Abstract: The spark plug comprises:—a central electrode (2),—an insulating core (6) bearing the central electrode (2),—an external body (8) in which the insulating core (6) is mounted and which has a region (18) where the external body (8) is crimped onto the insulating core (6), and—a force sensor (30). The force sensor (30) is mounted at the periphery of the external body (8) between, on the one hand, a bearing element (38) secured to a first peripheral region of the external body (8) and, on the other hand, a second peripheral region (24) of the external body (8). The second peripheral region (24) of the external body (8)is further away from the crimping region (18) than the first peripheral region. The bearing element (38) is prestressed against the force sensor (30).

Abstract: A spark plug having a particular firing end configuration that satisfies numerous dimensional ranges for improved performance. The spark plug generally includes a shell, an insulator, and center and ground electrodes, with the electrodes each having a copper core for improved thermal conductivity and a noble metal insert for improved erosion and corrosion resistance. The noble metal insert for the center electrode is preferably in the form of a cylindrical Ir-based tip, which is received within a complimentary recess formed in the center electrode. The noble metal insert for the ground electrode is in the form of a flat Pt-based pad attached to a surface of the ground electrode. Various dimensional ranges are provided for the various components of the spark plug assembly, both individually and in combination with other dimensions.

Abstract: A spark plug having a particular firing end configuration that satisfies numerous dimensional ranges for improved performance. The spark plug generally includes a shell, an insulator, and center and ground electrodes, with the electrodes each having a copper core for improved thermal conductivity and a noble metal insert for improved erosion and corrosion resistance. The noble metal insert for the center electrode is preferably in the form of a cylindrical Ir-based tip, which is received within a complimentary recess formed in the center electrode. The noble metal insert for the ground electrode is in the form of a flat Pt-based pad attached to a surface of the ground electrode. Various dimensional ranges are provided for the various components of the spark plug assembly, both individually and in combination with other dimensions.

Abstract: A spark plug having a ground electrode with a precious metal pad welded to the ground electrode through a series of weld steps. The precious metal pad is a Pt-based pad which is attached to a side surface of the ground electrode via an attachment process that includes a resistance tack weld to initially secure the pad in place, a coining step to flatten the pad, a second resistance weld to form a permanent weld of the pad to the ground electrode, and a laser capping weld about the exposed periphery of the pad to seal the resistance weld. The laser capping weld comprises numerous overlapping weld spots that together form an annular weld bead located at or just below the discharge surface of the pad.

Abstract: An ignition device for an internal combustion engine and method of construction therefore includes a housing with an insulator secured therein. A center electrode is mounted within the insulator. A ground electrode extends from the housing with a portion of the ground electrode defining a spark gap across from the center electrode. At least a selected one of the center electrode or ground electrode has a platinum or platinum-based alloy firing tip. A resistance weld joint bonds the firing tip to the selected electrode and defines a lower surface of the firing tip that is embedded a first distance beneath an outer surface of the selected electrode. A continuous bead of overlapping laser weld pools is formed over an outer periphery of the firing tip. The overlapping weld pools extend a second distance beneath the outer surface of the selected electrode, with the second distance being greater than the first distance.

Abstract: An ignition device for an internal combustion engine and method of construction therefore includes a housing with an insulator secured therein. A center electrode is mounted within the insulator. A ground electrode extends from the housing with a portion of the ground electrode defining a spark gap across from the center electrode. The center electrode has a firing tip, wherein a resistance weld joint initially bonds the firing tip to the center electrode and a continuous bead of overlapping first weld pools formed substantially from the material of the firing tip further bonds the firing tip to the electrode. A continuous bead of overlapping second weld pools formed radially outwardly from the first weld pools forms a rounded shoulder surface extending from the first weld pools to an outer surface of the center electrode.

Abstract: An ignition device such as a spark plug having ground and center electrodes, at least one of which includes a firing tip formed from an alloy containing iridium, rhodium, tungsten, and zirconium. With the inclusion of tungsten and zirconium in the alloy, the percentage of rhodium can be kept relatively low without sacrificing the erosion resistance or reduced sparking voltage of the firing tip. In one embodiment, the firing tip contains 2% rhodium, 0.3% tungsten, 0.02% zirconium, and the balance iridium.

Abstract: A spark plug for an internal combustion engine comprising a centre electrode and an earth electrode serving as a spark discharge section, as well as a noble metallic chip, which is inserted into one end of at least one of said electrodes along part of its length and which is subsequently welded thereto by irradiation with energy-condensing light, characterized in that said noble metallic chip is provided with a profile for holding said noble metallic chip onto said at least one electrode on at least part of the outer periphery of said part of its length, wherein a fusion layer extending between said profile and an inner region of the end of said at least one electrode locks said noble metallic chip onto said at least one electrode.

Abstract: A noble metal tip 20 for attachment to a spark plug center electrode 36 and/or a ground electrode. Noble metal tip 20 is a generally cylindrical component that includes a firing end 40, an attachment end 42, and one or more retention features 44, 46 and 60, 62. The retention features are generally conically shaped holes or recesses formed in the side of the noble metal tip, and are designed to receive molten material during a laser attachment process. Once the molten material has solidified in the retention features, a fusion layer is formed and acts as a mechanical bond or interlock between the noble metal tip and the electrode. Methods of manufacturing and attaching the noble metal tips are also provided.

Abstract: A spark plug having a particular firing end configuration that satisfies numerous dimensional ranges for improved performance. The spark plug generally includes a shell, an insulator, and center and ground electrodes, with the electrodes each having a copper core for improved thermal conductivity and a noble metal insert for improved erosion and corrosion resistance. The noble metal insert for the center electrode is preferably in the form of a cylindrical Ir-based tip, which is received within a complimentary recess formed in the center electrode. The noble metal insert for the ground electrode is in the form of a flat Pt-based pad attached to a surface of the ground electrode. Various dimensional ranges are provided for the various components of the spark plug assembly, both individually and in combination with other dimensions.

Abstract: A spark plug having a discharge portion formed of a metal alloy chip. The metal alloy is selected to prevent wear due to the interaction of Iridium with Calcium or Phosphorus during combustion.

Abstract: A spark plug having a ground electrode with a precious metal pad welded to the ground electrode through a series of weld steps. The precious metal pad is a Pt-based pad which is attached to a side surface of the ground electrode via an attachment process that includes a resistance tack weld to initially secure the pad in place, a coining step to flatten the pad, a second resistance weld to form a permanent weld of the pad to the ground electrode, and a laser capping weld about the exposed periphery of the pad to seal the resistance weld. The laser capping weld comprises numerous overlapping weld spots that together form an annular weld bead located at or just below the discharge surface of the pad.

Abstract: A spark plug having a particular firing end configuration that satisfies numerous dimensional ranges for improved performance. The spark plug generally includes a shell, an insulator, and center and ground electrodes, with the electrodes each having a copper core for improved thermal conductivity and a noble metal insert for improved erosion and corrosion resistance. The noble metal insert for the center electrode is preferably in the form of a cylindrical Ir-based tip, which is received within a complimentary recess formed in the center electrode. The noble metal insert for the ground electrode is in the form of a flat Pt-based pad attached to a surface of the ground electrode. Various dimensional ranges are provided for the various components of the spark plug assembly, both individually and in combination with other dimensions.

Abstract: An ignition device such as a spark plug having ground and center electrodes, at least one of which includes a firing tip formed from an alloy containing iridium, rhodium, tungsten, and zirconium. With the inclusion of tungsten and zirconium in the alloy, the percentage of rhodium can be kept relatively low without sacrificing the erosion resistance or reduced sparking voltage of the firing tip. In one embodiment, the firing tip contains 2.5% rhodium, 0.3% tungsten, 0.07% zirconium, and the balance iridium.

Abstract: A fuel injector (10; 100) comprises an inlet (60) from which fuel can be transferred into a cavity (61) of the injector, at least one outlet orifice (86) communicating with said cavity (61), and ejecting means (44, 88) operable to apply force to fuel in said cavity to cause said fuel to be ejected through said orifice as discreet charges at pre-determined intervals. The operation of said ejecting means (44, 88) is also operable to transfer further fuel into said cavity (61).

Abstract: A noble metal tip 20 for attachment to a spark plug center electrode 36 and/or a ground electrode. Noble metal tip 20 is a generally cylindrical component that includes a firing end 40, an attachment end 42, and one or more retention features 44, 46 and 60, 62. The retention features are generally conically shaped holes or recesses formed in the side of the noble metal tip, and are designed to receive molten material during a laser attachment process. Once the molten material has solidified in the retention features, a fusion layer is formed and acts as a mechanical bond or interlock between the noble metal tip and the electrode. Methods of manufacturing and attaching the noble metal tips are also provided.

Abstract: An ignition device such as a spark plug having ground and center electrodes, at least one of which includes a firing tip formed from an alloy containing iridium, rhodium, tungsten, and zirconium. With the inclusion of tungsten and zirconium in the alloy, the percentage of rhodium can be kept relatively low without sacrificing the erosion resistance or reduced sparking voltage of the firing tip. In one embodiment, the firing tip contains 2% rhodium, 0.3% tungsten, 0.02% zirconium, and the balance iridium.

Abstract: A spark plug for an internal combustion engine comprising a centre electrode and an earth electrode serving as a spark discharge section, as well as a noble metallic chip, which is inserted into one end of at least one of said electrodes along part of its length and which is subsequently welded thereto by irradiation with energy-condensing light, characterized in that said noble metallic chip is provided with a profile for holding said noble metallic chip onto said at least one electrode on at least part of the outer periphery of said part of its length, wherein a fusion layer extending between said profile and an inner region of the end of said at least one electrode locks said noble metallic chip onto said at least one electrode.

Abstract: An ignition device such as a spark plug having ground and center electrodes, at least one of which includes a firing tip formed from an alloy containing iridium, rhodium, tungsten, and zirconium. With the inclusion of tungsten and zirconium in the alloy, the percentage of rhodium can be kept relatively low without sacrificing the erosion resistance or reduced sparking voltage of the firing tip. In one embodiment, the firing tip contains 2.5% rhodium, 0.3% tungsten, 0.07% zirconium, and the balance iridium.

Abstract: A fuel injector (10; 100) comprises an inlet (60) from which fuel can be transferred into a cavity (61) of the injector, at least one outlet orifice (86) communicating with said cavity (61), and ejecting means (44, 88) operable to apply force to fuel in said cavity to cause said fuel to be ejected through said orifice as discreet charges at pre-determined intervals. The operation of said ejecting means (44, 88) is also operable to transfer further fuel into said cavity (61).