INTERNAL COMBUSTION ENGINE IGNITION APPARATUS HAVING A PRIMARY WINDING MODULE

Abstract: Ignition apparatus for developing and applying sparks to the cylinders of an internal combustion engine (16). A plurality of secondary spark developing units (18) are respectively associated with the cylinders of the engine. Each secondary unit comprises a spark plug and a secondary winding carried by the spark that is connected to the electrodes of the spark plug. Magnetic flux is coupled to the secondary winding of the secondary units by a primary winding module (10). The module has a support portion (12) and a plurality of spaced tubular members (14). A primary winding having a bore is located in each tubular member. A tubular flux carrying part formed of magnetic material is located about each primary winding. The module is supported by the engine in such a position that portions of the secondary units project into the bores when the module is mounted on an engine.

Description: This invention relates to ignition apparatus for developing sparks that are applied to the cylinders of an internal combustion engine and more particularly to a primary winding module for such ignition apparatus that includes a plurality of primary windings that cause voltages to be induced in the secondary windings of a plurality of secondary winding units that are associated with the cylinders of the internal combustion engine. A known type of integrated ignition system that utilizes an ignition module that is secured to an engine where the ignition module has means for making electrical connections to the spark plugs of the engine is disclosed in US patent no. 4,706,639. In this patent, a plurality of ignition coils are contained within the ignition module and the secondary windings of the ignition coils are connected to the spark plugs. The ignition module further has a plurality of connector assemblies which fit over the spark plugs which include means for making an electrical connection to a terminal of a spark plug. A primary winding module, and ignition apparatus including a primary winding module, in accordance with the present invention are characterised by the features specified in the characterising portions of claims 1 and 8 respectively. The ignition apparatus of this invention, like the apparatus disclosed in US patent no. 4,706,639, includes a module that is secured to the engine. However, unlike the module disclosed in US patent no. 4,706,639, the module of this invention does not support a plurality of ignition coils that have secondary windings. Thus, the primary winding module of this invention has a plurality of spaced primary windings each of which defines a bore. The primary windings are adapted to cooperate with a plurality of secondary winding units, where each secondary winding unit includes a spark plug and a secondary winding carried by an insulator of the spark plug. When the primary winding module is secured to an engine the bores of the primary windings are slipped over the portions of the secondary winding units that have the secondary windings. When the primary windings are energized, voltages are induced in the secondary windings of the secondary winding units by magnetic coupling of the flux developed by the primary windings to the secondary windings. It accordingly is one of the objects of this invention to provide an ignition apparatus that is adapted to be secured to an engine and wherein a primary winding module has a plurality of spaced primary windings that are adapted to be magnetically coupled to a plurality of separate secondary winding units, where each secondary winding unit includes a spark plug and a secondary winding. The primary windings may be associated with tubular parts formed of magnetic material that provide flux paths for the flux developed by a primary winding and wherein the secondary winding units have a magnetic core located within a secondary winding for providing a flux path for flux developed by a primary winding. The primary windings of the primary winding module may further be energized by a capacitor discharge type of ignition circuit. The present invention may still further provide ignition apparatus for developing sparks that are applied to the cylinders of an internal combustion engine, the ignition apparatus having a primary winding module that includes a plurality of spaced primary windings, each of which has a bore and wherein the primary winding module is secured to the engine in such a position that the bores receive the ends of respective secondary winding units, where each secondary winding unit comprises a spark plug having a threaded portion threadable into a respective engine spark plug opening and an insulator that carries a secondary winding, and further wherein the secondary winding of a respective secondary winding unit is located within a respective bore of a primary winding. The present invention will now be described, by way of example, with reference to the accompanying drawings, in which:- Figure 1 is a perspective view of a primary winding module made in accordance with this invention shown associated with a plurality of separate secondary winding units; Figure 2 is a sectional view illustrating the manner in which a primary winding of the primary winding module shown in Figure 1 is associated with one of the secondary winding units; Figure 3 is a sectional view of the primary winding module of Figure 1; Figure 4 is a top view of the primary winding module shown in Figure 3; Figure 5 is a sectional view of a modified secondary winding unit; and Figure 6 illustrates a capacitor discharge ignition circuit for energizing the primary windings of a primary winding module in accordance with the present invention. Referring now to the drawings and more particularly to Figure 1, reference numeral 10 generally designates a primary winding module made in accordance with this invention. This primary winding module includes an elongated body or support portion 12 that is formed of a plastic insulating material and which has four spaced, integral, tubular portions, each designated as 14. These tubular portions 14 each support a primary winding having a bore in a manner that will be described. In Figure 1, reference numeral 16 designates a four cylinder, internal combustion engine that has four threaded spark plug openings, each of which communicates with a respective cylinder of the engine. Threaded into these spark plug openings are the threaded ends of four secondary winding units (secondary spark developing units), each of which is designated as 18. Each secondary winding unit 18, as will be described, is comprised of a spark plug that has an insulator that carries a secondary winding that is connected to the electrodes of the spark plug. Further, as will be described, each secondary winding unit 18 has a magnetic core located inside of the secondary winding. The primary windings of primary winding module 10 are connected to a capacitor discharge ignition apparatus that is located in area 20 of primary winding module 10 by conductors that extend through support portion 12. In use, the secondary winding units 18 are threaded into the appropriate spark plug openings in engine 16. The primary winding module 10 is then secured to engine 16 by bolts or screws (not illustrated) that pass through openings 22. When securing primary winding module 10 to engine 16 the tubular portions 14 are slipped over the upper ends of secondary winding units 18 such that in the final assembled position of primary winding module 10 the upper ends of secondary winding units 18 are telescoped into the bores of the primary windings located in tubular portions 14 with a respective primary winding encircling a respective secondary winding on a secondary winding unit. Referring now to Figure 2, one of the primary windings contained in a tubular portion 14 of primary winding module 10 is shown associated with one secondary winding unit 18. It is seen that tubular portion 14 and support portion 12 support a coil support or coil spool 24 that is formed of a moulded plastic insulating material. This coil spool 24 has an outer spiral groove into which is wound a primary winding 26 formed of a plurality of turns of wire. By way of example, the primary winding 26 may be comprised of seven turns of wire. Tubular portion 14 also contains a tubular part 28 that is formed of magnetic material. This part is disposed about primary winding 26 and forms a low reluctance flux path for flux developed by primary winding 26. The tubular part 28 may be formed of steel or compacted powdered iron. Where it is formed of steel it may be slitted axially to permit it to expand when it is press fitted to outer surfaces of coil spool 24. After press fitting the tubular part 28 to coil spool 24, these parts are overmoulded with plastic material to form tubular portion 14 in a manner to be described. In Figure 2, the secondary winding unit 18 has an insulator 30 that is formed of a ceramic material that can be of the same type that is used for spark plug insulators. The insulator 30 has a portion 30A that supports a central (metallic) electrode 32 and outer (tubular metallic) shell 34 having a threaded portion 36. The outer shell 34 carries an electrode 38 that is in spark gap relationship to the end of central electrode 32. The threaded portion 36 is shown threaded into a threaded spark plug opening in a head 39 of engine 16. The spark gap is located in one of the cylinders or combustion chambers 40 of the engine 16. The insulator 30 has a tubular portion 30B that has an internal bore and an outer cylindrical surface. The outer cylindrical surface of tubular portion 30B carries a secondary winding 42 that is comprised of a number of spiral turns of metallic material that is bonded to the outer cylindrical surface of tubular portion 30B. The secondary winding 42 may be formed by known metallizing processes. For example, secondary winding 42 may be printed onto the outer cylindrical surface of tubular portion 30B. Another way of forming secondary winding 42 is to coat, plate or deposit the outer cylindrical surface of tubular portion 30B with a metallic material such as copper and then laser cut the material to form a spiral winding by laser evaporating a spiral pattern of material. The secondary winding 42 is a single larger winding and may, for example, be comprised of 500 turns of metallic material where the material is 0.0254 mm (0.001 inches) wide and where the spacing between adjacent turns is about 0.0254 mm (0.001 inches). The material may be about 0.0254 mm (0.001 inches) thick. As an alternative, secondary winding 42 could be formed by tightly winding a fine copper magnet wire to the outer cylindrical surface of tubular portion 30B and then encapsulating the secondary winding with a high temperature encapsulation material. By way of example, the wire could be an Awg. No. 44 diameter magnet wire having a diameter of about 0.0508 mm (0.002 inches). The secondary coil 42 can be formed of metallic material other than copper, for example, tungsten or silver. One end of secondary winding 42 is connected to outer shell 34 and hence to electrode 38 by a strip conductor having a portion 44 brazed or soldered to outer shell 34. The opposite end of secondary winding 42 is connected to the top end of central electrode 32 by strip conductors 46, 48 and 50. Strip conductor 46 is brazed or soldered to the top end of central electrode 32. Strip conductor 48 extends along an inner surface of tubular portion 30B of insulator 30. The bore in tubular portion 30B contains a (cylindrical) magnetic core 52 which is formed of a composite magnetic material. By way of example, magnetic core 52 may be comprised of fine particles of powdered iron where each particle is coated with an electrical insulating material that serves to insulate the iron particles from each other. Magnetic core 52 may be formed by compacting plastic coated iron particles into a solid mass by suitable pressure and heat. The magnetic core 52 is then secured in place in tubular portion 30B by a suitable adhesive such as a ceramic cement. The secondary winding unit 18 has an outer protective housing that is formed of a plastic insulating material. This outer protective housing encapsulates the upper end of secondary winding unit 18 and comprises a tubular portion 54 and an integral end cap portion 56. The lower end of tubular portion 54 engages and seals against the top end of outer shell 34. There is some clearance between the outer surface of tubular portion 54 and the inner surface of coil spool 24 which is large enough to allow the upper ends of secondary winding units 18 to be telescoped onto coil spools 24 when the primary winding module 10 is secured to the engine 16. Referring now to Figures 3 and 4, it is seen that the upper ends of each coil spool 24 has an integral annular portion 58 that each carry four integral posts, each designated as 60. Each annular portion 58 further has a pair of integral projections 62 that extend through openings formed in a conductor strap 64 that is formed of metallic material such as brass. The projections 62 are headed over to secure respective coil spools 24 to conductor strap 64. The conductor strap 64 should be rigid enough to support the four coil spools prior to overmoulding to form moulded support portion 12. The conductor strap 64 is connected to one side of all four primary windings 26. To this end, each primary winding 26 has an axially extending end lead or conductor 66. Conductor 66 is an integral extension of primary coil 26. The conductor 66 projects through an apertured, extruded, or bumped-out portion 68 of conductor strap 64 and is welded to conductor strap 64. The conductor strap 64 is connected to an electronic module 70 carried by one end of support portion 12. The opposite ends of the four primary windings 26 are connected by separate conductors or wire to electronic module 70. Thus, one side of the primary winding 26, located at the far right in Figures 3 and 4, is connected to electronic module 70 by a conductor or wire 72 that is an integral extension or end lead of one of the primary windings 26. This wire 72 is led out of a coil spool 24 through a slot formed in annular portion 58. The wire, or conductor 72, has portions respectively wrapped around four posts 60, one from each coil spool 24 to support wire 72. In a similar fashion, the next primary winding 26 to the left in Figure 4 is connected to electronic module 70 by wire 74. Another primary winding 26 is connected to electronic module 70 by wire 76 and the primary winding 26 at the far left in Figure 4 is connected to electronic module 70 by wire 78. The wires or conductors 72-78, as well as conductor strap 64 are shown schematically in the circuit diagram of Figure 6 which will be described. Conductor strap 64, conductor 66 and wires 72-78 define conductor means. In the manufacture of the primary winding module 10, the coil spools 24 with attached tubular parts 28 and primary windings 26 are attached to conductor strap 64. The wires 72-78 are then positioned with portions thereof being wrapped around posts 60. The conductors 66 are connected to conductor strap 64. This entire assembly is then overmoulded with a plastic insulating material to form the axially extending support portion 12 and the integral tubular portions 14. The support portion 12 is moulded to provide a space for electronic module 70. After the electronic module 70 is assembled in area 20 it is electrically connected to conductor strap 64, and wires 72, 74, 76 and 78 by suitable terminals. It should be appreciated that conductor strap 64, and wires 72, 74, 76 and 78 are totally enclosed by the plastic insulating material that forms support portion 12. Figure 5 illustrates a modified secondary winding unit that can be used in place of the secondary winding unit 18 shown in Figure 2. The secondary winding unit shown in Figure 5 uses many of the same parts as the secondary winding unit 18 shown in Figure 2 and the same reference numerals have been used in Figures 2 and 5 to identify corresponding parts. The secondary winding unit of Figure 5 differs from the secondary winding unit 18 shown in Figure 2 in that it has an additional insulator generally designated as 80. The additional insulator 80 can be formed of ceramic material of the same type that is used for insulator 30. Additional insulator 80 has a tubular portion 80A and a closed end 80B. The external surface of tubular portion 80A has a spiral secondary winding 82 bonded thereto. This secondary winding 82 is of the same type as secondary winding 42 which has previously been described. One end of secondary winding 82 is connected to the top end of central electrode 32 by conductor strips 84 and 85. The opposite end of secondary winding 82 is connected to outer shell 34 by conductor strip portions 86, 88 and 90. Conductor strip portion 88 extends axially along the outer surface of tubular portion 30B and conductor slip portion 90 is connected to outer shell 34. Additional insulator 80, with its secondary winding 82, can be secured in tubular portion 30B by a suitable ceramic cement. The bore of additional insulator 80 contains a magnetic core 52 which can be the same as magnetic core 52 described in connection with the description of Figure 2. Magnetic core 52 is secured in place by a suitable adhesive such as a ceramic cement. Referring now to Figure 6, a circuit diagram of a capacitor discharge ignition circuit is illustrated. In Figure 6 the same reference numerals have been used as were used in the other figures to identify corresponding elements. It will be assumed that the secondary winding units 18 of Figure 2 have been used in Figure 6. In Figure 6, the reference numeral 92 designates a capacitor of the capacitor discharge ignition circuit. Capacitor 92 is charged to about 400 or 500 volts by a direct voltage power supply 94. Power supply 94 may be a DC to DC converter which is connected to a 12 volt storage battery 95. The power supply 94 boosts the 12 volt input voltage to about 400 or 500 volts output. One side of capacitor 92 is connected to conductor strap 64 which in turn is connected to one side of primary windings 26. The opposite side of capacitor 92 is connected respectively to switches 96 which are semiconductor switches such as controlled rectifiers. When a given switch 96 is biased on or conductive the capacitor 92 discharges through one of the primary windings 26. This causes a voltage to be induced in a secondary winding 42 which is high enough to cause a spark arc to be developed across a pair of secondary unit electrodes 32 and 38. The switches 96 are biased sequentially conductive in synchronism with the angular position of the crankshaft of the engine 16. To this end, the crankshaft of engine 16 drives a crankshaft position sensor 98 that develops pulses of voltage at certain crankshaft angular positions. The crankshaft position sensor 98 is connected to an (electronic) cylinder selector 100 which in turn has outputs connected respectively to switches 96. With this arrangement, the cylinders 40 of the engine 16 are fired in the correct order and at the correct ignition timing. In this regard, cylinder selector 100 causes switches 96 to be turned on in the proper sequence and as a function of crankshaft annular position. Power supply 94, capacitor 92, switches 96 and cylinder selector 100 are parts of the electronic module 70 that is supported by one end of primary winding module 10. The head 39 of the engine 16 can be formed to provide spark plug wells that receive the secondary winding units like secondary winding unit 18. No specific hardware has been illustrated for attaching primary winding module 10 to engine 16. The hardware can take various forms, depending upon the configuration of engine 16. It will be appreciated that the engine 16 can be provided with mounting brackets that are carried by the engine for accommodating the screws or bolts that pass through openings 22 in support portion 12. Further, the shape of support portion 12 can be varied to accommodate the shape or configuration of engine 16. It will be appreciated that when capacitor 92 discharges through a primary winding 26, this winding develops magnetic flux that is coupled to a secondary winding 42. The flux path or magnetic circuit for the flux developed by primary winding 26 includes the low reluctance paths of tubular part 28 and the magnetic core 52. The tubular parts 28 can be eliminated if sufficient current is supplied to the primary windings 26 that is high enough to cause a voltage to be induced in a secondary winding 42 that is high enough to cause an arc to be developed across electrodes 32 and 38. If tubular parts 28 are not used, the efficiency of the ignition apparatus is reduced. If tubular parts 28 are not used, the plastic material of tubular portions 14 is moulded against outer surfaces of coil spool 24 and primary winding 26.

Claims: A primary winding module (10) that is adapted to be mounted on an internal combustion engine (16) and which is adapted to be magnetically coupled to a plurality of separate secondary spark developing units (18) associated with the cylinders (40) of the internal combustion engine, comprising an elongated support portion (12), a plurality of spaced tubular portions (14) carried by the support portion; a corresponding plurality of primary windings (26); and conductor means (64,66,72-78) carried by the support portion connected respectively to opposite ends of a respective primary winding for energizing a respective primary winding; characterised in that each primary winding (26) is located in an associated tubular portion (14); each primary winding having a bore adapted to receive portions of the secondary spark developing units when the primary winding module is mounted on the internal combustion engine. A primary winding module according to claim 1, wherein a tubular flux carrying part (28) formed of magnetic material is located in each tubular portion (14) and is disposed about a respective primary winding (26). A primary winding module according to claim 1 or claim 2, wherein the support portion (12) is formed of plastic electrical insulating material. A primary winding module according to claim 1 or claim 2, wherein the tubular portions (14) are integral with the support portion (12), and wherein the support portion and tubular portions are formed of a moulded plastic electrical insulating material. A primary winding module as claimed in claim 4, wherein the support portion (12) and tubular portions (14) are formed in one-piece, with the tubular portions substantially normal to the support portion. A primary winding module according to any one of claims 1 to 5, wherein each primary winding (26) is supported by a coil spool (24) of electrical insulating material that is located in its associated tubular portion (14) and supported thereby. A primary winding module according to any one of claims 1 to 6, comprising components of a capacitor discharge ignition circuit that is connected to the conductor means (64,66,72-78) to energize the primary windings (26). Ignition apparatus for developing and applying sparks to a plurality of cylinders (40) of an internal combustion engine (16), comprising a secondary spark developing unit (18) associated with each cylinder, each secondary spark developing unit comprising a spark plug having electrodes (32,38); a primary winding module (10) supported by the internal combustion engine, the primary winding module comprising an elongated support portion (12) and a plurality of spaced tubular portions (14) carried by the support portion and equal in number to the number of secondary spark developing units, a corresponding plurality of primary windings (26), and conductor means (64,66,72-78) carried by the support portion connected to opposite ends of a respective primary winding for energizing a respective primary winding; characterised in that the secondary spark developing unit (18) includes a secondary winding (42) that is connected to the electrodes (32,38); and in that each primary winding (26) is located in an associated tubular portion (14) and has a bore, the primary winding module being so positioned that a portion of a secondary spark developing unit that has a secondary winding is located in a respective said bore whereby a spark firing voltage is induced in the secondary winding when the primary winding is energized. Ignition apparatus according to claim 8, wherein each secondary spark developing unit (18) has a magnetic core (52). Ignition apparatus according to claim 8 or claim 9, wherein the primary windings (26) are energized by a capacitor discharge ignition circuit. Ignition apparatus according to any one of claims 8 to 10, wherein the support portion (12) and tubular portions (14) are formed as a one-piece plastic part of plastic insulating material.

Inventors: BOYER, JAMES ALVA, HUNTZINGER, DWAYNE ALLEN, WELSH, THOMAS EDWARD, JR.
Applicants: GENERAL MOTORS CORPORATION
Application year: 1990
Main classification: F02P13
IPC codes: F02P7, H01T13, F02P3, F02P15, F02P13, H01F38