JP3451179B2 - Engine ignition coil device and method of manufacturing the same - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an ignition coil device for an independent ignition type engine, which is mounted in each ignition plug hole of an engine and directly connected to each ignition plug for use.

[0002]

2. Description of the Related Art In recent years, the above-described ignition coil device for an independent ignition type engine has been developed and put into practical use. This type of independent ignition type engine ignition coil device does not require a distributor because the ignition coil and the ignition plug are directly connected, and as a result, the energy supplied to the ignition coil is reduced by the distributor and its high voltage cord. Since it is possible to design the ignition coil without consideration of lowering of ignition energy,
It is evaluated as being able to reduce the coil volume, downsize the ignition coil, and rationalize the parts mounting space in the engine room by eliminating the distributor.

The independent ignition type ignition coil device is generally called a pencil coil because it has a pencil shape, and has a slender cylindrical coil case with a center core (a plurality of silicon steel plates laminated by a magnetic path core) and a primary coil coil. The coil and the secondary coil are housed inside, and the primary and secondary coils are wound on their respective bobbins, and are arranged in a concentric circle around the center core. Insulation of the coil is ensured by injecting and hardening an insulating resin or encapsulating insulating oil in the coil case that houses the primary and secondary coils.

In the so-called pencil coil,
As the form when the secondary coils are arranged concentrically,
The one in which the primary coil is arranged inside and the one in which the secondary coil is arranged outside (for example, JP-A-8-255719, JP-A-9-
7860, JP-A-9-17662), a secondary coil disposed inside, and a primary coil disposed outside (for example, JP-A-8-93616, JP-A-8-97057, JP-A-8-144916 and JP-A-8-203757).

In the conventional pencil coil, as a manufacturing process, a step of winding the primary coil around the primary bobbin and a step of winding the secondary coil around the secondary bobbin are separately performed, and after the winding step, the primary coil and the secondary coil are wound. The next coil is assembled.

FIG. 6 shows an example of manufacturing a conventional pencil coil.
This will be described with reference to (a) and (c).

FIG. 6 (a) is a schematic circuit diagram of this kind of ignition coil device, and FIG. 6 (c) is a schematic explanatory view of a conventional pencil coil winding process and a primary / secondary coil assembly process.
FIG. 6C shows an example of manufacturing an ignition coil of the type in which the primary coil is arranged inside and the secondary coil is arranged outside.

In FIG. 6A, 1 is a center core,
Reference numeral 5 is a primary coil, 3 is a secondary coil, and these elements constitute a transformer for an ignition coil. 22 is a spark plug, 39 is a power transistor (ignition control drive element) for controlling energization of the primary current, 71 is a noise prevention capacitor for preventing noise generated in the ignition coil,
Is a terminal (primary coil terminal) for connecting the primary coil one end 5a to the power supply side, is a terminal (primary coil terminal) for connecting the primary coil other end 5b to the collector side of the power transistor 39, and is a secondary coil one end (Low voltage side) 3
terminal for connecting a to the power supply side (secondary coil terminal),
Is a terminal for connecting the other end (high voltage side) 3b of the secondary coil to the spark plug 22.

As shown in FIG. 6C, the step of winding the primary coil 5 on the primary bobbin 4 and the step of winding the secondary coil 3 on the secondary bobbin 2 are separately performed, and the primary coil 5 In the winding process, the one end 5a of the coil is connected to the primary coil terminal (terminal fitting) provided on the primary bobbin 4, and the other end 5 of the coil is connected.
b is connected to the primary coil terminal (terminal fitting), while in the winding process of the secondary coil 3, the coil end 3a is provided on the secondary bobbin 2 for the low voltage side secondary coil terminal (terminal fitting).
And the other end 3b of the coil is connected to the high-voltage side secondary coil terminal (terminal fitting). Coil connection to these terminals is generally performed by twisting (winding) the coil ends around the terminals and then soldering.

After the winding is completed, the primary coil 5 (including the primary bobbin 4) is inserted into the secondary bobbin 2, and then the primary coil terminal and the secondary coil terminal connected to the power input side are connected via the crossover wire M. It was electrically connected.

As described above, the assembling process of the primary and secondary coils is performed after the primary winding process and the secondary winding process are separately performed. The reason is that the primary bobbin and the secondary bobbin are overlapped. This is because it has been considered impossible to perform the coil winding step in the state of (fitting bobbins together) for the following reason.

That is, if the primary coil is wound around the primary bobbin, a secondary bobbin is fitted on the outside of the primary coil while the bobbins are prevented from rotating relative to each other, and the secondary coil is attached to the secondary bobbin. When winding is assumed (in other words, when the primary and secondary bobbins are overlapped in the winding process), the secondary coil that requires precise winding work is on the outside, and the winding accuracy is There is a problem that it drops significantly. This is because when the secondary bobbin is rotated for winding due to the winding of the primary bobbin, the outer secondary bobbin is shaken or displaced. In fact, when performing the secondary winding, the coil cannot be wound accurately unless the secondary bobbin is firmly fixed to the shaft of the winding machine, so the coil should be wound realistically with the primary bobbin inside. Is impossible (because winding winding is displaced or disturbed).

Contrary to FIG. 6 (c), an ignition coil of a type in which a secondary coil is arranged inside and a primary coil is arranged outside is conventionally shown in FIG. 6 (c) as shown in FIG. ) And the same primary winding process, secondary winding process, and coil assembling process. 22, the same symbols as in FIG. 6 indicate the same elements.

In addition, the above-mentioned Japanese Patent Laid-Open No. 8-93616.
JP-A-8-97057 and JP-A-8-14.
In the independent ignition coil device described in Japanese Patent No. 4916, Japanese Patent Laid-Open No. 8-203757, etc., the secondary coil (including the secondary bobbin) is primary after the primary winding process and the secondary winding process are separately performed. The coil is inserted inside the coil (including the primary bobbin). In this known example, a lid provided on the upper part of the primary bobbin is provided with a terminal fitting corresponding to the terminal shown in FIG. 6A. In this case, one end (one end on the low voltage side) of the secondary coil is temporarily fixed to the secondary bobbin in the winding process of the secondary coil, and after inserting this secondary bobbin into the primary bobbin, one end of the secondary coil is pulled out. Connected to a terminal provided on the primary bobbin side, and this terminal and the terminal are connected to each other by a crossover M.
Alternatively, they are connected via a connecting member similar thereto.

[0015]

SUMMARY OF THE INVENTION An object of the present invention is to provide a so-called pencil coil (independent ignition type ignition coil device for an engine) which has a manufacturing process more than a winding process and a primary / secondary coil assembly process. It is an object of the present invention to provide an ignition coil device for an engine and a method for manufacturing the same, which can streamline and improve productivity.

[0016]

A first invention is an ignition coil device in which a center case, a primary coil wound on a primary bobbin, and a secondary coil wound on a secondary bobbin are provided in a coil case. In an ignition coil device for an independent ignition type engine mounted in each spark plug hole and directly connected to each spark plug, a secondary bobbin wound with the secondary coil is arranged inside the primary bobbin. , The head of the secondary bobbin is above the top of the primary bobbin.
Ri is cued, the outer surface of the head of the secondary bobbin or
The outer peripheral surface is provided with a coil terminal for both primary and secondary coils for connecting one end of the primary coil and one end of the secondary coil to a power source, and a primary coil terminal for connecting the other end of the primary coil to a drive element for ignition control. It is characterized by being.

According to the present invention, the secondary coil which requires precision winding is pre-wound, and the primary bobbin is secured to the outside of the secondary bobbin wound with the secondary coil while ensuring the rotation prevention between the bobbins. If the primary coil is fitted (in other words, the secondary bobbin is interpolated in the primary bobbin = bobbin overlapped state), the primary bobbin is rotated together with the secondary bobbin, and the primary coil is wound around the primary bobbin. This was done with a focus on the fact that it does not require precise winding as much as a secondary coil and is easy to wind.

Then, a series of steps as described above (secondary coil winding step, secondary bobbin insertion step to primary bobbin,
As a structure of the ignition coil for realizing the primary coil winding process in the primary bobbin / secondary bobbin overlapping state, first, the secondary coil is arranged inside and the primary coil is arranged outside.

Further, a coil terminal for both primary and secondary coils for connecting one end of the primary coil and one end of the secondary coil to the power source by drawing them to the secondary bobbin side (also used as the terminal of FIG. 6A) And a primary coil terminal [corresponding to the terminal of FIG. 6 (a)] for connecting the other end of the primary coil to a drive element for ignition control.

According to such a terminal arrangement structure, as shown in FIG.
As shown in (b), the one end 3a of the secondary coil 3 is first connected to the primary / secondary coil combined terminal on the secondary bobbin 2 side in the secondary winding step, and then the secondary bobbin (including the secondary coil is included. ) 2 is inserted in the primary bobbin 4 to perform the primary winding, so that one end 5a of the primary coil 5 can be connected to the primary / secondary coil combined terminal provided on the secondary bobbin 2 side. Due to the existence of the combined primary / secondary coil terminal, there is no need to connect the primary terminal and the secondary terminal via the crossover M (see FIG. 6 (c)) as in the conventional case. The connecting step can be omitted. Furthermore, one
The head of the secondary bobbin interpolated to the next bobbin is moved to the primary bobbin.
To the outside and to the outer surface of the head
By setting the terminal mounting space,
Ignition coil drive circuit on top of coil case in pencil form
Even if it is the type of ignition device that is installed,
The space for installing the coil dual-use terminal and the primary coil terminal is
It can be secured on the next bobbin.

A second invention is an ignition coil device in which a center case, a primary coil wound on a primary bobbin, and a secondary coil wound on a secondary bobbin are provided in a coil case, and the ignition coil device is provided in each ignition plug hole of an engine. In an ignition coil device for an independent ignition type engine that is mounted and directly connected to each spark plug, a secondary bobbin wound with the secondary coil is arranged inside the primary bobbin, and both of these bobbins are provided. Is provided with a relative detent between the bobbins, the head of the secondary bobbin is located above the upper end of the primary bobbin, and the secondary bobbin head has the secondary bobbin attached to the rotary shaft of the winding machine. An engaging portion is provided which engages with a bobbin detent provided on the rotating shaft side when set.

According to the above construction, (a) the winding machine for the primary and secondary coils is shared, or (b) the winding machine for the primary and secondary coils is separately provided, and only the rotary shaft thereof is shared,
The rotating shaft has a common type to enable the winding work of the primary coil and the secondary coil. Especially, the primary coil is executed with the primary bobbin fitted outside the secondary bobbin around which the secondary coil is wound. It will be possible.

That is, according to the bobbin arrangement and the secondary bobbin head structure as described above, it becomes possible to construct the following manufacturing line of the ignition coil device.

In the case of (a), first, the secondary bobbin is inserted into the rotary shaft of the primary / secondary winding machine, and the engaging portion provided on the secondary bobbin head rotates around the bobbin provided on the rotary shaft side. Since the stopper is engaged, the secondary bobbin can rotate together with the rotating shaft, and the work of winding the secondary coil becomes possible. Also, with the secondary bobbin still attached to the winding machine, the primary bobbin is fitted (clearance fit) to the outside of the secondary bobbin, and the structure prevents relative rotation between both bobbins. The primary bobbin can be rotated together with the secondary bobbin in cooperation with the rotation stopper engagement of the secondary bobbin head with respect to the rotary shaft, and the primary coil can be wound by the shared winding machine.

Even if the primary winding machine and the secondary winding machine are separate from each other as shown in (b), the rotary shafts of which are detachable and commonly used, or the common shaft type,
Regardless of whether it is a primary winding machine or a secondary winding machine, the secondary bobbin can be engaged with the rotating shaft of the winding machine through its bobbin head in a non-rotating state, and the primary bobbin can be placed outside the secondary bobbin head. Since the head can be fitted while trying to prevent the bobbins from rotating with each other, first set the secondary bobbin on the primary or secondary common or common type rotary shaft on the secondary winding machine side, and after winding the secondary coil, The secondary bobbin is transferred to the primary winding machine, and the primary bobbin is fitted with the primary bobbin while the secondary bobbin is set on the rotary shaft of the primary / secondary shared or common type on the primary winding machine side. This makes it possible to rotate the primary bobbin together with the secondary bobbin to wind the primary coil around the primary bobbin.

Further, by locating the head of the secondary bobbin inserted in the primary bobbin from the primary bobbin, a sufficient installation space can be secured even when the coil terminal and the coil bobbin are provided on the secondary bobbin.

A third invention is an ignition coil device in which a center core, a primary coil wound on a primary bobbin, and a secondary coil wound on a secondary bobbin are internally provided in a coil case, and the ignition coil device is provided in each ignition plug hole of an engine. In an ignition coil device for an independent ignition type engine that is mounted and directly connected to each spark plug, a secondary bobbin wound with the secondary coil is arranged inside the primary bobbin, and both of these bobbins are provided. Is provided with a relative detent between the bobbins, the head of the secondary bobbin is located above the upper end of the primary bobbin, and the secondary bobbin head has a primary coil end and a secondary coil end. A coil terminal also serving as a primary / secondary coil for connecting to a power source and a primary coil terminal for connecting the other end of the primary coil to a drive element for ignition control are provided. The following bobbin head, wherein the engaging portion engaged with the bobbin detent provided on the rotary shaft side when set secondary bobbin to the rotation shaft of the winding machine is provided.

According to the third invention, both operations of the first and second inventions are performed.

A fourth aspect of the invention relates to the invention of a method for manufacturing a pencil coil related to the first aspect of the invention, which is shown in FIG. 6 (b).
The characteristic feature is that the outer diameter of the secondary bobbin is smaller than the inner diameter of the primary bobbin so that the secondary bobbin 2 is inserted inside the primary bobbin 4. A relative detent is provided (this detent is not shown in FIG. 6B), and the primary bobbin that serves as a power input terminal is provided on the secondary bobbin 2 side.
A secondary coil combined terminal and a primary coil terminal for connecting the primary coil 5 to a drive element for ignition control are provided,
A secondary coil winding step of rotating the secondary bobbin 2 to wind the secondary coil 3 around the secondary bobbin 2, and connecting one end 3a of the secondary coil 3 to the primary / secondary coil combined terminal, and thereafter. , The primary bobbin 4 is fitted on the outside of the secondary bobbin 2 and rotated together with the secondary bobbin 2 to wind the primary coil 5 on the primary bobbin 4, and the one end 5a of the primary coil is connected to the primary / secondary coil combined terminal, The other end 5b of the primary coil
Primary coil winding step of connecting the
Is in the point of having.

According to the present invention, the primary coil terminal provided on the primary bobbin 4 and the secondary coil terminal provided on the secondary bobbin 2 as in the prior art of FIG. Streamlining the manufacturing process by eliminating the work of connecting with M, or eliminating the complicated work of unwinding the temporary fixing of one coil temporarily fixed to each bobbin and then reconnecting it to a predetermined terminal. Can be planned.

A fifth aspect of the present invention relates to a method of manufacturing a pencil coil according to the first and second aspects of the present invention, which is characterized in that a secondary bobbin is inserted inside a primary bobbin. The outer diameter of the secondary bobbin is smaller than the inner diameter of the primary bobbin, and the both bobbins are provided with relative detents between the bobbins, and the bobbin head is located on the secondary bobbin above the upper end of the primary bobbin. The bobbin head is provided with an engaging portion that engages with a bobbin detent provided on the rotating shaft side when the secondary bobbin is set on the rotating shaft of the winding machine. The winding machine is shared so that the winding work is performed by one winding machine, and the secondary bobbin is first inserted and set on the rotating shaft of the winding machine through its head, and the winding machine is put together with the rotating shaft. To the secondary boobi And a secondary coil winding step of winding the secondary coil around the secondary bobbin by rotating the secondary bobbin, and then, while the secondary bobbin is attached to the winding machine, the primary bobbin of the bobbin to the outside of the secondary bobbin A primary coil winding step of fitting the coil through a detent and rotating the primary bobbin together with the secondary bobbin to wind the primary coil around the primary bobbin.

The sixth invention also relates to the pencil coil manufacturing method according to the first invention or the second invention, characterized in that the secondary bobbin is inserted inside the primary bobbin. The outer diameter of the next bobbin is smaller than the inner diameter of the primary bobbin, the bobbins are provided with relative detents between the bobbins, and the secondary bobbin is provided with a bobbin head that is positioned above the upper end of the primary bobbin. The bobbin head is provided with an engaging portion that engages with a bobbin detent provided on the rotating shaft side when the secondary bobbin is set on the rotating shaft of the winding machine. Separately from the winding machine for the primary coil, the rotating shaft for winding can be detached and shared by the primary winding machine and the secondary winding machine. First, the rotating shaft is attached to the secondary winding machine. On the rotary shaft A secondary coil winding step of winding a secondary coil around the secondary bobbin by inserting and setting the bobbin through the head, and rotating the secondary bobbin together with the rotating shaft, and thereafter, setting the secondary bobbin. With the rotary shaft removed from the secondary winding machine while still attached, the rotary shaft is mounted on the primary winding machine, and the primary bobbin is fitted to the outside of the secondary bobbin through the rotation stopper between the bobbins, A primary coil winding step of rotating the primary bobbin together with a secondary bobbin to wind a primary coil around the primary bobbin.

The seventh invention also relates to the pencil coil manufacturing method according to the first invention or the second invention, characterized in that the secondary bobbin is inserted inside the primary bobbin. The outer diameter of the next bobbin is smaller than the inner diameter of the primary bobbin, the bobbins are provided with relative detents between the bobbins, and the secondary bobbin is provided with a bobbin head that is positioned above the upper end of the primary bobbin. The bobbin head is provided with an engaging portion that engages with a bobbin detent provided on the rotating shaft side when the secondary bobbin is set on the rotating shaft of the winding machine. Separately from the winding machine of the primary coil, the rotary shaft for winding is of a common type, and first the secondary bobbin is inserted and set on the rotary shaft of the secondary winding machine through its head. The rotating shaft A secondary coil winding step of winding a secondary coil around the secondary bobbin by rotating the secondary bobbin together, and then removing the secondary bobbin from the secondary winding machine, The rotary bobbin is inserted and set through the secondary bobbin head, and the primary bobbin is fitted to the outside of the secondary bobbin through the detents between the bobbins, and the primary bobbin is rotated together with the secondary bobbin to rotate the primary bobbin. And a primary coil winding step of winding the primary coil on the bobbin.

[0034]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT An embodiment of the present invention will be described with reference to the drawings.

First, the ignition coil device (pencil coil) according to the first embodiment will be described with reference to FIGS.

FIG. 1 is a vertical sectional view of the ignition coil device 21 (a sectional view taken along the line BB 'in FIG. 3) and a partially enlarged E thereof.
2 is a sectional view taken along the line AA 'in FIG. FIG. 3 is a view of the ignition coil device of FIG. 1 as seen from above, and shows the inside of the circuit case 9 in a state before resin filling.

Elongated cylindrical coil case (exterior case)
A center core 1, a secondary bobbin 2, a secondary coil 3, a primary bobbin 4, and a primary coil 5 are arranged in this order from the center to the outside in the interior of 6, and a resin mold (insulation Epoxy resin) 8 is interposed.

The outer diameter of the secondary bobbin 2 around which the secondary coil 3 is wound is smaller than the inner diameter of the primary bobbin 4, and the secondary bobbin 2 and the secondary coil 3 are located inside the primary bobbin 4. is doing.

The primary bobbin 4 is made of polybutylene terephthalate (PBT) or polyphenylene sulfide (PP).
The primary coil 5 is wound by molding with a thermoplastic synthetic resin such as S). The primary coil 5 is made of enamel wire having a wire diameter of about 0.3 mm, and the total number of enamel wires is 1
It is wound about 00 to 300 times. In the enlarged sectional view of the E portion in FIG. 1, the primary coil 5 is schematically represented by one layer for convenience of drawing, but in reality, the primary coil 5 is composed of several layers as described above.

The secondary bobbin 2 is molded from a thermoplastic resin such as modified polyphenylene oxide (modified PPO), and the secondary coil 3 wound around the bobbin 2 has a wire diameter of 0.03 to 0.
A total of 5000-200 using 1 mm enameled wire
It is divided and wound about 00 times. The structures of the secondary bobbin 2 and the primary bobbin 4 and the bobbin assembly (coil assembly) thereof will be described in detail later with reference to FIGS.

The coil case 6 is formed of the same thermoplastic resin as that of the primary bobbin 4, and a circuit case (also referred to as an ignition control unit case or an igniter case) 9 with a connector 9B disposed on the upper side thereof. Are molded separately. The circuit case 9 houses the unit 40 of the drive circuit (ignition circuit) for ignition control and is integrally formed with the connector portion (connector housing) 9B. The circuit case 9 and its connector terminals will be described later.

The center core 1 is formed by pressing and laminating a large number of silicon steel plates whose widths are set in several stages so as to increase the cross-sectional area thereof, for example, as shown in FIG. Inserted in.

The side core 7 mounted on the outer surface of the coil case 6 forms a closed magnetic circuit in cooperation with the center core 1, and is formed by rolling a thin silicon steel plate into a tubular shape. The side core 7 is provided with an axial cut in at least one position on the circumference of the side core 7 in order to prevent a short circuit of the magnetic flux by one turn. In the present embodiment, the side core 7 is formed by stacking a plurality of silicon steel plates (two in this case) to reduce the eddy current loss and improve the output. It may be.

Epoxy resin 8 is injected between the center core 1 and the secondary bobbin 2, between the secondary coil 3 and the primary bobbin 4, and between the primary coil 5 and the coil case 6 to ensure insulation. ing.

The secondary bobbin 2 has a secondary coil 3 on its outer circumference.
A large number of flanges 2B for divided winding are arranged at predetermined intervals in the axial direction.

On the upper part of the secondary bobbin 2, the bobbin head 2
A is formed integrally with the secondary bobbin 2. The bobbin head 2A is set so that the bobbin head 2A is positioned above the upper end of the primary bobbin 4.

FIG. 7 shows an enlarged perspective view around the bobbin head 2A after the step of winding the secondary coil 3 around the secondary bobbin 2, and FIG. 8 shows the secondary bobbin 2 in FIG. The enlarged perspective view of the bobbin head 2A vicinity when inserted is shown. In FIG. 1, the bobbin head 2A is partially cross-sectioned, and the non-cross-sectioned part is a part of the outer surface of the bobbin head.

The bobbin head 2A of this embodiment has a rectangular box shape, and the secondary bobbin 2 is provided on the outer surface of the bobbin head 2A in the process of manufacturing the ignition coil.
There is provided an engaging portion 2D which engages with the bobbin positioning and detent 64 provided on the rotary shaft side when inserted and set in (see FIG. 15).

The engaging portion 2D of this example has a ridge extending in the axial direction of the bobbin, and the rotation stopper 64 on the rotating shaft 62 side is provided.
Is provided with two pins 64 parallel to the axial direction of the shaft 62 on one end surface of the coupling 63, and the ridge engaging portion 2D is fitted between the pins 64.

The bobbin head 2A is filled with a magnet 16 and a cover member 17 made of a soft epoxy resin as shown in FIG. 1 through the upper opening. Further, although it is on the side of the secondary bobbin 2, the coil terminal 18 and the primary coil terminal 19 for both primary and secondary coils are provided on the outer surface of the bobbin head 2A.

Here, the primary / secondary coil combined terminal 18
Corresponds to the dual-purpose terminal of FIG. That is,
A coil terminal for taking out one end 3a of the secondary coil 3 and connecting it to a power supply [corresponding to a terminal in the circuit of FIG. 6 (a)], and a coil for taking out one end 5a of the primary coil 5 and connecting it to the power supply. It functions as a terminal [corresponding to a terminal in the circuit of FIG. 6A].

On the other hand, the primary coil terminal 19 is shown in FIG.
Of the primary coil 5 and the other end 5b of the primary coil 5 is taken out and connected to the collector of the power transistor (ignition coil drive element) 39 of the ignition circuit unit.

As shown in FIGS. 7 and 8, the combined primary / secondary coil terminal 18 is formed of a strip-shaped metal plate, and is provided on one outer surface of the secondary bobbin head 2A via its mounting leg portions 18c. It is press-fitted and fixed in the pocket 20. One end 18 'of the rising portion 1 is formed by rising in an L shape.
8'is joined by welding or the like to one end 31b of the connector terminal 31 for power input as shown in FIGS. Note that FIG.
Removes the coil case 6 and the ignition circuit case 9 from the ignition coil device, and combines the primary bobbin 4 around which the primary coil 5 is wound with the bobbin group of the secondary bobbin 2 around which the secondary coil 3 is wound (primary / secondary coil). Assembly) and secondary bobbin head 2
FIG. 10 is an enlarged perspective view showing a coupling relationship with an ignition circuit unit (sometimes called an igniter) 40 installed on A, and the ignition circuit unit 40 and its lead terminals 32, 34, 36 in FIG. 9 are actually Is housed in the circuit case 9 as shown in FIG.
Part of the reference numerals 1, 33 and 35 are embedded in a circuit case (resin case) 9.

The primary / secondary coil combined terminal 18 is made of a single metal fitting, and as shown in FIGS. 7 and 8, one end 3a of the secondary coil 3 is pulled out and pulled out (wrapped) 18a.
And a portion 18b for pulling out and pulling out one end 5a of the primary coil 5 are integrally formed.
At 8b, the coil ends 3a and 5a are separated from each other and then soldered. Upper flange 2B 'of the secondary bobbin 2
Is formed with a notch 2C for guiding the secondary coil one end 3a to the terminal fitting 18, and similarly, a notch 4B for guiding the primary coil one end 5a to the terminal fitting 18 is also provided on the upper end flange 4A of the primary bobbin 4. Is formed.

The primary coil terminal 19 is also formed of a strip-shaped metal plate, and is press-fitted and fixed in a pocket (not shown) provided on the outer surface of the secondary bobbin 2 on the side opposite to the position where the pocket 20 is located, and one end thereof. 19 'is formed in an L-shape, and an arm portion 19 "protruding horizontally is extended toward the primary / secondary coil combined terminal 18 side so that a tip portion 19' is a tip portion on the terminal 18 side. The primary coil terminals 19 are connected by welding to lead-out terminals (lead terminals) 32 on the side of the ignition circuit unit 40 as shown in Fig. 9. Terminal 3
2 is electrically connected to the collector side of the power transistor 39 of the ignition circuit unit 40 via wire bonding 42 as shown in FIGS.

As shown in FIG. 9, the connector terminals (connector pins) include connector terminals 33 and 35 in addition to the above-mentioned connector terminal 31.

The relationship between the connector terminals 31, 33 and 35 and the drive circuit for ignition control will be described.

FIG. 4 shows the circuit case 9 of the ignition coil device 21.
FIG. 3 is an electrical wiring diagram of an ignition drive circuit 41 and a primary coil 5 and a secondary coil 3 mounted on the vehicle.

The one end 5a of the primary coil 5 and the one end 3a of the secondary coil 3 are connected to the + of the DC power source via the combined primary / secondary coil terminal 18 and the connector terminal 31 provided on the secondary bobbin 2.
Connected to the side. The primary / secondary coil combined terminal 18 corresponds to the primary / secondary coil combined terminal described in the ignition coil principle diagram of FIG.

The other end 5b of the primary coil 5 is connected to the collector side of the Darlington-connected power transistor 39 via the primary coil terminal 19 provided on the secondary bobbin and the lead terminal 32 provided on the ignition circuit unit 40. The primary coil terminal 19 corresponds to the primary coil terminal described above.

The other end 3b of the secondary coil 3 is connected to the spark plug 22 via the high voltage diode 10. The high voltage diode 10 serves to prevent premature ignition when the high voltage generated in the secondary coil 3 is supplied to the spark plug 22 via the leaf spring 11, the high voltage terminal 12 and the spring 13 shown in FIG.

An ignition control signal generated by an engine control unit (not shown) is input to the base of the power transistor 39 via the connector terminal 33 and the lead terminal 34 provided on the ignition circuit unit 40. Based on this ignition control signal, the power transistor 39 is on / off controlled to control the energization of the primary coil 5, and when the primary coil 5 is cut off, a high voltage for ignition is induced in the secondary coil 3.

The emitter side of the second-stage transistor of the power transistor 39 is connected to the ground via the lead terminal 36 and the connector terminal 35 provided on the ignition circuit unit 40.

From the above, as shown in FIGS. 3 and 9, one end 18 'of the combined primary / secondary coil terminal 18 and one end 31b of the connector terminal 31 are connected by welding, and one end of the primary coil terminal 19 is connected. 19 'and one end of the lead terminal 32 on the ignition circuit unit side are connected by welding, one end of the connector terminal 33 and one end of the lead terminal 34 on the ignition circuit unit side are connected by welding, and one end of the connector terminal 35 and the lead terminal 36. The two are connected by welding.

In FIG. 4, reference numeral 71 denotes a noise prevention capacitor for preventing noise generated by energization control of the ignition coil, which is arranged between the power supply line and the ground, and in this example, a case for accommodating the ignition circuit unit. It is located outside. For example, the noise prevention capacitor 71 is arranged at the ground point of the wiring (engine harness) in the engine room.

A resistor 72 provided between the ignition signal input terminal 34 and the base of the power transistor 39, and a resistor 72.
The capacitor 73 provided between the grounds forms a surge protection circuit. Resistors 74 and 76 and Zener diode 75
Forms an overcurrent limiting circuit of the ignition control system. Reference numeral 77 is a primary voltage limiting diode, and 78 is a diode that constitutes a protection circuit when a reverse current is applied.

As shown in FIGS. 1, 3 and 9, the lead terminals 32, 34 and 36 on the ignition circuit unit 40 side are made of a synthetic resin bonded to a box-shaped press-formed aluminum metal base 37. It is fixed on a terminal block 38 made of steel. Also, the above-mentioned terminals 18, 31, 19, 32, 33.
Since the joint portions of 34 and 35 and 36 are arranged in parallel in the same direction, welding is facilitated.

The ignition circuit unit 40 includes the resistor 7 described above.
2, a hybrid IC circuit 41 including a capacitor 73, a transistor 74, a Zener diode 75, a resistor 76, a Zener diode 77, and a diode 78, and a power transistor 39 are arranged in a metal base 37. Filled with silicon gel.

The circuit case (igniter case) 9 for accommodating the ignition circuit unit 40 is the connector terminal 3 described above.
It is molded integrally with the connector housing 9B that houses 1, 33, and 35.

The circuit case 9 as shown in FIGS.
The part that houses the ignition circuit unit 40 is the case side wall 9A.
And the ignition circuit unit 40 is shown in FIG.
Floor space (inside) of the space surrounded by the side wall 9A as shown in
It is mounted on 9E guided by positioning protrusion 9D. The center of the floor surface 9E is opened so as to face the opening surface on the coil course 6 side.

The circuit case 9 is formed separately from the coil case 6, and is joined to the upper end of the coil case 6 by fitting and bonding. In this combined state, as shown in FIG. 3, the projection 6A provided on the outer periphery of the upper portion of the coil case 6 engages with the concave groove 9F on the circuit case 9 side in a detented state.

The metal base 37 of the ignition circuit unit 40 housed in the circuit case 9 in the above-mentioned coupled state is arranged immediately above the head 2A of the secondary bobbin 2, and the circuit case 9 is also provided.
One end 31 ′ of the connector terminal 31 and one end of the lead terminal 32 are respectively provided on the secondary bobbin head 2A side.
The terminal 18 also serving as the secondary coil and the one end of the primary coil terminal 19 are set so as to overlap each other in the circuit case 9,
Care has been taken to facilitate the welding of these overlapping terminals. Further, when the ignition circuit unit 40 is set, the lead-out terminals 34 and 36 on the ignition circuit unit 40 side are also connected to the corresponding connector terminals 33 and 35, respectively.
It is naturally aligned.

The circuit case 9 has a flange 9C formed around the side wall 9A, and a screw hole 25 for attaching the ignition coil device 21 to the engine cover is provided in a part of the flange 9C. The inside of the circuit case 9 is covered with an insulating epoxy resin 43.

Next, the structures on the bottom side of the secondary bobbin 2 and the primary bobbin 4 will be described with reference to FIGS.

In FIG. 10, the primary bobbin 4 is replaced by the secondary bobbin 2.
The perspective view of the bottom part vicinity at the time of inserting the secondary coil 3 is shown. FIG. 11 shows a bottom view of the primary bobbin 4 and the secondary bobbin 2, and a bottom view of a state in which they are combined.

As shown in FIGS. 10 and 11, the secondary bobbin 2 is formed into a cylindrical shape with a closed bottom and a bottom, and a projection 2E for mounting the high voltage diode 10 is provided on the outer surface of the bottom. One end 3b of the secondary coil 3 is connected to a high voltage terminal 12 via a high voltage diode 10 and a leaf spring 11 as shown in FIG.

The bottom of the primary bobbin 4 is open, and when the secondary bobbin 2 is inserted into the primary bobbin 4, the high voltage diode 10 projects from the bottom opening 4'of the primary bobbin 4. In addition, a pair of secondary bobbin receivers 4D that oppose each other across the opening 4'on the bottom of the primary bobbin 4 are arranged so as to protrude below the bottom side flange (bottom one end surface) 4C of the primary bobbin 4. It is set up.

The secondary bobbin receiver 4D receives the secondary bobbin 2 via its flange 2B (the lowermost flange), and the opposite sides of the bobbin receivers 4D are straight and the remaining contours are arcuate. , A concave portion (groove portion 51) is provided in the radial direction from the center of the opposite side, and the convex portion 52 provided on the outer periphery of the bottom side of the secondary bobbin 2 engages with the secondary bobbin 2
And the primary bobbin 4 are prevented from rotating relative to each other.

The bottom flange 4C of the primary bobbin 4 is provided with a pair of downwardly directed projections 53. The projections 53 are provided on a part of the inner circumference of the coil case 6 as shown in FIG. The coil case 6 and the primary bobbin 4 are prevented from rotating relative to each other by engaging with the positioning groove 6B of the receiver 6A.

As shown in FIG. 11 (b), the bottom portion 2 of the secondary bobbin 2 has a cut surface 2G which is substantially circular but is slightly flat to the left and right. This cut surface 2G is shown in FIG. 11 (d). As shown in (), the secondary bobbin receiver 4D is fitted to the opposite side (straight line) and is located at the bottom opening 4'of the primary bobbin 4. Further, the convex portion 52 is provided at the position of the cut surface 2G.

The recess 51 formed in the secondary bobbin receiver 4D has a taper 51 'at its upper end as shown in FIG. 11 (c).
Is provided to widen the frontage of the recess 51, so that the secondary bobbin 2
Even if the convex portion 52 is slightly displaced from the concave portion 51 at the time of insertion, it is guided by the taper 51 'so that it can be easily inserted.

The secondary bobbin receiver 4D provided at the bottom of the primary bobbin 4 is disposed so as to face the bottom opening 4 ', and is projected downward from the bottom of the primary bobbin. It is possible to secure the side surface space 4 ″ without the next bobbin receiver 2D. Through this side surface space 4 ″, the insulating resin 8 ′ is provided as shown by an arrow P in FIG.
During injection, the gap between the inner and outer circumferences of the primary bobbin 4, the secondary bobbin 2 (secondary coil 3) and the coil case 6, the primary bobbin 4
(Primary coil 5) The resin flowability with the gap between the inner and outer circumferences is improved so that the bubbles in the injected insulating resin at the bottom of the primary bobbin 4 escape.

At the bottom of the secondary bobbin 2, the magnet 15 and the foam rubber 45 are arranged in a laminated manner, and the center core 1 is inserted therein. The magnet 15 and the magnet 16 provided on the secondary bobbin head 2A generate magnetic fluxes in opposite directions in the magnetic path (center core 1, side core 7), so that the ignition coil is kept below the saturation point of the magnetization curve of the core. It can be operated.

The foamed rubber 45 absorbs the difference in thermal expansion between the center core 1 and the secondary bobbin 2 due to temperature changes during the injection and use of the insulating resin 8 of the ignition coil device 21 (thermal stress relaxation).

At the lower end of the coil case 6, the spark plug 2
A cylindrical wall 6'for inserting 2 (see FIG. 5) is formed so as to surround the spring 13. The cylindrical wall 6'is integrally formed with the coil case 6, and the spark plug 22 is attached to the cylindrical wall 6 '.
A boot made of a flexible insulating material, for example, a rubber boot 14 is attached for insulating and mounting the boot.

FIG. 5 shows an ignition coil device 2 having the above structure.
1 shows a state in which 1 is mounted in the plug hole 23 of the engine.

The ignition coil device 21 has an engine cover 24.
Also, the rubber boot 14 is inserted into the plug hole 23 through the guide tube 23A, and the rubber boot 14 is brought into close contact with the periphery of the ignition plug 22. As a result, the ignition coil device 21 is directly connected to the ignition plug 22.
The ignition coil device 21 has a screw hole 2 provided in the circuit case 9.
5 (see FIG. 1) and the screw hole 26 provided in the engine cover 24 is tightened by the screw 27, and the seal rubber 28 provided on the upper part of the coil case 6 is provided at the periphery of the ignition coil device insertion hole 24 of the engine cover 24. It is fixed by fitting it to 29.

As shown in FIG. 1, a vertical groove 92 is provided on the inner surface of the seal rubber 28. When the seal rubber 28 is mounted together with the ignition coil device 21, the vertical groove 92 allows air in the flange of the seal rubber 28 (a portion fitted into the convex portion 29 on the engine cover side) to escape to facilitate the mounting work of the seal rubber 28. And the function of maintaining the atmospheric pressure by communicating the inside of the engine cover 24 with the atmosphere. If the groove 92 is not provided, the latter function will be in a negative pressure state when the inside of the engine cover, which is in a high temperature state due to engine heat, is suddenly cooled by water splashing on the engine cover, and as a result, the seal rubber 28 exists. However, since the negative pressure draws water accumulated around the seal rubber 28, it is for preventing such a negative pressure. The atmosphere intake port of the groove 92 has a pool water ( The vehicle is set at a position higher than the engine cover to some extent so that water that splashes on the road and invades water that adheres to the engine cover does not flow in.

Next, the ignition coil device 21 having the above structure
A procedure for manufacturing the will be described with reference to FIGS.

As shown in FIG. 13, first, the secondary coil 3 is wound around the secondary bobbin 2 and one end 3a of the secondary coil is connected to the primary / secondary coil combined terminal 18. This connection is made by winding one end 3a of the coil around the terminal 18 and soldering it. Further, the other end 3b of the secondary coil 3 is also a secondary coil terminal on the high voltage side (here, the high voltage diode 1
0). Then, the continuity test is performed.

The secondary bobbin 2 around which the secondary coil 3 is wound is inserted and fixed to the primary bobbin 4, and in this state (primary and secondary bobbin overlapped state), the primary coil 5 is wound around the primary bobbin 4 and , One end 5a of the primary coil is connected to the primary / secondary coil combined terminal 18, and the other end 5b of the primary coil is connected to the primary coil terminal 19. These connections are made by coil winding and soldering. In this case, even if the primary / secondary coil combined terminal 18 and the primary coil terminal 19 are provided on the secondary bobbin 2 side, the terminals 18 and 19 are located outside one end of the primary bobbin 4 together with the secondary bobbin head 2A. Therefore, both ends 5a and 5b of the primary coil 5 can be easily guided to the terminals 18 and 19 to perform the above-mentioned twisting and soldering work. Then, the continuity test of the primary coil is performed.

Next, after the leaf spring 11 (see FIG. 14) is connected to the lead terminal of the high voltage diode 10 so as to be connected to the high voltage diode 10, the foamed rubber 45, the magnet 15 and the center core 1 are placed in the secondary bobbin 2. , Magnet 1
6 is inserted, and then a soft epoxy resin is injected into the bobbin head 2A and cured.

Although a winding machine used in the winding process of the secondary coil 3 and the winding process of the primary coil 5 is not shown in the drawings, basically, the bobbin is set on the rotary shaft to set the bobbin. Although the enamel wire is wound by rotating it, various modes of application can be considered.

One is to equip one winding machine with an enamel wire reel for a primary coil and an enamel wire reel for a secondary coil, and draw out each enamel wire from these reels to surround the rotary shaft. It is conceivable that a single winding machine is equipped with a hand mechanism for performing reciprocating motions, turning motions, etc. necessary for winding and twisting, and performing winding of the primary coil and the secondary coil with one winding machine. According to the secondary bobbin structure used in the embodiment, the rotating shaft of the winding machine can be shared.

FIG. 15 shows the rotating mechanism of the above winding machine. The rotating mechanism is roughly divided into a rotating shaft 62 and a motor 61,
The rotating shaft 62 is detachably coupled to an output shaft 62 ′ (see FIG. 16) of the motor 61 via a joint (coupling) 63 that forms a part of the shaft 62, and the rotating shaft 62 is connected to the output shaft 62 ′. It has a joint structure that rotates together. Rotating shaft 62
Is formed into a split pin shape by cutting the slit 65 from its tip to a midway position of the shaft, and at least a part 62A of the split pin portion of the rotary shaft 62 of the secondary bobbin 2 is formed in a state before the secondary bobbin 2 is inserted. A taper 62B for expanding the inner diameter and guiding the secondary bobbin 2 is formed at the tip. Further, two bobbin positioning / rotation-preventing pins 64 that engage with the engaging portions 2D provided on the secondary bobbin head 2A are provided on a part of the rotary shaft 63 (here, one end surface of the joint 63). The engaging portion 2D on the secondary bobbin head 2A side is engaged between the pins 64.

When using the above-described common winding machine, as shown in FIGS. 15 (a) and 15 (b), first, the secondary bobbin 2 is attached to the rotary shaft 62 of the winding machine by the shaft taper 62B.
When you push it in using the split pin part 62A of the shaft 62
Is elastically deformed in the direction of decreasing the diameter, and the secondary bobbin 2 is inserted and set on the rotary shaft 62. At this time, the split pin portion 62A is pressed against the inner surface of the bobbin 2 by its elastic return force, and The engaging portion 2D provided on the head 2A engages between the rotation stopper pins 64 of the rotary shaft, so that both ends of the secondary bobbin 2 are firmly fixed on the rotary shaft 62.

Therefore, even if the secondary bobbin 2 is cantilevered by the rotating shaft 62 during the secondary winding and the secondary bobbin 2 is rotated at a high speed integrally with the rotating shaft 62, the secondary bobbin 2
It enables the winding of the secondary coil 3 which requires high precision precision winding without causing slippage or rotational shake.

After the winding of the secondary coil 3 and the winding of the end of the secondary coil to the coil terminal 18 (including soldering) are performed, the secondary bobbin is attached to the rotary shaft 62 as shown in FIG. 15C. The primary bobbin 4 is attached to the outer side of the secondary bobbin while the second bobbin 2 is attached, and the bobbins are prevented from rotating 52, 51 (see FIGS.
1)), and one end of the primary bobbin 4 (the side of the secondary bobbin on which the high-voltage diode 10 is located) is rotatably supported by a bobbin support tool (not shown), and the primary bobbin 4 is connected to the secondary bobbin 2. The primary coil 5 is wound around the primary bobbin 4 by rotating them together.

In addition to such a winding method, a winding machine for the secondary coil and a winding machine for the primary coil are separate, and only the rotary shaft 62 for winding is shown in FIG. It is also possible to make it detachable and share it with the primary winding machine and the secondary winding machine.

In this case, first, the rotary shaft 62 is attached to the winding machine (here, the motor of the secondary winding machine) in the same manner as in FIG. 15 (a), and the set form is the same as in FIG. 15 (b). The secondary bobbin 2 is inserted and set on the rotating shaft 62 via the head 2A thereof, and the secondary bobbin 2 is rotated together with the rotating shaft 62, whereby the secondary coil 3 is attached to the secondary bobbin 2.
Wrap around.

After that, the rotary shaft 62 is removed from the secondary winding machine with the secondary bobbin 2 attached (see FIG. 16), the rotary shaft 62 is attached to the primary winding machine, and the outside of the secondary bobbin 2 is attached. The primary bobbin 4 is shown in FIG.
(C) Similarly, the bobbins are fitted through the detents 51 and 52, the primary bobbin 4 is rotated together with the secondary bobbin 2, and the primary coil 5 is wound around the primary bobbin 4.

Further, instead of the above-described rotary shaft common system, the winding machine for the secondary coil and the winding machine for the primary coil are separate, and the rotary shafts for winding are prepared respectively.
It is also possible that the rotary shafts 62 are of the common type.

In this case, first, the secondary bobbin 2 is inserted and set on the rotary shaft 62 of the secondary winding machine via the head 2A (engaging portion 2D) of the secondary bobbin, and the secondary bobbin together with the rotary shaft 62 is set. The secondary coil 3 is wound around the secondary bobbin 2 by rotating 2. After that, the secondary bobbin 2 is removed from the secondary winding machine, inserted into the rotary shaft of the primary winding machine via the secondary bobbin head 2A (engagement portion 2D), and set to the outside of the secondary bobbin 2. The primary bobbin 4 is fitted through the detents 51 and 52 between the bobbins, and the primary bobbin 4 is rotated together with the secondary bobbin 2 to wind the primary coil 5 around the primary bobbin 4.

The coil assembly manufactured through the series of steps shown in FIG. 13 includes a coil case 6 and a circuit case 9 as shown in FIG.
It is inserted together with the ignition circuit unit 40. Here, as described above, the primary / secondary coil combined terminal 18 and the connector terminal 31, the primary coil terminal 19 and the lead terminal 32 on the ignition circuit unit side, the connector terminal 33 and the lead terminal 34 on the ignition circuit unit side, The connector terminal 35 and the lead terminal 36 are connected by projection welding.

Before inserting the above coil assembly into the coil case 6, the circuit case 9 and the coil case 6 are fitted and adhered to each other, and after the coil assembly is inserted, the side core 7 is press-fitted into the coil case 6 and The rubber boot 14 is press-fitted, and then the epoxy resin 43 is injected and cured.

The main actions and effects of this embodiment are as follows.

(1) Secondary coil 3 requiring precise winding
With regard to the above, the coil is wound in advance, and the primary bobbin 4 is fitted on the outside of the secondary bobbin 2 around which the secondary coil 3 is wound while ensuring the rotation prevention of the bobbins, and the primary bobbin 2 together with the secondary bobbin 2. 4 is rotated to move the primary coil 5 to the primary bobbin 4.
However, according to this method, the primary coil 5 does not need to be wound as precisely as the secondary coil 2, and the winding is easy, so there is no problem. Therefore, the coil winding work can be performed in the assembled (overlapping) state of the primary and secondary bobbins.

(2) As a result of enabling the winding work in such a bobbin assembly state, common use of the primary and secondary winding machines,
Alternatively, the rotary shafts of the primary and secondary winding machines can be shared, or the types of rotary shafts of the primary and secondary winding machines can be unified (shaft compatibility).

(3) Further, by providing the secondary bobbin 3 with the primary / secondary coil combined terminal 18 (), the primary terminal and the secondary terminal are provided with a crossover M as in the conventional case (see FIG. 6 (c)). There is no need to connect via the crossover, and the step of connecting the crossover M can be omitted. Further, as described above, by guaranteeing the primary winding in the assembled state of the bobbin, the primary coil 5 can be directly used on the secondary bobbin 2 side without temporarily fixing the primary coil 5 to the primary bobbin 4 for both primary and secondary coils. It can be connected to the terminal 18 and the primary coil terminal 19.

(4) The head 2A of the secondary bobbin 2 inserted in the primary bobbin 4 is moved from the primary bobbin 3 so that the primary / secondary coil combined terminal 18 and the primary coil terminal 19 are connected to the secondary bobbin. Even if it is installed in 2, the installation space can be sufficiently secured.

(5) When the circuit case 9 is joined to the upper end of the coil case 6 by fitting and bonding, one end 31 'of the connector terminal 31 and one end of the lead terminal 32 of the circuit case 9 are respectively on the secondary bobbin head 2A side. The terminals 18 and 19 for both the primary coil and the secondary coil, which are provided in the above, are set so as to overlap each other in the circuit case 9, and the overlapping terminals are easily welded to each other. Further, since the circuit unit 40 is accurately positioned via the positioning member 9D, the positioning with respect to the connector terminal 33 / lead terminal 34 on the circuit unit side and the connector terminal 34 / lead terminal 36 on the circuit unit side is also accurately performed. .
Therefore, no displacement occurs when the terminals are joined to each other, improving workability and quality.

(6) By securing the side surface space 4 ″ without the secondary bobbin receiver 2D at the bottom of the primary bobbin 4, the inner and outer circumferences of the primary bobbin 4 and the secondary bobbin 2 (secondary coil 3) when the insulating resin 8 is injected. Gap between coil case 6 and primary bobbin 4
(Primary coil 5) Improves resin flowability between the inner and outer peripheries of the inner and outer peripheries, improves air bubble removal in the injected insulating resin at the bottom of the primary bobbin 4, and improves the insulation performance of the ignition coil.

Next, a second embodiment of the present invention will be described with reference to FIGS.

FIG. 17 is a partial sectional view (sectional view taken along the line DD ′ of FIG. 18) of the ignition device according to the second embodiment. In the figure,
The same symbols as those used in the first embodiment indicate the same or common elements. FIG. 18 is a view of the ignition coil device of FIG. 17 as seen from above, showing the inside of the circuit case 9 in a state before resin filling. The sectional view taken along the line FF ′ of FIG. 17 is similar to that of FIG.

In this embodiment, the main differences from the first embodiment will be described.

Ignition noise prevention capacitor 71 in the present embodiment (hereinafter referred to as noise prevention capacitor 71)
Is installed in the circuit case 9. Therefore, the above-described metal fittings of the connector terminal (power supply connection connector terminal 31, ignition signal input connector terminal 33, ignition circuit ground terminal 3
In addition to 5), a metal fitting for a grounding connector terminal (capacitor ground terminal) 72 of the noise prevention capacitor 71 is added to be housed in the connector housing 9B, and between the connector terminal 72 and the power supply connection (+ power supply) connector terminal 31. A noise prevention capacitor 71 is connected to.

Ignition circuit unit 4 in circuit case 9
The noise-preventing capacitor 71 is installed in this accommodating space by expanding the space accommodating 0 in comparison with the first embodiment. The noise prevention capacitor 71 is installed on the floor of the case 9 near the buried position by burying the intermediate portions of the connector terminals 31 to 35 and 72 in the resin of the case 9.

In addition, a part of the terminal metal fitting is bent vertically (including almost vertical) at the intermediate portion of the power supply connector terminal 31 and one end of the capacitor ground terminal 72, and this bent portion ( The rising portion) 31c, 72 'is projected from the floor surface of the case 9 to prevent noise
It is placed on both sides of. Noise prevention capacitor 7
Both lead wires 73 of No. 1 are connected to the bent portions 31c and 72 ', respectively. In this example, the lead wire 73 of the capacitor 71 is bent and soldered to the terminal bent portions 31c and 72 '(see FIG. 23).

Here, one end (barbed portion) 73 'of the lead wire 73 is formed into a ring shape before being connected to the terminals 31 and 72, and this ring 73' is bent into the terminal bent portions 31c and 72 '.
It has a shape that can be fitted from above. 9K shown in FIG.
Is a protrusion provided on the floor surface (inner bottom) 9E of the case 9, and is formed so as to vertically project from the floor surface 9K adjacent to the terminal bent portions 31c and 72 '. One side of the projection 9K is molded so as to bite into the projection 9K, and the height of the projection 9K is the terminal bent portion 31c.
Therefore, when the lead wire end 73 ′ having the above-mentioned ring shape is fitted from the upper ends of the terminal bent portions 31c and 72 ′ and lowered, the lead wire end 73 ′ is at an intermediate position. It hits the upper end of the protrusion 9K and is prevented from descending further. In this way, the lead wire 73 and thus the noise prevention capacitor 71 are positioned in the height direction.

Further, 9J is a noise prevention capacitor 71
The two projections for lateral positioning are formed by protruding from the floor surface 9E of the circuit case 9.

Further, as shown in FIG. 24, the terminal bent portion 3
Slits 80 are formed in 1c and 72 'to form the capacitor 7
The first lead wire 73 may be sandwiched between the slits 80 and soldered. According to these lead wire connections, the lead wires can be easily fixed during soldering and workability can be improved.

By providing the noise prevention capacitor 72 as described above, the configuration of the ignition circuit 41 in the circuit case 9 is as shown in FIG.

By incorporating the noise prevention capacitor 71 in the circuit case 9 as described above, the following actions and effects are obtained as compared with the conventional case.

(1) In the conventional method, the noise prevention capacitor 71 is installed at the power source ground point in the harness of the engine room separately from the ignition coil device (pencil coil) 21, but according to such an installation method, ignition is performed. Since the noise of the coil rides on the harness between the ignition coil device and the capacitor 71, it leaks to the outside of the ignition coil device. On the other hand, in the case of the method of the present invention, the distance from the noise source of the ignition coil to the capacitor 71 is extremely short, and the noise prevention capacitor 71 is of the circuit case 9 internal type, so that the ignition coil device 21 is ignited outside. Prevents noise from leaking and improves noise prevention performance.

(2) In the conventional method, the noise prevention capacitor 71 is provided in the harness in the engine room. Therefore, if the capacitor 71 is installed naked, there is a risk that it will be corroded by water, salt, etc. that enter the engine room. Must be covered with resin, resulting in high cost. On the other hand, in the case of the method of the present invention, the encapsulation of the insulating resin 43 in the circuit case 9 also serves as the resin sealing of the capacitor 71. It is not necessary to do so, and the cost of the capacitor 71 can be reduced accordingly.

(3) In the conventional method, since the noise prevention capacitor 71 is provided in the harness in the engine room, the number of man-hours of the harness in the engine room increases, but in the case of the present invention, the noise prevention capacitor on such a harness is provided. 7
(1) Installation work is unnecessary, and if the ignition coil device 21 is installed in the engine room, the noise prevention capacitor 71 is automatically installed.
Since it is also installed, it is possible to reduce the burden of component mounting work in the engine room during automobile assembly.

In this embodiment, the secondary bobbin head 2
The shape of A is a cylindrical shape as shown in FIGS. 19 and 20, and the engaging portion 2D 'that engages with the detent of the winding machine.
Is composed of a pair of protrusions arranged in parallel. The detent on the winding machine side is in the form of a single pin (not shown) sandwiched between the pair of projection pieces.

Most of the spring 13 in the ignition coil device 21 is connected to the high-voltage terminal 12 at one end (upper end) of the spring 13 by entering the one end cylindrical wall 6 ′ of the coil case 6. Spring 13
The lower end (one end on the side opposite to the high-voltage terminal 12) of the coil case 6 is exposed to the outside of the lower end of the coil case 6 at least before being connected to the ignition plug 22. Therefore, the length of the one-end cylindrical wall 6'of the coil case 6 is made relatively shorter than that of the spring 13 as compared with that of the first embodiment (FIG. 1).

According to this mode, the spark plug 22
Is substantially not coupled (connected) to the lower end of the spring 13 in the coil case one end cylindrical wall 6 ′ (this point, in the first embodiment, the substantially upper half of the ignition plug 22 is the coil case one end cylindrical wall 6). ′) And is connected to the lower end of the spring 13), and the spring 13 at a position substantially at the same level as the lower end opening of the cylindrical wall 6 ′ or a position lower than that (a position outside the cylindrical wall 6 ′). Will be combined with the bottom edge of. for that reason,
Regarding the rubber boot 14, in order to compensate for the shortening of the tubular wall 6 ', the lower side of the lower end of the tubular wall 6'is made longer than the type of the first embodiment, and the rubber boot 14 is set to the spark plug 22.
And a substantially sealing connection can be made at a position below the cylindrical wall 6 '.

According to the above structure, even if there is a relative inclination θ between the axes of the ignition plug 22 and the ignition coil device 21, as shown in FIG. ′, The flexibility of the rubber boot 14 is utilized to make use of the ignition coil device 21 and the ignition plug 22.
And can be flexibly seal-coupled.

According to this embodiment, as shown in FIG. 22, even when the ignition plug 22 and the plug hole 23B are installed at an angle θ in the engine, the ignition coil device 21 is installed in the ignition plug 22. It can be guided into the guide tube 21 and the plug hole 23 without being aligned with the axis to be coupled with the spark plug 22. In particular, the spark plug 22 and the ignition coil device 21 are inclined with an inclination θ due to the restriction of the installation space of automobile parts. When they have to be combined, it can be realized without any change from the conventional pencil coil mounting operation.

The conventional ignition coil device (pencil coil) of this type is of a type in which the spark plug and the axis are aligned with each other and coupled, and as described above,
However, no consideration was given to connecting the ignition coil device at an angle.

The rubber boot 14 has a function of preventing the following creeping discharge. That is, when the ignition coil device 21 is set in the plug hole 23B, the high-voltage terminal 12 of the ignition coil device 21 is located near the plug hole 23B, but since the plug hole 23B is grounded, one of the cylindrical walls 6'is If a crack or the like occurs in the portion, creeping discharge may occur via the cylindrical wall 6 ′ between the high voltage terminal 12 and the plug hole 23B and the crack. When the rubber boot 14 is attached to the cylinder wall 6 ', the contact distance L between the cylinder wall 6'and the rubber boot 14 is substantially added to the distance between the high voltage terminal 12 and the plug hole 23B, so that the contact distance L is kept long. Therefore, the creeping discharge can be prevented. In this embodiment, the distance from the position of the high voltage terminal 12 to the lowermost end of the coil case cylinder wall 6'of the lower end cylinder wall 6'of the coil case is shortened, so that the coil case cylinder wall 6'of the rubber boot 14 is shortened. The portion that contacts the outside of the cylinder wall 6'is extended from the lowermost end of the cylindrical wall 6'to the vicinity of the center core 7 to secure a distance for preventing the above-described creeping discharge. In other words, the rubber boot 14 extends the part of the fitting portion of the cylindrical wall 6 ′ facing the outer surface of the cylindrical wall 6 ′ longer than the part facing the inner surface of the cylindrical wall 6 ′ to ensure a long total creeping discharge prevention distance. ing.

In this embodiment, as described above, the spring 1
In order to extend the lower end of the coil 3 below the lower end opening of the coil case 6, the method is to shorten the cylindrical wall 6 ′ under the coil case 6 as described above.
Even if the axial length of the high voltage terminal 12 housed in the coil case is extended to near the lower end opening position of the coil case 6 (in other words, from the portion of the high voltage terminal 12 that receives the spring 13 to the coil case 6). To the position where the length of the spring 13 is longer than the distance to the bottom end of the high voltage terminal 12
Is extended downward), the lower end of the spring 13 can be exposed to the outside (lower side) of the lower end opening of the coil case 6. By adjusting the amount (length) of the spring 13 that comes out of the lower end opening of the coil case 6 by adjusting the length of the high-voltage terminal 12, the ignition coil device 21 is adjusted to correspond to the relative inclination θ of the ignition plug 22. It can be combined with a spark plug (coupling through the flexible boot 14) as appropriate.

In the present embodiment, as shown in FIG. 22, an O-ring 91 is fitted in an annular groove 90 provided on the lower surface of the circuit case 9, and the surface of the engine cover 24 is maintained through the O-ring 91 while maintaining the sealing performance. The ignition coil device 21 is directly installed in the.

A recess 95 is provided in the circuit case 9 to reduce the substantial thickness of the circuit case 9 to prevent sink marks during resin molding.

Also in this embodiment, the same operation and effect as those of the first embodiment can be obtained.

Further, the arrangement configuration of the noise prevention capacitor 71 (circuit case interior type) and the shape and structure of the rubber boot 14 are also applied to the ignition coil device having the arrangement structure of the primary coil inside and the secondary coil outside. It is possible.

[0139]

As described above, according to the present invention, the coil winding work can be performed in a state where the so-called primary bobbin and secondary bobbin are superposed, and the primary and secondary coil winding machines can be commonly used or By sharing the rotary shaft or unifying the model of the rotary shaft, and by eliminating the work of connecting the crossover wire between the primary and secondary coils and the work of temporarily fixing the coil, which has been used in the past, The manufacturing process can be streamlined and productivity can be improved compared to the winding process and the primary / secondary coil assembly process.

[Brief description of drawings]

FIG. 1 is a vertical cross-sectional view (cross-sectional view taken along the line BB ′ of FIG. 3) of an ignition coil device according to a first embodiment of the present invention, and an enlarged cross-sectional view of an E part of the same.

FIG. 2 is a sectional view taken along the line AA ′ of FIG.

FIG. 3 is a view of the ignition coil device of FIG. 1 seen from above, showing the inside of the circuit case in a state before resin filling.

FIG. 4 is an ignition circuit diagram used in the first embodiment.

FIG. 5 is an explanatory diagram showing a state in which the ignition coil device according to the present embodiment is attached to the engine.

FIG. 6A is a circuit diagram showing the principle of an ignition coil device, and FIG.
Is an explanatory view showing the manufacturing principle of the ignition coil according to the present invention,
(C) is explanatory drawing which shows the manufacturing principle of the conventional ignition coil.

FIG. 7 is a partial perspective view of a secondary bobbin used in the first embodiment.

FIG. 8 is a partial perspective view showing a state of a combination of a primary bobbin and a secondary bobbin used in the first embodiment.

FIG. 9 is an explanatory diagram showing a positional relationship between an ignition coil assembly and a circuit unit used in the first embodiment.

FIG. 10 is a partial perspective view showing a state in which the secondary bobbin of the first embodiment is inserted into the primary bobbin.

FIG. 11A is a bottom view of the primary bobbin of the first embodiment,
(B) is a bottom view of the secondary bobbin, (c) is the above (a)
6 is a cross-sectional view taken along the line CC ′ of FIG. 3, (d) is a bottom view showing a state in which the primary bobbin and the secondary bobbin are assembled.

FIG. 12 is a sectional view of a coil case used in the first embodiment.

FIG. 13 is an explanatory view showing a manufacturing process of the ignition coil device.

FIG. 14 is an explanatory view showing a manufacturing example of the ignition coil device.

FIG. 15 is an explanatory diagram showing a mounting example of a rotating shaft of a winding machine, a primary bobbin, and a secondary bobbin.

FIG. 16 is an explanatory view showing a state in which the rotary shaft in the state where the secondary bobbin is inserted is removed from the motor of the winding machine.

FIG. 17 is a cross-sectional view of a main part of an ignition coil device according to a second embodiment of the present invention (cross-sectional view taken along the line DD ′ in FIG. 18).

FIG. 18 is a view of the ignition coil device of FIG. 17 seen from above, showing the inside of the circuit case in a state before resin filling.

FIG. 19 is a partial perspective view of a secondary bobbin used in the second embodiment.

FIG. 20 is a partial perspective view showing a state of a combination of a primary bobbin and a secondary bobbin used in the second embodiment.

FIG. 21 is an ignition circuit diagram used in the second embodiment.

FIG. 22 is an explanatory view showing a mounted state of the ignition coil device of the second embodiment.

FIG. 23 is an explanatory view showing a mounting state of the noise prevention capacitor used in the second embodiment.

FIG. 24 is an explanatory view showing a mounting state of the noise prevention capacitor used in the second embodiment.

FIG. 25 is an explanatory view showing an example of manufacturing a conventional ignition coil.

[Explanation of symbols]

1 ... Center core, 2 ... Secondary bobbin, 2A ... Secondary bobbin head, 3 ... Secondary coil, 4 ... Primary coil, 5 ... Primary coil, 6 ... Coil case, 7 ... Center core, 8 ... Insulating resin, 9 … Circuit case, 9B… Connector housing, 1
8 ... Primary / secondary coil combined terminal, 19 ... Primary coil terminal, 31, 33, 33 ... Connector terminal, 32, 34, 3
6 ... Lead-out terminal (lead terminal), 37 ... Metal base, 3
9 ... Ignition control drive element, 40 ... Ignition circuit unit, 41
... ignition circuit (hybrid IC), 62 ... rotating shaft, 71 ... capacitor for preventing ignition noise.

─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Yoichi Azo 2520 Takaba, Hitachinaka City, Ibaraki Prefecture Hitachi, Ltd. Automotive Equipment Division (72) Inventor Eiichiro Kondo 2477 Takaba, Hitachinaka City, Ibaraki Hitachi Ltd. Car Engineering (72) Inventor Takahide Kozai 2477 Takaba, Hitachinaka City, Ibaraki Hitachi Car Engineering Co., Ltd. (72) Inventor Toshiaki Ueda 2520 Takaba, Hitachinaka City, Ibaraki Hitachi Ltd. Automotive Equipment Division (72) Inventor Noboru Sugiura 2520, Takaba, Hitachinaka City, Ibaraki Prefecture, Hitachi, Ltd., Automotive Equipment Division (72) Inventor, Kazutoshi Kobayashi 2520, Takanaka, Hitachinaka City, Ibaraki Hitachi, Ltd., Automotive Equipment Division (56) References HEI 8-144916 (JP, A) JP HEI 9-17662 (JP, A) Actually developed 64-26818 (JP, U) (58) Fields investigated (Int.Cl. ⁷ , DB name) H01F 38 / 12 F02P 15/00 301

Claims (10)

(57) [Claims] 1. An ignition coil device comprising a coil case, a center core, a primary coil wound on a primary bobbin, and a secondary coil wound on a secondary bobbin. The ignition coil device is mounted in each ignition plug hole of an engine and individually mounted. In the ignition coil device for an independent ignition type engine that is directly connected to the spark plug of, the secondary bobbin wound with the secondary coil is arranged inside the primary bobbin, and the bobbins of the two bobbins are A relative detent is provided so that the head of the secondary bobbin is located above the upper end of the primary bobbin, and the secondary bobbin head rotates when the secondary bobbin is set on the rotating shaft of the winding machine. An ignition coil device for an engine, comprising: an engaging portion that engages with a bobbin detent provided on a shaft side. 2. An ignition coil device comprising a coil case, a center core, a primary coil wound on a primary bobbin, and a secondary coil wound on a secondary bobbin. The ignition coil device is mounted in each ignition plug hole of an engine and individually mounted. In the ignition coil device for an independent ignition type engine that is directly connected to the spark plug of, the secondary bobbin wound with the secondary coil is arranged inside the primary bobbin, and the bobbins of the two bobbins are A relative detent is provided so that the head of the secondary bobbin is located above the upper end of the primary bobbin, and one end of the primary coil and one end of the secondary coil are connected to a power source on the secondary bobbin head. A coil terminal for both primary and secondary coils, and a primary coil terminal for connecting the other end of the primary coil to a drive element for ignition control are provided. The de, engine ignition coil device, characterized in that the engagement portion to be engaged is provided on the bobbin detent provided on the rotary shaft side when set to a rotation shaft of the winder secondary bobbin. 3. A circuit case containing an ignition control drive circuit and having a power supply and a connector terminal for inputting an ignition signal is molded separately from the coil case, and the circuit case is fitted to an upper end of the coil case. The metal base of the drive circuit housed in the circuit case in this bonded state is directly above the head of the secondary bobbin, and one end of the connector terminal of the circuit case and the withdrawal of the drive circuit. Each one end of the terminal is set so as to overlap with the primary / secondary coil coil terminal and the primary coil terminal provided in the secondary bobbin head in the circuit case, and these overlapping terminals are welded to each other. Item 2. The engine ignition coil device according to item 2 . 4. The engine according to claim 2 or 3 , wherein the coil terminal for both primary and secondary coils comprises a terminal metal piece and a primary coil and a secondary coil. Ignition coil device. 5. The secondary bobbin has a bottomed cylindrical shape, a bottom side thereof is provided with a high-voltage diode connected to one end of the secondary coil on the high-voltage side, and a convex portion for alignment is provided on an outer periphery near the bottom portion. On the other hand, the bottom of the primary bobbin is opened, the high voltage diode is projected through the opening from the bottom of the primary bobbin to be connected to the high voltage terminal in the coil case, and the opening is formed in the bottom of the primary bobbin. A pair of secondary bobbin receivers facing each other in a sandwiched manner are provided so as to project downward from the bottom portion of the primary bobbin, and the secondary bobbin receiver is provided with a concave portion that engages with the convex portion. The ignition coil device for an engine according to any one of claims 1 to 4 , wherein the primary bobbin and the secondary bobbin are prevented from rotating relative to each other by engagement. 6. A circuit case for accommodating an ignition control drive circuit and having a power supply and a connector terminal for inputting an ignition signal is disposed above the coil case, and the circuit case is electrically connected to the ignition control drive circuit. claim a connected ignition noise prevention capacitor sealed in 1 to claim 5
The ignition coil device for an engine according to any one of items 1. 7. An ignition coil device comprising a coil case, a center core, a primary coil wound on a primary bobbin, and a secondary coil wound on a secondary bobbin. The ignition coil device is mounted in each ignition plug hole of an engine and is individually mounted. In the method for manufacturing an ignition coil device for an independent ignition type engine, which is directly connected to the spark plug, the outer diameter of the secondary bobbin is smaller than the inner diameter of the primary bobbin so that the secondary bobbin is inserted inside the primary bobbin. The bobbin is provided with a relative detent between the bobbins, and the secondary bobbin side has a primary / secondary coil combined terminal that serves as a power supply input terminal, and the primary coil serves as a drive element for ignition control. A primary coil terminal for connection is provided, and the secondary bobbin is rotated to wind the secondary coil around the secondary bobbin, and one end of the secondary coil is used as the primary / secondary coil combined end. A secondary coil winding step of connecting to the child, and then, the primary bobbin is fitted on the outside of the secondary bobbin and rotated together with the secondary bobbin to wind the primary coil around the primary bobbin, and one end of the primary coil is attached to the primary coil. A primary coil winding step of connecting to a terminal that also serves as a secondary coil and connecting the other end of the primary coil to the primary coil terminal. 8. An ignition coil device comprising a coil case, a center core, a primary coil wound on a primary bobbin, and a secondary coil wound on a secondary bobbin. The ignition coil device is mounted in each ignition plug hole of an engine and individually mounted. In the method for manufacturing an ignition coil device for an independent ignition type engine, which is directly connected to an ignition plug, the outer diameter of the secondary bobbin is smaller than the inner diameter of the primary bobbin so that the secondary bobbin is inserted inside the primary bobbin. In addition, the both bobbins are provided with relative detents between the bobbins, and the secondary bobbin is provided with a bobbin head that is located above the upper end of the primary bobbin. When the bobbin is set on the rotating shaft of the winding machine, an engaging portion that engages with the bobbin detent provided on the rotating shaft side is provided, and the winding work of the secondary coil and the primary coil is performed. The winding machine is shared so that it is performed by one winding machine. First, the secondary bobbin is inserted and set on the rotary shaft of the winding machine through its head, and the secondary bobbin is set together with the rotary shaft. And a secondary coil winding step of winding a secondary coil around the secondary bobbin by rotating the secondary bobbin, and thereafter, while the secondary bobbin is attached to the winding machine, the primary bobbin between the bobbins is attached to the outside of the secondary bobbin. And a primary coil winding step of winding the primary coil around the primary bobbin by rotating the primary bobbin together with the secondary bobbin. . 9. An ignition coil device comprising a coil case, a center core, a primary coil wound on a primary bobbin, and a secondary coil wound on a secondary bobbin. The ignition coil device is mounted in each ignition plug hole of an engine and individually mounted. In the method for manufacturing an ignition coil device for an independent ignition type engine, which is directly connected to the spark plug, the outer diameter of the secondary bobbin is smaller than the inner diameter of the primary bobbin so that the secondary bobbin is inserted inside the primary bobbin. In addition, the both bobbins are provided with relative detents between the bobbins, and the secondary bobbin is provided with a bobbin head that is positioned above the upper end of the primary bobbin, and the bobbin head has a secondary An engaging portion that engages with a bobbin detent provided on the rotating shaft side when the bobbin is set on the rotating shaft of the winding machine is provided, and the winding machine for the secondary coil and the primary coil are provided. This is a separate winding machine, and the rotating shaft for winding is made detachable and shared by the primary winding machine and the secondary winding machine. First, the rotating shaft is attached to the secondary winding machine and A secondary coil winding step of winding the secondary coil around the secondary bobbin by inserting and setting the secondary bobbin through the head on the shaft, and rotating the secondary bobbin together with the rotating shaft; With the secondary bobbin still attached, the rotary shaft is removed from the secondary winding machine, the rotary shaft is attached to the primary winding machine, and the primary bobbin is attached to the outside of the secondary bobbin via a detent between the bobbins. And a primary coil winding step of winding the primary coil around the primary bobbin by rotating the primary bobbin together with the secondary bobbin. 10. An ignition coil device comprising a coil case, a center core, a primary coil wound on a primary bobbin, and a secondary coil wound on a secondary bobbin. The ignition coil device is mounted in each ignition plug hole of an engine and individually mounted. In the method for manufacturing an ignition coil device for an independent ignition type engine, which is directly connected to the spark plug, the outer diameter of the secondary bobbin is smaller than the inner diameter of the primary bobbin so that the secondary bobbin is inserted inside the primary bobbin. In addition, the both bobbins are provided with relative detents between the bobbins, and the secondary bobbin is provided with a bobbin head that is positioned above the upper end of the primary bobbin, and the bobbin head has a secondary An engaging portion that engages with a bobbin detent provided on the rotating shaft side when the bobbin is set on the rotating shaft of the winding machine is provided, and the winding machine of the secondary coil and the primary coil are provided. And a rotary shaft for winding, which is a separate type from the winding machine of the secondary winding machine, first has the secondary bobbin inserted into the rotary shaft of the secondary winding machine through its head, and then set. A secondary coil winding step of winding a secondary coil around the secondary bobbin by rotating the secondary bobbin together with the shaft; and thereafter, removing the secondary bobbin from the secondary winding machine, The secondary bobbin is inserted and set on the rotary shaft of the machine through the secondary bobbin head, and the primary bobbin is fitted to the outside of the secondary bobbin through the rotation stopper between the bobbins, and the primary bobbin is rotated together with the secondary bobbin. A primary coil winding step of winding a primary coil around the primary bobbin, the method for manufacturing an ignition coil device for an engine.