Metal working – Method of mechanical manufacture – Electrical device making
Patent
1992-08-10
1994-09-06
Hall, Carl E.
Metal working
Method of mechanical manufacture
Electrical device making
29606, 26427219, H01F 4106
Patent
active
053436148
DESCRIPTION:
BRIEF SUMMARY
BACKGROUND OF THE INVENTION
The present invention relates to a method and device for manufacturing coils.
More particularly, it relates to a method for manufacturing coils, in particular ignition coils for ignition systems of internal combustion engines, of the type having a housing, an iron core in the housing, primary and secondary windings and a plastic block enclosing at least the primary winding.
In known ignition coils, in each case a winding form is used for their primary winding and secondary winding. In order to obtain the highest possible power yield in an ignition coil of a predetermined constructional size, the heat produced in its windings during operation must be effectively conducted away. This applies in particular to the primary winding which is covered by the secondary winding and whose maximum operating temperature ultimately limits the efficiency of the ignition coil.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a method of manufacturing coils, in accordance with which a primary winding is first wrapped onto a core rod of a wrapping machine, a secondary winding is arranged on a winding form and pushed coaxially over the primary winding and when thereafter the core rod is pulled out of the primary winding an iron core accommodated in a housing with respect to the core rod is inserted into the primary winding, while the housing which is carried along with the iron core and encloses the ignition coil is filled with casting resin forming the plastic block.
The method performed in accordance with the present invention has characterising features of claim 1 has the advantage that the primary winding of the ignition coil can be produced without winding forms and the heat transfer from the primary winding to the directly adjacent iron core can take place particularly effectively. As a result, it is possible with such an ignition coil with predetermined external diameters to obtain a power yield which is increased in comparison with an ignition coil of conventional design.
In accordance with another feature of the present invention the secondary winding is connected at its end with a connection of the end of the secondary winding to the high-voltage terminal is provided which favourable in terms of production technology.
The novel features which are considered as characteristic for the invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view showing a partial section of a wrapping machine with a core rod and a primary winding of a coil to be wound on the core rod;
FIG. 1a is a top view of FIG. 1;
FIG. 2 is a view illustrating a further step of the method of producing the coil, in which a secondary winding is produced and mounted coaxially to the primary winding;
FIG. 3 is a view showing still a further step of the inventive method in which an iron core is attached to the core rod, and other parts of the coil cooperate with it; and
FIG. 4 is a view showing a final step of the method in accordance with the present invention.
In FIG. 1 of the drawing a diagrammatic view of a partial section through a wrapping machine 11 is shown with a drive element 12 which has a cylindrical base shape and a core rod 13 which is shaped as a shaft stub, is attached coaxially to said element and is offset with respect to the drive element 12.
The core rod 13 has at its two ends flange-like boundary elements as a collar 14 and stop 16 which bound the wrapping area for a primary winding 17 to be wrapped onto the core rod for an ignition coil 18 which is indicated, and which boundary elements have a diameter which is at least equal in size to the external diameter of the primary winding 17.
The collar 14 is part of a connection plug 21 wh
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Almendro Jose Luis
Betz Dieter
Garcia Fernando
Nuebel Karl-Heinz
Ramirez Eduardo
Hall Carl E.
Robert & Bosch GmbH
Striker Michael J.
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