Ignition Coil Heat Sink Layout for Stable Cooling and Resin Sealing
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Solution Overview
Problem
Conventional internal-combustion-engine ignition coil apparatuses face challenges with heat radiation performance variability, igniter positioning restrictions, and potting resin-related issues, leading to increased size and reliability concerns.
Innovation Solution
The design includes a heat sink bonded to the igniter and case with adhesives, featuring an opening window for controlled exposure, ensuring consistent heat sink area and improved heat radiation, while simplifying assembly and reducing resin leakage risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the igniter is disposed at the opening-face side of the case with integrated heat sink, then the heat radiation performance is maintained, but the inner layout of the ignition coil apparatus is largely restricted and the position where the igniter is disposed is limited
Solution Approach 1:
The heat sink is separated from the igniter and case, forming an independent component. This segmentation allows the heat sink to be positioned optimally for heat radiation while the igniter can be disposed of at various positions within the case, improving layout flexibility without compromising heat radiation performance.
Solution Approach 2:
Adhesives are introduced as intermediary materials to bond the heat sink to both the igniter and the case. This intermediary bonding method provides flexibility in positioning and assembly while ensuring reliable thermal connection, resolving the contradiction between fixed positioning and layout flexibility.
2Reliability
If a large amount of potting resin is filled into the case, then the igniter and heat sink are enclosed, but the area of the heat sink to be exposed differs among respective ignition coil apparatuses causing variation in heat radiation performance and the apparatus becomes large
Solution Approach 1:
The heat sink is extracted from the potting resin enclosure and positioned to be exposed outside the case. This extraction ensures that the heat sink surface is always exposed to air for consistent heat radiation, eliminating the variation caused by different amounts of potting resin while maintaining component protection through selective encasement.
3Temperature
If the heat sink is bonded to the connector assembly, then the heat radiation performance is secured, but the fitting portion between the connector assembly and the case becomes large increasing the probability of potting resin leakage
Solution Approach 1:
The heat sink bonding is segmented into two separate bonding locations: one to the igniter and another to the case. This segmentation eliminates the need for a large fitting portion between connector assembly and case, reducing potting resin leakage risk while maintaining heat radiation performance through dual bonding points.
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 configuration enhances heat radiation performance and layout flexibility, stabilizes the bonding process, and prevents resin leakage, resulting in a more reliable and compact ignition coil apparatus.
Implementation Method 1
the heat sink integrated with the igniter radiates heat generated in the igniter to the air
Implementation Method 2
a heat sink is bonded, with an adhesive or the like, to a connector assembly
Data Source
AI summary
There is provided an internal-combustion-engine ignition coil apparatus in which an igniter in a connector assembly is contained in the case of the ignition coil apparatus, in which an adhesive bonds the igniter to a heat sink inserted into the case through an opening window of the case and an adhesive bonds the heat sink to the inner circumferential surface of the opening window, and in which the exposed portion of the heat sink is exposed to the outside of the case through the opening window.