Patent Grant
12088067
This application is a U.S. National Phase Application under 35 U.S.C. § 371 of International Patent Application No. PCT/JP2022/022752 filed on Jun. 6, 2022 and claims the benefit of priority to Japanese Patent Application No. 2021-113909 filed on Jul. 9, 2021, the contents of all of which are incorporated herein by reference in their entireties. The International Application was published in Japanese on Jan. 12, 2023 as International Publication No. WO/2023/281957 under PCT Article 21(2).
The present disclosure relates to a spark plug.
A known ignition spark plug used for internal combustion engines is a spark plug which is attached to an engine head and which generates spark discharge between a forward end of a center electrode and a ground electrode (see, for example, JP2019-046660A). In the spark plug described in JP2019-046660A, a through hole is formed in a metallic shell such that the through hole penetrates the metallic shell in a radial direction, and a rod-shaped ground electrode extending in the radial direction is inserted into the through hole and fixed thereto.
In general, in a spark plug, the closer to the forward end, the higher the temperature, and, thus, the closer to the forward end, the greater the degree of thermal expansion. Therefore, in the case where, as in the spark plug disclosed in JP2019-046660A, an external screw of the metallic shell is also formed on the forward end side of a welded portion of the ground electrode as viewed in the axial direction, as a result of thermal expansion of the external screw on the forward end side, the engine head may be damaged. Meanwhile, in the case where the diameter of the external screw of the metallic shell is decreased so as to prevent damage to the engine head, the gastightness between the external screw of the metallic shell and an internal screw of the engine head may deteriorate. Accordingly, a technique for preventing deterioration of gastightness while preventing damage to the engine head has been demanded.
The present disclosure can be realized as the following aspects.
Notably, the present invention can be realized in various aspects and can be realized, for example, as a spark pug manufacturing method, an engine head with a spark plug attached thereto, or the like.
The spark plug 100 includes an insulator 10, a center electrode 20, a metallic shell 30, the ground electrode 40, and the metallic terminal member 50. Notably, the axial line CA of the spark plug 100 coincides with the axial lines of the insulator 10, the center electrode 20, the metallic shell 30, and the metallic terminal member 50.
The insulator 10 has a generally tubular external shape and has an axial hole 11 extending in the axial direction AD. In the axial hole 11, a portion of the center electrode 20 is accommodated on the forward end side, and a portion of the metallic terminal member 50 is accommodated on the rear end side. Therefore, the insulator 10 holds the center electrode 20 on its inner circumferential side. A portion of the insulator 10 on the forward end side is accommodated in an axial hole 31 of the metallic shell 30, which will be described later, and a portion of the insulator 10 on the rear end side projects from the axial hole 31. The insulator 10 is composed of a ceramic insulator formed by firing a ceramic material such as alumina.
The center electrode 20 is a rod-shaped electrode extending in the axial direction AD and is disposed in the axial hole 11. A forward end portion 21 of the center electrode 20 projects forward from the axial hole 11. A noble metal tip formed of, for example, platinum, an iridium alloy, or the like may be joined to the forward end portion 21. The center electrode 20 of the present embodiment is formed of a nickel alloy whose main component is nickel.
Within the axial hole 11 of the insulator 10, a forward-end-side seal 61, a resistor 62, and a rear-end-side seal 63 are disposed in this order from the forward end side toward the rear end side between the center electrode 20 and the metallic terminal member 50. Therefore, the center electrode 20 is electrically connected, on its rear end side, to the metallic terminal member 50 via the forward-end-side seal 61, the resistor 62, and the rear-end-side seal 63.
The resistor 62 contains ceramic powder, conductive material, and glass as materials. The resistor 62 functions as an electrical resistor between the metallic terminal member 50 and the center electrode 20, thereby suppressing noise produced when spark discharge is generated. Each of the forward-end-side seal 61 and the rear-end-side seal 63 contains electrically conductive glass powder as a material. In the present embodiment, each of the forward-end-side seal 61 and the rear-end-side seal 63 contains, as a material, powder obtained by mixing powder of copper and powder of calcium borosilicate glass.
The metallic terminal member 50 is provided at an end portion of the spark plug 100 on the rear end side. A forward-end-side portion of the metallic terminal member 50 is accommodated in the axial hole 11 of the insulator 10, and a rear-end-side portion of the metallic terminal member 50 projects from the axial hole 11. An unillustrated high voltage cable is connected to the metallic terminal member 50, and a high voltage is applied to the metallic terminal member 50. As a result of the application, spark discharge is generated at a discharge gap G, which will be described later. The spark generated at the discharge gap G ignites an air-fuel mixture in the combustion chamber 95.
The metallic shell 30 has a generally tubular external shape and has the axial hole 31 formed to extend in the axial direction AD. The metallic shell 30 holds the insulator 10 in the axial hole 31. In other words, the metallic shell 30 holds the insulator 10 on its inner circumferential side. The metallic shell 30 is formed of, for example, low carbon steel, and the entirety of the metallic shell 30 is plated with, for example, nickel or zinc. A tool engagement portion 32 and a screw portion 33 are formed on an outer circumferential surface of the metallic shell 30. When the spark plug 100 is attached to the engine head 90, an unillustrated tool is engaged with the tool engagement portion 32. The screw portion 33 is provided in a forward-end-side region of the metallic shell 30 and has a screw thread formed on the outer circumferential surface. The screw portion 33 is screwed into an internal screw portion 93 of the engine head 90. The screw portion 33 will be described in detail later.
The ground electrode 40 is composed of a rod-shaped metal member and is disposed to extend in the radial direction. A first end portion 41 of the ground electrode 40 is inserted into the through hole 37 and is fixed thereto. Therefore, the first end portion 41 can be regarded as a fixed portion. A second end portion 42 of the ground electrode 40 faces the forward end portion 21 of the center electrode 20. The discharge gap G for spark discharge is formed between the second end portion 42 and the forward end portion 21 of the center electrode 20. The ground electrode 40 of the present embodiment is formed of a nickel alloy whose main component is nickel as in the case of the center electrode 20. Although the ground electrode 40 of the present embodiment is welded at the through hole 37, whereby the ground electrode 40 is fixed to the through hole 37, the method of fixing is not limited to welding, and the ground electrode 40 may be fixed by means of, for example, press-fitting or the like.
The screw portion 33 formed on the outer circumferential surface of the metallic shell 30 has a first screw portion 34 and a second screw portion 35. The first screw portion 34 is located on the rear end side of the through hole 37 in the axial direction AD. The second screw portion 35 is located on the forward end side of the through hole 37 in the axial direction AD. In the present embodiment, the length of the second screw portion 35 is shorter than the length of the first screw portion 34 as measured in the axial direction AD.
The pitch diameter of the first screw portion 34 is larger than the pitch diameter of the second screw portion 35. In the present specification, the “pitch diameter” shows a value prescribed in JIS B 0205 2001. The pitch diameter of the first screw portion 34 can be obtained by calculating the average of measured pitch diameters of screw threads of the first screw portion 34. Similarly, the pitch diameter of the second screw portion 35 can be obtained by calculating the average of measured pitch diameters of screw threads of the second screw portion 35. As shown in Examples, which will be described later, the pitch diameter of the first screw portion 34 is preferably 100.30% or more the pitch diameter of the second screw portion 35. Notably, the pitch diameter of the first screw portion 34 is preferably 101.00% or less of the pitch diameter of the second screw portion 35.
In the present embodiment, the screw portion 33 is formed such that its pitch diameter increases from the forward end side toward the rear end side in the axial direction AD. Instead of such a configuration, the screw portion 33 may have, for example, a configuration in which the screw threads of the first screw portion 34 are formed to have an approximately constant pitch diameter, the screw threads of the second screw portion 35 are formed to have an approximately constant pitch diameter, and the first screw portion 34 and the second screw portion 35 are continuously formed. Notably, in this case, the first screw portion 34 and the second screw portion 35 may be connected smoothly or connected via a step formed therebetween.
The screw portion 33 can be formed by means of, for example, rolling, cutting, or the like. In the case where the screw portion 33 is formed by means of rolling, the pitch diameter of the first screw portion 34 may be rendered larger than the pitch diameter of the second screw portion 35 by, for example, strengthening pressing forces of dies at a position for forming the second screw portion 35, as compared with those at a position for forming the first screw portion 34. Also, rolling may be performed by using dies each having a step formed at a position corresponding to a position between the position for forming the first screw portion 34 and the position for forming the second screw portion 35. Alternatively, the cylindrical metallic shell 30 before being threaded may have a step between the position for forming the first screw portion 34 and the position for forming the second screw portion 35 or be tapered beforehand at the position for forming the first screw portion 34 and the position for forming the second screw portion 35. Although the first screw portion 34 and the second screw portion 35 are formed as one portion in the present embodiment, the first screw portion 34 and the second screw portion 35 may be formed separately. Notably, the through hole 37 may be formed before formation of the screw portion 33 or after formation of the screw portion 33.
In general, the ground electrode 40 is exposed to combustion of an air-fuel mixture and its temperature becomes high. Therefore, in the spark plug 100 in which the ground electrode 40 is fixed to the through hole 37 formed in the metallic shell 30, the first end portion 41 of the ground electrode 40 may possibly oxidize as a result of overheating. However, in the spark plug 100 of the present embodiment, since the second screw portion 35 is formed on the forward end side of the through hole 37 in the axial direction AD, the second screw portion 35 of the metallic shell 30 can be brought into threading engagement with the internal screw portion 93 of the engine head 90 on the forward end side of the through hole 37 as well. In general, a coolant flow passage is provided in the engine head 90. Therefore, by bringing the second screw portion 35 into threading engagement with the internal screw portion 93, a route for conducting heat from the ground electrode 40 can be also secured in a region on the forward end side of the through hole 37, which region is likely to become higher temperature. Accordingly, since an excessive increase in the temperature of the first end portion 41 of the ground electrode 40 can be prevented, oxidation of the first end portion 41 of the ground electrode 40 can be suppressed. As a result, it is possible to prevent coming off of the ground electrode 40 from the through hole 37 in a thermal cycle of the combustion chamber 95, whereby durability of the spark plug 100 can be enhanced.
In general, the temperature of the vicinity of the forward end of the spark plug 100 tends to increase toward the forward end side in the axial direction AD. Therefore, in the case where the second screw portion 35 is formed on the forward end side (in the axial direction AD) of the through hole 37 to which the ground electrode 40 is fixed, the second screw portion 35 thermally expands more than does the first screw portion 34. If the dimension of the second screw portion 35 in the radial direction increases excessively due to thermal expansion, damage such as cracking may occur at the internal screw portion 93 formed in the engine head 90. However, in the spark plug 100 of the present embodiment, since the pitch diameter of the first screw portion 34 is larger than the pitch diameter of the second screw portion 35; namely, the pitch diameter of the second screw portion 35 is smaller than the pitch diameter of the first screw portion 34, it is possible to prevent excessive increase of the dimension of the second screw portion 35 in the radial direction, which excessive increase would otherwise occur due to thermal expansion. As a result, the spark plug 100 of the present embodiment can prevent damage to the engine head 90.
In the case where the screw portion 33 is formed such that its pitch diameter becomes smaller over the entirety in the axial direction AD unlike the present application, conceivably, damage to the engine head 90 can be prevented because excessive increase of the dimension of the second screw portion 35 in the radial direction can be prevented. However, if the pitch diameter of the screw portion 33 is made smaller, the gap between the screw portion 33 and the internal screw portion 93 becomes excessively large, which may result in deterioration of gastightness. However, in the spark plug 100 of the present embodiment, since the pitch diameter of the first screw portion 34 is larger than the pitch diameter of the second screw portion 35, it is possible to prevent the gap between the first screw portion 34 and the internal screw portion 93 from becoming excessively large, thereby preventing deterioration of gastightness.
As described above, in the spark plug 100 of the present embodiment, since the pitch diameter of the first screw portion 34 located on the rear end side of the through hole 37 in the axial direction AD is larger than the pitch diameter of the second screw portion 35 located on the forward end side of the through hole 37 in the axial direction AD, it is possible to prevent excessive increase of the dimension of the second screw portion 35 in the radial direction, which excessive increase would otherwise occur due to thermal expansion. Also, it is possible to prevent the gap between the first screw portion 34 and the internal screw portion 93 from becoming excessively large, thereby maintaining gastightness at the first screw portion 34. As a result, it is possible to prevent deterioration of gastightness while preventing damage to the engine head 90.
Also, since gastightness can be secured at the first screw portion 34, even when an air-fuel mixture leaks through the gap between the through hole 37 and the first end portion 41 of the ground electrode 40, it is possible to prevent the air-fuel mixture from leaking to the outside along a bearing surface of the spark plug 100. Accordingly, the spark plug 100 of the present embodiment can prevent deterioration of gastightness more reliably as compared with a configuration in which gastightness is secured at the second screw portion 35.
Also, since the pitch diameter of the first screw portion 34 is 100.30% or more the pitch diameter of the second screw portion 35, it is possible to further reduce the gap between the first screw portion 34 and the internal screw portion 93, and, as a result, deterioration of gastightness can be prevented further reliably.
Also, since the length of the second screw portion 35 is shorter than the length of the first screw portion 34 as measured in the axial direction AD, the first screw portion 34 can have a sufficient dimension in the axial direction AD, and, as a result, deterioration of gastightness can be prevented further reliably.
The present invention will next be described in more detail by way of examples; however, the present invention is not limited to the following examples.
<Samples>
Spark plugs 100 were produced as shown in Table 1 below. More specifically, spark plugs 100 in which the pitch diameter of the first screw portion 34 was larger than the pitch diameter of the second screw portion 35 were produced as Examples 1 to 5. Also, spark plugs in which the pitch diameter of the first screw portion 34 was the same as the pitch diameter of the second screw portion 35; i.e., the screw portion 33 had a constant pitch diameter over the entire length in the axial direction AD were produced as Comparative Examples 1 and 2. Comparative Examples 1 and 2 were different from each other in the internal diameter of the screw portion 33, and the pitch diameter of the screw portion 33 of Comparative Example 1 was smaller than the pitch diameter of the screw portion 33 of Comparative Example 2. More specifically, the pitch diameter of the screw portion 33 of Comparative Example 1 was rendered the same as the pitch diameters of the second screw portions 35 of Examples 1 and 5, and the pitch diameter of the screw portion 33 of Comparative Example 2 was rendered the same as the pitch diameters of the second screw portions 35 of Comparative Examples 3 and 4. Also, spark plugs in which the pitch diameter of the first screw portion 34 was smaller than the pitch diameter of the second screw portion 35 were produced as Comparative Examples 3 and 4. In each of Examples and Comparative Examples, 10 samples (spark plugs) having a nominal diameter of M10 and having the same configuration except for the pitch diameter of the screw portion 33 were produced.
<Bush Damage Test>
Each of the spark plugs 100 of Examples and the spark plugs of Comparative Examples was attached to a bush, imitating the engine head 90. The pitch diameter of an internal screw portion 93 formed on an inner circumferential surface of the bush was set to the lower limit of the standard range. The first end portion 41 of the ground electrode 40 and its vicinity were heated by a burner from the axial hole 31 side of the metallic shell 30. Heating of the ground electrode 40 at an electrode temperature of 1000° ° C. for two minutes and cooling of the ground electrode 40 at an electrode temperature of 200° ° C. for one minute were performed as a thermal cycle. This thermal cycle was repeated 1,000 times. Determination as to whether the bush was damaged was made by visually observing the bush, whereby damaging characteristic was evaluated. Evaluation criteria are shown below.
Each of the spark plugs 100 of Examples and the spark plugs of Comparative Examples was attached to a bush, imitating the engine head 90. The pitch diameter of the internal screw portion 93 formed on the inner circumferential surface of the bush was set to the lower limit of the standard range. Gastightness was evaluated in accordance with the ISO standard. Specifically, after holding the entirety of each sample spark plug at 200° C. for 30 minutes, a pressure of 2 MPa was applied, and the amount of gas leaked along the bearing surface of the spark plug was measured. Evaluation criteria are shown below.
The results of the bush damage test and the gastightness test are shown in Table 1.
The following was found from Table 1. Namely, no damage to the bush was found in Examples 1 to 5 and Comparative Example 1 in which the pitch diameter of the second screw portion 35 was small, and damage to the bush was found in Comparative Examples 2 to 4 in which the pitch diameter of the second screw portion 35 was large. Therefore, it was found that damage to the engine head 90 can be prevented by rendering the pitch diameter of the second screw portion 35 small. Also, through comparison between Examples 1 to 5 and Comparative Example 1, it was found that, in Examples 1 to 5 and in which the pitch diameter of the first screw portion 34 was larger than the pitch diameter of the second screw portion 35, deterioration of gastightness was able to be suppressed as compared with Comparative Example 1 in which the pitch diameter of the first screw portion 34 was the same as the pitch diameter of the second screw portion 35. In particular, in the case of Examples 1 to 3 in which the pitch diameter of the first screw portion 34 was 100.30% or more the pitch diameter of the second screw portion 35, no leakage was observed in the gastightness test. It was found from this that, in Examples 1 to 3, deterioration of gastightness was prevented more reliably. It is considered that, in Examples 1 to 5, since the pitch diameter of the first screw portion 34 was larger than the pitch diameter of the second screw portion 35, the first screw portion 34 and the internal screw portion 93 were able to be brought into close contact with each other, thereby making it possible to prevent deterioration of gastightness. It was found from the results described above that, by rendering the pitch diameter of the first screw portion 34 larger than the pitch diameter of the second screw portion 35, it is possible to prevent deterioration of gastightness while preventing damage to the engine head 90.
Also, it is considered that, in Comparative Example 1, since the screw portion 33 was formed to have a constant small pitch diameter over the entire length in the axial direction AD, damage to the engine head 90 was able to be prevented: however, the degree of close contact between the internal screw portion 93 and the screw portion 33 decreased, and thus, gastightness deteriorated. It is considered that, in Comparative Example 2, since the screw portion 33 was formed to have a constant large pitch diameter over the entire length in the axial direction AD, deterioration of gastightness was able to be prevented: however, damage to the engine head 90 occurred due to thermal expansion of the screw portion 33. It was found from the results of Comparative Examples 2 to 4 that the smaller the pitch diameter of the first screw portion 34, the lower the degree of close contact between the internal screw portion 93 and the first screw portion 34, whereby gastightness deteriorates.
The structure of the screw portion 33 in the above-described embodiment is merely an example, and various modifications are possible. For example, the length of the second screw portion 35 may be the same as the length of the first screw portion 34 or longer than the length of the first screw portion 34 as viewed in the axial direction AD. Also, the pitch diameter of the first screw portion 34 is not limited to 100.30% or more the pitch diameter of the second screw portion 35 and may be an arbitrary pitch diameter greater than 100% of the pitch diameter of the second screw portion 35. Even when such a configuration is employed, since the pitch diameter of the first screw portion 34 is larger than the pitch diameter of the second screw portion 35, it is possible to prevent deterioration of gastightness while preventing damage to the engine head 90.
The structure of the spark plug 100 in the above-described embodiment is merely an example, and various modifications are possible. For example, the spark plug 100 may be a pre-chamber plug which has a cover provided at the forward end of the metallic shell 30 and forming an auxiliary combustion chamber.
The present invention is not limited to the above-described embodiment and may be embodied in various other forms without departing from the scope of the invention. For example, the technical features in the embodiment corresponding to the technical features in the aspects described in the “SUMMARY OF INVENTION” section can be appropriately replaced or combined in order to solve some of or all the foregoing problems or to achieve some of or all the foregoing effects. A technical feature which is not described as an essential feature in the present specification may be appropriately deleted.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2021-113909 | Jul 2021 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2022/022752 | 6/6/2022 | WO |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2023/281957 | 1/12/2023 | WO | A |
| Number | Name | Date | Kind |
|---|---|---|---|
| 10714908 | Gozawa | Jul 2020 | B1 |
| 10790639 | Imai | Sep 2020 | B1 |
| 10944244 | Ban | Mar 2021 | B2 |
| 11050221 | Imai | Jun 2021 | B2 |
| 11431155 | Ban | Aug 2022 | B2 |
| 11456578 | Saito | Sep 2022 | B2 |
| 11637412 | Mishima | Apr 2023 | B2 |
| 11695256 | Sugiura | Jul 2023 | B2 |
| 11695258 | Gozawa | Jul 2023 | B2 |
| 11710947 | Sugita | Jul 2023 | B2 |
| 11715933 | Ban | Aug 2023 | B2 |
| 11929594 | Gozawa | Mar 2024 | B1 |
| 20200083674 | Imai | Mar 2020 | A1 |
| 20200313403 | Imai | Oct 2020 | A1 |
| Number | Date | Country |
|---|---|---|
| 102022208731 | Feb 2024 | DE |
| 2006236769 | Sep 2006 | JP |
| 2019046660 | Mar 2019 | JP |
| 2019242930 | Dec 2019 | WO |
| Entry |
|---|
| International Search Report mailed Jul. 19, 2022 for the corresponding International Patent Application No. PCT/JP2022/022752 (5 pages including English translation). |
| Number | Date | Country | |
|---|---|---|---|
| 20240250507 A1 | Jul 2024 | US |
