Ignition Coil Side Iron Core Segmentation and Non-Magnetic Spacers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The challenge is to maintain high output capability and small size for ignition coils in internal combustion engines while preventing assembly variations caused by the insertion of large magnets, which can lead to position deviations and capability worsening.
Innovation Solution
The design includes a center iron core with primary and secondary coils surrounded by side iron cores that are separated obliquely, with a magnet holding portion between them, using non-magnetic intervening components to prevent rotational position deviations and magnetic adsorption, and elastomers for shock absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a large magnet is inserted to increase output capability, then the magnet inserting portion must be upsized, but this causes position deviation and assembly variation when side iron cores are assembled
Solution Approach 1:
The side iron cores are divided into a first side iron core and a second side iron core that are separated from each other, with the magnet inserted between them. This segmentation allows the magnet to be held securely between the two cores without causing rotational position deviation, as each core can be independently positioned and fixed relative to the center iron core before assembly.
Solution Approach 2:
A non-magnetic intervening component is inserted between the first and second side iron cores at the facing portions. This intermediary component prevents magnetic adsorption between the side iron cores, eliminating assembly variation caused by magnetic attraction, while still allowing the magnet to function effectively between the separated cores.
2Adaptability or versatility
If side iron cores are separated obliquely to accommodate the magnet, then the magnet holding portion is formed, but this may cause gap length variation during assembly
Solution Approach 1:
The non-magnetic intervening component acts as a precision spacer between the separated side iron cores. It is configured with a specific thickness that is less than the distance between the separated surfaces, thereby defining and maintaining a precise gap length between the side iron cores during assembly, eliminating variation caused by magnetic adsorption or misalignment.
Solution Approach 2:
The facing portions at the end portions of the separated surfaces are designed to face each other at a surface vertical to the axis direction before the magnet is inserted. This preliminary positioning ensures that when the magnet and intervening component are assembled, the gap length is predetermined and maintained, preventing assembly variation.
3Power
If a large magnet is inserted between side iron cores, then output capability increases, but rotational position deviation of side iron cores occurs during assembly
Solution Approach 1:
By separating the side iron cores into two distinct cores with the magnet inserted between them, the structure prevents rotational position deviation. Each side iron core can be independently positioned and fixed relative to the center iron core, and the magnet held between them, ensuring stable assembly without rotation or misalignment.
Solution Approach 2:
The non-magnetic intervening component prevents magnetic adsorption between the side iron cores, which would otherwise cause rotational position deviation during assembly. By eliminating this magnetic attraction, the side iron cores maintain their intended positions without rotation, ensuring stable assembly while still allowing the magnet to function for high output capability.
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 inhibits assembly variations, maintains high magnetic flux, and prevents capability degradation by ensuring accurate gap lengths and magnetic force distribution, enhancing the ignition coil's reliability and performance.
Implementation Method 1
a primary coil and a secondary coil, which is coaxially provided at a circumference of the primary coil, are wound around an outer circumference of a center iron core
Implementation Method 2
form a closed magnetic passage with the center iron core
Implementation Method 3
intervening components, which are provided at the facing portions and are configured by using a non-magnetic material, are included; and the intervening components have a thickness which is less than a distance between the separated surfaces
Data Source
AI summary
Obtain an ignition coil in which a magnet is provided at a magnet holding portion which is formed between a first side iron core and a second side iron core, and intervening components which are configured by using a non-magnetic material, are included at facing portions which are provided at end portions of separated surfaces of the first side iron core and separated surfaces of the second side iron core, in a state where the magnet holding portion is formed by using the first side iron core and the second side iron core, and are faced at a surface which is vertical with respect to an axis direction of the side iron cores, and the intervening components have a thickness which is less than a distance between the separated surfaces of the first side iron core and the separated surfaces of the second side iron core.