Abstract: An ignition apparatus includes a cylindrical core made from magnetically-permeable material and a C-shaped magnetic return path structure that is made from a stack of silicon steel laminations. A tightly controlled air gap is provided between one leg of the C-shaped structure and an end face of the core, forming a magnetic circuit having a high magnetic permeability, which overall reduces the number of primary winding turns needed, thereby reducing the amount of copper wire. In addition, the circular cross-section of the core reduces the mean length per turn (MLT) of the primary winding because the primary winding can be wound directly on the core, which in turn also reduces the MLT of the secondary winding. The reduced MLT also reduces the amount of copper wire. The structure may be replaced using a magnetically-permeable, U-shaped shield.

Abstract: An ignition apparatus includes a transformer having a central core, a primary winding disposed thereabout, a secondary winding disposed outwardly of the primary winding, a case configured to house the central components, and an outer core or shield disposed outwardly of the secondary winding. The central core is formed from multiple, low carbon steel wires held together is a cylindrical shape with cured bond coating material such as an epoxy material or an aromatic polyamide material. In one configuration, at least two different sizes of wires are used in forming the core to increase the density of the magnetically-permeable wire material in the core.

Abstract: An ignition apparatus includes a transformer having a central core, a primary winding disposed thereabout, a secondary winding disposed outwardly of the primary winding, and an outer core or shield disposed outwardly of the secondary winding. The central and outer cores and the primary and secondary windings define a magnetic circuit through which magnetic flux flows during various phases of operation. An end-of-spark natural ringing of the secondary voltage is suppressed and limited by a control winding disposed in relation in the magnetic circuit. The control winding has a pair of terminals across which is connected a diode. The diode is oriented so that during a spark event, it is reverse biased but after the spark event it becomes forward-biased when the secondary voltage is positive so as to selectively facilitate dissipation of any residual electrical charge.

Abstract: An ignition apparatus includes a cylindrical core made from magnetically-permeable material and a C-shaped magnetic return path structure that is made from a stack of silicon steel laminations. A tightly controlled air gap is provided between one leg of the C-shaped structure and an end face of the core, forming a magnetic circuit having a high magnetic permeability, which overall reduces the number of primary winding turns needed, thereby reducing the amount of copper wire. In addition, the circular cross-section of the core reduces the mean length per turn (MLT) of the primary winding because the primary winding can be wound directly on the core, which in turn also reduces the MLT of the secondary winding. The reduced MLT also reduces the amount of copper wire. The structure may be replaced using a magnetically-permeable, U-shaped shield.

Abstract: An ignition coil engages an inner surface of a bore of an engine, the providing access to a spark plug. The engagement is a boltless cam-lock engagement. A spring is associated with the engagement to hold the assembly in tension, and the spring also contacts a ground terminal in the ignition coil and the base of the spark plug to provide a short electrical path for radiofrequency interference (RFI) dissipation.

Abstract: An ignition coil has a primary core supporting a primary winding that is connectable to an engine ignition system and a secondary winding inductively couplable to the primary winding and surrounding the primary winding. The secondary winding can be connected to an engine spark plug assembly. A flux director surroundingly engages the core. The flux director is a single, unitary piece of steel that is not made of composite Iron particles.

Abstract: An ignition apparatus includes a transformer having a central core, a primary winding disposed thereabout, a secondary winding disposed outwardly of the primary winding, a case configured to house the central components, and an outer core or shield disposed outwardly of the secondary winding. The central core is formed from multiple, low carbon steel wires held together is a cylindrical shape with cured bond coating material such as an epoxy material or an aromatic polyamide material. In one configuration, at least two different sizes of wires are used in forming the core to increase the density of the magnetically-permeable wire material in the core.

Abstract: An ignition apparatus includes a transformer having a central core, a primary winding disposed thereabout, a secondary winding disposed outwardly of the primary winding, and an outer core or shield disposed outwardly of the secondary winding. The central and outer cores and the primary and secondary windings define a magnetic circuit through which magnetic flux flows during various phases of operation. An end-of-spark natural ringing of the secondary voltage is suppressed and limited by a control winding disposed in relation in the magnetic circuit. The control winding has a pair of terminals across which is connected a diode. The diode is oriented so that during a spark event, it is reverse biased but after the spark event it becomes forward-biased when the secondary voltage is positive so as to selectively facilitate dissipation of any residual electrical charge.

Abstract: An ignition apparatus includes an oil seal integrated with a spark plug boot and configured to mate with a cylinder head so as to seal the oil that is found under the cam cover from the spark plug and high voltage terminal of the plug. The cylinder head includes a ring-cavity recessed in the head surrounding the spark plug. The spark plug boot includes an annular sealing rib on a lowermost axial end. The sealing rib is configured in size and shape to effect an interference fit in the ring cavity. The ignition apparatus includes another seal integrated at the top to seal to the cam cover. The two integrated seals eliminate the need for a spark plug tube.

Abstract: A twin spark ignition apparatus having two high-voltage (HV) outputs incorporates features for balancing load capacitance on each HV output. The ignition apparatus provides a first high-voltage (HV) connection configured for direct mounting on a first spark plug, and a second HV connection for coupling to a second spark plug by way of an HV cable. The HV cable adds capacitance at the second HV output, as compared to a direct mount. The secondary winding is shifted by a predetermined distance, relative to the primary winding, in direction toward the direct mount end of the ignition apparatus. The shifting reduces the internal load capacitance at the second end (top), so that when the capacitance added by the HV cable is considered, the respective load capacitances are balanced. The voltage variation between the two HV outputs is reduced.

Abstract: A twin spark ignition apparatus having two high-voltage (HV) outputs incorporates features for balancing load capacitance on each HV output. The ignition apparatus provides a first high-voltage (HV) connection configured for direct mounting on a first spark plug, and a second HV connection for coupling to a second spark plug by way of an HV cable. The HV cable would adds capacitance at the second HV output, as compared to a direct mount. Various structures are included to offset and balance the additional capacitance attributable to the HV cable so that the capacitance of the first HV connection and the second HV connection are balanced within a range. The voltage variation between the two HV outputs is reduced.

Abstract: A twin spark ignition apparatus having two high-voltage (HV) outputs incorporates features for balancing load capacitance on each HV output. The ignition apparatus provides a first high-voltage (HV) connection configured for direct mounting on a first spark plug, and a second HV connection for coupling to a second spark plug by way of an HV cable. The HV cable adds capacitance at the second HV output, as compared to a direct mount. The secondary winding is shifted by a predetermined distance, relative to the primary winding, in direction toward the direct mount end of the ignition apparatus. The shifting reduces the internal load capacitance at the second end (top), so that when the capacitance added by the HV cable is considered, the respective load capacitances are balanced. The voltage variation between the two HV outputs is reduced.

Abstract: An ignition apparatus includes a high voltage (HV) terminal to which a high voltage end of the secondary winding is attached. The ignition apparatus further includes an electrically conductive cup configured to surround the high voltage terminal when the secondary winding spool is inserted in the case. The high voltage terminal has one end that comes into engagement with an inner annular surface of the cup. Electromagnetic interference suppression is provided by a resistor disposed between the cup and a high voltage connector assembly that connects to a spark plug. The resistor is formed of electrically conductive plastic material.

Abstract: A twin spark ignition apparatus having two high-voltage (HV) outputs incorporates features for balancing load capacitance on each HV output. The ignition apparatus provides a first high-voltage (HV) connection configured for direct mounting on a first spark plug, and a second HV connection for coupling to a second spark plug by way of an HV cable. The HV cable would adds capacitance at the second HV output, as compared to a direct mount. Various structures are included to offset and balance the additional capacitance attributable to the HV cable so that the capacitance of the first HV connection and the second HV connection are balanced within a range. The voltage variation between the two HV outputs is reduced.

Abstract: A plastic case surrounds a primary winding of a multicharge ignition system, and has a rib in which the high voltage end is routed back to the low voltage end, so that the low and high voltage ends can be closely juxtaposed with each other while advantageously permitting the primary winding to have one and only one winding layer to reduce resistance and size. The rib of the case extends into the slot of the magnetic shields of the winding.

Abstract: An ignition apparatus having a pencil coil transformer assembly extending along a first axis is mounted horizontally in a case that is directed mounted to an internal combustion engine. The ignition apparatus is installed by insertion into a spark plug well where the spark plug well has a main axis. The case includes a high voltage tower and connector terminal extending along a second axis. Upon installation when the HV tower is inserted into the spark plug well, the second axis is aligned with the main axis, and where the first axis of the pencil coil transformer assembly is perpendicular to and offset from the second axis to provide a low profile.

Abstract: An ignition apparatus having twin spark high-voltage outputs incorporates features of a pencil coil wherein at least a portion of a transformer assembly is disposed within a spark plug well when installed in an internal combustion engine, thereby reducing the space required on the top of the engine. A secondary winding spool is configured to retain a secondary winding in first and second portions, wound either the same way for use in waste spark ignition systems or in opposite orientations for two-plug-per-cylinder systems. An alternate configuration includes an isolated shield that is internal to the case.

Abstract: An ignition coil assembly includes a cylindrical central core having a main axis, a primary winding outwardly of the central core, a secondary winding outwardly of the primary winding, and a case having a first tube formed of a material having mica dispersed in a binder. The binder is may be a silicone-based binder, an epoxy-based binder or any other binder configured to adhere to the mica. The overall diameter of the ignition coil assembly can reduced relative to conventional designs since the case thickness can be reduced over known designs.

Abstract: A distributorless ignition coil has two high voltage secondary windings wound around a primary winding, with each secondary winding being electrically connected to a respective spark plug. A shield surrounds the secondary windings. The secondary windings share a common center tap between them, and the center tap is electrically connected to the shield, which thus acts as a conductor to convey current back to an end of the shield that conveniently may be connected to ignition components to complete the electrical path, thus obviating the need for an interior wire extending from the center tap inside the coil to the end of the coil case.

Abstract: An ignition apparatus 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 configured for connection to a spark plug, a case formed of electrical insulating material, and a magnetically-permeable shield disposed inwardly of the case and allowed to electrically float with respect to ground and a power source.