Corona igniter with improved energy efficiency

An igniter for igniting a fuel-air mixture in a combustion chamber, comprising:

• a coil extending longitudinally along a coil center axis for receiving energy at a first voltage and for transmitting the energy at a second voltage higher than the first voltage,
• said coil including a plurality of windings each extending circumferentially around said coil center axis,
• each of said windings presenting a winding gap spacing said winding from an adjacent one of said adjacent windings,
• a magnetic core disposed along said coil center axis between said windings,
• said magnetic core including a plurality of discrete sections, each of said discrete sections being spaced axially from an adjacent one of said discrete sections by a core gap,
• wherein said coil extends longitudinally from a coil low voltage end for receiving the energy at the first voltage to a high voltage end, said coil presents a coil length between said coil low voltage end and said coil high voltage end, said magnetic core extends from a core low voltage end adjacent said coil low voltage end to a core high voltage end adjacent said coil high voltage end, said discrete sections of said magnetic core together present a core length extending from said core low voltage end to said core high voltage end, and said core length is greater than said coil length,
• wherein said coil length and said core length present a length difference therebetween, said windings include an interior winding surface facing said coil center axis and present an interior winding radius extending from said interior winding surface to said coil center axis, and said length difference is equal to or greater than said interior winding radius,
• a coil former made of an electrically insulating material and spacing said windings from said magnetic core,
• a coil filler formed of an electrically insulating material different from said coil former disposed in said winding gaps and spacing each of said windings from the adjacent one of said windings, and
• said coil filler having a dielectric strength of at least 3 kV/mm, a thermal conductivity of at least 0.125 W/m·K, and a relative permittivity of less than 6.

A corona igniter for providing a radio frequency electric field to ionize a portion of a fuel-air mixture and provide a corona discharge in a combustion chamber, comprising:

• a housing including a plurality of walls and presenting a housing volume therebetween,
• said walls presenting a low voltage inlet and a high voltage outlet each disposed along a coil center axis for allowing energy be transmitted through said housing volume,
• a shield of a conductive material surrounding said housing,
• a coil disposed in said housing for receiving energy at a first voltage and for transmitting the energy at a second voltage being at least 15 times higher than the first voltage,
• said coil having a coil length extending longitudinally along said coil center axis from a coil low voltage end adjacent said low voltage inlet for receiving the energy at the first voltage to a coil high voltage end adjacent said high voltage outlet for transmitting the energy at the second voltage,
• said coil having an inductance of at least 500 micro henries,
• said coil including a plurality of windings each extending circumferentially around and longitudinally along said coil center axis,
• each of said windings being horizontally aligned with an adjacent one of said windings and presenting a winding gap spacing said winding from said adjacent winding,
• said windings presenting an interior winding surface facing said coil center axis and an exterior winding surface facing opposite said interior winding surface,
• said windings presenting an interior winding diameter extending through and perpendicular to said coil center axis between opposite sides of said interior winding surface,
• said windings presenting an interior winding radius extending from said interior winding surface along said interior winding diameter to said coil center axis,
• said windings presenting a winding perimeter extending through and perpendicular to said coil center axis between opposite sides of said exterior winding surface,
• each of said windings presenting a winding thickness extending form said interior winding surface to said exterior winding surface,
• a low voltage connector for transmitting the energy form said power source to said low voltage end of said coil,
• an electrode electrically coupled to said coil for receiving the energy from said coil,
• a high voltage connector electrically coupling said coil and said electrode and for transmitting the energy form said coil to said electrode,
• a coil former made of electrically insulating non-magnetic material and extending longitudinally along said coil center axis and spacing said windings from said coil center axis,
• said coil former having a former exterior surface engaging said interior winding surface and a former interior surface facing opposite said former exterior surface toward said coil center axis and extending circumferentially around said coil center axis,
• said former interior surface presenting a former interior diameter extending through said coil center axis,
• said coil former presenting a former thickness between said former interior surface and said former exterior surface,
• a coil filler formed of electrically insulating material different from said coil former disposed in said winding gaps and spacing each of said windings from the adjacent one of said windings,
• said coil filler having a dielectric strength of at least 3 kV/mm, a thermal conductivity of at least 0.125 W/m·K, and a relative permittivity of less than 6,
• a magnetic core formed of a magnetic material disposed along said coil center axis between said windings,
• said magnetic core being received in said coil former and engaged by said former interior surface,
• said magnetic material having a relative permeability of at least 125,
• said magnetic core having a core length extending axially along said coil center axis from a core low voltage end adjacent said coil low voltage end to a core high voltage end adjacent said coil high voltage end,
• said magnetic core extending around said coil center axis continuously along said former interior surface and continuously across said former interior diameter,
• said magnetic core including a plurality of discrete sections together providing said core length,
• each of said discrete sections including a bottom surface facing toward said high voltage outlet and a top surface facing opposite said bottom surface toward said low voltage inlet,
• said bottom surface of one of said discrete sections facing and parallel to the top surface of the adjacent one of said discrete sections,
• said top surface and said bottom surface of said discrete sections being planar,
• said discrete sections being completely spaced axially from one another along said coil center axis,
• each of said discrete sections being spaced axially from an adjacent one of said discrete sections by a core gap,
• said core length being greater than said coil length,
• said core length and said coil length including a length difference therebetween,
• said length difference being equal to or greater than said former thickness,
• said length difference being equal to or greater than said interior winding radius,
• each of said core gaps extending continuously across said former interior diameter,
• each of said core gaps having a gap thickness extending axially along said coil center axis,
• said gap thickness of each of said core gaps being between 1 and 10% of said core length,
• said gap thicknesses of all of said core gaps together presenting a total gap thickness being not greater than 25% of said core length, and
• a gap filler formed of a non-magnetic material having a relative permeability of not greater than 15 disposed in said core gap.

A method of forming a igniter for providing a radio frequency electric field to ionize a portion of a fuel-air mixture and provide a corona discharge in a combustion chamber, comprising the steps of:

• providing a coil extending longitudinally along a coil center axis from a coil low voltage end to a coil high voltage end and including a plurality of windings each extending circumferentially around the coil center axis, wherein each of the windings presents a winding gap spacing the winding from an adjacent one of the windings, and wherein the coil presents a coil length between the coil low voltage end and the coil high voltage end,
• disposing a plurality of discrete sections of a magnetic core formed of a magnetic material along the coil center axis between the windings, wherein the magnetic core extends from a core low voltage end adjacent the coil low voltage end to a core high voltage end adjacent the coil high voltage end,
• spacing each of the discrete sections of the magnetic core axially from an adjacent one of the discrete sections by a core gap, wherein the discrete sections of the magnetic core together present a core length extending from the core low voltage end to the core high voltage end, the core length is greater than the coil length, and the coil length and the core length present a length difference therebetween,
• spacing the windings from the magnetic core by a coil former made of an electrically insulating non-magnetic material, wherein the coil former presents a former thickness spacing the windings from the magnetic core, and the length difference between the coil length and the core length is greater than the former thickness, and
• disposing a coil filler formed of electrically insulating material different from the coil former in the winding gaps and spacing each of said windings from the adjacent one of said windings with the coil filler, the coil filler having a dielectric strength of at least 3 kV/mm, a thermal conductivity of at least 0.125 W/m·K and a relative permittivity of less than 6.