Ignition Coil High-Voltage Terminal Resistor Pressure Management
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Solution Overview
Problem
Existing ignition coils for internal combustion engines face durability issues due to excessive pressure on the resistor and high-voltage tower, which can lead to decreased mechanical strength and potential resin leakage.
Innovation Solution
The design incorporates a hollow cylindrical high-voltage terminal with a pressed wall and a non-pressed wall, where the resistor is fitted in the non-pressed wall, minimizing pressure on the high-voltage tower and increasing the contact area between the high-voltage terminal and the tower, enhancing mechanical strength and hermetic sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the high-voltage output terminal is press-fit in the high-voltage tower to ensure firm retention, then the mechanical strength and hermetic sealing are improved, but excessive pressure is exerted on the resistor and high-voltage tower leading to decreased durability
Solution Approach 1:
The high-voltage output terminal is divided into two distinct wall sections: a pressed wall for firm retention and a non-pressed wall for resistor housing. This segmentation allows the pressed wall to provide hermetic sealing and mechanical strength while the non-pressed wall protects the resistor from excessive pressure, resolving the contradiction between reliable retention and component durability.
Solution Approach 2:
Different portions of the high-voltage output terminal are given different properties: the pressed wall is designed for press-fitting to ensure hermetic sealing, while the non-pressed wall is designed to minimize pressure on the resistor. This local differentiation of functional properties allows simultaneous achievement of firm retention and component protection.
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 reduces pressure on the resistor and high-voltage tower, ensuring increased mechanical strength and minimizing resin leakage, thereby improving the durability and sealing efficiency of the ignition coil.
Implementation Method 1
a primary coil (11) and a secondary coil (12) which are magnetically coupled with each other
Data Source
AI summary
An ignition coil for internal combustion engines is provided which includes a primary coil, a secondary coil, a case, a high-voltage terminal, a resistor, and a filled resin. The case has a case body and a high-voltage terminal extending downward from the case body. The high-voltage terminal is press-fit in the high-voltage tower to close the inside thereof. The resistor is fit in the high-voltage terminal. The high-voltage terminal includes a pressed wall and a non-pressed wall. The pressed wall is pressed against the high-voltage tower. The non-pressed wall is not pressed against the high-voltage tower. The resistor is fit in the non-pressed wall. This structure minimizes pressure exerted on the resistor and the high-voltage tower to secure a desired degree of durability of the resistor and the high-voltage tower.