Shell welding overhead ignition coil

Abstract

A shell welding overhead ignition coil comprises an upper shell and a lower shell connected to the lower portion of the upper shell, a low-voltage head is installed on the side of the upper shell, an ignition module is installed on the inner side of the low-voltage head, a high-voltage head is arranged at the bottom of the lower shell, a high-voltage sheath is installed on the high-voltage head, and a coil assembly is arranged between the upper shell and the lower shell. Wherein the inner edge of the lower end face of the upper shell extends downwards to form a circle of strip-shaped welding part, the top end of the welding part inclines towards the outer side to form a triangular convex edge, the welding part is dissolved through ultrasonic waves so that the upper shell can be welded to the lower shell, and when the welding part is dissolved, the triangular convex edge pulls the welding part to topple towards the outer side. According to the product, the coil shell is sealed by using an ultrasonic welding process, a triangular rib bulge is designed on the outer side of the welding part of the upper shell, ultrasonic waves are concentrated on a triangular vertex part in the welding process, the effect is obvious, welding is facilitated, welding marks of the shell can be remained on the inner side of a triangular inclined surface, and the influence on the appearance can be avoided.

Description

Technical Field

[0001] The invention relates to an ignition coil structure. Background Art

[0002] In the automobile engine ignition system, the ignition coil is an actuator that provides ignition energy for igniting the air and fuel mixture in the engine cylinder. It is a special pulse booster based on the principle of electromagnetic induction. It switches the low voltage of 8-16V on and off at a set frequency to generate a 20-40KV voltage on the secondary side to generate electric sparks through the spark plug. The invention patent with application number 201810931477.X discloses a top-mounted single-cylinder independent ignition coil, including a high-voltage rod, a channel inside the high-voltage rod, a high-voltage spring arranged in the channel, a high-voltage connection end at the bottom of the high-voltage rod, and an interconnection end at the top of the high-voltage rod; a mounting shell is connected to the interconnection end, the mounting shell has an opening facing the side, a drawer structure is installed in the opening, the drawer mechanism includes a frame body, a coil assembly, and a low-voltage head, the coil assembly includes a T-shaped iron core formed by powder metallurgy pressing, a PI insulating layer covering the core column of the T-shaped iron core, a primary winding wound on the PI insulating layer, a secondary skeleton sleeved on the outside of the primary winding, a secondary winding wound on the secondary skeleton, and a powder metallurgy pressed mouth-shaped iron core arranged outside the T-shaped iron core, the bottom surface of the T-shaped iron core and the inner wall of the mouth-shaped iron core are adsorbed together by a rare earth magnet, and the low-voltage head has a substrate, an ignition module and a low-voltage plug connected by resistance welding are arranged on the substrate. Since the ignition coil of this structure adopts an integrated shell design, the installation accuracy cannot be guaranteed during the assembly process, which leads to various hidden dangers of product defects. Summary of the invention

[0003] In order to solve the shortcomings of the prior art, the object of the present invention is to provide a shell-welded overhead ignition coil with higher installation accuracy.

[0004] In order to achieve the above-mentioned purpose, the technical solution adopted by the present invention is: a shell-welded top-mounted ignition coil, comprising an upper shell and a lower shell connected to the bottom of the upper shell, a low-pressure head is installed on the side of the upper shell, an ignition module is installed on the inner side of the low-pressure head, a high-pressure head is provided at the bottom of the lower shell, a high-pressure sheath is installed on the high-pressure head, and a coil assembly is arranged between the upper shell and the lower shell; wherein, the inner edge of the lower end surface of the upper shell extends downward to form a circle of strip-shaped welding part, the top end of the welding part is inclined outward to form a triangular convex ridge, the welding part is dissolved by ultrasonic wave to make the upper shell be welded to the lower shell, and when dissolved, the triangular convex ridge pulls the welding part to tilt outward.

[0005] As a further improvement, the outer edge of the lower shell forms an edge wrapping upwards, and the edge wrapping wraps the welding mark of the welding part.

[0006] As a further improvement, the coil assembly includes a T-shaped iron core, a primary frame sleeved on the outside of the T-shaped iron core, a secondary frame sleeved on the primary frame, a first C-shaped iron core and a second C-shaped iron core surrounded by the outside of the secondary frame, and the first C-shaped iron core and the second C-shaped iron core are relatively combined together to form an O shape and connected to the end of the T-shaped iron core.

[0007] As a further improvement, the outside of the first C-type iron core and the second C-type iron core are respectively wrapped with buffer covers, and the tops of the buffer covers of the first C-type iron core and the second C-type iron core respectively extend upward to form an arc-shaped upper cover, and the upper cover covers the top of the secondary frame.

[0008] As a further improvement, a plurality of reinforcing ribs are arranged at intervals on the surface of the upper cover.

[0009] As a further improvement, the second C-shaped iron core is provided with a grounding plug by laser welding, and the grounding plug is connected to the ignition module.

[0010] As a further improvement, the top surface of the T-shaped iron core is adsorbed together with the first C-shaped iron core and the second C-shaped iron core via a magnetic sheet.

[0011] As a further improvement, a primary winding is wound on the primary frame, a primary connecting piece connected to the primary winding is provided on the primary frame, and the primary connecting piece is connected to the ignition module.

[0012] As a further improvement, a secondary winding is wound on the secondary skeleton, a high-voltage diode and a negative high-voltage plug connected to the secondary winding are arranged on the secondary skeleton, and the high-voltage diode is connected to the ignition module.

[0013] As a further improvement, a negative high voltage connector and a suppression resistor are provided at the bottom of the coil assembly, one end of the negative high voltage connector is connected to the top of the suppression resistor, and the other end is connected to the negative high voltage plug in a vertical direction in a pin-like manner.

[0014] Due to the adoption of the above technical solution, the product uses ultrasonic welding technology to seal the coil shell. The outer side of the upper shell welding part is designed with "triangular rib protrusions". During the welding process, the ultrasonic wave is concentrated on the vertex of the triangle, which is obviously beneficial to the welding. The shell welding mark will remain on the inner side of the triangular slope to avoid affecting the appearance. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Attached Figure 1 A perspective view of a housing-welded overhead ignition coil according to the present invention; Attached Figure 2 An exploded view of a shell-welded overhead ignition coil according to the present invention; Attached Figure 3 It is a partial enlarged view of the welding part of the housing welding top-mounted ignition coil according to the present invention; Attached Figure 4 It is a schematic diagram of a buffer cover of a top-mounted ignition coil welded to a shell according to the present invention. DETAILED DESCRIPTION

[0016] Hereinafter, the terms used in the specification will be briefly described, and the embodiments will be described in detail. All terms including descriptive terms or technical terms used herein should be interpreted as having meanings understood by those of ordinary skill in the art. However, these terms may have different meanings according to the intentions of those of ordinary skill in the art, precedents, or the emergence of new technologies.

[0017] In addition, some terms can be selected by the applicant, and in this case, the meaning of the selected terms will be described in detail in the detailed description of the embodiment. Therefore, the terms used herein must be defined based on the meaning of the terms together with the description in the entire specification. In addition, when a component "includes" or "contains" an element, unless there is a specific description to the contrary, the component may also include other elements without excluding other elements. In the following description, terms such as "component" and "module" indicate a unit for processing at least one function or operation, wherein the unit and module can be implemented as hardware or software or by combining hardware and software and implemented.

[0018] Embodiments will now be described more fully with reference to the accompanying drawings. However, embodiments may be implemented in many different forms and should not be construed as being limited to the embodiments set forth herein. On the contrary, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the concept of the embodiments to those of ordinary skill in the art. In the following description, well-known functions or structures are not described in detail because they will obscure the embodiments with unnecessary details, and throughout the specification, the same reference numerals in the drawings represent the same or similar elements.

[0019] Attached Figure 1It is a stereoscopic diagram of a shell-welded overhead ignition coil according to the present invention; the shell-welded overhead ignition coil in this embodiment includes an upper shell 1 and a lower shell 2 connected to the lower part of the upper shell 1, a low-pressure head 3 is installed on the side of the upper shell 1, an ignition module 4 is installed on the inner side of the low-pressure head 3, a high-pressure head 21 is provided at the bottom of the lower shell 2, a high-voltage sheath 5 is installed on the high-pressure head 21, and a coil assembly is arranged between the upper shell 1 and the lower shell 2.

[0020] Attached Figure 2 The exploded view of the shell-welded top-mounted ignition coil according to the present invention; the coil assembly 6 includes a T-shaped iron core 61, a primary frame 62 sleeved on the outside of the T-shaped iron core 61, a secondary frame 63 sleeved on the primary frame 62, a first C-shaped iron core 64 and a second C-shaped iron core 65 arranged around the outside of the secondary frame 63, the first C-shaped iron core 64 and the second C-shaped iron core 65 are relatively combined together to form an O shape and connected to the end of the T-shaped iron core 61. The top surface of the T-shaped iron core 61 and the first C-shaped iron core 64 and the second C-shaped iron core 65 are adsorbed together by a magnetic sheet 68.

[0021] The second C-shaped iron core 65 is laser welded with a grounding plug 67, which is connected to the ignition module 4. The iron core inside the product is added with a grounding plug, which is connected to the iron core using a laser welding process, and then the grounding lead on the module is connected, which is firm and reliable and can effectively reduce the interference of the induced voltage generated during the working process of the coil on the coil.

[0022] A primary winding is wound on the primary frame 62, and a primary connecting piece 621 connected to the primary winding is provided on the primary frame 62, and the primary connecting piece 621 is connected to the ignition module 4. A secondary winding is wound on the secondary frame 63, and a high-voltage diode 631 and a negative high-voltage plug 632 connected to the secondary winding are provided on the secondary frame 63, and the high-voltage diode 631 is connected to the ignition module 4. A negative high-voltage connector 7 and a suppression resistor 8 are provided at the bottom of the coil assembly, and one end of the negative high-voltage connector 7 is connected to the top of the suppression resistor 8, and the other end is connected to the negative high-voltage plug 632 in a vertical direction by a pin.

[0023] Attached Figure 3This is a partial enlarged view of the welding part of the shell welding top-mounted ignition coil according to the present invention; the inner edge of the lower end surface of the upper shell 1 extends downward to form a circle of strip-shaped welding part 11, and the top of the welding part 11 is inclined outward to form a triangular convex ridge 12. The welding part 11 is dissolved by ultrasonic wave to make the upper shell 1 welded to the lower shell 2. The assembly process sequence of the coil is: install the low-pressure head with the module into the upper shell, then install the coil sub-assembly (primary, secondary, iron core, magnetic sheet) into the upper shell and place it in the ultrasonic welding fixture hole, with the opening facing upward, and then install the lower shell with the suppression resistor and the negative high-voltage plug onto the coil upper shell assembly, with the lower shell high-voltage tower facing upward, and finally perform ultrasonic welding on the ultrasonic welding equipment to melt the upper and lower shells into one. The product uses ultrasonic welding technology to seal the coil shell. The outer side of the upper shell body welding part is designed with "triangular rib protrusions". During the welding process, the ultrasonic wave is concentrated on the triangle vertex, so the triangular ridge 12 will melt the fastest and then pull the welding part 11 to tilt outward, which is obviously beneficial to the welding. The shell welding mark will remain on the inner side of the triangular slope, and the outer edge of the lower shell body 2 will form an edge 21 upward, which will wrap the welding mark of the welding part 11 to avoid affecting the appearance.

[0024] Attached Figure 4 The schematic diagram of the buffer cover of the shell-welded top-mounted ignition coil according to the present invention. The first C-type iron core 64 and the second C-type iron core 65 are wrapped with buffer covers on their exteriors, and the tops of the buffer covers of the first C-type iron core 64 and the second C-type iron core 65 extend upward to form an arc-shaped upper cover 66, which covers the upper part of the secondary skeleton 63. The contour of the upper cover 66 is designed according to the trend of the secondary skeleton structure, so that the resin around the primary and secondary windings is evenly distributed. A plurality of reinforcing ribs 661 are arranged at intervals on the surface of the upper cover 66, which can avoid local thick resin distribution sheets, and can also avoid resin cracking caused by excessive adhesion between the shell material and the resin.

[0025] It should be understood that the embodiments described herein should be considered in a descriptive sense only and not for the purpose of limitation. The description of the features or aspects within each implementation side should generally be considered to be applicable to other similar features or aspects in other embodiments. Although one or more embodiments have been described with reference to the accompanying drawings, it will be understood by those of ordinary skill in the art that various changes in form and detail may be made therein without departing from the spirit and scope defined by the appended claims.

Claims

1. A shell-welded top-mounted ignition coil, characterized in that: The invention comprises an upper shell (1) and a lower shell (2) connected to the lower part of the upper shell (1), wherein a low-pressure head (3) is installed on the side of the upper shell (1), an ignition module (4) is installed on the inner side of the low-pressure head (3), a high-pressure head (21) is installed on the bottom of the lower shell (2), a high-pressure sheath (5) is installed on the high-pressure head (21), and a coil assembly is arranged between the upper shell (1) and the lower shell (2); wherein the inner edge of the lower end surface of the upper shell (1) extends downward to form a strip-shaped welding portion (11), the top end of the welding portion (11) is inclined outward to form a triangular convex ridge (12), and the welding portion (11) is dissolved by ultrasonic wave so that the upper shell (1) is welded to the lower shell (2), and when dissolved, the triangular convex ridge (12) pulls the welding portion (11) to tilt outward.

2. The shell-welded top-mounted ignition coil according to claim 1, characterized in that: The outer edge of the lower shell (2) forms an edge wrapping (21) upwards, and the edge wrapping (21) wraps the welding mark of the welding portion (11).

3. The shell-welded top-mounted ignition coil according to claim 1, characterized in that: The coil assembly (6) comprises a T-shaped iron core (61), a primary frame (62) sleeved on the outside of the T-shaped iron core (61), a secondary frame (63) sleeved on the primary frame (62), a first C-shaped iron core (64) and a second C-shaped iron core (65) arranged around the outside of the secondary frame (63), wherein the first C-shaped iron core (64) and the second C-shaped iron core (65) are relatively combined together to form an O shape and are connected to the end of the T-shaped iron core (61).

4. The shell-welded top-mounted ignition coil according to claim 3, characterized in that: The outside of the first C-type iron core (64) and the second C-type iron core (65) are respectively wrapped with a buffer cover, and the tops of the buffer covers of the first C-type iron core (64) and the second C-type iron core (65) respectively extend upward to form an arc-shaped upper cover (66), and the upper cover (66) covers the upper part of the secondary frame (63).

5. The shell-welded top-mounted ignition coil according to claim 4, characterized in that: A plurality of reinforcing ribs (661) are arranged at intervals on the surface of the upper cover (66).

6. The shell-welded top-mounted ignition coil according to claim 3, characterized in that: The second C-shaped iron core (65) is welded with a grounding plug (67) by laser welding, and the grounding plug (67) is connected to the ignition module (4).

7. The shell-welded top-mounted ignition coil according to claim 3, characterized in that: The top surface of the T-shaped iron core (61) is adsorbed together with the first C-shaped iron core (64) and the second C-shaped iron core (65) via a magnetic sheet (68).

8. The shell-welded top-mounted ignition coil according to claim 3, characterized in that: A primary winding is wound on the primary frame (62), a primary connecting piece (621) connected to the primary winding is provided on the primary frame (62), and the primary connecting piece (621) is connected to the ignition module (4).

9. The shell-welded top-mounted ignition coil according to claim 3, characterized in that: A secondary winding is wound on the secondary frame (63), a high-voltage diode (631) and a negative high-voltage plug (632) connected to the secondary winding are arranged on the secondary frame (63), and the high-voltage diode (631) is connected to the ignition module (4).

10. The shell-welded top-mounted ignition coil according to claim 9, characterized in that: A negative high voltage connector (7) and a suppression resistor (8) are provided at the bottom of the coil assembly; one end of the negative high voltage connector (7) is connected to the top of the suppression resistor (8), and the other end is connected to the negative high voltage plug (632) in a vertical direction in a pin-like manner.

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