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EP1625601B1 - Method of producing an individual ignition coil and coil thus obtained - Google Patents

Method of producing an individual ignition coil and coil thus obtained Download PDF

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Publication number
EP1625601B1
EP1625601B1 EP04742782A EP04742782A EP1625601B1 EP 1625601 B1 EP1625601 B1 EP 1625601B1 EP 04742782 A EP04742782 A EP 04742782A EP 04742782 A EP04742782 A EP 04742782A EP 1625601 B1 EP1625601 B1 EP 1625601B1
Authority
EP
European Patent Office
Prior art keywords
coil
tubular body
primary winding
winding
primary
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Revoked
Application number
EP04742782A
Other languages
German (de)
French (fr)
Other versions
EP1625601A2 (en
Inventor
François FONTALBA
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
EFI Automotive SA
Original Assignee
Electricfil Automotive SAS
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
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Application filed by Electricfil Automotive SAS filed Critical Electricfil Automotive SAS
Publication of EP1625601A2 publication Critical patent/EP1625601A2/en
Application granted granted Critical
Publication of EP1625601B1 publication Critical patent/EP1625601B1/en
Anticipated expiration legal-status Critical
Revoked legal-status Critical Current

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F38/00—Adaptations of transformers or inductances for specific applications or functions
    • H01F38/12—Ignition, e.g. for IC engines
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/005—Impregnating or encapsulating
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/12—Insulating of windings
    • H01F41/122—Insulating between turns or between winding layers
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/12—Insulating of windings
    • H01F41/127—Encapsulating or impregnating
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/4902—Electromagnet, transformer or inductor
    • Y10T29/49073—Electromagnet, transformer or inductor by assembling coil and core

Definitions

  • the present invention relates to the technical field of internal combustion heat engines and more particularly spark ignition engines by means of candles.
  • the invention relates more particularly to ignition systems in which each spark plug is equipped with a unitary electrical energy transformation coil capable of supplying it from a low-voltage electrical energy source, an energy high voltage required for the production of an ignition spark between the electrodes of such a candle inside the combustion chamber of the cylinder.
  • an ignition coil comprises a secondary coil tubular body or carcass, made of a dielectric material and internally having a central magnetic core and on its outer face a secondary winding.
  • One of the terminals of the secondary winding is connected to electrical cooperation means with the connection terminal of the spark plug.
  • This secondary coil-tubular body assembly is inserted into a primary tubular carcass on the outer face of which is wound a primary winding connected to a low voltage connector.
  • the primary winding is surrounded by a magnetic cylinder ensuring the looping of the flux with the magnetic core.
  • this coil thus constituted or a part of the constituent parts is impregnated with a dielectric resin during a vacuum casting operation.
  • Such an ignition coil is intended to be inserted into a well arranged in the cylinder head and at the bottom of which is housed a spark plug. Such coils are subjected to high temperatures and vibrations and must have optimized insulation in a limited space of limited space.
  • this type of coil has a relatively large number of component parts whose assembly must be performed accurately and carefully to ensure the reliability of the coil. In the same direction, the assembly of these different parts requires fitting zones that create interfaces likely to break the dielectric insulation favoring the path of high voltage.
  • the impregnation made under vacuum requires large passage sections to allow the relatively viscous resin to flow by gravity between the various constituent parts before the atmospheric pressure is re-established around the coil and it comes compact the resin to areas still empty.
  • the polymerization of the resins used for this type of application requires gelling and polymerization furnaces in which the coils must remain for several hours.
  • the interlocking of the various component parts and of the resin poses problems of mechanical stress, in particular during thermal cycles, due to the differences in the coefficient of expansion of the materials in the presence.
  • the patent EP 0 843 394 proposes to make an ignition coil having no primary tubular carcass.
  • a dielectric resin which coats the secondary coil serves, after hardening, the winding of the primary winding.
  • the absence of a primary tubular carcass makes the winding operation of the primary winding difficult.
  • such an ignition coil does not provide a solution to the problem of the presence of interfaces likely to break the dielectric insulation promoting the high voltage path.
  • the drawbacks stated above relating to the implementation of resins remain intact for such an ignition coil.
  • the present invention therefore aims to overcome the disadvantages mentioned above by proposing a new technique for producing an integrated single ignition coil, designed to facilitate manufacturing operations while ensuring a safe and effective way, the dielectric insulation between the various constituent parts.
  • Another object of the invention is to provide a method for obtaining a new integrated single ignition coil designed to provide optimized insulation in a reduced diametral size.
  • the method consists in the overmolding step, to ensure the formation of a primary coil tubular body, provided at the opposite end of that equipped with the tip, means adapted to receive low voltage electrical connections.
  • the method according to the invention consists in the overmolding step, to seal the bore of the secondary coil tubular body.
  • the method according to the invention also comprises a step of mounting a magnetic core inside the bore of the secondary coil tubular body.
  • the method according to the invention also comprises a step of mounting a cylinder for looping the magnetic flux with the magnetic core mounted externally to the primary winding.
  • the method consists in providing the overmolding step, by the injection under pressure inside a mold, of a thermosetting dielectric material.
  • Another object of the invention is to propose a coil according to claim 7.
  • the ignition coil 1 is intended to ensure the individual power supply of a spark plug 2 of a heat engine shown simply schematically and implanted at the bottom of a well 3 of a cylinder head 4 of such an engine.
  • the coil designated as a whole by the reference 1, is intended to be mounted to be interposed between the spark plug 2 and an ignition system known to those skilled in the art, adapted to control the coil for the purpose of generating a current high voltage to the candle 2.
  • the Figures 2 to 4 illustrate various steps characteristic of the method of manufacturing an ignition coil 1 according to the invention.
  • the coil 1 comprises a carcass or a secondary coil tubular body 11 made of a dielectric material, for example a thermoplastic or thermosetting material.
  • this secondary carcass 11 is made by molding, by the injection of a thermoplastic or thermosetting material.
  • This tubular carcass 11 comprises a central bore 12 of longitudinal axis x intended to receive a magnetic core 13 constituted for example by a laminated mass oriented along the longitudinal axis x.
  • the secondary carcass 11 is delimited by an outer face 14 of revolution intended to receive a secondary winding 15 having a low voltage end 16 located in relation to an end portion 17 of the secondary carcass 11 and a high voltage end 18 located at a portion terminal 19 of the secondary carcass 11, located opposite the other end portion 17.
  • the method consists in implementing then an overmolding step of the whole secondary carcass 11 - secondary winding 15 by a dielectric material providing impregnation of the secondary winding 15 and forming a carcass or body tubular primary coil 21 adapted to allow in a subsequent step, the winding of a primary winding 23.
  • the method according to the invention thus consists in ensuring the injection under pressure in an overmolding mold, a dielectric material preferably thermosetting. Such a dielectric material ensures impregnation of the turns of the secondary winding 15 as well as a high voltage isolation function for the secondary coil.
  • this dielectric material is performed so as to obtain a primary carcass 21 serving as a support for the primary coil.
  • This primary carcass 21 thus extends concentrically to the secondary carcass 11 and outside the secondary winding 15 along at least the entire length of the secondary winding taken along the x axis .
  • this overmolding step is put to advantage so that the primary carcass 21 has conformations to assume additional functions such as mechanical assembly and / or electrical connections.
  • the method consists in ensuring during this overmolding step, the formation of a primary carcass 21 extending at one end, by a nozzle 21 1 connecting to a candle coming from to slip into the mouthpiece 21 1 .
  • the tip 21 1 incorporates electrical connection means to form a stud 25 high voltage ignition coil.
  • the high voltage stud 25 is formed by a high voltage tab on which is mounted a spring.
  • an extension 21 2 provided with means adapted to receive low voltage electrical connections.
  • Such an extension 21 2 can thus constitute a low voltage connector.
  • the overmolding of the primary carcass 21 makes it possible to limit the number of parts constituting the ignition coil by the fact that the shape given to the overmoulding mold alone can fulfill the functions usually performed by different parts.
  • This overmolded primary carcass 21 which constitutes a single piece makes it possible to eliminate the interfaces between various parts which can facilitate the path of the high voltage.
  • the bore 12 of the secondary carcass 11 is closed so as to subsequently allow the magnetic core to be mounted.
  • the overmoulding step it may be provided to perform a step of winding a primary winding 23 on the outer face 24 of the primary carcass 21 as it appears more precisely in the Figure 4 .
  • the method according to the invention then aims to implement a step of mounting a cylinder 26 for looping the magnetic flux with the magnetic core 13, mounted externally to the primary winding 23.
  • the manufacturing method according to the invention makes it possible to reduce the number of components constituting an ignition coil, thereby facilitating assembly operations. This reduction in the number of parts makes it possible to eliminate the interfaces and consequently the breakdown faults between the high-voltage terminal 25 and the looping cylinder 26, and between the high-voltage terminal 25 and the primary winding 23. Furthermore, in the Since the magnetic core 13 is not embedded in a resin, this magnetic core 13 can expand freely depending on the temperature without causing cracking of the secondary carcass 11.

Landscapes

  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Ignition Installations For Internal Combustion Engines (AREA)
  • Disintegrating Or Milling (AREA)

Abstract

The method involves winding a primary coil (23) concentrically and externally with respect to a secondary coil (15), and electrically isolating the coil (23) from the coil (15). The coil (15) is wound on a secondary carcass (11) made from dielectric material. The coil (15) and carcass assembly is molded in a dielectric material assuring an impregnation of the secondary coil and a formation of a primary carcass (21). An independent claim is also included for an ignition coil for a spark plug of an internal combustion engine.

Description

La présente invention concerne le domaine technique des moteurs thermiques à combustion interne et plus particulièrement des moteurs à allumage commandé par l'intermédiaire de bougies.The present invention relates to the technical field of internal combustion heat engines and more particularly spark ignition engines by means of candles.

L'invention vise plus particulièrement les systèmes d'allumage dans lesquels chaque bougie d'allumage est équipée d'une bobine unitaire de transformation d'énergie électrique apte à lui fournir à partir d'une source d'énergie électrique basse tension, une énergie haute tension nécessaire pour la production d'une étincelle d'allumage entre les électrodes d'une telle bougie à l'intérieur de la chambre de combustion du cylindre.The invention relates more particularly to ignition systems in which each spark plug is equipped with a unitary electrical energy transformation coil capable of supplying it from a low-voltage electrical energy source, an energy high voltage required for the production of an ignition spark between the electrodes of such a candle inside the combustion chamber of the cylinder.

Dans l'état de la technique, il est connu de nombreuses variantes de réalisation d'une bobine unitaire d'allumage. D'une manière générale, une bobine d'allumage comporte un corps ou une carcasse tubulaire de bobine secondaire, réalisé en un matériau diélectrique et comportant intérieurement un noyau magnétique central et sur sa face externe un enroulement secondaire. Une des bornes de l'enroulement secondaire est reliée à des moyens de coopération électrique avec la borne de connexion de la bougie. Cet ensemble bobine secondaire-corps tubulaire est inséré dans une carcasse tubulaire primaire sur la face externe de laquelle est bobiné un enroulement primaire raccordé à un connecteur basse tension. L'enroulement primaire est entouré par l'intermédiaire d'un cylindre magnétique assurant le bouclage du flux avec le noyau magnétique. D'une manière classique, cette bobine ainsi constituée ou une partie des pièces constitutives est imprégnée d'une résine diélectrique au cours d'une opération de coulée sous vide.In the state of the art, many variants of a unitary ignition coil are known. In general, an ignition coil comprises a secondary coil tubular body or carcass, made of a dielectric material and internally having a central magnetic core and on its outer face a secondary winding. One of the terminals of the secondary winding is connected to electrical cooperation means with the connection terminal of the spark plug. This secondary coil-tubular body assembly is inserted into a primary tubular carcass on the outer face of which is wound a primary winding connected to a low voltage connector. The primary winding is surrounded by a magnetic cylinder ensuring the looping of the flux with the magnetic core. In a conventional manner, this coil thus constituted or a part of the constituent parts is impregnated with a dielectric resin during a vacuum casting operation.

Une telle bobine d'allumage est destinée à être insérée dans un puits aménagé dans la culasse et au fond duquel est logée une bougie d'allumage. De telles bobines sont soumises à des hautes températures et à des vibrations et doivent présenter une isolation optimisée dans un volume d'encombrement diamétral limité.Such an ignition coil is intended to be inserted into a well arranged in the cylinder head and at the bottom of which is housed a spark plug. Such coils are subjected to high temperatures and vibrations and must have optimized insulation in a limited space of limited space.

Il doit être considéré que ce type de bobine possède un nombre relativement important de pièces constitutives dont l'assemblage doit être réalisé de manière précise et soignée pour garantir la fiabilité de la bobine. Dans le même sens, l'assemblage de ces différentes pièces nécessite des zones d'emmanchement qui créent des interfaces susceptibles de rompre l'isolation diélectrique favorisant le cheminement de la haute tension.It should be considered that this type of coil has a relatively large number of component parts whose assembly must be performed accurately and carefully to ensure the reliability of the coil. In the same direction, the assembly of these different parts requires fitting zones that create interfaces likely to break the dielectric insulation favoring the path of high voltage.

Par ailleurs, il est à considérer que l'imprégnation faite sous vide nécessite des sections de passage importantes pour permettre à la résine relativement visqueuse de s'écouler par gravité entre les différentes pièces constitutives avant que la pression atmosphérique soit rétablie autour de la bobine et qu'elle vienne compacter la résine vers des zones encore vides. De plus, la polymérisation des résines utilisées pour ce type d'application nécessite des fours de gélification et de polymérisation dans lesquels les bobines doivent séjourner plusieurs heures. Par ailleurs, l'imbrication des différentes pièces constitutives et de la résine pose des problèmes de contraintes mécaniques, en particulier lors des cycles thermiques, dus aux différences de coefficient de dilatation des matériaux en présence.Furthermore, it is to be considered that the impregnation made under vacuum requires large passage sections to allow the relatively viscous resin to flow by gravity between the various constituent parts before the atmospheric pressure is re-established around the coil and it comes compact the resin to areas still empty. In addition, the polymerization of the resins used for this type of application requires gelling and polymerization furnaces in which the coils must remain for several hours. Furthermore, the interlocking of the various component parts and of the resin poses problems of mechanical stress, in particular during thermal cycles, due to the differences in the coefficient of expansion of the materials in the presence.

Pour tenter de réduire notamment l'encombrement diamétral d'une telle bobine, le brevet EP 0 843 394 propose de réaliser une bobine d'allumage ne comportant pas de carcasse tubulaire primaire. En effet, une résine diélectrique qui enrobe la bobine secondaire sert, après durcissement, au bobinage de l'enroulement primaire. Cependant, l'absence d'une carcasse tubulaire primaire rend délicate l'opération de bobinage de l'enroulement primaire. Par ailleurs, une telle bobine d'allumage n'apporte pas de solution au problème lié à la présence d'interfaces susceptibles de rompre l'isolation diélectrique favorisant le cheminement haute tension. De plus, les inconvénients énoncés ci-dessus relatifs à la mise en oeuvre de résines restent entiers pour une telle bobine d'allumage.In an attempt to reduce in particular the diametral size of such a coil, the patent EP 0 843 394 proposes to make an ignition coil having no primary tubular carcass. Indeed, a dielectric resin which coats the secondary coil serves, after hardening, the winding of the primary winding. However, the absence of a primary tubular carcass makes the winding operation of the primary winding difficult. Moreover, such an ignition coil does not provide a solution to the problem of the presence of interfaces likely to break the dielectric insulation promoting the high voltage path. In addition, the drawbacks stated above relating to the implementation of resins remain intact for such an ignition coil.

Par ailleurs, il est connu par le brevet US 4831995 de noyer dans un enrobage diélectrique, la bobine de transformation d'un bloc transformateur d'allumage.Moreover, he is known by the U.S. Patent No. 4,831,995 to drown in a dielectric coating, the transformer coil of an ignition transformer block.

La présente invention vise donc à remédier aux inconvénients énoncés ci-dessus en proposant une nouvelle technique de réalisation d'une bobine intégrée d'allumage individuel, conçue pour faciliter les opérations de fabrication tout en assurant de manière sûre et efficace, l'isolation diélectrique entre les diverses pièces constitutives.The present invention therefore aims to overcome the disadvantages mentioned above by proposing a new technique for producing an integrated single ignition coil, designed to facilitate manufacturing operations while ensuring a safe and effective way, the dielectric insulation between the various constituent parts.

Un autre objet de l'invention vise à proposer un procédé permettant d'obtenir une nouvelle bobine intégrée d'allumage individuel conçue pour présenter une isolation optimisée dans un encombrement diamétral réduit.Another object of the invention is to provide a method for obtaining a new integrated single ignition coil designed to provide optimized insulation in a reduced diametral size.

Pour atteindre un tel objectif, on utilise le procédé dans la revendication 1.To achieve such an objective, the method of claim 1 is used.

Selon une autre caractéristique préférée de réalisation, le procédé consiste lors de l'étape de surmoulage, à assurer la formation d'un corps tubulaire de bobine primaire, pourvu à l'extrémité opposée de celle équipée de l'embout, de moyens adaptés pour recevoir des connexions électriques basse tension.According to another preferred embodiment, the method consists in the overmolding step, to ensure the formation of a primary coil tubular body, provided at the opposite end of that equipped with the tip, means adapted to receive low voltage electrical connections.

Avantageusement, le procédé selon l'invention consiste lors de l'étape de surmoulage, à obturer l'alésage du corps tubulaire de bobine secondaire.Advantageously, the method according to the invention consists in the overmolding step, to seal the bore of the secondary coil tubular body.

Le procédé selon l'invention comporte également une étape de montage d'un noyau magnétique à l'intérieur de l'alésage du corps tubulaire de bobine secondaire.The method according to the invention also comprises a step of mounting a magnetic core inside the bore of the secondary coil tubular body.

Le procédé selon l'invention comporte aussi une étape de montage d'un cylindre de bouclage du flux magnétique avec le noyau magnétique, monté extérieurement à l'enroulement primaire.The method according to the invention also comprises a step of mounting a cylinder for looping the magnetic flux with the magnetic core mounted externally to the primary winding.

Avantageusement, le procédé consiste à assurer l'étape de surmoulage, par l'injection sous pression à l'intérieur d'un moule, d'un matériau diélectrique thermodurcissable.Advantageously, the method consists in providing the overmolding step, by the injection under pressure inside a mold, of a thermosetting dielectric material.

Un autre objet de l'invention est de proposer une bobine selon la revendication 7.Another object of the invention is to propose a coil according to claim 7.

Diverses autres caractéristiques ressortent de la description faite ci-dessous en référence aux dessins annexés qui montrent, à titre d'exemples non limitatifs, des formes de réalisation de l'objet de l'invention.

  • La Figure 1 est une vue en coupe longitudinale d'un exemple de réalisation d'une bobine intégrée d'allumage conforme à l'invention.
  • Les Figures 2, 3 et 4 sont des vues en coupe longitudinale montrant différentes étapes caractéristiques du procédé de fabrication d'une bobine d'allumage conforme à l'invention.
Various other characteristics appear from the description given below with reference to the accompanying drawings which show, by way of non-limiting examples, embodiments of the subject of the invention.
  • The Figure 1 is a longitudinal sectional view of an embodiment of an integrated ignition coil according to the invention.
  • The Figures 2, 3 and 4 are views in longitudinal section showing different steps characteristic of the method of manufacturing an ignition coil according to the invention.

Tel que cela ressort plus précisément de la Figure 1 , la bobine d'allumage 1 conforme à l'invention est destinée à assurer l'alimentation électrique individuelle d'une bougie 2 d'un moteur thermique représenté simplement schématiquement et implantée au fond d'un puits 3 d'une culasse 4 d'un tel moteur. La bobine, désignée dans son ensemble par la référence 1, est destinée à être montée pour être interposée entre la bougie 2 et un système d'allumage connu de l'homme du métier, apte à commander la bobine dans le but de générer un courant haute tension à la bougie 2. As is more particularly apparent from the Figure 1 , the ignition coil 1 according to the invention is intended to ensure the individual power supply of a spark plug 2 of a heat engine shown simply schematically and implanted at the bottom of a well 3 of a cylinder head 4 of such an engine. The coil, designated as a whole by the reference 1, is intended to be mounted to be interposed between the spark plug 2 and an ignition system known to those skilled in the art, adapted to control the coil for the purpose of generating a current high voltage to the candle 2.

Les Figures 2 à 4 illustrent différentes étapes caractéristiques du procédé de fabrication d'une bobine d'allumage 1 conforme à l'invention.The Figures 2 to 4 illustrate various steps characteristic of the method of manufacturing an ignition coil 1 according to the invention.

Tel que cela ressort plus précisément de la Figure 2 , la bobine 1 comporte une carcasse ou un corps tubulaire de bobine secondaire 11 réalisé en un matériau diélectrique, par exemple en un matériau thermoplastique ou thermodurcissable. Par exemple, cette carcasse secondaire 11 est réalisée par moulage, par l'injection d'un matériau thermoplastique ou thermodurcissable. Cette carcasse tubulaire 11 comporte un alésage central 12 d'axe longitudinal x destiné à recevoir un noyau magnétique 13 constitué par exemple par une masse feuilletée orientée selon l'axe longitudinal x. As is more particularly apparent from the Figure 2 , the coil 1 comprises a carcass or a secondary coil tubular body 11 made of a dielectric material, for example a thermoplastic or thermosetting material. For example, this secondary carcass 11 is made by molding, by the injection of a thermoplastic or thermosetting material. This tubular carcass 11 comprises a central bore 12 of longitudinal axis x intended to receive a magnetic core 13 constituted for example by a laminated mass oriented along the longitudinal axis x.

La carcasse secondaire 11 est délimitée par une face externe de révolution 14 destinée à recevoir un enroulement secondaire 15 présentant une extrémité basse tension 16 située en relation d'une partie terminale 17 de la carcasse secondaire 11 et une extrémité haute tension 18 située à une partie terminale 19 de la carcasse secondaire 11, située à l'opposé de l'autre partie terminale 17. Ces étapes de réalisation de la carcasse secondaire 11 et de bobinage d'un enroulement secondaire sur la carcasse secondaire 11 ne sont pas décrites plus précisément car elles sont bien connues de l'homme du métier.The secondary carcass 11 is delimited by an outer face 14 of revolution intended to receive a secondary winding 15 having a low voltage end 16 located in relation to an end portion 17 of the secondary carcass 11 and a high voltage end 18 located at a portion terminal 19 of the secondary carcass 11, located opposite the other end portion 17. These steps of producing the secondary carcass 11 and winding a secondary winding on the secondary carcass 11 are not described more precisely because they are well known to those skilled in the art.

Selon une caractéristique de l'invention illustrée à la Figure 3 , le procédé consiste à mettre en oeuvre ensuite une étape de surmoulage de l'ensemble carcasse secondaire 11 - enroulement secondaire 15, par un matériau diélectrique assurant une imprégnation de l'enroulement secondaire 15 et la formation d'une carcasse ou d'un corps tubulaire de bobine primaire 21 adapté pour permettre lors d'une étape ultérieure, le bobinage d'un enroulement primaire 23. Le procédé selon l'invention consiste ainsi à assurer l'injection sous pression dans un moule de surmoulage, d'un matériau diélectrique de préférence thermodurcissable. Un tel matériau diélectrique assure une imprégnation des spires de l'enroulement secondaire 15 ainsi qu'une fonction d'isolation haute tension pour la bobine secondaire. De plus, le surmoulage de ce matériau diélectrique est réalisé de manière à obtenir une carcasse primaire 21 servant de support pour la bobine primaire. Cette carcasse primaire 21 s'étend ainsi de manière concentrique à la carcasse secondaire 11 et à l'extérieur de l'enroulement secondaire 15 selon au moins toute la longueur de l'enroulement secondaire prise selon l'axe x. According to a feature of the invention illustrated in Figure 3 , The method consists in implementing then an overmolding step of the whole secondary carcass 11 - secondary winding 15 by a dielectric material providing impregnation of the secondary winding 15 and forming a carcass or body tubular primary coil 21 adapted to allow in a subsequent step, the winding of a primary winding 23. The method according to the invention thus consists in ensuring the injection under pressure in an overmolding mold, a dielectric material preferably thermosetting. Such a dielectric material ensures impregnation of the turns of the secondary winding 15 as well as a high voltage isolation function for the secondary coil. In addition, the overmoulding of this dielectric material is performed so as to obtain a primary carcass 21 serving as a support for the primary coil. This primary carcass 21 thus extends concentrically to the secondary carcass 11 and outside the secondary winding 15 along at least the entire length of the secondary winding taken along the x axis .

Selon une caractéristique avantageuse du procédé selon l'invention, cette étape de surmoulage est mise à profit afin que la carcasse primaire 21 présente des conformations pour assumer des fonctions supplémentaires telles que d'assemblage mécanique et/ou de raccordement électriques.According to an advantageous characteristic of the method according to the invention, this overmolding step is put to advantage so that the primary carcass 21 has conformations to assume additional functions such as mechanical assembly and / or electrical connections.

Selon une caractéristique avantageuse de l'objet de l'invention, le procédé consiste à assurer lors de cette étape de surmoulage, la formation d'une carcasse primaire 21 se prolongeant à une extrémité, par un embout 211 de raccordement à une bougie venant s'emmancher à l'intérieur de l'embout 211. Bien entendu, l'embout 211 intègre des moyens de connexion électrique afin de constituer un plot haute tension 25 de la bobine d'allumage. Dans l'exemple illustré à la Figure 1 , le plot haute tension 25 est formé par une languette haute tension sur laquelle est monté un ressort.According to an advantageous characteristic of the subject of the invention, the method consists in ensuring during this overmolding step, the formation of a primary carcass 21 extending at one end, by a nozzle 21 1 connecting to a candle coming from to slip into the mouthpiece 21 1 . Of course, the tip 21 1 incorporates electrical connection means to form a stud 25 high voltage ignition coil. In the example shown in Figure 1 , the high voltage stud 25 is formed by a high voltage tab on which is mounted a spring.

Selon une autre caractéristique avantageuse de réalisation, lors de cette étape de surmoulage, il peut être prévu d'assurer la formation d'une carcasse primaire 21 pourvue à l'extrémité opposée de celle équipée de l'embout 211, d'un prolongement 212 pourvu de moyens adaptés pour recevoir des connexions électriques basse tension. Un tel prolongement 212 peut ainsi constituer un connecteur basse tension.According to another advantageous characteristic of embodiment, during this overmolding step, it can be provided to ensure the formation of a primary carcass 21 provided at the opposite end of that equipped with the tip 21 1 , an extension 21 2 provided with means adapted to receive low voltage electrical connections. Such an extension 21 2 can thus constitute a low voltage connector.

Ainsi, le surmoulage de la carcasse primaire 21 permet de limiter le nombre de pièces constitutives de la bobine d'allumage par le fait que la forme donnée au moule de surmoulage peut à elle seule remplir les fonctions habituellement remplies par différentes pièces. Cette carcasse primaire 21 surmoulée qui constitue une pièce unique permet de supprimer les interfaces entre diverses pièces qui peuvent faciliter le cheminement de la haute tension.Thus, the overmolding of the primary carcass 21 makes it possible to limit the number of parts constituting the ignition coil by the fact that the shape given to the overmoulding mold alone can fulfill the functions usually performed by different parts. This overmolded primary carcass 21 which constitutes a single piece makes it possible to eliminate the interfaces between various parts which can facilitate the path of the high voltage.

Selon une caractéristique préférée de réalisation, lors de cette étape de surmoulage, l'alésage 12 de la carcasse secondaire 11 est obturé de manière à permettre ultérieurement le montage du noyau magnétique.According to a preferred embodiment, during this overmolding step, the bore 12 of the secondary carcass 11 is closed so as to subsequently allow the magnetic core to be mounted.

Après l'étape de surmoulage, il peut être prévu de réaliser une étape de bobinage d'un enroulement primaire 23 sur la face externe 24 de la carcasse primaire 21 comme cela apparaît plus précisément à la Figure 4 . After the overmoulding step, it may be provided to perform a step of winding a primary winding 23 on the outer face 24 of the primary carcass 21 as it appears more precisely in the Figure 4 .

Le procédé selon l'invention vise ensuite à mettre en oeuvre une étape de montage d'un cylindre 26 de bouclage du flux magnétique avec le noyau magnétique 13, monté extérieurement à l'enroulement primaire 23. The method according to the invention then aims to implement a step of mounting a cylinder 26 for looping the magnetic flux with the magnetic core 13, mounted externally to the primary winding 23.

Le procédé de fabrication conforme à l'invention, permet de diminuer le nombre de pièces constitutives d'une bobine d'allumage facilitant ainsi les opérations d'assemblage. Cette diminution du nombre de pièces permet de supprimera les interfaces et par suite, les défauts de claquage entre le plot haute tension 25 et le cylindre de bouclage 26, et entre le plot haute tension 25 et le bobinage primaire 23. Par ailleurs, dans la mesure où le noyau magnétique 13 n'est pas noyé dans une résine, ce noyau magnétique 13 peut se dilater librement en fonction de la température sans entraîner une fissuration de la carcasse secondaire 11. The manufacturing method according to the invention makes it possible to reduce the number of components constituting an ignition coil, thereby facilitating assembly operations. This reduction in the number of parts makes it possible to eliminate the interfaces and consequently the breakdown faults between the high-voltage terminal 25 and the looping cylinder 26, and between the high-voltage terminal 25 and the primary winding 23. Furthermore, in the Since the magnetic core 13 is not embedded in a resin, this magnetic core 13 can expand freely depending on the temperature without causing cracking of the secondary carcass 11.

L'invention n'est pas limitée aux exemples décrits et représentés car diverses modifications peuvent y être apportées sans sortir de son cadre.The invention is not limited to the examples described and shown because various modifications can be made without departing from its scope.

Claims (9)

  1. A method for manufacturing an individual ignition coil for a spark plug (2) of a controlled ignition and internal combustion heat engine, including the following steps:
    - coiling a secondary winding (15) on a secondary coil tubular body (11);
    - overmolding the tubular body (11)/secondary winding (15) assembly with a dielectric material providing impregnation of the secondary winding and formation of a primary winding tubular body (21) on the one hand, and an end piece for connection (211) extending the primary coil tubular body (21) at one of its ends on the other hand, said end piece for connection (211) allowing for subsequent connection to a spark plug; and
    - coiling a primary winding (23) concentrically and externally relatively to the secondary winding (15), while being electrically insulated relatively to the latter by means of a dielectric material.
  2. The method according to claim 1, consisting of during the overmoulding step, ensuring formation of a primary coil tubular body (21), provided at the end opposite to the one fitted with the end piece, with means (212) adapted for receiving low voltage electrical connections.
  3. The method according to claim 1 or claim 2, consisting of during the overmolding step, closing up the bore (12) of the secondary coil tubular body (11).
  4. The method according to any one of claims 1 to 3, including a step for mounting a magnetic core (13) inside the bore (12) of the secondary coil tubular body (11).
  5. The method according to any one of claims 1 to 4, including a step for mounting a cylinder for sealing off the magnetic flux (26) with the magnetic core (13), externally mounted to the primary winding (23).
  6. The method according to any one of claims 1 to 3, consisting of providing the overmoulding step, by pressurized injection of a thermosetting dielectric material inside a mold.
  7. An individual integrated ignition coil for a spark plug of a controlled ignition and internal combustion heat engine, including at least one secondary coil tubular body (11) bearing on its external face (14), a secondary winding (15), said individual integrated ignition coil being characterized in that it includes a primary winding tubular body (21) that bears on its external face (24) a primary winding (23) and that is made in a dielectric material overmoulded on the secondary winding (15) also providing impregnation of the secondary winding, with the overmolded primary winding tubular body (21) being extended at one end by an end piece (211) adapted for connection to a spark plug.
  8. The individual integrated ignition coil according to claim 7, characterized in that the overmolded primary winding tubular body (21) includes at its end opposite to the one provided with the end piece (211), means (212) adapted for receiving low voltage electrical connections.
  9. The individual integrated ignition coil according to claim 7 or claim 8, characterized in that the overmolded primary winding tubular body (21) bears on its external surface (24) the primary winding (23) outside which a cylinder (26) is mounted for sealing-off the magnetic flux with a magnetic core (13) inserted inside the tubular body (11).
EP04742782A 2003-05-22 2004-05-19 Method of producing an individual ignition coil and coil thus obtained Revoked EP1625601B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FR0306132A FR2855317B1 (en) 2003-05-22 2003-05-22 METHOD FOR MANUFACTURING INDIVIDUAL IGNITION COIL AND COIL THUS OBTAINED
PCT/FR2004/001239 WO2004107372A2 (en) 2003-05-22 2004-05-19 Method of producing an individual ignition coil and coil thus obtained

Publications (2)

Publication Number Publication Date
EP1625601A2 EP1625601A2 (en) 2006-02-15
EP1625601B1 true EP1625601B1 (en) 2010-12-29

Family

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Application Number Title Priority Date Filing Date
EP04742782A Revoked EP1625601B1 (en) 2003-05-22 2004-05-19 Method of producing an individual ignition coil and coil thus obtained

Country Status (7)

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US (1) US20070006858A1 (en)
EP (1) EP1625601B1 (en)
CN (1) CN1795519A (en)
AT (1) ATE493743T1 (en)
DE (1) DE602004030782D1 (en)
FR (1) FR2855317B1 (en)
WO (1) WO2004107372A2 (en)

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2008053677A (en) * 2006-07-26 2008-03-06 Denso Corp Ignition coil
FR2905527B1 (en) * 2006-09-05 2014-10-10 Valeo Sys Controle Moteur Sas LOW VOLTAGE CONNECTION BLOCK OF AN IGNITION DEVICE, METHOD OF ASSEMBLING SUCH A DEVICE AND IGNITION DEVICE ASSEMBLED BY THE METHOD.
CN102522194B (en) * 2011-12-12 2013-09-11 陕西宝成航空仪表有限责任公司 Ladder winding method for transformer type sensor coil
CN105566020B (en) * 2015-12-16 2018-07-27 北京理工大学 A kind of electric cap of driving certainly and preparation method thereof without externally fed

Family Cites Families (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4831995A (en) * 1987-04-08 1989-05-23 Societe A Responsabilite Limitee: L'electricfil Industrie Integrated ignition-transformer assembly for the cylinder of a controlled ignition heat engine
JPH08213258A (en) * 1994-12-06 1996-08-20 Nippondenso Co Ltd Ignition coil for internal combustion engine
US5870012A (en) * 1995-12-27 1999-02-09 Toyo Denso Kabushiki Kaisha Engine ignition coil device
JPH10199737A (en) * 1996-11-18 1998-07-31 Matsushita Electric Ind Co Ltd Ignition coil device for internal combustion engine
FR2762442B1 (en) * 1997-04-17 1999-07-09 Electricfil IGNITION COIL FOR THE SUPPLY OF A THERMAL ENGINE SPARK PLUG
JP3727764B2 (en) * 1997-09-30 2005-12-14 株式会社日立製作所 Ignition coil device for engine and method for manufacturing the same
DE19805628C2 (en) * 1998-02-12 2001-09-20 Beru Ag Ignition coils and their manufacture
US6216679B1 (en) * 1999-07-27 2001-04-17 Delphi Technologies, Inc. Ignition coil for an internal combustion engine
EP1391901B1 (en) * 2001-05-31 2011-05-25 Denso Corporation Internal combustion engine ignition coil, and method of producing the same

Also Published As

Publication number Publication date
WO2004107372A3 (en) 2005-07-14
CN1795519A (en) 2006-06-28
US20070006858A1 (en) 2007-01-11
WO2004107372A2 (en) 2004-12-09
ATE493743T1 (en) 2011-01-15
FR2855317A1 (en) 2004-11-26
DE602004030782D1 (en) 2011-02-10
FR2855317B1 (en) 2008-09-26
EP1625601A2 (en) 2006-02-15

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