Abstract: An ignition apparatus includes a secondary winding spool having a secondary winding wound thereon. The secondary winding includes a low voltage end and a high voltage end that is configured for connection to a spark plug. The secondary winding at the high voltage end is configured in accordance with a predetermined radial thickness profile taken in the direction from the high voltage end towards the low voltage end. The profile is determined as a function of (1) a reflected voltage associated with the spark gap breakdown of the spark plug and (2) an induced voltage due to magnetic flux coupled through a central core. The profile is determined so as to reduce layer-to-layer voltage levels in the secondary winding near the high voltage end. The profile can be wound or can be molded in the secondary spool itself.

Abstract: An ignition assembly provides a current to a spark plug to combust fuel in a cylinder of an internal combustion engine. The ignition coil assembly includes a primary winding defining a central axis. A secondary winding is wrapped about the primary winding coaxial with the central axis. The ignition coil assembly also includes a central core extending through the primary winding coaxial with the central axis. The central core includes a plurality of core components each having a single exterior surface that is continuous. In addition, each of the single exterior surface extends through an arcuate path.

Abstract: An axially potted progressive wound remote mount ignition coil (axially potted ignition coil) includes a coil case, at least one coil assembly, and a quantity of potting material. Each coil assembly is progressively wound. The coil case includes a coil cavity for each coil assembly, a primary connector, and two secondary connectors for each coil cavity. Each primary coil is connected to the primary connector and an end of each secondary coil is connected to a single secondary connector. A quantity of potting material is poured over the open end of each coil cavity. A second embodiment of the axial potted ignition coil includes a modular coil case, at least one coil assembly, and a quantity of potting material. The modular coil case includes at least one coil tube, a rear end cap and a forward end cap. Each coil assembly is inserted into a respective coil tube.

Abstract: An ignition coil cassette having bushings retained by an irregularity of the bushings being encased by epoxy. As a result, the process by which the bushings are installed into the ignition coil cassette avoids the cost associated with the overmolding installation process, and further avoids the potential for damage associated with the ultrasonic insertion process. The irregularity is located generally adjacent one end of each of the bushings and may be, for example, in the form of an undercut or a protrusion.

Abstract: An electrical interface assembly is provided for an ignition system including at least one ignition coil per cylinder in a multi-cylinder engine. Each ignition coil includes a plurality of coil terminals for passing respective electrical signals. One of the electrical signals may be used for discharging a respective spark in a respective cylinder. The interface assembly comprises a respective miniaturized printed circuit board (PCB) on each ignition coil. Each miniaturized PCB is electrically coupled to the coil terminals therein. The interface assembly further comprises a separate electrically conductive structure for electrically interconnecting each miniaturized PCB. The electrically conductive structure may be configured to reduce ohmic losses due to inter-cylinder separation in the electrical signal used for discharging the respective spark.

Abstract: A product, product by process, and process according to the present invention integrates an ignition coil driver electronics or ignitor into a plughole coil housing. Electronic components are mounted directly to a printed circuit board serving as a direct connection to connector terminals and/or coil leads via plated-apertures. If required, at least one protective layer can be applied directly to an external surface of at least some of the electronic components mounted on the printed circuit board to compensate for differences in the coefficients of thermal expansion. The protective layer is selected from a group including a conformal coating, a soft buffer material, a hard epoxy globtop, and combinations thereof.

Abstract: Method for introducing encapsulating material into an ignition coil including a primary winding, a secondary winding and a secondary spool is provided. The method allows providing a fluid-directing device at a first end of the secondary spool. The method further allows providing flow communication between the fluid-directing device and a first channel defined between the outer diameter of the primary winding and the inner diameter of the secondary spool. Flow communication is provided between the first channel and a second channel at a distal end from the first end. The second channel defined between the outer diameter of the secondary winding and the housing of the ignition coil. Encapsulating material (either pressurized or non-pressurized) is introduced through the fluid-directing device for generally downwardly flow into the first channel.

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.

Abstract: An ignition coil for a spark ignition internal combustion engine has a central core. The central core is cylindrical in shape, and includes a plurality of laminations composed of magnetically-permeable plates that are sector-shaped. The sector-shaped laminations improve the fill percentage allotted for core material. The central core has a central bore extending therethrough that allows a return of a primary winding lead, allowing an odd number of primary winding layers.

Abstract: A product, product by process, and process according to the present invention integrates an ignition coil driver electronics or ignitor into a plughole coil housing. Electronic components are mounted directly to a printed circuit board serving as a direct connection to connector terminals and/or coil leads via plated-apertures. If required, at least one protective layer can be applied directly to an external surface of at least some of the electronic components mounted on the printed circuit board to compensate for differences in the coefficients of thermal expansion. The protective layer is selected from a group including a conformal coating, a soft buffer material, a hard epoxy globtop, and combinations thereof.

Abstract: An ignition apparatus includes a high resistivity ferrite central core with a secondary winding disposed directly thereon. The ignition apparatus also includes, in a progressively coaxial fashion, a primary spool, a primary winding disposed on the spool, a case, and an outer core or shield of magnetically permeable material. The ignition apparatus exhibits reduced capacitance, and eliminates radial partial discharge at the inside diameter of the secondary winding.

Abstract: A drive circuit for an ignition system includes an ignition coil and spark plug associated with each cylinder of an internal combustion engine. Each ignition coil has a primary winding with the first end connectable to a power source and a second end opposite the first end connected to a silicon-control rectifier (SCR). Each coil also has a secondary winding connectable to a respective spark plug. The SCR may be integrated with the coil. A main driver device is connected between the other end of the SCR and ground. The driver device is configured to conduct a primary current in response to a drive signal. The SCRs are controlled into conduction by a respective gating signal. A control circuit is configured to generate the gating signals and the drive signal in response to one or more ignition control signals. An SCR for each coil is used to select which coil is allowed to carry current when the main driver is turned on.

Abstract: An ignition system for use with a spark plug in an internal combustion engine comprising an ignition apparatus for producing a breakdown voltage on a first output thereof configured to breakdown a spark gap of the spark plug a power source having a second output configured for connection to the spark plug, said source being further configured to sustain power to the spark gap during discharge and an impedance having first and second terminals coupled between the first and second outputs, the impedance having an electrical characteristic configured to allow application of the breakdown voltage and suppress high voltage transient.

Abstract: The electronics partitioning for an ignition system with complex control circuits configures a first ignition coil out of a plurality of ignitions coils for an internal combustion engine to include an electronic circuit, such as a complex integrated circuit, that can be shared with the remainder of the plurality of ignition coils. An appropriate wiring harness is configured so that the remainder of the plurality of ignition coils can use the common, shared integrated circuit in the first ignition coil in response to the operation thereof. The inventive arrangement substantially reduces cost of electronics by a factor that is the reciprocal of the number of ignition coils, as well as increases reliability by reducing the absolute total number of complex integrated circuits.

Abstract: An ignition coil assembly includes a high voltage (HV) diode at both ends of the secondary winding. The diodes prevent a spark-on-make condition. The diode implementation has particular benefits when used in a 42 volt automotive electrical system.

Abstract: An ignition coil (10) has a core (16) composed of a plurality of laminations (46) and about which is directly disposed an insulating layer (22). A primary winding (24) is wound directly on the insulating layer (22), thereby eliminating the need for a primary winding spool and recovering the space conventionally occupied by such a primary winding spool for use in allocating greater space to the core (16) and/or windings.

Abstract: A method of assembling an ignition coil cassette assembly for use with an internal combustion engine having a plurality of cylinder assemblies each including a spark plug, and an ignition coil cassette assembly provided in accordance with the invention methodology. The cassette assembly includes a plurality of ignition coils for respective electrical coupling to the respective spark plugs, whereby to deliver high voltage charges to the spark plugs in accordance with a predetermined firing order, a cassette body structure interconnecting and mounting the ignition coils in spaced downstanding relation with respect to the body, a printed circuit board for delivering power to the coils, and electronic components mounted on the board.

Abstract: An ignition coil assembly includes a high voltage (HV) diode at both ends of the secondary winding. The diodes prevent a spark-on-make condition. The diode implementation has particular benefits when used in a 42 volt automotive electrical system.

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.

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.