Ignition Coil Winding Layout for Easier Coil-End Attachment
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Solution Overview
Problem
Existing ignition coils for internal combustion engines face difficulties in attaching the ends of the primary main coil and primary sub coil to the connection part of the primary bobbin, making it challenging to wind and fix the secondly-wound coil around the bobbin.
Innovation Solution
The ignition coil design includes a primary bobbin with a winding cylinder part and a connection part, where the primary main coil and primary sub coil are separately wound, with the firstly-wound ends having a shorter distance to the central axis than the secondly-wound ends, allowing for careful positioning and attachment to facilitate the winding and fixing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the primary main coil and primary sub coil are wound around the winding cylinder part, then the ignition coil can generate spark discharge, but it becomes difficult to attach the ends of both coils to the connection part without interference
Solution Approach 1:
The patent applies asymmetry by positioning the connection part offset from the central axis of the winding cylinder part. Specifically, the connection part is located at a position where the radial distance from the central axis is smaller than the radial distance to the outer surface of the winding cylinder part. This asymmetric positioning creates unequal radial distances for the firstly-wound ends and secondly-wound ends, allowing both sets of ends to be attached to the connection part without interference while maintaining the concentric winding structure necessary for spark discharge generation
2Adaptability or versatility
If the secondly-wound coil is wound around the bobbin after the firstly-wound coil, then both coils can be separately wound, but the attachment process becomes complex and time-consuming
Solution Approach 1:
The patent applies preliminary action by pre-positioning the connection part at an asymmetric location before the winding process. This pre-positioning establishes a fixed reference point that guides the attachment of both firstly-wound ends and secondly-wound ends. By having the connection part already in place at the optimized position, the attachment process becomes more efficient as workers can directly attach both sets of coil ends to the predetermined location without complex positioning or adjustment, reducing attachment time while maintaining separate winding capability
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 attachment of both coil ends to the connection part, preventing interference and ensuring proper handling and attachment, thereby streamlining the assembly process and improving the overall efficiency of the ignition coil.
Implementation Method 1
a primary coil including a primary main coil and a primary sub coil separately wound around the winding cylinder part; and a secondary coil that is concentric with the primary coil
Data Source
AI summary
An ignition coil for an internal combustion engine includes a primary bobbin including a winding cylinder part and a connection part between the winding cylinder part and a connector part, a primary coil including a primary main coil and a primary sub coil, and a secondary coil. When one of the primary main coil and the primary sub coil that includes an innermost coil part around the winding cylinder part is defined as a firstly-wound coil and the other is defined as a secondly-wound coil, firstly-wound ends, which are ends of the firstly-wound coil, and secondly-wound ends, which are ends of the secondly-wound coil, are attached to the connection part, and a shortest distance from a central axis of the winding cylinder part to each of the firstly-wound ends is smaller than a shortest distance from the central axis of the winding cylinder part to each of the secondly-wound ends.