Spark Plug Or Spark Gap Making Patents (Class 445/7)
  • Patent number: 10978857
    Abstract: A method of manufacturing a spark plug (1) including a disposing step, a contacting step, and a deforming step. In the disposing step, a mounting screw portion (30) is inserted into a gasket (50) and the gasket (50) is disposed between the mounting screw portion (30) and a seat portion (32). In the contacting step, from a front end side, a jig (60) is brought into contact with the gasket (50) disposed by the disposing step, and the jig (60) is moved toward the rear end side until a load applied to the jig (60) from the gasket (50) reaches a predetermined set load. In the deforming step, after the contacting step, the jig (60) is further moved toward the rear end side by a predetermined set distance XS. Consequently, the gasket (50) is pressed by the jig (60) and an inner edge portion (55) of the gasket (50) is deformed inward in a radial direction of the gasket (50).
    Type: Grant
    Filed: February 25, 2020
    Date of Patent: April 13, 2021
    Assignee: NGK SPARK PLUG CO., LTD.
    Inventor: Keijiro Kuroda
  • Patent number: 10879677
    Abstract: A corona igniter assembly which is designed to reduce the amount of air gaps between insulating components and thus reduce electrical fields concentrated in those air gaps and the associated unwanted corona discharge. The assembly includes a high voltage center electrode surrounded by a ceramic insulator and a high voltage insulator. A dielectric compliant insulator is disposed between the ceramic insulator and the high voltage insulator. A layer of metal is applied to at least one of the insulators, for example the ceramic insulator. A compliant collet formed of a partially resistive material covers a sharp edge of the layer of metal to reduce the electric field and smooth the electric field distribution at the sharp edge of the metal layer.
    Type: Grant
    Filed: January 3, 2019
    Date of Patent: December 29, 2020
    Assignee: Tenneco Inc.
    Inventors: Massimo Dal Re, Giovanni Betti Beneventi, Giulio Milan, Stefano Papi, Alessio Di Giuseppe
  • Patent number: 10784654
    Abstract: Spark plug has first and second electrodes. First electrode has tip principally made of noble metal and base material principally made of Ni. The tip is joined to the base material through fusion portion. Second electrode faces discharge surface of the tip. The fusion portion has overlap portion where first interface between the tip and the fusion portion and second interface between the base material and the fusion portion overlap in first direction perpendicular to the discharge surface. When viewing cross section which passes through a center of gravity of the overlap portion projected onto virtual surface parallel to the discharge surface and is perpendicular to the discharge surface, noble metal content is greater than 50 mass % at one end portion of the overlap portion in second direction extending along the discharge surface, and Ni content is greater than 50 mass % at the other end portion of the overlap portion.
    Type: Grant
    Filed: May 31, 2019
    Date of Patent: September 22, 2020
    Assignee: NGK SPARK PLUG CO., LTD.
    Inventor: Tomoki Kawai
  • Patent number: 10615577
    Abstract: A method for manufacturing a spark plug including a reference standard imaging step of imaging a plurality of reference standards to obtain a plurality of reference images, each reference standard having a reference part with a predetermined known dimension; a reference standard measuring step of measuring a measured dimension or a measured number of pixels of the reference part in the plurality of reference images; a regression line deriving step of obtaining a regression line by the least squares method from: the measured dimension or the measured number of pixels of the plurality of reference standards; and the known dimensions; and a determining step of determining whether a target part in a target image is within a predetermined range based on a correction value obtained by correcting a measured dimension of a target part by using a relational expression describing the regression line.
    Type: Grant
    Filed: July 8, 2019
    Date of Patent: April 7, 2020
    Assignee: NGK SPARK PLUG CO., LTD.
    Inventors: Kota Nishimura, Norihide Kachikawa
  • Patent number: 10439368
    Abstract: Standard image data representing standard image including image of slit of a standard device is produced by photographing the standard device including the slit which includes a standard slit segment having a predetermined width. A width of the standard slit segment in the standard image is determined by analyzing the standard image data. Gap image data representing a gap image which is an image including an image of a discharge gap of a spark plug is produced by photographing the spark plug. A distance of the discharge gap in the gap image is determined by analyzing the gap image data. By using the distance of the discharge gap in the gap image and the width of the standard slit segment in the standard image, it is determined whether an actual distance of the discharge gap is within a predetermined allowable range or not.
    Type: Grant
    Filed: September 26, 2018
    Date of Patent: October 8, 2019
    Assignee: NGK SPARK PLUG CO., LTD.
    Inventors: Kota Nishimura, Norihide Kachikawa
  • Patent number: 10283941
    Abstract: An electrode of the spark plug includes a first melt portion formed between a body portion of an intermediate member and a noble metal tip; and a second melt portion that is formed, between a flange portion of the intermediate member and an electrode base material, at least at a position of intersection with an axial line of the noble metal tip. In a cross section including the axial line of the noble metal tip, when: a diameter of the noble metal tip is denoted by Tw; the shortest distance between the second melt portion and a boundary between the first melt portion and the intermediate member is denoted by S1; and the longest distance between the second melt portion and the boundary between the first melt portion and the intermediate member is denoted by S2, 1.0 mm?Tw?1.2 mm and (S2?S1)?0.3 mm are met.
    Type: Grant
    Filed: October 11, 2016
    Date of Patent: May 7, 2019
    Assignee: NGK SPARK PLUG CO., LTD.
    Inventor: Tomoyuki Igarashi
  • Patent number: 10135228
    Abstract: The method of creating a metallic electrode on the ceramic insulator of a spark plug with a deposit of additional material using the laser weld deposition method, where this metallic electrode, formed by a diffusion metallic layer (3) of the joint between the weld deposit of the smelted wire and the insulator (1), is in the shape of a ring in the end part of the insulator body (1) around the central electrode (2) of the spark plug.
    Type: Grant
    Filed: June 1, 2015
    Date of Patent: November 20, 2018
    Assignee: BRISK TÁBOR
    Inventor: Mojmir Capka
  • Patent number: 10079477
    Abstract: A method of manufacturing a spark plug includes a step (a) of chucking, by mutually facing chucks, a metallic shell extending along its center axis so as to fix the metallic shell, and (b) a step of pressing a ground electrode against the fixed metallic shell and applying voltage between the ground electrode and the chucks for resistance-welding the ground electrode and the metallic shell. A first chuck facing a second chuck, wherein, as viewed on an imaginary plane of projection perpendicular to the center axis, the number of support points on the second chuck is smaller than the number of support points on the first chuck for supporting the metallic shell.
    Type: Grant
    Filed: June 21, 2016
    Date of Patent: September 18, 2018
    Assignee: NGK SPARK PLUG CO., LTD.
    Inventor: Daishi Uchiyama
  • Patent number: 9929540
    Abstract: A spark plug including a center electrode having a center electrode tip. A ground electrode strap has a ground electrode base to which a ground electrode pad is mounted. The ground electrode base is trapezoid-shaped in cross-section. The ground electrode strap is triangular-shaped in cross-section.
    Type: Grant
    Filed: August 1, 2017
    Date of Patent: March 27, 2018
    Assignees: DENSO International America, Inc., DENSO CORPORATION
    Inventors: Harrison Boll, Jeongung Hwang
  • Patent number: 9899805
    Abstract: Provided is a method for manufacturing a spark plug, wherein at least one of a center electrode and the ground electrode includes an electrode base material and a columnar noble metal tip welded to the electrode base material. The method includes a laser welding step of applying a pulse oscillation laser to form a plurality of unit fusion portions on a peripheral area of a boundary between the electrode base material and the noble metal tip and welding the electrode base material and the noble metal tip. One unit fusion portion is formed by one-time laser irradiation. In the laser welding step, an irradiation axis of the laser is displaced from a central axis of the noble metal tip in a radial direction of the noble metal tip. When a diameter of the noble metal tip is denoted as a diameter A and an amount of displacement of the irradiation axis of the laser is denoted as X, A/20?|X|?A/4 is satisfied.
    Type: Grant
    Filed: August 21, 2014
    Date of Patent: February 20, 2018
    Assignee: NGK SPARK PLUG CO., LTD.
    Inventors: Tomoaki Kato, Ryuichi Ohno
  • Patent number: 9705291
    Abstract: An ignition plug having a ground electrode that includes a base material layer and an erosion-resistant layer having a thermal conductivity of 40 w/m·K or more. The erosion-resistant layer extends at least from the center-electrode-facing portion to a location closer to the fixed end than a front end of the center electrode and 0.2 mm?thickness t1 of the erosion-resistant layer?thickness T of the ground electrode 30?0.6 mm is satisfied.
    Type: Grant
    Filed: March 17, 2016
    Date of Patent: July 11, 2017
    Assignee: NGK SPARK PLUG CO., LTD.
    Inventors: Yuichi Yamada, Takuya Kawade
  • Patent number: 9673593
    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.
    Type: Grant
    Filed: August 8, 2013
    Date of Patent: June 6, 2017
    Assignee: Federal-Mogul Ignition Company
    Inventors: Kevin J. Kowalski, Frederick J. Quitmeyer, Nathan A. Thomson, Curtis W. Verhoff, Richard L. Keller
  • Patent number: 9318878
    Abstract: In a section of a spark plug cut by a plane which passes through the center of gravity of the intermediate member and is in parallel with the facing direction between a center electrode and an extending portion of a ground electrode, a spark plug that satisfies the relational expression S1/(D1×H1)?0.005, where S1 is the total area of nuggets, H1 is the height of the end surface of a noble metal tip from the disposition surface of an electrode base metal, and D1 is the maximum width of the noble metal tip.
    Type: Grant
    Filed: May 15, 2012
    Date of Patent: April 19, 2016
    Assignee: NGK SPARK PLUG CO., LTD.
    Inventors: Yuji Kasuya, Yoshikazu Kataoka
  • Patent number: 9236715
    Abstract: A ground electrode comprised of a noble metal tip having an outer circumferential surface, a holder having an inner circumferential surface defining a through hole for the noble metal tip thereon, and a body to which the holder is joined. At least one of a) the inner circumferential surface of the holder which forms the through hole, and b) the outer circumferential surface of the noble metal tip which is disposed in the through hole, continuously reduces in diameter toward the forward side. A forward end surface of the noble metal tip is located on a forward side with respect to a forward end surface of the holder.
    Type: Grant
    Filed: November 10, 2014
    Date of Patent: January 12, 2016
    Assignee: NGK SPARK PLUG CO., LTD.
    Inventors: Yasushi Sakakura, Yukinobu Hasegawa
  • Patent number: 9190814
    Abstract: A manufacturing method for manufacturing a spark plug including a rod-shaped center electrode extending in an axial direction, an insulator having a tubular shape having an axial hole and holding the center electrode in the axial hole, a metal shell having a tubular shape having an end surface and an inner peripheral surface, a gap being formed between a leading end side of the insulator and the inner peripheral surface, and a ground electrode welded to the end surface, the manufacturing method including welding the ground electrode to the end surface, and removing welding sag, which is formed inside the metal shell by the welding, by causing a tip end portion of a linear member to come into contact with the welding sag while rotating a tool in which a base end portion of the linear member is fixed.
    Type: Grant
    Filed: May 21, 2015
    Date of Patent: November 17, 2015
    Assignee: NGK Spark Plug Co., Ltd.
    Inventor: Itaru Kamada
  • Patent number: 9170175
    Abstract: A method for determining an optimum positioning zone of an ignition plug fitted with a semiconductor element in a combustion chamber is provided. The method includes: determining, using a test ignition plug, of an optimum fuel flow rate value intended to ensure optimum long-term operation of the ignition plug; successively measuring quantities of fuel collected at the surface of one end of a test tool positioned in the combustion chamber in successive test ignition tests; determining the fuel flow rate values corresponding to the measured quantities of fuel; comparing the fuel flow rate values and of the optimum fuel flow rate value, and determining the optimum positioning zone following the comparing.
    Type: Grant
    Filed: September 14, 2012
    Date of Patent: October 27, 2015
    Assignee: SNECMA
    Inventors: Luc Henri Chatenet, David Gino Stifanic
  • Patent number: 9065257
    Abstract: A method of manufacturing an electrode composite for forming an electrode of a spark plug, the electrode composite being formed by laser-welding a first electrode member and a second electrode member together.
    Type: Grant
    Filed: September 20, 2011
    Date of Patent: June 23, 2015
    Assignee: NGK SPARK PLUG CO., LTD.
    Inventors: Hiroshi Ichihara, Ryuji Emoto
  • Publication number: 20150145402
    Abstract: A spark plug includes a center electrode, a ground electrode, and a cylindrical metal shell. The ground electrode is welded to the metal shell via a weld portion. The weld portion is formed along the outer circumference end part of an annular part in the ground electrode. The weld portion has a plurality of melt extending parts extending toward the inner circumference side from the outer circumference end part of the annular part and aligned such that adjacent ones are connected to each other at the end part. The plurality of melt extending parts partially include smaller melt extending parts whose melting depth is smaller than others.
    Type: Application
    Filed: November 26, 2014
    Publication date: May 28, 2015
    Applicant: NGK SPARK PLUG CO., LTD.
    Inventors: Yukinobu HASEGAWA, Kei TAKAHASHI
  • Patent number: 9041275
    Abstract: In a spark plug, a center electrode includes a base member and a discharge chip that has a higher melting point than the base member. The base member and the discharge chip are joined to each other by both a weld and a diffusion layer. The weld is formed, by fusion welding, along an outer periphery of an interface between the base member and the discharge chip into an annular shape. The weld is made up of those parts of the base member and the discharge chip which are molten and mixed together during the fusion welding and solidified after the fusion welding. The diffusion layer is formed radially inside the annular weld. The diffusion layer is made up of those parts of the base member and the discharge chip which are diffused into each other across the interface between the base member and the discharge chip.
    Type: Grant
    Filed: June 9, 2014
    Date of Patent: May 26, 2015
    Assignee: DENSO CORPORATION
    Inventors: Nobuo Abe, Yuki Murayama
  • Patent number: 9041273
    Abstract: A corona igniter (20) for emitting a radio frequency electric field and providing a corona discharge (24) includes a central electrode (22) at a positive voltage, a grounded metal shell (30), and an insulator (28) with an abruption (34) extending radially outward relative to the central electrode (22). The abruption (34) is typically an increase of at least 15% of a local thickness (t) of the insulator (28) over less than 25% of a nose length (el) of an insulator nose region (74). The abruption (34) is typically one flank (82) of a protrusion or a notch, and the flank (82) faces the shell (30). The abruption (34) reverses the electric field and voltage potential gradient along the insulator outer surface (32), repels charged ions away from the insulator (28), and thus prevents the formation of a conductive path between the central electrode (22) and the shell (22).
    Type: Grant
    Filed: December 14, 2011
    Date of Patent: May 26, 2015
    Assignee: Federal-Mogul Ignition Company
    Inventors: John Antony Burrows, James D. Lykowski
  • Publication number: 20150130345
    Abstract: A ground electrode comprised of a noble metal tip having an outer circumferential surface, a holder having an inner circumferential surface defining a through hole for the noble metal tip thereon, and a body to which the holder is joined. At least one of a) the inner circumferential surface of the holder which forms the through hole, and b) the outer circumferential surface of the noble metal tip which is disposed in the through hole, continuously reduces in diameter toward the forward side. A forward end surface of the noble metal tip is located on a forward side with respect to a forward end surface of the holder.
    Type: Application
    Filed: November 10, 2014
    Publication date: May 14, 2015
    Applicant: NGK SPARK PLUG CO., LTD.
    Inventors: Yasushi SAKAKURA, Yukinobu HASEGAWA
  • Patent number: 9028289
    Abstract: An industrial spark plug (20) includes a central electrode (24) with a central base (30) formed of a nickel-based material and a central firing tip (32) formed of an iridium-based material. The central firing tip (32) has a tip thickness (tct) of 0.02 to 0.03 inches, a tip diameter (dct) of 0.1184 to 0.1776 inches, and an aspect ratio of 4.736 to 7.104. The central firing tip (32) is electron beam welded to the central base (30) to provide a robust joint therebetween. The central electron beam weld (36) includes a mixture of re-crystallized iridium-based material and re-crystallized nickel-based material extending continuously along and over the entire welding interface. The spark plug (20) also includes a ground electrode (26) with a ground firing tip (38) electron beam welded to a ground base (42).
    Type: Grant
    Filed: December 13, 2011
    Date of Patent: May 12, 2015
    Assignee: Federal-Mogul Ignition Company
    Inventors: Andrew Stamper, Gordon McIntosh, Raymond Bayer
  • Publication number: 20150111458
    Abstract: A composite ignition device includes a positive electrode having a tip formed thereon that is bonded to a first insulator to form a firing cone assembly. A second insulator having a negative capacitive element embedded therein is attached to the firing cone assembly. A positive capacitive element is disposed in the second insulator and is separated from the negative capacitive element by the second insulator. The positive capacitive element is coupled to the positive electrode. The positive and negative capacitive elements form a capacitor. A resistor is coupled to the positive capacitive element. An electrical connector is coupled to the resistor and attached to the second insulator. A shell including a negative electrode having a tip is attached to the second insulator and the firing cone assembly and coupled to the negative capacitive element. The negative electrode tip is spaced apart from the positive electrode tip.
    Type: Application
    Filed: December 29, 2014
    Publication date: April 23, 2015
    Inventor: Louis S. Camilli
  • Publication number: 20150102721
    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. The ceramic material of the firing tip (32, 34) includes at least one perovskite structure and/or at least one a spinel structure.
    Type: Application
    Filed: December 19, 2014
    Publication date: April 16, 2015
    Inventor: William J. Walker, JR.
  • Patent number: 9004969
    Abstract: A method of making a spark plug electrode includes several steps. One step includes providing an inner core of a ruthenium (Ru) based alloy or an iridium (Ir) based alloy. Another step includes providing an outer skin over a portion or more of the inner core in order to produce a core and skin assembly. The outer skin can be made of platinum (Pt), gold (Au), silver (Ag), nickel (Ni), or an alloy of one of these. Yet another step includes increasing the temperature of the core and skin assembly. And another step includes hot forming the core and skin assembly at the increased temperature.
    Type: Grant
    Filed: October 24, 2012
    Date of Patent: April 14, 2015
    Assignee: Federal-Mogul Ignition Company
    Inventor: Shuwei Ma
  • Patent number: 8994257
    Abstract: The spark plug has a configuration satisfying the relationships of B?0.7A and 0.3 mm?A?0.6 mm, where B is an axial thickness along the central axis line Q of the weld portion formed between the base material electrode and the noble-metal chip, and A is an axial distance along the central axis line Q between the intersection points P3 and X. The intersection point P3 is a point at which a phantom axis line radially distant from the central axis line Q by D/2 (D being a diameter of the noble-metal chip) intersects with the boundary line between the weld portion and the noble-metal chip. The intersection point X is a point at which an extension of the contour line of the base material electrode in the vicinity of the weld portion intersects with a boundary line between the weld portion and the base material electrode.
    Type: Grant
    Filed: February 28, 2013
    Date of Patent: March 31, 2015
    Assignee: Denso Corporation
    Inventors: Hiroya Ishiguro, Masaya Nakamura
  • Patent number: 8979606
    Abstract: A method of making an electrode material for use 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 ruthenium-based material that includes ruthenium as the single largest constituent. The disclosed method includes hot-forming a layered structure that includes a ruthenium-based material core, an interlayer having a refractory metal disposed over the ruthenium-based material core, and a nickel-based cladding disposed over the interlayer.
    Type: Grant
    Filed: June 20, 2013
    Date of Patent: March 17, 2015
    Assignee: Federal-Mogul Ignition Company
    Inventor: Shuwei Ma
  • Patent number: 8981633
    Abstract: A technique of reducing occurrence of multiple discharge in a spark plug. The spark plug has a main ground electrode and three auxiliary ground electrodes. The position at which first auxiliary ground electrode is joined to a metallic shell is located opposite the position at which main ground electrode is joined to the metallic shell, with respect to a center electrode. The positions at which second and third auxiliary ground electrodes are joined to the metallic shell are located opposite to each other with respect to the center electrode. When the width of first auxiliary ground electrode is represented by W, the shortest distance between second auxiliary ground electrode and third auxiliary ground electrode is represented by T, and a distance which is a component of the shortest distance T in a direction orthogonal to first auxiliary ground electrode is represented by Tp, a relation W?Tp is satisfied.
    Type: Grant
    Filed: March 7, 2012
    Date of Patent: March 17, 2015
    Assignee: NGK Spark Plug Co., Ltd.
    Inventors: Yasushi Sakakura, Yuichi Matsunaga
  • Publication number: 20150048733
    Abstract: 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: Application
    Filed: October 29, 2014
    Publication date: February 19, 2015
    Inventors: William J. Walker, JR., James D. Lykowski
  • Patent number: 8941385
    Abstract: A spark plug, including an insulator embedding a first metallic electrode axially extending therethrough from a high voltage outer end terminal to the center of the inner end of the insulator from which it protrudes; a metallic ground electrode isolated from the first electrode and having an extended inner termination facing toward the first electrode extending from the insulator tip for defining therebetween a spark gap, a resistive element connected to the ground electrode such that upon mounting the spark plug in an internal combustion engine, the ground electrode electrically connects to the engine body through the resistive element; and a second outer termination of the ground electrode, adapted to constitute an accessible sensing terminal.
    Type: Grant
    Filed: October 18, 2012
    Date of Patent: January 27, 2015
    Assignee: STMicroelectronics S.R.L.
    Inventors: Davide Giuseppe Patti, Mario Paparo, Domenico Rossi
  • Patent number: 8939808
    Abstract: A spark plug includes a ceramic insulator extending in the direction of an axis (CL1) and a metallic shell provided around the ceramic insulator. Talc is pressed charged between the ceramic insulator and the metallic shell and a crimp portion is formed for fixing the metallic shell and the ceramic insulator while the metallic shell having the ceramic insulator inserted thereinto is supported by a tubular receiving member. The receiving member is made movable in relation to a pressing jig in its radial direction. Thus, at the time of pressing of the talc, etc., the eccentricity between the center axis (CL2), (CL3) of the pressing jig and the axis (CL1) in the radial direction can be reduced, whereby the misalignment between the axis (CL1) and the center axis of the metallic shell or the like assembly error can be suppressed.
    Type: Grant
    Filed: November 11, 2011
    Date of Patent: January 27, 2015
    Assignee: NGK Spark Plug Co., Ltd.
    Inventors: Jiro Kyuno, Keiji Ozeki, Tomoaki Kato, Akiko Maruno
  • Publication number: 20150022074
    Abstract: A spark plug includes a center electrode, a ground electrode, and a ground-electrode-side tip joined to the ground electrode such that at least a portion of the tip along its thickness direction is embedded in the ground electrode. The ground-electrode-side tip is joined to the ground electrode through a fusion zone formed between the ground electrode and a proximal side of the tip. On a section containing a center axis of the ground electrode and in parallel with the thickness direction of the ground-electrode-side tip, E/F?1.1 is satisfied, where E (mm) is the longest distance along the thickness direction from an inner side of the ground electrode to a boundary between the fusion zone and the ground electrode, and F (mm) is the largest amount of embedment of the tip in the inner side surface along the thickness direction.
    Type: Application
    Filed: July 14, 2014
    Publication date: January 22, 2015
    Applicant: NGK SPARK PLUG CO., LTD.
    Inventors: Masahiro Inoue, Satoshi Nagasawa
  • Patent number: 8912713
    Abstract: A method of producing an electrode support for a spark plug is provided. The method includes providing the electrode support. The method includes brazing a chip to the electrode support.
    Type: Grant
    Filed: January 24, 2012
    Date of Patent: December 16, 2014
    Assignee: General Electric Company
    Inventor: Peter John DeSalvo
  • Publication number: 20140361679
    Abstract: In a spark plug, a center electrode includes a base member and a discharge chip that has a higher melting point than the base member. The base member and the discharge chip are joined to each other by both a weld and a diffusion layer. The weld is formed, by fusion welding, along an outer periphery of an interface between the base member and the discharge chip into an annular shape. The weld is made up of those parts of the base member and the discharge chip which are molten and mixed together during the fusion welding and solidified after the fusion welding. The diffusion layer is formed radially inside the annular weld. The diffusion layer is made up of those parts of the base member and the discharge chip which are diffused into each other across the interface between the base member and the discharge chip.
    Type: Application
    Filed: June 9, 2014
    Publication date: December 11, 2014
    Inventors: Nobuo ABE, Yuki MURAYAMA
  • Patent number: 8896194
    Abstract: A spark ignition device has a ceramic insulator surrounded by a metal shell. The metal shell extends along a longitudinal axis to a distal end. A center electrode is received in the ceramic insulator and extends along the longitudinal axis. A ground electrode has an attachment end fixed by a weld joint to the distal end of the shell and a free end extending from the distal end to provide a spark gap. The weld joint includes a capacitive pulse discharge weld joint and a laser weld joint, which in combination inhibit material expulsion; provide a reliable, strong attachment of the ground electrode to the shell; provide an improved heat transfer path between the ground electrode and the shell, and facilitate repeatable and accurate positioning of the ground electrode to the shell. The weld joint includes a homogeneous mixture of the metal shell and the ground electrode.
    Type: Grant
    Filed: March 22, 2012
    Date of Patent: November 25, 2014
    Assignee: Federal-Mogul Ignition Company
    Inventor: Frederick James Quitmeyer
  • Patent number: 8896192
    Abstract: A spark plug and manufacturing method. The spark plug (1) includes a metallic shell (3) extending along an axis CL1, a ceramic insulator (2), a center electrode (5), and a ground electrode (27) having a base end portion joined to a front end face (26) of the metallic shell (3). The method includes assembling the metallic shell (3) and a center electrode assembly (41); and joining the ground electrode (27) to the front end face (26). The distance between a reference plane SP perpendicular to the axis CL1 and the front end face (26) as measured along the axis CL1 varies in the circumferential direction. In the joining step, the position of the distal end portion of the ground electrode (27) relative to the front end portion of the center electrode assembly (41) along the axis CL1 is adjusted by changing the region of the front end face (26) to which the ground electrode (27) is joined.
    Type: Grant
    Filed: June 21, 2010
    Date of Patent: November 25, 2014
    Assignee: NGK Spark Plug Co., Ltd.
    Inventor: Tomoaki Kato
  • Patent number: 8890397
    Abstract: A corona igniter (20) includes a metal shell (32) with a corona reducing lip (38) spaced from an insulator (26) and being free of sharp edges (40) to prevent arcing (42) in a rollover region and concentrate the electrical field at an electrode firing end (48). The corona reducing lip (38) includes lip outer surfaces (88) being round, convex, concave, or curving continuously with smooth transitions (90) therebetween. The corona reducing lip (38) includes lip outer surfaces (88) presenting spherical lip radii (r1) being at least 0.004 inches. The corona igniter (20) also includes shell inner surfaces (104) and insulator outer surfaces (75) facing one another being free of sharp edges (40).
    Type: Grant
    Filed: May 26, 2011
    Date of Patent: November 18, 2014
    Assignee: Federal-Mogul Ignition Company
    Inventors: James Lykowski, Keith Hampton
  • Patent number: 8878424
    Abstract: A spark plug having an insulator that can be restrained from cracking in an environment of heating and cooling cycles. The spark plug includes an insulator having an axial bore extending in the direction of the axis, and a center electrode held in one end portion of the axial bore. The center electrode has an outer layer, and a core provided within the outer layer and formed from a material higher in thermal conductivity than the outer layer. After a heat treatment, the outer layer has a high-hardness region having a hardness of 190 Hv or higher and a thickness of 30 ?m to 200 ?m, and an element supply region having a thickness of 50 ?m or more.
    Type: Grant
    Filed: February 9, 2012
    Date of Patent: November 4, 2014
    Assignee: NGK Spark Plug Co., Ltd.
    Inventors: Daisuke Sumoyama, Tomoo Tanaka, Tsutomu Shibata
  • Patent number: 8878427
    Abstract: The spark plug has a configuration satisfying the relationships of B?0.7A and 0.3 mm?A?0.6 mm, where B is an axial thickness along the central axis line Q of the weld portion formed between the base material electrode and the noble-metal chip, and A is an axial distance along the central axis line Q between the intersection points P3 and X. The intersection point P3 is a point at which a phantom axis line radially distant from the central axis line Q by D/2 (D being a diameter of the noble-metal chip) intersects with the boundary line between the weld portion and the noble-metal chip. The intersection point X is a point at which an extension of the contour line of the base material electrode in the vicinity of the weld portion intersects with a boundary line between the weld portion and the base material electrode.
    Type: Grant
    Filed: February 28, 2013
    Date of Patent: November 4, 2014
    Assignee: Denso Corporation
    Inventors: Hiroya Ishiguro, Masaya Nakamura
  • Patent number: 8866369
    Abstract: A spark plug (20) for being threaded into a cylinder head (28) includes a shell (24) with threads (26) disposed at a predetermined angled relative to the ground electrode (34). The position of the threads (26) relative to the ground electrode (34) places the ground electrode (34) in a predetermined position in the combustion chamber (22) and relative to components of the engine, thus allowing the ground electrode (34) to provide a robust and reliable ignition. The threads (26) are formed by a thread forming apparatus (102) that includes an orientation tool (38) to position the ground electrode (34) relative to a thread forming apparatus (102), allowing the thread forming apparatus (102) to form the threads (26) at the desired angle (?).
    Type: Grant
    Filed: January 13, 2012
    Date of Patent: October 21, 2014
    Assignee: Federal-Mogul Ignition Company
    Inventors: Patrick M. Gfell, Donald R. Gregg, Kevin J. Kowalski
  • Patent number: 8860291
    Abstract: A spark plug having an integral gasoline combustion sensor is disclosed. The spark plug includes a center electrode assembly with a terminal stud at one end and a center electrode with a sparking surface at an opposite end; a generally tubular insulator surrounding the center electrode assembly; a shell surrounding the insulator and having along its length a turn-over on a first end, a barrel having an outer surface and barrel shoulder on a gasket flange thereof, a threaded portion, and a ground electrode; and a piezo sensor assembly located on the barrel shoulder proximate the outer surface of the barrel which includes a lower electrode contact, a piezo transducer, an upper electrode contact, an isolator having a convex upper surface, and an upper bushing which is attached to the barrel.
    Type: Grant
    Filed: October 29, 2008
    Date of Patent: October 14, 2014
    Assignee: Federal-Mogul Ignition Company
    Inventors: Benjamin L'Henoret, Jan Haag, John A. Burrows, Robin Clarke, Paul Tinwell
  • Patent number: 8860292
    Abstract: A spark plug and a method of forming the same. The spark plug having a rod-shaped center electrode extending in an axial direction, a tubular insulator having an axial hole and holding the center electrode in the axial hole, a tubular metallic shell having an end surface, an inner circumferential surface, and a gap formed between the inner circumferential surface and a forward end portion of the insulator, and a ground electrode welded to the end surface. A method of manufacturing the spark plug includes a welding step of welding the ground electrode to the end surface; and a shaping step which is performed after the welding step so as to form the inner circumferential surface, through shaping, on the metallic shell having the ground electrode welded to the end surface thereof.
    Type: Grant
    Filed: February 10, 2014
    Date of Patent: October 14, 2014
    Assignee: NGK Spark Plug Co., Ltd.
    Inventor: Tomoki Kawai
  • Patent number: 8853924
    Abstract: A spark ignition device, metal shell, and methods of construction are provided. The spark ignition device has a ceramic insulator extending along a longitudinal axis and a metal shell. The metal shell extends along the longitudinal axis to a distal end. A center electrode is received in the ceramic insulator and extends along the longitudinal axis. A ground electrode has an attachment end fixed by a weld joint to the distal end of the shell and a free end extending from the distal end to provide a spark gap. The weld joint includes a resistance weld joint and a laser weld joint, which in combination inhibit material expulsion; provide a reliable, strong attachment of the ground electrode to the shell; provide an improved heat transfer path between the ground electrode and the shell, and facilitate repeatable and accurate positioning of the ground electrode to the shell.
    Type: Grant
    Filed: March 31, 2010
    Date of Patent: October 7, 2014
    Assignee: Federal-Mogul Ignition Company
    Inventor: Frederick J. Quitmeyer
  • Patent number: 8853928
    Abstract: A spark plug includes at least one of a center electrode or a ground electrode that is produced by the steps of: mixing a matrix metal with carbon so that the carbon content of the resultant mixture is adjusted to 80 vol. % or less; subjecting the mixture to powder compacting or sintering, to thereby form a core; placing the core in a cup formed of nickel or a metal containing nickel as a main component; and subjecting the cup to cold working. The thus-produced electrode exhibits favorable thermal conductivity and good heat dissipation, by virtue of the small difference in thermal expansion coefficient between the core and an outer shell. The spark plug including the above electrode exhibits excellent durability.
    Type: Grant
    Filed: August 24, 2011
    Date of Patent: October 7, 2014
    Assignee: NGK Spark Plug Co., Ltd.
    Inventors: Tomo-o Tanaka, Tsutomu Shibata, Takaaki Kikai
  • Patent number: 8853930
    Abstract: An ignition plug that reliably restrains generation of corona discharge for enhancing accuracy in detection of ionic current and method of manufacturing same. The ignition plug is configured such that a metallic shell and an insulator are fixed together by means of a crimped portion provided at a rear end portion of the metallic shell and bent radially inward. An electrically insulative filling member fills a space formed between the crimped portion and the insulator. The filling member covers at least a portion of an outer circumferential surface of a rear trunk portion of the insulator along the entire circumference and the entirety of a rear end surface of the metallic shell, which is a portion of the outer surface of the crimped portion and is visible from the rear side with respect to the direction of an axial line CL1.
    Type: Grant
    Filed: January 14, 2014
    Date of Patent: October 7, 2014
    Assignee: NGK Spark Plug Co., Ltd.
    Inventors: Tatsunori Yamada, Naofumi Yamamura, Kenji Ban
  • Publication number: 20140292178
    Abstract: A spark plug includes: a center electrode, a ground electrode, which is side-mounted on the center electrode, and a noble metal insert, which is situated on the center electrode. The noble metal insert is situated in a cutout provided in a base material of the center electrode and connected in a continuous material to the base material of the center electrode. The noble metal insert is directed with one surface towards the side-mounted ground electrode.
    Type: Application
    Filed: August 2, 2012
    Publication date: October 2, 2014
    Inventors: Detlef Hartmann, Andreas Benz
  • Patent number: 8841828
    Abstract: A spark plug has a center electrode having an electrode base member and a core material which is disposed in the electrode base member and which predominantly contains copper, and a noble metal tip disposed at a forward end of the center electrode, and a fusion portion formed between the noble metal tip, and the electrode base member and the core material. The fusion portion is in contact with the core material in a cross section which is parallel to the center axis of the center electrode and which passes through the center axis and the fusion portion. The fusion portion contains a component of the noble metal tip, a component of the electrode base member, and a copper component forming the core material.
    Type: Grant
    Filed: June 8, 2012
    Date of Patent: September 23, 2014
    Assignee: NGK Spark Plug Co., Ltd.
    Inventors: Tomoyuki Igarashi, Ryuichi Ohno, Tatsunori Yamada, Katsutoshi Nakayama
  • Publication number: 20140265813
    Abstract: A spark plug having a metal shell, an insulator, a center electrode, a ground electrode, and a multi-layer sparking component. The multi-layer sparking component is attached at a firing end of the ground electrode and includes a thin precious metal layer formed overtop a base metal layer and, according to some embodiments, overhangs the end of the ground electrode. The precious metal and base metal layers may be pre-manufactured together as a bi-metal ribbon, sheet or laminate before the multi-layer sparking component is attached to the ground electrode.
    Type: Application
    Filed: March 7, 2014
    Publication date: September 18, 2014
    Inventors: Kevin J. Kowalski, Frederick J. Quitmeyer, Nathan A. Thomson, Curtis W. Verhoff, Richard L. Keller
  • Publication number: 20140265812
    Abstract: A method of manufacturing an electrode material for use in spark plugs and other ignition devices. The electrode material may be manufactured into a desirable form by hot-forming a layered structure that includes a ruthenium-based material core, an iridium-based interlayer disposed over an exterior surface of the ruthenium-based material core, and a nickel-based cladding disposed over an exterior surface of the iridium-based material interlayer. The elongated layered wire produced by the hot-forming then has its nickel-based cladding removed to derive an elongated electrode material wire that includes the ruthenium-based material core encased in the iridium-based material. The elongated electrode material wire can be used to make many different spark plug/ignition device components.
    Type: Application
    Filed: February 28, 2014
    Publication date: September 18, 2014
    Applicant: FEDERAL-MOGUL IGNITION COMPANY
    Inventor: Shuwei Ma
  • Publication number: 20140265814
    Abstract: A spark plug has a metal shell, an insulator, a center electrode, and a ground electrode. One or more firing tips can be attached to the center electrode, to the ground electrode, or to both electrodes. The metal shell and ground electrode are attached together by way of one or more laser keyhole welds at an interface of the shell and electrode. Before the laser keyhole welds, resistance welding can be executed for a temporary attachment.
    Type: Application
    Filed: March 11, 2014
    Publication date: September 18, 2014
    Inventor: Frederick J. Quitmeyer