Patents by Inventor William J. Walker, Jr.
William J. Walker, Jr. has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Publication number: 20150102721Abstract: 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. The ceramic material of the firing tip (32, 34) includes at least one perovskite structure and/or at least one a spinel structure.Type: ApplicationFiled: December 19, 2014Publication date: April 16, 2015Inventor: William J. Walker, JR.
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Publication number: 20150048733Abstract: A spark plug 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. The body of the center electrode is formed of a compacted and sintered conductive or semi-conductive ceramic material. The ceramic material of the body comprises at least one oxide. For example, the body of the center electrode can be formed of a perovskite structure or a spinel structure.Type: ApplicationFiled: October 29, 2014Publication date: February 19, 2015Inventors: William J. Walker, JR., James D. Lykowski
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Patent number: 8933617Abstract: 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.Type: GrantFiled: November 20, 2013Date of Patent: January 13, 2015Assignee: Federal-Mogul Ignition CompanyInventor: William J. Walker, Jr.
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Patent number: 8901805Abstract: 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.Type: GrantFiled: May 21, 2013Date of Patent: December 2, 2014Assignee: Federal-Mogul Ignition CompanyInventors: William J. Walker, Jr., James D. Lykowski
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Patent number: 8776751Abstract: An igniter (20) emitting an electrical field including a plurality of streamers forming a corona includes a corona enhancing tip (52) at an electrode firing end (28). The corona enhancing tip (52) includes an emitting member (58) such as a wire, layer, or sintered mass, formed of a precious metal and disposed on a base member (54). The base member (54) is formed of a nickel alloy. The emitting member (58) has a lower electrical erosion rate and chemical corrosion rate than the base member (54). The emitting member (58) presents the smallest spherical radius of the corona enhancing tip (52) at the outermost radial point (56) to concentrate the electrical field emissions and provide a consistently strong electrical field strength over time.Type: GrantFiled: April 13, 2011Date of Patent: July 15, 2014Assignee: Federal—Mogul Ignition CompanyInventors: Keith Hampton, William J. Walker, Jr., James D. Lykowski
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Publication number: 20140138122Abstract: A method for making an extruded insulator for a spark plug in a manner that minimizes pores, relics and/or other defects in the insulator microstructure so that the overall dielectric strength or performance of the insulator is improved. The method may be used to manufacture an extruded insulator that avoids many of the drawbacks associated with such defects, but also has a stepped internal bore for receiving a center electrode. In one embodiment, the method uses a multi-phase extrusion process to extrude a ceramic paste around an elongated arbor and form an extruded section, and then removes the arbor from the extruded section to reveal a stepped internal bore.Type: ApplicationFiled: November 11, 2013Publication date: May 22, 2014Inventor: William J. Walker, JR.
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Patent number: 8729782Abstract: An igniter (20) of a corona ignition system emits a non-thermal plasma in the form of a corona (30) to ionize and ignite a fuel mixture. The igniter (20) includes an electrode (32) and a ceramic insulator (22) surrounding the electrode (32). The insulator (22) surrounds a firing end (38) of the electrode (32) and blocks the electrode (32) from exposure to the combustion chamber (28). The insulator (22) presents a firing surface (56) exposed to the combustion chamber (28) and emitting the non-thermal plasma. A plurality of electrically conducting elements (24) are disposed in a matrix (26) of the ceramic material and along the firing surface (56) of the insulator (22), such as metal particles embedded in the ceramic material or holes in the ceramic material. The electrically conducting elements (24) reduce arc discharge during operation of the igniter (20) and thus improve the quality of ignition.Type: GrantFiled: October 28, 2011Date of Patent: May 20, 2014Assignee: Federal-Mogul IgnitionInventors: James D. Lykowski, Keith Hampton, William J. Walker, Jr.
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Patent number: 8680758Abstract: 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.Type: GrantFiled: October 19, 2009Date of Patent: March 25, 2014Assignee: Federal-Mogul Ignition CompanyInventors: Kevin L. Miller, Richard L. Keller, William J. Walker, Jr., James D. Lykowski, Shuwei Ma, Matthew C. Ware, John W. Hoffman, Mark S. McMurray, Brian A. Bolduc, David Walker, Myron J. Schmenk, James L. May, Kevin J. Kowalski
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Publication number: 20140077683Abstract: 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.Type: ApplicationFiled: November 20, 2013Publication date: March 20, 2014Applicant: Federal-Mogul Ignition CompanyInventor: William J. Walker, JR.
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Patent number: 8614541Abstract: 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.Type: GrantFiled: October 24, 2011Date of Patent: December 24, 2013Assignee: Federal-Mogul Ignition CompanyInventor: William J. Walker, Jr.
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Publication number: 20130249379Abstract: 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.Type: ApplicationFiled: May 21, 2013Publication date: September 26, 2013Applicant: Federal-Mogul Ignition CompanyInventors: William J. Walker, JR., James D. Lykowski
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Patent number: 8471450Abstract: 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.Type: GrantFiled: September 23, 2011Date of Patent: June 25, 2013Assignee: Federal-Mogul Ignition CompanyInventors: William J. Walker, Jr., James D. Lykowski
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Patent number: 8410403Abstract: A heater probe assembly, a metallic glow plug assembly therewith and method of constructing the heater probe assembly is provided. The metallic glow plug assembly includes a metal shell having a through bore and a metal sheath extending between a distal end and a terminal end. The terminal end of the metal sheath is fixed in the through bore of the shell. Further, an electrode is provided having an end with a heating element attached to thereto. The heating element and end of the electrode are received in the sheath. A packing powder is disposed in the sheath about the heating element. Further, a ceramic seal has an outer surface attached to the sheath by a braze joint and an inner surface attached to the electrode by a braze joint. The ceramic seal provides a hermetic seal between the packing powder and an environment external to the sheath.Type: GrantFiled: October 22, 2009Date of Patent: April 2, 2013Assignee: Federal Mogul Ignition CompanyInventor: William J. Walker, Jr.
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Publication number: 20120126682Abstract: 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.Type: ApplicationFiled: October 24, 2011Publication date: May 24, 2012Inventor: William J. Walker, JR.
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Publication number: 20120112620Abstract: An igniter (20) of a corona ignition system emits a non-thermal plasma in the form of a corona (30) to ionize and ignite a fuel mixture. The igniter (20) includes an electrode (32) and a ceramic insulator (22) surrounding the electrode (32). The insulator (22) surrounds a firing end (38) of the electrode (32) and blocks the electrode (32) from exposure to the combustion chamber (28). The insulator (22) presents a firing surface (56) exposed to the combustion chamber (28) and emitting the non-thermal plasma. A plurality of electrically conducting elements (24) are disposed in a matrix (26) of the ceramic material and along the firing surface (56) of the insulator (22), such as metal particles embedded in the ceramic material or holes in the ceramic material. The electrically conducting elements (24) reduce arc discharge during operation of the igniter (20) and thus improve the quality of ignition.Type: ApplicationFiled: October 28, 2011Publication date: May 10, 2012Inventors: James D. Lykowski, Keith Hampton, William J. Walker, JR.
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Publication number: 20120038262Abstract: A spark plug, center electrode and method of construction is provided. The spark plug has a generally annular ceramic insulator and a conductive shell surrounding at least a portion of the ceramic insulator. A ground electrode is operatively attached to the shell, with the ground electrode having a ground electrode sparking surface. A center electrode has an elongate body with a center electrode sparking surface. The center electrode sparking surface and the ground electrode sparking surface provide a spark gap. The center electrode body is constructed of a composite material including at least one ceramic material.Type: ApplicationFiled: October 24, 2011Publication date: February 16, 2012Applicant: FEDERAL-MOGUL IGNITION COMPANYInventors: William J. Walker, JR., James D. Lykowski
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Publication number: 20120013240Abstract: 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.Type: ApplicationFiled: September 23, 2011Publication date: January 19, 2012Inventors: William J. Walker, JR., James D. Lykowski
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Patent number: 8079136Abstract: A monolithic, multi-layer heating element forms the high temperature tip of a glow plug assembly. The heating element includes a conductive core which is surrounded by an insulator layer, which in turn supports a resistive layer. An optional conductive jacket can surround the resistive layer. These layered components are pre-formed in prior operations and then assembled one into the other to form a precursor structure. The precursor structure is transferred to a die, where it is compressed to form a so-called green part having dimensional attributes proportional to the finished heating element. The individual layers remain substantially intact, with some boundary layer mixing possible to enhance material-to-material bonding. The green part is sintered to bond to various materials together into an essentially solid mass. Various finishing operations may be required, following which the heating element is assembled to form a glow plug.Type: GrantFiled: September 21, 2009Date of Patent: December 20, 2011Assignee: Federal-Mogul World Wide, Inc.Inventors: William J. Walker, Jr., John W. Hoffman, James L. May
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Patent number: 8053966Abstract: An insulator for a spark ignition device is disclosed which includes an electrically insulating ceramic core tube having a terminal end, a firing end and an inner bore which extends along a longitudinal bore axis from the terminal end to the firing end and an electrically insulating, ceramic core nose tube having a second outer surface and a second bore where the second outer surface of said ceramic core nose tube is in nested engagement with and directly bonded to the bore of the ceramic core tube proximate the firing end. The insulator also may include a similarly nested and directly bonded shoulder tube on an outer surface of the core tube, or a nested and directly bonded mast tube on an outer surface of the core tube. The ceramics may include alumina-based ceramics, as well other suitable ceramic materials, and the tube may be made from the same ceramic compositions or different ceramic compositions.Type: GrantFiled: April 10, 2009Date of Patent: November 8, 2011Assignee: Federal-Mogul Ignition CompanyInventor: William J. Walker, Jr.
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Patent number: 8044561Abstract: 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.Type: GrantFiled: August 28, 2008Date of Patent: October 25, 2011Assignee: Federal-Mogul Ignition CompanyInventors: William J. Walker, Jr., James D. Lykowski