JPH0922826A - Ignition coil and its manufacture - Google Patents

Abstract

PROBLEM TO BE SOLVED: To allow cheap manufacture without requiring a metal mold with high efficiency by forming a magnetic core of a movable magnetic flux and forming the primary and secondary coil winding beds by extrusion coating of an insulating material respectively. SOLUTION: An ignition coil body 10 makes the projected other end of an iron core 11 bend to one end side of the magnet core 11 so as to move along the rim of an insulation layer 16 so as to house it in a case. In this way, since the other end side of the magnetic core 11 is adjacent to one end side of the magnetic core 11, this ignition coil can obtain an electromagnetic energy near to that of the ignition coil of a closed magnetic path type. Further, in company with formation of the magnetic core 11 of a plurality of united rods 11a, a primary coil winding bed 12 and a secondary coil winding bed 14 corresponding to a primary coil bobbin and a secondary coil bobbin are formed by an extrusion coating of insulating materials respectively, so that a metal mold is dispensed with at the time of manufacturing these components as conventionally, thus allowing a cut of mold expense.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an ignition coil for an independent ignition system used in an internal combustion engine and a method for manufacturing the same.

[0002]

2. Description of the Related Art As shown in FIG. 12, an ignition coil of this type includes a magnetic core 51 in which electromagnetic steel sheets are laminated, a primary coil bobbin 52 mounted on the magnetic core 51, and an enamel on the primary coil bobbin 52. A primary coil 53 formed by winding a wire, a secondary coil bobbin 54 fitted on the outside of the primary coil bobbin 52 in which the primary coil 53 is formed, and an enamel wire wound on the secondary coil bobbin 54. Ignition coil body 50 having a secondary coil 55 formed by turning, and this ignition coil body 50
And a case 60 for accommodating the secondary coil 55 and a primary connector portion 61 having a connection terminal 62 to which the primary coil 53 is connected, and a connection to which the secondary coil 55 is connected. A secondary connector portion 63 having terminals 64 is formed.

A thermosetting resin such as an epoxy resin is filled in the space inside the case 60 in which the ignition coil body 50 is housed.
The secondary coil 53 and the secondary coil 55 are impregnated and fixed, and at the same time, the insulating property of withstanding the high output voltage of the secondary coil 55 is ensured.

In the ignition coil constructed as described above, the case 60 is directly fixed to the internal combustion engine with the secondary connector portion 63 fitted and inserted in the plug hole of the internal combustion engine.
The primary connector portion 61 is connected to a battery via a cable, and the secondary connector portion 63 is connected to an ignition plug via a connection terminal in the plug hole.

[0005]

By the way, the above-mentioned ignition coil has the magnetic core 51, the primary coil bobbin 52, and the secondary coil bobbin 52, 2.
After the components such as the secondary coil bobbin 54 and the like are manufactured in advance using a mold, the work of winding the enamel wire around the primary coil bobbin 52 and the secondary coil bobbin 54, the magnetic core 51,
It is manufactured through a series of steps such as an assembling work of the components such as the primary coil bobbin 52, the secondary coil bobbin 54 and the like into the case 60 and an epoxy casting work into the case 60 in which the ignition coil body 50 is accommodated. .

As described above, in this type of ignition coil, the above-mentioned steps have to be carried out in batch operation for each individual ignition coil, so that the work efficiency is poor, and the manufacturing cost of the mold is high and the number of steps is also high. However, there is a problem in that the manufacturing cost of the ignition coil itself increases.

SUMMARY OF THE INVENTION An object of the present invention is to provide an ignition coil which does not require a mold, has good working efficiency, and can be manufactured at low cost, and a manufacturing method thereof.

[0008]

In order to solve the above problems, the present invention provides a flexible magnetic core formed by bundling wire rods made of a ferromagnetic material, and extruded coating on one end side of the magnetic core. Formed primary coil winding bed, a primary coil formed by winding an electric wire on the primary coil winding bed, and extrusion coating on the primary coil winding bed on which the primary coil is formed. A secondary coil winding bed, a secondary coil formed by winding an electric wire around the secondary coil winding bed, and an insulating layer coated on the secondary coil winding bed having the secondary coil formed thereon. A main body having a body and a case accommodating the main body, and the other end of the magnetic core is bent in the one end side of the magnetic core along the outer periphery of the insulating layer. An ignition coil housed therein is provided.

Further, in a state where the wire rod on the other end side of the magnetic core is separated, each of the wire rods may be bent so as to extend substantially uniformly around the entire circumference of the insulating layer.

Further, the ignition coil is made into a magnetic core having flexibility by binding a plurality of wire rods formed by a continuously supplied ferromagnetic material, and a step of continuously feeding the magnetic core is continuously fed. The outer peripheral surface of the magnetic core is intermittently extruded and coated with an insulating organic material to obtain a predetermined length of 1
Forming a secondary coil winding bed on the continuous magnetic core at regular intervals, and winding an electric wire on the primary coil winding bed to form 1
A step of forming a secondary coil, and a step of forming a secondary coil winding bed of a predetermined length by intermittently extrusion coating an insulating organic material on the primary coil winding bed having the primary coil formed thereon, Forming an insulating layer by winding an electric wire on the secondary coil winding bed to form a secondary coil, and coating an insulating organic material on the secondary coil winding bed on which the secondary coil is formed. And a step of separating the ignition coil body in which the primary coil and the secondary coil are formed on one end side of the magnetic core having a predetermined length by cutting the magnetic core continuously supplied at a predetermined position, A magnetic core on the other end side of the ignition coil body is bent to one end side of the magnetic core along the outer circumference of the insulating layer, and is housed in a case. You can

[0011]

In the ignition coil constructed as described above, the magnetic core is formed of a flexible wire bundle, and the primary coil winding bed and the secondary coil winding floor are formed by extrusion coating the insulating material. Therefore, it is not necessary to use a conventional die for manufacturing the bobbin, and the bending of the magnetic core can be performed in the assembly process.

Further, since the other end side of the magnetic core is bent to be brought close to the one end side of the magnetic core, electromagnetic energy close to that of a closed magnetic circuit type can be obtained.

In the method for manufacturing an ignition coil constructed as described above, each step is continuously processed to continuously manufacture a plurality of ignition coil bodies.

[0014]

Embodiments will be described below with reference to the drawings. As shown in FIG. 1, the ignition coil 1 includes an ignition coil body 10 and a case 20 that houses the ignition coil body 10.

As shown in FIG. 2, the ignition coil body 10 has a magnetic core 11 of a predetermined length, which is a ferromagnetic material, and a primary coil winding formed from one end of the magnetic core 11 to a central portion thereof. Enameled wire 13a on the floor 12 and the primary coil winding floor 12
A primary coil 13 formed by winding
The primary coil winding bed 1 in which the primary coil 13 is formed
Secondary coil winding floor 14 formed over the entire area of the second coil 14
A secondary coil 15 formed by winding an enamel wire 15a around the secondary coil winding floor 14;
The secondary coil winding bed 14 on which the secondary coil 15 is formed is composed of an insulating layer 16 formed over the entire area.

The magnetic core 11 is an electromagnetic soft iron wire (JISC2).
503-90SUYB1) is a bundle of several to several tens of wire rods 11a drawn to a diameter of 0.3 to 1.0, and has a certain degree of flexibility and can be freely bent. .

The primary coil winding bed 12 includes the magnetic core 11
It is formed by extrusion-coating an insulating organic material (for example, fluororubber or silicone rubber) with a thickness of 0.5 to 2.0 mm on the top, and the outer surface thereof is formed to be smooth. On the other hand, the secondary coil winding bed 14 also has a thickness of an insulating organic material (fluorine rubber, silicone rubber) on the primary coil winding floor 12 on which the primary coil 13 is formed as in the primary coil winding floor 12. It is formed by extrusion coating with a thickness of 1.0 to 2.0 mm, and the outer surface thereof is provided with a plurality of flange portions 14a extending in the radial direction at regular intervals, and the enamel wire is provided between the flange portions 14a. 15a has a section winding.

The enamel wire 13a which is the winding of the primary coil 13 has a diameter of 0.3 to 0.7 mm, and the enamel wire 15a which is the winding of the secondary coil 15 is used. , With a diameter of 0.03 to 0.07 mm. The insulating layer 16 is formed by extrusion coating an insulating organic material (for example, liquid silicone rubber) and has a thickness of 1.5 to 3.0 mm.
It is a degree.

In the ignition coil body 10, as shown in FIG. 1, the protruding magnetic core 11 on the other end side is bent to one end side of the magnetic core 11 so as to extend along the outer periphery of the insulating layer 16, This is housed in the case 20. In this way, since the other end side of the magnetic core 11 is close to the one end side of the magnetic core 11, the ignition coil 1 can obtain electromagnetic energy close to that of a closed magnetic circuit type ignition coil.

A plurality of wire rods 1 in which the magnetic cores 11 are bound
1a, and the primary coil bobbin 12 and the secondary coil bobbin 14 corresponding to the conventional primary coil bobbin and the secondary coil bobbin are formed by extrusion coating an insulating material. You don't have to use molds to manufacture these components,
It is possible to reduce the die cost.

The ignition coil 1 configured as described above is
It is manufactured as follows. First, in the first step,
Since the electromagnetic soft iron wire (JISC2503-90SUYB1) is continuously supplied with a plurality of wire rods 11a drawn to φ0.3 to 1.0 by a wire drawing machine (not shown), as shown in FIG. A plurality of wire rods 11a are bundled by a binding device 31 and sent as a continuous magnetic core 11 to the next step.

In the second step, as shown in FIG. 4, the first magnetic core 11 continuously sent out in this way
The insulating organic material is intermittently extrusion-coated by the organic material extrusion device 32 to sequentially form the primary coil winding bed 12 having a predetermined length, and the primary coil winding bed 12 is sent to the next step. The interval between the primary coil winding beds 12 formed at this time is determined by the ignition coil body 10 shown in FIG.
It is necessary to set such that a length corresponding to the length of the protruding portion of the magnetic core 11 is secured.

In the third step, the primary coil winding bed 12 intermittently formed on the magnetic core 11 thus continuous.
As shown in FIG. 5, the enamel wire 13a is horizontally wound by the primary coil winding device 33 to form the primary coil 13 on each primary coil winding bed 12 and send it to the next step. .

In the fourth step, on the respective primary coil winding beds 12 on which the primary coils 13 have been formed in this way, as shown in FIG. The material is intermittently extrusion-coated to sequentially form the secondary coil winding bed 14 having a plurality of flange portions 14a protruding in the radial direction at regular intervals as described above, and sent to the next step.

In the fifth step, as shown in FIG. 7, the enamel wire 15a is provided between the flange portions 14a of the intermittently formed secondary coil winding floor 14 by the secondary coil winding device 35 as shown in FIG. By section winding, the secondary coil 15 is formed on each secondary coil winding bed 14 and sent to the next step.

In the sixth step, as shown in FIG. 8, on each of the secondary coil winding beds 14 on which the secondary coils 15 are formed in this way, an insulating organic material is applied by a third organic material extruding device 36. Insulation layer 16 formed by intermittent extrusion coating of material
Are sequentially formed and sent to the next step. In this state, the plurality of ignition coil bodies 10 are connected like a string of beads.

In the seventh step, as shown in FIG.
The ignition coil body 10 having the above-described structure is separated by sequentially cutting the downstream end of the portion in which the next coil winding bed 12 to the insulating layer 16 are sequentially laminated by the cutting device 37. It is supplied to the next process.

In the eighth step, the other end side of the protruding magnetic core 11 of the ignition coil body 10 thus formed is connected to one end side of the magnetic core 11 along the outer periphery of the insulating layer 16. When bent and housed in the case 20,
The ignition coil 1 is completed.

By the above method, the ignition coil 10
The manufacturing process can reduce the manufacturing cost because each process for manufacturing the ignition coil body 10 can be continuously processed in one line. Further, regarding the production of the primary coil winding bed 12 and the secondary coil winding floor 14, the extrusion coating device used when manufacturing the coated electric wire can be diverted, so that the facility cost can be reduced.

In this embodiment, the magnetic core 1 protruding to the other end side
1 is bent in a bound state, but as shown in FIG. 10, the protruding magnetic core 11 on the other end side is separated into each wire rod 11a, and each wire rod 11a is evenly arranged on the outer periphery of the insulating layer 16. After being bent so as to be along, it may be fixed by the convergence band 21 or the like.

FIG. 11 shows another embodiment. As shown in the figure, this ignition coil differs from the above embodiment in that the primary coil winding bed 12 is formed over the entire length of the magnetic core 11 of the ignition coil body 10. 13, the secondary coil winding bed 14, the secondary coil 15, and the insulating layer 16 are formed only on one end side of the magnetic core 11.

The ignition coil body 10 is not intermittent in the second step of the manufacturing process of the above embodiment,
It is manufactured by continuously extrusion-coating an insulating organic material on the magnetic core 11.

In these examples, each wire 11a
The magnetic core 11 is formed by simply bundling
For example, the wire rods 11a may be bundled and twisted. The insulating layer 16 is formed by extrusion-coating an insulating organic material, but the present invention is not limited to this. For example, a tube made of an insulating material is covered, or an insulating tape is used. Can also be formed by winding, coating a liquid resin, or molding with an insulating resin.

Further, a magnetic shield function can be provided by coating the outer side of the insulating layer 16 with a ferromagnetic material such as iron foil (sleeve), cobalt or amorphous alloy. Further, in these examples, the primary coil 13
The secondary coil 15 and the secondary coil 15 are continuously formed in a series of steps. For example, the secondary coil side is separately formed by previously winding the enameled wire around the tubular secondary coil winding bed in advance. After that, it is also possible to manufacture it by a method of fitting it into the one in which the primary coil 13 is formed.

[0035]

As described above, in the ignition coil of the present invention, the magnetic core is formed of the flexible wire bundle, and the primary coil winding bed and the secondary coil winding floor are extrusion-coated with the insulating material. By adopting the configuration formed by the above, there is no need to use a mold when manufacturing parts,
Since the bending of the magnetic core can be easily done in the assembly process,
An ignition coil close to a closed magnetic circuit type can be manufactured at low cost.

Further, according to the method for manufacturing an ignition coil of the present invention, each manufacturing process can be continuously processed by one line when manufacturing the ignition coil body, so that the manufacturing cost can be further reduced. it can.

[Brief description of drawings]

FIG. 1 is a perspective view showing an embodiment according to the present invention.

FIG. 2 is a cross-sectional view showing an ignition coil body of the same.

FIG. 3 is a process drawing showing the method for manufacturing the ignition coil of the same.

FIG. 4 is a process drawing showing the method for manufacturing the ignition coil of the same.

FIG. 5 is a process drawing showing the method for manufacturing the above ignition coil.

FIG. 6 is a process drawing showing the method for manufacturing the ignition coil of the same.

FIG. 7 is a process drawing showing the method of manufacturing the ignition coil of the same.

FIG. 8 is a process drawing showing the method for manufacturing the ignition coil of the same.

FIG. 9 is a process drawing showing the method for manufacturing the ignition coil of the same.

FIG. 10 is a perspective view showing a modified example of the above ignition coil.

FIG. 11 is a cross-sectional view showing another embodiment.

FIG. 12 is a sectional view showing a conventional example.

[Explanation of symbols]

 1 Ignition Coil 10 Ignition Coil Main Body 11 Magnetic Core 12 Primary Coil Rolled Bed 13 Primary Coil 14 Secondary Coil Rolled Bed 15 Secondary Coil 16 Insulating Layer 20 Case 21 Focusing Band 31 Bundling Device 32 First Organic Material Extrusion Device 33 1 Next coil winding device 34 Second organic material extrusion device 35 Secondary coil winding device 36 Third organic material extrusion device 37 Cutting device

Claims (3)

[Claims] 1. A flexible magnetic core formed by bundling wire rods made of a ferromagnetic material, and a primary coil winding bed formed by extruding an insulating material on one end side of the magnetic core. A primary coil formed by winding an electric wire around the primary coil winding bed, and a secondary formed by extrusion coating an insulating material on the primary coil winding bed on which the primary coil is formed. A coil winding bed, a secondary coil formed by winding an electric wire around the secondary coil winding bed, and an insulating material formed on the secondary coil winding bed on which the secondary coil is formed. A main body having an insulating layer formed thereon, and a case accommodating the main body, and the other end of the magnetic core is bent to one end of the magnetic core along the outer periphery of the insulating layer. Ignition coil housed in the case in the state. 2. The ignition coil according to claim 1, wherein each of the wire rods is bent so as to extend substantially evenly around the entire circumference of the insulating layer in a state where the wire rods on the other end side of the magnetic core are separated. 3. A step of continuously sending out a magnetic core by binding a plurality of wires formed by a continuously supplied ferromagnetic material, and insulating the outer peripheral surface of the continuously sent out magnetic core. Forming a primary coil winding bed of a predetermined length on the continuous magnetic core at regular intervals by intermittently extrusion-coating a volatile organic material, and winding an electric wire on the primary coil winding bed to form 1 A step of forming a secondary coil, and intermittently extrusion-coating an insulating organic material on the primary coil winding bed on which the primary coil has been formed to form a predetermined length of 2
Forming a secondary coil winding bed, winding an electric wire on the secondary coil winding bed to form a secondary coil, and insulating organic material on the secondary coil winding bed having the secondary coil formed thereon A step of forming an insulating layer by covering the magnetic core, and cutting the continuously supplied magnetic core at a predetermined position to form the primary coil and the secondary coil on one end side of the magnetic core having a predetermined length. And a step of separating the ignition coil main body, and a step of bending the magnetic core on the other end side of the ignition coil main body to one end side of the magnetic core along the outer periphery of the insulating layer, and housing this in a case A method for manufacturing an ignition coil, comprising: