Patent Application
20100259172
The present invention relates to a plasma jet ignition plug for an internal combustion engine adapted to generate plasma and ignite an air-fuel mixture by means of the plasma.
Conventionally, a spark plug has been used to ignite an air-fuel mixture through spark discharge (which may be referred to merely as “discharge”) for operation of an engine, such as an internal combustion engine for an automobile. In recent years, high output and low fuel consumption have been required of internal combustion engines. To fulfill such requirements, use of a plasma jet ignition plug is known, since the plasma jet ignition plug provides quick propagation of combustion and exhibits such high ignition performance as to be capable of reliably igniting even a lean air-fuel mixture having a higher ignition-limit air-fuel ratio.
When such a plasma jet ignition plug is used while being connected to a power supply, a spark discharge gap is formed between a center electrode and a ground electrode. The plasma jet ignition plug has a structure in which an insulator formed from ceramics or the like surrounds the spark discharge gap, thereby forming a small-volume discharge space called a cavity. A plasma jet ignition plug used with a superposition-type power supply (refer to, for example, Japanese Patent Application Laid-Open (kokai) No. 2002-327672) is described by way of example. For ignition of an air-fuel mixture, first, high voltage is applied between the center electrode and the ground electrode, thereby generating spark discharge (also called “trigger discharge”). By virtue of associated occurrence of dielectric breakdown, current can be applied between the center electrode and the ground electrode with a relatively low voltage. Thus, through transition of a discharge state effected by further supply of energy, plasma is generated within the cavity. The generated plasma is jetted out through a communication hole (a so-called orifice), thereby igniting the air-fuel mixture. This process corresponds to a single cycle of jetting-out of plasma.
In generation of plasma, such a plasma jet ignition plug requires application, to the spark discharge gap, of current greater than that applied for generation of spark discharge in an ordinary spark plug. In order to increase current to be applied, electric resistance of a circuit through which the current flows must be lowered. Thus, there has not been an idea of providing a resistor in the interior of a plasma jet ignition plug (refer to, for example, Japanese Patent Application Laid-Open (kokai) No. 57-28869).
Since large current is applied to a plasma jet ignition plug in a short period of time, fluctuations in current per unit time are great. Thus, at the time of capacitive discharge, a plasma jet ignition plug having no resistor involves great erosion of an insulator and an electrode caused by capacitive discharge, as well as generation of electric noise (in the present specification, electromagnetic waves radiated to the exterior of equipment or like noise may be called “electric noise”; the flow of high-frequency current in electronic equipment induces the radiation of electric noise, which has an interference effect on external equipment and other signals). Meanwhile, in order to restrain erosion of the insulator and the electrode caused by capacitive discharge, and generation of great electric noise at the time of capacitive discharge, it is conceived to restrain current flowing to the plasma jet ignition plug. However, as a result of reduction in discharge current to be generated at the time of capacitive discharge, energy associated with capacitive discharge may fail to be sufficient for generation of plasma. In this manner, a trade-off relation exists between, on the one hand, generation of capacitive discharge of sufficient magnitude for generation of plasma, and on the other hand, restraining erosion of the insulator and the electrode caused by capacitive discharge and generation of great electric noise at the time of capacitive discharge. A plasma jet ignition plug which has an optimum structure under the limitation of this trade-off relation is sought.
The present invention has been conceived in view of the above circumstances, and an object of the invention is to provide a plasma jet ignition plug which can restrain generation of electric noise while allowing application of sufficiently large current for generation of plasma to a spark discharge gap at the time of ignition.
To achieve the above-mentioned object, the present invention provides a plasma jet ignition plug as configured below in (1) to (3).
(1) A plasma jet ignition plug comprises an insulator having an axial hole extending in an axial direction; a center electrode disposed within the axial hole such that a front end is located rearward of a front end of the insulator with respect to the axial direction; a substantially tubular metallic shell disposed radially outward of the insulator; and a ground electrode defining a spark discharge gap in cooperation with the center electrode. The plasma jet ignition plug is characterized in that a resistor having an inductance of 1 μH to 100 μH inclusive and a resistance of 1Ω or less is electrically connected to at least one of the center electrode and the ground electrode.
(2) In a plasma jet ignition plug configured as mentioned above in (1), the resistor is provided while being connected to a rear end portion of the center electrode.
(3) In a plasma jet ignition plug configured as mentioned above in (1), the resistor is provided such that one end of the resistor is connected to the ground electrode, and the other end of the resistor is connected to the metallic shell.
The plasma jet ignition plug configured as mentioned above in (1) can restrain generation of electric noise while allowing application of sufficiently large current for generation of plasma to a spark discharge gap at the time of ignition by the plasma jet ignition plug.
A certain spark plug, which does not consider ignition of an air-fuel mixture by means of plasma as practiced in a plasma jet ignition plug, has a resistor having a resistance of several kΩ to several tens of kΩ. Conventionally, there is no idea of providing a resistor in the interior of a plasma jet ignition plug. Thus, an idea of applying a resistor used in a spark plug to a plasma jet ignition plug is not probable. Even if a resistor used in a spark plug is applied to a plasma jet ignition plug, the resistor to which excessively high resistance is imparted without consideration of ignition of an air-fuel mixture by means of plasma causes a failure to apply sufficiently large current for generation of plasma to a spark discharge gap. As a result, ignition of an air-fuel mixture by means of plasma fails.
The plasma jet ignition plug configured as mentioned above in (2) or (3) allows provision of a resistor by a simple structure.
The plasma jet ignition plug of the present invention can restrain generation of electric noise while allowing application of sufficiently large current for generation of plasma to a spark discharge gap at the time of ignition by the plasma jet ignition plug.
The present invention has been summarized above. The details of the present invention will be clarified by the following detailed description and with reference to the appended drawings.
A plasma jet ignition plug according to an embodiment of the present invention will be described with reference to the drawings.
The plasma jet ignition plug 100 shown in
A rodlike center electrode 20 is inserted into the electrode-accommodating portion 15 of the axial hole 12. The center electrode 20 has a core of copper or a copper alloy and an outer layer of an Ni alloy. Alternatively, the center electrode 20 may be configured such that a disklike electrode chip 25 formed from an alloy which predominantly contains a noble metal or tungsten (W) is joined to the front end of the center electrode 20 (in the present embodiment, the entirety of the center electrode 20 and the electrode chip 25 joined to each other is referred to as the “center electrode”). The center electrode 20 is disposed in the electrode-accommodating portion 15 such that the front end thereof (or the front end of the electrode chip 25 joined to the center electrode 20) is located rearward of the front end surface 16 of the leg portion 13 of the insulator 10 with respect to the axial direction. Thus, the front end of the center electrode 20 and the wall of the electrode-accommodating portion 15 of the axial hole 12 define a discharge space having a small volume. In the present embodiment, the discharge space is called the cavity 60. The center electrode 20 extends rearward in the axial hole 12 and is electrically connected to a metal terminal 40 provided at a rear end portion of the axial hole 12, via a wire-wound resistor 21, which will be described later, and an electrically conductive seal body 4 formed from a metal-glass mixture. A high-tension cable (not shown) is connected to the metal terminal 40 via a plug cap (not shown) for application of high voltage from an ignition system 200 (see
The insulator 10 is held through crimping in a metallic shell 50 formed substantially cylindrically by use of an iron-based material, such that a region extending from a portion of the rear trunk portion 18 to the leg portion 13 is surrounded by the metallic shell 50. The metallic shell 50 disposed in such a manner as to surround the insulator 10 is adapted to fix the plasma jet ignition plug 100 to the engine head of an internal combustion engine and has a mounting threaded portion 52 having threads to be threadingly engaged with a mounting hole of the engine head. An annular gasket 5 is fitted to the metallic shell 50 at the proximal end of the mounting threaded portion 52 in order to prevent gas leakage from inside the engine through the mounting hole.
A disklike ground electrode 30 is provided at the front end of the metallic shell 50. The ground electrode 30 is formed from an Ni alloy having excellent resistance to spark-induced erosion, such as INCONEL 600 or 601 (trademark). The ground electrode 30 is joined to the metallic shell 50 while being in contact with the front end surface 16 of the insulator 10, with its thickness direction coinciding with the axial direction O. The ground electrode 30 has a communication hole 31 formed at the center thereof. The communication hole 31 is coaxially continuous with the opening portion 14 of the cavity 60, whereby the cavity 60 communicates with the ambient atmosphere through the communication hole 31. A spark discharge gap is formed between the ground electrode 30 and the center electrode 20. The cavity 60 encompasses at least a portion of the spark discharge gap. At the time of spark discharge generated across the spark discharge gap, energy is supplied, thereby forming plasma within the cavity 60. The plasma is jetted out from the opening portion 14 through the communication hole 31.
As shown in
One end 21a of the wire-wound resistor 21 is electrically connected to one end 20b of the center electrode 20, and the other end 21b of the wire-wound resistor 21 is electrically connected to the metal terminal 40 via the seal member 4 shown in
An electrode which surrounds the center electrode 20 is composed of the ground electrode 30 and the metallic shell 50. The ground electrode 30 and the metallic shell 50 are electrically connected to each other and grounded. The insulator 10 electrically insulates the center electrode 20 from the ground electrode 30 and the metallic shell 50.
At the front end of the plasma jet ignition plug 100, the communication hole 31 is formed at a central portion of the ground electrode 30. The cavity 60 is formed between the communication hole 31 and one end 20a of the center electrode 20 and serves as a space for discharge. When high voltage is applied between the center electrode 20 and the ground electrode 30, a spark discharge is generated in the cavity 60 while being accompanied by dielectric breakdown. Through supply of great electric energy subsequent to generation of spark discharge, plasma is generated through discharge. The plasma is discharged from the communication hole 31 in a columnar form in the direction of the arrow Y and ignites an air-fuel mixture.
The high-voltage generation circuit 210 shown in
An unillustrated control circuit applies an ignition-coil energization signal to the base electrode, which serves as a control terminal, of the transistor Q1. The ignition-coil energization signal is a binary signal in which a pulse signal emerges once every discharge cycle in the plasma jet ignition plug 100, and is utilized for switching control of the transistor Q1.
Specifically, when the ignition-coil energization signal becomes a high level, the transistor Q1 becomes conductive, and electric power supplied from the direct-current power supply 230 causes current to flow through the primary winding L1 of the ignition coil 211. When the ignition-coil energization signal becomes a low level, the transistor Q1 is switched to a nonconductive state, and current flowing through the primary winding L1 of the ignition coil 211 is shut off rapidly. When current starts to flow through the primary winding L1 of the ignition coil 211 and when current flowing through the primary winding L1 of the ignition coil 211 is shut off, high voltage is generated across the secondary winding L2. Voltage to be generated across the secondary winding L2 depends on the turns ratio between the primary winding L1 and the secondary winding L2.
As shown in
Meanwhile, a capacitor C is connected between the ground and the output terminal of the high-voltage generation circuit 220. The cathode terminal of a diode D2 is connected to the output terminal of the high-voltage generation circuit 220. The anode terminal of the diode D2 is electrically connected to the metal terminal 40 of the plasma jet ignition plug 100. The diode D2 is provided to prevent reverse flow of current. That is, the diode D2 controls polarity such that voltage of negative polarity causes current at the time of plasma discharge to flow only in a direction from the metal terminal 40 toward the output terminal of the high-voltage generation circuit 220.
When discharge is to be started in the plasma jet ignition plug 100, first, in order to generate a spark discharge (also called trigger discharge), the high-voltage generation circuit 210 supplies high voltage to the plasma jet ignition plug 100. Specifically, when the transistor Q1 shown in
Meanwhile, stray capacitances are present between inner electrodes of the plasma jet ignition plug 100, between the ground and a high-tension cable (a conductor line including D1 and R1) connecting the high-voltage generation circuit 210 and the plasma jet ignition plug 100, and between the ground and the secondary winding L2 of the ignition coil 211.
When high voltage emerges instantaneously at the output terminal 210a of the high-voltage generation circuit 210, the high voltage causes storage of charges in the above-mentioned stray capacitances. At the initial stage of discharge (called “capacitive discharge”; in several nanoseconds) in the plasma jet ignition plug 100, high voltage causes the occurrence of dielectric breakdown and the associated generation of spark discharge in the cavity 60. At this time, charges stored in the stray capacitances are released, thereby supplying electric energy to the plasma jet ignition plug 100. After release of charges from the stray capacitances (called “inductive discharge”; in several microseconds), energy stored in inductance of the secondary winding L2 of the ignition coil 211 is released, so that discharge continues.
Meanwhile, in order to generate plasma through discharge, large electric energy must be supplied to the plasma jet ignition plug 100. Since current which the high-voltage generation circuit 210 can supply to the plasma jet ignition plug 100 is relatively small, energy for generating plasma is supplied from the separate high-voltage generation circuit 220. In actuality, electric power output from the high-voltage generation circuit 220 is stored in the capacitor C, and charges stored in the capacitor C are supplied to the plasma jet ignition plug 100 via the diode D2. When plasma discharge is to be performed after spark discharge, discharge can be continued with a relatively low voltage, since the occurrence of dielectric breakdown at the time of spark discharge establishes a condition for easy occurrence of discharge.
In actuality, when voltage of negative polarity which the high-voltage generation circuit 210 applies to the metal terminal 40 of the plasma jet ignition plug 100 becomes lower than voltage of negative polarity which emerges between the terminals of the capacitor C connected to the high-voltage generation circuit 220, the diode D2 becomes conductive. Thus, charges stored in the capacitor C are supplied to the plasma jet ignition plug 100 via the diode D2. That is, current which flows in association with plasma generated in the cavity 60 of the plasma jet ignition plug 100 (called plasma current) flows from the metal terminal 40 to the capacitor C via the diode D2. Accordingly, the plasma current starts to flow in the midst of the timing of “capacitive discharge” and continues to flow according to the amount of charges stored in the capacitor C.
The capacitance of the capacitor C is set such that sufficient energy is supplied for generation of plasma; i.e., such that the sum of the amount of energy supplied from stray capacitances to the spark discharge gap at the time of trigger discharge and the amount of energy supplied from the capacitor C becomes the amount of energy required for single jetting-out of plasma (e.g., 150 mJ). Through supply of these energies, plasma can be jetted out from the opening portion (the communication hole 31) in the form of a pillar of fire (in the form of flame), whereby the plasma can ignite an air-fuel mixture.
Meanwhile, at the timing of the aforementioned “capacitive discharge,” charges of high voltage cause emergence of high-frequency current having a large amplitude in the waveform of discharge current in a very short period of time (e.g., waveform of 112 in
In the ignition system 200 having a configuration shown in
Meanwhile, when current associated with “capacitive discharge” is small, difficulty is encountered in applying plasma current to the plasma jet ignition plug 100 at the time of plasma discharge. Specifically, when current associated with “capacitive discharge” is small, the release of stored charges from the aforementioned stray capacitances consumes a long time, thereby elongating time for attenuation of high voltage of negative polarity applied from the high-voltage generation circuit 210 to the plasma jet ignition plug 100. The diode D2 does not become conductive unless the high voltage attenuates sufficiently. Thus, charges stored in the capacitor C cannot be supplied to the plasma jet ignition plug 100 for initiation of plasma discharge.
As for a line through which plasma current flows (a current path in which the diode D2 and the like are present), reducing direct-current resistance is desirable. The reduction of direct-current resistance increases the peak value of plasma current, thereby improving plasma generation efficiency.
By means of the resistor R1 being inserted between the output terminal 210a of the high-voltage generation circuit 210 and the metal terminal 40 of the plasma jet ignition plug 100 as shown in
Since there is no need to cause current to flow between the output terminal 210a of the high-voltage generation circuit 210 and the metal terminal 40 of the plasma jet ignition plug 100, the resistor R1 having a relatively large resistance (100Ω or higher) can be inserted into the current path.
However, stray capacitances which influence current associated with “capacitive discharge” are not limited to those which are present between the ground and the high-tension cable (the conductor line including D1 and R1) connecting the high-voltage generation circuit 210 and the plasma jet ignition plug 100 and between the ground and the secondary winding L2 of the ignition coil 211; other stray capacitances also exist. Therefore, mere insertion of the resistor R1 fails to reduce noise sufficiently.
The wire-wound resistor 21 incorporated in the plasma jet ignition plug 100 is useful for controlling current derived from the stray capacitance C100. Specifically, since the wire-wound resistor 21 has a direct-current resistance component R21 and an inductance component L21, current which is derived from the stray capacitance C100 and flows at the time of “capacitive discharge” is restrained, and the period of time when current flows is adjusted.
Now, the reason for forming the wire-wound resistor 21 to have a direct-current resistance of 1Ω or less and an inductance of 1 μH to 100 μH inclusive will be described with reference to
At the time of capacitive discharge, as shown in
The inventors of the present invention examined the relationship between the values of the direct-resistance component R21 and the inductance component L21, and the degree of reduction in noise caused by current derived from the stray capacitance C100 and the ignition performance of the plasma jet ignition plug 100. Table 1 shows the results of the examination.
As shown in Table 1, in the case where the direct-current resistance component R21 was in excess of 1Ω, and the inductance component L21 was in excess of 100 μH, the degree of reduction in noise was excellent, but the plasma jet ignition plug 100 failed to exhibit high ignition performance. In the case where the direct-current resistance component R21 was 1Ω or less, and the inductance component L21 was in excess of 100 μH, the degree of reduction in noise was excellent, but the plasma jet ignition plug 100 failed to exhibit high ignition performance. In the case where the direct-current resistance component R21 is 1Ω or less, and the inductance component L21 was 1 μE to 100 μH inclusive, the degree of reduction in noise was excellent, and the plasma jet ignition plug 100 exhibited high ignition performance. In the case where the direct-current resistance component R21 was 1Ω or less, and the inductance component L21 was less than 1 μH, the plasma jet ignition plug 100 exhibited high ignition performance, but the degree of reduction in noise was poor. The examination has revealed that, in the case where the direct-current resistance component R21 is 1Ω or less, and the inductance component L21 is 1 μH to 100 μH inclusive, the degree of reduction in noise is excellent, and the plasma jet ignition plug 100 exhibits high ignition performance. By contrast, in the case where one or both of the direct-current resistance component R21 and the inductance component L21 fall outside the respective favorable ranges, the degree of reduction in noise is poor, or the plasma jet ignition plug 100 fails to exhibit excellent ignition performance. In the present invention, on the basis of the results of the examination, the thickness of wire and the number of turns of the wire-wound resistor 21 are determined such that the wire-wound resistor 21 has a direct-current resistance of 1Ω or less and an inductance of 1 μH to 100 μH inclusive.
As shown in
The wire-wound resistor 21 yields an effect other than restraint of noise. Specifically, the provision of the wire-wound resistor 21 restrains erosion of insulator located in the vicinity of the cavity 60 at the time of discharge.
Next, modifications of the above-described plasma jet ignition plug 100 will be described.
In the plasma jet ignition plug 100B shown in
A conductive wire used to form the wire-wound resistor 21B is spirally wound onto the outer circumference of the projecting portion of the insulator 10. Similar to the wire-wound resistor 21, the wire-wound resistor 21B has a direct-current resistance of 1Ω or less and an inductance of 1 μH to 100 μH inclusive. One end 21Ba of the wire-wound resistor 21B is electrically connected to a ground electrode 30B assuming substantially the form of a straight bar. The one end 21Ba of the wire-wound resistor 21B is electrically connected to the ground electrode 30B by, for example, welding. The other end 21Bb of the wire-wound resistor 21B is electrically connected to the front end portion 50Ba of the metallic shell 50B. As shown in
Similar to the case of use of the plasma jet ignition plug 100 shown in
In the plasma jet ignition plug 100C shown in
The wire-wound resistor 21C is configured such that a conductive wire is wound spirally onto a bobbin 23 formed from an electrically insulative material. Similar to the wire-wound resistor 21, the wire-wound resistor 21C has a direct-current resistance of 1Ω or less and an inductance of 1 μH to 100 μH inclusive. One end 21Ca of the wire-wound resistor 21C is electrically connected to a ground electrode 30C located at the position of one end portion of the bobbin 23. The other end portion 21Cb of the wire-wound resistor 21C is electrically connected to a conductor located at the position of the other end portion of the bobbin 23, thereby being electrically connected to the front end surface 50Ca of the metallic shell 50C via the conductor. The opposite ends 21Ca and 21Cb of the wire-wound resistor 21C are electrically connected by, for example, welding to the ground electrode 30C and the conductor, respectively, located at the respective end portions of the bobbin 23. The ground electrode 30C located at one end portion of the bobbin 23 is disposed in the vicinity of a cavity 60C and utilized for generating discharge in cooperation with the center electrode 20. An equivalent circuit of the interior of the plasma jet ignition plug 100C is similar to that shown in
In the plasma jet ignition plug 100D shown in
As shown in
Conceivably, the above-mentioned wire-wound resistors 21, 21B, 21C, and 21D are disposed on either the center electrode 20 side or the metallic shell 50 side, or on both sides. By means of the wire-wound resistor 21 being disposed on at least one of the center electrode 20 side and the metallic shell 50 side, there can be controlled the amplitude of current derived from stray capacitance present in the plasma jet ignition plug and the period of time when the current flows; radiated noise can be reduced; and insulator erosion and electrode erosion can be restrained.
4: seal body
5: gasket
10: insulator
12: axial hole
13: leg portion
14: opening portion
15: electrode-accommodating portion
16: front end surface
17: front trunk portion
18: rear trunk portion
19: intermediate trunk portion
20: center electrode
21, 21B, 21C, 21D: wire-wound resistor
22, 23: bobbin
25: electrode chip
30, 30B, 30C: ground electrode
31: communication hole
32: electrode chip
40: metal terminal
50, 50B, 50C, 50D: metallic shell
52: mounting threaded portion
60, 60B, 60C, 60D: cavity
100: plasma jet ignition plug
200: ignition system
210, 220: high-voltage generation circuit
211: ignition coil
230: direct-current power supply
300: engine head
| Number | Date | Country | Kind |
|---|---|---|---|
| JP 2009-086425 | Mar 2009 | JP | national |
| JP 2010-059396 | Mar 2010 | JP | national |
