Patent Publication Number: US-9887039-B2

Title: Motorcycle ignition coil assembly

Description:
RELATED APPLICATION 
     This application claims the priority of U.S. Provisional Application No. 61/935,268 filed Feb. 3, 2014, which is specifically incorporated in its entirety by reference. 
    
    
     FIELD OF INVENTION 
     The present disclosure relates to an ignition coil assembly. More particularly, the present disclosure relates to an ignition coil assembly for use with an internal combustion engine of a motorcycle. 
     BACKGROUND 
     Ignition coils are systems attached to or integrated with internal combustion engines used with vehicles such as automobiles and motorcycles. Ignition coils are induction coils that cooperate with a vehicle&#39;s battery to provide the energy required to power spark plugs. Specifically, the ignition coil typically converts relatively low voltage current from the vehicle&#39;s battery to the high voltage current required to generate a spark from the spark plug that ignites the air-fuel mixture within the internal combustion engine. 
     Ignition coil systems for motorcycles commonly include the ignition coil being positioned remotely from the spark plugs. Typically ignition coils are connected to the spark plugs by high-voltage insulated ignition wires that run from one location on the engine (i.e., the location of the ignition coil) to another location on the engine (i.e., the location of the spark plugs). Such an arrangement can cause clutter in and around the engine, expose the ignition wires to potentially harsh environments, and lead to suboptimal performance of the ignition system and engine. 
     In some cases, engines can comprise a “coil-on-plug” design, in which an ignition coil is disposed in contact with the spark plug, meaning that no such wire is required. In motorcycles, for example, some such systems are implemented into liquid-cooled engines. Such engines are specifically designed by their manufacturers to accommodate the coil-on-plug arrangement, with structural features built into the engine that hold the coil in position as it mates with the spark plug. 
     SUMMARY 
     In accordance with one embodiment, an ignition coil assembly can include an ignition coil cover, a boot, and an ignition coil. The ignition coil cover can include a plurality of fins, an opening, and a channel. The boot can include a slotted opening and a centralized orifice and can be configured to be disposed within the opening of the ignition coil cover. The ignition coil can include a seat and a tab. The ignition coil can be configured to be disposed within the centralized orifice. The seat can be capable of supporting the ignition coil within the centralized orifice of the boot. The tab can be configured to be inserted into the slotted opening and the channel when the ignition coil is disposed within the centralized office and the boot is disposed within the opening. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In the accompanying drawings, structures are illustrated that, together with the detailed description provided below, describe exemplary embodiments of the invention. Like elements may be identified with the same reference numerals for convenience. It should be understood that elements shown as a single component may be replaced with multiple components, and elements shown as multiple components may be replaced with a single component. The drawings are not to scale and the proportion of certain elements may be exaggerated for the purpose of illustration. 
         FIG. 1  is a front perspective view of one embodiment of the ignition coil assembly; 
         FIG. 2  is a exploded view of one embodiment of the ignition coil assembly; 
         FIG. 3  is a rear perspective view of one embodiment of the ignition coil assembly 
         FIG. 4  is a detailed front perspective view of one embodiment of an ignition coil cover used in the ignition coil assembly; 
         FIG. 5  is a perspective view of a boot used in one embodiment of the ignition coil assembly; 
         FIG. 6  is a perspective view of an ignition coil used in one embodiment of the ignition coil assembly; 
         FIG. 7  is a perspective view of an ignition coil used in one embodiment of the ignition coil assembly; 
         FIG. 8  is a rear perspective view of one embodiment of an ignition coil assembly showing the boot and ignition coil disengaged from the ignition coil cover; and 
         FIG. 9  is a rear perspective view of one embodiment of the ignition coil assembly showing the boot and ignition coil engaged with the ignition coil cover; and 
         FIG. 10  is a perspective view of a mount used in one embodiment of the ignition coil assembly. 
         FIG. 11  is a view of an exemplary engine having spark plugs located in plug recesses and connected to a coil by wires. 
         FIG. 12  is a view of the exemplary engine of  FIG. 11  wherein ignition coil assemblies substantially fill the plug recesses. 
         FIGS. 13A and 13B  illustrate front and back views of an exemplary ignition coil systems having similar features as embodiments herein described. 
         FIG. 14  illustrates an exploded view of a further embodiment of an ignition coil system. 
         FIG. 15  is a process flow diagram illustrating an exemplary method for implementing a coil on plug system into a traditionally wired engine. 
     
    
    
     DETAILED DESCRIPTION 
     The apparatuses and methods disclosed in this document are described in detail by way of examples and with reference to the figures. It will be appreciated that modifications to disclosed and described examples, arrangements, configurations, components, elements, apparatuses, methods, materials, etc. can be made and may be desired for a specific application. In this disclosure, any identification of specific shapes, materials, techniques, arrangements, etc. are either related to a specific example presented or are merely a general description of such a shape, material, technique, arrangement, etc. Identifications of specific details or examples are not intended to be and should not be construed as mandatory or limiting unless specifically designated as such. Selected examples of ignition coil assemblies are hereinafter disclosed and described in detail with reference made to figures. 
     Disclosed herein are exemplary embodiments of ignition coil assemblies including examples of such ignition coil assemblies where an ignition coil assembly can be directly mounted proximate to the spark plugs of an engine such that the need for ignition wires is eliminated. Ignition coil assemblies mounted proximate to the spark plugs can reduce current leakage and reduce electronic interference. In one exemplary application, ignition coil assemblies as described and disclosed herein can be arranged for use with motorcycle engines such as, for example, air cooled v-twin engines. 
       FIGS. 1-3  illustrate an exemplary embodiment of an ignition coil assembly  10 . The ignition coil assembly  10  includes an ignition coil  20 , a boot  30 , an ignition coil cover  40 , a pair of mounts  50 ,  60 , and a pair of posts  70 ,  80 . In some embodiments, the coil assembly  10  can include or otherwise be coupled to a low voltage (i.e., primary) wiring harness comprising one or more electrical conductors and electrically coupling the ignition coil to a motorcycle electrical system. The ignition coil  20  and boot  30  can be arranged so that the ignition coil  20  and boot  30  can cooperatively engage. For example, the ignition coil  20  can be arranged so that the ignition coil  20  can be inserted or otherwise positioned within the boot  30 . In one example, as illustrated in the exploded view of  FIG. 2 , a portion of the ignition coil  20  can have a generally cylindrical outer shape, and a portion of the boot  30  can have a generally cylindrical inner shape. Therefore, the generally cylindrical outer shape portion of the ignition coil  20  can be inserted into and engage with the generally cylindrical inner shape portion of boot  30 . 
     The boot  30  and ignition coil cover  40  can be arranged to cooperatively engage. In one example, the ignition coil cover  40  can include an opening  90  that accommodates the boot  30 . As illustrated in exploded view of  FIG. 2 , in one embodiment, the opening  90  can be arranged as a generally u-shaped opening, and the boot  30  can be arranged so that a portion of the boot  30  fits within the generally u-shaped opening  90 , where a portion of the exterior surface of the boot  30  engaging a portion of the parameter of the u-shaped opening  90 . Although the opening  90  of the ignition coil cover  40  is described and illustrated as u-shaped, it will be understood that the opening can be arranged in any number of other shapes and proportions necessary to receive the boot  30 . For example, the opening can be, without limitation, square, round, angular or any other geometric shape necessary to receive a boot. 
     The mounts  50 ,  60  and the posts  70 ,  80  can be arranged to be utilized cooperatively to discreetly and directly secure the ignition coil system  10  to an engine of a motorcycle in a position proximate to the spark plugs. Such positioning can result in the elimination of any exterior wiring from the ignition coil to the engine&#39;s spark plugs. For example, in some configurations, a motorcycle having external wiring as described can include a plug recess proximate to the spark plugs into which the ignition coil assembly  10  can be disposed. An exemplary plug recess is shown in  FIG. 11 , in which cable  330  is shown connecting to spark plugs  332  within plug recess  334 . In some embodiments, the cover  40  can be such that, when the ignition coil assembly  10  is secured in the plug recess, the cover  40  substantially fills the plug recess. In general, the cover  40  can be configured to fill any amount of the plug recess as desired. In various embodiments, the cover  40  can include an aperture for receiving an end of the spark plug to enable physical and electrical communication with the ignition coil  20 .  FIG. 12  illustrates an exemplary ignition coil assembly  10  and cover  40 , substantially filling the plug recess  334  ( FIG. 11 ). 
     As illustrated in  FIG. 3 , the ignition coil cover  40  can include a first aperture  100  and a second aperture  110 . One end of a first post  70  can be secured to the ignition coil cover  40  via the first aperture  100 , and one end of a second post  80  can be secured to the ignition coil cover  40  via the second aperture  110 . Another end of the first post  70  can be secured to a first mount  50 , and another end of the second post  80  can be secured to a second mount  60 . As will be understood, the first and second posts  70 ,  80  can be secured to the ignition coil cover by a fastener such as a bolt  115  (as illustrated in  FIG. 2 ). As will be further described herein, the first and second mounts  50 ,  60  can be secured to an engine, thus, securing the ignition coil assembly  10  to the engine. 
       FIG. 4  illustrates an exemplary embodiment of the ignition coil cover  40 . The ignition coil cover  40  can include a plurality of fins. For example, in the embodiment illustrated in  FIG. 4 , the ignition coil cover  40  includes a top fin  120 , a pair of intermediate fins  130 ,  140 , and a bottom fin  150 . The top fin  120  is arranged as two segments. It will be understood that in the embodiment as shown in  FIG. 4 , the top fin  120  is arranged in two segments to accommodate the boot  30  as it engages the opening  90  upon assembly of the ignition coil assembly  10 . Although the embodiment of  FIG. 4  illustrates a ignition coil cover  40  with four fins, it will be understood that an ignition coil cover can be arranged to have more than four or fewer than four fins. 
     In some embodiments, fins can be configured to conceal wiring, such as a wiring harness for connecting the ignition coil  20  to the electrical system of the motorcycle. In such examples, the wiring harness from the ignition coil assembly  10  is disposed between any pair of adjacent fins of the existing engine housing such that it is concealed from the view of an observer of the motorcycle. In other embodiments, the ignition coil cover  40  is configured to provide clearance or an opening for wiring such as the wiring harness to exit the ignition coil assembly  10  and be concealed from view by fins or other existing features on the motorcycle. Thus, the electrical ignition components of the motorcycle can appear “wireless,” as the wired electrical communication between the electrical system of the motorcycle and the ignition coil assembly  10  is concealed from view. 
     As previously discussed, the ignition coil cover  40  can include an opening  90  and a pair of apertures  100 ,  110 . Furthermore, the ignition coil cover  40  can include at least one channel  160 . The at least one channel  160  can be positioned in the top fin  120 . Although only one channel  160  is illustrated in  FIG. 4 , it will be understood that more than one channel can be positioned in the top fin  120 . For example a second channel can be positioned opposite the illustrated channel  160  so that one channel is positioned in each of the two segments of the top fin  120 , and each channel is exposed to the opening  90  of the ignition coil cover  40 . 
     In the embodiment illustrated in  FIG. 4 , the fins  120 ,  130 ,  140 ,  150  can be arranged as generally planar and parallel fins. Furthermore, the fins  120 ,  130 ,  140 ,  150  can be generally arranged horizontally. It will be understood that the fins  120 ,  130 ,  140 ,  150  can also be arranged in other relative configurations. For example, the fins  120 ,  130 ,  140 ,  150  can be arranged vertically, diagonally, or in any other suitable arrangement. In one embodiment, the fins  120 ,  130 ,  140 ,  150  of the ignition coil cover  40  are arranged so as to correspond to or match the configuration of the fins of an air cooled v-twin motorcycle engine. Correspondingly, in other embodiments, the fins  120 ,  130 ,  140 ,  150  of the ignition coil cover  40  can be arranged so as to correspond to or match the configuration of the fins of any type of engine. 
     In general, the ignition coil cover  40  can be die-cast or molded and painted and/or polished into a shape and finish that is aesthetically compatible with the motorcycle and will fit into the plug recess for physical and electrical engagement with the spark plug. For example, the ignition coil cover  40  can be machined and/or designed to match or otherwise complement the design of the surrounding portions of the motorcycle into which the ignition coil assembly  10  is being incorporated. In some embodiments, the ignition coil cover  40  comprises aluminum for convenient manufacturing of a desired ignition coil cover  40 . 
     The fins  120 ,  130 ,  140 ,  150  can be aligned in a stadium style arrangement. This is to say that the each fin extends further forward and/or to the side than the fin above. An example of a stadium style arrangement is illustrated in  FIGS. 3 and 4 , and will be described in reference to a central axis  170  passing through the first aperture  100  and first post  70 . With reference to  FIG. 3 , in a stadium style arrangement the distance between the central axis  170  and a side edge  180  of the bottom fin  150  is greater than the distance between the center axis  170  and a side edge  190  of the top fin  120 . With reference to  FIG. 4 , in a stadium style arrangement the distance between the central axis  170  and a front edge  200  of the bottom fin  150  is greater than the distance between the center axis  170  and a front edge  210  of the top fin  120 . 
     In one embodiment, the posts  70 ,  80  are generally disposed on opposing sides of the opening  90  and abut the underside of the top fin  120 . In another example, the posts  70 ,  80  can abut any of the plurality fins  120 ,  130 ,  140 ,  150  of the ignition coil cover  40 . In one embodiment, each post  70 ,  80  is substantially vertical and has a central axis  170  that is substantially perpendicular to the plurality of horizontal fins  120 ,  130 ,  140 ,  150 . Alternatively, the posts  70 ,  80  can be oriented at an angle with reference to the horizontal fins  120 ,  130 ,  140 ,  150 . One of ordinary skill in the art upon reading this disclosure would recognize that posts can be located elsewhere in the ignition coil assembly  10 , including without limitation, the boot  30  or the ignition coil  20 . In yet another embodiment posts may be omitted altogether. 
     Although the ignition coil assembly  10  is illustrated with the ignition coil cover  40  having a pair of apertures  100 ,  110 , a pair of corresponding posts  70 ,  80 , and corresponding mounts  70 ,  80  disposed on either side of the opening  90 , it will be understood that an ignition coil assemblies can include other quantities and arrangements of apertures, posts and mounts. For example an ignition coil assembly may include more or less than two apertures, posts, and/or mounts. The functions performed by the mounts and posts can be served by a single component instead of individual components. 
       FIG. 5  illustrates an exemplary embodiment of a boot  30 , and  FIGS. 6 and 7  illustrate an exemplary embodiment of an ignition coil  20 . The ignition coil  20 , the boot  30  and the ignition coil cover  40  can be arranged so that the ignition coil  20  and the boot  30  engage via a snap-fit arrangement; and, furthermore, the assembly of the ignition coil  20  and the boot  30  engage the ignition coil cover  40  via a snap-fit arrangement. As noted above, the ignition coil cover  40  includes at least one channel  160 , and in an embodiment, the ignition coil cover  40  includes two channels  160 . As illustrated in  FIG. 5 , the boot  30  can include two slotted openings  220 ,  230  positioned on either side of a centralized orifice  240 . The centralized orifice  240  is arranged to support the ignition coil  20 . 
     As illustrated in  FIGS. 6 and 7 , the ignition coil  20  includes a seat  250  for supporting the ignition coil  20  within the centralized orifice  240  of the boot  30 . The ignition coil  20  further includes two tabs  260 ,  270  on opposing sides of the ignition coil  20 . The tabs  260 ,  270  are dimensioned to be insertable into the slotted openings  220 ,  230  on either side of the boot  30  so as to secure the ignition coil  20  to the boot  30 . The ignition coil  20  can further include at least one wire  280  and a plug receptor  290  disposed at a distal end of the ignition coil  20 . The plug receptor  290  can be electrically connected to a spark plug (not shown). 
     In general, the ignition coil assembly  10  is configured to engage and mate with a spark plug in an ignition system. The ignition coil  20  can be physically and electrically coupled to the spark plug via, for example, a plug receptor  290 . To secure the ignition coil  20  in place, the ignition coil  20  can be secured to a boot  30 . The boot  30  can then be received by the ignition coil cover  40 , which can be mounted to the engine in direct contact with the spark plug. In various embodiments, various methods of securing these components to one another and the engine can be incorporated. In addition, components can be assembled or secured to one another or the engine in varying order. 
       FIGS. 8 and 9  illustrate a rear view of an assembly of the ignition coil  20 , boot  30 , and ignition coil cover  40 . As discussed previously and as illustrated in  FIG. 3 , the ignition coil cover  40  can include channels  160  that are configured to attach the boot  30  and the ignition coil  20  to the ignition coil cover  40 . Channels  160  can be arranged on either side of the opening  90  of the ignition coil cover  40  and arranged and dimensioned to receive the tabs  260 ,  270  located on either side of the ignition coil  20 . In such an embodiment, when the ignition coil  20  is assembled with the boot  30 , the tabs  260 ,  270  protrude through the slotted openings  220 ,  230  of the boot  30 . As illustrated in  FIGS. 8 and 9 , the tabs  260 ,  270  not only secure the ignition coil  20  to the boot  30  by engaging the slotting openings  220 ,  230 , but also secure the assembly of the ignition coil  20  and the boot  30  to the ignition coil cover  40  by further engaging the channels  160  of the ignition coil cover. It will be understood that the ignition coil  20  and/or boot  30  can alternatively be secured in the channels  160  in any number of ways, including without limitation, snapping, molding, interlocking, screwing, and equivalents thereof. 
     Referring again to  FIG. 2 , the ignition coil  20  can be snap-fitted to the boot  30  and the ignition coil cover  40  at an angle (θ) that is less than 90 degrees with respect to the central axis  170  through the first aperture  100  and the first post  70 . In alternative embodiments, the ignition coil  20  may be disposed in the boot  30  and the ignition coil cover  40  at an angle that is equal to or greater than 90 degrees with respect to the central axis  170 . 
     As shown in  FIG. 10 , a mount  50  of the ignition coil assembly  10  can be dimensioned to receive a post  70 . The mount  50  can be used to attach the ignition coil assembly  10  to an engine by one or more attachment member  310  passing through one or more apertures  320 . The attachment member  310  may be a bolt, screw, rivet, nail, weld, tie, or any fastener, and equivalents thereof. Alternatively, the mount  50  can be secured to the engine with an adhesive or other suitable method of attachment.  FIGS. 13A and 13B  illustrate front and back views of an exemplary ignition coil systems having similar features as embodiments herein described.  FIG. 14  illustrates an exploded view of a further embodiment of an ignition coil system. 
     Various examples have been described. It will be appreciated that, in various embodiments, the assembly of the ignition coil assembly  10  can be done in a number of ways. For example, in some embodiments, the ignition coil  20  can be secured to the boot  30  and the ignition coil cover  40  secured to the engine proximate the spark plug, after which the ignition coil/boot assembly can be secured to the engine via the ignition coil cover. In other embodiments, the ignition coil  20  and boot  30  are secured to the ignition coil cover  40  prior to securing the ignition coil assembly  10  to the engine proximate the spark plug. In general, among various embodiments, the components of the ignition coil assembly  10  can be assembled in any order while securing the ignition coil assembly  10  to an engine. 
     As discussed, present coil-on-plug systems are specifically designed for the engine with which is it being used by the engine manufacturer. However, because such systems are specifically designed, incorporating a coil-on-plug arrangement into an engine not originally designed for it can be difficult. Accordingly, some embodiments of the invention are directed toward a method for implementing a coil-on-plug system into a traditionally wired engine.  FIG. 15  is a process flow diagram illustrating such an exemplary method. In an exemplary method, the wires connecting an existing ignition coil and a spark plug are removed or disconnected  350 . A coil-on-plug ignition coil is electrically coupled  358  to the spark plug. In some configurations, the coil-on-plug ignition coil is housed and secured  352  within a boot. An ignition coil cover is secured  356  to the engine, and the ignition coil and/or boot is secured  354  to the ignition coil cover. 
     It should be noted that the method described above can be performed with various steps omitted or permuted. For example, in an alternative method, an ignition coil, boot, and ignition coil cover can be assembled separately from the engine, forming an ignition coil assembly (steps  352 ,  354 ). Among various embodiments, the ignition coil assembly can be assembled in a variety of configurations and methods. The assembled ignition coil assembly can be secured to the engine proximate the spark plug (in a step similar to  356 ), and the ignition coil can be physically and electrically coupled  358  to the spark plug. In some embodiments, the method further comprises electrically coupling  360  a wire harness from the ignition coil assembly to the electrical system of, for example, a motorcycle. The wire harness can be concealed  362  from view by disposing the wire harness within various components of the ignition coil assembly and/or the engine. Any method herein described can be repeated for each existing spark plug. If  362  all spark plugs are configured in a coil-on-plug arrangement, the conversion from the standard wired configuration to a coil-on-plug configuration is complete  364  and appears wireless. 
     While the present disclosure has been illustrated by the description of embodiments thereof, and while the embodiments have been described in considerable detail, it is not the intention of the applicants to restrict or in any way limit the scope of the described embodiments to such detail. Additional advantages and modifications will readily appear to those skilled in the art. Therefore, the disclosure, in its broader aspects, is not limited to the specific details, the representative apparatus and method, and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of the applicant&#39;s general inventive concept. 
     The foregoing description of examples has been presented for purposes of illustration and description. It is not intended to be exhaustive or limiting to the forms described. Numerous modifications are possible in light of the above teachings. Some of those modifications have been discussed, and others will be understood by those skilled in the art. The examples were chosen and described in order to best illustrate principles of various examples as are suited to particular uses contemplated. The scope is, of course, not limited to the examples set forth herein, but can be employed in any number of applications and equivalent devices by those of ordinary skill in the art. 
     Various features herein described can be found in one or more of the following embodiments: 
     1. An ignition coil assembly comprising: an ignition coil cover comprising an opening, at least one channel, and a plurality of fins; a boot comprising at least one slotted opening and a centralized orifice, and configured to be disposed within the opening of the ignition coil cover; and an ignition coil configured to be disposed within the centralized orifice of the boot and comprising at least one tab configured to be inserted into the slotted opening and the channel when the ignition coil is disposed within the centralized office and the boot is disposed within the opening.
 
2. The ignition coil of embodiment 1 further comprising at least one post attached to a top fin of the plurality of fins and at least one aperture in the top fin.
 
3. The ignition coil of embodiment 2 further wherein a central axis of the at least one post is substantially perpendicular to the plurality of fins.
 
4. The ignition coil of embodiment 3 where the ignition coil further comprising a seat capable of supporting the ignition coil within the centralized orifice of the boot.
 
5. The ignition coil assembly of embodiment 4 further comprising at least one mount attached to the at least one post.
 
6. The ignition coil assembly of embodiment 4 wherein the fins are aligned in a stadium style arrangement.