Visteon Global Technolgoies, Inc.

Ford Motor Company Limited

Alex William Widiger

William Douglas Walker

Todd Christopher Sexton

David Charles Stine

Richard William St John

Gregg Michael Stefansky

Rick S Burchett

Francis Martin Donahue

A magnetic core assembly for an ignition coil assembly allows unique exterior shapes to be formed by an outer insulation layer, while speeding up the manufacturing process. Generally, the magnetic core assembly comprises a core of ferromagnetic material and an overmold over the exterior of the core. The overmold generally comprises an insulating layer injection molded over the core. Various structures may be incorporated into the core assembly for injection molding, while a second insulative layer provides additional thermal and electrical insulation.

Pencil ignition coil

A pencil ignition coil assembly module () that has a frusto-conically tapered core () and encapsulation () surrounding the side of the core. Features () center the core to a bobbin. A retainer (A) captures the core within the bobbin.

Ignition coil core isolation

A pencil ignition coil assembly module ( ) that has a frusto-conically tapered core ( ) and encapsulation ( ) surrounding the side of the core. Features ( ) center the core to a bobbin . A retainer ( A) captures the core within the bobbin.

An ignition coil assembly of the type which is directly mounted onto an associated internal combustion engine spark plug. The coil assembly includes a spark plug boot section made of a highly elastic material with an inside cylindrical passageway. The inside passageway features ribs which engage a high voltage connection coil spring positioned in the passageway to make an electrical connection between the coil and spark plug high voltage terminals. The spring has a generally constant outside diameter outer section except its end segments have a reduced diameter where they contact the high voltage terminals. The passageway ribs retain the spring in position prior to its installation and after its removal from the associated spark plug.

Ignition coil assembly with spark plug connector

An ignition coil assembly module (,) that can be connected to and disconnected from an engine spark plug. The module elements are arranged as a succession of cylindrical layers about a central ferromagnetic core (,). From innermost to outermost, the succession is: a) a secondary bobbin (,), b) a secondary coil (,), c) a secondary encapsulant (,) encapsulating the secondary coil, d) a primary bobbin (,), e) a primary coil (,), f) an inner wall (,) of an environmental shield (,) encapsulating the primary coil, g) a ferromagnetic shell (,), and h) an outer wall (,) of the environmental shield encapsulating the shell. The primary bobbin forms a liquid container for holding secondary coil encapsulant. A terminal (,) extends through a transverse wall (,) of the primary bobbin for carrying secondary current from the secondary coil to another terminal (,) on the other side of the transverse wall that connects to a spark plug (,). The two terminals are connected together by a mechanical locking connection that keeps them together when the module is disconnected from the spark plug.

Pencil ignition coil assembly module

An ignition coil assembly module (40) that can be connected to and disconnected from an engine spark plug. The module elements are arranged as a succession of cylindrical layers about a central ferromagnetic core (46). From innermost to outermost, the succession is: a) a secondary bobbin (48), b) a secondary coil (58), c) a secondary encapsulant (194) encapsulating the secondary coil, d) a primary bobbin (50), e) a primary coil (56), f) an inner wall (181) of an environmental shield (42) encapsulating the primary coil, g) a ferromagnetic shell (52), and h) an outer wall (180) of the environmental shield encapsulating the shell. The primary bobbin forms a liquid container for holding secondary coil encapsulant. A terminal (100) extends through a transverse wall (71) of the primary bobbin for carrying secondary current from the secondary coil to another terminal (118) on the other side of the transverse wall that connects to a spark plug (80). The two terminals are connected together by a mechanical locking connection that keeps them together when the module is disconnected from the spark plug.

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Canton, MI, United States of America

Alex William Widiger