Delphi Technologies, Inc.

Viorel N Moga

Albert Anthony Skinner

Mark Albert Paul

Brian Dewayne Lively

Raymond O Butler, Jr

James Alva Boyer

James Patrick Henry

Norman H Bracken

Kenneth P Senseman

Andreas Aye

David D Jackson

Ronald M Eicher

Rick E Funkhouser

Paul G Knight

Antony V Hirudayaraj

Steve T Kowalke

Mark A Paul

Pedro Carreira

An electrical spring connection assembly electrically connects a conducting case, and a spark plug. The electrical spring connection assembly includes a base having a securing aperture for receiving the conducting case therein. The base fixedly secures the electrical spring connection assembly within the conducting case. The electrical spring connection assembly also includes a leaf spring portion that extends radially out from the base for receiving the spark plug therein. The leaf spring portion creates an engagement force the spark plug must overcome to be positioned within the electrical spring connection assembly. The electrical spring connection assembly also includes a beam spring portion extending out from the leaf spring portion. The beam spring portion creates a retention force to retain the spark plug within the electrical spring connection assembly. The retention force is greater than the engagement force.

High retention connection

An ignition apparatus includes a secondary winding spool having a secondary winding wound thereon. The secondary winding includes a low voltage end and a high voltage end that is configured for connection to a spark plug. The secondary winding at the high voltage end is configured in accordance with a predetermined radial thickness profile taken in the direction from the high voltage end towards the low voltage end. The profile is determined as a function of (1) a reflected voltage associated with the spark gap breakdown of the spark plug and (2) an induced voltage due to magnetic flux coupled through a central core. The profile is determined so as to reduce layer-to-layer voltage levels in the secondary winding near the high voltage end. The profile can be wound or can be molded in the secondary spool itself.

Ignition apparatus with secondary winding having reduced breakdown failures

An ignition apparatus includes a high voltage (HV) terminal formed of stamped sheet metal configured to be disposed in a secondary winding spool, and to which a high voltage end of the secondary winding is attached and soldered. The ignition apparatus further includes an electrically conductive cup configured to surround the high voltage terminal when the secondary winding spool is inserted in the case. The high voltage terminal has one end that comes into engagement with an inner annular surface of the cup. The cup includes an annular sidewall that extends axially up to a winding flange where a HV end of the secondary winding exits a winding bay thereby surrunding the exiting HV secondary winding wire. The cup provides for a reduced electric field concentration.

Ignition apparatus having feature for shielding the HV terminal

A method for inhibiting or eliminating case erosion in a pencil ignition coil having an internal primary winding and an external secondary winding and shield. Three alternative means for resisting damage due to the partial discharge phenomenon arising from a high electric field in such coil configurations are provided: (i) applying an ozone resistant coating on the case; (ii) applying a coating on the case for eliminating partial discharge under the shield; and (iii) applying a polyimide tape covering to the case for resisting partial discharge under the shield. Several significant benefits include: an increased commercial value by allowing the use of an efficient internal primary winding which increases energy density and eliminates the need for a spool, thereby lowering the manufacturing costs, the processing costs falling well beneath that of liquid polymer processing, the ease of processing by coating or molding, the reduction of electrical noise, the improved durability even through thermal cycling, and the lowering of case manufacturing costs by allowing the use of lower cost plastic.

Erosion resistant pencil coil having external secondary winding and shield

A method and apparatus for securing at least one ignition coil to an ignition coil cassette, the ignition coil cassette having a main body portion being adapted to receive and engage a plurality of coils for generating a high voltage signal to be received by a spark plug of an internal combustion engine. The coils being ultrasonically welded to the main body portion of the ignition coil cassette. The coils being secured in a manner which correctly positions the coils in an appropriate location as well as providing a rigid securement of the coil to the main body portion.

Cassette for ignition coils and method of joining

An ignition apparatus includes a magnetic circuit comprising a central core and a side core or shield, and primary and secondary windings. The shield is allowed to electrically float, thereby reducing the capacitance of the secondary winding. A housing is external to and surrounds the shield to inhibit arcing. A silicone boot overlaps a housing/case interface to further suppress arcing.

Ignition apparatus having an electrically floating shield

An interface device for interfacing a pencil coil to a spark plug is provided. The interface device comprises a substantially C-shaped spring adapted to mechanically and electrically engage a pencil coil shield and also adapted to make electrical contact with a spark plug ground while the spring remains mechanically and electrically engaged to the pencil coil shield. Also provided is a pencil coil shield assembly for interfacing a pencil coil to a spark plug. The pencil coil shield assembly comprises a substantially cylindrical pencil coil and a spring. The substantially cylindrical pencil coil shield is adapted to surround the pencil coil. The spring is mechanically and electrically engaged with the pencil coil shield and is adapted to make electrical contact with a spark plug ground while the spring remains mechanically and electrically engaged to the pencil coil shield. The interface device and/or pencil coil shield assembly can be configured to reduce RFI from the secondary current winding currents of a pencil coil. In addition, each can be manufactured using inexpensive and uncomplicated manufacturing and installation techniques, and using starting materials and parts that are relatively inexpensive. Also provided is a method of reducing RFI from secondary winding currents of a pencil coil by, among other things, electrically connecting the substantially cylindrical shield to a low voltage terminal of a secondary winding of the pencil coil, and electrically connecting the substantially cylindrical shield to a spark plug ground of a spark plug associated with the pencil coil.

Shield and spring interface to a spark plug from a pencil coil

An electrical connection between a high voltage terminal and a spark plug head. A case contains a high voltage terminal connected to a high voltage source. A connector portion extends from a bottom portion of the case, which in turn is secured to an insulator boot for attachment to a spark plug. The high voltage terminal has a nipple extending within the connector portion. A leaf spring member engages the nipple and is positively retained thereto. The head of the spark plug is inserted into the connector portion and engages the leaf spring member. The resilient characteristics of the leaf spring member provided by the interaction of the leaf spring member and the connector portion enable a compact yet positive connection system.

Electrical connection for a spark plug and method of assembling the same

An ignition coil assembly adapted to be mounted directly in a plug hole of an internal combustion engine. The coil assembly includes a primary coil and a secondary coil. The spool upon which the secondary coil is wound is cylindrical in shape and has ramp structures provided at each end thereof. The ramps decrease voltage concentration between the secondary and primary windings, decrease the voltage gradient along the end wall of the secondary spool, and minimize adverse effects of gaps created during thermal expansion/contraction.

Ignition coil assembly with spool having ramps at both ends thereof

An electrical connection between a high voltage terminal and a spark plug head. A case contains a high voltage terminal connected to a high voltage source. A connector portion extends from a bottom portion of the case, which in turn is secured to an insulator boot for attachment to the spark plug. The high voltage terminal has a nipple extending within the connector portion. A barrel shaped coil spring is snapped over the nipple and positively retained thereto. The head of the spark plug is inserted within the connector portion and engages the barrel shaped coil spring. The barrel shape of the coil spring offers a smaller height with an increased working length thereby providing a larger tolerance between the high voltage terminal and the spark plug head.

An ignition coil for a spark ignition engine generally includes primary and secondary windings disposed about a magnetic core. The secondary winding is wound around a spool. The spool includes a cylindrical body having opposite first and second ends and a winding section between the ends. A conical winding surface at one of the ends tapers from a large diameter at the one end to a smaller diameter. A grooved surface extends axially toward another of the ends of the body and extends to adjacent the smaller diameter of the conical surface. The grooved surface contains longitudinally spaced continuous circular grooves that have unequally angled sides. The sides toward the one end are sloped at a greater angle relative to a radial direction than are the sides toward the other end. The secondary winding is wound around the winding section forming a plurality of turns of wire wound one over the other at a desired angle. The grooves are sized such that only one turn of the wire is disposed within each groove.

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Anderson, IN, United States of America

Viorel N Moga