Gm Global Technolgoy Operations, Inc.

Ronnalee House

Roger W Kellams

Albert Anthony Skinner

Jose A Cruz

Ronald G Davis

John Delaplane

Byron W Johnson

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.

Method of making an ignition coil core

An elongated unitary arm of a rigid material is tiltably mounted upon a rotor supported for rotation about a central axis and is spring force tilted in a first direction. This assembly is located in such a manner that the arm may be placed in register with any one of the operating tabs of a plurality of electrical load switches so mounted and oriented that the operating tabs extend toward the central axis to define a circle. Upon being placed in register with a switch operating tab, the arm is tilted in the opposite direction by the action of a solenoid actuated plunger.

Switch actuator assembly

In an internal combustion engine ignition distributor, an ignition spark energy conductive circuit arranged for connection to the secondary winding of an ignition coil is so formed and positioned that it is substantially equally radially spaced from each of the distributor output circuits and an annular insulating rib rotated with the rotor is disposed within the space between the ignition spark energy conductive circuit and the distributor output circuits. The annular insulating rib supports and locates radial circumferentially spaced juxtaposed conductive inserts in spark gap relationship with both the ignition spark energy conductive circuit and successive ones of the distributor output circuits upon the rotation thereof.

Ignition distributor

An ignition distributor wherein a movable output electrical contact having at least two diametrically opposed tip portions is mounted upon the distributor rotor at a location at which it is revolved by the rotor through a circular path about the axis of the distributor shaft. As the movable electrical contact is revolved by the rotor, it is rotated about its axis through driving gearing and is so arranged that, as it is rotated by the driving gearing, each successive one of the tip portions is rotated into electrical circuit relationship with the next successive one of the distributor output terminals and the diametrically opposed tip portion is rotated into electrical circuit relationship with the distributor input terminal.

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Anderson, IN, United States of America

Ronnalee House