Ignition coil and method of assembly

A method of assembling an ignition coil for delivering a spark-generating current to a spark plug, the ignition coil comprising a magnetically-permeable core, a primary winding disposed outward of said core, a secondary winding disposed outward of said primary winding and inductively coupled to said primary winding, said secondary winding terminating at one end thereof in a low-voltage end and terminating at another end thereof in a high-voltage end, a terminal, and a case defining an interior having an interior surface such that said core, said primary winding, and said secondary winding are received within said interior of said case, said interior surface defining a recess;

• said method comprising:
• positioning one of said low-voltage end of said secondary winding and said high-voltage end of said secondary winding and said terminal within said recess;
• providing an electrically conductive polymer in direct contact with said interior surface within said recess;
• and
• using said electrically conductive polymer to directly electrically connect at least one of said low-voltage end of said secondary winding and said high-voltage end of said secondary winding to said terminal through said electrically conductive polymer.

An ignition coil for delivering a spark-generating current to a spark plug;

• said ignition coil comprising:
• a magnetically-permeable core;
• a primary winding disposed outward of said core;
• a secondary winding disposed outward of said primary winding and inductively coupled to said primary winding, said secondary winding terminating at one end thereof in a low-voltage end and terminating at another end thereof in a high-voltage end, wherein one of said low-voltage end of said secondary winding and said high-voltage end of said secondary winding is electrically connected directly to a terminal through an electrically conductive polymer;
• and
• a case defining an interior having an interior surface such that said core, said primary winding, and said secondary winding are received within said interior of said case, said interior surface defining a recess therein such that said at least one of said low-voltage end of said secondary winding and said high-voltage end of said secondary winding, said terminal, and said electrically conductive polymer are disposed within said recess and such that said electrically conductive polymer is in direct contact with said interior surface within said recess.