Ignition Coil Core Cover With Flexible Support Portions

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Solution Overview

Problem

Conventional ignition coils face challenges in assembling the outer peripheral core with the core cover due to manufacturing tolerance issues, where the core's dimensions exceed the interval between support portions, making reliable attachment difficult.

Innovation Solution

Incorporating a flexible portion in the core cover's support portions that elastically presses the outer peripheral core, allowing the interval between support portions to be adjusted, enabling secure attachment despite manufacturing tolerances.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a rigid core cover with fixed support portions is used, then the structure is simple and easy to manufacture, but the assembly reliability deteriorates when manufacturing tolerances cause the core dimensions to exceed the interval between support portions

Engineering Contradiction:

Improveassembly reliabilityVSAvoidcore cover structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The core cover incorporates a flexible portion that enables dynamic adjustment of the interval between support portions. This flexible section allows the support portions to move relative to each other, adapting to variations in outer peripheral core dimensions and ensuring reliable assembly despite manufacturing tolerances.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The flexible portion changes the physical state of the core cover from rigid to flexible in specific regions. This parameter change allows the interval between support portions to vary, accommodating dimensional variations in the outer peripheral core while maintaining structural integrity.

Inventive Principle:

Principle #35Parameter changes

2Adaptability or versatility

If the interval between support portions is fixed, then the manufacturing process is simple, but the assembly ability deteriorates when core dimensions exceed the available interval

Engineering Contradiction:

Improveassembly abilityVSAvoidcore cover manufacturing complexity

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The flexible portion introduces dynamic adjustability to the interval between support portions, allowing the core cover to adapt to different core dimensions. This dynamic feature enhances assembly ability without requiring complex adjustable mechanisms, as the flexibility is achieved through the material properties and geometric design of the flexible portion.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The core cover incorporates a flexible portion made from flexible material that can elastically deform. This flexible section acts as a compliant element that accommodates dimensional variations in the outer peripheral core, enabling reliable assembly while maintaining a relatively simple manufacturing process.

Inventive Principle:

Principle #30Flexible shells and thin films

3Ease of operation

If rigid support portions are used, then the structural integrity is maintained, but the assembly process fails when manufacturing tolerances cause dimensional mismatches

Engineering Contradiction:

Improveassembly easeVSAvoidcore cover structural strength

Core Design Contradiction:

Ease of operationVSStrength

Solution Approach 1:

The flexible portion allows the support portions to dynamically adjust their positions during assembly, making the assembly process easier by accommodating dimensional variations. The flexible section maintains structural strength through its elastic properties, ensuring that the core cover remains intact while enabling successful assembly.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The flexible portion acts as a compliant element that bridges the gap between rigid structural requirements and assembly tolerance requirements. It maintains structural integrity while enabling easier assembly by elastically deforming to accommodate dimensional mismatches caused by manufacturing tolerances.

Inventive Principle:

Principle #30Flexible shells and thin films

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

The flexible portion facilitates reliable assembly of the outer peripheral core with the core cover, improving the assembly process by accommodating larger manufacturing tolerances and preventing detachment, thus enhancing the overall assembly ability.

Implementation Method 1

at least one of the pair of support portions includes a flexible portion that elastically presses the outer peripheral core

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS11482376B2Ignition coil provided with core cover including supporting structure

Publication Date: 2022.10.25 DENSO CORP

AI summary

An ignition coil includes a primary coil and a secondary coil magnetically coupled from each other; a core cover disposed around the primary coil and the secondary coil; and an outer peripheral core supported by the core cover. The core cover includes a pair of support portions that support the outer peripheral core; and at least one of the pair of support portions includes a flexible portion that elastically presses the outer peripheral core, the flexible portion having flexibility in an arrangement direction separating the pair of support portions.