Rectangular Ignition Coil Asymmetric Terminal Layout
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Solution Overview
Problem
Conventional ignition coils, particularly rectangular coils, face challenges in downsizing while maintaining performance due to the need for larger housing heights, which hinders space efficiency in vehicles for pedestrian protection and other purposes.
Innovation Solution
The design optimizes the layout of the central and peripheral cores within a rectangular housing, with an elongated central core and a hollowed rectangular peripheral core, allowing for a smaller housing height by adjusting the position and size of components such as the primary and secondary coils, and using compacted magnetic powder for the central core, along with a terminal treatment portion to reduce overall size without compromising magnetic performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a rectangular coil configuration is used with conventional core and peripheral core arrangements, then high voltage generation capability is maintained, but the housing height becomes relatively large
Solution Approach 1:
The patent repositions the terminal treatment portion from the traditional vertical arrangement to a horizontal arrangement along the longitudinal direction of the central core. Specifically, the first terminal treatment portion is positioned at a first end of the central core in the longitudinal direction, while the second terminal treatment portion is positioned at a second end of the central core in the longitudinal direction. This dimensional reconfiguration allows the terminals to be arranged along the length of the core rather than extending the housing height, thereby reducing the vertical dimension while maintaining electrical connectivity and magnetic performance.
Solution Approach 2:
The patent employs asymmetric positioning of the terminal treatment portions relative to the central core. The first and second terminal treatment portions are positioned at opposite ends of the central core in the longitudinal direction, creating an asymmetric layout that optimizes space utilization. This asymmetric arrangement allows for compact housing design by distributing components along the longitudinal axis rather than requiring symmetric vertical extension, thus reducing housing height while maintaining functional performance.
2Power
If the number of turns and outer diameter of coils are increased to raise output, then high voltage generation capability is improved, but the overall size of the ignition coil increases
Solution Approach 1:
The patent utilizes the longitudinal direction of the central core as an additional dimension for arranging terminal treatment portions. By positioning terminals at the ends of the core in the longitudinal direction rather than extending vertically, the design accommodates increased coil turns and larger coil dimensions without proportionally increasing overall volume. This spatial optimization allows for higher output capability through increased winding density while maintaining compact ignition coil dimensions.
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 enables a more compact ignition coil that maintains high voltage generation capabilities while reducing the housing height, thereby addressing the need for downsizing without sacrificing performance.
Implementation Method 1
an ignition coil, in which high voltage is generated in a secondary coil by mutual induction effect
Implementation Method 2
a central core, a primary coil, a secondary coil and a hollowed rectangular peripheral core are arranged in a housing
Data Source
AI summary
A housing of an ignition coil has an approximately rectangular shape. A central core is in parallel with both side surfaces of the housing. The peripheral core has a larger size than the central core in a direction of a height of the housing. A first and second side portions of the peripheral core are opposed to both axial end surfaces of the central core, respectively. A third and fourth side portions of the peripheral core interpose the central core, a primary coil and a secondary coil therebetween to magnetically connect the first side portion to the second side portion. A terminal treatment portion for electrically connecting the primary coil to an external electric power source is arranged above or below the first side portion of the peripheral core. The peripheral core is positioned off-center with respect to the central core in the direction of the height of the housing.