Potted Type Patents (Class 336/96)
  • Patent number: 6639498
    Abstract: In an individual ignition type ignition coil for use in an internal combustion engine in which a center core 1, a secondary coil 3 wound on a secondary bobbin 2 and a secondary coil 5 wound on a primary bobbin 4 are installed concentrically from an inner side of a coil case 6 in order. Among these interior constituting members, insulation resins 17 and 8 are filled up. Each of the primary bobbin 4 and the secondary bobbin 2 is made of a synthetic resin and at least a skin layer on an inner surface of the primary bobbin 4 and a skin layer on an outer surface of the secondary bobbin 2 are removed, and to the surfaces of the bobbins, the insulation resin 8 is adhered closely. By heightening a close adhesion strength (a bonding strength) of a bobbin and an insulation resin in an individual ignition type ignition coil, an anti-heat shock is improved and an insulation performance of the coil is attained.
    Type: Grant
    Filed: October 12, 2001
    Date of Patent: October 28, 2003
    Inventors: Junichi Shimada, Manabu Hashimoto, Katsuhiko Yasu, Hiroyuki Tanaka, Nobuhiko Ishida
  • Publication number: 20030197584
    Abstract: An ignition coil has a high voltage connector for connecting a high voltage output to a spark plug. The connector includes a terminal having a base, an annular sidewall axially extending from the base defining an interior, and a circumferentially-extending groove on an interior surface of the sidewall. A contact assembly of a spring clip sandwiched between a pair of wave washers is disposed in the groove, with a spring contact being disposed between the contact assembly and the base. The spring rates of the wave washers and the contact spring are low relative to the mass of the ignition coil, resulting in a low natural frequency for the overall combination. The connector provides vibration isolation between the coil and the spark plug, to thereby allow omitting the conventional connection of the coil to the engine via a bolt through a bolt hole on the coil case.
    Type: Application
    Filed: April 17, 2002
    Publication date: October 23, 2003
    Inventors: Dean M. Ford, Diane E. Hageman
  • Patent number: 6636138
    Abstract: An ignition coil for a motor vehicle, comprising: a magnetic core (12) having an elongated shape, a primary spool (20) supporting a low-voltage winding (22), and a secondary spool (16) supporting a high-voltage winding (18). The two spools are set coaxially with respect to the magnetic core. The coil includes a tubular shaped outer casing (24) carrying, at a first end, a low-voltage connector (28) and, at a second end, a high-voltage connector (30) which is designed to connect with a spark plug. A diode (42) is set at one end of the high-voltage spool (16) and has both a first rheophore (44), which is electrically connected to one end of the high-voltage winding (18), and a second rheophore (46), which is electrically connected to the high-voltage connector (30).
    Type: Grant
    Filed: June 1, 2001
    Date of Patent: October 21, 2003
    Assignee: Federal-Mogul Ignition Srl
    Inventors: Giorgio Bernardi, Graziano Gualdi, Roberto Righi
  • Publication number: 20030183214
    Abstract: In an ignition device for an internal combustion engine, comprising a spark plug made to carry out an electric discharge between an center electrode and an earth electrode and an ignition coil having a primary winding and a secondary winding for supplying a high voltage to the spark plug, notch portions are made in a ceramic spool on which one of the primary and secondary windings is wound and projecting portion are made in an insulating-resin-made holding member into which connector terminals are incorporated, with the projecting portions being engaged with the notch portions. The engagement of the projecting portions and the notch portions prevents the connector terminals from moving with respect to the ceramic spool in circumferential directions of the ceramic spool during terminal connection work.
    Type: Application
    Filed: March 18, 2003
    Publication date: October 2, 2003
    Inventors: Hiromi Hiramatsu, Masamichi Shibata, Tetsuya Miwa, Takeo Maekawa
  • Patent number: 6624734
    Abstract: An internal heating method for drying, gelling and final curing of epoxy resin insulation systems used for encapsulating dry type cast distribution transformer coils is disclosed. The internal method uses a Direct-Current (DC) power source to control and supply DC current to resistively heat the transformer coil encapsulated with a liquid resin under vacuum in a mold. DC current is applied to a given coil based on its conductor cross-sectional area and its epoxy resin quantity to achieve a specified temperature for drying, gelling and final curing. The temperature, controlled by DC resistive heating is maintained for a given period for each step.
    Type: Grant
    Filed: September 21, 2001
    Date of Patent: September 23, 2003
    Assignee: ABB Technology AG
    Inventors: Thomas J. Lanoue, Charles H. Sarver, Harold Younger, Rush B. Horton, Jr., Michael D. White, Paul Szász
  • Patent number: 6622712
    Abstract: An ignition coil includes a center core, a primary coil a secondary coil, a coil housing, a tower housing disposed under the coil housing, and a high tension terminal disposed inside the tower housing. The high tension terminal has an upper flange disposed at a first circumferential gap opposite the inside surface of the tower housing and a middle barrel disposed at a second circumferential gap opposite the inside surface of the coil housing. The first circumferential gap is made smaller than the second circumferential gap. The tower housing or the upper flange has a void-purging passage for purging air from the insulation resinous members when filled in the coil housing.
    Type: Grant
    Filed: January 14, 2003
    Date of Patent: September 23, 2003
    Assignee: Denso Corporation
    Inventors: Hidetoshi Nakashima, Kazutoyo Osuka
  • Patent number: 6621397
    Abstract: The present invention provides a low profile inductor and a method of making the same. First, a core seat including a cavity and two openings is provided. Then, a flat coil is embedded in the cavity of the core seat. The flat coil includes a first terminal and a second terminal extending outward or revealed by the openings so as to serving as the pins of the inductor. Further, a core cover is formed on the flat coil and the core seat.
    Type: Grant
    Filed: July 19, 2001
    Date of Patent: September 16, 2003
    Assignee: Delta Electronics Inc.
    Inventor: Han-Cheng Hsu
  • Publication number: 20030169141
    Abstract: An ignition coil includes an insulating resin, a primary coil, and a secondary coil. The primary coil is formed by winding a primary wire coated with a primary coating, and is disposed in the insulating resin. The secondary coil is formed by winding a secondary wire coated with a secondary coating, and is disposed in the insulating resin to be concentric with the primary coil. A glass transition temperature of the insulating resin is set to 130° C. or below, and a glass transition temperature of the secondary coating is set to 150° C. or above. Therefore, thermal stress between the insulating resin and parts adhered to the insulating resin in the ignition coil can be effectively reduced, and the life of the ignition coil with cooling/heating cycle can be elongated.
    Type: Application
    Filed: March 10, 2003
    Publication date: September 11, 2003
    Inventors: Takashi Nagata, Kazutoyo Osuka
  • Publication number: 20030156000
    Abstract: The invention relates to an inductive component (10) whose soft magnetic core (11) is produced by pouring a casting resin into a mold (1a) filled with a soft magnetic alloy powder and by subsequently hardening the casting resin with the alloy powder in order to form a solid soft magnetic core. Contrary to conventional injection molding methods, this technique prevents the surface insulation of the alloy particles from becoming damaged so that the formation of bulk eddy currents in the resulting soft magnetic cores can be prevented to a large extent. This enables a distinct reduction in the electric loss of the inductive component.
    Type: Application
    Filed: March 25, 2003
    Publication date: August 21, 2003
    Inventor: Markus Brunner
  • Patent number: 6608543
    Abstract: An ignition system for igniting fuel in a gas turbine or diesel engine is described. The system includes a magnetic core-coil assembly having a magnetic core comprising at least one tape wound toroid of ferromagnetic amorphous metal alloy, a primary winding and a secondary winding. Also included are driver electronics for applying voltage to a spark plug to cause a spark to ignite the fuel. The core-coil assembly and driver electronics are capable of operating with a rapid charge and discharge cycle to produce a high spark pulse rate. In another aspect, a magnetic core-coil assembly is disclosed which has a magnetic core comprising at least one tape wound toroid of ferromagnetic amorphous metal alloy having a permeability ranging from about 250 to 500, a primary winding for low voltage excitation and a secondary winding for high voltage output.
    Type: Grant
    Filed: October 28, 2002
    Date of Patent: August 19, 2003
    Assignee: Honeywell International, Inc.
    Inventors: William R. Rapoport, Paul A. Papanestor, Donald Allen Grimes, Bruce VanBuskirk, Gordon E. Fish
  • Publication number: 20030150440
    Abstract: In an ignition coil having an outer coil unit, an inner coil unit, a coil case in which the outer and inner coil units are housed and a tower case accommodating lower parts of outer and inner spools, the outer spool is made of resin material whose bonding strength to resin insulating material, with which the tower case is filled, is weak and an axial leading end of the outer spool is positioned axially away from a reference position by a distance equal to or shorter than 60% of a reference length or by a distance equal to or longer than 90% of the reference length. With this ignition coil, cracks hardly occur on the resin insulating material opposed to the axial leading end of the outer spool by thermal stress.
    Type: Application
    Filed: February 3, 2003
    Publication date: August 14, 2003
    Inventors: Koji Tsunenaga, Kazutoyo Osuka, Jyunichi Wada
  • Publication number: 20030136391
    Abstract: An ignition coil includes a center core, a primary coil a secondary coil, a coil housing, a tower housing disposed under the coil housing, and a high tension terminal disposed inside the tower housing. The high tension terminal has an upper flange disposed at a first circumferential gap opposite the inside surface of the tower housing and a middle barrel disposed at a second circumnferential gap opposite the inside surface of the coil housing. The first circumferential gap is made smaller than the second circumferential gap. The tower housing or the upper flange has a void-purging passage for purging air from the insulation resinous members when filled in the coil housing.
    Type: Application
    Filed: January 14, 2003
    Publication date: July 24, 2003
    Inventors: Hidetoshi Nakashima, Kazutoyo Osuka
  • Patent number: 6593840
    Abstract: A device for electrically interconnecting and packaging electronic components. A non-conducting base member having a component recess and a set of specially shaped lead channels formed therein is provided. At least one electronic component is disposed within the recess, and the conductors of the component are routed through the lead channels. A set of insertable lead terminals, adapted to cooperate with the specially shaped lead channels, are received and captured within the lead channels, thereby forming an electrical connection between the lead terminals and the conductors of the electronic component(s). A method of fabricating the device is also disclosed.
    Type: Grant
    Filed: January 31, 2001
    Date of Patent: July 15, 2003
    Assignee: Pulse Engineering, Inc.
    Inventors: Timothy J. Morrison, Aurelio J. Gutierrez, Thomas Rascon
  • Publication number: 20030128090
    Abstract: A case free ignition apparatus includes a cylindrical-shaped central core with a main axis, a secondary spool radially outwardly of the core, a secondary winding disposed on the secondary spool, a primary spool radially outwardly of the central core and secondary winding, where the primary spool is configured to receive a primary winding on a winding surface thereof. An outer core or shield is received on a flange on the primary spool, and is located radially outwardly of the primary winding, and spaced apart therefrom. A membrane is applied on a radially outer surface of the outer core and is configured so as to seal the ignition apparatus during a subsequent encapsulant filling stage so as to allow the formation of an encapsulant layer between the primary winding and an inner surface of the outer core. Further outer core or shield elements may be added outwardly of the membrane.
    Type: Application
    Filed: January 10, 2002
    Publication date: July 10, 2003
    Inventors: Mark Albert Paul, Albert Anthony Skinner
  • Patent number: 6590487
    Abstract: The invention provides a moulded coil wherein a sheathing surrounding a coil has no joints. A coil 13, while being supported by movable pins 37, is maintained in a suspended state with a cavity 35 formed between an upper mould 31 and a lower mould 32. From this state, molten plastic R is injected into the cavity 35. When the amount of molten plastic R that has been injected reaches 70-80% of a specified amount, the movable pins 37 move outwards until they have retreated to a position whereby they form a unified face with opposing faces of the cavity 35. At this juncture, the coil 13 remains in its original position even though it is no longer supported by the movable pins 35. After the movable pins 37 have retreated, the molten plastic R continues to be injected, and fills the area formerly occupied by the movable pins 37. A moulded coil 10 is obtained in which the coil 13 is entirely surrounded by the sheathing 14 which has no joints.
    Type: Grant
    Filed: July 10, 2001
    Date of Patent: July 8, 2003
    Assignee: Sumitomo Wiring Systems, Ltd.
    Inventor: Takahiro Uchiyama
  • Publication number: 20030122645
    Abstract: A stick-type ignition coil have a central core, a cylindrical member, primary spool, primary coil, secondary spool, secondary coil, outer core and a resin insulator. The two longitudinal end corners and faces of the core are covered by respective buffer members. The inner circumferential corners of the outer core is supported by ring members. Some of the members disposed radially inside and other members disposed radially outside of the inside members are held slidably to each other in the ignition coil. The spools are made of resin containing a rubber in excess of 5 weight percent and reinforcing materials. The resin insulator contains a flexible material.
    Type: Application
    Filed: December 17, 2002
    Publication date: July 3, 2003
    Applicant: DENSO CORPORATION
    Inventors: Kazutoyo Oosuka, Keisuke Kawano, Hiroyuki Wakabayashi, Akimitsu Sugiura, Tomonori Ishikawa, Naruhiko Inayoshi, Masahiko Aoyama, Tomonari Chiba, Katsuhisa Kato
  • Publication number: 20030112110
    Abstract: An embedded inductor which includes a spiral conductive inductor embedded in a magnetically permeable body composed of particles of pre-sintered magnetically permeable (e.g. ferromagnetic) material and an epoxy binder.
    Type: Application
    Filed: September 17, 2002
    Publication date: June 19, 2003
    Inventor: Mark Pavier
  • Publication number: 20030107461
    Abstract: An ignition apparatus includes a central core extending along a main axis, and a primary winding disposed radially outwardly thereof. The ignition apparatus further includes a secondary winding. The primary winding has a greater axial length than the secondary winding, this additional axial length being implemented on the low-voltage axial end of the ignition apparatus, relative to the main axis. The extended primary winding provides an increased leakage inductance spike, which may be used by an ion sense system to (i) obtain increased bias voltages, and, (ii) increase the effective turns ratio, thereby reducing the amount of wire required for the secondary winding.
    Type: Application
    Filed: December 10, 2001
    Publication date: June 12, 2003
    Inventors: Raymond O. Butler, Mark Albert Paul, Albert Anthony Skinner
  • Patent number: 6575151
    Abstract: An ignition coil for an internal combustion engine with a compact height and width includes an actuated magnetic portion of an iron core around which a primary coil is wound having an axis line crossing an ignition plug axis line of the internal combustion engine at a right angle; and a switching unit which is disposed at an end of the actuated magnetic portion vertically to the axis line of the actuated magnetic portion and intercepts a primary current flowing through the primary coil. This ignition coil can be manufactured at a greatly reduced cost, compared to the conventional ignition coil in which only one of the height or width is made compact, by reducing the required size of the press mold for the case and by reducing the initial investment for the equipment.
    Type: Grant
    Filed: December 4, 2000
    Date of Patent: June 10, 2003
    Assignee: Mitsubishi Denki Kabushiki Kaisha
    Inventors: Shigemi Murata, Mitsuru Koiwa
  • Patent number: 6571784
    Abstract: An individual ignition type ignition coil is adopted to an engine having a plastic head cover. A secondary coil is positioned at an inner side of a primary coil and between a secondary bobbin and a center core a soft epoxy resin is filled up. The soft epoxy resin hash a dent according t a compression molding and has a glass transition point Tg which satisfies a specified condition. The secondary bobbin is formed by PPS and the primary bobbin is set to the primary coli at outer side of the secondary assembling body and under an assembling condition the winding is carried out.
    Type: Grant
    Filed: October 23, 2001
    Date of Patent: June 3, 2003
    Assignees: Hitachi, Ltd., Hitachi Car Engineering Co., Ltd.
    Inventors: Junichi Shimada, Noboru Sugiura, Yoichi Anzo, Eiichiro Kondo, Kazutoshi Kobayashi, Takahide Kosai, Toshiaki Ueda
  • Publication number: 20030098764
    Abstract: The ignition coil in this invention has a coil portion and a high voltage tower portion. The coil portion has a primary coil, a secondary coil, and a coil case. The high voltage tower portion has a high voltage spring which attaches to the terminal of the ignition plug under the coil in the central portion of the ignition coil. A feature of the ignition coil is that a secondary terminal composed of a connector portion connected with a secondary winding and an attaching portion directly attaches at the end of the high voltage spring under the coil portion. Since the secondary terminal functions as a terminal of the high voltage spring, the high voltage spring terminal, such as in the prior art, can be eliminated.
    Type: Application
    Filed: November 22, 2002
    Publication date: May 29, 2003
    Inventor: Jyunichi Wada
  • Patent number: 6566993
    Abstract: A surface mountable coil is provided with a drum-shaped core including a body portion and raised portion each raised portion having a peripheral surface and an end surface, a winding wire wound around the body portion, an encapsulating member, base electrodes, and terminal electrodes. The encapsulating member exposes some portions of the base electrodes on the peripheral surfaces and substantially the whole base electrodes on the end surfaces. By exposing the portions of the base electrodes on the peripheral surfaces and whole base electrodes on the end surfaces, the contact strength between the base electrodes and the terminal electrodes can be substantially increased.
    Type: Grant
    Filed: November 22, 2000
    Date of Patent: May 20, 2003
    Assignee: Taiyo Yuden Co., Ltd.
    Inventors: Kazuhiko Otsuka, Satoshi Kinoshita, Tomohiko Morijiri, Tomoo Kashiwa
  • Patent number: 6561173
    Abstract: An ignition system for an internal combustion engine is designed so that it can be inexpensively produced in a manner advantageous from a standpoint of production engineering. The ignition system includes a shaft in a cylinder head of an internal combustion engine and a coil rod, which can be inserted over a portion of its longitudinal extension into the shaft. The coil rod forms an open magnetic circuit which is controlled by a tubular, longitudinally slit return plate. This return plate is set apart from the coil rod, in the shaft of the cylinder head. The ignition system is intended to be used in the automobile industry.
    Type: Grant
    Filed: March 29, 2001
    Date of Patent: May 13, 2003
    Assignee: Robert Bosch GmbH
    Inventors: Dieter Betz, Wolfram Schoellig
  • Patent number: 6559747
    Abstract: In order to prevent a crack of plastic parts caused by a shrinkage force of a resin filler filled in an ignition coil casing, a cylindrical coil casing houses a primary coil and a secondary coil concentrically, and the resin filler such as epoxy resin is filled in the coil casing to insulate between the parts in the coil casing and to fix the parts. A ring-shaped partition member is provided at the upper portion in the coil casing to separate the resin filler locating above the primary coil and the secondary coil inside and outside. The partition member is made of a resin whose adhesive strength against the resin filler is weak, such as polypropylene (PP). The partition member reduces the shrinkage force between the outside resin filler and the inside resin filler, and prevents a crack of plastic parts, such as the secondary spool.
    Type: Grant
    Filed: December 13, 1999
    Date of Patent: May 6, 2003
    Assignee: Denso Corporation
    Inventors: Yoshihiro Shimoide, Kazuhide Kawai
  • Patent number: 6556118
    Abstract: An ignition coil assembly includes a core formed of magnetically-permeable material extending along a main axis, a primary winding disposed about the core, a secondary winding disposed on a secondary winding spool wherein at least one of the secondary winding leads is connected to a high-voltage connector terminal portion of the ignition coil assembly configured for connection to a remotely disposed spark plug, a case formed of electrical insulating material, and a magnetically-permeable shield disposed outwardly of the case. The secondary winding is progressively wound on the secondary winding spool, thereby eliminating failure modes associated with the segment-wound secondary windings, and, eliminating the need for pole pieces in the magnetic circuit, thereby reducing components, cost, weight, and size of the ignition coil assembly.
    Type: Grant
    Filed: March 3, 2000
    Date of Patent: April 29, 2003
    Assignee: Delphi Technologies, Inc.
    Inventor: Albert Anthony Skinner
  • Patent number: 6556116
    Abstract: A method for inhibiting or eliminating case erosion in a pencil ignition coil having an internal primary winding and an external secondary winding and shield. Three alternative means for resisting damage due to the partial discharge phenomenon arising from a high electric field in such coil configurations are provided: (i) applying an ozone resistant coating on the case; (ii) applying a coating on the case for eliminating partial discharge under the shield; and (iii) applying a polyimide tape covering to the case for resisting partial discharge under the shield.
    Type: Grant
    Filed: August 20, 2001
    Date of Patent: April 29, 2003
    Assignee: Delphi Technologies, Inc.
    Inventors: Albert Anthony Skinner, Kenneth P. Senseman, James Alva Boyer, David D. Jackson, Viorel N. Moga, Mark Albert Paul
  • Patent number: 6552641
    Abstract: A transformer comprises a first support carrying a primary winding and a second support carrying a partial secondary winding connected electrically to an electrical unit by way of conductive wires. A flange of the second support exhibits at least two indentations for receiving a conductive wire which are separated by a recess filled with insulating material.
    Type: Grant
    Filed: July 17, 2000
    Date of Patent: April 22, 2003
    Assignee: Thomson Licensing S.A.
    Inventors: Paul Carvalheiro, Philippe Fuentes
  • Publication number: 20030070665
    Abstract: A “pencil” ignition coil includes a seal member having features that cooperate with complementary features provided on the engine cam cover/spark plug well into which the coil is inserted to provide a retention and tactile feel insertion feature. In particular, the cooperating features are configured to longitudinally align and position the ignition coil in the spark plug well in a predetermined relationship. In one embodiment, the seal member includes a circumferentially-extending rib on an outside diameter thereof, while the cam cover/spark plug well includes an undercut groove portion on an inside diameter portion thereof. The rib has an increased diameter relative to the surrounding, outside diameter surface of the seal member, while the undercut groove portion has an increased diameter relative to the surrounding land portions.
    Type: Application
    Filed: October 17, 2001
    Publication date: April 17, 2003
    Inventors: Mark Albert Paul, Harry Oliver Levers, Steve T. Kowalke
  • Patent number: 6549111
    Abstract: A description is given of a method of manufacturing an inductive element for SMD applications. This method comprises the following steps: a) providing a number of predominantly parallel electroconductive wires in the mould of an injection-molding device, b) circumferentially providing a part of the wires with a synthetic resin by injection molding, in such a manner that the ends of the wires remain free, c) providing an envelope of a soft-magnetic material around the circumferentially injection molded part of the wires, and d) reshaping the ends of the wires. In accordance with the invention, the method is characterized in that the parts of the wires to be circumferentially injection molded are fixed inside the mold during the injection molding process. It has been found that inductive elements of the type manufactured in accordance with the inventive method generate, in operation, optimally homogeneous magnetic fields. Also the risk of electric short-circuits proves to be small.
    Type: Grant
    Filed: May 16, 2001
    Date of Patent: April 15, 2003
    Assignee: Koninklijke Philips Electronics N.V.
    Inventors: Martinus J. M. De Graaf, Eelco G. Visser
  • Patent number: 6545581
    Abstract: An ignition unit for at least two sparkplugs of an internal combustion engine, the unit being in the form of a box having therein a reception cavity receiving an electronic printed circuit, a plurality of mutually separate housings extending side by side transversely relative to the reception cavity, a separating partition disposed between the reception cavity and the housings which defines a through opening between each of the housings and the reception cavity, and a plurality of ignition coils, each mounted in a corresponding one of the housings. Each ignition coil is fitted with a primary connector including 1) a fixing member for fixing the ignition coil to the box to enable the ignition coil to be mounted in a corresponding one of the housings, and 2) connection terminals between the ignition coil and the printed circuit.
    Type: Grant
    Filed: November 17, 2000
    Date of Patent: April 8, 2003
    Assignee: L'Electricfil Industrie
    Inventors: Thierry Munsch, Raphaël Monavon
  • Patent number: 6545582
    Abstract: A magnetic core (10) is provided with a flange portion (12) protruding outward a winding core portion (11) in a radial direction perpendicular to a center axis (19) of the winding core portion. The winding core portion has an outer peripheral surface (11a) which surrounds the center axis to have a first distance (d1) therebetween. The flange portion is provided with a permanent magnet (15) apart from the center axis by a second distance (d2) greater than the first distance.
    Type: Grant
    Filed: August 31, 2001
    Date of Patent: April 8, 2003
    Assignee: NEC Tokin Corporation
    Inventor: Kunitake Sato
  • Publication number: 20030058076
    Abstract: An internal heating method for drying, gelling and final curing of epoxy resin insulation systems used for encapsulating dry type cast distribution transformer coils is disclosed. The internal method uses a Direct-Current (DC) power source to control and supply DC current to resistively heat the transformer coil encapsulated with a liquid resin under vacuum in a mold. DC current is applied to a given coil based on its conductor cross-sectional area and its epoxy resin quantity to achieve a specified temperature for drying, gelling and final curing. The temperature, controlled by DC resistive heating is maintained for a given period for each step.
    Type: Application
    Filed: September 21, 2001
    Publication date: March 27, 2003
    Inventors: Thomas J. Lanoue, Charles H. Sarver, Harold Younger, Rush B. Horton, Michael D. White
  • Patent number: 6538546
    Abstract: In a magnetic core for a non-contact displacement sensor comprising a detecting coil, a coil receiving member and a terminal, the coil receiving member is comprised of a green compact made of insulated soft magnetic powder and an insulating layer covering the green compact, and an organic resin is filled in a closed space of the coil receiving member.
    Type: Grant
    Filed: June 29, 2001
    Date of Patent: March 25, 2003
    Assignees: Tokyo Sintered Metal Company Limited, Koyo Seiko Co., Ltd.
    Inventors: Yoichi Serino, Masayuki Yamamoto, Masaki Sugiyama, Hideaki Tsuchiya, Masakazu Moriyama, Shunsuke Nakaura, Norio Nakatani, Takahiro Sanada, Hidenobu Nagano
  • Patent number: 6535097
    Abstract: To allow simple performance of a voltage test of a high-voltage system, a transformer system having a transformer housing (1) that receives a voltage converter (4) and having an electrical terminal (6) electrically connected to the voltage converter (4) and extended out of the transformer housing (1) for connecting the transformer system to a high- or medium-voltage system, is improved in that a decoupling system (12, 25) actuatable from outside the transformer housing (1) for temporarily interrupting the electrical connection between the voltage converter (4) and the first terminal (6) is disposed in the transformer housing (1). For performing a direct voltage test, the transformer system of the invention no longer has to be detached from the high-voltage system.
    Type: Grant
    Filed: May 10, 2000
    Date of Patent: March 18, 2003
    Assignee: Kommanditgesellschaft Ritz Messwandler GmbH & Co.
    Inventors: Olaf Brockmann, Joerg Pscheidl
  • Patent number: 6535096
    Abstract: An ignition system for igniting fuel in a gas turbine or diesel engine is described. The system includes a magnetic core-coil assembly having a magnetic core comprising at least one tape wound toroid of ferromagnetic amorphous metal alloy, a primary winding and a secondary winding. Also included are driver electronics for applying voltage to a spark plug to cause a spark to ignite the fuel. The core-coil assembly and driver electronics are capable of operating with a rapid charge and discharge cycle to produce a high spark pulse rate. In another aspect, a magnetic core-coil assembly is disclosed which has a magnetic core comprising at least one tape wound toroid of ferromagnetic amorphous metal alloy having a permeability ranging from about 250 to 500, a primary winding for low voltage excitation and a secondary winding for high voltage output.
    Type: Grant
    Filed: September 11, 2000
    Date of Patent: March 18, 2003
    Assignee: Honeywell International Inc.
    Inventors: William R. Rapoport, Paul A. Papanestor, Donald Allen Grimes, Bruce VanBuskirk, Gordon E. Fish
  • Patent number: 6529111
    Abstract: In an ignition coil for an internal combustion engine, the primary coil and the secondary coil of the coil unit are fabricated of self-welding wire and fixed in a coil case by an elastic material and an ignition control circuit unit is fixed in the coil case by an elastic material. Similarly, the primary coil and the secondary coil are integrally joined by an adhesive. The terminal of the primary coil and the lead of the ignition control circuit unit are joined together by fusion and the joint is partially molded, while the terminal of the secondary coil and the terminal of a high-tension cord outlet are joined together by fusing and the joint is partially molded. Moreover, the coil case is provided with an inner cap such that the fusing and partial molding of the terminals can be conducted on the inner cap, thereby ensuring a high recycle rate and enabling efficient resource recovery and reuse.
    Type: Grant
    Filed: May 25, 2000
    Date of Patent: March 4, 2003
    Assignee: Honda Giken Kogyo Kabushiki Kaisha
    Inventors: Ryuichi Kimata, Kazutomo Nishida, Naoya Toida
  • Patent number: 6525636
    Abstract: A stick-type ignition coil have a central core, a cylindrical member, primary spool, primary coil, secondary spool, secondary coil, outer core and a resin insulator. The two longitudinal end corners and faces of the core are covered by respective buffer members. The inner circumferential corners of the outer core is supported by ring members. Some of the members disposed radially inside and other members disposed radially outside of the inside members are held slidably to each other in the ignition coil. The spools are made of resin containing a rubber in excess of 5 weight percent and reinforcing materials. The resin insulator contains a flexible material.
    Type: Grant
    Filed: August 9, 2000
    Date of Patent: February 25, 2003
    Assignee: Denso Corporation
    Inventors: Kazutoyo Oosuka, Keisuke Kawano, Hiroyuki Wakabayashi, Akimitsu Suguira, Naruhiko Inayosi, Tomonari Chiba, Katsuhisa Kato
  • Publication number: 20030034866
    Abstract: A method for inhibiting or eliminating case erosion in a pencil ignition coil having an internal primary winding and an external secondary winding and shield. Three alternative means for resisting damage due to the partial discharge phenomenon arising from a high electric field in such coil configurations are provided: (i) applying an ozone resistant coating on the case; (ii) applying a coating on the case for eliminating partial discharge under the shield; and (iii) applying a polyimide tape covering to the case for resisting partial discharge under the shield.
    Type: Application
    Filed: August 20, 2001
    Publication date: February 20, 2003
    Inventors: Albert Anthony Skinner, Kenneth P. Senseman, James Alva Boyer, David D. Jackson, Viorel N. Moga, Mark Albert Paul
  • Patent number: 6522232
    Abstract: An ignition apparatus includes a high voltage (HV) terminal formed of stamped sheet metal attached to a secondary winding spool, and to which a high voltage end of the secondary winding is soldered. The ignition apparatus further includes an electrically conductive cup formed of stamped aluminum or brass that is disposed in a case and is configured to receive the high voltage terminal when the secondary winding spool is inserted in the case. The high voltage terminal has a spring tab or the like that is biased radially outwardly into engagement with an inner annular surface of the cup. A bottom outer surface of the cup is arranged to be engaged by a high voltage spring or the like for making the connection to the spark plug. The cup is substantially free of burrs, sharp edges, and the like, and therefore reduces localized occurrences of high electric field concentrations, which could otherwise lead to insulating material, and thus ignition coil, failure.
    Type: Grant
    Filed: July 2, 2001
    Date of Patent: February 18, 2003
    Assignee: Delphi Technologies, Inc.
    Inventors: Mark Albert Paul, Albert Anthony Skinner, Harry Oliver Levers, Jr.
  • Patent number: 6512175
    Abstract: A device for electrically interconnecting and packaging electronic components. A non-conducting base member having a component recess and a plurality of specially shaped lead channels formed therein is provided. At least one electronic component is disposed within the recess, and the wire leads of the component are routed through the lead channels. A plurality of lead terminals, adapted to cooperate with the specially shaped lead channels, are received within the lead channels, thereby forming an electrical connection between the lead terminals and the wire leads of the electronic component(s). The special shaping of the lead channels and lead terminals restricts the movement of the lead terminals within the lead channels in multiple directions during package fabrication, thereby allowing for the manufacture of larger, more reliable devices.
    Type: Grant
    Filed: September 4, 2001
    Date of Patent: January 28, 2003
    Assignee: Pulse Engineering, Inc.
    Inventor: Aurelio J. Gutierrez
  • Patent number: 6512438
    Abstract: Disclosed are a gapped magnetic core which may be coated or uncoated with an insulating layer or housed in an insulting box having a physical gap whose dimension is close to that of the gapped magnetic core and automated or semi-automated methods of applying copper wire on the gapped core or the core assembly and filling the gap with a spacer in the core or core assembly. The disclosed processes allow various combinations of core and spacer materials and gap configurations, resulting in a wide variety of core-coil assemblies which are useful as inductive components in electric and electronic circuits. Also disclosed is a core-coil assembly wherein a magnetic core with a gap directed off the conventional radial direction of a toroidally-wound core.
    Type: Grant
    Filed: December 16, 1999
    Date of Patent: January 28, 2003
    Assignee: Honeywell International Inc.
    Inventors: Hitoshi Yoshimori, Ryusuke Hasegawa
  • Patent number: 6508239
    Abstract: An individual ignition type ignition coil device for engine which is directly connected to each spark plug for use, comprises a coil case 6, and a center core 1, a secondary coil 3 wound on a secondary bobbin 2 and a primary coil 5 wound on the primary bobbin 4 each concentrically installed inside the coil case 6 in turn from the inside to the outside. Insulating resin 17, 8 is filled between the interiorly installed structural members. The secondary bobbin is made of material of modified PPO mixed with inorganic matter of 30% or more.
    Type: Grant
    Filed: April 26, 2002
    Date of Patent: January 21, 2003
    Assignees: Hitachi, Ltd., Hitachi Car Engineering Co., Ltd.
    Inventors: Junichi Shimada, Eiichiro Shimada, Manabu Hashimoto
  • Patent number: 6501360
    Abstract: An ignition coil for motor vehicles with a single output terminal comprises a body (16) carrying at one of its ends a flexible cap (18) provided with a seat (24) designed to receive an end (10) of a spark plug. The cap (18) comprises a high-voltage terminal (38, 40) electrically connected to the high-voltage winding of the coil and provided with a connection portion designed to receive a terminal (14) of the plug (10). A diode (26) is housed inside said cap (18) and is connected in series between two portions (38, 40) of said high-voltage terminal.
    Type: Grant
    Filed: July 2, 2001
    Date of Patent: December 31, 2002
    Assignee: Federal-Mogul Ignition SRL
    Inventors: Enrico Martagni, Gabriele Poletti, Giorgio Bernardi
  • Patent number: 6501365
    Abstract: An ignition coil contains an elongated substantially circular coil core which includes a primary coil and a secondary coil each disposed radially outwardly of the core with the core composed of a plurality of generally rectangular elements at least some of which have a different width than others and the elements being in surface-to-surface contact with each other. The lateral walls of the elements may have a shape which is not perpendicular to the longitudinal extent of the elements. The core may be welded at its ends. A core contained within this ignition coil, which may be an automotive ignition coil, is disclosed.
    Type: Grant
    Filed: September 8, 2000
    Date of Patent: December 31, 2002
    Assignee: Oberg Industries
    Inventors: E. Wesley Elliott, D. Bradley Williams, Joseph A. DeAngelo
  • Publication number: 20020195092
    Abstract: An ignition coil 1 according to the invention is an ignition coil having a case 2 and a coil portion 7 accommodated in the case. The case comprises a base resin whose dielectric breakdown voltage exceeds that of polyphenylene sulfide and whose spiral flow length exceeds that of polybutyrene terephthalate. As the base resin has a high fluidity, there is only a limited risk that a defect such as a weld line is caused when molding a thin case. In addition, while the thickness of the case and the electrical insulation properties are in proportion to each other, the case comprising the base resin can ensure sufficient electrical insulation properties even if the case is formed thin.
    Type: Application
    Filed: May 31, 2002
    Publication date: December 26, 2002
    Inventors: Takashi Nagata, Kazutoyo Osuka, Atsuyuki Konishi, Junichi Wada
  • Publication number: 20020175796
    Abstract: In a stick coil, there is disclosed an ignition coil for an internal combustion engine which can prevent a crack (a collar leak) from being generated due to a thermal stress. In this ignition coil, the structure is made such that a size (L) of a portion which is in parallel to an axial direction of a primary spool (121) in a projection portion (121b) is larger than a size (T) of a portion which is in parallel to an orthogonal direction to the axial direction of the primary spool (121). Accordingly, a frontal projected area of the projection portion (121b) as seen from a flowing direction of a resin becomes small, a resin flow is hard to get out of order at a time when the resin flows through a portion corresponding to the projection portion (121b) at the forming time, and a convoluted void and a weld are hard to be generated.
    Type: Application
    Filed: May 7, 2002
    Publication date: November 28, 2002
    Inventors: Kazuhide Kawai, Masafuyu Sano, Shigeya Abe, Masahiro Inagaki, Hajime Kasai, Hidetoshi Nakashima, Jyunichi Wada, Koji Tsunenaga, Kazutoyo Osuka, Masahiko Aoyama, Takashi Tauchi, Kaneo Buma, Yoshitaka Sato, Katsunori Akimoto
  • Patent number: 6486763
    Abstract: An inductive component intended to be installed on a printed circuit includes at least one winding, a body, and a magnetic core. The winding is made of an electrically conductive wire wound to form a flat coil the ends of which are connected to the inner ends of connecting terminals. The body is formed from a block of insulating material over-moulded onto the coil and onto the said inner ends of the terminals, the body including a central opening which passes through the body along the axis of the coil. The magnetic core is made of a ferrite layer that surrounds the body in a center plane containing the axis of the coil. A center element passes through the opening in the body.
    Type: Grant
    Filed: March 30, 2000
    Date of Patent: November 26, 2002
    Assignee: Microspire
    Inventor: Jean-François Kummel
  • Publication number: 20020171524
    Abstract: An ignition coil provides a socket between an outer iron core and an excitation core, and to place a non-magnetic metal therein. A U-shaped non-magnetic metal is placed in the socket with the two inner sides wrapping two permanent magnets. The outer iron core contacts the excitation coil in a deeper of depth, so that it produces a best excitation effect and collects more magnetic power that increases the magnetization of the ignition coil, it not only minimizes the size but also increases the magnetization.
    Type: Application
    Filed: May 16, 2001
    Publication date: November 21, 2002
    Inventor: Mu-Shui Tsai
  • Patent number: 6483410
    Abstract: An ignition coil for motor vehicles, comprising: a magnetic core (12) having a rectilinear axis; a secondary spool (16) supporting a high-voltage winding (18) and being set coaxially with respect to the magnetic core (12); a primary spool (20) supporting a low-voltage winding (22) and being set coaxially with respect to the secondary spool (16) and outside the latter; a tubular-shaped outer casing (24) which encloses the assembly comprising the magnetic core (12) and the spools (16, 20); and a low-voltage connector (28) including a connector body (30) made of plastic material and a plurality of metal contacts (32) fixed to the connector body (30). In the ignition coil, the connector body (30) is made of a single piece with the primary spool (20).
    Type: Grant
    Filed: June 1, 2001
    Date of Patent: November 19, 2002
    Assignee: Federal-Mogul Ignition-Srl
    Inventors: Giorgio Bernardi, Graziano Gualdi, Roberto Righi
  • Patent number: 6476703
    Abstract: The invention describes a control unit of a valve mechanism with an electromagnetic coil (1) where the electromagnetic coil (1) is electrically and mechanically connected to the control unit via a connection device which has an electrically conducting spring-mounted connecting ridge (10).
    Type: Grant
    Filed: January 24, 2001
    Date of Patent: November 5, 2002
    Assignee: Framatone Connectors International
    Inventors: Hans-Otto Geltsch, Josef Koiner