Ignition Coil High Voltage Contact with Concave Surface
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Solution Overview
Problem
Existing ignition coil manufacturing methods require additional components for establishing electrical connections, which increases complexity and cost, and may be prone to field peak issues and contact failures.
Innovation Solution
A concave contact surface, such as a cup-shaped or annular bead, is used to guide and secure a wire end, eliminating the need for a separate contact spring, with the wire's spring force maintaining contact and a rounded end surface reducing field peaks, and the wire can be bent into an L-shape or integrated with a diode lead for cost-effective fabrication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate contact spring with an electrically nonconductive carrier element is used to establish electrical connection, then reliable electrical contact is achieved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the contact spring function and the carrier element into a single integrated contact element. The contact element features a resilient contact portion that directly provides both the spring force for maintaining contact and the structural support, eliminating the need for a separate nonconductive carrier element. This merging reduces component count while maintaining reliable electrical contact.
Solution Approach 2:
The contact element is designed to perform multiple functions simultaneously: it provides mechanical support, establishes electrical connection, and maintains contact pressure through its resilient properties. This multi-functional design replaces what previously required multiple specialized components, simplifying the overall device structure.
2Ease of manufacture
If a sharp wire end is used for contact, then manufacturing is simpler, but field peaks occur causing contact failures
Solution Approach 1:
The patent specifies that the end of the wire forming the contact point should be rounded or spheroidal rather than sharp. This curvature eliminates field peaks that would otherwise occur at sharp edges, preventing contact failures. The rounded end maintains ease of manufacture while significantly improving contact reliability by distributing electrical field stress evenly.
3Reliability
If additional components like contact springs are used, then contact reliability is improved, but manufacturing cost and process complexity increase
Solution Approach 1:
The contact spring function is integrated directly into the contact element itself through its resilient contact portion. This eliminates the need for separate contact spring components and their associated assembly steps, reducing manufacturing complexity while maintaining the reliability benefits of spring-loaded contact.
Solution Approach 2:
The resilient contact element is designed to automatically maintain contact pressure through its own elastic properties without requiring additional active components or complex assembly procedures. The element self-regulates the contact force, simplifying both manufacturing and assembly processes while ensuring reliable electrical connection.
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 method simplifies ignition coil manufacturing by eliminating extra components, enhances contact reliability through increased contact area and reduced field peaks, and maintains electrical connection during resin filling, ensuring robust and cost-effective high-voltage contacting.
Implementation Method 1
The spring force of the wire itself is sufficient for maintaining an electrical contact between the wire and the concave contact surface
Implementation Method 2
The end surface is preferably rounded, for example, spherically rounded. Rounding the end surface prevents field peaks
Data Source
AI summary
Described is an ignition coil comprising a housing, in which a transformer is arranged, and a plug connector, wherein the plug connector has a high voltage contact, which is connected to the secondary side of the transformer by means of a wire, which resiliently presses against an electrical contact surface. The contact surface is concavely shaped.