JPH0945571A - Method of manufacturing secondary coil of ignition coil unit for internal combustion engine - Google Patents

Abstract

PROBLEM TO BE SOLVED: To enhance the productivity of a secondary coil by leaving an extension piece of a connecting member to lie along the side face of a secondary bobbin at winding, coupling the winding end of a secondary wire to the base of the extension piece and bending the piece to lie along the side face of the secondary coil after fishing the winding. SOLUTION: Connecting members 15 are each composed of a U-shaped base 16 and extension piece 17 extending from one leg 16a of the base. The base 16 is inserted into a hole 14 to fix the member 15 with the other leg 16b of the base shortly protruded from the hole 14. In this condition, a secondary bobbin is set on a winder, which then winds a winding start end 2a of a secondary wire is wound round one end of the leg of a coupling member 9 to separately wind the wire between flanges of the bobbin and the winding end 2b is wound round the leg 16b of the base of the connecting member to form a secondary coil. The coil is removed from the winder, the piece 17 is bent at right angles to lie along the side face of the coil, thus allowing the work of winding round the base of the connecting member to be automated by machines.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an ignition coil for supplying a high voltage to a spark plug of an internal combustion engine such as an engine of an automobile to generate a spark discharge, and particularly to a high-voltage end of a secondary coil. The present invention relates to a method of manufacturing a secondary coil that simplifies the assembly of a connecting member that is electrically connected to a terminal or a spark plug.

[0002]

2. Description of the Related Art As shown in FIG. 3, a high voltage tower 4 having a high voltage terminal 5 therein projects upward from an opening 3'of an insulating case 3 which integrally projects from a side surface thereof. And the base 7 with the winding end of the secondary wire bent at a right angle
Attached to the secondary coil and extending along the side surface of the secondary coil 6
The secondary coil 2 provided with is concentrically housed in the vertical direction, the tip of the connecting member is electrically connected to the high-voltage terminal 5 in the high-voltage tower, and the insulating resin is cast in the insulating case. A mold type ignition coil in which the primary coil and the secondary coil are fixed in a cured insulating resin layer 8 is conventionally known.

[0003]

In the case of the secondary coil of the ignition coil described above, if a connecting member having a base fixed to the collar of the secondary bobbin is provided along the side surface of the bobbin, the secondary member is obstructed by the connecting member. It is not possible to wind the wire around the secondary bobbin. Therefore, conventionally, the secondary bobbin 10 is provided with a collar 11 at one end.
A connecting member 9 for winding the winding start end of the next electric wire is attached, and a winding portion 13 for winding the winding end end is provided on the other end of the collar 12 to set the secondary bobbin to the winding machine. The winding start end 2a of the electric wire is wound around the connecting member, the secondary electric wire is wound around the secondary bobbin by the winding machine, and the winding end end 2b is wound around the winding portion 13 to wind the secondary coil. After removing from the machine, as shown in FIG. 4, the base of the connecting member 6 whose base 7 is bent at a right angle is fixed to the collar at the other end of the secondary bobbin so that the connecting member extends along the side surface of the secondary coil. It was However, with this, the work of fixing the base portion 7 of the connecting member to the collar 12 at the other end of the secondary bobbin,
And the end portion 2 of the secondary wire wound around the winding portion
The rewinding work of removing b from the winding part 13 and winding it around the base part 7 of the connecting member 6 cannot be automated by a machine, so it has to be done manually, which is very troublesome and hinders productivity. .

[0004]

The present invention was developed in order to solve the above problems, and a connecting member for connecting a winding start end of a secondary wire is attached to one end of a secondary bobbin.
A base portion for connecting the winding end portions of the secondary electric wire, and 2 from the base portion.
A connecting member, which extends along the side surface of the next bobbin and is composed of an extension piece connected to the high-voltage terminal or the spark plug at the tip, is formed by the base portion without the extension piece along the side surface of the secondary bobbin. Attached to the other end of the bobbin, the winding start end of the secondary electric wire is connected to the connecting member, the secondary electric wire is wound on the secondary bobbin, and the winding end end is connected to the base of the connecting member. It is characterized in that the wire is finished and then the extension piece of the connecting member is bent to extend along the side surface of the secondary coil.

[0005]

1 shows a first embodiment of the present invention, and FIG. 2 shows a second embodiment of the present invention. The same components as those in FIGS. 3 and 4 are designated by the same reference numerals. In each embodiment,
The secondary bobbin 10 is for split winding having a large number of flanges in the axial direction, and a connecting member 9 formed by bending a metal wire into a U-shape is provided on the flange 11 at one end thereof so that both ends of the connecting bobbin 9 are outside when forming the bobbin. It is taken out and fixed integrally by insert molding. The end of one leg of the connecting member is for winding the winding end end of the primary coil, and the other leg is for winding the winding start end 2a of the secondary wire. is there. The collar 12 at the other end of the secondary bobbin is formed with a slot 14 into which the base of the connecting member is inserted and fixed.

The connecting member 15 of the first embodiment is shown in FIG.
As shown in (A), a U-shaped base portion 16 and an extension piece 17 in which one leg 16a of the base portion is extended,
The base member 16 is inserted into the slot 14 to form a connecting member as shown in FIG.
It is fixed as shown in (B), and the other leg 16b of the base is made to project out of the slot shortly.

In this state, the secondary bobbin is set in the winding machine, the winding start end 2a of the secondary wire is wound around one end of the leg of the connecting member 9, and the secondary wire is placed between the collars of the bobbin. After the divided winding, the winding end portion 2b is wound around the leg 16b at the base of the connecting member to form a secondary coil. Then, after removing the secondary coil from the winding machine, the extension piece 17 is bent at a right angle as shown by an arrow in FIG.
(D) product.

The connecting member 15 of the second embodiment is shown in FIG.
As shown in (A), it is composed of a U-shaped base portion 16 and an extension piece 17 which is bent in a right angle from one leg 16a of the base portion in the same plane as the base portion, and the base portion 16 is inserted into the slot 14. Then, the connecting member is fixed as shown in FIG. 2 (B), and the other leg 16b of the base portion is projected to the outside of the slot for a short time.

In this state, the secondary bobbin is set in the winding machine, the winding start end 2a of the secondary wire is wound around one end of the leg of the connecting member 9, and the secondary wire is placed between the collars of the bobbin. After the divided winding, the winding end portion 2b is wound around the leg 16b at the base of the connecting member to form a secondary coil. Then, after removing the secondary coil from the winding machine, the extension piece 17 is bent at a right angle as shown by an arrow in FIG. Product.

In the illustrated embodiments, the tip of the connecting member is described as being connected to the high-voltage terminal held in the high-voltage tower, but it is an ignition coil attached to one of the cylinders of the engine. The high voltage tower may not have a high voltage terminal, and the high voltage tower may be directly fitted to the ignition plug of the engine and the tip of the connecting member may be brought into contact with the electrode of the ignition plug.

Further, the connecting member is formed of a phosphor bronze wire material having an appropriate elasticity, but it may be formed of a thin strip plate of the same metal.

[0012]

As is apparent from the above, according to the present invention, the extension piece of the connecting member which should be provided along the side surface of the secondary coil is provided along the side surface of the secondary bobbin so as not to interfere with the secondary wire during winding. The end of the secondary wire is connected to its base, and after the end of winding, the extension piece is bent so that it extends along the side surface of the secondary coil. A winding part for temporarily connecting the winding end end of the secondary wire is provided on the winding wire, or a connecting member is manually attached to the other end of the secondary bobbin after winding, and the winding of the secondary wire connected to the winding part is performed. There is no need to manually rewind the end end to the base of the connecting member, and the work of attaching the base of the connecting member to the other end of the secondary coil, the extension piece of the connecting member after winding the side surface of the secondary coil It is possible to mechanize the work to go along with, and to remarkably improve the productivity of the secondary coil.

[Brief description of drawings]

FIG. 1A is a perspective view of a secondary bobbin and a connection member according to the first embodiment in an exploded state, FIG. 1B is a perspective view of the same winding, and FIG. 1C is an extension piece after winding. FIG. 3D is an explanatory view of bending and setting it along the side surface of the secondary coil, and FIG.

FIG. 2A is a perspective view of a secondary bobbin and a connection member of the second embodiment in an exploded state, FIG. 2B is a perspective view of the same winding, and FIG. FIG. 3D is an explanatory view of bending and setting it along the side surface of the secondary coil, and FIG.

FIG. 3 is a cross-sectional view of an ignition coil having a high voltage terminal portion on a side surface of an insulating case.

FIG. 4 is a perspective view showing a mounting state of a conventional secondary coil connecting member.

[Explanation of symbols]

 2 Secondary coil 3 Insulation case 4 High-voltage tower 5 High-voltage terminal 9 Connecting member 10 Secondary bobbin 11 Collar at one end of the secondary bobbin 12 Collar at the other end of the secondary bobbin 14 Groove hole 15 Connection member 16 Base of connection member 17 Connection Extension piece of member

Claims (1)

[Claims] 1. A connecting member for connecting a winding start end of a secondary wire to one end of the secondary bobbin, a base connecting the winding end of the secondary wire, and a side surface of the secondary bobbin from the base. A connecting member that is formed along the side surface of the secondary bobbin and that has a connecting member that extends along the side surface of the secondary bobbin and that is connected to the high-voltage terminal or the extending piece that connects to the ignition plug at the tip end. Attached to the winding wire, the winding start end of the secondary wire is connected to the connecting member, the secondary wire is wound on the secondary bobbin, and the winding end is connected to the base of the connecting member to finish the winding. A method for manufacturing a secondary coil of an ignition coil for an internal combustion engine, comprising bending an extension piece of a connecting member so as to extend along a side surface of the secondary coil.