Abstract: An ignition coil and a method for its manufacturer are provided, the ignition coil including a housing, a primary winding and a secondary winding disposed in the housing, and a terminal including a connection portion in electrical communication with the secondary winding and a threaded portion engaging the housing. The threaded portion of the terminal may include a self-tapping threaded portion. Furthermore, the terminal may include a first body portion having a first threaded portion and a first median diameter and a second body portion having a second threaded portion and a second median diameter, where the second median diameter is greater than the first median diameter. The terminal may also include a shoulder portion having a diameter greater than the second median diameter and a third body portion having a third median diameter greater than the second median diameter.

Abstract: An ignition coil for an internal combustion engine minimizes the propagation of cracks in the encapsulate material surrounding the components of the ignition coil and provides a supplemental dielectric barrier. In one embodiment, the ignition coil comprises a housing, an outer core, an inner coil, and a coil assembly. The housing includes a bottom wall connected to an outer wall extending around the periphery of the housing. The outer core is positioned inside the outer wall, while the inner core is positioned inside the outer core. The coil assembly includes a primary winding and a secondary winding concentrically positioned relative to each other. The coil assembly is mounted to the inner core and positioned inside the outer core. The housing further includes an inner wall extending along the inner periphery of the outer core and positioned between the outer core and the coil assembly to prevent propagation of cracks.