Patent ID: 9097232
Filing Date: 2015-08-04
Classification: F02P,H01F,Y10T

Abstract:
1. An ignition coil assembly, comprising: a magnetic core; a first spool having a first hollow portion defining a first spool outer surface and a first spool cavity defining a first spool inner surface, wherein said magnetic core is disposed within the first spool cavity; a first coil, wherein said first coil is wound around the first spool outer surface; a second spool having a second hollow portion defining a second spool cavity defining a second spool inner surface, wherein said first spool and said first coil are disposed within the second spool cavity; and an electrically insulating material injected into an annular space defined between a first coil outer surface and the second spool inner surface, wherein said first hollow portion defines a longitudinal slot therethrough from the first spool outer surface to the first spool inner surface, wherein the longitudinal slot defines a closed end in the first spool outer surface, and wherein the longitudinal slot is configured such that tension in the first wire coil narrows said longitudinal slot to decrease a first spool circumference, whereby the decrease of the first spool circumference increases the annular space sufficient to inject said electrically insulating material into the annular space without creating substantial voids in said electrically insulating material.