Abstract: 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.

Abstract: 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.

Abstract: A spark plug and method of construction is provided, wherein the spark plug has a generally annular ceramic insulator and a metal shell surrounding at least a portion of the insulator. A ground electrode is operatively attached to the shell, wherein the ground electrode has a ground electrode sparking surface. The spark plug further includes a center electrode having an elongate body with a center electrode sparking surface. The sparking surface of the center electrode and the ground electrode sparking surface provide a spark gap. A brazed joint bonds at least one of the insulator to the shell or the center electrode to the insulator.

Abstract: An electrode for an ignition device is made from a conductive ceramic of the form Mn+1AXn, where M is a transition metal, A is a group IIIA or IVA element, and X is nitrogen, carbon, or both carbon and nitrogen. M may be transition metals selected from the group of Ti, Mb, Ta, V, Cr, Mo, Sc, Zr and Hf. A may be selected from a group consisting of Al, Ga, In, Tl, Si, Ge, Sn, Pb, P, As and S. The spark ignition device may include a spark plug having an insulator, conductive shell, center electrode and ground electrode where the conductive ceramic electrode is at least one of the center or ground electrodes.

Abstract: A spark plug which includes a center electrode metal shell and an insulator disposed therebetween utilizes for the insulator or ceramic with improved high temperature electrical properties which includes alumina in an amount between about 90 and about 99% by weight, a zirconium containing compound in an amount between about 0 and about 1% by weight, and an oxide mixture in an amount between about 1 and about 10% by weight. The oxide mixture includes a glass former, a network modifier and alumina in an amount between about 16% and about 40% by weight after firing, wherein the molar ratio of the glass former to the network modifier ranges between about 0.8:1 and 1.2:1. The ceramic insulator is particularly adapted for use as an insulator in a spark plug to provide improved dielectric strength and shunt resistance of greater than one 1000 megaohms at 1000 degrees Fahrenheit, so as to reduce the shunting of the spark plug and thereby improve the quality of the spark generated by the spark plug.

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 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.

Abstract: An electrode for an ignition device is made from a conductive ceramic of the form Mn+1 AXn, where M is a transition metal, A is a group IIIA or IVA element, and X is nitrogen, carbon, or both carbon and nitrogen. M may be transition metals selected from the group of Ti, Mb, Ta, V, Cr, Mo, Sc, Zr and Hf. A may be selected from a group consisting of Al, Ga, In, Tl, Si, Ge, Sn, Pb, P, As and S. The spark ignition device may include a spark plug having an insulator, conductive shell, center electrode and ground electrode where the conductive ceramic electrode is at least one of the center or ground electrodes.

Abstract: 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.

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 and method of construction is provided, wherein the spark plug has a generally annular ceramic insulator and a metal shell surrounding at least a portion of the insulator. A ground electrode is operatively attached to the shell, wherein the ground electrode has a ground electrode sparking surface. The spark plug further includes a center electrode having an elongate body with a center electrode sparking surface. The sparking surface of the center electrode and the ground electrode sparking surface provide a spark gap. A brazed joint bonds at least one of the insulator to the shell or the center electrode to the insulator.

Abstract: 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.

Abstract: 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.

Abstract: A spark plug insulator having high dielectric strength, high density, and an optical property that allows the passage of light.

Abstract: A multilayer ceramic structure is formed by building up a plurality of layers by sequentially coating a substrate with a series of suspensions comprising particles in a fluid medium. A composition of the sequential layers are varied to produce a structure with the desired properties. The thickness of the layers can be controlled by rheological properties of the suspension and/or by the utilization of a gelling or coagulating agent. An advantage of this method is that complete drying between the subsequent coatings is not required.

Abstract: A ceramic includes alumina in an amount between about 90 and about 99% by weight, a zirconium containing compound in an amount between about 0 and about 1% by weight, and an oxide mixture in an amount between about 1 and about 10% by weight. The oxide mixture includes a glass former and a network modifier, wherein the molar ratio of the glass former to the network modifier ranges between about 0.8:1 and 1.2:1. The ceramic insulator is particularly adapted for use as an insulator in a spark plug to provide improved dielectric strength and shunt resistance of greater than one 1000 megaohms at 1000 degrees Fahrenheit, so as to reduce the shunting of the spark plug and thereby improve the quality of the spark generated by the spark plug.

Abstract: A method of preparing ceramics having the steps of forming an aqueous slurry of deflocculant, ceramic powder and binder and causing the slurry to get into a semi-rigid solid by adding a chemical initiator and/or increasing the temperature of the slurry.