Universal Primary Coil Former for Bidirectional Winding

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Solution Overview

Problem

Conventional primary coil formers can only be wound in one direction, making them incompatible with reversed pin assignments in ignition coils, requiring separate formers for different magnetic field orientations.

Innovation Solution

A primary coil former design that allows winding in both clockwise and anticlockwise directions, featuring a winding carrier surface with two primary winding stops, holders for winding wire ends, and deflection domes that enable the winding wire to be guided around either dome depending on the desired direction, allowing for flexible pin assignment compatibility.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a conventional primary coil former is used, then the winding direction is fixed in one direction, but the adaptability to different pin assignments is reduced

Engineering Contradiction:

Improvecompatibility with different pin assignmentsVSAvoidnumber of different former designs required

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The primary coil former is designed with symmetric deflection domes and multiple holders that enable it to accommodate both clockwise and anticlockwise winding directions. This universal design allows a single former type to be used across different pin assignments, eliminating the need for multiple specialized former designs and improving adaptability without increasing device complexity

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The deflection domes are positioned asymmetrically relative to the winding carrier surface, creating different winding paths that can accommodate both winding directions. The holders are arranged to allow flexible positioning of winding wire ends, enabling the same former structure to support asymmetric winding patterns in both directions

Inventive Principle:

Principle #4Asymmetry

2Adaptability or versatility

If separate primary coil formers are used for different winding directions, then the magnetic field orientation can be controlled, but the manufacturing complexity and inventory requirements increase

Engineering Contradiction:

Improvemagnetic field direction controlVSAvoidmanufacturing efficiency

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

A single primary coil former design serves multiple functions by supporting both clockwise and anticlockwise windings. The symmetric deflection dome configuration and multiple holders enable the same component to produce different magnetic field orientations depending on the winding direction, thereby improving productivity by reducing the number of different parts that need to be manufactured and managed

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The former design incorporates flexible elements including deflection domes that can guide the winding wire in different directions, and multiple holders that can accommodate winding wire ends in various positions. This dynamic adaptability allows the static former structure to support multiple winding configurations, enabling magnetic field direction control without requiring multiple fixed former designs

Inventive Principle:

Principle #15Dynamics

3Ease of manufacture

If a single primary coil former design is used, then manufacturing is simplified, but the ability to accommodate different pin assignments is limited

Engineering Contradiction:

Improvestandardization of former productionVSAvoidcompatibility with various pin assignments

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The primary coil former is designed as a universal component with symmetric deflection domes and multiple holders that can accommodate both clockwise and anticlockwise windings. This design allows a single standardized former to be used across different pin assignments, maintaining ease of manufacture through standardization while simultaneously achieving high adaptability to various configurations

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The former is segmented into functional elements including multiple holders and deflection domes that can independently guide the winding wire. This segmentation allows the same former structure to support different winding paths and pin assignments by utilizing different combinations of these segmented elements, thereby achieving both manufacturing simplicity and configuration flexibility

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS11527355B2Primary coil former for an ignition coil, and ignition coil with such a primary coil former

Publication Date: 2022.12.13 BORGWARNER LUDWIGSBURG GMBH

AI summary

A primary coil former for an ignition coil has a winding carrier surface configured for a primary coil wound thereon. Two primary winding stops limit the winding carrier surface at first and second axial ends of the carrier surface, respectively. Two holders are formed at the first axial end, each configured for holding one end of a winding wire. Two deflection domes are formed at the second axial end, one of the domes configured for guiding a winding wire back to the winding carrier surface for a clockwise winding and the other dome configured for guiding a winding wire back to the winding carrier surface for a counterclockwise winding. A groove in the winding carrier surface receives a winding wire which leads from one of the ends of the winding carrier surface up to a gap between the two deflection domes at the opposite end of the winding carrier surface.