Abstract
This paper focuses on the ignition coil failure caused primarily by environmental factors. Two environmental parameters (i.e., environmental temperature and relative humidity) were considered to highlight their potential consequences using potting method. Environmental temperature affects the bubble sizes in lamination. Inside these bubbles at high voltage, there is a possibility of spark occurrence, which ultimately leads to failure of ignition coils. Second factor is relative humidity, which plays more severe role in the failure of the coil by enhancing the possibility of occurrence of corona even in small-size bubbles. In addition, we analyze both environmental parameters in combination. Results of the study reveal that both environmental parameters in combination play a devastating role in the failure of the coils. Additionally, this study also concludes that potting method can only be done in open environment in the month in which relative humidity is less than 25%.