A core structure for a high-energy ignition coil used in automobiles

Abstract

This utility model discloses a core structure for a high-energy ignition coil used in automobiles, including a core structure installed inside the ignition coil housing. The core structure comprises a magnetic sheet, a primary coil, a secondary coil, and a toroidal core. The magnetic sheet is embedded in the primary coil, which is interference-fitted into the secondary coil. The toroidal core simultaneously surrounds both the primary and secondary coils and is tightly fitted to the magnetic sheet. The end of the primary core furthest from the magnetic sheet is tightly fitted against the toroidal core. The closed magnetic circuit structure of the toroidal core concentrates the magnetic field almost entirely within the core, resulting in minimal magnetic leakage, uniform magnetic field distribution, low magnetic reluctance, and high magnetic flux density. This leads to high energy conversion efficiency, minimal energy loss, and the efficient energy conversion capability enables the ignition coil to generate higher secondary voltage and stronger spark energy. It is suitable for lean-burn and high-performance engines, ensuring reliable ignition and better fuel economy.

Description

Technical Field

[0001] This utility model relates to a core structure, specifically a core structure for a high-energy ignition coil used in automobiles. Background Technology

[0002] The ignition coil is the core component of the ignition system, responsible for converting low voltage to high voltage to ignite the air-fuel mixture in the engine cylinders, driving the vehicle. Lean-burn technology improves fuel economy and reduces emissions by increasing the air-fuel ratio (exceeding the stoichiometric ratio of 14.7:1), but it places higher demands on the ignition system. Lean-burn mixtures contain fewer fuel molecules, requiring higher ignition energy to ensure reliable ignition. Traditional ignition coils have limited energy output, which may lead to ignition failure or incomplete combustion, causing engine misfire, reduced power, and increased emissions. Most ignition coils currently on the market use a primary coil that receives low voltage and generates a magnetic field. The iron core concentrates the magnetic field, improving energy conversion efficiency. The secondary coil induces a high voltage, which ignites the air-fuel mixture through the spark plug. The ignition energy is determined by the primary winding current and the primary inductance, while the primary magnetic field is determined by the shape, structure, and size of the iron core. Increasing the ignition coil energy presents technical challenges, such as excessive size and excessive heat generation due to high current. Utility Model Content

[0003] The purpose of this invention is to provide a core structure for a high-energy ignition coil used in automobiles. The structure is simple, the magnetic field path is closed and uniformly distributed, the leakage magnetic field is minimal, and the energy conversion efficiency is high. It is suitable for the toroidal core structure of ignition coils with high energy and high efficiency requirements, thereby solving the technical problems mentioned in the background art of excessive volume and excessive heat generation caused by high current in order to increase the energy of the ignition coil.

[0004] To achieve the above objectives, this utility model provides the following technical solution:

[0005] A core structure for a high-energy ignition coil used in automobiles includes a core structure installed inside the ignition housing. The core structure includes a magnetic sheet, a primary coil, a secondary coil, and a toroidal core. The magnetic sheet is embedded in the primary coil, which is interference-fitted into the secondary coil. The toroidal core is simultaneously wrapped around the outside of both the primary and secondary coils and is tightly fitted to the magnetic sheet. The primary coil includes a primary core, a primary frame, and a primary enameled wire. The primary enameled wire is wound around the outside of the primary frame, which has a long annular groove for winding the primary enameled wire. The primary core is embedded inside the primary frame, and the magnetic sheet is magnetically connected to the primary core. The secondary coil includes a secondary frame and a secondary enameled wire, which is wound around the outside of the secondary frame. The end of the primary core away from the magnetic sheet is tightly fitted to the toroidal core.

[0006] As a further embodiment of this utility model: the primary skeleton is provided with an installation cavity for embedding a magnetic sheet, the thickness of which is 1-4mm.

[0007] As a further improvement of this utility model: the primary iron core is made of multiple layers of silicon steel sheets riveted together, and the thickness of the silicon steel sheets is 0.3-0.5mm.

[0008] As a further embodiment of this utility model: the secondary skeleton has a positioning slot inside, and the end face of the secondary skeleton has an embedding slot. The primary skeleton has a positioning protrusion corresponding to the positioning slot. The positioning protrusion is adapted to the positioning slot and the mating surface is beveled. Through bevel compression, the positioning protrusion is centered in the positioning slot. The primary skeleton has an embedding protrusion corresponding to the embedding slot. The embedding protrusion is inserted into the embedding slot and has an interference fit.

[0009] As a further improvement of this utility model: the secondary frame is provided with winding grooves at equal intervals, and a partition is provided between each winding groove on the secondary frame. The height of the partition increases from both sides to the middle, and a wire routing notch is provided on the partition. The secondary frame is provided with two first terminal slots.

[0010] As a further improvement of this utility model: a wiring groove is provided on the primary frame, and two second terminal slots are provided on the primary frame.

[0011] Compared with the prior art, the beneficial effects of this utility model are:

[0012] 1. The closed magnetic circuit structure of the toroidal iron core of this invention concentrates the magnetic field almost entirely inside the iron core, resulting in minimal magnetic leakage, uniform magnetic field distribution, low magnetic reluctance, and high magnetic flux density. This leads to high energy conversion efficiency and minimal energy loss. The high energy conversion efficiency enables the ignition coil to generate higher secondary voltage and stronger spark energy. It is suitable for lean-burn and high-performance engines, ensuring reliable ignition and better fuel economy.

[0013] 2. The closed magnetic circuit structure of this invention reduces magnetic field leakage and electromagnetic interference. Low electromagnetic interference makes the ignition system operate more stably and causes less interference to other electronic devices.

[0014] 3. The toroidal core structure of this invention is compact and has a high material utilization rate. The ignition coil is small in size and light in weight, making it easy to install and integrate.

[0015] 4. The toroidal iron core of this invention has low hysteresis loss and eddy current loss, making it suitable for high-frequency operation. It performs excellently in high-frequency ignition systems, exhibiting fast response speed. Ignition is more precise, and combustion is more complete. Attached Figure Description

[0016] Figure 1This is a schematic diagram of the core structure of a high-energy ignition coil for automobiles.

[0017] Figure 2 This is a diagram illustrating the core structure of a high-energy ignition coil for automobiles.

[0018] Figure 3 This is an exploded view of the core structure of a high-energy ignition coil for automobiles.

[0019] Figure 4 This is a cross-sectional view of the core structure in a high-energy ignition coil for automobiles.

[0020] Figure 5 This is a longitudinal sectional view of the core structure in a high-energy ignition coil for automobiles.

[0021] Figure 6 This is a diagram illustrating the primary skeleton of the core structure of a high-energy ignition coil for automobiles.

[0022] Figure 7 This is a diagram illustrating the secondary frame in the core structure of a high-energy ignition coil for automobiles.

[0023] Figure 8 This is a top view of the toroidal core in the core structure of a high-energy ignition coil for automobiles.

[0024] In the diagram: 1. Igniter; 2. Iron core structure; 3. Magnetic sheet; 4. Primary coil; 5. Secondary coil; 6. Toroidal iron core; 7. Primary iron core; 8. Primary frame; 9. Primary enameled wire; 10. Secondary frame; 11. Secondary enameled wire; 12. Mounting cavity; 13. Positioning slot; 14. Embedding slot; 15. Positioning protrusion; 16. Embedding protrusion; 17. Winding groove; 18. Partition plate; 19. Wiring notch; 20. First terminal slot; 21. Wiring groove; 22. Second terminal slot. Detailed Implementation

[0025] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0026] Please see Figures 1-8In this embodiment of the present invention, a core structure for a high-energy ignition coil for automobiles includes a core structure 2 installed inside the housing of an igniter 1. The core structure 2 includes a magnetic sheet 3, a primary coil 4, a secondary coil 5, and a ring-shaped core 6. The magnetic sheet 3 is embedded in the primary coil 4, and the primary coil 4 is interference-fitted into the secondary coil 5. The ring-shaped core 6 is simultaneously wrapped around the outside of the primary coil 4 and the secondary coil 5 and is tightly fitted with the magnetic sheet 3. The primary coil 4 includes a primary core 7, a primary frame 8, and a primary enameled wire 9. The primary enameled wire 9 is wound around the outside of the primary frame 8. The primary frame 8 has a long annular groove for winding the primary enameled wire 9. The primary core 7 is embedded inside the primary frame 8. The magnetic sheet 3 is magnetically connected to the primary core 7. The secondary coil 5 includes a secondary frame 10 and a secondary enameled wire 11. The secondary enameled wire 11 is wound around the outside of the secondary frame 10. The end of the primary core 7 away from the magnetic sheet 3 is tightly fitted and pressed against the ring-shaped core 6.

[0027] The primary skeleton 8 has an installation cavity 12 for embedding the magnetic sheet 3, and the thickness of the magnetic sheet 3 is 1-4mm.

[0028] The primary iron core 7 is made of multiple layers of silicon steel sheets riveted together, with the thickness of the silicon steel sheets being 0.3-0.5mm.

[0029] The secondary frame 10 has a positioning slot 13 inside and an embedding slot 14 on its end face. The primary frame 8 has a positioning protrusion 15 corresponding to the positioning slot 13. The positioning protrusion 15 is adapted to the positioning slot 13 and the mating surface is beveled. By bevel compression, the positioning protrusion 15 is centered in the positioning slot 13. The primary frame 8 has an embedding protrusion 16 corresponding to the embedding slot 14. The embedding protrusion 16 is inserted into the embedding slot 14 and is interference-fitted.

[0030] The secondary frame 10 has winding grooves 17 at equal intervals. A partition 18 is provided between each winding groove 17 on the secondary frame 10. The height of the partition 18 increases from both sides to the middle. A wiring notch 19 is provided on the partition 18. The secondary frame 10 has two first terminal slots 20.

[0031] The primary frame 8 has a wiring groove 21 and two second terminal slots 22.

[0032] The working principle of this utility model is as follows:

[0033] In use, the magnetic sheet 3 is magnetically attached to the primary iron core 7 of the primary coil 4. The primary coil 4 is press-fitted onto the secondary coil 5 with an interference fit. The toroidal iron core 6 is then assembled with the above components and then tightly fitted with the primary iron core 7 and the magnetic sheet 3 to form the winding component of the ignition coil.

[0034] Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A core structure for a high-energy ignition coil for automobiles, comprising a core structure (2) installed inside the housing of an igniter (1), characterized in that: The core structure (2) includes a magnetic sheet (3), a primary coil (4), a secondary coil (5), and a toroidal core (6). The magnetic sheet (3) is embedded in the primary coil (4), and the primary coil (4) is interference-fitted into the secondary coil (5). The toroidal core (6) is simultaneously wrapped around the outside of the primary coil (4) and the secondary coil (5) and is tightly fitted with the magnetic sheet (3). The primary coil (4) includes a primary core (7), a primary frame (8), and a primary varnish. The primary enameled wire (9) is wound around the outside of the primary frame (8), the primary iron core (7) is embedded inside the primary frame (8), the magnetic sheet (3) is magnetically connected to the primary iron core (7), the secondary coil (5) includes the secondary frame (10) and the secondary enameled wire (11), the secondary enameled wire (11) is wound around the outside of the secondary frame (10), and the end of the primary iron core (7) away from the magnetic sheet (3) is pressed against the toroidal iron core (6).

2. The core structure of a high-energy ignition coil for automobiles according to claim 1, characterized in that: The primary skeleton (8) has an installation cavity (12) for embedding the magnetic sheet (3), and the thickness of the magnetic sheet (3) is 1-4 mm.

3. The core structure of a high-energy ignition coil for automobiles according to claim 1, characterized in that: The primary iron core (7) is made of multiple layers of silicon steel sheets riveted together, with the thickness of the silicon steel sheets being 0.3-0.5 mm.

4. The core structure of a high-energy ignition coil for automobiles according to claim 1, characterized in that: The secondary frame (10) has a positioning slot (13) inside and an embedding slot (14) on the end face of the secondary frame (10). The primary frame (8) has a positioning protrusion (15) corresponding to the positioning slot (13). The positioning protrusion (15) is adapted to the positioning slot (13) and the mating surface is beveled. The primary frame (8) has an embedding protrusion (16) corresponding to the embedding slot (14). The embedding protrusion (16) is inserted into the embedding slot (14) and is interference-fitted.

5. The core structure of a high-energy ignition coil for automobiles according to claim 1, characterized in that: The secondary frame (10) has winding grooves (17) at equal intervals. A partition (18) is provided between each winding groove (17) on the secondary frame (10). The height of the partition (18) increases from both sides to the middle. A wire routing notch (19) is provided on the partition (18). Two first terminal slots (20) are provided on the secondary frame (10).

6. The core structure of a high-energy ignition coil for automobiles according to claim 1, characterized in that: The primary frame (8) has a wiring groove (21) and two second terminal slots (22).

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