Ignition Coil Insulation Eliminates Assembly Gaps
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Solution Overview
Problem
Existing ignition coils face issues with undesirable assembly gaps and reduced capacitive potential due to tolerances, which affects their ability to meet increased voltage requirements for modern engine concepts.
Innovation Solution
Incorporating insulation between the I-core and peripheral core, with thin polyimide foils or sprayed plastic, to create a defined air gap and prevent capacitive coupling, allowing the peripheral core to achieve higher potentials and reducing insulation load.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the I-core and peripheral core are arranged without gaps to eliminate assembly gaps, then manufacturing precision is improved, but the capacitive coupling between the secondary winding and the peripheral core increases, reducing the potential of the peripheral core
Solution Approach 1:
An insulator is introduced as an intermediary element between the I-core and the peripheral core. This insulator serves dual purposes: it eliminates assembly gaps and tolerance issues (improving manufacturing precision) while simultaneously preventing capacitive coupling between the secondary winding and peripheral core (maintaining peripheral core potential and reliability).
Solution Approach 2:
The magnetic circuit is segmented by introducing the insulator as a distinct component between the I-core and peripheral core. This segmentation allows independent optimization of each component's function while controlling the interaction between them, specifically managing the capacitive coupling effects.
2Reliability
If insulation is added between the I-core and peripheral core to prevent capacitive coupling, then the peripheral core potential is improved, but the device complexity increases
Solution Approach 1:
A thin insulating film or foil is used between the I-core and peripheral core. This thin film approach provides effective electrical insulation to prevent capacitive coupling and maintain peripheral core potential, while adding minimal structural complexity and maintaining compact device dimensions.
3Reliability
If the insulation thickness is increased to ensure better isolation, then the capacitive coupling is reduced, but the device volume increases
Solution Approach 1:
A thin insulating film is used to provide adequate electrical isolation between the I-core and peripheral core. The film thickness is optimized to provide sufficient insulation properties while minimizing the increase in device volume, maintaining compact ignition coil dimensions suitable for modern engine applications.
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 solution enables a higher potential for the peripheral core, eliminating issues with assembly gaps and increased voltage requirements, while reducing the load on the insulation system, thus optimizing the magnetic circuit and supporting modern engine technologies.
Implementation Method 1
the potential of the peripheral core that is produced by the capacitive coupling between the secondary winding and the forming core is reduced because of the capacitive coupling with the first coil former
Implementation Method 2
In order to convert electrical energy into magnetic energy, the on-board current of the motor vehicle flows through a first coil, which usually is a winding made of copper wire. This creates a magnetic field around this coil
Implementation Method 3
In order to release the stored electrical energy in the form of high-voltage pulses, the previously built-up magnetic field is forced to change direction by switching off the electrical current, whereby a second coil, which is spatially close to the first coil and has a much higher number of turns, an electrical high voltage is generated
Data Source
Figure 1
AI summary
The present invention relates to a device for storing energy and for transforming energy, particularly an ignition coil of an ignition system of a motor vehicle, comprising a magnetically acting I-core (3), a first coil body (5) receiving a first winding (6) connected to a supply voltage, a second coil body (7) comprising a second winding (8) connected to a high-voltage terminal, a circumferential core (2) surrounding the I-core (3), the first winding (6) and the second winding (8), and a permanent magnet (9) disposed at one end (3b) of the I-core (3), characterized in that between the permanent magnet (9) and the circumferential core (3) a first insulation (10) and between the other end (3a) of the I-core and the circumferential core (2) a second insulation (11) are provided.