Ignition Coil Side Core Narrow Portion Insulation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Increasing the compression ratio in internal combustion engines to improve fuel efficiency requires higher output voltages from ignition coils, which can lead to electrical discharges to the ground if the high-voltage side of the side core is not properly insulated, risking electrical discharge to the surroundings.
Innovation Solution
The ignition coil design includes a side core with a narrow portion on the high-voltage side and a wide portion on the low-voltage side, both coated with elastomer material, and filled with insulating resin, forming a closed magnetic path without increasing dimensions, thus preventing electrical discharge to the outside.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the entire side core is coated with elastomer material to prevent electrical discharge, then insulation performance is improved, but dimensions of the ignition coil are increased
Solution Approach 1:
The patent applies elastomer material coating selectively only to the high-voltage side of the side core (the narrow portion) rather than coating the entire side core. This localized coating approach provides sufficient insulation to prevent electrical discharge to the ground while avoiding the dimension increase that would result from coating the entire side core, thus resolving the contradiction between insulation performance and compact dimensions.
2Power
If the output voltage of the ignition coil is increased to meet higher compression ratio requirements, then fuel efficiency is improved, but the risk of electrical discharge to the surroundings increases
Solution Approach 1:
The patent addresses the increased electrical discharge risk associated with higher output voltages by applying elastomer material coating specifically to the high-voltage side of the side core. This localized insulation measure provides targeted protection against electrical discharge to the ground and surroundings, enabling the ignition coil to operate at higher voltages required for improved fuel efficiency without increasing the risk of harmful electrical discharge.
Solution Approach 2:
The elastomer material coating acts as an intermediary insulating layer between the high-voltage side core and the surrounding environment (ground). This intermediate protective layer prevents direct electrical discharge paths, allowing the ignition coil to safely operate at higher output voltages needed for high compression ratio engines while mitigating the harmful effect of electrical discharge to the surroundings.
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 configuration effectively suppresses electrical discharge to the outside while maintaining the compact size of the ignition coil even at higher output voltages, ensuring reliable operation without dimension increase.
Implementation Method 1
a primary coil and a secondary coil are wound around an outer periphery of the center core
Implementation Method 2
an insulating material such as an epoxy resin is filled in a space inside the case to secure insulation of the components
Data Source
AI summary
An ignition coil, including: a center core; a primary coil wound around the center core; a secondary coil wound around the primary coil; a side core, which is arranged around the secondary coil, and is coupled to the center core to from a closed magnetic path; a case configured to accommodate the center core, the primary coil, the secondary coil, and the side core; and an insulating resin filled in the case, wherein the side core includes a wide portion having a larger width in a direction from the center core to the side core, and a narrow portion having a smaller width than the wide portion, and wherein the narrow portion is formed on a high-voltage side of the side core.