Ignition Coil Pole Joint Rib Vibration Resistance
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Solution Overview
Problem
Conventional ignition coils for internal combustion engines lack sufficient vibration resistance due to low rigidity, particularly in the high-voltage joint, which is prone to deformation and reduced insertion load when connected to the plug hole.
Innovation Solution
An ignition coil design featuring a resin-made pole joint with a rib that abuts the inner peripheral surface of the plug hole, supported by a rubber seal, enhancing vibration resistance by restraining the high-voltage tower's swing within the coil case.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the protrusion is pressure-welded to the inner peripheral surface of the plug hole using a rubber material, then the insertion load of the ignition coil to the plug hole is reduced, but the rigidity of the protrusion is low, making it difficult to improve vibration resistance of the ignition coil
Solution Approach 1:
The pole joint is designed with a rib that protrudes toward the outer periphery, creating a localized rigid structure that abuts against the inner peripheral surface of the plug hole. This local rigid structure provides vibration resistance while the rest of the pole joint maintains its resin material properties for ease of insertion and sealing functionality.
Solution Approach 2:
The ignition coil assembly combines multiple materials with different properties: the pole joint uses resin material for ease of manufacture and sealing, while the rib provides structural support. The rubber seal material is used for sealing purposes. This composite approach allows each material to contribute its optimal properties to the overall system performance.
2Ease of manufacture
If the mounting flange section is fastened to the internal combustion engine by a bolt, then the ignition coil can be mounted to the engine, but the ignition coil is not designed to be sufficiently strongly resistant to vibration generated in the internal combustion engine
Solution Approach 1:
Instead of relying solely on the mounting flange for vibration resistance, the invention adds a second support dimension by having the rib of the pole joint abut against the inner peripheral surface of the plug hole. This creates a dual-support system that significantly improves vibration resistance while maintaining the original mounting capability.
3Reliability
If the rib of the pole joint abuts the inner peripheral surface of the plug hole, then the high-voltage tower is restrained from swinging, but the pole joint must be precisely positioned within the plug hole
Solution Approach 1:
The rib is designed with specific dimensional parameters including a predetermined outer diameter that is slightly smaller than the inner diameter of the plug hole, allowing for controlled clearance. The height and position of the rib are optimized to ensure proper abutment against the plug hole surface while accommodating manufacturing tolerances.
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 design significantly improves vibration resistance by supporting the high-voltage tower through the rib and rubber seal, ensuring the ignition coil remains securely positioned and resistant to engine-generated vibrations.
Implementation Method 1
a rubber seal that is made of rubber, the rubber seal being attached to an outer periphery of the high-voltage tower section
Data Source
AI summary
In an ignition coil for an internal combustion engine, a coil case includes a housing section and a high-voltage tower section. The housing section houses a primary coil, a secondary coil, a center core, and an outer peripheral core, and is arranged outside a plug hole in a cylinder of an internal combustion engine in which an ignition plug is arranged. The high-voltage tower section protrudes from the housing section, and is disposed within the plug hole. A pole joint is disposed within the plug hole, and is mounted to the high-voltage tower section via a seal rubber. The pole joint is provided with a rib that protrudes to an outer periphery and faces an inner peripheral surface of the plug hole. The inner peripheral side of the rib faces the high-voltage tower section via the seal rubber.