EP2489051A1 - Ignition coil having closed magnetic core and permanent magnet, and method for manufacturing said coil - Google Patents

Ignition coil having closed magnetic core and permanent magnet, and method for manufacturing said coil

Info

Publication number
EP2489051A1
EP2489051A1 EP10773121A EP10773121A EP2489051A1 EP 2489051 A1 EP2489051 A1 EP 2489051A1 EP 10773121 A EP10773121 A EP 10773121A EP 10773121 A EP10773121 A EP 10773121A EP 2489051 A1 EP2489051 A1 EP 2489051A1
Authority
EP
European Patent Office
Prior art keywords
core
core element
contact
protective housing
core member
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.)
Withdrawn
Application number
EP10773121A
Other languages
German (de)
French (fr)
Inventor
Vincent Gepel
Laurent Decool
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.)
Valeo Systemes de Controle Moteur SAS
Original Assignee
Valeo Systemes de Controle Moteur SAS
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 Valeo Systemes de Controle Moteur SAS filed Critical Valeo Systemes de Controle Moteur SAS
Publication of EP2489051A1 publication Critical patent/EP2489051A1/en
Withdrawn legal-status Critical Current

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Classifications

    • 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

Definitions

  • the present invention relates to a magnetic core closed ignition coil and permanent magnet. It finds a general application in electrical engineering and more particularly in internal combustion engine engines with spark ignition, in which the combustion of the gaseous mixture in the cylinders is caused by a spark generated between the electrodes of a spark plug ordered by an ignition coil.
  • a closed permanent magnet magnetic core (or circuit) ignition coil comprises a first U-shaped magnetic core element and a second bar-shaped magnetic core element around which are wound a primary winding and a secondary winding. forming with the second core member a "coil module".
  • the coil module is mounted transversely between the two branches of the U of the first core element and the assembly is inserted into a housing of protection.
  • the inside of the protective case can then be filled with resin to electrically isolate the various elements of the ignition coil and form a sealed block suitable for use in a motor vehicle.
  • the end surfaces of the second bar-shaped core member are in contact with inner end surfaces of the legs of the first U-shaped core member.
  • the permanent magnet generally forms one of ends of the second bar-shaped core member; it makes it possible to increase the power of the ignition coil and / or to reduce its bulk.
  • the inner end surface of a U-limb of the first core member of WO 94/06134 has a tapered shape, as does the complementary end surface of the second core member. bar, to define a mounting ramp for the inclined surfaces in contact with each other.
  • Deformable protuberances protruding from the other end surface of the second bar-shaped core element (or that of the permanent magnet), are intended to provide, by their crushing, a margin of error for the clamping between the two magnetic core elements.
  • the air gap is not completely reduced to zero, which leaves air gaps between the facing surfaces. These air spaces can be the seat of a resin infiltration during the resin of the housing, which reduces the efficiency of the magnetic core and therefore the ignition coil.
  • the present invention aims to overcome these disadvantages.
  • the invention relates to an ignition coil comprising a protective housing, a magnetic core closed with a permanent magnet, the magnetic core comprising a first substantially U-shaped core element housed in the protective housing and a second substantially bar-shaped core member, the first core member having at least two contact surfaces with the second core member, the coil having at least one primary winding and a secondary winding around the second core member and forming with it a coil module, characterized in that the contact surfaces of the first core member are both beveled to allow mounting of the coil module in the housing.
  • the introduction of the coil module in the protective housing is simpler, which facilitates the industrialization of the process of manufacturing the ignition coil.
  • this may allow a "blind" mounting step of the coil module in the protective housing, the first U-shaped core element having previously been mounted in the housing.
  • the beveled contact surfaces can serve as a guide ramp when placing the coil module in the protective housing, the second core element can for example be moved and guided along one of these surfaces, the presence of a bevel on the other side ensuring sufficient clearance for a gradual movement while allowing to catch any errors, without it being necessary to provide other means securing the establishment such as for example the stops or protuberances of the prior art; the core elements are thus simpler and less expensive.
  • the presence of two bevels also allows the support, intentionally or by mistake, on one surface instead of the other.
  • the second core element having at least two contact surfaces with the contact surfaces of the first core element, these contact surfaces have a beveled shape complementary to the beveled shape of the contact surfaces of the first element. of core.
  • Complementary form means a form allowing contact plan of the surfaces considered. The gap between the surfaces facing each other is thus reduced to a minimum and may advantageously be zero.
  • At least one contact surface of the second core element is formed by a surface of the permanent magnet.
  • the second core element is in the form of a T-shaped bar having a main branch extending along an axis and a transverse branch inclined with respect to the axis of the main branch. , the transverse branch supporting the permanent magnet.
  • the first core element comprising two branches corresponding to the branches of the U of which it has the shape, its contact surfaces are end surfaces of said branches.
  • each branch having an inner side and an outer side, the contact surfaces of the first core member are located on the inner side of the branches.
  • each branch extending generally along an axis, each contact surface is inclined at an acute angle with respect to the axis of the branch considered.
  • the protective casing is overmoulded around the first core element.
  • Such a housing makes it easy to respect precise mounting dimensions.
  • the contact surfaces of the first core element have different lengths. This makes it possible to favor contact with one of these surfaces, in particular if the permanent magnet forms one end of the second core element, the contact surface with the permanent magnet then preferably being the largest to favor the contact. with the magnet.
  • an insert is connected to the secondary winding and is arranged to make contact with an electrical conductor housed in the protective housing and connected to a high voltage insert. The invention, which guarantees a good implementation of the coil module on the first core element, thus guarantees the proper placement of the secondary winding in the protective housing and therefore the good contact of the insert with the electrical conductor.
  • the invention further relates to a method of manufacturing an ignition coil having a protective housing, a magnetic core closed with a permanent magnet, the magnetic core having a first substantially U-shaped core member housed in the housing of protection and a second substantially rod-shaped core member, the first core member having at least two beveled contact surfaces with the second core member, the coil having at least one primary winding and a secondary winding around the second core member. kernel, the method comprising the following steps:
  • the first core element is housed in the protective casing
  • the coil module is mounted in the protective housing by contacting the second core element with the contact surfaces of the first core element.
  • the first core element is housed in the over-molded protective casing of the protective casing around the first core element. Such a step is simple to implement and perfectly encapsulates the first core element in the housing.
  • the second core element having at least two contact surfaces with the contact surfaces of the first core element and having a beveled shape complementary to the beveled shape of the contact surfaces of the first core element, mounting the coil module in the protective case by moving a contact surface of the second core member along a contact surface of the first core member.
  • at least one end surface of the second core element being formed by a surface of the permanent magnet, the the contact surface of the second core member displaced along a contact surface of the first core member is that of the permanent magnet.
  • contact is made between an insert connected to the secondary winding and an electrical conductor housed in the protective housing and connected to a high voltage insert.
  • FIG. 1 shows a wired perspective view of a protective housing overmolded around a first U-shaped core element according to the invention
  • FIG. 2 represents an exploded view of the elements of a coil module according to the invention
  • FIG. 3 shows the coil module of Figure 2 mounted in the protective housing of Figure 1, in wire profile view;
  • FIG. 4 shows a perspective view of the first U-shaped core element of FIG. 1;
  • FIG. 5 is a perspective view of the second bar-shaped core element of the coil module of FIG. 2;
  • FIG. 6 represents a perspective view of the second core element of FIG. 5 mounted between the two branches of the U of the first core element of FIG. 4.
  • An ignition coil 1 comprises a magnetic core (or circuit) closed with a permanent magnet 21, the magnetic core comprising a first substantially U-shaped core element 4, housed in a protective casing 2, and a second substantially rod-shaped core element 20 around which are wound a primary winding 23 and a secondary winding 36 in which respectively an electrical input current of the coil and an electrical output current of the coil are circulated, respectively classic.
  • the second core element 20 and the primary 23 and secondary 36 windings form a coil module 3.
  • the coil 1, shown in FIG. Figure 3 is formed by the assembly of the coil module 3 (shown in Figure 2) in the housing 2 in which is housed the first core element 4 (shown in Figure 1). With reference to FIG.
  • the first U-shaped core element 4 is formed, in this case, of a stack of sheets held together and is named, in the following description, first core element 4
  • This core element 4 comprises a base 42 and two branches 6a, 6b corresponding to the base and the branches of the U of which it has the shape.
  • the first core element 4 comprises two surfaces 5a, 5b of contact with the second core element 20; these contact surfaces 5a, 5b are planar and bevelled to allow mounting of the coil module 3 (including the second core element 20) in the protective housing 2 (in which is mounted the first core element 4).
  • the second core element 20 also has two surfaces 21a, 31b (in this case end) contact with the contact surfaces 5a, 5b of the first core element 4.
  • a surface 21a is formed by a surface of the permanent magnet 21, the latter being fixed on a surface 31a of the second core member 20, as described in more detail below.
  • the contact surfaces 21a, 31b of the second core member 20 are planar and beveled, each of complementary shape to the shape of the contact surface 5a, 5b of the first core member 4 with which it is intended to come into contact; this complementarity of shapes allows plane contact between the surfaces (5a, 21a), (5b, 31b) of each pair of contact surfaces (the shapes being of course arranged to allow contact at each of the branches of the U).
  • the protective housing 2 is substantially parallelepipedal in shape and has an inner surface shaped to match the outer shape of the first core member 4, of which only the inner surfaces are visible in the housing 2 when it is housed therein. More specifically, the protective casing 2 is in this case overmolded around the first core element 4. In this case, the protective casing 2 has an opening 7 on the upper side, through which the coil module 3 can be mounted. in the case 2; it also comprises a bottom wall 8 and solid side walls, shaped to fit the outer surfaces of the first core member 4 and allow the assembly of the coil module 3.
  • the shape of the housing 2 is accessible to the man of the profession and it is not necessary to further detail its description.
  • Fastening means may be provided on the housing 2, to cooperate with corresponding means of the vehicle (not shown) to allow the attachment of the housing 2 to the vehicle, in a conventional manner.
  • a conductive element 15 such as a resistor is disposed inside the first cylindrical housing 13 and is electrically connected to a part conventionally called a high-voltage insert 16, housed in the second cylindrical housing 14 and intended to be connected to a spark plug. ignition, not shown, to transmit the voltage necessary for its ignition.
  • the coil module 3 comprises the second core element 20, which supports the permanent magnet 21, the primary winding 23 and the secondary winding 36, in a known manner.
  • the primary 23 and secondary windings 36 are each wound around a plastic carcass or bobbin 22, 35, respectively, in a known manner that it is not necessary to describe in detail.
  • the casing 22 of the primary winding 23 is fitted around the second core element 20 and the casing 35 of the secondary winding 36 is fitted around the primary winding 23, in a known manner.
  • the second core element 20 is for example formed of a stack of sheets held together, similarly to the first core element 4.
  • the second core element 20 is in the form of a T-shaped bar comprising a main branch 24 extending generally along the X axis and an inclined transverse branch 25, the permanent magnet 21 being in this case fixed to a flat end surface 31a of the transverse branch 25.
  • the second core member 20 may be in the form, not of a T but of an I, arranged to be mounted between the two branches 6a, 6b of the first core element 4.
  • the bobbin 35 of the secondary winding 36 is in the form of a hollow body for housing the primary winding 23 and its winding 22. At its end opposite to that corresponding to the side of the permanent magnet 21, the bobbin 35 comprises, in the upper part, a tongue 38 projecting generally parallel to the axis X. Two notches 40 are formed under the tongue 38, on either side of the bobbin 35; they are arranged to receive tabs of a T-shaped electrical contact element 41, conventionally called insert 41 or secondary insert 41 and whose function is to establish an electrical contact between the secondary winding 36 and the conductive element 15 connected to the high voltage insert 16, in known manner.
  • the tongue 38 provides protection and positioning of the secondary insert 41. In the mounting position of the ignition coil 1 (as illustrated in FIG.
  • the relative positions of the core elements 4, 20 guarantee the relative position. of the secondary insert 41 (integral with the coil module 3 and therefore the first core element 20) with respect to the conductive element 15 (integral with the protective housing 2).
  • the two branches 6a, 6b of the first core element 4 are asymmetrical, the bevelled surface 5a intended to be in contact with the surface 21a of the magnet 21 being of larger dimension, in the plane of cut formed by the X and Y directions, than the other bevelled surface 5b.
  • This conformation is chosen to confer particularly on the surface 5a of contact with the magnet 21 a guide ramp function of the second core element 20 via the magnet 21; thus, when mounting the coil module 3 in the protective housing 2, the surface 21a of the magnet 21 is moved along the corresponding contact surface 5a of the first core element 4 until the opposite surfaces 5b, 31b of the first and second core members 4, 20 come into contact with each other.
  • the dimension of the branch 6a with the largest bevelled surface 5a is larger, in the direction of the Y direction, than the dimension of the other branch 6b, which ensures that the first contact established with the second core element 20 is preferably on this larger branch 6a.
  • the contact surfaces 5a, 5b of the first core element 4 are provided on its inner side. They each extend from one end 43a, 43b of a branch 6a, 6b, respectively, the corresponding thickness of the branch 6a, 6b in the X and Y plane increasing from this end to the base 42 of the core element 4, as seen in Figure 4.
  • the contact surfaces 5a, 5b are inclined at an acute angle a, a ', respectively, with respect to the direction Y, the angles a, a 'being in this case identical value, these angles being opposite trigonometrically.
  • the two branches 6a, 6b of the first core element 4 may be symmetrical; other arrangements of the shape of the branches 6a, 6b are also conceivable, the essential being that each branch 6a, 6b of the first element of core 4 have a bevelled surface 5a, 6b to allow the displacement of the second core member 20 when it is put in place of the coil module 3 in the protective housing 2.
  • the end surfaces 21a , 31b of the second core member 20 are inclined at an acute angle ⁇ , ⁇ ', respectively, relative to a direction P perpendicular to the direction of the main branch 24 of the T whose second core member 20 is shaped.
  • angles ⁇ , ⁇ ' are in this case respectively equal to the angles a, a' that are the contact surfaces 5a, 5b of the first core member 4 with the direction Y.
  • the second core member 20 is arranged to be mounted in the housing 2 so that the main direction of its main bar 24 extend parallel to the X direction of the base of the U whose first core element 4 has the shape, that is to say that the direction P perpendicular to its main branch 24 then extends parallel to the Y direction of the branches of the U.
  • the contact surfaces (5a, 5b), (21a, 31b) are complementary and arranged to come into plane contact, ensuring a zero gap between the first core member 4 and the second core member 20.
  • This relative position of the core members 4, 20 is shown in Fig. 6 (only the core members 4, 20 being shown in this figure without the primary and secondary windings 23 36 or the protection box 2).
  • the protective casing 2 is overmoulded around the first core element 4. Furthermore, the coil module 3 has been previously mounted, that is to say the second core element 20 has been inserted in the winding 22 of the primary winding 23 which has itself been inserted into the winding 35 of the secondary winding 36.
  • the second core member 20 is brought into contact and then displaced by the surface 21a of the permanent magnet 21 along the beveled contact surface 5a of the first core member 20; this displacement is effected until the opposite contact surface 31b of the second core member 20 comes into contact with the other contact surface 5b of the first core element 4.
  • this contacting of the opposite contact surfaces 5b, 31b is accompanied by a sound snap which attests the good positioning of the second core element 20 with respect to the first core element 4, that is to say the good positioning of the coil module 3 with respect to the housing 2.
  • the magnetic core of the ignition coil 1, formed by the first and the second core elements 4, 20 is thus closed.
  • the permanent magnet 21 is fixed at another location of the magnetic core. Wherever the magnet 21 is fixed, the displacement of the second core member 20 with respect to the first core member 4 may or may not be along a surface of the magnet 21; it is preferably along a surface of the magnet 21 insofar as the magnet 21 tends to be attracted by the core element 20, 4 on which it is not fixed.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Ignition Installations For Internal Combustion Engines (AREA)

Abstract

The invention relates to an ignition coil, comprising a protective housing (2) a closed magnetic core having a permanent magnet (21), the magnetic core comprising a substantially U-shaped first core element (4) that is housed inside the protective housing (2) and a substantially bar-shaped second core element (20). The first core element (4) comprises at least two surfaces (5a, 5b) for contact with the second core element (20). The coil comprises at least one primary winding (23) and a secondary winding (36) that are situated around the second core element (20) and form a coil module (3) therewith. The contact surfaces (5a, 5b) of the first core element (4) are both beveled so as to enable the mounting of the coil module (3) inside the housing (2). The invention simplifies the placement of the coil module in the protective housing.

Description

Bobine d'allumage à noyau magnétique fermé et à aimant permanent et procédé de fabrication de la bobine  Magnetic core ignition coil with permanent magnet and coil manufacturing process
La présente invention concerne une bobine d'allumage à noyau magnétique fermé et à aimant permanent. Elle trouve une application générale en électrotechnique et plus particulièrement dans les moteurs de véhicule automobile à combustion interne à allumage commandé, dans lesquels la combustion du mélange gazeux dans les cylindres est provoquée par une étincelle générée entre les électrodes d'une bougie d'allumage commandée par une bobine d'allumage. The present invention relates to a magnetic core closed ignition coil and permanent magnet. It finds a general application in electrical engineering and more particularly in internal combustion engine engines with spark ignition, in which the combustion of the gaseous mixture in the cylinders is caused by a spark generated between the electrodes of a spark plug ordered by an ignition coil.
Une bobine d'allumage à noyau (ou circuit) magnétique fermé et à aimant permanent comprend un premier élément de noyau magnétique en forme de U et un second élément de noyau magnétique en forme de barre autour duquel sont bobinés un enroulement primaire et un enroulement secondaire, formant avec le second élément de noyau un "module de bobine". A closed permanent magnet magnetic core (or circuit) ignition coil comprises a first U-shaped magnetic core element and a second bar-shaped magnetic core element around which are wound a primary winding and a secondary winding. forming with the second core member a "coil module".
Lors du montage de la bobine d'allumage, comme par exemple décrit dans le document WO 94/06134, le module de bobine est monté transversalement entre les deux branches du U du premier élément de noyau puis l'ensemble est inséré dans un boîtier de protection. L'intérieur du boîtier de protection peut ensuite être rempli de résine pour isoler électriquement les différents éléments de la bobine d'allumage et former un bloc étanche apte à être utilisé dans un véhicule automobile. During assembly of the ignition coil, as described for example in WO 94/06134, the coil module is mounted transversely between the two branches of the U of the first core element and the assembly is inserted into a housing of protection. The inside of the protective case can then be filled with resin to electrically isolate the various elements of the ignition coil and form a sealed block suitable for use in a motor vehicle.
En position montée finale, les surfaces d'extrémité du second élément de noyau en forme de barre sont en contact avec des surfaces intérieures d'extrémité des branches du premier élément de noyau en forme de U. L'aimant permanent forme généralement l'une des extrémités du second élément de noyau en forme de barre; il permet d'augmenter la puissance de la bobine d'allumage et/ou de réduire son encombrement. In the final mounted position, the end surfaces of the second bar-shaped core member are in contact with inner end surfaces of the legs of the first U-shaped core member. The permanent magnet generally forms one of ends of the second bar-shaped core member; it makes it possible to increase the power of the ignition coil and / or to reduce its bulk.
Cependant, en raison des tolérances de fabrication, des problèmes se posent pour le montage et la tenue des éléments de noyau magnétique entre eux. En particulier, une fois les éléments de noyau magnétique montés, l'entrefer entre eux doit être nul, et ce au niveau des deux interfaces entre leurs paires de surface en contact, au niveau de chaque branche du U; or, il est très complexe de monter l'un dans l'autre deux éléments destinés à présenter un entrefer nul entre deux paires de surfaces, surtout en présence d'un aimant qui les attire l'un contre l'autre. Pour résoudre ces problèmes, la surface intérieure d'extrémité d'une branche du U du premier élément de noyau du document WO 94/06134 présente une forme biseautée, de même que la surface d'extrémité complémentaire du second élément de noyau en forme de barre, afin de définir une rampe de montage pour les surfaces inclinées en contact l'une avec l'autre. Des protubérances déformables, en saillie hors de l'autre surface d'extrémité du second élément de noyau en forme de barre (ou de celle de l'aimant permanent), visent à offrir, par leur écrasement, une marge d'erreur pour le serrage entre les deux éléments de noyau magnétique. Cependant, entre les protubérances, l'entrefer n'est pas complètement réduit à zéro, ce qui laisse des espaces d'air entre les surfaces en regard. Ces espaces d'air peuvent être le siège d'une infiltration de résine lors du résinage du boîtier, ce qui réduit l'efficacité du noyau magnétique et donc de la bobine d'allumage. On remarquera, de plus, que la mise en place et la tenue du second élément de noyau entre les deux branches du U du premier élément de noyau impose, outre les protubérances déformables, la présence d'un épaulement de butée sur une branche du U. La fabrication des protubérances et de l'épaulement de butée est fastidieuse et coûteuse. However, due to manufacturing tolerances, problems arise in mounting and holding the magnetic core elements together. In particular, once the magnetic core elements mounted, the air gap between them must be zero, and at the two interfaces between their pairs of surface in contact, at each branch of the U; it is very difficult to climb one in the other two elements intended to have a zero gap between two pairs of surfaces, especially in the presence of a magnet that attracts them against each other. To solve these problems, the inner end surface of a U-limb of the first core member of WO 94/06134 has a tapered shape, as does the complementary end surface of the second core member. bar, to define a mounting ramp for the inclined surfaces in contact with each other. Deformable protuberances, protruding from the other end surface of the second bar-shaped core element (or that of the permanent magnet), are intended to provide, by their crushing, a margin of error for the clamping between the two magnetic core elements. However, between the protuberances, the air gap is not completely reduced to zero, which leaves air gaps between the facing surfaces. These air spaces can be the seat of a resin infiltration during the resin of the housing, which reduces the efficiency of the magnetic core and therefore the ignition coil. It will be noted, moreover, that the establishment and the holding of the second core element between the two branches of the U of the first core element imposes, in addition to the deformable protuberances, the presence of a stop shoulder on a branch of the U The manufacture of the protuberances and the abutment shoulder is tedious and expensive.
Il est donc souhaitable de proposer une bobine permettant une mise en place et un maintien plus simples et plus sûrs des deux éléments de noyau magnétique l'un par rapport à l'autre, d'une part, et comportant deux éléments de noyau magnétique simples et donc moins onéreux à fabriquer, d'autre part. It is therefore desirable to provide a coil allowing a simpler and safer introduction and maintenance of the two magnetic core elements with respect to each other, on the one hand, and having two simple magnetic core elements and therefore less expensive to manufacture, on the other hand.
Il serait par ailleurs souhaitable de pouvoir monter le module de bobine - comportant le second élément de noyau en forme de barre et les enroulements primaire et secondaire - directement dans le boîtier de protection dans lequel aurait préalablement été monté le premier élément de noyau. Un tel montage de la bobine d'allumage n'est actuellement pas possible industriellement. En effet, du fait de la présence d'un aimant permanent dans le dispositif, les deux éléments de noyau magnétique sont attirés l'un contre l'autre, ce qui interdit leur approche et leur mise en place progressive et précise. It would further be desirable to be able to mount the coil module - having the second bar-shaped core element and the primary and secondary windings - directly into the protective housing in which the first core element would have been previously mounted. Such an assembly of the ignition coil is currently not possible industrially. Indeed, because of the presence of a permanent magnet in the device, the two elements magnetic core are attracted to each other, which precludes their approach and their gradual and precise implementation.
La présente invention vise à pallier ces inconvénients. The present invention aims to overcome these disadvantages.
A cet effet, l'invention concerne une bobine d'allumage comportant un boîtier de protection, un noyau magnétique fermé avec un aimant permanent, le noyau magnétique comportant un premier élément de noyau sensiblement en forme de U logé dans le boîtier de protection et un second élément de noyau sensiblement en forme de barre, le premier élément de noyau comportant au moins deux surfaces de contact avec le second élément de noyau, la bobine comportant au moins un enroulement primaire et un enroulement secondaire autour du second élément de noyau et formant avec lui un module de bobine, caractérisé par le fait que les surfaces de contact du premier élément de noyau sont toutes deux biseautées pour permettre le montage du module de bobine dans le boîtier. For this purpose, the invention relates to an ignition coil comprising a protective housing, a magnetic core closed with a permanent magnet, the magnetic core comprising a first substantially U-shaped core element housed in the protective housing and a second substantially bar-shaped core member, the first core member having at least two contact surfaces with the second core member, the coil having at least one primary winding and a secondary winding around the second core member and forming with it a coil module, characterized in that the contact surfaces of the first core member are both beveled to allow mounting of the coil module in the housing.
Grâce à l'invention, la mise en place du module de bobine dans le boîtier de protection est plus simple, ce qui facilite l'industrialisation du procédé de fabrication de la bobine d'allumage. En particulier, cela peut autoriser une étape de montage "à l'aveugle" du module de bobine dans le boîtier de protection, le premier élément de noyau en forme de U ayant préalablement été monté dans le boîtier. Les surfaces de contact biseautées peuvent servir de rampe de guidage lors de la mise en place du module de bobine dans le boîtier de protection, le second élément de noyau pouvant par exemple être déplacé et guidé le long de l'une de ces surfaces, la présence d'un biseau de l'autre côté assurant un dégagement suffisant pour un déplacement progressif tout en autorisant de rattraper d'éventuelles erreurs, sans qu'il soit nécessaire de prévoir d'autres moyens sécurisant la mise en place comme par exemple les butées ou protubérances de l'art antérieur; les éléments de noyau sont ainsi plus simples et moins onéreux. La présence de deux biseaux autorise par ailleurs l'appui, volontairement ou par erreur, sur une surface au lieu de l'autre. Thanks to the invention, the introduction of the coil module in the protective housing is simpler, which facilitates the industrialization of the process of manufacturing the ignition coil. In particular, this may allow a "blind" mounting step of the coil module in the protective housing, the first U-shaped core element having previously been mounted in the housing. The beveled contact surfaces can serve as a guide ramp when placing the coil module in the protective housing, the second core element can for example be moved and guided along one of these surfaces, the presence of a bevel on the other side ensuring sufficient clearance for a gradual movement while allowing to catch any errors, without it being necessary to provide other means securing the establishment such as for example the stops or protuberances of the prior art; the core elements are thus simpler and less expensive. The presence of two bevels also allows the support, intentionally or by mistake, on one surface instead of the other.
Selon une forme de réalisation avantageuse, le second élément de noyau comportant au moins deux surfaces de contact avec les surfaces de contact du premier élément de noyau, ces surfaces de contact présentent une forme biseautée complémentaire de la forme biseautée des surfaces de contact du premier élément de noyau. Par forme complémentaire, on entend une forme permettant un contact plan des surfaces considérées. L'entrefer entre les surfaces en vis-à-vis est ainsi réduit à son minimum et peut avantageusement être nul. According to an advantageous embodiment, the second core element having at least two contact surfaces with the contact surfaces of the first core element, these contact surfaces have a beveled shape complementary to the beveled shape of the contact surfaces of the first element. of core. Complementary form means a form allowing contact plan of the surfaces considered. The gap between the surfaces facing each other is thus reduced to a minimum and may advantageously be zero.
Selon une forme de réalisation avantageuse, au moins une surface de contact du second élément de noyau est formée par une surface de l'aimant permanent. According to an advantageous embodiment, at least one contact surface of the second core element is formed by a surface of the permanent magnet.
Selon une forme de réalisation avantageuse, le second élément de noyau se présente sous la forme d'une barre en forme de T ayant une branche principale s'étendant suivant un axe et une branche transversale inclinée par rapport à l'axe de la branche principale, la branche transversale supportant l'aimant permanent. According to an advantageous embodiment, the second core element is in the form of a T-shaped bar having a main branch extending along an axis and a transverse branch inclined with respect to the axis of the main branch. , the transverse branch supporting the permanent magnet.
Selon une forme de réalisation avantageuse, le premier élément de noyau comportant deux branches correspondant aux branches du U dont il a la forme, ses surfaces de contact sont des surfaces d'extrémité desdites branches. According to an advantageous embodiment, the first core element comprising two branches corresponding to the branches of the U of which it has the shape, its contact surfaces are end surfaces of said branches.
Selon une forme de réalisation avantageuse dans ce cas, chaque branche présentant un côté intérieur et un côté extérieur, les surfaces de contact du premier élément de noyau sont situées du côté intérieur des branches. Selon une forme de réalisation avantageuse, chaque branche s'étendant globalement suivant un axe, chaque surface de contact est inclinée d'un angle aigu par rapport à l'axe de la branche considérée. According to an advantageous embodiment in this case, each branch having an inner side and an outer side, the contact surfaces of the first core member are located on the inner side of the branches. According to an advantageous embodiment, each branch extending generally along an axis, each contact surface is inclined at an acute angle with respect to the axis of the branch considered.
Selon une forme de réalisation avantageuse, le boîtier de protection est surmoulé autour du premier élément de noyau. Un tel boîtier permet de respecter aisément des cotes de montage précises. According to an advantageous embodiment, the protective casing is overmoulded around the first core element. Such a housing makes it easy to respect precise mounting dimensions.
Selon une forme de réalisation avantageuse, les surfaces de contact du premier élément de noyau présentent des longueurs différentes. Cela permet de privilégier le contact avec l'une de ces surfaces, en particulier si l'aimant permanent forme une extrémité du deuxième élément de noyau, la surface de contact avec l'aimant permanent étant alors de préférence la plus grande pour privilégier le contact avec l'aimant. Selon une forme de réalisation avantageuse, un insert est relié à l'enroulement secondaire et est agencé pour réaliser un contact avec un conducteur électrique logé dans le boîtier de protection et relié à un insert haute tension. L'invention, qui garantit une bonne mise en place du module de bobine sur le premier élément de noyau, garantit donc la bonne mise en place de l'enroulement secondaire dans le boîtier de protection et donc le bon contact de l'insert avec le conducteur électrique. According to an advantageous embodiment, the contact surfaces of the first core element have different lengths. This makes it possible to favor contact with one of these surfaces, in particular if the permanent magnet forms one end of the second core element, the contact surface with the permanent magnet then preferably being the largest to favor the contact. with the magnet. According to an advantageous embodiment, an insert is connected to the secondary winding and is arranged to make contact with an electrical conductor housed in the protective housing and connected to a high voltage insert. The invention, which guarantees a good implementation of the coil module on the first core element, thus guarantees the proper placement of the secondary winding in the protective housing and therefore the good contact of the insert with the electrical conductor.
L'invention concerne encore un procédé de fabrication d'une bobine d'allumage comportant un boîtier de protection, un noyau magnétique fermé avec un aimant permanent, le noyau magnétique comportant un premier élément de noyau sensiblement en forme de U logé dans le boîtier de protection et un second élément de noyau sensiblement en forme de barre, le premier élément de noyau comportant au moins deux surfaces biseautées de contact avec le second élément de noyau, la bobine comportant au moins un enroulement primaire et un enroulement secondaire autour du second élément de noyau, le procédé comportant les étapes suivantes: The invention further relates to a method of manufacturing an ignition coil having a protective housing, a magnetic core closed with a permanent magnet, the magnetic core having a first substantially U-shaped core member housed in the housing of protection and a second substantially rod-shaped core member, the first core member having at least two beveled contact surfaces with the second core member, the coil having at least one primary winding and a secondary winding around the second core member. kernel, the method comprising the following steps:
- on forme un module de bobine en disposant l'enroulement primaire et l'enroulement secondaire autour du second élément de noyau; - forming a coil module by arranging the primary winding and the secondary winding around the second core element;
- on loge le premier élément de noyau dans le boîtier de protection;  the first core element is housed in the protective casing;
- on monte le module de bobine dans le boîtier de protection en mettant en contact le second élément de noyau avec les surfaces de contact du premier élément de noyau.  the coil module is mounted in the protective housing by contacting the second core element with the contact surfaces of the first core element.
Selon une forme de réalisation avantageuse, on loge le premier élément de noyau dans le boîtier de protection par surmoulage du boîtier de protection autour du premier élément de noyau. Une telle étape est simple à mettre en œuvre et permet de parfaitement encapsuler le premier élément de noyau dans le boîtier. According to an advantageous embodiment, the first core element is housed in the over-molded protective casing of the protective casing around the first core element. Such a step is simple to implement and perfectly encapsulates the first core element in the housing.
Selon une forme de réalisation avantageuse, le second élément de noyau comportant au moins deux surfaces de contact avec les surfaces de contact du premier élément de noyau et présentant une forme biseautée complémentaire de la forme biseautée des surfaces de contact du premier élément de noyau, on monte le module de bobine dans le boîtier de protection en déplaçant une surface de contact du second élément de noyau le long d'une surface de contact du premier élément de noyau. Selon une forme de réalisation avantageuse, au moins une surface d'extrémité du second élément de noyau étant formée par une surface de l'aimant permanent, la surface de contact du second élément de noyau déplacée le long d'une surface de contact du premier élément de noyau est celle de l'aimant permanent. According to an advantageous embodiment, the second core element having at least two contact surfaces with the contact surfaces of the first core element and having a beveled shape complementary to the beveled shape of the contact surfaces of the first core element, mounting the coil module in the protective case by moving a contact surface of the second core member along a contact surface of the first core member. According to an advantageous embodiment, at least one end surface of the second core element being formed by a surface of the permanent magnet, the the contact surface of the second core member displaced along a contact surface of the first core member is that of the permanent magnet.
Selon une forme de réalisation avantageuse, en fin de déplacement de la surface de contact du second élément de noyau, de préférence simultanément au contact entre l'ensemble des surfaces de contact des premier et second éléments de noyau, on réalise un contact entre un insert relié à l'enroulement secondaire et un conducteur électrique logé dans le boîtier de protection et relié à un insert haute tension. According to an advantageous embodiment, at the end of displacement of the contact surface of the second core element, preferably simultaneously with the contact between all the contact surfaces of the first and second core elements, contact is made between an insert connected to the secondary winding and an electrical conductor housed in the protective housing and connected to a high voltage insert.
L'invention sera mieux comprise à l'aide de la description suivante de la forme de réalisation préférée de la bobine et du procédé de l'invention, en référence aux planches de dessin annexées, sur lesquelles: The invention will be better understood with the aid of the following description of the preferred embodiment of the coil and the method of the invention, with reference to the appended drawing plates, in which:
- la figure 1 représente une vue filaire en perspective d'un boîtier de protection surmoulé autour d'un premier élément de noyau en forme de U conforme à l'invention ;  - Figure 1 shows a wired perspective view of a protective housing overmolded around a first U-shaped core element according to the invention;
- la figure 2 représente une vue éclatée des éléments d'un module de bobine conforme à l'invention ;  FIG. 2 represents an exploded view of the elements of a coil module according to the invention;
- la figure 3 représente le module de bobine de la figure 2 monté dans le boîtier de protection de la figure 1 , en vue filaire de profil;  - Figure 3 shows the coil module of Figure 2 mounted in the protective housing of Figure 1, in wire profile view;
- la figure 4 représente une vue en perspective du premier élément de noyau en forme de U de la figure 1 ;  FIG. 4 shows a perspective view of the first U-shaped core element of FIG. 1;
- la figure 5 représente une vue en perspective du deuxième élément de noyau en forme de barre du module de bobine de la figure 2 ; et  FIG. 5 is a perspective view of the second bar-shaped core element of the coil module of FIG. 2; and
- la figure 6 représente une vue en perspective du second élément de noyau de la figure 5 monté entre les deux branches du U du premier élément de noyau de la figure 4. FIG. 6 represents a perspective view of the second core element of FIG. 5 mounted between the two branches of the U of the first core element of FIG. 4.
Une bobine d'allumage 1 selon l'invention comporte un noyau (ou circuit) magnétique fermé avec un aimant permanent 21, le noyau magnétique comportant un premier élément de noyau 4 sensiblement en forme de U, logé dans un boîtier de protection 2, et un second élément de noyau 20 sensiblement en forme de barre, autour duquel sont bobinés un enroulement primaire 23 et un enroulement secondaire 36 dans lesquels circulent respectivement un courant électrique d'entrée de la bobine et un courant électrique de sortie de la bobine, de manière classique. Le second élément de noyau 20 et les enroulements primaire 23 et secondaire 36 forment un module de bobine 3. La bobine 1, représentée sur la figure 3, est formée par l'assemblage du module de bobine 3 (représenté sur la figure 2) dans le boîtier 2 dans lequel est logé le premier élément de noyau 4 (représenté sur la figure 1). En référence à la figure 1, le premier élément de noyau 4 en forme de U est formé, en l'espèce, d'un empilage de tôles maintenues entre elles et est nommé, dans la suite de la description, premier élément de noyau 4. Cet élément de noyau 4 comporte une base 42 et deux branches 6a, 6b correspondant à la base et aux branches du U dont il a la forme. Le premier élément de noyau 4 comporte deux surfaces 5a, 5b de contact avec le second élément de noyau 20; ces surfaces de contact 5a, 5b sont planes et biseautées pour permettre le montage du module de bobine 3 (comportant notamment le second élément de noyau 20) dans le boîtier de protection 2 (dans lequel est monté le premier élément de noyau 4). Le second élément de noyau 20 comporte également deux surfaces 21a, 31b (en l'espèce d'extrémité) de contact avec les surfaces de contact 5a, 5b du premier élément de noyau 4. En l'espèce, une surface 21a est formée par une surface de l'aimant permanent 21, ce dernier étant fixé sur une surface 31a du second élément de noyau 20, comme décrit plus en détails plus bas. Les surfaces de contact 21a, 31b du second élément de noyau 20 sont planes et biseautées, chacune de forme complémentaire à la forme de la surface de contact 5 a, 5b du premier élément de noyau 4 avec laquelle est elle destinée à venir en contact; cette complémentarité de formes permet un contact plan entre les surfaces (5a, 21a), (5b, 31b) de chaque paire de surfaces de contact (les formes étant bien entendu agencées pour permettre un contact au niveau de chacune des branches du U). An ignition coil 1 according to the invention comprises a magnetic core (or circuit) closed with a permanent magnet 21, the magnetic core comprising a first substantially U-shaped core element 4, housed in a protective casing 2, and a second substantially rod-shaped core element 20 around which are wound a primary winding 23 and a secondary winding 36 in which respectively an electrical input current of the coil and an electrical output current of the coil are circulated, respectively classic. The second core element 20 and the primary 23 and secondary 36 windings form a coil module 3. The coil 1, shown in FIG. Figure 3 is formed by the assembly of the coil module 3 (shown in Figure 2) in the housing 2 in which is housed the first core element 4 (shown in Figure 1). With reference to FIG. 1, the first U-shaped core element 4 is formed, in this case, of a stack of sheets held together and is named, in the following description, first core element 4 This core element 4 comprises a base 42 and two branches 6a, 6b corresponding to the base and the branches of the U of which it has the shape. The first core element 4 comprises two surfaces 5a, 5b of contact with the second core element 20; these contact surfaces 5a, 5b are planar and bevelled to allow mounting of the coil module 3 (including the second core element 20) in the protective housing 2 (in which is mounted the first core element 4). The second core element 20 also has two surfaces 21a, 31b (in this case end) contact with the contact surfaces 5a, 5b of the first core element 4. In this case, a surface 21a is formed by a surface of the permanent magnet 21, the latter being fixed on a surface 31a of the second core member 20, as described in more detail below. The contact surfaces 21a, 31b of the second core member 20 are planar and beveled, each of complementary shape to the shape of the contact surface 5a, 5b of the first core member 4 with which it is intended to come into contact; this complementarity of shapes allows plane contact between the surfaces (5a, 21a), (5b, 31b) of each pair of contact surfaces (the shapes being of course arranged to allow contact at each of the branches of the U).
Dans un souci de simplification de l'exposé, la suite de la description sera faite en référence à un repère cartésien comportant trois directions X, Y, Z orthogonales entre elles, ces directions X, Y, Z étant respectivement parallèles à la grande dimension de la base 42 du U dont le premier élément de noyau 4 a la forme, à la grande dimension des branches 6a, 6b du U et à la direction de l'épaisseur de la base 42 du U, comme on le voit bien, par exemple, sur la figure 1. Les éléments de la bobine d'allumage sont décrits en relation avec ces directions dans leur position montée dans le boîtier 2. De plus, lorsqu'il est fait référence à l'inclinaison d'une surface par rapport à une direction, on considère l'inclinaison de la direction de cette surface comprise dans le plan de coupe de la pièce formé par les directions X et Y. Par ailleurs, les notions d'intérieur, extérieur, supérieur ou inférieur sont définies comme les notions correspondantes sur la représentation du boîtier 2 de la figure 1. For the sake of simplification of the presentation, the following description will be made with reference to a Cartesian coordinate system comprising three directions X, Y, Z orthogonal to each other, these directions X, Y, Z being respectively parallel to the large dimension of the base 42 of the U whose first core element 4 has the shape, the large dimension of the branches 6a, 6b of the U and the direction of the thickness of the base 42 of the U, as can be seen, for example , in Figure 1. The elements of the ignition coil are described in relation to these directions in their position mounted in the housing 2. In addition, when reference is made to the inclination of a surface with respect to a direction, consider the inclination of the direction of this surface included in the plane of section of the part formed by the directions X and Y Moreover, the concepts of interior, exterior, upper or lower are defined as the corresponding notions on the representation of the housing 2 of FIG.
Le boîtier de protection 2 est de forme sensiblement parallélépipédique et comporte une surface intérieure conformée pour épouser la forme extérieure du premier élément de noyau 4, dont seules les surfaces intérieures sont apparentes dans le boîtier 2 lorsqu'il y est logé. Plus précisément, le boîtier de protection 2 est en l'espèce surmoulé autour du premier élément de noyau 4. En l'espèce, le boîtier de protection 2 présente une ouverture 7 du côté supérieur, par laquelle peut être monté le module de bobine 3 dans le boîter 2; il comporte par ailleurs une paroi inférieure 8 et des parois latérales pleines, de formes agencées pour épouser les surfaces extérieures du premier élément de noyau 4 et permettre le montage du module de bobine 3. La forme du boîtier 2 est accessible à l'homme du métier et il n'est pas nécessaire de détailler plus encore sa description. The protective housing 2 is substantially parallelepipedal in shape and has an inner surface shaped to match the outer shape of the first core member 4, of which only the inner surfaces are visible in the housing 2 when it is housed therein. More specifically, the protective casing 2 is in this case overmolded around the first core element 4. In this case, the protective casing 2 has an opening 7 on the upper side, through which the coil module 3 can be mounted. in the case 2; it also comprises a bottom wall 8 and solid side walls, shaped to fit the outer surfaces of the first core member 4 and allow the assembly of the coil module 3. The shape of the housing 2 is accessible to the man of the profession and it is not necessary to further detail its description.
Des moyens de fixation (non représentés) peuvent être ménagés sur le boîtier 2, pour coopérer avec des moyens correspondant du véhicule (non représentés) pour permettre la fixation du boîtier 2 au véhicule, de manière classique. Fastening means (not shown) may be provided on the housing 2, to cooperate with corresponding means of the vehicle (not shown) to allow the attachment of the housing 2 to the vehicle, in a conventional manner.
A une première extrémité du boîtier de protection 2 est ménagé un premier logement 13 de forme globalement cylindrique, d'axe parallèle à la direction Y des branches du U et débouchant dans un deuxième logement 14 de forme globalement cylindrique, d'axe parallèle à la direction X de la base 42 du U et formant un embout 14. At a first end of the protective housing 2 is provided a first housing 13 of generally cylindrical shape, of axis parallel to the Y direction of the branches of the U and opening into a second housing 14 of generally cylindrical shape, of axis parallel to the X direction of the base 42 of the U and forming a tip 14.
Un élément conducteur 15 tel qu'une résistance est disposé à l'intérieur du premier logement cylindrique 13 et est reliée électriquement à une pièce classiquement dénommée insert haute tension 16, logée dans le deuxième logement cylindrique 14 et destinée à être reliée à une bougie d'allumage, non représentée, pour lui transmettre la tension nécessaire à son allumage. En référence à la figure 2, le module de bobine 3 comporte le second élément de noyau 20, qui supporte l'aimant permanent 21, l'enroulement primaire 23 et l'enroulement secondaire 36, de manière connue. Les enroulements primaire 23 et secondaire 36 sont chacun bobinés autour d'une carcasse ou bobinot plastique 22, 35, respectivement, de manière connue qu'il n'est pas nécessaire de décrire en détails. La carcasse 22 de l'enroulement primaire 23 est emmanchée autour du second élément de noyau 20 et la carcasse 35 de l'enroulement secondaire 36 est emmanchée autour de l'enroulement primaire 23, de manière connue. A conductive element 15 such as a resistor is disposed inside the first cylindrical housing 13 and is electrically connected to a part conventionally called a high-voltage insert 16, housed in the second cylindrical housing 14 and intended to be connected to a spark plug. ignition, not shown, to transmit the voltage necessary for its ignition. With reference to FIG. 2, the coil module 3 comprises the second core element 20, which supports the permanent magnet 21, the primary winding 23 and the secondary winding 36, in a known manner. The primary 23 and secondary windings 36 are each wound around a plastic carcass or bobbin 22, 35, respectively, in a known manner that it is not necessary to describe in detail. The casing 22 of the primary winding 23 is fitted around the second core element 20 and the casing 35 of the secondary winding 36 is fitted around the primary winding 23, in a known manner.
Le second élément de noyau 20 est par exemple formé d'un empilage de tôles maintenues entre elles, de manière similaire au premier élément de noyau 4. The second core element 20 is for example formed of a stack of sheets held together, similarly to the first core element 4.
En l'espèce, plus précisément, le second élément de noyau 20 se présente sous la forme d'une barre en forme de T comprenant une branche principale 24 s'étendant globalement suivant l'axe X et une branche transversale inclinée 25, l'aimant permanent 21 étant en l'espèce fixé à une surface d'extrémité plane 31a de la branche transversale 25. Selon une autre forme de réalisation non représentée, le second élément de noyau 20 peut se présenter sous la forme, non pas d'un T mais d'un I, agencé pour être monté entre les deux branches 6a, 6b du premier élément de noyau 4. In this case, more specifically, the second core element 20 is in the form of a T-shaped bar comprising a main branch 24 extending generally along the X axis and an inclined transverse branch 25, the permanent magnet 21 being in this case fixed to a flat end surface 31a of the transverse branch 25. According to another embodiment not shown, the second core member 20 may be in the form, not of a T but of an I, arranged to be mounted between the two branches 6a, 6b of the first core element 4.
Le bobinot 35 de l'enroulement secondaire 36 se présente sous la forme d'un corps creux pour le logement de l'enroulement primaire 23 et de son bobinot 22. A son extrémité opposée à celle correspondant au côté de l'aimant permanent 21, le bobinot 35 comporte, en partie supérieure, une languette 38 s'étendant en saillie globalement parallèlement à l'axe X. Deux encoches 40 sont ménagées sous la languette 38, de part et d'autre du bobinot 35; elles sont agencées pour recevoir des pattes d'un élément 41 de contact électrique en forme de T, classiquement dénommé insert 41 ou insert secondaire 41 et dont la fonction est d'établir un contact électrique entre l'enroulement secondaire 36 et l'élément conducteur 15 relié à l'insert haute tension 16, de manière connue. La languette 38 assure la protection et le positionnement de l'insert secondaire 41. En position de montage de la bobine d'allumage 1 (comme illustrée sur la figure 3), lorsque les surfaces de contact 21a, 31b du second élément de noyau 20 sont en contact avec les surfaces de contact 5a, 5b du premier élément de noyau 4 autour duquel est surmoulé le boîtier de protection 2, les positions relatives des éléments de noyau 4, 20 garantissent la position relative de l'insert secondaire 41 (solidaire du module de bobine 3 et donc du premier élément de noyau 20) par rapport à l'élément conducteur 15 (solidaire du boîtier de protection 2). The bobbin 35 of the secondary winding 36 is in the form of a hollow body for housing the primary winding 23 and its winding 22. At its end opposite to that corresponding to the side of the permanent magnet 21, the bobbin 35 comprises, in the upper part, a tongue 38 projecting generally parallel to the axis X. Two notches 40 are formed under the tongue 38, on either side of the bobbin 35; they are arranged to receive tabs of a T-shaped electrical contact element 41, conventionally called insert 41 or secondary insert 41 and whose function is to establish an electrical contact between the secondary winding 36 and the conductive element 15 connected to the high voltage insert 16, in known manner. The tongue 38 provides protection and positioning of the secondary insert 41. In the mounting position of the ignition coil 1 (as illustrated in FIG. 3), when the contact surfaces 21a, 31b of the second core element 20 are in contact with the contact surfaces 5a, 5b of the first core element 4 around which the protective housing 2 is molded, the relative positions of the core elements 4, 20 guarantee the relative position. of the secondary insert 41 (integral with the coil module 3 and therefore the first core element 20) with respect to the conductive element 15 (integral with the protective housing 2).
Dans la forme de réalisation présentée, les deux branches 6a, 6b du premier élément de noyau 4 sont dissymétriques, la surface biseautée 5a destinée à être en contact avec la surface 21a de l'aimant 21 étant de plus grande dimension, dans le plan de coupe formé par les directions X et Y, que l'autre surface biseautée 5b. Cette conformation est choisie pour conférer particulièrement à la surface 5a de contact avec l'aimant 21 une fonction de rampe de guidage du deuxième élément de noyau 20 par l'intermédiaire de l'aimant 21 ; ainsi, lors du montage du module de bobine 3 dans le boîtier de protection 2, on déplace la surface 21a de l'aimant 21 le long de la surface de contact correspondante 5a du premier élément de noyau 4 jusqu'à ce que les surfaces opposées 5b, 31b des premier et deuxième éléments de noyau 4, 20 viennent en contact l'une avec l'autre. En l'espèce, la dimension de la branche 6a avec la plus grande surface biseautée 5a est plus grande, dans la direction de la direction Y, que la dimension de l'autre branche 6b, ce qui assure que le premier contact établi avec le second élément de noyau 20 se fait bien préférentiellement sur cette plus grande branche 6a. In the embodiment shown, the two branches 6a, 6b of the first core element 4 are asymmetrical, the bevelled surface 5a intended to be in contact with the surface 21a of the magnet 21 being of larger dimension, in the plane of cut formed by the X and Y directions, than the other bevelled surface 5b. This conformation is chosen to confer particularly on the surface 5a of contact with the magnet 21 a guide ramp function of the second core element 20 via the magnet 21; thus, when mounting the coil module 3 in the protective housing 2, the surface 21a of the magnet 21 is moved along the corresponding contact surface 5a of the first core element 4 until the opposite surfaces 5b, 31b of the first and second core members 4, 20 come into contact with each other. In the present case, the dimension of the branch 6a with the largest bevelled surface 5a is larger, in the direction of the Y direction, than the dimension of the other branch 6b, which ensures that the first contact established with the second core element 20 is preferably on this larger branch 6a.
Les surfaces de contact 5a, 5b du premier élément de noyau 4 sont ménagées de son côté intérieur. Elles s'étendent chacune à partir d'une extrémité 43a, 43b d'une branche 6a, 6b, respectivement, l'épaisseur correspondante de la branche 6a, 6b dans le plan X et Y allant en augmentant depuis cette extrémité vers la base 42 de l'élément de noyau 4, comme on le voit sur la figure 4. Les surfaces de contact 5a, 5b sont inclinées d'un angle aigu a, a', respectivement, par rapport à la direction Y, les angles a, a' étant en l'espèce de valeur identique, ces angles étant opposés trigonométriquement. The contact surfaces 5a, 5b of the first core element 4 are provided on its inner side. They each extend from one end 43a, 43b of a branch 6a, 6b, respectively, the corresponding thickness of the branch 6a, 6b in the X and Y plane increasing from this end to the base 42 of the core element 4, as seen in Figure 4. The contact surfaces 5a, 5b are inclined at an acute angle a, a ', respectively, with respect to the direction Y, the angles a, a 'being in this case identical value, these angles being opposite trigonometrically.
Bien entendu, selon une variante de réalisation non représentée, les deux branches 6a, 6b du premier élément de noyau 4 peuvent être symétriques; d'autres agencements de la forme des branches 6a,6b sont d'ailleurs envisageables, l'essentiel étant que chaque branche 6a, 6b du premier élément de noyau 4 présentent une surface biseautée 5a, 6b pour autoriser le déplacement du second élément de noyau 20 lors de sa mise en place du module de bobine 3 dans le boîtier de protection 2. Comme représenté sur la figure 5, les surfaces d'extrémité 21a, 31b du second élément de noyau 20 sont inclinées d'un angle aigu β, β', respectivement, par rapport à une direction P perpendiculaire à la direction de la branche principale 24 du T dont le second élément de noyau 20 a la forme. Ces angles β, β' sont en l'espèce respectivement égaux aux angles a, a' que font les surfaces de contact 5a, 5b du premier élément de noyau 4 avec la direction Y. Le second élément de noyau 20 est agencé pour être monté dans le boîtier 2 de telle sorte que la direction principale de sa barre principale 24 s'étendent parallèlement à la direction X de la base du U dont le premier élément de noyau 4 a la forme, c'est- à-dire que la direction P perpendiculaire à sa branche principale 24 s'étend alors parallèlement à la direction Y des branches du U. Ainsi, les surfaces de contact (5a, 5b), (21a, 31b) sont complémentaires et agencées pour venir en contact plan, assurant un entrefer nul entre le premier élément de noyau 4 et le second élément de noyau 20. Cette position relative des éléments de noyau 4, 20 est représentée sur la figure 6 (seuls les éléments de noyau 4, 20 étant représentés sur cette figure, sans les enroulements primaire 23 et secondaire 36 ni le boîtier de protection 2). Of course, according to an alternative embodiment not shown, the two branches 6a, 6b of the first core element 4 may be symmetrical; other arrangements of the shape of the branches 6a, 6b are also conceivable, the essential being that each branch 6a, 6b of the first element of core 4 have a bevelled surface 5a, 6b to allow the displacement of the second core member 20 when it is put in place of the coil module 3 in the protective housing 2. As shown in FIG. 5, the end surfaces 21a , 31b of the second core member 20 are inclined at an acute angle β, β ', respectively, relative to a direction P perpendicular to the direction of the main branch 24 of the T whose second core member 20 is shaped. These angles β, β 'are in this case respectively equal to the angles a, a' that are the contact surfaces 5a, 5b of the first core member 4 with the direction Y. The second core member 20 is arranged to be mounted in the housing 2 so that the main direction of its main bar 24 extend parallel to the X direction of the base of the U whose first core element 4 has the shape, that is to say that the direction P perpendicular to its main branch 24 then extends parallel to the Y direction of the branches of the U. Thus, the contact surfaces (5a, 5b), (21a, 31b) are complementary and arranged to come into plane contact, ensuring a zero gap between the first core member 4 and the second core member 20. This relative position of the core members 4, 20 is shown in Fig. 6 (only the core members 4, 20 being shown in this figure without the primary and secondary windings 23 36 or the protection box 2).
Le procédé de montage du module de bobine 3 dans le boîtier de protection 2 va maintenant être décrit plus en détails. The method of mounting the coil module 3 in the protective housing 2 will now be described in more detail.
Comme expliqué plus haut, le boîtier de protection 2 est surmoulé autour du premier élément de noyau 4. Par ailleurs, le module de bobine 3 a préalablement été monté, c'est-à-dire que le second élément de noyau 20 a été inséré dans le bobinot 22 de l'enroulement primaire 23 qui a lui-même été inséré dans le bobinot 35 de l'enroulement secondaire 36. As explained above, the protective casing 2 is overmoulded around the first core element 4. Furthermore, the coil module 3 has been previously mounted, that is to say the second core element 20 has been inserted in the winding 22 of the primary winding 23 which has itself been inserted into the winding 35 of the secondary winding 36.
Grâce à forme biseauté des surfaces de contact 5a, 5b du premier élément de noyau 4, il est possible d'introduire le module de bobine 3 directement dans le boîtier de protection 2 dans lequel est logé le premier élément de noyau 4; ce montage se fait, en quelque sorte, "à l'aveugle", ce qui n'était pas envisageable industriellement dans l'art antérieur. En particulier, en cas de mauvais positionnement d'un côté ou de l'autre, la présence de biseaux de part et d'autre permet de compenser ce mauvais positionnement. Thanks to beveled form of the contact surfaces 5a, 5b of the first core element 4, it is possible to introduce the coil module 3 directly into the protective housing 2 in which is housed the first core element 4; this assembly is, so to speak, "blind", which was not feasible industrially in the prior art. In particular, in case of bad positioning on one side or the other, the presence of bevels on both sides compensates for this poor positioning.
Au cours de cette introduction, le second élément de noyau 20 est mis en contact puis déplacé, par la surface 21a de l'aimant permanent 21, le long de la surface de contact biseautée 5a du premier élément de noyau 20; ce déplacement est opéré jusqu'à ce que la surface de contact 31b opposée du second élément de noyau 20 entre en contact avec l'autre surface de contact 5b du premier élément de noyau 4. Généralement, cette mise en contact des surfaces de contact opposées 5b, 31b s'accompagne d'un claquement sonore qui atteste du bon positionnement du second élément de noyau 20 par rapport au premier élément de noyau 4, c'est- à-dire du bon positionnement du module de bobine 3 par rapport au boîtier de protection 2. Le noyau magnétique de la bobine d'allumage 1, formé par le premier et le second éléments de noyau 4, 20, est ainsi fermé. During this introduction, the second core member 20 is brought into contact and then displaced by the surface 21a of the permanent magnet 21 along the beveled contact surface 5a of the first core member 20; this displacement is effected until the opposite contact surface 31b of the second core member 20 comes into contact with the other contact surface 5b of the first core element 4. Generally, this contacting of the opposite contact surfaces 5b, 31b is accompanied by a sound snap which attests the good positioning of the second core element 20 with respect to the first core element 4, that is to say the good positioning of the coil module 3 with respect to the housing 2. The magnetic core of the ignition coil 1, formed by the first and the second core elements 4, 20 is thus closed.
De plus, et de manière particulièrement avantageuse, en position montée finale, simultanément au contact entre les deux paires de surfaces de contact (5a, 31a), (5b, 31b), un contact est réalisé entre l'insert secondaire 41 et l'élément conducteur électrique 15 relié à l'insert haute-tension 16. On est ainsi assuré de la continuité de conduction électrique depuis l'enroulement secondaire 36 jusqu'à la bougie d'allumage, garantissant que la bobine d'allumage 1 pourra convenablement remplir sa fonction. In addition, and particularly advantageously, in the final mounted position, simultaneously with the contact between the two pairs of contact surfaces (5a, 31a), (5b, 31b), a contact is made between the secondary insert 41 and the electrical conductive element 15 connected to the high-voltage insert 16. It is thus ensured continuity of electrical conduction from the secondary winding 36 to the spark plug, ensuring that the ignition coil 1 can properly fill his function.
Selon une autre forme de réalisation non représentée, l'aimant permanent 21 est fixé à un autre endroit du noyau magnétique. Où que l'aimant 21 soit fixé, le déplacement du second élément de noyau 20 par rapport au premier élément de noyau 4 peut se faire ou ne pas se faire le long d'une surface de l'aimant 21 ; il se fait de préférence le long d'une surface de l'aimant 21 dans la mesure où l'aimant 21 a tendance à être attiré par l'élément de noyau 20, 4 sur lequel il n'est pas fixé. According to another embodiment not shown, the permanent magnet 21 is fixed at another location of the magnetic core. Wherever the magnet 21 is fixed, the displacement of the second core member 20 with respect to the first core member 4 may or may not be along a surface of the magnet 21; it is preferably along a surface of the magnet 21 insofar as the magnet 21 tends to be attracted by the core element 20, 4 on which it is not fixed.

Claims

Revendications  claims
1- Bobine d'allumage comportant un boîtier de protection (2), un noyau magnétique fermé avec un aimant permanent (21), le noyau magnétique comportant un premier élément de noyau (4) sensiblement en forme de U logé dans le boîtier de protection (2) et un second élément de noyau (20) sensiblement en forme de barre, le premier élément de noyau (4) comportant au moins deux surfaces (5a, 5b) de contact avec le second élément de noyau (20), la bobine comportant au moins un enroulement primaire (23) et un enroulement secondaire (36) autour du second élément de noyau (20) et formant avec lui un module de bobine (3), caractérisé par le fait que les surfaces de contact (5a, 5b) du premier élément de noyau (4) sont toutes deux biseautées pour permettre le montage du module de bobine (3) dans le boîtier (2). An ignition coil comprising a protective housing (2), a magnetic core closed with a permanent magnet (21), the magnetic core having a first substantially U-shaped core element (4) housed in the protective housing. (2) and a second substantially rod-shaped core member (20), the first core member (4) having at least two contact surfaces (5a, 5b) with the second core member (20), the coil having at least one primary winding (23) and a secondary winding (36) around the second core element (20) and forming with it a coil module (3), characterized in that the contact surfaces (5a, 5b ) of the first core element (4) are both beveled to allow mounting of the coil module (3) in the housing (2).
2. Bobine d'allumage selon la revendication 1 dans laquelle, le second élément de noyau (20) comportant au moins deux surfaces (21a, 31b) de contact avec les surfaces de contact (5a, 5b) du premier élément de noyau (4), ces surfaces de contact (21a, 31b) présentent une forme biseautée complémentaire de la forme biseautée des surfaces de contact du premier élément de noyau (4). Ignition coil according to Claim 1, in which the second core element (20) has at least two surfaces (21a, 31b) in contact with the contact surfaces (5a, 5b) of the first core element (4). ), these contact surfaces (21a, 31b) have a beveled shape complementary to the beveled shape of the contact surfaces of the first core member (4).
3. Bobine d'allumage selon la revendication 2, dans laquelle au moins une surface de contact (31a) du second élément de noyau (20) est formée par une surface de l'aimant permanent (21). The ignition coil of claim 2, wherein at least one contact surface (31a) of the second core member (20) is formed by a surface of the permanent magnet (21).
4. Bobine d'allumage selon l'une des revendications 1 à 3 dans laquelle, le premier élément de noyau (20) comportant deux branches (6a, 6b) correspondant aux branches du U dont il a la forme, ses surfaces de contact (5a, 5b) sont des surfaces d'extrémité desdites branches (6a, 6b). 4. Ignition coil according to one of claims 1 to 3 wherein, the first core member (20) having two branches (6a, 6b) corresponding to the branches of the U in which it has the shape, its contact surfaces ( 5a, 5b) are end surfaces of said legs (6a, 6b).
5. Bobine d'allumage selon la revendication 4 dans laquelle, chaque branche présentant un côté intérieur et un côté extérieur, les surfaces de contact (5a, 5b) du premier élément de noyau (4) sont situées du côté intérieur des branches (6a, 6b). Ignition coil according to Claim 4, in which, each branch having an inner side and an outer side, the contact surfaces (5a, 5b) of the first core element (4) are situated on the inside of the branches (6a). , 6b).
6. Bobine d'allumage selon l'une des revendications 4 et 5 dans laquelle, chaque branche (6a, 6b) s'étendant globalement suivant un axe (Y), chaque surface de contact (5a, 5b) est inclinée d'un angle aigu par rapport à l'axe de la branche (6a, 6b) considérée. 6. ignition coil according to one of claims 4 and 5 wherein, each branch (6a, 6b) extending generally along an axis (Y), each contact surface (5a, 5b) is inclined at an acute angle with respect to the axis of the branch (6a, 6b) considered.
7. Bobine d'allumage selon l'une des revendications 1 à 6, dans laquelle le boîtier de protection (2) est surmoulé autour du premier élément de noyau (4). 7. Ignition coil according to one of claims 1 to 6, wherein the protective housing (2) is overmolded around the first core member (4).
8. Bobine d'allumage selon l'une des revendications 1 à 7, dans laquelle les surfaces de contact (5a, 5b) du premier élément de noyau (4) présentent des longueurs différentes. 8. ignition coil according to one of claims 1 to 7, wherein the contact surfaces (5a, 5b) of the first core member (4) have different lengths.
9. Bobine d'allumage selon l'une des revendications 1 à 8, dans laquelle un insert (41) est relié à l'enroulement secondaire (36) et est agencé pour réaliser un contact avec un conducteur électrique (15) logé dans le boîtier de protection (2) et relié à un insert haute tension (16). 9. Ignition coil according to one of claims 1 to 8, wherein an insert (41) is connected to the secondary winding (36) and is arranged to make contact with an electrical conductor (15) housed in the protective housing (2) and connected to a high voltage insert (16).
10. Procédé de fabrication d'une bobine d'allumage comportant un boîtier de protection (2), un noyau magnétique fermé avec un aimant permanent (21), le noyau magnétique comportant un premier élément de noyau (4) sensiblement en forme de U logé dans le boîtier de protection (2) et un second élément de noyau (20) sensiblement en forme de barre, le premier élément de noyau (4) comportant au moins deux surfaces biseautées (5a, 5b) de contact avec le second élément de noyau (20), la bobine comportant au moins un enroulement primaire (23) et un enroulement secondaire (36) autour du second élément de noyau (20), le procédé comportant les étapes suivantes: A method of manufacturing an ignition coil having a protective housing (2), a closed magnetic core with a permanent magnet (21), the magnetic core having a first substantially U-shaped core element (4). housed in the protective housing (2) and a second substantially bar-shaped core element (20), the first core element (4) having at least two bevelled surfaces (5a, 5b) in contact with the second element of core (20), the coil having at least one primary winding (23) and a secondary winding (36) around the second core member (20), the method comprising the steps of:
- on forme un module de bobine (3) en disposant l'enroulement primaire (23) et l'enroulement secondaire (36) autour du second élément de noyau (20) ; - forming a coil module (3) by arranging the primary winding (23) and the secondary winding (36) around the second core element (20);
- on loge le premier élément de noyau (4) dans le boîtier de protection (2) ;  the first core element (4) is housed in the protective housing (2);
- on monte le module de bobine (3) dans le boîtier de protection (2) en mettant en contact le second élément de noyau (20) avec les surfaces de contact (5a, 5b) du premier élément de noyau (4).  - The coil module (3) is mounted in the protective housing (2) by contacting the second core element (20) with the contact surfaces (5a, 5b) of the first core element (4).
1 1. Procédé de fabrication selon la revendication 10, dans lequel on loge le premier élément de noyau (4) dans le boîtier de protection (2) par surmoulage du boîtier de protection (2) autour du premier élément de noyau (4). A manufacturing method according to claim 10, wherein the first core element (4) is housed in the protective housing (2) by overmolding the protective housing (2) around the first core element (4).
12. Procédé de fabrication selon l'une des revendications 10 ou 1 1 dans lequel, le second élément de noyau (20) comportant au moins deux surfaces (31a, 31b) de contact avec les surfaces de contact (5a, 5b) du premier élément de noyau (4) et présentant une forme biseautée complémentaire de la forme biseautée des surfaces de contact (5a, 5b) du premier élément de noyau (4), on monte le module de bobine (3) dans le boîtier de protection (2) en déplaçant une surface de contact (31a, 31b) du second élément de noyau (20) le long d'une surface de contact (5 a, 5b) du premier élément de noyau (4). 12. Manufacturing method according to one of claims 10 or 1 1 wherein the second core member (20) having at least two surfaces (31a, 31b) contacting the contact surfaces (5a, 5b) of the first core member (4) and having a beveled shape complementary to the beveled shape of the contact surfaces (5a, 5b) of the first core member (4), the coil module (3) is mounted in the protective housing (2) by moving a contact surface (31a, 31b) of the second core element (20) along a contact surface (5a, 5b) the first core element (4).
13. Procédé de fabrication selon la revendication 12 dans lequel, au moins une surface d'extrémité (31a) du second élément de noyau (20) étant formée par une surface de l'aimant permanent (21), la surface de contact (31a) du second élément de noyau (20) déplacée le long d'une surface de contact (5 a, 5b) du premier élément de noyau (4) est celle de l'aimant permanent (21). The manufacturing method according to claim 12 wherein, at least one end surface (31a) of the second core member (20) being formed by a surface of the permanent magnet (21), the contact surface (31a ) of the second core member (20) moved along a contact surface (5a, 5b) of the first core member (4) is that of the permanent magnet (21).
14. Procédé de fabrication selon l'une des revendications 12 ou 13, dans lequel, en fin de déplacement de la surface de contact (31a, 31b) du second élément de noyau (20), de préférence simultanément au contact entre l'ensemble des surfaces de contact (5a, 5b, 31a, 31b) des premier et second éléments de noyau (4, 20), on réalise un contact entre un insert (41) relié à l'enroulement secondaire (36) et un conducteur électrique (15) logé dans le boîtier de protection (2) et relié à un insert haute tension (16). 14. The manufacturing method according to one of claims 12 or 13, wherein, at the end of displacement of the contact surface (31a, 31b) of the second core member (20), preferably simultaneously to the contact between all contact surfaces (5a, 5b, 31a, 31b) of the first and second core members (4, 20), contact is made between an insert (41) connected to the secondary winding (36) and an electrical conductor ( 15) housed in the protective housing (2) and connected to a high voltage insert (16).
EP10773121A 2009-10-15 2010-09-22 Ignition coil having closed magnetic core and permanent magnet, and method for manufacturing said coil Withdrawn EP2489051A1 (en)

Applications Claiming Priority (2)

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FR0957235A FR2951579B1 (en) 2009-10-15 2009-10-15 CLOSED MAGNETIC CORE IGNITION COIL AND PERMANENT MAGNET AND METHOD FOR MANUFACTURING THE COIL
PCT/FR2010/051988 WO2011045498A1 (en) 2009-10-15 2010-09-22 Ignition coil having closed magnetic core and permanent magnet, and method for manufacturing said coil

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BR112012008856A2 (en) 2020-09-15
FR2951579A1 (en) 2011-04-22

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