Ford Motor Company Limited

Steven E Pritz

Robert L Hancock

Robert C Bauman

Shawn J Nowlan

James P Morris

Philip C Chapekis

An ignition coil having primary and secondary coils, the primary coil wound around a central core member and including a permanent magnet made of a magnetic material that is less than fully dense, and is interposed between one end of the central core member and one end of an outer core surrounding the primary and secondary coil assembly and assuring the elimination of any air gap between the iron core and the central core member. The ignition coil further having a common modular design for a slip-in fit into differing modular housing designs depending upon the number of cylinders in the engine.

Ignition coil

An ignition coil having annular primary and secondary coils, the primary coil wound around a central core member and including a permanent magnet made of a magnetic material that is less than fully dense, and is interposed between one end of the central core member and one end of a C-shaped iron core surrounding the primary and secondary coil assembly and assuring the elimination of any air gap between the C-shaped iron core and the central core member. Alternatively, the permanent magnet may be replaced with an electrically non-conductive shim of substantially equal dimension such that the energy output is substantially reduced and the charge/discharge interval substantially increased to thereby allow use of the same basic modularly constructed coil assembly for totally different ignition strategies.

An ignition coil having annular primary and secondary coils, the primary coil wound around a central core member and including a permanent magnet made of a magnetic material that is less than fully dense, and is interposed between one end of the central core member and one end of a C-shaped iron core surrounding the primary and secondary coil assembly and assuring the elimination of any air gap between the C-shaped iron core and the central core member.

A method of making a unitary spark distribution cassette involves molding a cassette and placing electrically conductive lead frames within the cassette during molding. Electrically conductive sleeves for fitting over spark plugs are also provided on the cassette. An ignition system circuit using high voltage diodes in conjunction with an alternating flux ignition coil is placed in the cassette and connected to the lead frames and the sleeves to create a complete electrical circuit. The cassette is then filled with epoxy resin to encase the electrical components to form a unitary package.

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Westland, MI, United States of America

Steven E Pritz