Ignition Coil Core Assembly Orthogonal Contact
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Solution Overview
Problem
The existing ignition coil assembly process is complicated due to the need to press side cores close to each other in both perpendicular and axial directions, leading to decreased productivity.
Innovation Solution
The ignition coil design includes first and second core members with angled contact regions that facilitate assembly by allowing the core members to be aligned and attached in the orthogonal direction, simplifying the assembly process and enhancing productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the first and second side cores are designed with surfaces extending parallel to the axial direction of the center core to ensure proper alignment, then the assembly reliability is improved, but the assembly process becomes complicated requiring pressing in both perpendicular and axial directions
Solution Approach 1:
The patent changes the contact surfaces of the first and second core members from axial orientation to orthogonal orientation. Specifically, the first core member has a contact surface extending in the orthogonal direction, and the second core member has a contact surface extending in the axial direction. This dimensional reorientation allows assembly to be accomplished by pressing in only the orthogonal direction, simplifying the assembly process while maintaining reliable alignment through the geometric relationship between the contact surfaces.
2Reliability
If the side cores are pressed close to each other in both perpendicular and axial directions to eliminate air gaps, then the ignition coil performance is improved, but the productivity is reduced due to complicated assembly process
Solution Approach 1:
The patent reorients the contact surfaces so that the first core member's contact surface extends in the orthogonal direction while the second core member's contact surface extends in the axial direction. This allows the assembly to be completed by pressing in only the orthogonal direction, eliminating the need for dual-directional pressing operations and thereby improving productivity while maintaining performance.
Solution Approach 2:
The patent employs asymmetric design where the first core member and second core member have different orientations of their contact surfaces relative to the center core. The first core member contacts with its surface extending orthogonally, while the second core member contacts with its surface extending axially. This asymmetric arrangement enables simplified single-direction pressing while ensuring proper alignment and eliminating air gaps.
3Productivity
If the first and second core members are designed with contact surfaces extending in different directions, then the assembly process is simplified to require pressing in only one direction, but the design complexity increases
Solution Approach 1:
The patent applies dimensional reorientation by designing the first core member with a contact surface extending in the orthogonal direction and the second core member with a contact surface extending in the axial direction. This strategic use of different spatial dimensions for contact surfaces simplifies the assembly operation to single-direction pressing while the increased design complexity is confined to the geometric configuration of the core members themselves.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design simplifies the assembly process by allowing the core members to be aligned and attached in the orthogonal direction, reducing the complexity and improving the overall productivity of the ignition coil assembly.
Implementation Method 1
a primary coil and a secondary coil which are magnetically coupled with each other
Implementation Method 2
a permanent magnet arranged on an end of the center core
Data Source
AI summary
An ignition coil includes a center core, a first core member, and a second core member. The first core member includes a first core-facing portion facing a front core surface of the center core and a first core side portion extending rearward from the first core-facing portion. The second core member includes a second core-facing portion facing a rear core surface of the center core and a second core side portion extending frontward from the second core-facing portion. The first core-facing portion has an end surface contacting a portion of the second core side portion to create a first contact region. Similarly, the second core-facing portion has an end surface contacting a portion of the first core side portion to create a second contact region. The first and second contact regions are shaped to approach frontward close to the first core side portion. This structure enhances productivity of the ignition coil.