Integrated single-cylinder independent ignition coil

Abstract

A one-piece single-cylinder independent ignition coil comprises a long shell, the bottom of the long shell protrudes in the transverse direction to form a plurality of high-pressure heads, a low-pressure head is formed at the side end of the long shell, the long shell is provided with a containing cavity with an upward opening, and a plurality of coil assemblies are installed on the inner side of the containing cavity in the transverse direction. A coil assembly is arranged on the low-voltage head, a long-strip-shaped PCB is installed above the coil assembly, the low-voltage head and the coil assembly are electrically connected to the PCB through upward contact pins respectively, a negative-high-voltage connector is arranged below the coil assembly, and the coil assembly is electrically connected to the high-voltage head through the negative-high-voltage connector. According to the design of the ignition coil, four high-voltage packs are placed in the same shell, the function of each coil is independent, independent ignition can be achieved, and the ignition coil has the design advantage that fewer connecting wire harnesses are needed, and a compact plug is enough. By means of the structure, engine cabins can be arranged more clearly and neatly.

Description

Technical Field

[0001] This invention relates to an engine ignition coil. Background Technology

[0002] In existing technologies, integrated single-cylinder independent ignition coils are composed of multiple individual ignition coils. The primary winding of each coil needs to be connected to a low-voltage plug. Current designs use PCB circuit boards for wiring, resulting in numerous and intersecting lines. Using a single double-sided PCB board is insufficient, requiring two PCB boards stacked to solve the wiring problem. However, PCB board manufacturing is costly and the production process is complex. Patent 201610787788.4 discloses an integrated ignition coil, including a large rectangular shell with multiple mounting holes along the vertical direction. Each mounting hole houses a single pen-type ignition coil unit. The large shell has an internal mounting cavity, and a circuit board unit is located within the mounting cavity above each pen-type ignition coil unit. Each pen-type ignition coil unit is electrically connected to the circuit board unit. A low-voltage head is located on one side of the mounting cavity and is electrically connected to the circuit board unit. Summary of the Invention

[0003] In order to solve the problems in the prior art, the purpose of this invention is to provide a single-cylinder independent ignition coil that is applied to the 14V system engine of passenger vehicles and has stable performance.

[0004] To achieve the above objectives, the technical solution adopted by this invention is: an integrated single-cylinder independent ignition coil, comprising an elongated housing, the bottom of which protrudes laterally to form multiple high-voltage heads, and the side end of which forms a low-voltage head. The elongated housing has an upward-opening receiving cavity, and multiple coil assemblies are installed laterally inside the receiving cavity. A long strip-shaped PCB circuit board is installed above the coil assemblies. The low-voltage head and the coil assembly are each electrically connected to the PCB circuit board via upward-facing pins. A negative high-voltage connector is provided below the coil assembly, and the coil assembly is electrically connected to the high-voltage head via the negative high-voltage connector.

[0005] Preferably, 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, and a first C-shaped iron core and a second C-shaped iron core surrounding the outside of the secondary frame. The primary frame is wound with primary windings, and the secondary frame is wound with secondary windings. The first C-shaped iron core and the second C-shaped iron core are wrapped with thermoplastic elastic buffer covers. The first C-shaped iron core and the second C-shaped iron core are combined together at both ends of the secondary frame.

[0006] Preferably, the top surface of the T-shaped iron core is attracted to the first C-shaped iron core and the second C-shaped iron core by a magnetic sheet.

[0007] Preferably, a first primary connecting piece and a second primary connecting piece are provided above the primary skeleton, the primary winding is connected to the first primary connecting piece and the second primary connecting piece, the first primary connecting piece and the second primary connecting piece are flexibly disposed on the primary skeleton, and when the secondary skeleton is sleeved on the primary skeleton in the transverse direction, the first primary connecting piece and the second primary connecting piece are bent to extend in the longitudinal direction.

[0008] Preferably, a positive high-voltage plug is provided above the secondary frame, one end of the secondary winding is connected to the positive high-voltage output terminal of the positive high-voltage plug, and a negative high-voltage plug is provided below the secondary frame, the other end of the secondary winding is connected to the negative high-voltage output terminal of the negative high-voltage plug.

[0009] Preferably, a high-voltage sheath is installed on the high-voltage head, a high-voltage spring is installed inside the high-voltage sheath, a suppression resistor and a high-voltage pin are installed inside the high-voltage head, the suppression resistor is connected to the upper end of the high-voltage spring through the high-voltage pin, and the negative high-voltage connector is connected above the suppression resistor.

[0010] Preferably, the negative high-voltage plug is in pin-type contact with the negative high-voltage connector.

[0011] Preferably, the receiving cavity is filled with epoxy resin and the coil assembly is completely covered therein, and the top of the thermoplastic elastic buffer cover of the first C-shaped iron core and the second C-shaped iron core each forms a plurality of mutually spaced grooves.

[0012] Preferably, the PCB circuit board has multiple potting holes arranged horizontally, and the position of each potting hole corresponds to the position of the corresponding coil assembly.

[0013] Preferably, the PCB circuit board integrates and mounts four high-voltage diodes and one capacitor.

[0014] Thanks to the above technical solutions, this ignition coil design houses four high-voltage coils within a single housing. However, each coil functions independently and can ignite individually. The design advantage is that it requires fewer wiring harnesses; a single compact plug suffices. This structure helps to make the engine compartment layout clearer and neater, saving time on the engine assembly line. Attached Figure Description

[0015] Appendix Figure 1A three-dimensional exploded view of the integrated single-cylinder independent ignition coil according to the present invention; Appendix Figure 2 A perspective view of the integrated single-cylinder independent ignition coil according to the present invention; Appendix Figure 3 A three-dimensional exploded view of the coil assembly of the integrated single-cylinder independent ignition coil according to the present invention; Appendix Figure 4 and attached Figure 5 An assembly diagram of the coil assembly of the integrated single-cylinder independent ignition coil according to the present invention; Appendix Figure 6 A circuit connection diagram of the coil assembly of the integrated single-cylinder independent ignition coil according to the present invention; Appendix Figure 7 The low-voltage head pin definition of the integrated single-cylinder independent ignition coil according to the present invention; Appendix Figure 8 The circuit diagram of the integrated single-cylinder independent ignition coil according to the present invention is shown. Detailed Implementation

[0016] In the following description, the terminology used in the specification will be briefly described, and embodiments will be described in detail. All terms used herein, including descriptive or technical terms, should be interpreted as having the meaning understood by one of ordinary skill in the art. However, these terms may have different meanings depending on the intent of one of ordinary skill in the art, precedent, or the emergence of new technologies.

[0017] Furthermore, some terms may be chosen by the applicant, and in such cases, the meaning of the chosen terms will be described in detail in the detailed description of the embodiments. Therefore, the terms used herein must be defined based on their meanings in conjunction with the description throughout the specification. Additionally, when a component “comprises” or “contains” an element, the component may also include other elements without excluding them, unless there is a specific description to the contrary. In the following description, terms such as “component” and “module” indicate a unit for performing at least one function or operation, wherein units and modules may be implemented as hardware or software or by combining hardware and software.

[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 limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the concept of the embodiments to those skilled in the art. In the following description, well-known functions or structures are not described in detail, as they would obscure the embodiments with unnecessary detail, and throughout the specification, the same reference numerals in the drawings denote the same or similar elements.

[0019] Appendix Figure 1 A three-dimensional exploded view of the integrated single-cylinder independent ignition coil according to the present invention; attached. Figure 2 This is a perspective view of the integrated single-cylinder independent ignition coil according to the present invention. This embodiment is an integrated single-cylinder independent ignition coil composed of four sets of individual ignition coils, including an elongated housing 1. Multiple high-voltage heads 2 are formed by a transverse convex shape at the bottom of the elongated housing 1, and low-voltage heads 3 are formed at the side ends of the elongated housing 1. The elongated housing 1 has an upward-opening receiving cavity, and multiple coil assemblies 4 are installed transversely inside the receiving cavity. Multiple partitions are spaced apart within the receiving cavity, and each coil assembly is fixedly installed between adjacent partitions. A long strip-shaped PCB circuit board 5 is mounted above the coil assembly 4. The low-voltage heads 3 and coil assemblies 4 are each electrically connected to the PCB circuit board 5 via upward-facing pins. A negative high-voltage connector 6 is provided below the coil assembly 4, and the coil assembly 4 is electrically connected to the high-voltage heads 2 via the negative high-voltage connector 6.

[0020] A high-voltage sleeve 7 is installed on the high-voltage head 2. A high-voltage spring 8 is installed inside the high-voltage sleeve 7. A suppression resistor 9 and a high-voltage pin 10 are installed inside the high-voltage head 2. The suppression resistor 9 is connected to the upper end of the high-voltage spring 8 through the high-voltage pin 10, providing EMC noise filtering. The negative high-voltage connector 6 is connected above the suppression resistor 9.

[0021] Appendix Figure 3 This is a three-dimensional exploded view of the coil assembly of the integrated single-cylinder independent ignition coil according to the present invention; the coil assembly 4 includes a T-shaped iron core 41, a primary frame 42 sleeved on the outside of the T-shaped iron core 41, a secondary frame 43 sleeved on the primary frame 42, and a first C-shaped iron core 441 and a second C-shaped iron core 442 surrounding the outside of the secondary frame 43. The primary frame 42 is wound with primary windings, and the secondary frame 43 is wound with secondary windings. The first C-shaped iron core 441 and the second C-shaped iron core 442 are wrapped with a thermoplastic elastic buffer cover 45. Due to the difference in the linear expansion coefficient of the internal materials, the thermoplastic elastic buffer cover 45 uses an elastic polymer material. Under the condition of temperature change of the ignition coil, the risk of cracking of the filling material (epoxy resin) is greatly reduced, thereby improving the stability of the ignition coil.

[0022] The first C-type iron core 441 and the second C-type iron core 442 are combined at both ends of the secondary frame 43. The iron core structure adopts a closed design consisting of two (double) C-type cores on both sides and a (single) T-type core in the middle. Due to the low magnetic resistance and concentrated magnetic flux, the energy conversion efficiency of the closed magnetic circuit structure is significantly improved. The top surface of the T-type iron core 41 is attracted to the first C-type iron core 441 and the second C-type iron core 442 by a magnetic sheet 46. The magnetic sheet uses permanent magnet material, which can increase the energy storage of the primary coil, so that the ignition coil has a higher output voltage and energy.

[0023] Appendix Figure 4 and attached Figure 5 An assembly diagram of the coil assembly of the integrated single-cylinder independent ignition coil according to the present invention is attached; Figure 6 The circuit connection diagram of the coil assembly of the integrated single-cylinder independent ignition coil according to the present invention is shown below. A first primary connecting piece 421 and a second primary connecting piece 422 are disposed above the primary frame 42. The primary winding is connected to the first primary connecting piece 421 and the second primary connecting piece 422. During primary winding, the primary enameled wire is automatically stripped of its enamel coating by a winding machine. The first primary connecting piece 421 and the second primary connecting piece 422 are flexibly disposed on the primary frame 42. When the secondary frame 43 is laterally fitted onto the primary frame 42, the first primary connecting piece 421 and the second primary connecting piece 422 are bent vertically upwards.

[0024] A positive high-voltage connector 431 is disposed above the secondary frame 43, and one end of the secondary winding is connected to the positive high-voltage output terminal of the positive high-voltage connector 431. A negative high-voltage connector 432 is disposed below the secondary frame 43, and the other end of the secondary winding is connected to the negative high-voltage output terminal of the negative high-voltage connector 432. The negative high-voltage connector 432 makes pin-type contact with the negative high-voltage connector 6.

[0025] The cavity is filled with epoxy resin, which completely encapsulates the coil assembly 4. The tops of the thermoplastic elastic buffer covers 45 of the first C-shaped iron core 441 and the second C-shaped iron core 442 each have a plurality of spaced-apart grooves 451, thereby reducing the amount of epoxy resin used and dispersing the internal stress of the epoxy resin. Multiple potting holes are provided laterally on the PCB circuit board 5, with each potting hole corresponding to the position of the corresponding coil assembly 4.

[0026] The PCB circuit board 5 connects directly to the connecting pieces on multiple sets of coils and converges at the low-voltage connector, eliminating the need for lead wire connections, reducing operational complexity, and improving production efficiency and stability. It integrates high-voltage diodes 51 and capacitors 52, with each high-voltage diode 51 connected to the positive high-voltage connector 431 of the corresponding coil assembly 4. This diode typically functions as a freewheeling diode and absorbs voltage spikes, protecting the electronic components inside the ECU from damage caused by the reverse induced electromotive force (voltage spike) generated when the primary current is suddenly interrupted.

[0027] Appendix Figure 7 For the low-voltage head pin definition of the integrated single-cylinder independent ignition coil according to the present invention: C1-, C2-, C3-, C4-: These are the negative terminals of the ignition control signals for the four cylinders. The ECU controls the ignition of the corresponding cylinder by controlling the on and off states of these four pins to ground. B+: Positive power supply, controlled by the ignition switch or main relay. GND: Common reference ground of the circuit, connected to the vehicle body.

[0028] Appendix Figure 8This is a circuit diagram of the integrated single-cylinder independent ignition coil according to the present invention. It shows four completely independent and structurally identical ignition coil circuits connected in parallel to a common power supply (B+) and ground (GND). Each ignition coil consists of a drive circuit (represented in the diagram by a suppression resistor R and a high-voltage diode) and a transformer (primary coil and secondary coil). These four independent ignition coils are encapsulated in a single housing. Each coil (C1- to C4-) is individually controlled by the ECU, without interference. This means that if the internal circuit of one coil (e.g., the transformer corresponding to C1) fails, only one cylinder will misfire, while the other three cylinders will continue to operate normally. As can be seen from the diagram, the ECU's control signal is implemented by controlling the grounding circuit of the primary coil. The ECU acts as a switch; when it connects C1- to ground, the primary coil is energized and stores energy; when it disconnects, the current in the primary coil disappears, inducing a high-voltage current in the secondary coil, thus achieving ignition. This ignition coil is used in 14V system engines for passenger vehicles. This design houses four high-voltage coils within a single housing; however, each coil functions independently and can ignite individually. The advantage of this design is that it requires less wiring harness; a single, compact connector suffices. The integrated ignition coil design also helps to make the engine compartment layout clearer and neater.

[0029] It should be understood that the embodiments described herein should be considered in a descriptive sense only and not for limiting purposes. The description of features or aspects within each embodiment should generally be considered applicable to other similar features or aspects in other embodiments. Although one or more embodiments have been described with reference to the accompanying drawings, those skilled in the art will understand 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 one-piece single cylinder independent ignition coil characterized by: The utility model provides a high voltage transformer, including long shell (1), the bottom of long shell (1) is along transversely convex and forms a plurality of high pressure head (2), the side end of long shell (1) forms low pressure head (3), long shell (1) has the receiving cavity that opens upwards, the inside of receiving cavity is along transversely installed with a plurality of coil assembly (4), the top of coil assembly (4) is installed with the PCB circuit board (5) of strip shape, low pressure head (3) and coil assembly (4) are electrically connected to PCB circuit board (5) respectively through the pin of upwards, the lower of coil assembly (4) is provided with negative high voltage connector (6), coil assembly (4) is electrically connected to high pressure head (2) through negative high voltage connector (6).

2. The integrated single cylinder independent ignition coil of claim 1, wherein: The coil assembly (4) includes a T-shaped core (41), a primary skeleton (42) sleeved outside the T-shaped core (41), a secondary skeleton (43) sleeved on the primary skeleton (42), a first C-shaped core (441) and a second C-shaped core (442) arranged outside the secondary skeleton (43), the primary skeleton (42) is wound with a primary winding, the secondary skeleton (43) is wound with a secondary winding, the first C-shaped core (441) and the second C-shaped core (442) are wrapped with a thermoplastic elastic buffer cover (45), and the first C-shaped core (441) and the second C-shaped core (442) are combined together at two ends of the secondary skeleton (43).

3. The integrated single cylinder independent ignition coil of claim 2, wherein: The top surface of the T-shaped core (41) is adsorbed together with the first C-shaped core (441) and the second C-shaped core (442) through a magnetic sheet (46).

4. The integrated single cylinder independent ignition coil of claim 2, wherein: The primary skeleton (42) is provided with a first primary connecting piece (421) and a second primary connecting piece (422) above, the primary winding is connected to the first primary connecting piece (421) and the second primary connecting piece (422), the first primary connecting piece (421) and the second primary connecting piece (422) are flexibly arranged on the primary skeleton (42), when the secondary skeleton (43) is sleeved on the primary skeleton (42) in the transverse direction, the first primary connecting piece (421) and the second primary connecting piece (422) are bent to extend in the longitudinal direction.

5. The integrated single cylinder independent ignition coil of claim 2, wherein: The secondary skeleton (43) is provided with a positive high voltage plug (431) above, one end of the secondary winding is connected to the positive high voltage output end of the positive high voltage plug (431), and the secondary skeleton (43) is provided with a negative high voltage plug (432) below, the other end of the secondary winding is connected to the negative high voltage output end of the negative high voltage plug (432).

6. The integrated single cylinder independent ignition coil of claim 5, wherein: The high-pressure head (2) is provided with a high-pressure sheath (7), the high-pressure sheath (7) is provided with a high-pressure spring (8), the high-pressure head (2) is provided with a suppression resistor (9) and a high-pressure pin (10), the suppression resistor (9) is connected to the upper end of the high-pressure spring (8) through the high-pressure pin (10), and the negative high-voltage connector (6) is connected above the suppression resistor (9).

7. The integrated single cylinder independent ignition coil of claim 6, wherein: The negative high-voltage plug (432) is in plug-pin contact with the negative high-voltage connector (6).

8. The integrated single cylinder independent ignition coil of claim 1, wherein: The accommodating cavity is filled with epoxy resin and the coil assembly (4) is integrally coated, and the top of the thermoplastic elastic buffer cover (45) of the first C-shaped core (441) and the second C-shaped core (442) is respectively formed with a plurality of grooves (451) spaced apart from each other.

9. The integrated single cylinder independent ignition coil of claim 8, wherein: A plurality of glue filling holes are arranged on the PCB circuit board (5) in the transverse direction, and the position of each glue filling hole corresponds to the position of the corresponding coil assembly (4).

10. The integrated single cylinder independent ignition coil of claim 1, wherein: Four high-voltage diodes (51) and one capacitor (52) are integrally installed on the PCB circuit board (5).

Images