Spark developing apparatus for internal combustion engines

Abstract: Apparatus for developing and applying sparks to a combustion chamber of an internal combustion engine. The apparatus comprises separate primary (12) and secondary (10) winding units. The secondary unit includes a spark plug having an insulator (14). The insulator carries a secondary winding (30) which is connected to the electrodes (16,20) of the spark plug. The insulator has a bore (26) which contains a magnetic core (40) for the secondary winding. The primary winding unit includes a primary winding (52) and a tubular flux carrying part (58) formed of magnetic material. The primary winding unit has a bore which is slipped over a portion of the secondary unit that has the secondary winding. A voltage is induced in the secondary winding by magnetic coupling to the primary winding when it is energized.

Description: This invention relates to spark developing apparatus for igniting the combustible mixture supplied to a cylinder of an internal combustion engine, and more particularly to such spark developing apparatus that includes a spark plug that has a winding that forms a secondary winding of an ignition coil. Ignition apparatus for generating sparks to ignite the combustible mixture of a spark ignited internal combustion that combines a spark plug and an ignition coil into one unit have been proposed in the prior art. US patent nos. 1,164,113; 1,302,308; 2,441,047; 2,459,856; 2,467,531; and 2,467,534 all disclose combined ignition coil and spark plugs. DE-A-2,838,334 discloses spark developing apparatus, having features as in the pre-characterising portion of claim 1, in which a secondary unit includes the spark developing electrodes and a secondary winding wound round one of the electrodes, and a completely separable primary unit comprising a primary winding adapted in use to induce a current in the secondary winding for developing a spark. A spark developing apparatus, and a secondary unit therefor, in accordance with the present invention are characterised over DE-A-2,838,334 by the features specified in the characterising portions of claims 1 and 7 respectively. The spark developing apparatus of this invention differs from DE-A-2,838,334 in that, among other things, it utilizes a combined spark plug and secondary winding in which the secondary winding has a voltage induced therein by magnetic coupling to the primary winding by means of a magnetic core providing a flux path for the magnetic flux developed by the separate primary unit. It, accordingly, is one of the objects of this invention to provide a spark developing apparatus that combines into a single unit, a spark plug, a secondary winding and a magnetic core for the secondary winding. The magnetic core may be comprised of small particle size magnetic powder such as iron powder wherein the particles are electrically insulated from each other by insulating material that coats the particles. Another object of this invention is to provide apparatus for developing and applying sparks to a cylinder of an internal combustion engine that comprises a combined spark plug and secondary winding mounted on the internal combustion engine and a primary unit that is separate from the secondary unit, and wherein the primary unit has a primary winding that is magnetically coupled to the secondary winding of the secondary unit. The primary winding of the primary unit may be energized by a capacitor discharge ignition circuit. The present invention will now be described, by way of example, with reference to the accompanying drawings, in which:- Figure 1 is a sectional view of spark developing apparatus made in accordance with this invention mounted on an internal combustion engine; Figures 2 and 3 are sectional views of modified spark developing apparatus made in accordance with this invention; Figure 4 is a perspective view illustrating the spark developing apparatus of this invention for use on a four cylinder engine; and Figure 5 is a schematic circuit diagram of an ignition apparatus that utilizes the spark developing apparatus of this invention. Referring now to the drawings and more particularly to Figure 1, a spark developing apparatus is illustrated that comprises two separate units generally designated respectively as 10 and 12. The secondary unit 10 comprises a spark plug, a secondary winding and a magnetic core. The primary unit 12 comprises a primary winding. Secondary unit 10 includes an insulator 14 which is formed of a suitable ceramic electrical insulating material. This ceramic material may be of the same type that is used for the insulator of a conventional spark plug. Thus, by way of example, and not by way of limitation, a ceramic material that has a high alumina base material containing upwards of 85% aluminium oxide may be used. The insulator 14 defines a first insulator which carries a (metallic) central electrode 16 and an outer (tubular metallic) shell 18, which in turn carries an electrode 20 located in arc gap relationship to the end of central electrode 16. The outer shell 18 has a threaded portion 21 which is shown in Figure 1 threaded into a threaded spark plug opening in the head 22 of an internal combustion engine. The spark plug gap is located in a combustion chamber or cylinder 23 of the engine. The insulator 14 has an axially extending, annular, tubular shaped portion 24 that has a tubular bore 26. In this case, the insulator portion 24 defines a second insulator. The insulator portion 24 has an outer surface 28 and bonded to this surface is a spiral secondary winding 30. One end turn of secondary winding 30 is electrically connected to outer shell 18 and hence to electrode 20 by strip conductors 31 and 32. Strip conductor 32 is soldered or brazed to outer shell 18. The opposite end turn of secondary winding 30 is electrically connected to a portion 16A of central electrode 16 by strip conductors 34, 36 and 38. Strip conductor 34 is soldered or brazed to an upper surface of portion 16A. The strip conductors 31-38 and secondary winding 30 are formed of metallic material such as copper which is bonded to the ceramic material of insulator 14. By way of example, the secondary winding 30 may be comprised of about 500 turns of metallic material with the conductor that forms a turn being about 0.0254 mm (0.001 inches) wide and with the spacing between adjacent turns being about 0.0254 mm (0.001 inches). The material may be about 0.0254 mm (0.001 inches) thick. The secondary winding 30 is a single layer winding. The secondary winding 30 can be formed by metallizing the outer surface 28 of insulator portion 24 with a metallic conductor material that has a spiral pattern where the material is bonded to outer surface 28. The metallic material, which may be copper can be plated or deposited on the outer surface 28. The metallizing can be accomplished by a number of methods. For example, the outer surface 28 can be coated or plated with a metallic material and then portions of the metallic material is removed to form a spiral coil winding. The material can be removed by etching away a spiral pattern that ultimately forms spaces between adjacent turns of the secondary winding. The material could also be removed by use of a laser to evaporate a thin spiral pattern of metallic material. In general any known insulator metallizing process may be used to form secondary winding 30 as long as the process used is capable of bonding a spiral metallized coil on the outer surface 28. The secondary winding 30 can be formed of a metallic material other than copper, for example tungsten or silver. As an alternative, secondary winding 30 could be formed by tightly winding a fine copper magnet wire to outer surface 28 and then encapsulating the 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 tubular bore 26 in insulator portion 24 contains a (cylindrical) magnetic core 40 that extends the entire length of tubular bore 26. This magnetic core 40 is formed of a composite magnetic and electrical insulating material. By way of example magnetic core 40 can be formed of fine powdered iron particles where each particle is coated with an electrical insulating material such as a thermoplastic resin. The particles may also be coated with other electrical insulating material that form a glass-like overcoat or film. The magnetic core 40 can be formed by compacting coated iron powder in a suitable press to form a solid mass of magnetic material having a cylindrical shape. The electrical insulating material insulates the iron particles from each other. The insulation of the particles from each other performs the function of reducing eddy current loss in magnetic core 40. After the secondary winding 30 and associated strip conductors 31-38 have been formed, the magnetic core 40 is assembled by inserting it into tubular bore 26. The magnetic core 40 is attached to insulator 14 by a suitable adhesive such as a ceramic cement which has not been illustrated. After the magnetic core 40 has been assembled, the upper end of secondary unit 10 is overmoulded with a plastic moulding material to form an outer housing having a tubular portion 42, an end wall 44 and a boss or post 46. The outer housing is an electrical insulator and also serves to seal the area containing the secondary winding 30 and associated conductors from moisture or other contaminants. The outer lower end of tubular portion 42 is moulded to the upper end of outer shell 18 such that it engages and is moulded to an entire upper annular surface of outer shell 18. The primary unit 12 may be termed a primary unit since it has a primary winding which, when energized, causes a spark firing voltage to be induced in secondary winding 30. The primary unit 12 comprises a coil spool 50 that is formed of plastic electrical insulating material. The coil spool 50 carries a primary winding 52 which may be comprised of about seven turns of wire. It can be seen that the wire that forms primary winding 52 is wound into grooves formed in the exterior of coil spool 50. One end of primary winding 52 has an end lead or conductor 54 and the opposite end of primary winding 52 has an end lead or conductor 56. The primary unit 12 has a tubular, primary, flux carrying, part 58 that is formed of magnetic material and which engages coil spool 50. The flux carrying part 58 forms a low reluctance magnetic path for flux developed by primary winding 52 when it is energized. The flux carrying part 58 may be formed of cold rolled steel or compacted powdered iron. The flux carrying part 58 can be press-fitted to the coil spool 50. Where flux carrying part 58 is formed of cold rolled steel, it may have an axial slit to allow it to expand slightly when it is assembled to coil spool 50. The primary unit 12 has a cover or housing that is formed of a plastic insulating material that is overmoulded to flux carrying part 58 and coil spool 50. This housing is comprised of an axially extending tubular portion 60, a lower wall 62 which has an annular bore or opening 64 and an upper wall 66 which has an annular bore or opening 68. In the use of this invention, the secondary units 10 are assembled to an internal combustion engine in the same manner that a conventional spark plug is assembled to an engine, that is the threaded portion 21 is threaded into an appropriate threaded spark plug opening in the engine. With a secondary unit 10 assembled to an engine, a primary unit 12 is now slipped over the upper end of secondary unit 10 with the post 46 passing through annular bore 68. The lower surface of lower wall 62 engages an upper portion of outer shell 18. A metal retaining clip 70 is now fastened to post 46. This retaining clip 70 engages an outer surface of upper wall 66 of primary unit 12 and serves to hold the primary unit 12 in place relative to secondary unit 10. There is sufficient clearance between the telescoped portions of secondary and primary units 10 and 12 to allow primary unit 12 to be slipped over the upper portion of secondary unit 10. The primary winding 52 is energized by a capacitor discharge ignition circuit shown in Figure 5. Whenever a primary winding 52 is energized, it develops a flux field which is magnetically coupled to secondary winding 30. The flux path for flux generated by primary winding 52 has inner and outer paths which are through magnetic material. The inner flux path is through the magnetic material of magnetic core 40 and the outer path is through flux carrying part 58 of primary unit 12. It will be appreciated that there is no electrical connection between primary winding 52 and secondary winding 30. The voltage induced in secondary winding 30 is due solely to its magnetic coupling with primary winding 52. Further, the secondary and primary units 10 and 12 are separate parts. When using the embodiment of the invention shown in Figure 1, a plurality of units like primary unit 12 is required for a multi-cylinder engine. Thus, for a four cylinder engine, four units like primary unit 12 would be required. Each primary unit would be connected to a capacitor discharge ignition circuit by suitable cables. This is only one way of implementing this invention and as will be described in connection with Figure 4, the primary units like primary unit 12 can be integrated into a single module that is secured to the engine. Further, where separate units like primary unit 12 are used, one for each secondary unit 10, it is not necessary that the secondary unit 10 be provided with means like post 46 for securing the primary unit 12 in place. Thus, separate units, like primary units 12 could be attached to the engine by suitable mounting brackets or hardware. Referring now to Figure 2, a modified spark developing apparatus is illustrated. The secondary unit shown in Figure 2 has no means for securing a primary unit thereto and is adapted to be used with a module shown in Figure 4 that is fastened to the engine. The secondary unit shown in Figure 2 is identical with secondary unit 10 shown in Figure 1 with the exception that it has no post like post 46. The secondary unit of Figure 2 has an outer plastic housing or cover comprised of a tubular portion 72 and integral end wall 74. The other parts in Figure 2 have been identified by the same reference numerals as were used in Figure 1 to identify corresponding parts. Figure 3 illustrates still another modified spark developing apparatus. This secondary unit like the secondary unit shown in Figure 2 is adapted to be used with the module shown in Figure 4. In the Figure 3 secondary unit the insulator 14 has an axially extending, annular, tubular shaped, portion 76 provided with a bore 78. Disposed within bore 78 is a second insulator 80 that is formed of a ceramic insulating material which may be of the same type that is used for insulator 14. The second insulator 80 has a tubular portion 80A and a closed end 80B which define a tubular bore. The tubular bore contains a magnetic core 82 which can be formed of the same type of magnetic material as the material that forms the magnetic core 40 of Figure 1. Bonded to the outer surface of tubular portion 80A is a secondary winding 84. One end of secondary winding 84 is connected to central electrode 16 by strip conductor 86. The other end of secondary winding 84 is connected to outer shell 18 and, hence, to electrode 20 by strip conductors 88 and 90. The secondary winding 84 can be formed in the same manner as the formation of secondary winding 30 which has been described in connection with Figure 1. In the assembly of the Figure 3 embodiment, a unit that is comprised of part 80, magnetic core 82 and secondary winding 84 can be manufactured. This unit is then inserted into the bore 78 of portion 76 and is secured in place by a suitable ceramic paste or cement. To make the connections to secondary winding 84, the strip conductors 86-90 are provided by, for example, by metallization. The connection to central electrode 16 from strip conductor 86 can be made by coating the contacting parts with silver solder and heating the solder to a bonding temperature. In Figure 3 the secondary unit has an outer housing or cover that is formed of overmoulded plastic material and which is comprised of tubular portion 92 and integral end wall 94. Since the secondary winding 84 is already covered by portion 76 of insulator 14, the outer housing or cover may not be required. Thus, strip conductors 88 and 90 may remain exposed or alternatively could be covered by a thin film of insulating material or any other coating material that will provide some external protection and which would bond to strip conductors 88 and 90. As previously mentioned, the secondary units shown in Figures 2 and 3 are adapted to be used with the module shown in Figure 4. For the purpose of describing the arrangement shown in Figure 4, it will be assumed that the secondary units used in Figure 4 are identical with the secondary unit shown in Figure 2. In Figure 4, four secondary units each designated as 96 are shown associated with a four cylinder, spark ignited, internal combustion engine 98. The threaded portions 21 of each secondary unit 96 is threaded into threaded spark plug openings in engine 98 that communicate with the cylinders of the engine. In Figure 4 the reference numeral 100 generally designates a module that has four primary units integrated into one package. The module 100 has an elongated housing or support 102 which is formed of plastic insulating material and which carries four integral tubular parts each designated as 104. Each tubular part 104 contains a primary winding and tubular metallic flux carrying part. More specifically, each tubular part 104 has a coil spool like coil spool 50 that carries a primary winding like primary winding 52 and a magnetic flux carrying part like flux carrying part 58. The outer plastic housing of each tubular part 104 can be like tubular portion 60 (Figure 1) and as mentioned is integral with the support or housing 102. The respective primary windings of tubular parts 104 are connected to a capacitor discharge ignition circuit contained in portion 106 of module 100 by conductors that are located in housing or support 102. In the use of the Figure 4 arrangement, let it be assumed that secondary units 96 have been screwed into the appropriate threaded spark plug openings in engine 98. The module 100 is now assembled to the engine by slipping the primary windings in tubular parts 104 over the top ends of secondary units 96 so that the relationship of the primary and secondary units is like that shown in Figure 1. There is sufficient clearance between the parts to allow the top ends of the secondary units 96 to telescope into the coil spools located in tubular parts 104 that carry the primary windings when module 100 is assembled to the engine 98. The module 100 is secured to engine 98 by suitable bolts or screws not illustrated that can pass through openings 108. The bolts or screws are attached to suitable parts of the engine 98 which may include mounting brackets secured to and carried by the engine. It should be understood that the secondary units 96 can be located in spark plug wells formed in the head of the engine in a manner disclosed in US patent no. 4,706,639. Referring now to Figure 5, a capacitor discharge ignition circuit is illustrated. In Figure 5 the reference numeral 110 designates a four cylinder, spark ignited, internal combustion engine. The spark gap electrodes of each secondary unit associated with each cylinder have each been designated as 112. These electrodes correspond to electrodes 16 and 20 in Figure 1. The spark gap electrodes 112 are connected respectively to opposite ends of secondary windings 114. Each secondary winding 114 corresponds to, for example, secondary winding 30 in Figure 1. Each secondary winding 114 is associated with a primary winding 116. Each primary winding 116 corresponds to primary winding 52 in Figure 1. The primary windings 116 are connected between conductor 118 and respective semiconductor switches 120 that are turned on in a predetermined sequence to be described. Semiconductor switches 120 may be controlled rectifiers. The circuit of Figure 5 has a capacitor 122 which is discharged into a primary winding 116 when one of the semiconductor switches 120 is turned on. The capacitor 122 is charged from a direct voltage power supply 124 which may take the form of a D.C. to D.C. converter. Power supply 124 receives input voltage from a 12 volt battery 126 on a motor vehicle. The power supply 124 transforms the 12 volt input to about 400 or 500 volts output which is used to charge capacitor 122. The engine 110 drives a crankshaft position sensor 128 which develops electrical signals indicative of engine crankshaft angular position. The output of crankshaft position sensor 128 is connected to a cylinder selector circuit 130 which has four outputs connected respectively to semiconductor switches 120. The circuit operates such that semiconductor switches 120 are sequentially turned on in synchronism with rotation of the crankshaft of engine 110. Each time that a semiconductor switch 120 is turned on, the capacitor 122 discharges through one of the primary windings 116 which, in turn, causes a voltage to be induced in an associated secondary winding 114 that is high enough to cause a spark or arc to be developed across one pair of spark gap electrodes 112. The circuit shown in Figure 5 can be used in an arrangement where separate primary units are associated respectively with a secondary unit like Figure 1 or can be used where all of the primary windings are parts of a module like the module 100 shown in Figure 4. In the Figure 4 arrangement the conductors connecting the capacitor discharge ignition circuit to the primary windings are located in elongated housing 102. The flux carrying parts 58 are not required but if not used the efficiency of the ignition apparatus would be reduced. If flux carrying parts 58 are not used the housing portion like tubular portion 60 would be moulded to outer surfaces of the coil spool 50 and to the primary winding 52.

Claims: Spark developing apparatus for igniting the combustible mixture in a cylinder (23) of an internal combustion engine, the apparatus comprising a secondary spark developing unit (10) comprising a spark plug supportable by the internal combustion engine and having a pair of electrodes (16,20) associated with said cylinder, the spark plug further having a first insulator (14) for supporting and for electrically insulating the electrodes from each other and a secondary winding (30,84), the opposite ends of the secondary winding being electrically connected respectively to the electrodes; the apparatus further including means (12) for causing a voltage to be induced in the secondary winding which is high enough to cause an arc to be developed across the electrodes comprising a primary unit (12) completely separable from the secondary unit (10) and including an annular bore (64,68), means (46,108) for supporting the primary unit relative to the secondary unit (10) such that the secondary winding (30,84) is located within the annular bore and a primary winding (52) disposed about the annular bore; characterised in that the secondary spark developing unit (10) comprises a second insulator (24,80) extending axially of the first insulator and including a tubular bore (26) and a magnetic core (40,82) formed of a magnetic material located within the tubular bore, the secondary winding (30,84) being carried by the second insulator and disposed about the magnetic core; and in that the primary winding when energized develops a magnetic flux that passes through the magnetic core to induce said voltage in the secondary winding. Spark developing apparatus according to claim 1, wherein the first and second insulators are comprised of a one-piece insulator (14). Spark developing apparatus according to claim 1, wherein the second insulator (80) is disposed within a bore (78) in an axially extending portion (76) that is an integral extension of the first insulator (14). Spark developing apparatus according to any one of claims 1 to 3, wherein the primary winding (52) is energized by a capacitor discharge ignition circuit. Spark developing apparatus according to any one of claims 1 to 4, wherein the primary unit (12) has a tubular member (58) that is formed of magnetic material that forms a flux path for magnetic flux developed by the primary winding (52). Spark developing apparatus according to any one of claims 1 to 5, wherein the primary unit (12) is mountable on the internal combustion engine. A secondary unit for igniting the combustible mixture of a spark ignited internal combustion engine and for use with a completely separable primary unit (12) adapted to cause the secondary unit to develop an electrical arc for igniting combustible mixture in an engine and which primary unit includes an annular bore (64,68) for receiving the secondary unit, means (46,108) for supporting the primary unit relative to the secondary unit and a primary winding (52) disposed about the annular bore; the secondary unit comprising a first insulator (14) supporting a pair of electrodes (16,20) forming a spark gap, a secondary winding (30,84) and means (31-38, 86-90) electrically connecting opposite ends of the secondary winding respectively to said electrodes; characterised in that the secondary unit (10) comprises a second insulator (24,80) having a tubular bore (26) and extending axially of the first insulator (14) and a magnetic core (40,82) formed of magnetic material located in the tubular bore and adapted in use to receive magnetic flux from the primary winding for inducing a voltage in the secondary winding; and in that the secondary winding (30,84) is carried by an outer surface (28) of the second insulator and disposed about the magnetic core. A secondary unit according to claim 7, wherein the secondary winding (30,84) is comprised of turns of metallic material that are bonded to the outer surface (28) of the second insulator (24,80). A secondary unit according to claim 7 or claim 8, wherein one (20) of said electrodes is connected to an outer metallic shell (18) that is supported by the first insulator (14), and wherein the outer metallic shell has an external threaded portion (21) that is adapted to be threaded into a threaded spark plug opening in an internal combustion engine. A secondary unit according to any one of claims 7 to 9, wherein the magnetic core (40,82) is formed of a composite magnetic powder and electrical insulating material. A secondary unit according to any one of claims 7 to 10, wherein the secondary winding (30, 84) is covered by an outer housing (42,44; 72,74; 92,94) formed of insulating material. A secondary unit according to any one of claims 7 to 11, wherein the first and second insulators (14,24) are integrally formed in one piece. A secondary unit according to any one of claims 7 to 11, wherein the second insulator (80) is positioned within a bore (78) in an axially extending portion (76) that is an integral extension of the first insulator (14). A secondary unit according to any one of claims 7 to 13, wherein the first and second insulators are formed of a ceramic material.

Inventors: BASSETT NORRIS JAMES, BOYER JAMES ALVA, SAVAGE JOHN B, BASSETT, NORRIS JAMES, BOYER, JAMES ALVA, SAVAGE, JOHN B.
Applicants: GEN MOTORS CORP, GENERAL MOTORS CORPORATION
Application year: 1990
Main classification: H01T13
IPC codes: H01T13, H01F38, F02P7, F02P13