An ignition module that is adapted to be secured to an internal combustion engine. The module has a plastic housing and a metallic cover that is adapted to be secured to an engine. A plurality of ignition coils are located within the housing and cover. The lower wall of the plastic housing has conductors embedded therein that electrically connect the secondary windings of the coils to electrical connector assemblies that are carried by the housing and which are adapted to slip over the spark plugs of an engine. The connector assemblies include means for making an electrical connection to the terminals of the spark plugs. The ignition coils have laminated cores that are clamped between the housing and the cover. The cores directly contact the metallic cover so that the cores have a heat transfer path to the cover and are electrically connected to the cover.

Integrated direct ignition module

An external connection terminal connector as a separate part that mounts the igniter is abolished, and the external connection terminal is integrated with the igniter itself. The igniter has the electronic components mounted on an internal wiring substrate, and the electronic components within the igniter and the external connection terminal are directly connected by wire bonding.

Ignition device for internal combustion engine

An ignition coil assembly for an internal combustion engine including an ignition coil housing having integrally molded mounting members arranged on the outer perimeter of the housing in non-interfering relationship with the internal coil/core assembly components. C-Shaped laminated cores are encased entirely within the ignition assembly housing material or encased in an elastomer such as a rubber modified polypropylene and inserted into the housing assembly. The ignition coil assembly provides for use either in a internal combustion engine with a distributor-based or distributor-less ignition system.

Ignition coil assembly and method of manufacture thereof

In a distributorless ignition system for an internal combustion engine, a single ignition coil unit, detachably mountable to a cylinder head, is provided for each pair of spark plugs. The ignition coil unit includes a coil portion having a core and primary and secondary windings wound on the core, a pair of plug couplers formed on the coil portion in correspondence to the spark plugs arranged on adjacent two cylinders of the engine, a pair of high tension couplers formed on the coil portion in directions different from those of the plug couplers, a first connecting member for electrically connecting one end of the secondary winding to one of the plug couplers, a second connecting member for electrically connecting the other end of the secondary winding to one of the high tension couplers, and a third connecting member for electrically connecting the other of the plug couplers to the other of the high tension couplers. Therefore, the ignition coil unit can be easily engaged and disengaged with the spark plugs. Then, a pair of connecting cords are crossed between two such ignition coil units to respectively interconnect different pairs of the high tension couplers. When each of the coil units generates high voltages in a predetermined sequence, the plurality of spark plugs are fired in a given order.

Ignition coil unit for internal combustion engines

An ignition coil is described having primary and secondary coils (208, 412), the primary coil (208) wound around a central core member (300) and including a permanent magnet (310) made of a magnetic material that is less than fully dense, and is interposed between one end of the central core member (300) and one end of an outer core (100) surrounding the primary and secondary coil assembly and assuring the elimination of any air gap between the outer core (100) and the central core member (300). The ignition coil further having a common modular design for a slip-in fit into differing modular housing designs depending upon the number of cylinders in the engine.

Ignition coil assembly

A module for use in the ignition system of a spark ignited engine combines in one unit a spark plug connector or cap and an ignition coil for converting low voltage current changes into the high voltage pulses required for firing the associated plug, the module, therefore, eliminating the need for a separate high-tension conductor of substantial length between the ignition coil and the spark plug. The module is mounted to an engine shroud directly outboard of the spark plug so as to electrically cooperate with the plug while nevertheless not relying on the plug for its structural support.

John J. Donovan

Papers

Spark plug connector and ignition coil module for engine ignition system