JP2001076946A - Ignition coil - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an ignition coil in which effective recovery and recycling of resources are realized by improving the recycle ratio. SOLUTION: In this ignition coil 10, a coil part 24 constituted of a primary coil 20 and a secondary coil 22 and an ignition control circuit unit 30 are included in a case main body 12a, and terminals 20a, 20b of the primary coil 20 and terminals 30a, 30b of the circuit unit 30 are jointed by fusing. The jointing part is partially molded by using a mold material 44. A terminal 22a of the secondary coil 22 and a terminal 36a of a high-tension cord lead-out port 36 are jointed similarly, and partially molded by using a mold material 46.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an ignition coil, and more particularly, to an ignition coil having an improved recycling rate.

[0002]

2. Description of the Related Art In recent years, efficient recovery and reuse of resources in various fields, that is, so-called recycling, has been desired. In the case of an ignition coil used in an internal combustion engine, vibration resistance, water resistance,
Since heat resistance and the like are required, the coil portion is usually housed in a coil case, filled with a thermosetting resin (for example, epoxy resin), and embedded and fixed in the resin.

[0003]

As described above, in the ignition coil according to the prior art, since the coil portion is embedded and fixed in the filling resin, it is difficult to disassemble the ignition coil at the time of disposal. The coil and other parts had to be discarded as they were, and the recycling rate was low.

[0004] Accordingly, an object of the present invention is to solve the above-mentioned problems, and an object of the present invention is to provide an ignition coil in which the recycling rate is improved, and thereby the resources can be efficiently recovered and reused. .

[0005]

In order to solve the above-mentioned problems, according to the present invention, an ignition coil having a coil section comprising a primary coil and a secondary coil and an ignition control circuit unit incorporated in a coil case. In the above structure, the terminal of the primary coil and the terminal of the ignition control circuit unit are joined by fusing, and the joint is partially molded.

[0006] This makes it easier to comply with the lead disposal regulation because no solder joint is used, and facilitates the separation and recovery of the coil part by partial molding, thereby improving the recycling rate. Furthermore, the water resistance and vibration resistance of the joint are not lost.

According to a second aspect of the present invention, the terminal of the secondary coil and the terminal of the high tension cord outlet are joined by fusing, and the joint is partially molded.

[0008] This makes it easier to comply with the lead disposal regulations as well, and the partial molding makes it easier to separate and collect the coil portion, thereby improving the recycling rate.

According to a third aspect of the present invention, an inner cap integrally formed with the high tension cord outlet on the terminal side of the primary coil and the secondary coil is disposed inside the coil case. It was configured to perform the fusing and the partial molding on the inner cap.

[0010] Thus, the inner cap can be used as a work table, and the connection work is facilitated, the process can be simplified, and the reliability can be improved.

[0011]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, an ignition coil according to an embodiment of the present invention will be described with reference to the accompanying drawings.

FIG. 1 is an explanatory side sectional view of the ignition coil,
2 is a cross-sectional view taken along the line II-II of FIG. 1, FIG. 3 is a top view of the ignition coil shown in FIG. 1 with a lid of a case body removed,
4 and FIG. 4 are top views of a state where the case lid is attached (a state shown in FIG. 1).

In the following, the ignition coil 10 according to the present invention includes an outer case (coil case) 12 and a core (iron core) 14 having a substantially C-shaped cross section attached thereto.

The outer case 12 comprises a substantially cylindrical case body 12a having one end opened and a case lid 12b for closing the open end thereof.
b is also made from PBT. In addition, 12c is a drain hole.

The core 14 comprises a core piece 14a having an inverted L-shaped cross section and a core piece 14b having an I-shaped cross section.
4b is configured to be detachable and openable at one end 14c.

The core 14 is attached to the outer case 12 by inserting the core piece 14b into the central through hole of the case body 12a of the outer case 12, attaching the case cover 12b, and assembling the core piece 14a.

The core 14 is notched at an end opposite to the one end 14c, and is curved in accordance with a circular flywheel 16 of an internal combustion engine (not shown) rotating closely, so that the separation distance is uniform. It is configured as follows. That is, the core 14 is configured to form a closed magnetic flux circuit using the flywheel 16.

The core 14 is formed by stacking graded silicon steel plates. Since silicon is unevenly distributed on the surface side in graded silicon steel sheets, iron loss is smaller and magnetic saturation characteristics are lower than those of general silicon steel sheets with so-called directivity, in which silicon is uniformly distributed. Also excellent. 14d is a mounting hole.

Inside the outer case 12, a coil portion 24 including a primary coil 20 and a secondary coil 22 is accommodated. That is, the primary coil 20 is arranged on the outer periphery of the core piece 14b of the core 14, and the secondary coil 22 is arranged on the outer periphery of the primary coil 20, as shown in FIG.

Both the primary coil 20 and the secondary coil 22 use a self-welding wire (a so-called cementing enamel wire in which a self-adhesive layer is provided on the surface of various synthetic enamel wires) 200 made of PIW as a winding. Be produced.

As shown schematically in FIG. 5, the self-bonding wire 200 includes a copper wire 200a and an insulating layer 2 formed around the copper wire 200a.
00b and a self-adhesive layer 200c formed on the outer periphery of the outermost layer.

The primary coil 20 and the secondary coil 22 are
The self-fusing wire 200 is wound around a bar (not shown), heated, and then cooled to form a cylindrical shape as schematically shown in FIG. 6, then integrally joined with an adhesive 24a to form a coil. Completed as part 24. By using the self-fusing wire 200 as described above, the primary coil 20 and the secondary coil 22 can be easily manufactured without requiring a bobbin.

As the adhesive 24a, for example, a hot melt adhesive based on a thermoplastic polymer such as polyamide, EVA or polyolefin is used.

The coil portion 24 composed of the primary coil 20 and the secondary coil 22 manufactured as described above is fixed to the bottom surface of the case body 12a using an elastic material 26 having adhesiveness. As the elastic member 26, for example, silicon gel is used. Silicon gel is excellent in vibration absorption,
It also has tackiness.

As described above, the coil portion 24 is not fixed in the case body 12a by being buried in the resin mold resin, but is fixed in the case body 12a by the elastic member 26. Therefore, the space between the coil portion 24 and the space 24b in the case body 12a is left as an air gap.

The case body 12a is partitioned on one side to form a compartment 12d, in which the ignition control circuit unit 30 is housed. The ignition control circuit unit 30 is fixed to the bottom surface of the case main body 12a with the same type of elastic material 32 as the coil unit 24.

The ignition control circuit unit 30 comprises a waveform shaping circuit, a switching element (power transistor), and the like. As is well known, the primary coil 20 is energized from a battery power supply (not shown) in accordance with a command from a control unit (not shown). Then, the power supply is cut off at a predetermined timing to generate an ignition voltage in the secondary coil 22.

The ignition control circuit unit 30 is formed of a ceramic substrate, and as shown in FIG.
0 is connected to the battery power supply and the ground side, and two leads 30a and 30b are provided. The leads 30a and 30b are made of a brass material.

An inner cap 34 is provided near the open end of the case body 12a. The inner cap 34 comes into contact with the coil portion 24, and the coil portion 24 is
It is configured to press against the bottom surface of. Inner cap 3
4 is manufactured from PBT similarly to the case main body 12a. Reference numeral 34a indicates a drain hole.

The inner cap 34 is protruded into a cylindrical shape near the upper part of the compartment 12d of the case main body 12 to form a high tension cord outlet 36,
A high tension code (indicated by an imaginary line in FIG. 1) 38 is inserted therein. The high tension cord outlet has a terminal 36a (made of brass) having an L-shaped cross section for connecting to the secondary coil 22. FIG.
Shows the upper end side of the terminal 36a.

The ignition coil 10 according to this embodiment
Has a stop terminal 42. The stop terminal 42 comes into contact with the lead 42b and, when pressed by an operator or the like, stops the ignition and immediately stops the internal combustion engine via a circuit (not shown).

The connection between the primary coil 20 and the two leads 30a and 30b of the ignition control circuit unit 30 will be described. As shown in FIG. 3, the terminals 20a and 20b of the primary coil 20 and the ignition control circuit The leads 30a and 30b extending from the unit 30 are joined by fusing, that is, the terminals 20a and 20b and the leads 30 are joined together.
A large current is applied while a and 30b are pressurized, joined by heating and melting, and the joint is partially molded and fixed with a molding material 44 (the thickness of the molding material 44 is exaggerated in FIG. 1). Shown).

In other words, the terminals 20a, 20b and the leads 30a, 30b are joined without using a solder joint using a lead material, and the joint is partially molded and fixed with a molding material 44.

Similarly, the terminal 22a of the secondary coil 22 and the terminal 36a of the high tension cord outlet 36 (the lower end of the L-shaped section) are joined by fusing, and then partially molded with a molding material 46. And fix it.
The other terminal of the secondary coil 22 is connected to the primary coil 20 at a position not shown.

As the molding materials 44 and 46, the same kind of hot melt adhesive as the adhesive 24a is used.

This connection work is performed by the inner cap 34.
Since the above operation is performed, the inner cap 34 can be used as a work table, and the connection operation is facilitated, the process can be simplified, and the reliability can be improved.

Here, the manufacturing process of the ignition coil 10 will be outlined.

First, the case body 12a, the case lid 12
b, while the inner cap 34 is manufactured from PBT,
While the core pieces 14a and 14b are manufactured from a graded silicon steel sheet, the primary coil 20 and the secondary coil 22 are manufactured using the self-bonding wire 200 as described above, and the adhesive 24a is formed.
To form the coil portion 24. The ignition control circuit unit 30 is also manufactured as a ceramic substrate.

Next, the elastic members 26 and 32 are applied to the bottom surface of the case body 12a, and the coil 24 and the ignition control circuit unit 30 are assembled and fixed. Next, the inner cap 34 is attached, the terminals are joined by fusing, and the joints are molded (coated) with molding materials 44 and 46.
I do.

Next, when the case lid 12b is attached and the core is inserted, the ignition coil 10 is completed. Thereafter, it is mounted at a predetermined position of the internal combustion engine via a mounting hole 14d formed in the core 14, and the high tension cord 38 is inserted into the high tension cord outlet 36, and the ignition control circuit unit 30 is connected to the battery power supply and the control unit. Just connect.

In this embodiment, as described above, one end of the core 14 is configured to be openable, and the primary coil 2
In the ignition coil 10 in which the coil portion 24 composed of the 0 and secondary coils 22 is configured to be detachable, the primary coil 20 and the secondary coil 22 are manufactured from the self-bonding wire 200 and a coil case (case body). 12a and the case lid 12b) are fixed by an elastic material (for example, silicone gel) 26.

As described above, one end of the core 14 is configured to be openable, the coil portion 24 including the primary coil 20 and the secondary coil 22 is configured to be detachable, and the primary coil 20 and the secondary coil 22 are further configured. Is manufactured from the self-bonding wire 200 and is configured to be fixed in the coil case by the elastic material 32, in other words, the coil portion 24.
The resin is not filled in the space 24b between the case 24 and the case body 12a, and the bobbin-less operation is possible by using the self-bonding wire 200. As a result, the recycling rate can be improved, so that efficient collection and reuse of resources can be achieved. Also, the core can be easily separated.

The primary coil 20 and the secondary coil 2
2 is fixed in the coil case by an elastic material 26 (e.g., silicone gel) having excellent vibration absorption, so that vibration resistance equal to or higher than that of the ignition coil according to the related art can be provided.

By using the self-fusing wire 200,
The copper wire 200a is connected to the self-adhesive layer 200c (and the insulating layer 20).
0b), the number of windings per unit area is reduced as a result, but it is necessary to manufacture the core 10 from a graded silicon steel sheet and to use the flywheel 16 as a part of the magnetic flux path. It is possible to obtain a proper ignition voltage.

On the other hand, the copper wire 200a is connected to the self-adhesive layer 200c.
Adjacent via (and the insulating layer 200b)
Since the copper wire 200a can be kept air-tight and liquid-tight so that the water resistance can be improved, and the insulation between the copper wires 200a can be improved and the leakage therebetween can be reduced. And the ignition voltage characteristics can be improved.

Further, the ignition control circuit unit 30 is built in the coil case, and the ignition control circuit unit 30 is fixed to the coil case (case main body 16a) by an elastic material 32.

Thus, when the ignition coil 10 is discarded, the ignition control circuit unit 30 can be easily separated and recovered, and the recycling rate can be further improved.

Further, the ignition control circuit unit 30 is fixed by an elastic material (for example, silicon gel) 32 having excellent vibration absorption, so that vibration resistance equal to or higher than that of the ignition coil according to the prior art is provided. be able to.

The primary coil 20 and the secondary coil 22 are integrally joined via an adhesive 24a.

As a result, the insulation between the primary coil 20 and the secondary coil 22 can be improved, and the assembly can be facilitated by integrally joining the coil portion 24 to improve the working efficiency. Can be improved.

The primary coil 20 and the secondary coil 22
In the ignition coil 10 in which the coil portion 24 and the ignition control circuit unit 30 are built in a coil case (case main body 12a), the terminals 20a and 2 of the primary coil 20 are connected.
0b and the terminal 30a of the ignition control circuit unit are fused by fusing, and the joint is partially molded, more specifically, partially molded via a molding material 44.

This makes it easier to comply with lead disposal regulations because no solder joint is used, and the molding material 4
By partially molding through the coil 4, the separation and recovery of the coil section 24 is further facilitated, and the recycling rate can be improved, so that efficient recovery and reuse of resources can be achieved.

Further, by partially molding through the molding material 44, the water resistance and vibration resistance of the joint portion are not lost.

Further, the terminal 24a of the secondary coil 24 and the terminal 36a of the high tension cord outlet 36 are joined by fusing, and the joint is partially molded, more specifically, partially molded via a molding material 46. Configured.

Accordingly, it is also easy to comply with the lead disposal regulations, and the separation and collection of the coil portion 24 is further facilitated by forming a partial mold via the molding material 46, thereby improving the recycling rate. Can be.

Further, the coil case (case body 12)
a), an inner cap 3 in which the high tension cord outlet 36a is integrally formed on the terminals 20a and 20b of the primary coil 20 and the secondary coil 22.
4 was arranged, and the fusing and the partial molding were performed on the inner cap.

As a result, the inner cap 34 can be used as a work table, and the connecting operation is facilitated, the process can be simplified, and the reliability can be improved.

In the above-described ignition coil 10,
Although a part of the flywheel 16 close to the core 14 is used for a magnetic flux path, the present invention is not limited to this, and a closed magnetic flux circuit may be formed only by the core 14.

[0059]

According to the first aspect of the present invention, since no solder joint is used, it is easy to comply with lead disposal regulations, and
The partial molding facilitates the separation and recovery of the coil portion, and can improve the recycling rate. further,
There is no lack in water resistance and vibration resistance of the joint.

According to the second aspect of the present invention, similarly, it becomes easy to comply with the lead disposal regulations, and the partial molding further facilitates the separation and recovery of the coil portion, thereby improving the recycling rate. .

According to the third aspect of the present invention, the inner cap can be used as a work table, and the connecting operation is facilitated, the process can be simplified, and the reliability can be improved.

[Brief description of the drawings]

FIG. 1 is an explanatory side sectional view of an ignition coil according to the present invention.

FIG. 2 is a sectional view taken along line II-II of FIG.

FIG. 3 is a top view of the ignition coil shown in FIG. 1 with a lid of a case main body removed.

FIG. 4 is a top view of a state where the lid of the case main body is attached from the state shown in FIG. 3 to complete the ignition coil.

FIG. 5 is an explanatory sectional view schematically showing a self-bonding wire used in a coil portion of the ignition coil shown in FIG.

FIG. 6 is an explanatory perspective view schematically showing the production of the coil portion of the ignition coil shown in FIG. 1;

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 10 Ignition coil 12 Outer case (coil case) 14 Core 20 Primary coil 20a, 20b Primary coil terminal 22 Secondary coil 22a Secondary coil terminal 24 Coil part 24a Connecting material 26, 32 Elastic material 30 Ignition control circuit unit 34 Inner Cap 36 High tension cord outlet 36a High tension cord outlet terminal 38 High tension cord 44, 46 Molding material 200 Self-fusing wire

Claims (3)

[Claims] 1. An ignition coil in which a coil portion including a primary coil and a secondary coil and an ignition control circuit unit are built in a coil case, a terminal of the primary coil and a terminal of the ignition control circuit unit are joined by fusing. An ignition coil characterized in that the joint is partially molded. 2. The ignition coil according to claim 1, wherein the terminal of the secondary coil and the terminal of the high tension cord outlet are joined by fusing, and the joint is partially molded. 3. An inner cap in which the high tension cord outlet is formed integrally on the terminal side of the primary coil and the secondary coil inside the coil case, and the inner cap and the fusing are formed on the inner cap. 3. The ignition coil according to claim 2, wherein partial molding is performed.