Ignition coil with non-filtering/non-segregating secondary winding separators

An ignition coil for an internal combustion engine comprising:

• a magnetically permeable core having an axially extending core bar;
• an electrically insulated housing made from an encapsulation compound;
• a primary winding wound around the core bar and having an input terminal for inputting electrical energy from a voltage source;
• a secondary winding having a plurality of layers of wire continuously wound around the core bar and having an output terminal for outputting high voltage electrical energy to ignite a combustible fuel mixture in an internal combustion engine, said secondary winding including a plurality of secondary winding separator strips embedded between adjacent layers of the secondary winding, each of the secondary winding separator strips being made of a material that does not absorb or adsorb the encapsulation compound, wherein each respective layer of secondary winding is separated by at least one layer of the secondary winding separator strip material;
• wherein the primary winding is coaxial with the secondary winding and both the primary winding and the secondary winding are impregnated in the electrically insulated housing and the secondary winding separator strip material does not alter the chemistry of the encapsulation compound within the secondary winding during the manufacturing process.

A method of making an ignition coil comprising the steps of:

• winding a primary winding;
• winding a secondary winding to provide a continuous winding of a plurality of layers of insulated wire, wherein each respective layer of the secondary winding is separated from the adjacent layers in the secondary winding by a secondary winding separator strip that is embedded between adjacent layers of wire when winding the secondary winding, each of the secondary winding separator strips being made from a flexible non-filtering, non-segregating material;
• assembling internal parts for the ignition coil including the primary winding and the secondary winding;
• placing the assembled internal parts of the ignition coil in a cast mold;
• vacuum encapsulating the assembled internal parts in the cast mold by impregnating the parts with an encapsulation compound having solid additives;
• and
• curing the encapsulation compound to solidify a housing for the ignition coil.

A method of making an ignition coil comprising the steps of:

• winding a primary winding;
• winding a secondary winding to provide a continuous winding of a plurality of layers of insulated wire, wherein each respective layer of the secondary winding is separated from the adjacent layers in the secondary winding by a secondary winding separator strip that is embedded between adjacent layers of wire when winding the secondary winding, each of the secondary winding separator strips being made from a material that does not absorb or adsorb the encapsulation compound used to encapsulate the internal components of the ignition coil and that does not otherwise substantially alter the chemistry of the encapsulation compound when in contact therewith;
• assembling internal parts for the ignition coil including the primary winding and the secondary winding;
• placing the assembled internal parts of the ignition coil in a cast mold;
• vacuum encapsulating the assembled internal parts in the cast mold by impregnating the parts with the encapsulation compound;
• and
• curing the encapsulation compound to solidify a housing for the ignition coil.