JP3351187B2 - Igniter and manufacturing method thereof - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to an igniter and a method for manufacturing the igniter .

[0002]

Conventionally, a coil case for accommodating Lee Gunaita with an ignition coil of an internal combustion engine are known. In this type of coil case, for example, as described in JP-A-7-29747, the direction in which the igniter and the ignition coil are housed and the direction in which the tip of the connector pin electrically connected to the igniter protrudes. , Are arranged in the same direction.

[0003]

However, with this type of ignition coil (in which the coil case and the connector are integrated), a sufficient size reduction cannot be achieved as follows. That is, since the ends of the connector pins are arranged in parallel to the direction in which the ignition coil and the like are accommodated, the connector must be arranged in parallel with the coil case body. For this reason, a path for conducting between the circuit terminal provided on the coil case opening side of the igniter and the vicinity of the connector pin tip becomes long, and the space around the conduction path occupies a relatively large volume.

On the other hand, in recent vehicles, it is required to mount a great number of devices near an internal combustion engine, and miniaturization of an ignition coil is an urgent issue. Also, devices other than the ignition coil are required to be reduced in size, and it is urgently desired to reduce the size of an igniter which is a part of the housing of the device.

Accordingly, the present invention provides an igniter
It was made to facilitate its manufacture while achieving good miniaturization.

[0006]

According to the first aspect of the present invention, which has been made to achieve the above object, an opening is formed.
A case, an igniter circuit, and the igniter circuit
And a connector to be connected to the connector, wherein the connector is
A base integrally disposed near the opening of the case.
It has a bottom and a mating hole at its base.
A shell protruding from the case and the igniter
Connector terminals connected to the terminals formed in the
A, the connector terminals, the exposed inside the shell
(1) in the direction in which the igniter is stored in the case
And a second plane portion formed in the opening at right angles.
And the second plane portion is connected to the terminal.
A connection portion and a fitting portion fitted into the fitting hole of the base portion
Formed between the connection portion and the fitting portion,
The connecting part is formed to bend easily with respect to the fitting part
A manufacturing method of the igniter and a groove, said Ke
Molding the over scan and the connector shell, the Iguna
Iter circuit is housed in the case, and then the connector
Terminal from the shell side to the igniter circuit
At right angles to the case
And further connect the connection terminal and the end of the connector terminal.
It is characterized by connecting to the child by projection welding
The gist of the present invention is a method of manufacturing an igniter .

According to a second aspect of the present invention, the connecting portion is a plane parallel to an insertion direction of the connector terminal and a housing direction of the igniter circuit.
The gist is a method for manufacturing the igniter described.

[0008]

[0009] According to a third aspect, the gist above case, the manufacturing process of the igniter according to claim 1 or 2, wherein the formed integrally with the coil accommodating portion for accommodating the ignition coil of an internal combustion engine And

[0010]

[0011]

According to the first aspect of the present invention, the connector shell is integrally disposed near the opening of the case , and the connector terminal is orthogonal to the housing direction of the igniter circuit. Is inserted. For this reason, the base end of the connector terminal and the opening side end face of the igniter circuit are extremely close to each other. Therefore, the path for conducting the connector terminal and the terminal provided in the igniter circuit is extremely short, and the igniter can be downsized satisfactorily. In addition, since a groove is formed in the second flat portion of the connector terminal between the connection portion connected to the terminal of the igniter circuit and the fitting portion fitted to the base of the shell, the connection portion is formed by projection. When welding, the second flat portion is easily bent at the portion where the groove is formed. Therefore, it is possible to prevent an undesired force from acting on the above-mentioned welded portion and to secure welding strength. The case and connector shells
Since the connector terminal is inserted after molding the
Ignition without positioning the connector terminals during molding
Ita case can be easily manufactured. Also,
Gnitter circuit is easy without being disturbed by connector terminals
Can be accommodated in the case. In addition, Ignay
Terminal formed on the data circuit and the connection portion of the connector terminal.
Easily by projection welding inside the case opening
Can be connected.

According to a second aspect of the present invention, in addition to the configuration of the first aspect, the connection portion is a plane parallel to the insertion direction of the connector terminal and the housing direction of the igniter circuit. Therefore, the connection part and the circuit end
The process of connecting with the child can be easily performed from the opening side.
it can.

[0013]

[0014]

[0015] invention 請 Motomeko 3 described claim 1 or 2
In addition to the configuration described, the igniter circuit housing portion, form an ignition coil of an internal combustion engine integrally with the coil housing portion to yield capacity
It is characterized by having been achieved . As described above, there is an urgent need to reduce the size of ignition coils for internal combustion engines. In the present invention, since the invention described in claim 1 or 2 is applied to the ignition coil, the effect of the invention becomes more remarkable.

[0016]

[0017]

[0018]

Next, specific embodiments of the present invention will be described with reference to the drawings. FIG. 1 is a cross-sectional view illustrating a configuration of an ignition coil 1 to which the present invention is applied . Co-Irukesu 3, connector 5
Is integrally formed with the shell 7 of resin. Further, the coil case 3 includes an igniter accommodating section 13 accommodating an igniter 11 including at least a semiconductor switching element for interrupting the primary coil current of the ignition coil 1 and a coil accommodating section 17 accommodating a primary coil 21 and the like described later. The shell 7 is formed in parallel with the direction orthogonal to the direction protruding from the coil case 3 and with the openings 13 a and 17 a facing the side close to the shell 7. The igniter 11
Is configured to include a primary coil current value control circuit and the like in addition to a power transistor as a semiconductor switching element. In the present embodiment, the igniter 11 and the
The igniter housing 13 and the connector 5 become igniters
Igniter 11 is connected to the igniter circuit.
The housing 13 corresponds to an igniter circuit housing.

A rectangular cylindrical primary bobbin 17b into which the core 15 that can be divided into two is inserted is formed in the coil housing 17, and a primary coil 21 is disposed around the primary bobbin 17b. A secondary bobbin 25 around which a secondary coil 23 is wound is fitted around the periphery. A high-voltage fitting 27 is fixed to the bottom of the coil accommodating portion 17 (the side opposite to the opening 17a), and the secondary terminals 23a at both ends of the secondary coil 23 are connected to the high-voltage fitting 27. .

Next, an opening 13a is provided inside the shell 7.
4 pins 31 extending to the center of the igniter 1
Four terminals 41 are formed on one end surface 11a on the opening 13a side (FIG. 3). Base end of pin 31 (opening 1
The second flat portion 33 is formed on the 3a side), and the flat portion 41a is formed on each terminal 41 in parallel with the insertion direction of the pin 31 and the housing direction of the igniter 11, respectively. The second flat portion 33 and the flat portion 41a are connected by projection welding as described later. Further, the igniter 1 disposed inside the coil case 3 is provided.
1, the resin 43 is filled so as to cover the secondary coil 23 and the like.

Next, the configuration of the pins 31 and the terminals 41 will be described in detail. FIGS. 2A and 2B are a right side view (right direction in FIG. 1) and a front view (FIG.
Front direction). As shown in FIGS. 2A and 2B,
The pin 31 is formed by bending a planar metal member by 90 ° at the ridgeline 35, and includes a planar first planar portion 37 entirely exposed in the shell 7 and the above-described second planar portion 33. The distal end 37a of the first flat portion 37 is chamfered so that it can easily fit into a socket contact (not shown). The second flat portion 33 includes a connection portion 33a connected to the terminal 41 and a fitting portion 33b fitted to the base of the shell 7, and the connection portion 33a and the fitting portion 33
A groove 33c is formed between the groove 33b and the groove 33b.

FIGS. 3A and 3B are a rear view and a right side view showing the structure of the igniter 11. FIG. Igniter 1
Reference numeral 1 denotes a circuit assembled as a hybrid substrate using a thick film technique, which is housed in a dish-shaped container made of stainless steel and sealed with a resin, and is configured as an integrated circuit unit. The igniter 11 may be unitized by covering the entire circumference with resin. FIG. 3 (A),
As shown in (B), four terminals 41 are erected on the end face 11a of the igniter 11 disposed on the opening 13a side, and each terminal 41 is perpendicular to the end face 11a (the insertion direction of the pin 31 and the igniter). 11 parallel to the housing direction)
1a. In addition, approximately in the center of the plane portion 41a,
A circular protrusion (dent when viewed from the back surface) 41b is formed. Further, at both ends of the end face 11a, primary terminals 45 connected to both ends of the primary coil 21 are provided.

In the ignition coil 1 of the present embodiment having the above-described configuration, the igniter 11 controls the supply of the primary current to the primary coil 21 based on the signal input through the pin 31, and The high voltage generated by 23 can be output at a desired timing via the high voltage fitting 27. Then, the high voltage is sent to the ignition plug of the internal combustion engine (not shown), and the internal combustion engine can be ignited at the desired timing.

In the ignition coil 1 of this embodiment, the connector 5 is integrally provided near the opening 13a,
1 is an opening 13a orthogonal to the housing direction of the igniter 11.
And is directly connected to the terminal 41. For this reason,
While the inside of the opening 13a can be effectively utilized,
The conduction path from the terminal 41 to the tip of the pin 31 can be extremely short. Therefore, the size of the coil case 3 can be extremely reduced. If the ignition coil 1 of the present embodiment is applied, it becomes possible to mount a great number of devices near the internal combustion engine of the vehicle.

Next, a method of manufacturing the ignition coil 1 of the present embodiment will be described. FIG. 4 is an explanatory diagram illustrating a manufacturing process of the ignition coil 1. The ignition coil 1 of this embodiment is manufactured by the following procedure. In FIG. 4, hatching indicating a cross section is omitted. . The primary coil 21 is wound, and both ends thereof are igniter 1
1 primary terminal 45. . The secondary coil 23 is wound around the secondary bobbin 25, and both ends are connected to the secondary terminal 23a. . The coil case 3 and the shell 7 are integrally formed of resin. At this time, a fitting hole 7a into which the fitting portion 33b of the pin 31 fits is formed in the base of the shell 7. . Is accommodated in the coil accommodating portion 17 of the coil case 3 formed by (arrow). . The primary coil 21 and the igniter 11 are accommodated in the coil accommodating portion 17 and the igniter accommodating portion 13, respectively, of the coil case 3 molded by the arrows (arrows). . The pin 31 is connected to the connection portion 33a in the fitting hole 7a formed by
The fitting portion 33b is fitted into the fitting hole 7a (arrow). When the pin 31 is inserted in this step, as shown in the right side view of FIG. 5, the side of the terminal 41 on which the projection 41b of the flat portion 41a is provided and the connection portion 33a of the pin 31 are opposed to each other. Further, the fitting portion 33b is in close contact with the fitting hole 7a, and can prevent the resin 43 from leaking into the shell 7 when filling the coil case 3 with the resin 43 as described later. . As shown in FIG. 6, while pressing the flat portion 41 a and the connecting portion 33 a facing each other with a pair of welding electrodes 51,
A high voltage is applied between the welding electrodes 51, and the flat portions 41a,
The connection portion 33a is projection-welded. At this time,
Even if the gap between the flat portion 41a and the connection portion 33a varies, as shown by a two-dot chain line in FIG.
The flat portion 33 is easily bent at a portion where the groove 33c is formed. Therefore, it is possible to prevent an undesired force from acting on the above-mentioned welded portion and to secure welding strength. . The resin 43 that has been fluidized from the openings 13a and 17a is filled in the coil case 3, and then the resin 43 is solidified. By filling the resin 43, the igniter 11,
Water can be prevented from entering the coils 21, 23 and the like. . Finally, the core 15 divided into two parts is put into the primary bobbin 17.
b, from both sides, and the two are combined to complete the ignition coil 1.

As described above, in this embodiment, since the pins 31 are inserted into the coil case 3 after the coil case 3 is formed, there is no need to position the pins 31 when the coil case 3 is formed. Further, since the pin 31 has a structure bent at 90 ° at the ridgeline 35, when the pin 31 is inserted into the fitting hole 7a, the flat portion 41a and the connecting portion 33a are arranged to face each other, and projection welding can be easily performed from the right side surface. It can be carried out. For this reason, the ignition coil 1 of the present embodiment can be manufactured very easily despite the fact that the tip of the pin 31 is formed in a plane parallel to the direction in which the pins 31 are arranged.

[0027]

[0028]

[0029]

[0030]

[0031]

Next, another embodiment in which the present invention is applied to a device other than an ignition coil will be described with reference to FIG. In the embodiment of FIG. 8, only the igniter circuit for controlling the primary current of the ignition coil intermittently is accommodated in a resin case with a connector. This circuit is disposed separately from the ignition coil and is used for an internal combustion engine, or is used in combination outside the ignition coil or inside the ignition coil.

In the case 201 formed of resin,
Square-bottomed tubular circuit housing portion 202 and its circuit housing portion 20
The connector housing 204 is formed integrally with the connector housing 204 so as to protrude in a direction orthogonal to the second axis. The circuit accommodating portion 202 has a rectangular opening 203 that is long in a direction perpendicular to the paper surface.

An igniter unit 213 in which a hybrid circuit board 210 having an igniter circuit is potted and sealed with a resin 212 in a stainless steel case 211 is press-fitted into the circuit housing portion 202. The igniter unit 213 has a plate-like appearance having a rectangular cross section, and has a plurality of terminals 21 connected to a circuit on one side.
4 are provided. These terminals 214 extend in the direction of the opening 203 of the circuit accommodating portion 202, and are bent such that their tips 215 are parallel to the paper surface. That is, the tip 215 of the terminal 214 is arranged so as to face the longitudinal direction of the opening 203.

On the other hand, a plurality of pins 31 identical to those described with reference to FIG. A slit-shaped hole for receiving and fixing the bent portion of the pin 31 is formed in the connector housing 204 in advance, a part of which is a penetrating hole, and a part of the pin 31 is penetrated. The pin 31 is press-fitted after accommodating the igniter unit 213 in the circuit accommodating portion 202, and the connection portion 33a protrudes toward the opening 203 of the igniter unit 213 so as to prevent the igniter unit 213 from being removed.

Thereafter, the connection portion of each pin 31 and the tip 215 of each terminal 214 are projection-welded.
At this time, the two arms for projection welding are arranged so as to open and close along the longitudinal direction of the opening 203. Finally, the resin 230 is injected and filled to complete the igniter circuit.

Also in this embodiment, the igniter unit 21
When the igniter unit 213 passes when storing 3,
Since the terminal 214 from the igniter unit 213 and the pin 31 from the connector are connected in the space in the circuit accommodating portion 202 left thereafter, the connection between the igniter unit 213 and the connector can be made without increasing the overall physical size. You can get a connection. In particular, it is important to insert the pin 31 into the connector housing 204 after the igniter unit 213 is press-fitted. Also, a connection portion 33a between the tip 215 of the terminal 214 and the pin 31
Are arranged so as to face the longitudinal direction of the opening 203, that is, in parallel with the plane of the paper of FIG. 8, so that the tip 215 and the connecting portion 33a can be electrically connected. Can be secured without excessively increasing the interval between the plurality of pins 31.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view illustrating a configuration of an ignition coil according to an embodiment.

FIG. 2 is a right side view and a front view showing a configuration of a pin of the ignition coil.

FIG. 3 is a rear view and a right side view showing the structure of an igniter terminal of the ignition coil.

FIG. 4 is an explanatory view showing a manufacturing process of the ignition coil.

FIG. 5 is a right side view showing a configuration of the ignition coil when a pin is inserted.

FIG. 6 is an explanatory view showing a projection welding step of the ignition coil.

FIG. 7 is a cross-sectional view illustrating a configuration of an igniter circuit according to another embodiment.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 ... Ignition coil 3 ... Coil case 5 ... Connector 7 ... Shell 11 ... Igniter 13 ... Igniter accommodating part 17
... Coil accommodating part 21 ... Primary coil 23 ... Secondary coil 31 ... Pin 33 ... Second plane part 37 ... First plane part 41 ... Terminal 41a ... Plane part 51 ... Welding electrode

Continuation of front page (58) Field surveyed (Int.Cl. ⁷ , DB name) H01F 38/12 F02P 15/00 303

Claims (3)

(57) [Claims] A case having an opening formed therein, an igniter circuit, and a connector electrically connected to the igniter circuit.
The connector is provided with a base which is integrally disposed near the opening of the case.
It has a bottom and a mating hole at its base.
A shell protruding from the case and a connector connected to a terminal formed on the igniter circuit.
And a first terminal exposed in the shell.
And the igniter perpendicular to the direction in which the igniter is stored in the case.
And a pin having a second flat portion formed in the opening
Wherein the second plane portion is a connection portion connected to the terminal.
And a fitting portion that fits into the fitting hole of the base portion;
The connection portion is formed between the connection portion and the fitting portion, and the connection portion is
And a groove formed to bend easily to the joint.
A method of manufacturing an igniter, comprising: forming a shell of the case and the connector; housing the igniter circuit in the case; and subsequently, connecting the connector terminal from the side of the shell.
The igniter circuit should be
Into the opening of the case, and further plug the connection part of the connector terminal and the terminal.
Igu characterized by connection by projection welding
The manufacturing method of Nighta. 2. The igniter according to claim 1, wherein said connecting portion is a plane parallel to an insertion direction of said connector terminal and a housing direction of said igniter circuit .
Construction method . 3. The method for manufacturing an igniter according to claim 1, wherein said case is formed integrally with a coil accommodating portion accommodating an ignition coil of the internal combustion engine.