Ignition Coil Side Core Superimposed Magnetic Circuit Resistance
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Solution Overview
Problem
Existing ignition coils for internal combustion engines face increased magnetic circuit resistance due to displacement at divided surfaces, which deteriorates performance and is difficult to mitigate without compromising assembly workability.
Innovation Solution
The ignition coil design features a side core formed from laminated magnetic steel plates divided at different positions, with adjacent portions superimposing to create a large contact surface, reducing magnetic circuit resistance while maintaining assembly workability through the use of thermoplastic elastomer for molding and positioning adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the side core is divided into two parts to improve assembly workability, then assembly workability is improved, but magnetic circuit resistance increases due to displacement at divided surfaces
Solution Approach 1:
The side core is divided into two separate parts (first side core and second side core) that can be assembled independently around the primary and secondary coils, improving assembly workability while maintaining magnetic circuit integrity through superimposed portions
Solution Approach 2:
The first and second side cores are superimposed and integrated together to form a complete side core structure, where the divided surfaces are positioned to overlap rather than abut, eliminating gaps while maintaining the segmented assembly advantage
2Reliability
If the divided surfaces are formed diagonally to reduce displacement, then magnetic circuit resistance is reduced, but assembly workability deteriorates
Solution Approach 1:
Instead of forming complex diagonal surfaces, the patent uses superimposed portions where the first and second side cores overlap, allowing simple planar divided surfaces to achieve both low magnetic circuit resistance and easy assembly
3Reliability
If a large number of magnetic steel sheets are laminated to reduce magnetic circuit resistance, then magnetic circuit resistance is reduced, but manufacturing complexity and cost increase
Solution Approach 1:
The side core is divided into two parts that are assembled separately, allowing each part to be manufactured with a reasonable number of laminated sheets, reducing overall manufacturing complexity while maintaining low magnetic circuit resistance through the superimposed configuration
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 significantly suppresses the increase in magnetic circuit resistance, enhances assembly workability, and allows for cost-effective manufacturing with improved performance and reliability.
Implementation Method 1
a center core (1) disposed on an inner side of a primary coil (2) and a secondary coil (3) and a side core (4) disposed on an outer side of the primary coil (2) and the secondary coil (3)
Implementation Method 2
The side core (4) is formed of a plurality of side core portions (9, 10) obtained by dividing laminated magnetic steel plates at different positions in a longitudinal direction thereof
Data Source
AI summary
An ignition coil for internal combustion engine includes: a center core disposed on an inner side of a primary coil and a secondary coil and a side core disposed on an outer side of the primary and secondary coils whose one end face abuts on one end face of the center core and the other end face abuts on the other end face of the center core via a magnet. The side core is formed of a plurality of side core portions obtained by dividing laminated magnetic steel plates at different positions in a longitudinal direction thereof and has a superimposed portion in which the magnetic steel plates of the adjacent side core portions mutually superimpose between the different positions in the longitudinal direction. It thus becomes possible to provide an ignition coil for internal combustion engine capable of suppressing an increase of magnetic circuit resistance markedly without deteriorating assembly workability.