Abstract: An apparatus for making cores for ignition coil assemblies using powdered metal having magnetically permeable material is disclosed. The apparatus includes an ultrasonic tool that includes a cavity having a first axis. The tool vibrates to provide radial compression of powdered metal placed in the cavity. The apparatus also includes a first ram and a second ram. The cavity is located between the rams; the rams are located along the first axis. The rams are configured for opposing movement toward the cavity to provide axial compression of the powdered metal placed in the cavity. The apparatus also includes a control unit that controls the operation of the ultrasonic tool and the rams, allowing for simultaneous radial and axial compression of the powdered metal for a pre-determined time into a completed core. The control unit also controls removal of the core.

Abstract: A method and apparatus for securing at least one ignition coil to an ignition coil cassette, the ignition coil cassette having a main body portion being adapted to receive and engage a plurality of coils for generating a high voltage signal to be received by a spark plug of an internal combustion engine. The coils being ultrasonically welded to the main body portion of the ignition coil cassette. The coils being secured in a manner which correctly positions the coils in an appropriate location as well as providing a rigid securement of the coil to the main body portion.

Abstract: A method and apparatus for securing at least one ignition coil to an ignition coil cassette, the ignition coil cassette having a main body portion being adapted to receive and engage a plurality of coils for generating a high voltage signal to be received by a spark plug of an internal combustion engine. The coils being ultrasonically welded to the main body portion of the ignition coil cassette. The coils being secured in a manner which correctly positions the coils in an appropriate location as well as providing a rigid securement of the coil to the main body portion.

Abstract: Disclosed is an apparatus 10 and method of ultrasonic injection molding a plastic part including: providing plastic pellets 12; passing the pellets into a defined space 14 in an ultrasonic horn apparatus 16; applying ultrasonic energy to the horn thereby permitting flow of the melted plastic; applying a force to a plunger 18 which forces the melted plastic into a mold 24 of a desired shape; and recovering the desired part.