Ignition Coil Split Core Oblique Surface Assembly
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Solution Overview
Problem
Conventional ignition coils face assembly complexity and reduced productivity due to the need for precise alignment and pressing of side iron cores and permanent magnets, which can lead to performance deterioration if gaps form during assembly.
Innovation Solution
The design includes a central core with oblique surfaces and split cores that form closed magnetic paths, allowing for precise positioning and assembly by sliding and pressure contact, enhancing the alignment and contact between components without requiring simultaneous orthogonal and axial direction pressing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the first and second side iron cores are assembled by pressing them to approach each other both in the orthogonal direction and the winding axis extension direction simultaneously, then the alignment precision between the side iron cores and the permanent magnet/central iron core is improved, but the assembly process becomes complicated and productivity is lowered
Solution Approach 1:
The side iron core is divided into a first side iron core and a second side iron core that are assembled separately and then combined. This segmentation allows each half to be positioned independently using the oblique surfaces, simplifying the assembly process while maintaining alignment precision.
Solution Approach 2:
The oblique surfaces are designed to convert pressing force applied in the orthogonal direction into simultaneous positioning in both the orthogonal direction and the winding axis extension direction. This dimensional transformation eliminates the need for complex dual-directional pressing mechanisms.
2Manufacturing precision
If the contact surfaces of the first and second side iron cores are arranged parallel to the winding axis extension direction to allow sliding contact, then the alignment between components is improved, but the assembly process becomes more complex requiring simultaneous pressing in multiple directions
Solution Approach 1:
The oblique surfaces are inclined at specific angles (e.g., 45 degrees) relative to the pressing direction, creating a geometric conversion mechanism that transforms linear pressing motion into simultaneous positioning in multiple directions, reducing assembly complexity.
Solution Approach 2:
The oblique surfaces enable the side iron core halves to self-position and self-align during assembly when pressed together, eliminating the need for complex external alignment mechanisms or procedures.
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 simplifies the assembly process, reduces the likelihood of gaps, and improves the productivity of the ignition coil by allowing for precise positioning of the central core and split cores in both the axial and orthogonal directions, thereby maintaining performance.
Implementation Method 1
a primary coil (11) and a secondary coil (12) magnetically coupled to the primary coil (11)
Implementation Method 2
The pair of split cores (3) respectively form two closed magnetic paths with the central core (2)
Data Source
AI summary
An ignition coil has primary and secondary coils, a central core and a pair of split cores. One of the split cores has a first opposing face orthogonal to a coil axial direction X facing a core front end face of the central core in the coil axial direction X. The respective split cores have second opposing surfaces mutually facing each other in a lateral direction Y at a rear end of the central core. At least one of the second opposing surfaces and one of rear end surfaces of the central core contacting the least one of the second opposing surfaces collectively constitute a pair of oblique surfaces and come to close to the other one of the second opposing surfaces in the lateral direction Y as a portion of each of the oblique surfaces recedes further from the first opposing face in the coil axial direction X.