[go: up one dir, main page]
More Web Proxy on the site http://driver.im/

USRE38536E1 - Spark plug and method of producing the same - Google Patents

Spark plug and method of producing the same Download PDF

Info

Publication number
USRE38536E1
USRE38536E1 US10/023,157 US2315701A USRE38536E US RE38536 E1 USRE38536 E1 US RE38536E1 US 2315701 A US2315701 A US 2315701A US RE38536 E USRE38536 E US RE38536E
Authority
US
United States
Prior art keywords
spark
spark plug
electrodes
layer
resistant material
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Fee Related
Application number
US10/023,157
Inventor
Alexander Reznik
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
DAY ALLOYING LLC
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Priority to US10/023,157 priority Critical patent/USRE38536E1/en
Application granted granted Critical
Publication of USRE38536E1 publication Critical patent/USRE38536E1/en
Assigned to DAY ALLOYING L.L.C. reassignment DAY ALLOYING L.L.C. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: REZNIK, ALEXANDER
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

Links

Images

Classifications

    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01TSPARK GAPS; OVERVOLTAGE ARRESTERS USING SPARK GAPS; SPARKING PLUGS; CORONA DEVICES; GENERATING IONS TO BE INTRODUCED INTO NON-ENCLOSED GASES
    • H01T13/00Sparking plugs
    • H01T13/20Sparking plugs characterised by features of the electrodes or insulation
    • H01T13/39Selection of materials for electrodes
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01TSPARK GAPS; OVERVOLTAGE ARRESTERS USING SPARK GAPS; SPARKING PLUGS; CORONA DEVICES; GENERATING IONS TO BE INTRODUCED INTO NON-ENCLOSED GASES
    • H01T21/00Apparatus or processes specially adapted for the manufacture or maintenance of spark gaps or sparking plugs
    • H01T21/02Apparatus or processes specially adapted for the manufacture or maintenance of spark gaps or sparking plugs of sparking plugs

Definitions

  • the present invention relates generally to spark plugs and methods of producing the spark plugs.
  • a spark plug for internal combustion engine usually has a center electrode and another ground electrode, which upon supplying of an electrical potential generate a spark for igniting fuel in an internal combustion engine. Since the ignition is performed many thousand times due to an electrical discharge at the electrodes, the electrodes are subjected to erosion which reduces their service life. In order to increase the service life, it was proposed to apply reinforcing materials on the facing surfaces of the electrodes by the range of different techniques. Some techniques require sophisticated equipment and control, following shaping electrode tips into final configuration (attaching by welding small reinforce metal pieces to electrode ends, inserting metal wire in a hole of central electrode tip, plasma welding technique, etc.).
  • a spark plug which includes at least two electrodes producing a spark by an electrical discharge and having ends facing toward one another, wherein an additional layer of the material, in particular tungsten, is applied on the ends of the electrodes facing toward one another by electro-spark deposition.
  • the spark plugs When the spark plugs are formed in accordance with the present invention, their erosion resistance and therefore their service life is substantially increased.
  • the layer produced on the facing surfaces of the electrodes is finally shaped and its bonding to the electrodes is strong due to the diffusion.
  • the diffusion transient zone has linear coefficient of expansion between such of the erosion resistant layer and an electrode material. Thereby, heat stresses that occur on a border between layer and electrode body during the spark plug operation will relieve.
  • a method of producing the spark plug is proposed, in accordance with which at least two electrodes are made, and then an additional layer is applied on the end of each electrode facing the other electrodes, the layer composed of tungsten and applied by electro-spark deposition, so that a reliable diffusion bonding is provided between the coating and the spark plug electrode material and heat stresses that occur on a border between the layer and the electrode body during the spark plug operation will be relieved.
  • FIGURE of the drawings is a view showing a spark plug in accordance with the present invention.
  • a spark plug in accordance with the present invention is identified as a whole with reference numeral 1 . It has a central electrode 2 and an additional ground electrode 3 . The electrodes are arranged so that their ends face one another. When electric potential is applied to the spark plug, a discharge is produced between the facing ends or tips of the electrodes, and generates a spark which ignites a fuel of an internal combustion engines.
  • sparks plugs are generally known in the art, and therefore additional elements of the spark plugs, such as insulators, casing, etc. are not shown in the drawings.
  • an erosion-resistant layer is applied by electro-spark deposition on an end or a tip of each electrode which faces an end or a tip of another electrode.
  • the tips or the faces of the electrodes facing one another are covered with the additional layers of tungsten 3 2 ′, 3 ′, the layers are reliably bonded to the corresponding electrodes, and the heat stresses that occur on a border between the layer and the electrode body during the spark plug operation will be relieved. Since the layer is erosion-resistant, the service life of the electrodes is substantially increased.
  • the deposited layer can have a thickness of 10-50 ⁇ m.
  • the transient zone formed due to diffusion of the layer material into the substrate of the spark plug electrode relieves heat stresses on the border between the layer and the electrode body during the spark plug operation. Following machining is not needed after the electro-spark deposition.

Landscapes

  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Spark Plugs (AREA)

Abstract

A spark plug has at least two electrodes having ends facing toward one another so as to produce an electrical discharge when an electrical potential is applied to said electrodes, and a layer of an erosion-resistant material applied on each of said electrodes by electro-spark deposition so the lifetime of the spark plug comparing to existing is substantially increased.

Description

BACKGROUND OF THE INVENTION
The present invention relates generally to spark plugs and methods of producing the spark plugs.
A spark plug for internal combustion engine usually has a center electrode and another ground electrode, which upon supplying of an electrical potential generate a spark for igniting fuel in an internal combustion engine. Since the ignition is performed many thousand times due to an electrical discharge at the electrodes, the electrodes are subjected to erosion which reduces their service life. In order to increase the service life, it was proposed to apply reinforcing materials on the facing surfaces of the electrodes by the range of different techniques. Some techniques require sophisticated equipment and control, following shaping electrode tips into final configuration (attaching by welding small reinforce metal pieces to electrode ends, inserting metal wire in a hole of central electrode tip, plasma welding technique, etc.). Other processes apply a layer of reinforcing material by sputtering or coating methods which can not provide reliable bonding between the electrode substrate and the layer material at high temperature spark plug operating conditions and could result in failure of a spark plug. Most of techniques use precious metals as a reinforcing material, which have extremely high cost. Some spark plugs of the above mentioned general type are disclosed in U.S. Pat. Nos. 3,673,452, 4,810,220, 4,881,913, 5,179,313, 5,456,624; 5,779,842; etc.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a spark plug and a method of producing the same which avoids the disadvantages of the prior art.
In keeping with these objects and with others which will become apparent hereinafter, one feature of present invention resides, briefly stated, in a spark plug which includes at least two electrodes producing a spark by an electrical discharge and having ends facing toward one another, wherein an additional layer of the material, in particular tungsten, is applied on the ends of the electrodes facing toward one another by electro-spark deposition.
When the spark plugs are formed in accordance with the present invention, their erosion resistance and therefore their service life is substantially increased. The layer produced on the facing surfaces of the electrodes is finally shaped and its bonding to the electrodes is strong due to the diffusion. The diffusion transient zone has linear coefficient of expansion between such of the erosion resistant layer and an electrode material. Thereby, heat stresses that occur on a border between layer and electrode body during the spark plug operation will relieve.
In accordance with another feature of present invention, a method of producing the spark plug is proposed, in accordance with which at least two electrodes are made, and then an additional layer is applied on the end of each electrode facing the other electrodes, the layer composed of tungsten and applied by electro-spark deposition, so that a reliable diffusion bonding is provided between the coating and the spark plug electrode material and heat stresses that occur on a border between the layer and the electrode body during the spark plug operation will be relieved.
The novel features which are considered as characteristic for the present invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The single FIGURE of the drawings is a view showing a spark plug in accordance with the present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
A spark plug in accordance with the present invention is identified as a whole with reference numeral 1. It has a central electrode 2 and an additional ground electrode 3. The electrodes are arranged so that their ends face one another. When electric potential is applied to the spark plug, a discharge is produced between the facing ends or tips of the electrodes, and generates a spark which ignites a fuel of an internal combustion engines. These sparks plugs are generally known in the art, and therefore additional elements of the spark plugs, such as insulators, casing, etc. are not shown in the drawings.
In accordance with the present invention, an erosion-resistant layer is applied by electro-spark deposition on an end or a tip of each electrode which faces an end or a tip of another electrode. In accordance with the present invention For example, the tips or the faces of the electrodes facing one another are covered with the additional layers of tungsten 3 2′, 3′, the layers are reliably bonded to the corresponding electrodes, and the heat stresses that occur on a border between the layer and the electrode body during the spark plug operation will be relieved. Since the layer is erosion-resistant, the service life of the electrodes is substantially increased.
The deposited layer can have a thickness of 10-50 μm. The transient zone formed due to diffusion of the layer material into the substrate of the spark plug electrode relieves heat stresses on the border between the layer and the electrode body during the spark plug operation. Following machining is not needed after the electro-spark deposition.
It is believed to be clear that other materials can be used for forming the erosion-resistant layers on the tips or facing ends of the electrode, for example platinum, etc.
It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of constructions and methods differing from the types described above.
While the invention has been illustrated and described as embodied in spark plug and method of producing the same, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention.
What is claimed as new and desired to be protected by letters patent is set forth in the appended claims:

Claims (27)

What is claimed is:
1. A spark plug comprising
two electrodes having ends facing toward one another, so that when electrical potential is supplied to the electrodes, an electrical discharge is produced and a spark is generated to ignite a fuel; and
a layer of an erosion resistant material applied to each end of each of said electrodes by the electro-spark deposition so that a reliable diffusion bonding Is is provided between a coating and a spark plug electrode material.
2. A spark plug as defined in claim 1, wherein said layer of erosion-resistant material is composed of tungsten.
3. A spark plug as defined in claim 1, wherein said layer of erosion-resistant material is composed of platinum.
4. A spark plug as defined in claim 1, wherein said layer of erosion-resistant material is composed of a metal of 5-6th period of The Periodic Table.
5. A spark plug comprising
at least two electrodes, said electrodes having ends facing toward one another so as to produce an electric discharge when an electrical potential is applied to said electrodes and to generate a spark for igniting a fuel; and
a layer of an erosion-resistant material applied on each of said ends of each of said electrodes by electro-spark deposition so that a reliable diffusion bonding is provided between the a coating and the spark plug electrode substrate , and heat stresses occurring on a border between the layer and the electrode body, during the spark plug operation, are relived and a lifetime of the spark plugs plug is substantially increased.
6. A method of producing a spark plug, comprising the steps of forming two electrodes having ends facing toward one another so that when electrical potential is supplied to the electrodes an electrical discharge is produced and a spark is generated to ignite a fuel; and applying a layer of an erosion resistant material to each end of each of said electrodes by the electro-spark deposition so that a reliable diffusion bonding is provided between the coating and the spark plug electrode material.
7. A method as defined in claim 6, wherein said layer of erosion-resistant material is composed of tungsten.
8. A method as defined in claim 6, wherein said layer erosion-resistant material is composed of platinum.
9. A method as defined in claim 6, wherein said layer of erosion-resistant material is composed of a metal of 5-6th period of The Periodic Table.
10. A spark plug comprising:
at least two electrodes having respective ends; and
a layer of an erosion resistant material which is electro-spark deposited on a surface of the respective end of at least one of the electrodes.
11. The spark plug according to claim 10, wherein the surface of the respective end is capable of forming a spark.
12. The spark plug according to claim 10, wherein the layer is electro-spark deposited on the surface to establish a diffusion bonding between the surface and the layer.
13. The spark plug according to claim 10, wherein a diffusion transient zone is formed on a border between the deposited layer and the surface of the respective end, and wherein the diffusion transient zone reduces a stress as the border during an operation of the spark plug.
14. The spark plug according to claim 10, wherein the erosion resistant material includes tungsten.
15. The spark plug according to claim 10, wherein the erosion resistant material includes platinum.
16. The spark plug according to claim 10, wherein the erosion resistant material includes a metal of a 5-6th period of The Periodic Table.
17. The spark plug according to claim 10, wherein the at least two of the electrodes face toward one another.
18. The spark plug according to claim 10, wherein the layer is electro-spark deposited on the surface of the respective end of each of the at least two electrodes.
19. A method for producing a spark plug, comprising the steps of:
providing at least two electrodes having respective ends; and
electro-spark depositing a layer of an erosion resistant material on a surface of the respective end of at least one of the electrodes.
20. The method according to claim 19, wherein the surface of the respective end is capable of forming a spark.
21. The method according to claim 19, wherein the electro-spark depositing step establishes a diffusion bonding between the surface and the layer.
22. The method according to claim 19, wherein a diffusion transient zone is formed on a border between the deposited layer and the surface of the respective end, and wherein the diffusion transient zone reduces a stress at the border during an operation of the spark plug.
23. The method according to claim 19, wherein the erosion resistant material includes tungsten.
24. The method according to claim 19, wherein the erosion resistant material includes platinum.
25. The method according to claim 19, wherein the erosion resistant material includes a metal of a 5-6th period of The Periodic Table.
26. The method according to claim 19, wherein the at least two of the electrodes face toward one another.
27. The method according to claim 19, wherein the electro-spark depositing step is performed on the surface of the respective end of each of the at least two electrodes.
US10/023,157 1999-03-04 2001-12-18 Spark plug and method of producing the same Expired - Fee Related USRE38536E1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US10/023,157 USRE38536E1 (en) 1999-03-04 2001-12-18 Spark plug and method of producing the same

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US09/262,633 US6265815B1 (en) 1999-03-04 1999-03-04 Spark plug and method of producing the same
US10/023,157 USRE38536E1 (en) 1999-03-04 2001-12-18 Spark plug and method of producing the same

Related Parent Applications (1)

Application Number Title Priority Date Filing Date
US09/262,633 Reissue US6265815B1 (en) 1999-03-04 1999-03-04 Spark plug and method of producing the same

Publications (1)

Publication Number Publication Date
USRE38536E1 true USRE38536E1 (en) 2004-06-22

Family

ID=22998351

Family Applications (2)

Application Number Title Priority Date Filing Date
US09/262,633 Expired - Lifetime US6265815B1 (en) 1999-03-04 1999-03-04 Spark plug and method of producing the same
US10/023,157 Expired - Fee Related USRE38536E1 (en) 1999-03-04 2001-12-18 Spark plug and method of producing the same

Family Applications Before (1)

Application Number Title Priority Date Filing Date
US09/262,633 Expired - Lifetime US6265815B1 (en) 1999-03-04 1999-03-04 Spark plug and method of producing the same

Country Status (1)

Country Link
US (2) US6265815B1 (en)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20060028106A1 (en) * 2004-08-03 2006-02-09 Lineton Warran B Ignition device having a reflowed firing tip and method of making
US20080036353A1 (en) * 2006-08-08 2008-02-14 Federal-Mogul World Wide, Inc. Ignition device having a reflowed firing tip and method of construction
US20080185948A1 (en) * 2007-02-02 2008-08-07 Lineton Warran B Spark plug electrode and process for making

Citations (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3673452A (en) * 1970-09-21 1972-06-27 Ronald F Brennen Spark plug
US4551603A (en) * 1971-04-02 1985-11-05 Rocklin Isadore J Device and method for surfacing a workpiece
US4810220A (en) 1988-06-06 1989-03-07 Allied-Signal Inc. Method for manufacturing electrodes for a spark plug
US4826462A (en) * 1988-08-19 1989-05-02 Champion Spark Plug Company Method for manufacturing a spark plug electrode
US4881913A (en) 1988-06-16 1989-11-21 General Motors Corporation Extended life spark plug/igniter
US5179313A (en) 1989-08-11 1993-01-12 Ford Motor Company Forming an erosion resistant tip on an electrode
US5456624A (en) 1994-03-17 1995-10-10 Alliedsignal Inc. Spark plug with fine wire rivet firing tips and method for its manufacture
US5465022A (en) * 1992-08-12 1995-11-07 Nippondenso Co., Ltd. Spark plug for internal-combustion engine and manufacture method of the same
US5779842A (en) 1994-01-25 1998-07-14 Ford Global Technologies, Inc. Forming an erosion resistant coating on an electrode
US5897966A (en) * 1996-02-26 1999-04-27 General Electric Company High temperature alloy article with a discrete protective coating and method for making

Patent Citations (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3673452A (en) * 1970-09-21 1972-06-27 Ronald F Brennen Spark plug
US4551603A (en) * 1971-04-02 1985-11-05 Rocklin Isadore J Device and method for surfacing a workpiece
US4810220A (en) 1988-06-06 1989-03-07 Allied-Signal Inc. Method for manufacturing electrodes for a spark plug
US4881913A (en) 1988-06-16 1989-11-21 General Motors Corporation Extended life spark plug/igniter
US4826462A (en) * 1988-08-19 1989-05-02 Champion Spark Plug Company Method for manufacturing a spark plug electrode
US5179313A (en) 1989-08-11 1993-01-12 Ford Motor Company Forming an erosion resistant tip on an electrode
US5465022A (en) * 1992-08-12 1995-11-07 Nippondenso Co., Ltd. Spark plug for internal-combustion engine and manufacture method of the same
US5779842A (en) 1994-01-25 1998-07-14 Ford Global Technologies, Inc. Forming an erosion resistant coating on an electrode
US5456624A (en) 1994-03-17 1995-10-10 Alliedsignal Inc. Spark plug with fine wire rivet firing tips and method for its manufacture
US5897966A (en) * 1996-02-26 1999-04-27 General Electric Company High temperature alloy article with a discrete protective coating and method for making

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20060028106A1 (en) * 2004-08-03 2006-02-09 Lineton Warran B Ignition device having a reflowed firing tip and method of making
US7385339B2 (en) 2004-08-03 2008-06-10 Federal Mogul World Wide, Inc. Ignition device having a reflowed firing tip and method of making
US20080036353A1 (en) * 2006-08-08 2008-02-14 Federal-Mogul World Wide, Inc. Ignition device having a reflowed firing tip and method of construction
US7851984B2 (en) 2006-08-08 2010-12-14 Federal-Mogul World Wide, Inc. Ignition device having a reflowed firing tip and method of construction
US20110057554A1 (en) * 2006-08-08 2011-03-10 Zdeblick William J Ignition Device Having a Reflowed Firing Tip and Method of Construction
US20080185948A1 (en) * 2007-02-02 2008-08-07 Lineton Warran B Spark plug electrode and process for making
US7795790B2 (en) 2007-02-02 2010-09-14 Federal-Mogul Worldwide, Inc. Spark plug electrode and process for making
US20100273385A1 (en) * 2007-02-02 2010-10-28 Lineton Warran B Spark plug electrode and process for making

Also Published As

Publication number Publication date
US6265815B1 (en) 2001-07-24

Similar Documents

Publication Publication Date Title
EP2013953B1 (en) Spark plug
US5132587A (en) Spark plug electrodes
US4881913A (en) Extended life spark plug/igniter
KR100965741B1 (en) Spark plug and method for manufacturing the same
US5731654A (en) Spark plug having a creepage spark gap
US6819031B2 (en) Spark plug and a method of producing the same
US5461210A (en) Method of manufacturing a spark plug electrode
USRE34778E (en) Spark plug and method of manufacturing the same
CN101507067A (en) Spark plug with fine wire ground electrode
EP0575163A1 (en) A spark plug
US5497045A (en) Spark plug having a noble metal electrode portion
KR20090004919A (en) Spark plug
WO2004008596A2 (en) Ignition device having an electrode formed from an iridium-based alloy
US4771209A (en) Spark igniter having precious metal ground electrode inserts
US7816845B2 (en) Ceramic electrode and ignition device therewith
US6232704B1 (en) Spark plug with specific electrode structure
US4910428A (en) Electrical-erosion resistant electrode
JP4255519B2 (en) Spark plug for internal combustion engine and method for manufacturing the same
US20070188064A1 (en) Metallic insulator coating for high capacity spark plug
USRE38536E1 (en) Spark plug and method of producing the same
US6833658B2 (en) Middle electrode with precious metal reinforcement and a process for producing the same
CA1168531A (en) Spark igniter
CN1198848A (en) Electrode for spark plugs of internal combustion engines and process for manufacturing the same
US6455988B1 (en) Spark plug having a particular resistor
US6956319B2 (en) Structure of spark plug designed to provide higher wear resistance to center electrode and production method thereof

Legal Events

Date Code Title Description
AS Assignment

Owner name: DAY ALLOYING L.L.C., NEW YORK

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:REZNIK, ALEXANDER;REEL/FRAME:015829/0285

Effective date: 20040923

FPAY Fee payment

Year of fee payment: 4

SULP Surcharge for late payment
FEPP Fee payment procedure

Free format text: PAYOR NUMBER ASSIGNED (ORIGINAL EVENT CODE: ASPN); ENTITY STATUS OF PATENT OWNER: SMALL ENTITY

FPAY Fee payment

Year of fee payment: 8

REMI Maintenance fee reminder mailed
LAPS Lapse for failure to pay maintenance fees