Ignition Coil Relay Member Elastic Grounding
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Solution Overview
Problem
The existing ignition coil for internal combustion engines faces difficulties in manufacturing efficiency due to the precise positioning requirements for the conductive member connecting the outer circumferential core to the grounding terminal, especially in densely spaced areas, leading to challenges in welding and assembly.
Innovation Solution
An ignition coil design featuring a relay member with a curved portion that can be elastically deformed to contact the outer circumferential core, eliminating the need for precise positioning and welding, and allowing the outer circumferential core to be grounded without interfering with the igniter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conductive member is welded at both ends to the grounding terminal member and the terminal extending from the outer circumferential core, then reliable electrical connection is achieved, but manufacturing efficiency deteriorates due to precise positioning requirements and complex welding processes
Solution Approach 1:
The patent replaces the welding process (thermal/mechanical system) with a mechanical pressing system. The pressing member is pressed against the outer circumferential core by elastic force or external pressure, establishing electrical connection without welding. This substitution eliminates the need for precise positioning and complex welding operations, significantly improving manufacturing efficiency while maintaining reliable electrical connection.
Solution Approach 2:
The patent introduces a pressing member as an intermediary component between the grounding terminal member and the outer circumferential core. This pressing member serves as a mediator that transmits the grounding potential to the outer circumferential core through mechanical contact, simplifying the connection process and eliminating the need for direct welding between the grounding terminal and the core.
2Area of stationary object
If the signal terminal member, grounding terminal member, and electronic components are densely spaced, then compact design is achieved, but work space for connecting the conductive member is reduced, increasing manufacturing difficulty
Solution Approach 1:
The patent replaces the welding process with a mechanical pressing operation that requires minimal work space. The pressing member can be easily positioned and pressed against the outer circumferential core even in the densely spaced connector unit, eliminating the need for complex welding equipment and large work spaces while maintaining compact design.
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 improves manufacturing efficiency by facilitating the connection between the relay member and the outer circumferential core, reducing the complexity of assembly and enhancing the reliability of the ignition coil while maintaining stable ground potential.
Implementation Method 1
the curved portion is elastically deformed and is urged against a front surface of the outer circumferential core
Data Source
AI summary
An ignition coil for an internal combustion engine according to the present embodiment includes a primary coil, a secondary coil, a center core, an outer circumferential core, an igniter, a case, a connector unit, and a relay member. The relay member electrically connects the outer circumferential core and a grounding terminal member. The relay member includes: a base portion provided along the rear surface of an engagement wall; a standing portion standing rearward of the base portion; and a curved portion that extends from a rear end of the standing portion in a vertical direction Z orthogonal to a coil axis direction X and is curved to protrude rearward. The base portion is in contact with an inner grounding terminal at one end in the vertical direction Z. The standing portion is provided further outward than the igniter in a horizontal direction Y. The curved portion is elastically deformed and is urged against a front surface of the outer circumferential core.