Pencil ignition coil assembly module

An ignition coil assembly module for a spark plug, the module having an imaginary centerline and comprising:

• a secondary bobbin comprising a secondary coil and an first electric terminal connected to a termination of the secondary coil;
• a primary bobbin comprising a tubular wall that contains a primary winding and that bounds a hollow interior within which the secondary bobbin, including the secondary coil, is disposed;
• the primary bobbin further comprising a transverse wall disposed transverse to the centerline across the hollow interior bounded by the tubular wall;
• a second electric terminal that passes through the transverse wall and that connects to the first electric terminal at a location proximal to the transverse wall;
• and
• a third electric terminal having a proximal end that attaches to the second terminal distal to the transverse wall and a distal end adapted for repeatable connection to, and disconnection from, a terminal of an engine spark plug.

A method of making an ignition coil assembly module, the method comprising:

• providing a secondary bobbin comprising a cylindrical wall having an exterior on which a secondary coil is disposed and an electric terminal to which a termination of the secondary coil is connected;
• providing a primary bobbin comprising a cylindrical wall bounding a hollow interior and having an exterior on which a primary coil is disposed, the primary bobbin also having a transverse wall disposed transverse to an imaginary centerline of the module, and together with the primary bobbin cylindrical side wall, forming a liquid container, the transverse wall containing an electric terminal that passes through the transverse wall, that has electric continuity to one termination of the secondary coil within the hollow interior of the primary bobbin, and that serves to conduct electric current from the secondary coil to a terminal of a spark plug;
• disposing the secondary bobbin and coil within the hollow interior of the primary bobbin to establish electric continuity between the electric terminal of the secondary bobbin and the electric terminal contained in the transverse wall of the primary bobbin;
• and
• introducing a liquid into the liquid container to encapsulate the secondary coil.