Abstract: A high-voltage electric machine has one or more terminals at which wires are to be electrically connected to the machine. The machine's housing includes a cable entrance leading to the terminal(s) through which the wire is inserted. Access holes through the housing enable a technician to reach the terminals (for example, with a tool, such as a screwdriver) to connect each wire to a terminal. In some embodiments, the direction of the access through the hole to the terminal is substantially perpendicular to the direction from which the wire reaches the terminal. A plug may be inserted into each access hole to prevent accidental contact with the terminal(s), such as screw-type or friction-fit plugs.

Abstract: A stator assembly for an electric machine including a stator core supporting a plurality of electrical conductors. A plurality of elongated insulator spacers is interwoven between the conductors proximate connection ends thereof in axially spaced relation to the stator core.

Abstract: A method of joining a plurality of electrical conductors in an electric machine. The method comprises the steps of providing a core and positioning the plurality of conductors within the core in concentric rings. The conductors include ends extending from the core. The method further comprises the steps of holding together at least two adjacent ends of the conductors, joining the adjacent ends to form a joint, and forming the joint to include at least a substantially planar portion. The method further comprises the step of releasing the adjacent ends of the conductors.

Abstract: An electrical machine is described that has a ceramic material as insulation around the winding wire. In some embodiments, the ceramic material is hexagonal boron nitride (HVR), aluminum oxide, aluminum nitride, or beryllium oxide. The ceramic material may be rolled, brush, sprayed, or dipped onto the wire using a binder-less or binder-containing solution. The whole wire may be coated, or just parts that are particularly subject to abrasion of the conductor and/or electrical contact with other conductive materials.

Abstract: Embodiments of the invention provide an electric machine module including a housing which can include a machine cavity. In some embodiments, an electric machine can be at least partially positioned within the machine cavity and can include a stator assembly. The stator assembly includes a stator core with slots. In some embodiments, conductors can be positioned in the slots and can include a first insulation. At least one insulation member can be disposed over at least a portion of the conductors. The insulation member can include a first element and a second element that can each comprise different constituent materials that include different properties.

Abstract: An ignition apparatus includes a core, primary and secondary windings and a loop-shaped magnetic return path structure. The structure includes layers of wound strip steel or wound ferritic wire stacked in an outward fashion. The core is placed in an interior of the loop forming at least one air gap between a core end surfaces and the structure. A combined core and magnetic return path structure includes a continuous loop formed by winding ferritic wire either on a spool or on a mandrel and is then bonded. The bonded winding is cut to form two C-shaped portions. Each C-shaped portion has a central yoke that extends into a pair of parallel legs. The C-shaped portions are re-assembled over primary and second windings so that the legs form a pair of parallel branches. One branch acts as the core and the other branch acts as the magnetic return path.

Abstract: A secondary winding spool for an ignition coil has two segments, one residing within a spark plug well and the other having a larger diameter than the well and residing above the well, to maximize exploitation of coil space in an engine.

Abstract: An ignition apparatus includes a core, primary and secondary windings and a loop-shaped magnetic return path structure. The structure includes layers of wound strip steel or wound ferritic wire stacked in an outward fashion. The core is placed in an interior of the loop forming at least one air gap between a core end surfaces and the structure. A combined core and magnetic return path structure includes a continuous loop formed by winding ferritic wire either on a spool or on a mandrel and is then bonded. The bonded winding is cut to form two C-shaped portions. Each C-shaped portion has a central yoke that extends into a pair of parallel legs. The C-shaped portions are re-assembled over primary and second windings so that the legs form a pair of parallel branches. One branch acts as the core and the other branch acts as the magnetic return path.

Abstract: An ignition coil intended for application in automotive internal combustion engines includes a generally cylindrically magnetic core defining opposed first and second ends and a primary coil concentrically wound externally about the core axially between the opposed ends. A secondary coil assembly including an insulating spool and a secondary coil wound thereon is concentrically disposed externally of the primary coil and magnetic core. One terminal of the primary coil is connected to a controlled voltage source and the other terminal to an electrical ground. One terminal of the secondary coil is connected to the high voltage terminal of at least one spark plug and the other terminal is connected to an electrical ground. The magnetic core is constructed from low carbon steel rope, preferably in a 1x37 format.

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: 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: 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 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: A spool assembly retains a winding of an electrical wire thereabout. The electrical wire is covered by a liquid insulating material. The spool assembly includes a cylinder to finding a longitudinal axis and an outer diameter. The cylinder extends between a high voltage end and a low voltage end along the longitudinal axis. The spool assembly also includes a high retainer disposed about the cylinder at the high voltage end. The high retainer has a high retainer diameter greater than the outer diameter of the cylinder. The spool assembly also includes a low retainer disposed about the cylinder at the low voltage end. The low retainer has a low retainer diameter greater than the outer diameter of the cylinder. This spool assembly also includes a channel extending along the cylinder inwardly from the outer diameter to receive the liquid insulating material when the liquid insulating material is forced through the winding to prevent air voids from forming at the inside diameter of the winding.

Abstract: A spool assembly retains a winding of an electrical wire thereabout. The electrical wire is covered by a liquid insulating material. The spool assembly includes a cylinder to finding a longitudinal axis and an outer diameter. The cylinder extends between a high voltage end and a low voltage end along the longitudinal axis. The spool assembly also includes a high retainer disposed about the cylinder at the high voltage end. The high retainer has a high retainer diameter greater than the outer diameter of the cylinder. The spool assembly also includes a low retainer disposed about the cylinder at the low voltage end. The low retainer has a low retainer diameter greater than the outer diameter of the cylinder. This spool assembly also includes a channel extending along the cylinder inwardly from the outer diameter to receive the liquid insulating material when the liquid insulating material is forced through the winding to prevent air voids from forming at the inside diameter of the winding.

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 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.