has an elongated coil housing. In the coil housing several, pre-assembled modules or components are used. These components include u.a. a rod-shaped magnetic core which is concentrically surrounded by a secondary coil body having a secondary winding and by a primary coil body having a primary winding. After assembly or insertion of the components and assemblies in the coil housing, the coil housing is filled with an insulating resin. Such an ignition coil is inserted into the cylinder head of the engine in a corresponding receiving bore and contacted with the spark plug of the internal combustion engine. Since the space in the cylinder head of the internal combustion engine is limited, the receiving bore for the ignition coil is limited in diameter. This contradicts the requirement to provide the highest possible ignition energy for the spark plug, as this would require a maximum in terms of installation space in the diameter of the ignition coil.
Aus der DE 102 47 411 Al ist weiterhin eine hinsichtlich ihres Bauraums optimierte Primärdrahtwicklung für eine Stabzündspule bekannt. Dabei wird der Primärdraht für eine Primärwicklung in einem ersten Arbeitsschritt auf einen Dorn gewickelt, welcher gleichzeitig als Innenteil für ein Spritzwerkzeug dient. Die Primärwicklung samt Dorn wird anschließend mit einem Kunststoff umspritzt, wobei der Kunststoff gleichzeitig das äußere Gehäuse der Stabzündspule ausbildet. Bei der bekannten Primärwicklung ist somit in Bezug auf ihre radiale Ausdehnung eine sehr günstige Ausbildung möglich, da auf einen separaten, den Durchmesser der Stabzündspule vergrößernden Primärspulenkörper sowie auf ein zusätzliches äußeres Gehäuse verzichtet wird.From DE 102 47 411 Al a further optimized with respect to their space primary wire winding for a pencil ignition coil is known. In this case, the primary wire for a primary winding is wound in a first step on a mandrel, which also serves as an inner part for an injection molding tool. The primary winding together with mandrel is then encapsulated with a plastic, wherein the plastic simultaneously forms the outer housing of the pencil ignition coil. In the known primary winding is thus in terms of their radial extent a very favorable education possible because of a separate, the diameter the rod ignition coil enlarging primary coil body and is dispensed with an additional outer housing.
Vorteile der ErfindungAdvantages of the invention
Das erfindungsgemäße Verfahren zum Herstellen einer Spule, insbesondere einer Zündspule für ein Kraftfahrzeug mit den Merkmalen des Anspruchs 1 hat den Vorteil, dass es bei Reduzierung des Bauraums durch den Verzicht auf einen separaten Primärspulenkörper eine einfache und kostengünstige Herstellung ermöglicht.The inventive method for producing a coil, in particular an ignition coil for a motor vehicle with the features of claim 1 has the advantage that it enables a simple and inexpensive production by reducing the space by dispensing with a separate primary coil body.
Vorteilhafte Weiterbildungen des erfindungsgemäßen Verfahrens sowie eine Vorrichtung zum Durchführen des erfindungsgemäßen Verfahrens sind in den Unteransprüchen aufgeführt.Advantageous developments of the method according to the invention and a device for carrying out the method according to the invention are listed in the subclaims.
Um eine möglichst einfache Kontaktierung der Enden der Primärwicklung mit den die Primärwicklung in der Spule kontaktierenden Bauteilen zu ermöglichen, ist es in einer erfindungsgemäßen Weiterbildung vorgesehen einen Anschlussring vorzusehen, welcher vorab mit den Enden der Primärwicklung verbunden wird und zusammen mit dem Wickeldorn in das Gehäuse der Spule eingeführt wird.In order to allow the simplest possible contacting of the ends of the primary winding with the primary winding in the coil contacting components, it is provided in a development of the invention to provide a connection ring which is connected in advance with the ends of the primary winding and together with the winding mandrel in the housing Coil is inserted.
Um eine bessere elektrische Isolierung zwischen der Sekundärwicklung und der Primärwicklung zu ermöglichen, ist es weiterhin vorteilhaft, zwischen der Primärwicklung und der Sekundärwicklung eine Zwischenschicht vorzusehen, welche bereits vor dem Aufwickeln der Primärwicklung auf dem Wickeldorn auf den Wickeldorn aufgebracht wird.In order to enable a better electrical insulation between the secondary winding and the primary winding, it is also advantageous to provide an intermediate layer between the primary winding and the secondary winding, which is already applied to the winding mandrel before winding the primary winding on the winding mandrel.
Besonders gute Isolationseigenschaften erreicht man ferner, wenn das Gehäuse bzw. die Zwischenräume im Gehäuse nach der Montage der einzelnen Bauteile mit einem Isolierharz befüllt werden.Particularly good insulation properties are also achieved if the housing or the interstices in the housing are filled after assembly of the individual components with an insulating resin.
Um ein besonders gutes Überführen bzw. Abstreifen der Primärwicklung im Gehäuse der Spule zu ermöglichen, ist es in einer weiteren vorteilhaften Ausführungsform vorgesehen, ein zusätzliches Abstreifelement vorzusehen, das die Primärwicklung hält bzw. fixiert, wenn der Wickeldorn aus dem Gehäuse der Spule herausgezogen wird. Anstelle eines Abstreifelements ist es auch denkbar, den Wickeldorn mit einem variablen Durchmesser vorzusehen, derart, dass zum Herausziehen des Wickeldorns der Durchmesser des Wickeldorns verkleinert wird, so dass die Haftung bzw. Bindung zwischen dem Wickeldorn und der Primärwicklung beim Herausziehen des Wickeldorns aus dem Gehäuse aufgehoben wird.In order to allow a particularly good transfer or stripping of the primary winding in the housing of the coil, it is provided in a further advantageous embodiment to provide an additional stripping element that holds the primary winding or fixed when the winding mandrel is pulled out of the housing of the coil. Instead of a stripping element, it is also conceivable to provide the winding mandrel with a variable diameter, such that for pulling out of the winding mandrel, the diameter of the winding mandrel is reduced so that the adhesion or bond between the winding mandrel and the primary winding when pulling out the winding mandrel from the housing will be annulled.
Zeichnungdrawing
Ausführungsbeispiele der Erfindung sind in der Zeichnung dargestellt und werden nachfolgend näher erläutert. Es zeigen:Embodiments of the invention are illustrated in the drawings and are explained in more detail below. Show it:
Figur 1 eine Zündspule in einem vereinfachten Längsschnitt,1 shows an ignition coil in a simplified longitudinal section,
Figur 2 einen Längsschnitt durch einen ersten Wickeldorn mit auf dem Wickeldorn aufgewickelter Primärwicklung undFigure 2 shows a longitudinal section through a first mandrel with wound on the winding mandrel primary winding and
Figuren 3 und 4 Querschnitte durch einen zweiten Wickeldorn während verschiedener Arbeits- Stellungen.Figures 3 and 4 are cross-sections through a second mandrel during different working positions.
Beschreibung der AusführungsbeispieleDescription of the embodiments
Die in der Figur 1 dargestellte Stabspule 10 dient insbesondere als Zündspule in Brennkraftmaschinen von Kraftfahrzeugen, und ist zur Direktkontaktierung mit einer nicht dargestellten Zündkerze vorgesehen, die ihrerseits zusammen mit der Stabspule 10 in einem Schacht im Zylinderkopf der Brennkraftmaschine eingesetzt ist. Die Stabspule 10 enthält in koaxialer Anordnung zu einer Längsachse 12 in einem Gehäuse 13 aus Kunststoff in zentraler Lage einen langgezogenen zylindrischen Kern 14, der auch als I-Kern bezeichnet wird. Der Kern 14 besteht aus geschichtetem magnetisierbarem Material und ist Teil eines offenen Magnetkreises.The bar coil 10 shown in Figure 1 is used in particular as an ignition coil in internal combustion engines of motor vehicles, and is provided for direct contacting with a spark plug, not shown, which in turn is used together with the rod coil 10 in a shaft in the cylinder head of the internal combustion engine. The rod coil 10 includes in coaxial arrangement to a longitudinal axis 12 in a housing 13 made of plastic in a central position an elongated cylindrical core 14, which is also referred to as the I-core. The core 14 is made of layered magnetizable material and is part of an open magnetic circuit.
Konzentrisch um den Kern 14 ist ein Sekundärspulenkörper 18 mit einer Hochspannung führenden Sekundärwicklung 19 angeordnet. Die Sekundärwicklung 19 ist von einer Primär- wicklung 20 umgeben. Die Primärwicklung 20 ist mit geringem Radialabstand umgeben von einem zylindrischen Abschnitt 22 des Gehäuses 13, der eine den Wicklungen 19, 20 angepasste Längserstreckung aufweist. Der Abschnitt 22 des Gehäuses 13 wiederum ist ohne radiales Spiel umhüllt von einem längsgeschlitzten hülsenförmigen Rückschlussblech 23, das in diesem Bereich der Stabspule 10 deren Außenhülle bildet. Das Rückschlussblech 23 dient als Rückschlusselement des Magnetkreises der Stabspule 10 der Führung des Magnetfeldes und wird auch als äußerer Kern bezeichnet.Concentrically around the core 14, a secondary coil body 18 is arranged with a high-voltage secondary winding 19. The secondary winding 19 is surrounded by a primary winding 20. The primary winding 20 is surrounded with a small radial distance from a cylindrical portion 22 of the housing 13, which has a winding 19, 20 adapted longitudinal extent. The section 22 of the housing 13 in turn is enveloped without radial play by a longitudinally slotted sleeve-shaped return plate 23, which forms the outer shell in this area of the bar coil 10. The return plate 23 serves as Inference element of the magnetic circuit of the bar coil 10 of the leadership of the magnetic field and is also referred to as the outer core.
An den zentralen Abschnitt 23 des Gehäuses 13 schließt sich einerseits ein erster Endabschnitt 24 des Gehäuses 13, und andererseits ein zweiter Endabschnitt 26 des Gehäuses 13 an. Im ersten Endabschnitt 24 sind metallische Anschlussstecker 27 angeordnet, über die die Primärwicklung 20 der Stabspule 10 mit Niederspannung versorgt wird. Der zweite Endabschnitt 26 enthält eine mit der Sekundärwicklung 19 verbundene metallische Anschlusshülse 28, über die die Hochspannung der Stabspule 10 an die (nicht dargestellte) Zündkerze abgeleitet wird.On the one hand, a first end section 24 of the housing 13 and, on the other hand, a second end section 26 of the housing 13 adjoin the central section 23 of the housing 13. In the first end portion 24 metallic connector 27 are arranged, via which the primary winding 20 of the bar coil 10 is supplied with low voltage. The second end portion 26 includes a metallic ferrule 28 connected to the secondary winding 19, through which the high voltage of the bar coil 10 is dissipated to the spark plug (not shown).
Die radial zumindest nahe der Innenwand des Gehäuses 13 angeordnete Primärwicklung 20 ist in axialer Richtung auf der dem zweiten Endabschnitt 26 zugewandten Seite von einem vorzugsweise aus Kunststoff bestehenden Ring 29 begrenzt. Auf der dem ersten Endabschnitt 24 zugewandten Seite ist ein Anschlussring 30 vorgesehen, der einerseits mit derThe primary winding 20, which is arranged radially at least close to the inner wall of the housing 13, is delimited in the axial direction on the side facing the second end section 26 by a ring 29 preferably made of plastic. On the first end portion 24 side facing a connection ring 30 is provided, on the one hand with the
Primärwicklung 20, und andererseits über einen Anschlussdraht 32 mit den Anschlusssteckern 27 verbunden ist. In dem Anschlussring 30 kann ggf. eine Kontur zu Führung der Primärwicklung 20 eingearbeitet sein.Primary winding 20, and on the other hand connected via a connecting wire 32 to the connector plugs 27. If necessary, a contour for guiding the primary winding 20 can be incorporated in the connection ring 30.
Der Innenraum des Gehäuses 13 ist vorzugsweise mit einem Isolierharz 33 befüllt, das insbesondere auch den radialen Spalt zwischen der Primärwicklung 20 und der ihr gegenüber liegenden Sekundärwicklung 19 ausfüllt.The interior of the housing 13 is preferably filled with an insulating resin 33, which also fills in particular the radial gap between the primary winding 20 and the opposite secondary winding 19.
Zur Montage der Stabspule 10 ist es erforderlich, zunächst die Primärwicklung 20 innerhalb des Gehäuses 13 anzuordnen, bevor dieses mit den anderen Bauteilen, wie beispielsweise derFor mounting the bar coil 10, it is first necessary to arrange the primary winding 20 within the housing 13, before this with the other components, such as
Sekundärwicklung 19 oder dem Kern 14 bestückt wird. Hierzu findet entsprechend der Figur 2 ein Wickeldorn 35 Verwendung. Der Wickeldorn 35 weist zumindest in dem für die Primärwicklung 20 vorgesehenen Bereich eine zylindrische oder vorzugsweise leicht konische Form auf. Die Länge des Wickeldorns 35 ist so bemessen, dass zumindest die Primärwicklung 20 sowie der Ring 29 und der Anschlussring 30 auf ihm Platz finden. Dabei sollte derSecondary winding 19 or the core 14 is populated. For this purpose, a winding mandrel 35 is used according to FIG. The winding mandrel 35 has a cylindrical or preferably slightly conical shape, at least in the region provided for the primary winding 20. The length of the mandrel 35 is dimensioned so that at least the primary winding 20 and the ring 29 and the connecting ring 30 find space on it. It should be the
Innendurchmesser des Rings 29 und des Anschlussrings 30 so auf den Außendurchmesser des Wickeldorns 35 abgestimmt sein, dass ein leichtes Abstreifen des Rings 29 und des Anschlussrings 30 in axialer Richung des Wickeldorns 35 möglich ist. Vorzugsweise werden zunächst der Ring 29 und der Anschlussring 30 in entsprechendem Abstand zueinander auf dem Wickeldorn 35 positioniert, worauf anschließend der Draht der Primärwicklung 30 in wenigstens einer Lage zwischen dem Ring 29 und dem Anschlussring 30 auf den Wickeldorn 35 aufgewickelt wird. Dies erfolgt entweder dadurch, dass der Wickeldorn 35 relativ zu einer (nicht dargestellten) Drahtabgabeeinrichtung dreh- und in axialer Richtung verschiebbar ist, oder aber bevorzugt dadurch, dass sich bei ortsfestem Wickeldorn 35 die Drahtabgabeeinrichtung um den Wickeldorn 35 dreht und dabei gleichzeitig in axialer Richtung des Wickeldorns 35 bewegt.Inner diameter of the ring 29 and the connecting ring 30 to be matched to the outer diameter of the winding mandrel 35 that a slight stripping of the ring 29 and the connecting ring 30 in the axial direction of the winding mandrel 35 is possible. Preferably, first, the ring 29 and the connecting ring 30 are positioned at a corresponding distance from each other on the winding mandrel 35, whereupon subsequently the wire of the primary winding 30 in at least one layer between the ring 29 and the connecting ring 30 is wound onto the winding mandrel 35. This is done either by the fact that the winding mandrel 35 relative to a (not shown) wire dispenser rotatable and displaceable in the axial direction, or preferably characterized in that with fixed winding mandrel 35, the wire dispensing device rotates about the mandrel 35 and at the same time in the axial direction the winding mandrel 35 moves.
Nachdem die Primärwicklung 20 auf den Wickeldorn 35 aufgewickelt ist, werden die Drahtenden 36, 37 der Primärwicklung 20 mit dem Anschlussring 30 elektrisch kontaktiert, beispielsweise verschweißt. Um eine gewisse Bindung bzw. Haftung zwischen den einzelnen Lagen der Primärwicklung 20 zu ermöglichen, kann der Draht der Primärwicklung 20 als sogenannter Backlackdraht ausgebildet sein. Die Backlackschicht der Primärwicklung 20 wird durch eine entsprechende Wärmebehandlung aktiviert, so dass danach die Primärwicklung 20 als kompakte, feste Einheit bildet ist.After the primary winding 20 is wound on the winding mandrel 35, the wire ends 36, 37 of the primary winding 20 are electrically contacted with the connection ring 30, for example, welded. In order to allow a certain bond or adhesion between the individual layers of the primary winding 20, the wire of the primary winding 20 may be formed as a so-called baked enamel wire. The baked enamel layer of the primary winding 20 is activated by a corresponding heat treatment, so that thereafter the primary winding 20 is formed as a compact, solid unit.
Anschließend wird der Wickeldorn 35 zusammen mit der Primärwicklung 20 in das Gehäuse 13 eingeschoben, bis sich die Primärwicklung 20 an der vorgesehenen Position im Gehäuse 13 befindet (Figur T). Zum Abstreifen der Primärwicklung 20 in das Gehäuse 13 wirkt der Wickeldorn 35 bzw. der Ring 29 anschließend mit einem im Ausführungsbeispiel rohrförmigen Abstreifelement 38 zusammen, welches beim Herausziehen des Wickeldorns 35 aus demSubsequently, the mandrel 35 is inserted together with the primary winding 20 in the housing 13 until the primary winding 20 is located at the intended position in the housing 13 (Figure T). For stripping the primary winding 20 in the housing 13 of the winding mandrel 35 and the ring 29 then cooperates with a tubular stripping element 38 in the exemplary embodiment, which upon removal of the winding mandrel 35 from the
Gehäuse 13 ortsfest in Kontakt mit dem Ring 29 verbleibt, während der Wickeldorn 35 relativ dazu in Längsrichtung des Gehäuses 13 bewegbar ist. Vorteilhafterweise ist der Wickeldorn 35 zur Erleichterung des Abstreifvorgangs der Primärwicklung 20 von dem Wickeldorn 35 leicht konisch ausgebildet, derart, dass sich der Durchmesser des Wickeldorns 35 in Richtung des Anschlussrings 30 betrachtet verringert.Housing 13 stationary in contact with the ring 29 remains, while the winding mandrel 35 is movable relative thereto in the longitudinal direction of the housing 13. Advantageously, the winding mandrel 35 to facilitate the stripping operation of the primary winding 20 of the winding mandrel 35 is slightly conical, such that the diameter of the winding mandrel 35 is reduced viewed in the direction of the connection ring 30.
Nachdem der Wickeldorn 35 aus dem Gehäuse 13 entfernt ist, können weitere Bauteile der Stabspule 10 in das Gehäuse 13 eingesetzt, sowie die Anschlussdrähte 32 mit dem Anschlussring 30 verbunden werden. Zum Schluss findet ggf. ein Ausgießen des Innenraums des Gehäuses 13 mit dem Isolierharz 33 statt.After the winding mandrel 35 is removed from the housing 13, further components of the bar coil 10 can be inserted into the housing 13, and the connecting wires 32 are connected to the connecting ring 30. Finally, if necessary, a pouring out of the interior of the housing 13 with the insulating resin 33 takes place.
Um die elektrischen Isolationseigenschaften zwischen der Primärwicklung 20 und der Sekundärwicklung 19 zu verbessern bzw. das Abstreifen der Primärwicklung 20 von dem Wickeldorn 35 zu erleichtern, kann es vorgesehen sein, eine zusätzliche Zwischenschicht 40 vorzusehen (Figur 1). Die Zwischenschicht 40 besteht beispielsweise aus einer eventuell beschichteten Papier- oder Kunststoffolienschicht, die ggf. perforiert sein kann. Die Zwischenschicht 40 wird hierbei vor dem Aufwickeln der Primärwicklung 20 auf den Wickeldorn 35 als erstes auf den Wickeldorn 35 aufgebracht, und anschließend zusammen mit der Primärwicklung 20 in dem Gehäuse 13 abgestreift.In order to improve the electrical insulation properties between the primary winding 20 and the secondary winding 19 and to facilitate the stripping of the primary winding 20 from the winding mandrel 35, it may be provided to provide an additional intermediate layer 40 (FIG. 1). The intermediate layer 40 consists for example of a possibly coated paper or plastic film layer, which may be perforated if necessary. The intermediate layer 40 is here applied to the winding mandrel 35 before winding the primary winding 20 onto the winding mandrel 35 first, and then stripped together with the primary winding 20 in the housing 13.
Im Gegensatz zu dem starren Wickeldorn 35 ist in den Figuren 3 und 4 ein modifizierter Wickeldorn 35a dargestellt. Der Wickeldorn 35a zeichnet sich dadurch aus, dass er im Durchmesser veränderbar ist. Im dargestellten Beispiel wird dies durch in Richtung der Doppelpfeile 41 bewegbare Segmente 42 verwirklicht, jedoch sind selbstverständlich auch andere Ausführungsformen denkbar. Zum Aufwickeln der Primärwicklung 20 bzw. derIn contrast to the rigid winding mandrel 35, a modified winding mandrel 35a is shown in FIGS. 3 and 4. The mandrel 35a is characterized in that it is variable in diameter. In the example shown, this is realized by movable in the direction of the double arrows 41 segments 42, but of course other embodiments are conceivable. For winding up the primary winding 20 or the
Zwischenschicht 40 weist hierbei der Wickeldorn 35a entsprechend der Figur 3 seinen größten Durchmesser auf. Zum Abstreifen der Primärwicklung 20 bzw. der Zwischenschicht 40 im Gehäuse 13 wird der Durchmesser des Wickeldorns 35a entsprechend der Figur 4 verringert, so dass die Haftung der Zwischenschicht 40 bzw. der Primärwicklung 20 zum Wickeldorn 35a aufgehoben wird. Bei dem modifizierten Wickeldorn 35a kann ggf. auf das Abstreifelemnt 38 verzichtet werden. Interlayer 40 in this case has the winding mandrel 35a according to the figure 3 its largest diameter. For stripping the primary winding 20 or the intermediate layer 40 in the housing 13, the diameter of the winding mandrel 35a is reduced as shown in FIG 4, so that the adhesion of the intermediate layer 40 and the primary winding 20 is lifted to the winding mandrel 35a. If necessary, the stripping element 38 can be dispensed with in the case of the modified winding mandrel 35a.

Claims

Ansprüche claims
1. Verfahren zum Herstellen einer Spule (10), insbesondere einer Zündspule für ein Kraftfahrzeug, bei dem eine Primärwicklung (20) auf einen Wickeldorn (35; 35a) aufgewickelt wird, anschließend der Wickeldorn (35; 35a) in einem Gehäuse (13) der Spule (10) eingeführt wird, danach der Wickeldorn (35; 35a) aus dem Gehäuse (13) entfernt wird, wobei die1. A method for producing a coil (10), in particular an ignition coil for a motor vehicle, in which a primary winding (20) is wound on a winding mandrel (35; 35a), then the winding mandrel (35; 35a) in a housing (13) the coil (10) is inserted, then the winding mandrel (35; 35a) is removed from the housing (13), wherein the
Primärwicklung (20) in dem Gehäuse (13) verbleibt, und wobei anschließend weitere Bauteile der Spule (10), insbesondere ein mit einer Sekundärwicklung (19) bewickelter Sekundärspulenkörper (18) in das Gehäuse (13) eingebracht werden, so dass die Sekundärwicklung (19) konzentrisch innerhalb der Primärwicklung (20) unter Verzicht eines separaten Primärspulenkörpers angeordnet ist.Primary winding (20) in the housing (13) remains, and wherein subsequently further components of the coil (10), in particular a wound with a secondary winding (19) secondary coil body (18) are introduced into the housing (13), so that the secondary winding ( 19) is arranged concentrically within the primary winding (20) waiving a separate primary coil body.
2. Verfahren nach Anspruch 1 , dadurch gekennzeichnet, dass das Ende bzw. der Anfang der Primärwicklung (20) mit einem vorzugsweise ringförmigen Anschlusselement (30) verbunden wird, dass das Anschlusselement (30) zusammen mit der Primärwicklung (20) auf dem Wickeldorn (35; 35a) aufgebracht wird, und dass das Anschlusselement (30) zur Kontaktierung der Primärwicklung (20) mit einer Versorgungsspannung der Spule (10) in dem Gehäuse (13) verbleibt.2. The method according to claim 1, characterized in that the end or the beginning of the primary winding (20) with a preferably annular connection element (30) is connected, that the connection element (30) together with the primary winding (20) on the mandrel ( 35; 35a) is applied, and that the connection element (30) for contacting the primary winding (20) with a supply voltage of the coil (10) in the housing (13) remains.
3. Verfahren nach Anspruch 1 oder 2, dadurch gekennzeichnet, dass zwischen dem Wickeldorn (35; 35a) und der Primärwicklung (20) eine Zwischenschicht (40) auf dem Wickeldorn (35;3. The method according to claim 1 or 2, characterized in that between the winding mandrel (35; 35a) and the primary winding (20) has an intermediate layer (40) on the winding mandrel (35;
35a) aufgebracht wird, welche zusammen mit der Primärwicklung (20) in dem Gehäuse (13) verbleibt.35a) which remains in the housing (13) together with the primary winding (20).
4. Verfahren nach einem der Ansprüche 1 bis 4, dadurch gekennzeichnet, dass der Zwischenraum im Gehäuse (13) zwischen der Sekundärwicklung (19) und der Primärwicklung (20) mit einem Isolierharz (33) ausgegossen wird.4. The method according to any one of claims 1 to 4, characterized in that the intermediate space in the housing (13) between the secondary winding (19) and the primary winding (20) with an insulating resin (33) is poured out.
5. Vorrichtung zum Durchführen des Verfahrens nach einem der Ansprüche 1 bis 4, mit einem Wickeldorn (35), auf dem der Draht einer Primärwicklung (20) aufwickelbar ist, dadurch gekennzeichnet, dass der Wickeldorn (35) zum Abstreifen der Primärwicklung (20) im Gehäuse (13) der Spule (10) mit einem Abstreifelement (38) zusammenwirkt, wobei der Wickeldorn (35) und das Abstreifelement (38) relativ zueinander bewegbar sind.5. A device for carrying out the method according to one of claims 1 to 4, with a winding mandrel (35) on which the wire of a primary winding (20) can be wound, characterized in that the winding mandrel (35) for stripping the primary winding (20) in the case (13) of the coil (10) cooperates with a stripping element (38), wherein the winding mandrel (35) and the stripping element (38) are movable relative to each other.
6. Vorrichtung nach Anspruch 5, dadurch gekennzeichnet, dass das Abstreifelement (38) auf ein Rückhalteelement (29) wirkt, das auf der dem Anschlusselement (30) gegenüberliegenden Seite der Primärwicklung (20) angeordnet ist.6. The device according to claim 5, characterized in that the stripping element (38) acts on a retaining element (29) which is arranged on the connecting element (30) opposite side of the primary winding (20).
7. Vorrichtung nach Anspruch 5 oder 6, dadurch gekennzeichnet, dass der Wickeldorn (35) im Bereich der Primärwicklung (20) eine konische Form aufweist.7. Apparatus according to claim 5 or 6, characterized in that the winding mandrel (35) in the region of the primary winding (20) has a conical shape.
8. Vorrichtung zum Durchführen des Verfahrens nach einem der Ansprüche 1 bis 4, mit einem Wickeldorn (35a), auf dem eine Primärwicklung (20) aufwickelbar ist, dadurch gekennzeichnet, dass der Durchmesser des Wickeldorns (35a) zumindest im Bereich der Primärwicklung (20) veränderbar ist. 8. An apparatus for carrying out the method according to one of claims 1 to 4, with a winding mandrel (35a) on which a primary winding (20) can be wound, characterized in that the diameter of the winding mandrel (35a) at least in the region of the primary winding (20 ) is changeable.
EP07788167A 2006-08-09 2007-08-02 Method for producing a coil, in particular an ignition coil for a motor vehicle Expired - Fee Related EP2052394B1 (en)

Applications Claiming Priority (2)

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DE102006037169A DE102006037169A1 (en) 2006-08-09 2006-08-09 Method for producing a coil, in particular an ignition coil for a motor vehicle
PCT/EP2007/058014 WO2008017631A2 (en) 2006-08-09 2007-08-02 Method for producing a coil, in particular an ignition coil for a motor vehicle

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EP2052394B1 EP2052394B1 (en) 2012-03-21

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US20100018033A1 (en) 2010-01-28
JP2010500744A (en) 2010-01-07
WO2008017631A2 (en) 2008-02-14
WO2008017631A3 (en) 2008-04-10
DE102006037169A1 (en) 2008-02-14
EP2052394B1 (en) 2012-03-21
US8230584B2 (en) 2012-07-31

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