Abstract: A welding system for welding small precious metal firing tips to spark plug electrodes, such as ground and/or center electrodes. According to one embodiment, the welding system includes a firing tip storage assembly and a firing tip welding assembly, where the firing tip storage assembly uses pressurized gas introduced at the bottom of a part container to float or lift the firing tips so that the firing tip welding assembly can more easily acquire them with a vacuum-driven nozzle that also doubles as a welding electrode. The firing tip welding assembly is mounted to a robotic apparatus that can index or move the firing tip welding assembly between the firing tip storage assembly, a welding station and/or any other suitable positions.

Abstract: A spark plug and method of construction thereof is provided. The spark plug includes a metal shell having a through cavity, a lower insulator and a plastic upper insulator. The lower insulator is received in the through cavity and has a through passage with a center electrode received therein. A ground electrode is operatively attached to the shell in spaced relation from the ground electrode to provide a spark gap. The plastic upper insulator has a distal end received in the through cavity of the shell and a terminal end extending axially outwardly from the shell. The upper insulator has a through passage extending between the terminal end and the distal end. An elongate conductive member is received in the through passage of the upper insulator and is configured for electrical communication with the center electrode.

Abstract: A spark plug (20) for igniting a mixture of fuel and air of an internal combustion engine comprises a center electrode (22) and a ground electrode (24). At least one of the electrodes (22, 24) includes a body portion (28, 30) formed of thermally conductive material and a firing tip (32, 34) disposed on the body portion (28, 30). The firing tip (32, 34) includes a ceramic material, providing an exposed firing surface (36, 38). The ceramic material is an electrically conductive, monolithic ceramic material. Examples of preferred ceramic materials include titanium diboride, silicon carbide, ternary carbide, and ternary nitride. The ceramic material can also include oxides, borides, nitrides, carbides, silicides, or MAX phases.

Abstract: A spark plug has a firing pad attached to a center electrode or to a ground electrode. The firing pad is attached via laser welding and has a sparking surface with an overall fused area and an unfused area. In one or more embodiments, the overall fused area is located in part or more inboard of a peripheral edge of the firing pad.

Abstract: A spark ignition device, ground electrode therefor, and methods of construction thereof are provided. The spark ignition device includes a generally annular ceramic insulator with a metal shell surrounding at least a portion of the ceramic insulator. A center electrode is received at least in part in the ceramic insulator and a ground electrode extends from the shell to a free end portion. A firing tip is attached adjacent the free end portion of the ground electrode to provide a spark gap between the center electrode and the firing tip. The free end portion is at least partially bounded by at least one “as laser cut” peripheral side extending adjacent the firing tip.

Abstract: A spark ignition device, ground electrode therefor, and methods of construction thereof are provided. The spark ignition device includes a generally annular ceramic insulator with a metal shell surrounding at least a portion of the ceramic insulator. A center electrode is received at least in part in the ceramic insulator and a ground electrode extends from the shell to a free end portion. A firing tip is attached adjacent the free end portion of the ground electrode to provide a spark gap between the center electrode and the firing tip. The free end portion is at least partially bounded by at least one “as laser cut” peripheral side extending adjacent the firing tip.

Abstract: A corona igniter (20) includes an ignition coil (26) providing a high voltage energy to an electrode. The coil (26) is disposed in a housing (34) and electrically isolated by a coil filler (36) and a capacitance reducing component (38) which together improve energy efficiency of the system. The coil filler (36) includes an insulating resin permeating the coil (26). The capacitance reducing component (38) has a permittivity not greater than 6, for example ambient air, pressurized gas, insulating oil, or a low permittivity solid. The capacitance reducing compound (38) surrounds the coil (26) and other components and fills the remaining housing volume. The coil filler (36) has a filler volume and the capacitance reducing component (38) has a component volume greater than the filler volume.

Abstract: A corona igniter (20) comprises a central electrode (22) surrounded by an insulator (26), which is surrounded by a conductive component. The conductive component includes a shell (34) and an intermediate part (36) both formed of an electrically conductive material. The intermediate part (36) is typically attached to a lower ledge (52) of the insulator outer surface (50) prior to inserting the insulator (26) into the shell (34). The shell firing end (56) is typically aligned with the lower edge and the intermediate firing end. The conductive inner diameter (Dg) is less than an insulator outer diameter (Dio) directly below the lower ledge (52) such the insulator thickness (ti) increases toward the electrode firing end (40).

Abstract: A spark plug (20) for igniting a mixture of fuel and air of an internal combustion engine comprises a center electrode (22) and a ground electrode (24). At least one of the electrodes (22, 24) includes a body portion (28, 30) formed of thermally conductive material and a firing tip (32, 34) disposed on the body portion (28, 30). The firing tip (32, 34) includes a ceramic material, providing an exposed firing surface (36, 38). The ceramic material is an electrically conductive, monolithic ceramic material. Examples of preferred ceramic materials include titanium diboride, silicon carbide, ternary carbide, and ternary nitride. The ceramic material can also include oxides, borides, nitrides, carbides, silicides, or MAX phases.

Abstract: A spark plug includes an insulator formed of a ceramic material. The ceramic material comprises Al2O3 in an amount of 98.00 wt % to 99.50 wt %; Group 2 oxides in an amount of 0.16 wt % to 0.70 wt %; SiO2 in an amount of 0.25 wt % to 0.75 wt %, Group 4 oxides in an amount of 0.01 wt % to 0.16 wt %, Group 1 oxides in an amount less than 0.0060 wt %, and P2O5 in an amount of less than 0.0040 wt %. The Al2O3 is formed of particles having a D50 median particle size by volume of 1.2 ?m to 1.8 ?m. The ceramic material is pressed, sintered, and formed to a predetermined shape. The sintered ceramic material includes a glass phase comprising the Al2O3, Group 2 oxides, and SiO2. The sintered ceramic material also includes secondary crystals of calcium hexa-aluminate (CaAl12O19) spinel (MgAl2O4), anorthite (CaAl2Si2O8), and mullite (Al6Si2O13).

Abstract: A spark plug assembly has a ceramic insulator with a metal outer shell surrounding at least a portion of the insulator. A ground electrode is operatively attached to the outer shell and a center electrode having an elongate body extends through the insulator. The center electrode and the ground electrode provide a spark gap. A force sensor is received about the insulator. An annular inner shell is received between the outer shell and the insulator, wherein the inner shell has a surface configured to confront the insulator along an axial direction.

Abstract: The cup receptacle has an annular outer wall configured to receive a cup and a light source operably attached to the cup receptacle. The outer wall of the cup receptacle is constructed of a light transmitting material that is uniformly illuminated by light emitted from the light source.

Abstract: A spark plug assembly includes an insulator having an upper shoulder and a lower shoulder and a metal annular outer shell having an outer surface and a cavity bounded by an inner surface. The inner surface has a flange extending inwardly to confront the lower shoulder of the insulator. The outer shell has a proximal end and an opposite fastening end. The fastening end has an external threaded region and an annular sealing seat extending outwardly adjacent the flange. The outer shell has an annular shoulder extending radially between the sealing seat and the proximal end. The proximal end has a turnover axially confronting the upper shoulder of the insulator. A sensor assembly is received about the outer shell between the shoulder of the shell and the turnover. The sensor assembly is responsive to send a signal in response to relative axial movement between the insulator and the outer shell.

Abstract: An igniter (20) includes an outer insulator (24) formed of an outer ceramic material hermetically sealed to a conductive core (26). The conductive core (26) is formed of a core ceramic material and a conductive component, such as an electrically conductive coating applied to the core ceramic material or metal particles or wires embedded in the core ceramic material. The conductive core (26) is typically sintered and disposed in the green outer insulator (24). The components are then sintered together such that the outer insulator (24) shrinks onto the conductive core (26) and the hermetic seal forms therebetween. The conductive core (26) fills the outer insulator (24), so that the conductive core (26) is disposed at an insulator nose end (34) of the outer insulator (24) and the electrical discharge (22) can be emitted from the conductive core (26), eliminating the need for a separate firing tip.

Abstract: An electrode material that may be used in spark plugs and other ignition devices including industrial plugs, aviation igniters, glow plugs, or any other device that is used to ignite an air/fuel mixture in an engine. The electrode material is a metal composite and includes a particulate component embedded or dispersed within a matrix component such that the metal composite has a multi-phase microstructure. In one embodiment, the metal composite includes a matrix component that includes a precious metal and makes up about 2-80% wt of the overall composite and a particulate component that includes a ruthenium-based material and makes up about 20-98% wt of the overall composite.

Abstract: A spark plug includes at least one electrode having a sparking end. The sparking end is formed of a high temperature performance alloy including chromium in an amount of 10.0 weight percent to 60.0 weight percent, palladium in an amount of 0.5 weight percent to 10.0 weight percent, and a balance substantially of at least one of molybdenum and tungsten. The sparking end presents a spark contact surface, and at a temperature of at least 500° C., such as during use of the spark plug in an internal combustion engine, a layer of chromium oxide (Cr2O3) forms at said spark contact surface. The layer of Cr2O3 protects the bulk of the sparking end from the extreme conditions of the combustion chamber and prevents erosion, corrosion, and balling.

Abstract: A spark plug includes a metallic shell, an insulator, a center electrode body, a ground electrode body, and a ground electrode tip. In one embodiment, the ground electrode tip includes a non-precious metal piece and a precious metal piece attached to each other. The non-precious metal piece has a side surface attached to a free end surface of the ground electrode body.

Abstract: A piston for an internal combustion engine including a piston body (20). The piston body (20) defines a first cooling chamber (46) that is sealed closed and contains a first cooling medium (48) other than air. During operation of the piston, the first cooling medium (48) extracts heat from the surrounding regions of the piston body (20) to cool the piston body (20). The piston body (20) also defines a second cooling chamber (50) adjacent to the first cooling chamber (46). A cooling oil (51) is projected into the second cooling chamber (50) and against the portion of the piston body (20) separating the first and second cooling chambers (46, 50) to extract heat from the first cooling medium (48). The cooling oil (51) is redirected within the second cooling chamber (50) to extract additional heat from the first cooling medium (48) or directly from the piston body (20).

Abstract: A spark plug, a center electrode therefore and method of construction is provided. The spark plug has a generally annular ceramic insulator extending between a terminal end and a nose end. A conductive shell surrounds at least a portion of the ceramic insulator and a ground electrode having a ground electrode sparking surface is operatively attached to the shell. An elongate center electrode has a body extending between opposite ends, wherein the body is compacted and sintered of a conductive or semi-conductive ceramic material. One of the electrode ends provides a center electrode sparking surface to provide a spark gap between the center electrode sparking surface and the ground electrode sparking surface.

Abstract: A spark plug includes an electrode tip assembly located at an axially-facing free end surface of an electrode body. The electrode tip assembly includes an electrode tip body and a firing tip and has a longitudinal axis that is generally perpendicular to a longitudinal axis of the electrode body. The electrode tip body may be a Ni-alloy piece and is attached to the electrode body, and the firing tip may be an Ir-alloy piece with a sparking surface that faces a spark gap. The electrode body may include a groove formed in the axially-facing free end surface that is useful to help position the electrode tip assembly for attachment. The spark gap can be formed between opposing electrode tip assemblies, and the size of the spark gap can be adjusted during assembly without the need for bending the electrode body.