Ignition Coil Primary Spool Radial Overhangs Winding Stability
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Solution Overview
Problem
The existing ignition coils for internal combustion engines face challenges in stabilizing the engagement of the second winding end portion of the primary winding with the circumferential overhangs, leading to potential loosening and instability.
Innovation Solution
The design incorporates a primary spool made of resin with annular cross-section and radially protruding overhangs, where the first winding end portion engages with one overhang and the second winding end portion engages with another, ensuring stable winding and preventing loosening by being wound between these overhangs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the second winding end portion is engaged with the circumferential overhangs of the primary spool, then the winding structure is simplified, but the engagement becomes unstable and may loosen
Solution Approach 1:
The patent divides the single circumferential overhang structure into multiple radial overhangs (first radial overhang and second radial overhang) positioned at different angular locations. This segmentation allows the first winding end portion to be engaged with one overhang while the second winding end portion is engaged with another overhang, preventing mutual interference and stabilizing the engagement of both ends simultaneously.
Solution Approach 2:
The patent transitions from a single circumferential overhang arrangement to a multi-dimensional radial overhang configuration. By positioning overhangs in different radial directions and angular positions, the design creates additional spatial dimensions for engagement, allowing winding end portions to be secured at multiple locations without interfering with each other, thus improving engagement stability.
2Reliability
If the primary winding is wound in multiple layers, then the electrical performance is improved, but the risk of loosening at winding end portions increases
Solution Approach 1:
The patent segments the winding end portions into distinct engagement zones by providing multiple radially protruding overhangs at different angular positions. This allows each winding end portion to be independently engaged with a specific overhang, preventing the loosening that occurs when multiple layers are wound without sufficient anchoring points.
Solution Approach 2:
The patent applies different structural features to different locations of the primary spool. The radial overhangs are positioned at specific angular locations to provide localized engagement points for the winding end portions. This local quality enhancement ensures that critical areas (winding ends) have improved stability while maintaining the multi-layer winding structure for optimal electrical performance.
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 stabilizes the winding end portions, preventing loosening and ensuring reliable operation of the ignition coil by maintaining secure engagement between the winding layers and overhangs, enhancing the coil's performance and durability.
Implementation Method 1
An ignition coil for use in an internal combustion engine includes a primary coil, a secondary coil, a center core, and an outer core. The primary coil is provided coaxially with the secondary coil to face with the second coil in a radial direction.
Data Source
AI summary
An ignition coil includes primary and secondary coils. The primary coil includes a primary spool and a primary winding wound on the spool. The primary winding has a second winding layer wound around a first winding layer. The primary spool has first and second overhangs protruding radially outwardly from a first spool end portion of the primary spool. The first overhang is positioned away from the second overhang toward a second spool end portion. The first winding layer has a first winding end portion extending from the first winding layer through a space between the first overhangs, and being wound on the first spool end portion between the first and second overhangs. The second winding layer has a second winding end portion extending from the second winding layer between the first overhangs, and being wound on the first spool end portion between the first and second overhangs.