Ignition Coil Wire Coating Reduces AC Resistance
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Solution Overview
Problem
Conventional ignition coil wires in igniter assemblies face issues with high electrical AC resistance and insufficient heat dissipation, affecting the efficiency of combustion systems.
Innovation Solution
A copper-based wire core coated with materials such as carbon-based materials, magnetic nanoparticles, iron, nickel, and cobalt is used to reduce AC resistance and enhance heat dissipation, providing improved mechanical support and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional copper wires are used in ignition coil assemblies, then the structure is simple and manufacturing is easy, but the electrical AC resistance is high and heat dissipation is insufficient
Solution Approach 1:
The patent applies composite materials by coating copper wire core with carbon-based materials (such as carbon nanotubes or graphene) to create a composite wire structure. This composite structure reduces electrical AC resistance by utilizing the superior electrical conductivity of the carbon-based coating material while maintaining the mechanical properties of the copper core, thereby resolving the contradiction between energy loss reduction and structural simplicity.
Solution Approach 2:
The patent changes the physical and chemical parameters of the wire by applying surface coatings with specific electrical and thermal properties. The coating process modifies the surface characteristics of the copper wire to achieve lower AC resistance and improved heat dissipation, allowing the wire to operate more efficiently without fundamentally changing the overall wire structure.
2Temperature
If conventional copper wires are used in ignition coil assemblies, then the manufacturing process is simple, but heat dissipation capability is insufficient
Solution Approach 1:
The patent uses composite materials with enhanced thermal conductivity properties by coating the copper wire core with carbon-based materials. These composite structures provide superior heat dissipation capabilities compared to pure copper, while the coating process can be integrated into existing manufacturing lines, maintaining reasonable manufacturing ease.
Solution Approach 2:
The patent modifies the thermal parameters of the wire through surface coating applications. The coating process changes the thermal conductivity and heat dissipation characteristics of the wire surface, enabling improved temperature management in ignition coil assemblies without requiring complete redesign of the manufacturing process.
3Productivity
If wire coating is applied to reduce AC resistance and improve heat dissipation, then electrical efficiency is enhanced, but manufacturing process becomes more complex
Solution Approach 1:
The patent optimizes electrical efficiency by applying coatings that change the electrical parameters of the wire surface. The coating process, while adding a step to manufacturing, uses established techniques such as electroplating or chemical vapor deposition that can be automated, thereby improving electrical efficiency with manageable increases in manufacturing complexity.
Solution Approach 2:
The patent employs composite material structures where the coating layer is specifically designed to work synergistically with the copper core. This composite approach achieves superior electrical efficiency through the combined properties of the materials, and the manufacturing process leverages existing composite material deposition technologies to minimize process complexity.
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
The solution effectively reduces electrical AC resistance and improves heat dissipation, leading to enhanced electrical efficiency and mechanical support in ignition coil assemblies.
Implementation Method 1
The wire core includes a copper-based material, and the coating includes at least one of a carbon-based material, magnetic nanoparticles, iron, nickel, and cobalt
Implementation Method 2
improved heat dissipation
Data Source
AI summary
A wire for an ignition coil assembly and/or a corona ignition assembly is provided. The wire comprises a wire core including a copper-based material, and a coating applied to the wire core. The coating includes at least one of a carbon-based material and magnetic nanoparticles. The carbon-based material can include graphene and/or carbon nanotubes, and the magnetic nanoparticles can include graphene and iron oxide (Fe3O4). Typically, the coating includes a plurality of layers. For example, the coating can include a layer of the graphene and/or carbon nanotubes, and/or a layer of the magnetic nanoparticles. The coating can also include a layer of insulating material, such as enamel. According to another embodiment, the coating includes iron, nickel, and/or cobalt plated onto the wire core.