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 ignition coil is provided for an internal combustion engine. The ignition coil comprises a primary winding and a secondary winding. The primary winding is adapted to be electrically connected to a low-voltage ignition signal. The secondary winding is inductively coupled to the primary winding with more turns than the primary winding so that the secondary winding develops a high-voltage ignition signal in response to switching of the low-voltage ignition signal. The turns of the secondary winding are provided in successive layers. An uncured material is applied to the secondary winding prior to the placement of the successive layers. By using an uncured stage material, the coil can be made without the need for complex, expensive, time-consuming, and potentially unreliable impregnation techniques. The ignition coil can be used as a pencil coil for spark plugs of an internal combustion engine. Also provided is a method of manufacturing an ignition coil.

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 comprising polyimide material. In one embodiment, a secondary winding spool comprises polyimide material. The overall diameter of the ignition coil assembly is reduced relative to conventional designs.

Abstract: An ignition apparatus includes a suppression device comprising a suppression winding that is in series with the secondary winding and is further located outside of a magnetic circuit. The suppression winding is made from the same wire as used in the secondary winding and is wound on a reduced diameter portion of a secondary winding spool. A carbon resistor is disposed in series with the suppression winding in another embodiment. Nickel wire may be substituted for the suppression winding and carbon resistor in order to obtain both inductance and resistance characteristics for the suppression device.

Abstract: An ignition apparatus includes a central core, a primary winding, a secondary winding wound on a secondary winding spool, a case and a shield. The primary winding is covered with a release layer comprising one of PTFE, polyamide, polyester or silicone rubber material. The release layer is configured to demote adhesion of an encapsulant disposed between the release layer and an inside diameter of the secondary winding spool. The encapsulant adheres more consistently and completely to the secondary winding spool reducing localized stresses on the spool which otherwise cause cracking or the like to occur.

Abstract: An ignition apparatus includes a suppression device comprising a suppression winding that is in series with the secondary winding and is further located outside of a magnetic circuit. The suppression winding is made from the same wire as used in the secondary winding and is wound on a reduced diameter portion of a secondary winding spool. A carbon resistor is disposed in series with the suppression winding in another embodiment. Nickel wire may be substituted for the suppression winding and carbon resistor in order to obtain both inductance and resistance characteristics for the suppression device.

Abstract: A suppressor diode for use in an ignition coil, the suppressor diode provides a diode that prevents “make voltages” from breaking down a spark gap of a spark plug. In addition, the resistive inductor prevents electromagnetic interference from the spark plug. The suppressor diode is configured for securement in a confined area of an ignition coil. In particular, the suppressor diode is located between a high-voltage terminal and a high-voltage end of a secondary coil. The suppressor diode includes a spool with a winding surface, a diode is molded into the spool and the diode has a first end connection and a second end connection. The diode is oriented to prevent current flow from the first end connection to the second end connection. A suppressive winding is disposed on to the winding surface, an end cap electrically connects the first end connection of the diode to the suppressor winding.