IGNITION COIL FOR INTERNAL COMBUSTION ENGINE

Abstract

An ignition coil for an internal combustion engine is provided with a primary coil, a secondary coil, a center core, an outer peripheral core, a core cover, a case, and a filling resin. The core cover is formed to cover an inner surface, a surface on one end in the penetration direction, and a surface on the other end in the penetration direction of the outer peripheral core. The core cover has a one end-side cover part, that is, a portion located on a high voltage side of the secondary coil, the cover part facing the surface on one end of the outer peripheral core in the penetration direction, and being formed with a wall portion having an inner surface, an outer surface and a surface on one end in the penetration direction, all of which are formed with a plurality of continuous grooves. The plurality of continuous grooves are filled with the filling resin for filling in the case.

Claims

1. An ignition coil for an internal combustion engine comprising: a primary coil; a secondary coil disposed concentrically around the outer periphery of the primary coil; a center core disposed on the inner periphery of the primary coil; an annular outer peripheral core surrounding the secondary coil; a core cover formed to cover an inner surface, a surface on one end in a penetration direction, and a surface on the other end in the penetration direction of the outer peripheral core; a case provided with an accommodation opening on a side on which the surface on one end of the outer peripheral core in the penetration direction is located, the opening accommodating the primary coil, the secondary coil, the center core, the outer peripheral core, and the core cover; and a filling resin filling gaps in the case, wherein, recesses or steps are formed on at least one of an inner surface, an outer side surface, and a surface on one end in the penetration direction of a wall portion that is formed in the core cover so as to be located in a portion on a high voltage side of the secondary coil, the portion facing the surface on one end of the outer peripheral core in the penetration direction, and the filling resin is in contact with the recesses or the steps.

2. The ignition coil for an internal combustion engine according to claim 1, wherein the recesses are constituted by either a plurality of continuous grooves formed in the wall portion so as to be parallel to each other along an annular direction of the outer peripheral core annularly rotates in the wall portion, or a plurality of recessed holes repeatedly formed in the wall portion along the annular direction of the outer peripheral core and along a direction orthogonal to the annular direction.

3. The ignition coil for an internal combustion engine according to claim 1, wherein either the plurality of continuous grooves or the plurality of recessed holes are formed in all the inner surface, the outer surface and the surface on one end in the penetration direction of the wall portion.

4. The ignition coil for an internal combustion engine according to claim 1, wherein the steps are formed in the inner surface and the outer surface of the wall portion so as to have a step shape in which the width between the inner surface and the outer side surface of the wall portion becomes gradually narrower toward one end in the penetration direction.

5. The ignition coil for an internal combustion engine according to claim 1, wherein the wall portion has inner and outer corners each formed into a curved shape, and located on the surface on one end in the penetration direction of the wall portion.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0025] FIG. 1 is a cross-sectional view illustrating an ignition coil, according to a first embodiment;

[0026] FIG. 2 is a drawing illustrating the ignition coil that is, a cross-sectional view taken along line II-II of FIG. 1, according to the first embodiment;

[0027] FIG. 3 is a perspective view illustrating an outer peripheral core and a core cover as well as the peripheral components, according to the first embodiment;

[0028] FIG. 4 is a perspective view illustrating the outer peripheral core and the core cover as viewed from the inside, according to the first embodiment;

[0029] FIG. 5 is a perspective view illustrating the core cover and the outer peripheral core as viewed from the outside, according to the first embodiment;

[0030] FIG. 6 is an enlarged cross-sectional view illustrating a wall portion of the core cover as well as the peripheral components, according to the first embodiment;

[0031] FIG. 7 is a perspective view illustrating another core cover and outer peripheral core as viewed from the inside, according to the first embodiment;

[0032] FIG. 8 is a perspective view illustrating another core cover and outer peripheral core as viewed from the outside, according to the first embodiment;

[0033] FIG. 9 is an enlarged cross-sectional view illustrating a wall portion of another core cover as well as the peripheral components, according to the first embodiment;

[0034] FIG. 10 is a perspective view illustrating a core cover and an outer peripheral core as viewed from the inside, according to a second embodiment; and

[0035] FIG. 11 is an enlarged cross-sectional view illustrating a wall portion of the core cover as well as the peripheral components, according to the second embodiment.

DESCRIPTION OF THE EMBODIMENTS

[0036] Hereinafter, some embodiments of the present invention will be described in greater detail with reference to the appended drawings. This invention may, however, be embodied in many different modes and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that the disclosure of the invention will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. It should be noted that the like reference signs indicate the like components throughout the drawings

First Embodiment

[0037] As shown in FIGS. 1 and 2, an ignition coil for an internal combustion engine 1 of the present embodiment (hereinafter, simply referred to as ignition coil 1), is provided with a primary coil 21, a secondary coil 22, a center core 5, an outer peripheral core 6, a core cover 7, a casing 11, and a filling resin 13. The secondary coil 22 is arranged concentrically on the outer periphery of the primary coil 21. The center core 5 is formed of stacked electromagnetic steel sheets, and arranged on the inside of the primary coil 21. The outer peripheral core 6 is formed of stacked electromagnetic steel sheets, and has an annular shape surrounding the secondary coil 22. The core cover 7 is formed to cover an inner surface 61, a surface 62 on one end in a penetration direction L, and a surface 63 on the other end in the penetration direction L of the outer peripheral core 6. The casing 11 is configured to accommodate the primary coil 21, the secondary coil 22, the center core 5, the outer peripheral core 6 and the core cover 7 from an opening 111 formed on the side on which the surface 62 on one end of the outer peripheral core 6 in the penetration direction L is arranged. The filling resin 13 fills gaps in the casing 11.

[0038] As shown in FIGS. 4 to 6, the core cover 7 has a one-end-side cover part 72 facing the surface 62 on one end of the outer peripheral core 6. The cover part 72 has a wall portion 75 formed in a portion located on the high-voltage side of the secondary coil 22. The wall portion 75 has an inner surface 751, an outer surface 752, and a surface 753 on one end in the penetration direction L. In all of the surfaces 751, 752 and 753, a plurality of continuous grooves 76 are formed as recesses. The plurality of continuous grooves 76 are filled with the filling resin 13 which is filled in the casing 11.

[0039] With reference to FIGS. 1 to 9, the ignition coil 1 of the present embodiment will hereinafter be described.

[0040] The ignition coil 1 is arranged in each cylinder of the engine, and generates a sparking voltage for generating a spark from a spark plug arranged in a plug hole of each cylinder.

[0041] In the ignition coil 1 of the present embodiment, the primary coil 21, the secondary coil 22, the center core 5 and the outer peripheral core 6 are arranged in an outer part of the plug hole. In the plug hole, a joint part 12 connected to the spark plus is arranged.

[0042] As shown in FIGS. 1 and 2, the center core 5 is formed in a cuboid-shape. The primary coil 21 is wound around the outer periphery of a primary spool 3 having a substantially quadrilateral-cylinder-shaped cross section with rounded corners. The secondary coil 22 is wound around the outer periphery of a secondary spool 4 having a substantially quadrilateral-cylinder-shaped cross section with rounded corners. The outer peripheral core 6 is formed to a substantially rectangular-ring-shape with rounded outside corners. The electromagnetic steel sheets configuring the center core 5 and the outer peripheral core 6 are stacked in the penetration direction L of the outer peripheral core 6. The penetration direction L of the outer peripheral core 6 coincides with a direction in which the opening 111 is provided in the casing 11. The casing 11 is formed to a substantially cuboid vessel shape conforming to the substantially rectangular-ring-shaped outer peripheral core 6. The casing 11 has the opening 111 on the side opposite to the side on which the joint part 12 is formed in the ignition coil 1.

[0043] The primary spool 3 has a cylindrical portion 31 around which the primary coil 21 is wound, and a connector portion 32 connected to an end of the cylindrical portion 31. In the casing 11, an igniter 33 is arranged, with a switching element being integrated to supply or interrupt current to the primary coil 21. The secondary spool 4 has a cylindrical portion 41 around which the secondary coil 22 is wound. A part of the connector portion 32 of the primary spool 3 is fitted in a notched part formed in the casing 11 to constitute a part of the casing 11.

[0044] In the casing 11, the filling resin 13, which is a thermosetting resin such as an epoxy resin, insulates and adheres the primary coil 21 and the secondary coil 22 and the like from/with each other.

[0045] As shown in FIGS. 1 to 3, the core cover 7 is provided substantially the entire periphery of the substantially quadrilateral-cylinder-shaped outer peripheral core 6. In the outer peripheral core 6, the core cover 7 covers the inner surface 61, the surface 62 on one end in the penetration direction L, and the surface 63 on the other end in the penetration direction L to relieve the thermal stress produced in the filling resin 13 due to the difference in the coefficient of thermal expansion between the filling resin 13 and the outer peripheral core 6. The core cover 7 has an inner cover part 71 facing the inner surface 61 of the outer peripheral core 6, the one end-side cover part 72 facing the surface 62 on one end of the outer peripheral core 6 in the penetration direction L, and another end-side cover part 73 facing the surface 63 on the other end of the outer peripheral core 6 in the penetration direction L. The one end-side cover part 72 and the other end-side cover part 73 are connected to each other by the inside cover part 71.

[0046] The core cover 7 can be formed being divided into a plurality of segments so as to be assembled to the outer peripheral core 6.

[0047] As shown in FIG. 3, the wall portion 75 of the core cover 7 is formed so as to be projected from the portion of the one end-side cover part 72, the portion being located on the high-voltage side of the secondary coil 22, toward the one end side in the penetration direction L. The thermal stress produced in the filling resin 13 is efficiently relaxed by increasing the thickness of the one end-side cover part 72 in the penetration direction L with the wall portion 75. The wall portion 75 of the present embodiment is formed on a high voltage-side side part 741, and a part of a pair of opposing side parts 742 continuing from the high voltage side part 741 and opposing each other, which are located on the high-voltage side of the secondary coil 22, among the four side parts constituting the substantially quadrilateral-cylinder-shaped core cover 7. When L1 is defined as a total length of the pair of opposing side parts 742, a length L2 along which the wall portion 75 is formed on the pair of opposing side parts 742, can be set to a range of 0.3 L1 to 0.5 L1.

[0048] The wall portion 75 may be formed in only the high voltage-side side part 741 of the core cover 7. Further, the core cover 7 may be provided at only the high voltage-side portion of the outer peripheral cover, other than being provided at substantially the entire periphery of the outer peripheral core 6.

[0049] As shown in FIGS. 4 and 5, the plurality of continuous grooves 76 are formed in the wall portion 75 of the present embodiment so as to be in parallel to each other along the annular direction of the outer peripheral core 6. The plurality of continuous grooves 76 are formed in each of all the inner surface 751, the outer surface 752, and the surface 753 on one end in the penetration direction L of the wall portion 75. In the present embodiment, three continuous grooves 76 are formed side by side in parallel to each other in the penetration direction L in each of the inner and outer surfaces 751 and 752 of the wall portion 75, while two continuous grooves 76 are formed side by side in parallel to each other along the inner and outer peripheries in the surface 753 on one end in the penetration direction L of the wall portion 75. Further, each of the continuous grooves 76 is continuously formed from an end face to the other end face of the wall portion 75. Further, in the rest of the wall portion 75 not formed with the continuous grooves 76, a plurality of projections 761 are continuously formed being extended in the annular direction of the outer peripheral core 6.

[0050] As shown in FIG. 6, in the cross-section orthogonal to the annular direction, the surface 753 on one end in the penetration direction L of the wall portion 75 has an arc shape. The surface 753 on one end in the penetration direction L of the wall portion 75 has inner and outer corners 743 which are each formed into a curved shape.

[0051] Minute gaps are formed between the outer surface of the outer peripheral core 6 and an inner wall surface 112 of the casing 11, between the outer surface 752 of the wall portion 75 of the core cover 7 and the inner wall surface 112 of the casing 11, and between the outer peripheral core 6 and the core cover 7. The minute gaps are filled with the filling resin 13.

[0052] The gap between the wall portion 75 of the core cover 7 and the inner wall surface 112 of the casing 11 can be eliminated.

[0053] Specifically, the dimension between portions of the outer surface 752 of the wall portion 75 on the pair of opposing side parts 742 of the core cover 7 may be made larger than the dimension between portions of the inner wall surface 112 of the casing 11 respectively facing the portions of the outer surface 752, so that the outer surface 752 of the wall portion 75 on the pair of opposing side parts 742 can contact the inner wall surface 112 of the casing 11. Further, the dimension between the outer surface 752 of the wall portion 75 on the high voltage-side side part 741 of the core cover 7 and a portion of the connector portion 32 forming the casing 11 may be made larger than the dimension between portions of the inner wall surface 112 of the casing 11 respectively facing the outer surface 752 and the portion of the connector portion 32, so that the outer surface 752 of the wall portion 75 of the high voltage-side side part 741 can contact the inner wall surface 112 of the casing 11. In these cases, the progression of the separation caused in the interface between the core cover 7 and the filling resin 13 is suppressed by the intimately contacting portions between the plurality of projections 761 and the inner wall surface 112 of the casing 11, and the plurality of continuous grooves 76.

[0054] The center core 5 and the outer peripheral core 6 are made of a soft magnetic material. The coefficient of thermal expansion (linear expansion coefficient) of the center core 5 and the outer peripheral core 6 is smaller than that of the filling resin 13 that is a thermosetting resin. The coefficient of thermal expansion of the core cover 7 has an intermediate value between the coefficient of thermal expansion of the center core 5 and the outer peripheral core 6 and the coefficient of thermal expansion of the filling resin 13. When the ignition coil 1 is cooled in the heating and cooling cycle of the engine, the expanded filling resin 13 contracts. When the contraction of the filling resin 13 is stopped by the outer peripheral core 6, a thermal stress acts on the filling resin 13. Since the core cover 7 is provided to the outer peripheral core 6, the thermal stress acting from the filling resin 13 to the outer peripheral core 6 is relaxed.

[0055] As shown in FIGS. 7 to 9, the recesses provided in the wall portion 75 of the core cover 7 may be replaced by a plurality of recessed holes 77. In the wall portion 75, the recessed holes 77 may be repeatedly formed along the annular direction of the outer peripheral core 6 and the direction orthogonal to the annular direction. Alternatively, in the wall portion 75 a plurality of continuous grooves 76 may be combined with a plurality of recessed holes 77 to prevent an undercut from being formed when forming the core cover 7. For example, as shown in FIGS. 7 and 8, a plurality of continuous grooves 76 may be formed in the inner surface 751 and the outer surface 752 of the wall portion 75 on the pair of opposing parts 742, and a plurality of recessed holes 77 may be formed in the inner surface 751, the outer surface 752 and the surface 753 on one end in the penetration direction L of the remaining wall portion 75.

[0056] Hereinafter will be described advantageous effects of the ignition coil of the present embodiment.

[0057] As shown in FIG. 6, the interface between the core cover 7 and the filling resin 13 is brought into a state in which separation is easily caused by the thermal stress produced in the filling resin 13 due to the difference in the coefficient of thermal expansion between the outer peripheral core 6 and the filling resin 13. The separation caused in the interface between the core cover 7 and the filling resin 13 progresses toward an end in the penetration direction L of the core cover 7 over the interface. When the separation reaches the corners of the core cover 7 at the end in the penetration direction L, cracks are generated in the filling resin 13 due to the stress concentration. It is known that, thereafter, the cracking progresses to an end surface 131 of the filling resin 13 located at the opening 111 of the casing 11. Specifically, the high voltage side of the secondary coil 22, will have a high voltage, and thus, is likely to suffer from voltage leaking due to the occurrence of cracks.

[0058] In the ignition coil 1 of the present embodiment, the core cover 7 has the one end-side cover part 72 facing the surface 62 on one end of the outer peripheral core 6 in the penetration direction L. Further, the wall portion 75 is formed on a part of the high voltage-side side part 741 and the pair of opposing side parts 742. In the wall portion 75, the plurality of continuous grooves 76 are formed for resisting the thermal contraction of the filling resin 13 caused in the heating and cooling cycle of the engine, or for preventing the separation from progressing to cracks.

[0059] As shown in FIG. 6, when the ignition coil 1 is cooled in the heating and cooling cycle of the engine, the filling resin 13 thermally contracts toward the center of a plane (indicated by the reference sign C in FIG. 6) orthogonal to the penetration direction L of the outer peripheral core 6. At this time, the portion of the filling resin 13 filled in the plurality of continuous grooves 76 is latched to the plurality of continuous grooves 76 in the surface 753 on one end in the penetration direction L of the wall portion 75 of the core cover 7. Accordingly, the thermal contraction of the filling resin 13 is prevented to thereby prevent the occurrence of separation.

[0060] Therefore, if separation occurs, the progression of separation is suppressed, and as a result, cracking is unlikely to occur in the filling resin 13. Therefore, the lifetime of the ignition coil 1 is extended. Also, in the case where a plurality of recessed holes 77 are formed in the wall portion 75 (refer to FIG. 9), advantageous effects similar to those in the case of forming a plurality of continuous grooves 76 can be obtained.

[0061] The separation occurred at the interface between the core cover 7 and the filling resin 13 near an outer corner 63B, which is located on the outer side of the surface 62 on one end of the outer peripheral core 6 in the penetration direction L, progresses over the interface between the plurality of continuous grooves 76 and the filling resin 13 in the outer surface 752 of the wall portion 75 of the core cover 7. The separation occurred at the interface between the cover 7 covering an inner corner 63A of the outer peripheral core 6 and the filling resin 13 progresses over the interface between the plurality of continuous grooves 76 and the filling resin 13 in the inner surface 751 of the wall portion 75 of the core cover 7. In these cases, a creepage distance can be increased. The creepage distance in these cases is a distance through which separation progresses to a corner at an end of the core cover 7 in the penetration direction L. Therefore, separation is unlikely to progress to the corner at an end of the core cover 7 in the penetration direction L. Moreover, the cracking in the filling resin 13 is suppressed to extend the lifetime of the ignition coil 1. Also, in the case where a plurality of recessed holes 77 are formed in the wall portion 75 (refer to FIG. 9), advantageous effects similar to those in the case of forming a plurality of continuous grooves 76 can be obtained.

[0062] In the ignition coil 1 of the present embodiment, the occurrence or the progression of separation is suppressed by forming a plurality of continuous grooves 76 in the wall portion 75 of the core cover 7. The core cover 7 does not require the use of a stress relaxing material or the like which is prepared separately from the core cover 7 and the labor for the assembly of the ignition coil 1 does not increase. Furthermore, without the need of forming a gap in the casing 11 for the arrangement of the stress relaxing material or the like, the ignition coil 1 is prevented from becoming large.

[0063] Therefore, with the ignition coil 1 of the present embodiment, the occurrence or the progression of separation in the interface between the core cover 7 and the filling resin 13 is suppressed, and the lifetime of the ignition coil 1 is extended.

Second Embodiment

[0064] The present embodiment shows the case in which a plurality of steps 78 are formed on the inner surface 751 and the outer surface 752 of the wall portion 75 of the core cover 7.

[0065] The plurality of steps 78 of the present embodiment are formed in a step shape in which the width between the inner and outer surfaces 751 and 752 of the wall portion 75 is gradually narrowed toward one end side in the penetration direction L. The surface 753 on one end in the penetration direction L of the wall portion 75 of the present embodiment includes the continuous grooves 76 which are formed along the annular direction of the outer peripheral core 6.

[0066] In the ignition coil 1 of the present embodiment, separation occurred at the interface between the core cover 7 and the filling resin 13 near the outer corner 63B, which is located on the surface 62 on one end of the outer peripheral core 6 in the penetration direction L, progresses over the interface between the plurality of steps 78 and the filling resin 13 in the outer surface 752 of the wall portion 75 of the core cover 7. Further, separation occurred at the interface between the core cover 7 covering the inner corner 63A of the outer peripheral core 6 and the filling resin 13 progresses over the interface between the plurality of steps 78 and the filling resin 13 in the inner surface 751 of the wall portion 75 of the core cover 7. In these cases, a creepage distance is increased. The creepage distance in these cases is a distance through which separation progresses to the corner 743 on one end side in the penetration direction L of the core cover 7. Therefore, separation is unlikely to progress to the corner 743 on one end side in the penetration direction L of the core cover 7, cracks which would occur in the filling resin 13 are suppressed, and the lifetime of the ignition coil 1 can be extended.

[0067] In the ignition coil 1 of the present embodiment, the rest of the configuration and the reference signs in the drawings are the same as those of the first embodiment, and thus advantageous effects similar to those of the first embodiment can be obtained.