Abstract: A method of manufacturing for a spark plug (82) having a center electrode (80) and a side wire electrode (62) with a sphere of platinum (34, 68) mechanically retained in a cylindrical hole (34, 66) by an annular rib (40, 70) formed by a staking operation. Thereafter a force is applied that flattens the sphere (34, 66) to produce a disc (48, 72) which substantially covers the annular rib (40, 70) from exposure to the corrosive effects of gases in a combustion chamber.

Abstract: An improved method for manufacturing a spark plug electrode having a substrate formed from a first metal and a spark gap surface area formed from a second metal, such as a precious metal. The spark gap surface area is formed by heating the portion of the first metal at which the spark gap surface is to be formed with a plasma arc and applying the second metal as a consumable welding electrode, cooling the first metal and the applied second metal, and, optionally, shaping the second metal to form a desired surface configuration.

Abstract: A method of manufacturing electrodes for a spark plug (82) whereby a set gap "g" between the tip (12) of a center electrode (80) and a side electrode (62) is substantially uneffected by the exposure to combustive gases in an engine. The center 34 of the tip of the center electrode (80) and center of the side wire (62) are located by a mark. A first sphere (36) of platinum is placed in a fixture and the center (34) on the tip of the center electrode (80) aligned over the first sphere (36). Pressure is applied to the center electrode (80) while electrical current is applied thereto. Thermal energy created at the junction of the axial center (34) and first sphere (36) causes the inconel material in the center electrode (80) to flow and surround the sphere of platinum (36). The side electrode (62) is attached to the metal shell (60) and a second sphere (36') of platinum is similarly metalurgically bonded thereto. The center electrode (80) is placed in a ceramic insulator (30) and retained in a metal shell (60).

Abstract: In a center electrode structure for spark plug including a tublar insulator, the inner side of which has a stepped shoulder to provide a diameter-reduced bore therein; a center electrode having a flange, and concentrically placed into the insulator with the flange engaging against the shoulder, and with one end being axially through the bore so as to be exposed to outside of the insulator; the center electrode having an electrically conductive core of copper or copper-based alloy which is encased into an enclosure made of oxidation and heat resistant nickel-based alloy; and the core being provided with a number of fractures in its granular structure so as to absorb thermal stress due to the thermal expansional difference between the core and enclosure.

Abstract: This process consists in introducing a copper slug (5) into a nickel cup (1), extruding the cup-and-slug assembly and shaping it to produce a bimetallic electrode. It is characterized in that before the introduction of the said copper slug into the cup, a platinum point (2) is fixed onto the nickel cup (1). The invention applies to electrodes for electrical ignition plugs for heat engines.

Abstract: At least one of center and ground electrodes of a spark plug has a thin layer formed by bonding noble metal powder on a discharge-related surface area of the electrode stock of said at least one of said center and ground electrodes in accordance with ultrasonic bonding. Instead of the thin layer, a discharge tip may be formed there by boring a hole in the electrode stock, filling noble metal powder, which has been obtained by coating spherical or flaky metal particles with a corresponding noble metal or noble metal alloy, in the hole and then bonding the thus-filled noble metal powder in accordance with ultrasonic bonding. As a further alternative, a tip made of a noble metal or an alloy thereof may be bonded by ultrasonic bonding or resistance welding in the hole with a layer of metal powder of a metal having good high-temperature erosion resistance or an alloy thereof interposed therebetween. The spark plug enjoys a long operating life.

Abstract: A method and apparatus for constructing an electrical contact including welding means for welding a base element to a blank comprised of contact facing material, separating means for separating finished electrodes from the balance of the contact facing material, examining means for examining an aperture formed within the contact material blank when the finished electrode is separated from the blank, and classifying means for classifying the finished electrode as acceptable or unacceptable depending upon the examination.

Abstract: In a spark plug with center electrode and body electrode in which the cylindrical center electrode comprises in its end face a blind bore in which a pin-shaped small-volume noble metal insert is inserted and fixed by upsetting, it is provided that the front region (1a) of the center electrode (1), provided with end-side bore (2) and insert (3) disposed therein, is reduced radially over almost the entire length of the bore (2), the reduced region (1a) having a constant diameter, and that a further pin-shaped small-volume noble metal insert (5) is fixed in a bore (4) formed coaxially with the bore (2) in the body electrode (6). The production of the spark plug can proceed from commercially usual spark plug parts made on conventional production machines; the noble metal insert of the spark plug is securely attached in the center electrode and the body electrode part opposite the noble metal insert has a reduced burnup, thus increasing the life of the spark plug.

Abstract: A method of manufacturing an electrode (20) for a spark plug (32) wherein a platinum cup member or (54) cap is attached to a tip (12) that extends from an extruded inconel body (10). The inconel body (10) is sequentially extruded from a cylindrical blank to produce a tip (12) on a first end (12) and a cup shaped (16) opening that extends from a second end (14) toward the first end (12). A copper core (18) is inserted into the cup (16) and the cylindrical blank (10) thereafter extruded to a substantially final length for the resulting center wire (20). In order to assure a uniform thickness, a source of platinum (38) is roller into a thin strip and a (44) disc is punched therefrom. The disc (44) is formed into a cap member (54) which has the shape of a cup . The resulting cap member (54) and center wire (20) are placed in a fixture and the cap member (54) is moved toward the center wire (20) until the cap member surrounds the tip (12).

Abstract: A spark plug for internal combustion engines provided with a noble metal tip on the pointed top of a spark plug center electrode. The noble metal tip is welded to the center electrode top end by heating and pressing the portion to be welded. After the welding, the center electrode is shaped to provide the pointed top. The noble metal tip is a platinum alloy consisting of platinum of 85 through 70 in weight percentage and iridium of 15 through 30 in weight percentage.

Abstract: The present invention relates to a composite spark plug center electrode having a sparking tip composed of a precious or semi-precious metal and a method for producing same is disclosed. A right circular cylindrical billet of a corrosion-resistant material is initially formed into a cylindrical cup having an opened end and a closed end. A small conical recess may be formed in the center of the exterior of the closed end during the formation. A hole is next formed in the closed end of the cup. A right circular cylindrical billet of a high thermal conductivity material is next inserted within the opened end of the cup and pressed to fit tightly against the sidewall and bottom of the cup cavity to form a composite billet. An insert formed of a precious or semi-precious metal is then inserted within the hole and pressed to fit tightly therein. The opened end of the cup is formed inwardly to partially encase the billet therein.

Abstract: An improved method for fabricating electrode structures, particularly flame-front sensors, spark plugs and the like, wherein the center electrode, the insulating housing therefor, and an outer housing are dimensioned such that a small clearance space is provided between each of the parts; a fluid glue is inserted in the clearance or spacing provided in a fixation zone at one end of the structure by capillary action, so that the device is self-centering and heat sealed and not more than 3 mm in diameter, thus facilitating quick and easy installation in engine cylinder heads and combustion chambers.

Abstract: A method of and apparatus for forming a pressed body (54) with a bore (56) therein and with a notch (58) in the exterior surface thereof. The body (54) is formed by isostatically pressing particulate material (52) in an elastic mold (14) so that the material (52) is compacted into a self-supporting mass. Used in conjunction with the elastic mold is a mold closure and core holder member (32) to which is fixed a rigid core (42) and a resilient notch defining bar (44).

Abstract: A method for assembling a spark plug 20, 66 which includes providing a ground electrode 24 on a spark plug shell 22 having a predetermined final configuration and position and then mounting an insulator 34 in the shell. The distance from a step 38 in an insulator bore 37 to the ground electrode is measured. Based upon this measurement and a desired dimension for a spark gap 56, the dimension on a center electrode 48, 68, 74 between a shoulder 50, 76 and a tip 52, 80 is adjusted so that when the center electrode is disposed in the insulator bore with the shoulder seated on the bore step, the tip forms the desired spark gap with the ground electrode. The center electrode then is assembled into the insulator.

Abstract: A method of producing bimetal electrodes in which a core of copper is enclosed within an outer covering of a nickel alloy. The alloy is extruded into a relatively small diameter, deep cup by first forming a cylindrical blank with a rounded indentation in one face and thereafter extruding the cup using a punch having an end conforming with said indentation to form a central opening having a diameter at least three times the diameter of the punch. A cylindrical copper core is then firmly seated within the cup, which is then extruded by two stages to form an elongated, cylindrical blank. In one embodiment, the end is finished by trimming away a flaring skirt portion at the open end and thereafter upsetting the blank. In another embodiment, the flared skirt portion of the nickel alloy is bottled inwardly and pressed flat against the exposed end of the core so that no scrap is produced.

Abstract: An assembly machine is disclosed in which a slug of one metal is inserted and staked in a cup formed of another metal. During the staking operation, the shape of the slug and the cup is altered by forming loads thereon. Cups are fed to an assembly position through a plurality of feed chutes which supply the cups to a shuttle. The shuttle operates to alternately receive cups from one feed chute and then the other and to position such cups at an assembly position. A cutter cuts slugs from wire stock and delivers the slugs to the assembly position, where the slugs are inserted in the cups and staked in place. The shuttle operates at a cyclic speed equal to one-half the cyclic speed of the cutter so that the total output of the apparatus is substantially higher than the cyclic operating speed of the shuttle. A combined stock gauge and staking tool is carried by the cutter and the cutter forcibly removes the assembled cup and slug from the assembly position.

Abstract: A method of making a bimetal electrode for spark plugs on a single progressive header starts with a cylindrical bimetal blank having a diameter substantially equal to that of the finished electrode, with a core of high temperature-resistant metal and an outer layer of highly thermally conductive material, with the outer layer comprising substantially one-third of the material of the blank. In progressive operations, the blank is coned and then headed to a diameter so that the core at the headed portion has a diameter greater than that of the blank. A shearing operation then shears the outer portion of the headed portion and the thermally conductive material away to leave an end for the firing tip having a diameter equal to that of the rest of the blank but consisting essentially of the temperature-resistant core material.

Abstract: A protector module (30) for protecting tip and ring conductors of a telephone loop includes a pair of protector assemblies (40-40') which are supported within a common housing (32). A voltage protection subassembly (42) of each protector assembly is connected electrically to a grounding subassembly (44) for causing current associated with excessive voltage surges to be conducted to ground. Each protector assembly also includes a current protection subassembly (41) which comprises a dielectric base and a line pin (61) and a central office pin (57) with the line and central office pins being connected together electrically to establish electrical contact between a conductor of the circuit and its protector assembly. A shunting element (62) is disposed concentrically about the line pin and is releasably secured to one end of the line pin in an initial position by a fusible bonding material.

Abstract: A method of producing bimetal electrodes is disclosed in which a core of one metal is positioned within a cup of another metal so that the core is recessed back from the open end of the cup. In two embodiments, where the core is fully encapsulated, the open end of the cup is initially bottled or bent inward and subsequently the assembly is pressed through an extrusion die with a tool having a nose with an area substantially equal to the area of the core. In one such embodiment, a weld lug is produced by said tool during the extrusion. Such tool completes the closing of the open end of the cup to fully encapsulate the core and applies the principal extrusion force through the closed end to the core and from the core to the forward end or originally closed end of the cup. Subsequently, the extruded part is trimmed and additionally worked as required. In another embodiment, similar tooling is provided to produce an electrode in which the core is not fully encapsulated.

Abstract: A fuel ignition plug (10) includes an outer electrode (12) defined by a conductive shell which surrounds a central electrode (28) and an insulator body (22) between the central electrode (28) and outer electrode (12). Fused glass powder seals (40,42) between the shell and the insulator body (22), and between the insulator body (22) and the central electrode (28), prevent combustion gasses from passing through the interior of the device (10). The device (10) is assembled by holding the electrodes (12,28) and insulator body (22) in fixed, concentric relationship with each other while the seals (40,42) are heated and extruded into sealing position against a shoulder (38,52) of the insulator body (22). The seals (40,42) are extruded into sealing position by applying force to push rings (44,46) which are respectively sleeved over the insulator body (22) and central electrode (28) and bear against the seals (40,42).

Abstract: A method for producing a composite spark plug electrode is disclosed. The method comprises forming a first metal into a cup having an open end, a closed end and a wall surrounding a central opening which extends a distance z from the closed end to the open end. The method also comprises forming, from a second and different metal, a right circular cylindrical core sized to be received in the central opening in close fitting relationship with the wall therearound, and extending from the closed end toward the open end a distance less than z, and positioning the core in the central opening, thereby forming a composite billet having first and second ends corresponding, respectively, with the open and closed ends of the cup. Finally, a portion of the composite billet is extruded, second end first, through an extrusion orifice of a die with a force applied to the first end of the composite billet by an end of a tool.

Abstract: To securely seat a ceramic electrode (23, 28) in an insulator (15) of a spark plug, so that it can be sintered together with the insulator, a ceramic plug element (28) has added thereto an additive which renders the ceramic plastically deformable upon application of external energy; the additive may, for example, be a thermoplastic, which permits plastic deformation upon application of heat; or a thixotropic agent, such as glycerin, rendering the material plastically deformable when vibrated. A pellet or plug (28) is introduced into the end portion (32) of the central opening (21) of the insulator, preshaped to be slightly smaller by, for example, 0.2 mm, than the clearance opening in the insulator. The plug is then rendered plastically deformable, compressed by a plunger (34/1) acting against a counter plate (33).

Abstract: A method of making a tubular electrical insulator assembly for an igniter plug comprising the steps of making a recess (11) in one end of a tubular insulator (10); cementing a portion of a tubular semi-conductor (20) into the recess (11) so that the remaining portion of said semi-conductor (20) extends slightly beyond the end of said insulator (10); and grinding an annular chamfer (21) into the ends of the insulator (10) and semi-conductor (20).

Abstract: The present invention relates to a process for manufacturing an ignition device or connector for an internal combustion engine and the ignition device or convection obtained by such process. The ignition convector, in use, creates a plasma for igniting lean mixtures. Said device an insulator 2 containing a central electrode 3 and a metal shell 4, in which the insulator is fixed. The ground electrode of conventional spark-plugs is replaced by a circular capsule 17 welded to the shell base, after having been subjected to a hard chromizing treatment. The shell comprises an annular recess 14 provided in the thickness of its wall, and is welded to the ceramic insulator 2 by brazing.

Abstract: The combination of a frame and an igniter body secured in an opening passing through opposed sides of the frame so that an igniter electrode carried by the igniter body projects beyond one of the sides of the frame and a lead of the igniter electrode extends beyond the other of the sides of the frame. The igniter body is a one-piece member having an integral medial shoulder abutting against the other side of the frame. A fastening member engages the one side of the frame and is operatively interconnected to the ingniter body to hold the shoulder thereof against the other side of the frame.

Abstract: A plier (35, 36) of which the jaws are provided with claws (38, 39) of electrically good conductor metal, threaded in a complementary way to that of the threaded portion (10) of the cap (4) of the device (1), grips the device (1) by that threaded portion (10) of the cap (4) while strongly pressing the capsule (17) on the threaded end (10) of the cap (4) and heating those parts by Joule effect. The plier rests on a portion (26) which rests itself on the frame (25) of the machine. Hence, the insulating portion of ceramic material (2) of the device is not subjected to any stress due to the pressure exerted during such welding operation.

Abstract: An electrical ignition probe having an electrode wire provided with a sparking end and an opposed end spliced to an end of an ignition wire that has electrical insulation thereon and disposed inboard of the end of the ignition wire, the probe having a rigid electrically insulating body provided with opposed ends and telescoped on the electrode wire in such a manner that the opposed ends of the body are respectively disposed inboard of the ends of the electrode wire, and an electrically insulating unit overlapping adjacent parts of the body and the electrical insulation on the ignition wire to electrically insulate the spliced ends of the electrode wire and the ignition wire. The insulating unit comprises a rigid electrically insulating tubular member having opposed ends and an opening passing through the opposed ends thereof and telescopically receiving the spliced ends and the adjacent parts of the electrode wire and the ignition wire therein.

Abstract: An electrical ignition probe having an electrode provided with a sparking end and an opposed end interconnected to an end of an ignition wire, the probe having a rigid electrical insulating one-piece body provided with opposed ends interrupted by a bore passing through the body. The body is telescoped on part of the electrode and part of the ignition wire so that the ignition wire extends from one end of the body and the sparking end of the electrode extends from the other end of the body whereby the interconnected ends of the electrode and the ignition wire are disposed in the bore of the body intermediate the ends thereof. The bore in the insulating body is substantially uniform in its cross-sectional configuration and size throughout the entire length of the insulating body.

Abstract: A spark plug with a spark electrode prepared by mixing at least a matrix material of a titanium compound (e.g., TiO.sub.2, TiC, TiN, etc.) with an electrical conductivity-imparting substance (e.g., Pt and Pd, or a mixture of Pt, Pd and a noble metal, e.g., Au, Ru, Ag, Rh, etc.) and sintering the resulting mixture.

Abstract: A spark plug with a rivet-like tip center discharge electrode is obtained by melting powdery metal essentially consisting of noble metal Au, Ag and/or alloys thereof with Pd or the like charged in a small end bore formed at a discharge end bottom of a ceramic insulator then allowing to cool. Sealing and/or resistor incorporation together with setting (sealing) of a terminal rod may be done one-stepwise with the center electrode formation or two-stepwise after the center electrode formation. A resultant space in the center bore may be utilized for various purposes.

Abstract: A spark plug center electrode comprises a core of material having good thermal conductivity surrounded by a sheath of corrosion resisting material. During manufacture of the electrode, the core is joined to the sheath by means of a welded joint which extends only over the zone of the inner basal surface of the sheath part.

Abstract: A spark plug with a sphere-like center discharge electrode is obtained by pressing a sphere-like metal essentially consisting of noble metal Au, Ag and/or alloys thereof with Pd or the like set on a small end bore formed at a discharge end bottom of a ceramic insulator. Sealing of a sealing material and/or resistor material together with setting (sealing) of a terminal body may be done simultaneously with the pressing of the sphere-like metal on the small end bore by means of hot-pressing applied on the terminal rod head.

Abstract: An igniter plug having a center electrode and annular electrode with an air gap therebetween is provided having a nickel coating on the tungsten electrode and a portion of the supporting pin therefor, and a collar situate within a portion of the annular electrode to retain a ceramic sleeve within the air gap.

Abstract: The combination of an igniter body and an outer target bracket that has a target electrode disposed in spaced relation to an igniter electrode carried by the igniter body to define a spark gap therewith and that has a mounting portion for securing the bracket to a frame adjacent the igniter body to provide the spark gap, the target bracket having holding tabs holding the igniter body therein to provide a self-contained assembly that can be subsequently secured as a single unit to the frame by the mounting portion of the target bracket. The target bracket has slots therethrough defining opposed surfaces of the target bracket and respectively receiving abutments of the igniter body therethrough, the tabs respectively being engageable with the abutments and defining one of the opposed surfaces of the bracket.