Ignition Coil Resistor Integration for Discharge Prevention
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Solution Overview
Problem
Existing ignition coils with resistors face complexity and increased assembly costs due to the need for additional components to prevent discharge, which complicates the structure and reduces assembly efficiency.
Innovation Solution
An ignition coil design featuring a bar-shaped resistor inserted into an annular holding portion within a case, where a filler covers the resistor's surface, preventing discharge between ends while maintaining a simple structure and reducing component count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a resistor is held in a resistor storage portion by fixation means composed of projections and holding means formed by O ring or the like, then discharge at the resistor is prevented, but the structure becomes complicated and assembly cost increases
Solution Approach 1:
The holding portion is formed integrally with the output portion of the case as a single molded structure, merging the case structure with the resistor holding function. This eliminates the need for separate fixation means such as projections and O rings, thereby preventing discharge while simplifying the overall structure and reducing assembly complexity
Solution Approach 2:
The output portion of the case serves multiple functions: it provides the structural housing for the output terminal and simultaneously forms the holding portion that secures the resistor. This multi-functional design reduces the number of components needed while maintaining effective discharge prevention
2Reliability
If fixation means and holding means components are added to prevent discharge, then discharge prevention is achieved, but assembly efficiency decreases and assembly cost increases
Solution Approach 1:
By integrating the holding portion directly into the case structure as a single molded component, the assembly process is simplified. The resistor can be directly inserted into the holding portion without requiring separate fixation means or holding means components, thereby improving assembly efficiency while maintaining discharge prevention functionality
3Reliability
If additional components are added to prevent discharge, then discharge prevention is improved, but the ignition coil size and weight increase
Solution Approach 1:
The holding portion is formed as an integral part of the case structure, eliminating the need for additional separate components. This integration prevents discharge while avoiding any increase in the overall size and weight of the ignition coil, as no extra materials are added beyond what is already required for the case structure
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 effectively suppresses electric noise from discharge at the spark plug, enhances assembly efficiency, and reduces costs by eliminating the need for additional components, allowing for size and weight reduction of the ignition coil.
Implementation Method 1
a filler filling a gap inside the case... The filler fills the first internal area so as to cover a surface of the resistor... discharge at the resistor is prevented
Implementation Method 2
An ignition coil includes a coil assembly that generates a high voltage... a primary coil, a secondary coil... By the voltage application, a spark due to discharge from the spark plug occurs to ignite fuel
Data Source
AI summary
This ignition coil includes: a bar-shaped resistor electrically connected to a terminal of a coil assembly via a relay; a case for storing these; and a filler filling gaps inside the case. The case includes a body, a cylindrical output portion protruding from the body, and an annular holding portion protruding inward from an inner circumferential surface of the output portion and formed integrally with the output portion. A part of the resistor is inserted into the holding portion, and thus a first internal area located on the body side with respect to the holding portion and shut off from outside is formed in an internal area of the output portion. The filler fills the first internal area.