Appropriate Polymer Selection for Insulation of High Voltage Ignition Coils by Combination of Material Index Determination and Novel Heuristical Approach

Islam, Sara; Arbab, Muhammad Naeem; Nawaz, Ahmad; Islam, Bilal; Bibi, Saira; Hussain, Iftikhar

doi:10.1007/s12666-021-02223-8

Cited by 2 publications

(2 citation statements)

References 9 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…The IS-14380 results were also in agreement with the results of Islam et al, at 1500, 2500, and 3000 rpm, accordingly [37]. Islam et al used 0.05% or 1.28 kg per lot of chopped fiber glass in polyester, which is an uneconomical method [37]. However, our study reported a significant improvement without the addition of any costly procedure or material addition.…”

Section: Discussionsupporting

confidence: 90%

“…Finally, heat gained via the polyester resin by LEDs forces entrapped air to evacuate the liquid polyester resin. The IS-14380 results were also in agreement with the results of Islam et al, at 1500, 2500, and 3000 rpm, accordingly [37]. Islam et al used 0.05% or 1.28 kg per lot of chopped fiber glass in polyester, which is an uneconomical method [37].…”

Section: Discussionsupporting

confidence: 80%

See 1 more Smart Citation

One Factor at a Time Analysis to Modify Potting Technique for Manufacturing of Bubble-Free High-Voltage Polyester Insulated Automotive Coils

Nawaz

Ahmad

Akram

et al. 2022

Designs

Self Cite

View full text Add to dashboard Cite

The current study focuses on minimising the bubbles in polyester-insulated ignition coils, which were produced with a defect level of ~21–25% or 210–250 coils per 1000 batch size by using the potting method. This high-level rejection makes a substantial financial impact by increasing waste material, manufacturing, and after-sales costs. Hence, to control the bubbled problem without using expensive and maintenance-heavy techniques, the process parameters in the potting method were alternated and investigated using one factor at a time, which played a vital role in the formation/reduction of bubbles in the ignition coil insulation. Process parameters, including pre/process heating, the appropriate MEKP/cobalt naphthenate ratio, the pouring amount/increments, and the stirring speeds, reduced the bubble formation per lot from 205 ± 30 to 146 ± 25, 108 ± 21, 61 ± 17, and 10 ± 2 per 1000 lot accordingly. In addition, a comparative study was conducted in terms of performance and life cycle endurance, using Japanese and Indian standards. Furthermore, an after-sale warranty claim also supports the proposed changes in the potting technique. This modification may reduce the after-sales rejection within two years to approximately ~85%. This modification in the potting technique is extremely cost-effective in comparison to expensive processes, i.e., vacuum-pressure impregnation and vacuum impregnation, which require extensive labour and maintenance.

show abstract

Section: Discussionsupporting

confidence: 90%

Section: Discussionsupporting

confidence: 80%