Gm Global Technolgoy Operations, Inc.

Roger W Kellams

Ronnalee House

Albert Anthony Skinner

Jose A Cruz

An ignition coil for developing spark plug firing voltages. The magnetic current for the coil comprises an axially extending core that joins axially spaced annular parts. The core and parts can be formed of iron particles in a binder of electrical insulating material. A primary winding is disposed about the core and a secondary winding is disposed about the primary winding. An axially extending circular part that is formed of magnetic material is positioned to provide air gaps with outer surfaces of said annular parts. The circular part forms a shield that increases the capacitance of the secondary winding. The total stored magnetic energy does not vary substantially with variations in air gap length. The cross-sectional area A of the air gap is large as compared to the length L of the air gap so that the ratio A/L does not vary much with variations in L.

Ignition coil

An overmolded electrical connector in which a flexible spring finger contact is encased in a rigid plastic material in such a manner that the spring finger is not restrained from flexing by the rigid plastic material. The connector comprises an assembly that includes a terminal block, a cover and a terminal that has the flexible spring finger. The terminal is assembled to the terminal block such that the spring finger is located in a cavity in the block. The cover is now attached to the block and the assembly is overmolded by injection molding apparatus. The cover and block have a cooperating tongue and groove to prevent molding material from entering the cavity that contains the spring finger. The cover has crush ribs that engage a tab portion of the terminal that extends from the cavity to a point exterior of the assembly.

Overmolded electrical connector

A laminated core for an ignition coil is made from E shaped and bar shaped laminated members. The E shaped member has equal length outer legs and a shorter center leg with oblique surfaces on the inner free ends of the outer legs. The bar shaped member has oblique surfaces at the ends thereof adapted to engage the oblique surfaces of the first member when the second member is oriented perpendicularly to the center leg of the first member and further to bend the outer legs of the first member outward to generate a restoring spring force as the second member is advanced toward the center leg to reduce the air gap. A coil assembled on the center leg is used to monitor a physical parameter indicative of a desired magnetic or electrical characteristic as the air gap is reduced and the members are fixed together when said characteristic is obtained. The angles formed by the oblique surfaces of the first member with a surface of the center leg are smaller before assembly and no greater after assembly than corresponding angles of the corresponding oblique surfaces of the second member.

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Anderson, IN, United States of America

Roger W Kellams