Visteon Global Technolgoies, Inc.

Ford Motor Company Limited

William Douglas Walker

Todd Christopher Sexton

Alex William Widiger

Rick S Burchett

David Charles Stine

James John Klocinski

Robert C Bauman

Gregg Michael Stefansky

Richard William St John

Michael T Nation

Francis Martin Donahue

An ignition coil for an internal combustion engine minimizes the propagation of cracks in the encapsulate material surrounding the components of the ignition coil and provides a supplemental dielectric barrier. In one embodiment, the ignition coil comprises a housing, an outer core, an inner coil, and a coil assembly. The housing includes a bottom wall connected to an outer wall extending around the periphery of the housing. The outer core is positioned inside the outer wall, while the inner core is positioned inside the outer core. The coil assembly includes a primary winding and a secondary winding concentrically positioned relative to each other. The coil assembly is mounted to the inner core and positioned inside the outer core. The housing further includes an inner wall extending along the inner periphery of the outer core and positioned between the outer core and the coil assembly to prevent propagation of cracks.

Ignition coil with separating wall

An ignition coil and a method for its manufacturer are provided, the ignition coil including a housing, a primary winding and a secondary winding disposed in the housing, and a terminal including a connection portion in electrical communication with the secondary winding and a threaded portion engaging the housing. The threaded portion of the terminal may include a self-tapping threaded portion. Furthermore, the terminal may include a first body portion having a first threaded portion and a first median diameter and a second body portion having a second threaded portion and a second median diameter, where the second median diameter is greater than the first median diameter. The terminal may also include a shoulder portion having a diameter greater than the second median diameter and a third body portion having a third median diameter greater than the second median diameter.

Screw in high voltage housing terminal for ignition coil

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 circuit board for an ignition coil in an internal combustion engine is provided. The ignition coil is in electrical connection with a control module and a spark plug having a pair of gap posts. The ignition coil includes a primary winding having an electrical current, a secondary winding in electrical connection with the spark plug and configured to induce a second electrical current between the gap posts, and an ionization current sensing integrated circuit configured to generate an ionization signal based on the secondary current between the gap posts. The ignition coil also includes a circuit board having an ionization connection in electrical connection with the secondary winding and with the ionization current sensing integrated circuit.

Using a circuit board for ignition coil internal connections

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.

Growing community of inventors

Saline, MI, United States of America

William Douglas Walker