Abstract: An ignition coil assembly with internal diagnostic features that can be used to monitor and evaluate different aspects of an ignition system and provide continuous feedback. The ignition coil assembly may be a coil-on-plug type device that converts low-voltage battery power into high-voltage ignition pulses, and may include several input terminals, an ignition coil with primary and secondary windings, ignition circuitry, an output terminal, a spark plug connector, and a housing. The ignition circuitry includes an ignition operational circuit and an ignition diagnostic circuit, which in turn has a charging evaluation circuit for monitoring a charging phase, a discharging evaluation circuit for monitoring a discharging phase, and a feedback integration circuit for combining outputs into a multiplexed digital signal that can then be sent to an engine control unit (ECU) or the like over a single output terminal.

Abstract: An ignition diagnostic system and method for evaluating and optimizing the ignition performance of internal combustion engines (ICEs), such as those that burn hydrogen (H2) and/or other fuels. According to one example, the ignition diagnostic system and method use an artificial intelligence (AI) model with one or more machine learning (ML) algorithm(s) to identify, predict and/or otherwise evaluate abnormal combustion events, and to provide such information to an electronic control unit (ECU) in real-time. The ECU, in turn, can make combustion-related modifications to one or more components of the ignition system to optimize performance. By integrating the AI model into the ignition diagnostic system and method, a fast and simplified solution is provided that can be implemented across a wide variety of ICEs, including those that burn alternative fuels, where detecting abnormal combustion events and monitoring combustion-related parameters can be important.

Abstract: An ignition coil assembly with internal diagnostic features that can be used to monitor and evaluate different aspects of an ignition system and provide continuous feedback. The ignition coil assembly may be a coil-on-plug type device that converts low-voltage battery power into high-voltage ignition pulses, and may include several input terminals, an ignition coil with primary and secondary windings, ignition circuitry, an output terminal, a spark plug connector, and a housing. The ignition circuitry includes an ignition operational circuit and an ignition diagnostic circuit, which in turn has a charging evaluation circuit for monitoring a charging phase, a discharging evaluation circuit for monitoring a discharging phase, and a feedback integration circuit for combining outputs into a multiplexed digital signal that can then be sent to an engine control unit (ECU) or the like over a single output terminal.

Abstract: A wire for an ignition coil assembly and/or a corona ignition assembly is provided. The wire comprises a wire core including a copper-based material, and a coating applied to the wire core. The coating includes at least one of a carbon-based material and magnetic nanoparticles. The carbon-based material can include graphene and/or carbon nanotubes, and the magnetic nanoparticles can include graphene and iron oxide (Fe3O4). Typically, the coating includes a plurality of layers. For example, the coating can include a layer of the graphene and/or carbon nanotubes, and/or a layer of the magnetic nanoparticles. The coating can also include a layer of insulating material, such as enamel. According to another embodiment, the coating includes iron, nickel, and/or cobalt plated onto the wire core.

Abstract: A corona igniter assembly which is designed to reduce the amount of air gaps between insulating components and thus reduce electrical fields concentrated in those air gaps and the associated unwanted corona discharge. The assembly includes a high voltage center electrode surrounded by a ceramic insulator and a high voltage insulator. A dielectric compliant insulator is disposed between the ceramic insulator and the high voltage insulator. A layer of metal is applied to at least one of the insulators, for example the ceramic insulator. A compliant collet formed of a partially resistive material covers a sharp edge of the layer of metal to reduce the electric field and smooth the electric field distribution at the sharp edge of the metal layer.

Abstract: A corona ignition assembly including a firing end assembly and an ignition coil assembly connected by a high voltage connection is provided. The high voltage connection includes a high voltage insulator formed of silicon rubber. A shield formed of metal surrounds the high voltage insulator. The high voltage connection also includes an upper insert formed of metal connecting the shield to the ignition coil assembly and a lower insert formed of metal connecting the shield to the firing end assembly. First portions of the outer surface of the high voltage insulator adhere to the shield, the upper insert, and the lower insert, while second portions of the outer surface do not adhere to at least one of the shield, the upper insert, and the lower insert. A metal braid can be embedded in the high voltage insulator.

Abstract: A corona igniter assembly which is designed to reduce the amount of air gaps between insulating components and thus reduce electrical fields concentrated in those air gaps and the associated unwanted corona discharge. The assembly includes a high voltage center electrode surrounded by a ceramic insulator and a high voltage insulator. A dielectric compliant insulator is disposed between the ceramic insulator and the high voltage insulator. A layer of metal is applied to at least one of the insulators, for example the ceramic insulator. A compliant collet formed of a partially resistive material covers a sharp edge of the layer of metal to reduce the electric field and smooth the electric field distribution at the sharp edge of the metal layer.

Abstract: A wire for an ignition coil assembly and/or a corona ignition assembly is provided. The wire comprises a wire core including a copper-based material, and a coating applied to the wire core. The coating includes at least one of a carbon-based material and magnetic nanoparticles. The carbon-based material can include graphene and/or carbon nanotubes, and the magnetic nanoparticles can include graphene and iron oxide (Fe3O4). Typically, the coating includes a plurality of layers. For example, the coating can include a layer of the graphene and/or carbon nanotubes, and/or a layer of the magnetic nanoparticles. The coating can also include a layer of insulating material, such as enamel. According to another embodiment, the coating includes iron, nickel, and/or cobalt plated onto the wire core.

Abstract: A corona ignition assembly comprising a plurality of different insulators disposed between an ignition coil assembly and firing end assembly is provided. A high voltage center electrode extends longitudinally between an igniter central electrode and the ignition coil assembly. A high voltage insulator formed of a fluoropolymer surrounds the high voltage center electrode, and a firing end insulator formed of alumina surrounds the igniter central electrode. According to one embodiment, a glue formed of a compliant and insulating material, such as a silicon-based material, forms a seal between the high voltage insulator and the firing end insulator. According to another embodiment, a dielectric compliant insulator is disposed between the high voltage insulator and the ignition coil assembly, and the glue forms a seal therebetween. The glue fills air gaps to prevent unwanted corona discharge, and thus extends the life of the materials and directs energy to the firing end.

Abstract: A corona ignition assembly comprising a plurality of different insulators disposed between an ignition coil assembly and firing end assembly is provided. A high voltage center electrode extends longitudinally between an igniter central electrode and the ignition coil assembly. A high voltage insulator formed of a fluoropolymer surrounds the high voltage center electrode, and a firing end insulator formed of alumina surrounds the igniter central electrode. According to one embodiment, a glue formed of a compliant and insulating material, such as a silicon-based material, forms a seal between the high voltage insulator and the firing end insulator. According to another embodiment, a dielectric compliant insulator is disposed between the high voltage insulator and the ignition coil assembly, and the glue forms a seal therebetween. The glue fills air gaps to prevent unwanted corona discharge, and thus extends the life of the materials and directs energy to the firing end.