Abstract:
An ignition coil for an internal combustion engine includes a magnetically-permeable core extending along a core longitudinal axis, the core having a pair of end surfaces on axially-opposite ends thereof. The ignition coil also includes a primary winding disposed outward of the core, a secondary winding disposed outward of the primary winding, and a structure comprising magnetically-permeable steel laminations having a base and a pair of legs, the structure defining a magnetic return path. The core is disposed between the pair of legs such that the core longitudinal axis extends through the legs and the end surfaces face toward the legs and at least one of the end surfaces of the core is spaced apart from a respective one of the legs to define an air gap. The structure is over-molded with an over-molding material such that the over-molding material fills at least a portion of the air gap.