Ignition coil for internal combustion engine

• US 10,431,376 B2
• Filed: 09/01/2016
• Issued: 10/01/2019
• Est. Priority Date: 09/16/2015
• Status: Active Grant

• Current Assignee: DENSO Corporation
• Original Assignee: DENSO Corporation
• Inventors: Kawai, Kazuhide
• Primary Examiner(s): Kwon, John
• Assistant Examiner(s): Hoang, Johnny H
• Application Number:
  US15/760,308
• Publication Number:
  US 20180254144A1
• Time in Patent Office: 1,125 Days
• Field of Search: 123149 A, 123149 D, 123149 F, 123634, 123635, 336192, 336199, 336205-209
• CPC Class Codes: F02P 13/00 Sparking plugs structurally combined with other parts of internal-combustion engines connection of ignition coil to spark plug connector F02P3/02; with fuel injectors F02M57/06 ; spark plug connector per se H01T13/04 – H01T13/06; predominant aspects of sparking plug, see H01T13/40 – H01T13/44
• CPC Class Codes: F02P 15/00 Electric spark ignition having characteristics not provided for in, or of interest apart from, groups F02P1/00 - F02P13/00 and combined with layout of ignition circuits not combined F02B, F02C, F02G, F02K
• CPC Class Codes: F02P 3/02 having inductive energy storage, e.g. arrangements of induction coils ignition coils structurally combined with sparking plugs F02P13/00; constructional details of ignition coils H01F38/12
• CPC Class Codes: H01F 27/04 Leading of conductors or axles through casings, e.g. for tap-changing arrangements
• CPC Class Codes: H01F 27/40 Structural association with built-in electric component, e.g. fuse
• CPC Class Codes: H01F 38/12 Ignition, e.g. for IC engines

Abstract

An ignition coil for an internal combustion engine according to the present embodiment includes a primary coil, a secondary coil, a center core, an outer circumferential core, an igniter, a case, a connector unit, and a relay member. The relay member electrically connects the outer circumferential core and a grounding terminal member. The relay member includes: a base portion provided along the rear surface of an engagement wall; a standing portion standing rearward of the base portion; and a curved portion that extends from a rear end of the standing portion in a vertical direction Z orthogonal to a coil axis direction X and is curved to protrude rearward. The base portion is in contact with an inner grounding terminal at one end in the vertical direction Z. The standing portion is provided further outward than the igniter in a horizontal direction Y. The curved portion is elastically deformed and is urged against a front surface of the outer circumferential core.

Claims

1. An ignition coil for an internal combustion engine comprising:

a primary coil wound around a primary spool;

a secondary coil wound around a secondary spool provided on an outer circumference side of the primary coil;

a center core disposed on an inner circumference side of the primary coil and the secondary coil;

an outer circumferential core disposed on the outer circumference side of the primary coil and the secondary coil;

an igniter provided on a front side of the center core in a coil axis direction which is a direction of an axis about which the primary coil and the secondary coil are wound;

a case which houses the primary coil, the secondary coil, the center core, the outer circumferential core, and the igniter;

a connector unit mounted on a front end of the case and including at least a signal terminal member for transmitting a switching signal to the igniter and a grounding terminal member for grounding the igniter; and

a relay member that electrically connects the outer circumferential core and the grounding terminal member, wherein

the connector unit includes an engagement wall that is engaged with the case and faces the igniter from front of the igniter in the coil axis direction,

the signal terminal member penetrates the engagement wall and includes an inner signal terminal projecting into the case,

the grounding terminal member penetrates the engagement wall and includes an inner grounding terminal projecting into the case,

the relay member includes a base portion provided along a rear surface of the engagement wall, a standing portion standing rearward of the base portion, and a curved portion that extends from a rear end of the standing portion in a vertical direction orthogonal to the coil axis direction and is curved to protrude rearward,

the base portion is in contact with the inner grounding terminal at one end in the vertical direction,

the standing portion is provided further outward than the igniter in a horizontal direction orthogonal to both the coil axis direction and the vertical direction, and

the curved portion is elastically deformed and is in pressure-contact with a front surface of the outer circumferential core.

2. The ignition coil for the internal combustion engine according to claim 1, wherein

a plurality of the inner grounding terminals are arranged side by side in the horizontal direction, and a part of the base portion is inserted and fitted between the inner grounding terminals that are adjacent to each other.

3. The ignition coil for the internal combustion engine according to claim 1, wherein

the inner grounding terminal has a through-hole passing therethrough in the vertical direction, and the base portion is inserted and fitted into the through-hole.

4. The ignition coil for the internal combustion engine according to claim 1, wherein

the primary spool and the connector unit are integrally formed to constitute a connector module.

5. The ignition coil for the internal combustion engine according to claim 4, wherein

the connector module includes a supporting portion that supports, from front, an end of the curved portion opposite the standing portion.

6. The ignition coil for the internal combustion engine according to claim 4, wherein

the connector module includes a positioning portion that positions the standing portion from both ends in the horizontal direction.

7. The ignition coil for the internal combustion engine according to claim 1, wherein

the relay member includes a pair of the standing portions and a pair of the curved portions, the pair of standing portions are provided on both sides of the igniter in the horizontal direction, and each of the pair of curved portions is in pressure-contact with the front surface of the outer circumferential core.

8. The ignition coil for the internal combustion engine according to claim 1, wherein

the relay member is formed of a wire member.

9. The ignition coil for the internal combustion engine according to claim 1, wherein

the base portion includes:

a first base portion formed along the vertical direction;

a second base portion extending along the horizontal direction from a leading end of the first base portion which is on one side in the vertical direction; and

a third base portion extending from an end of the second base portion opposite the first base portion toward a proximal end which is on a side opposite the leading end in the vertical direction, the first base portion includes;

a rectangular portion in the form of a rectangle when viewed in the coil axis direction; and

an insertion fitting portion projecting from the rectangular portion toward the proximal end, the standing portion projects from an end of the third base portion opposite the second base portion, and the curved portion extends toward the proximal end from an end of the standing portion opposite the base portion.