Abstract: The present invention provides a spark plug coil and pressure sensor assembly for providing a spark to a cylinder of an internal combustion engine. The assembly comprises a spark plug configured for mounting in a cylinder and a pressure sensor associated with the spark plug configured to detect a pressure in the cylinder and generate a pressure signal in response thereto. The assembly includes a first electrically conductive ring connector configured to receive the pressure signal and a housing having a main axis and having at least one electrically conductive leaf spring member. The leaf spring member is configured to resiliently engage the first electrically conductive ring connector over a first predetermined circumferential angle relative to the main axis of the coil housing.

Abstract: A system and method is disclosed that uses an empirically-derived thermal transfer function for an ignition coil taken with respect to an ambient temperature and responsive internal temperatures. The system combines the transfer function with a minimum cure-induced stress profile, in order to obtain a time-temperature profile for minimizing cure-induced residual stress in an epoxy resin impregnated ignition coil. An accelerated minimal-stress profile is obtained by increasing an initial gel isotherm temperature of the above-mentioned time-temperature profile.

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 coil, spark plug, and pressure sense assembly for an internal combustion engine are, in a preferred embodiment, integrated into a single assembly and mounted directly on a plug hole of an internal combustion engine. A pressure sense assembly is welded to a spark plug shell which serves as a pressure member. The pressure sense assembly includes a base plate onto which first and second pairs of strain gauges are printed using a thick film ink process (piezoresistive) in a full bridge arrangement. The geometry of the base plate and the fashion in which it is welded to the shell allow one pair of the gauges to function as strain sensing elements while the other pair can function for temperature compensation. Changes in the pressure in the combustion chamber deform the shell, causing a corresponding change in the bridge producing the pressure signal.

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 coil, spark plug, and pressure sensor for an internal combustion engine are, in a preferred embodiment, integrated into a single assembly and mounted directly on a plug hole of an internal combustion engine. A hard spark plug shell serves as a pressure member and on which a strain gage is affixed. Changes in the pressure in the combustion chamber deform the shell, causing a corresponding change in the resistance of the strain gage. A bridge circuit or the like is used to measure the resistance change thereby providing a direct indication of cylinder pressure.

Abstract: A system and method is disclosed that uses an empirically-derived thermal transfer function for an ignition coil taken with respect to an ambient temperature and responsive internal temperatures. The system combines the transfer function with a minimum cure-induced stress profile, in order to obtain a time-temperature profile for minimizing cure-induced residual stress in an epoxy resin impregnated ignition coil. An accelerated minimal-stress profile is obtained by increasing an initial gel isotherm temperature of the above-mentioned time-temperature profile.

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.

Abstract: An ignition coil, spark plug, and pressure sensor for an internal combustion engine are, in a preferred embodiment, integrated into a single assembly and mounted directly on a plug hole of an internal combustion engine. A hard spark plug shell serves as a pressure member and on which a strain gage is affixed. Changes in the pressure in the combustion chamber deform the shell, causing a corresponding change in the resistance of the strain gage. A bridge circuit or the like is used to measure the resistance change thereby providing a direct indication of cylinder pressure.