Abstract:
Here in is disclosed a system of heat removal for the electrode part of a sparkplug that is used in the internal combustion engine. This is so as to use electrodes that have a very large mass as compared to the smaller, to very small electrodes, as in the case of using precious metals. 
     Here in is further disclosed a sparkplug that is made using recycled parts from old used sparkplugs.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefits of provisional patent application, Ser. No. 60/994,009, Filed Sep. 17, 2007 by the present inventors, which is incorporated by reference here in. 
     
    
     FEDERALLY SPONCERED RESEARCH 
       [0002]    Not applicable 
       SEQUENCE LISTING OR PROGRAMS 
       [0003]    Not applicable 
       BACKGROUND 
       [0004]    1. Field 
         [0005]    This application relates to the sparkplug of an internal combustion engine, and more particularly, to the efficiency of the heat removal process and core construction of that sparkplug. 
         [0006]    2. Prior Art 
         [0007]    In a 4 cycle internal combustion engine, the cycles are, starting at top dead center; this means that the piston is all the way at the top of the cylinder at the start of the cycle. The piston moves downward and the intake valve opens letting the air fuel mixture into the firing chamber, this is the intake cycle. When the piston reaches bottom dead center, the intake valve closes, and the piston moves up compressing the air fuel mixture, this is the compression cycle, and this creates a very fast moving wind storm type environment. When the piston reaches top dead center, the sparkplug will fire causing the compressed air fuel mixture to explode and force the piston downward, this is the power cycle. This is where the fuel is actually turned to kinetic energy that causes the internal combustion engine to operate. This is also where the heat is generated. When the piston reaches bottom dead center, the exhaust valve will open and the piston will move upward and force the burnt air fuel mixture out of the firing chamber, which is 1 revolution of the internal combustion engine. 1 revolution happens, from 800 to over 10,000 times a minute this is called revolutions per minute or RPM&#39;S. 
         [0008]    The internal combustion engine creates a lot of heat, some a little, some a lot. The present technology has been going towards smaller electrodes made of precious metals and the present technology, as far as the heat transfer is concerned, has been adequate. The technology of the larger more massive electrodes require a greater heat transfer than just the design of the insulator and its role in removing heat from the electrode. In recent years the demand of the sparkplug has been greatly diversified do to the fact that there is a tremendous diversity in the applications of the internal combustion engine. This diversity has created a demand for a more precise and wider range of heat transfer. 
         [0009]    In the course of the operation of the internal combustion engine heat from the firing chamber will accumulate in the electrode and if this heat is not removed fast enough, that will cause the electrode to get red hot and the engine will pre-detonate, and eventually the electrode will be destroyed. 
         [0010]    The standard sparkplugs generally have a relatively small positive electrode and very little ground area, the ground prong is generally welded to the shell and protrudes up and over the positive electrode. 
       SUMMARY 
       [0011]    With the preferred embodiments there is provided the removal of heat from the electrode of a sparkplug used in an internal combustion engine, so as to use larger more massive electrodes on that spark plug. This is done by adding a heat sink that the electrode can screw directly into. The heat sink adds surface area to the contacting surfaces of the electrode and insulator. The heat sink is located were the seal and resister are in conventional spark plugs. In the preferred embodiments a sealing ring is located between the electrode and the insulator at the end of the insulator that protrudes into the firing chamber, and the resistor is located just on the other side of the heat sink. 
         [0012]    There is in addition provided the process of recycling used sparkplugs to restore them to a condition equal to or better than original, using the insulator and the shell of a previously used sparkplug. 
         [0013]    There is in addition provided a complete core to replace the used cores of existing sparkplugs to be used in the process of recycling used sparkplugs. 
       DRAWINGS—FIGURES 
       [0014]      FIG. 1  is a front cut away view of the first embodiment  10 . 
         [0015]      FIG. 2  is a front cut away view of the electrode  20  showing its constituents. 
         [0016]      FIG. 3  is a front cut away view of the seal ring  26  showing its constituents. 
         [0017]      FIG. 4  is a front cut away view of the heat sink  24  showing its constituents. 
         [0018]      FIG. 5  is an exploded perspective view of the first embodiment  10  showing the electrode  20  and the seal ring  26 . 
         [0019]      FIG. 6  is an exploded perspective view of standard spark plug. 
         [0020]      FIG. 7  is a front cut away view of a standard spark plug after recycling preparation. 
         [0021]      FIG. 8  is an exploded perspective view of the bolt core assembly. 
         [0022]      FIG. 9  is a front cut away view of the bolt core terminal  22  showing its constituents. 
         [0023]      FIG. 10  is a perspective view of the second embodiment. 
         [0000]    
       
         
               
             
               
               
               
               
             
           
               
                   
               
               
                 DRAWINGS - Reference Numerals 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                  10 
                 First Embodiment 
                 205 
                 External Threads 
               
               
                  12 
                 Second Embodiment 
                 207 
                 Electrode Seal Cup 
               
               
                  20 
                 Bolt Core Electrode 
                 22 
                 Bolt Core Terminal 
               
               
                 201 
                 Firing End 
                 221 
                 Terminal End 
               
               
                 225 
                 Internal Threads 
                 281 
                 Electrode Seal Surface 
               
               
                 227 
                 Terminal Seal Cup 
                 30 
                 Standard Insulator 
               
               
                 229 
                 Terminal Nut 
                 301 
                 Electrode End Seal Surface 
               
               
                  24 
                 Heat Sink 
                 303 
                 Terminal End Seal Surface 
               
               
                 241 
                 Cooling Fins 
                 32 
                 Shell 
               
               
                 243 
                 Heat Sink Internal Threads 
                 321 
                 Ground Prong 
               
               
                  26 
                 Seal Ring General 
                 323 
                 Replacement Ground Prong 
               
               
                  26E 
                 Seal Ring used at Electrode 
                 34 
                 Standard Electrode 
               
               
                   
                 End 
               
               
                  26T 
                 Seal Ring used at Terminal 
                 36 
                 Standard Terminal 
               
               
                   
                 End 
               
               
                 261 
                 Inside Surface 
                 38 
                 Resistor 
               
               
                 263 
                 Outside Surface 
                 40 
                 Cavity 
               
               
                  28 
                 Heat Sink Insulator 
               
               
                   
               
             
          
         
       
     
     
    
     DETAILED DESCRIPTION 
     First Embodiment 
       [0024]      FIG. 1  shows a front cut away view of the first embodiment  10 . A firing end  201  is used in reference to indicate the end that protrudes into the cylinder of the internal combustion engine. A terminal end  221  is used in reference to indicate the end that protrudes out of the head of the internal combustion engine where the high voltage from the distributor system is terminated. These terms will be used to reference the direction of parts and their constituents. 
         [0025]    A heat sink  24  is located between a bolt core electrode  20  and a standard terminal  36 . A resistor  38  is provided for the use in some applications but is not required. The heat sink  24 , the bolt core electrode  20 , the standard terminal  36  and the resistor  38 , are lined contiguously from the terminal end  221  to the firing end  201  this is the core of the sparkplug. A heat sink insulator  28  is used for the electrical isolation of the core. The heat sink insulator  28  surrounds the core so that the firing end of the bolt core electrode  20  will protrude out of the firing end  201  of the sparkplug and the terminal end of the standard terminal  36  will protrude out of the firing end  221 . A seal ring  26 E is located at the firing end  201  sandwiched between the bolt core electrode  20  and the firing end of the heat sink insulator  28 . A shell  32  surrounds the firing end portion of the heat sink insulator  28  and covers about half of the heat sink insulator  28 . 
         [0026]      FIG. 2 , shows the bolt core electrode  20  and its constituents. 
         [0027]      FIG. 3 , shows the seal ring  26 E and its constituents. 
         [0028]      FIG. 4  shows the heat sink  24  and its constituents. 
         [0029]    The parts and their constituents shown in  FIGS. 2 ,  3  and  4  will be explained in the operations explanation of  FIG. 5 . 
         [0030]      FIG. 5  shows the first embodiment  10 , were the electrode  20  is inserted through the seal ring  26 E and through the firing end of the heat sink insulator  28  and screws into the heat sink internal threads  243 . The seal cup  207  of the bolt core electrode  20  is the same angle as surface area  241  with respect to the center line of the core. Surface area  263  of the sealing ring  26 E is the same angle as sealing surface  281  of the heat sink insulator  28 , also with respect to the center line of the core. Sealing ring  26 E seals the high pressure of the air fuel mixture from leaking into the spark plug. The sealing ring  26 E is made of a slightly softer material with respect to the bolt core electrode  20  so when it&#39;s sandwiched between the seal cup  207  of the bolt core electrode  20  and the electrode end seal surface  301  of the heat sink insulator  28 , the screwing action of the bolt core electrode into the heat sink  24  will smash the seal ring  26 E tight to seal off the core of the sparkplug from the firing chamber. 
         [0031]    The external threads  205  of the bolt core electrode  20  screw tight into the internal threads  243  of the heat sink  24 , this is a tight fit so as to create a direct path from the firing end of the bolt core electrode  20 , through the electrode shaft  203  to the heat sink  24  were the heat will be removed from the core through the cooling fins  241  and through the heat sink insulator  28  and out through the shell  32  were it will dissipate into the cooling system of the engine. The heat sink  24  does this by greatly multiplying the surface area that comes in contact with the insulator  28  by use of cooling fins  241 . 
         [0032]    The heat sink  24  is made of a metallic material so as to be electro conductive to complete the distributor circuit between the terminal end  221 , and the firing end  201  of the sparkplug. The heat sink  24  is disk shaped with the cooling fins  241  protruding out in a radial direction so as to surround the heat sink  24  and wrap around the core at a point in the middle where the heat sink insulator  28  and the shell  32  surround them. 
         [0033]    The amount of heat that is removed can be precisely adjusted to fit the application by increasing the number of the cooling fins  241 . By increasing the number of the cooling fins  241  we are again increasing the amount of surface area that comes in contact with the heat sink insulator  28 .  FIG. 4  shows the heat sink  24  with 5 cooling fins  241 . This number of cooling fins  241  can be increased or decreased to precisely adjust the amount of heat that is removed. This is important because a sparkplug has to be set to operate at a certain temperature. If the electrode gets to hot it will cause the engine to pre-detonate resulting in damage to the engine. If it doesn&#39;t get hot enough it will not self clean and carbon will build up on the electrode and the shell portion that protrudes into the firing chamber and cause the sparkplug to foul out. 
         [0034]    The firing end of the bolt core electrode  201  can be very large with respect to the standard sparkplug electrodes and basically any shape that is desired. 
       Second Embodiment 
       [0035]      FIG. 6-FIG .  10  explain the recycling process and the parts needed to rebuild and reuse standard spark plugs that have been on the market for many years and are still on the market now. The recycling presses will restore a standard sparkplug to a condition as good as or better than original. The second embodiment reuses the standard insulator  30  and the shell  32 . 
         [0036]      FIG. 6  shows a standard sparkplug and how a standard electrode  34 , a resistor  38  and a standard terminal  36  are arranged inside a standard insulator  30  and shell  32 . A ground prong  321  is located at the firing end of the shell  32 . The standard electrode  34  is placed in the standard insulator  30  so that the firing end protrudes out and comes in close proximity with the ground prong  321 . The resistor  38  is placed in between the standard electrode  34  and the standard terminal  36 . The function of the resistor  38  is to cancel out radio frequencies that are created by the high voltage of the spark. The radio frequencies may interfere with radios, stereos, citizen band radios and devices that use radio waves to operate, but the resistor is not required in many applications and can be added to the circuit at almost any point. The standard terminal  36  is placed in the standard insulator  30  so that the terminal end of the standard terminal  36  protrudes out. This for the connection of the high voltage from the distributor system that will pass though the core and discharge as the spark, between the firing end of the standard electrode  34  and the ground prong  321 . 
         [0037]    The first step is to remove the ground prong  321  by cutting it off and machining off the surface that it was welded to. This will precisely clean the surface in preparation for the attachment of the replacement prong  323 . 
         [0038]    The second step is to remove the used core. This can be done by pressing it out through the terminal end of the standard insulator  30 , as shown by the arrows. 
         [0039]    The third step is to remove the very outer layer of the shell  32  by using a corrosive material such as acid. The acid will dissolve the outer layer precisely even over the entire shell  32 , down and into the raw metal completely removing everything on the surface. The acid will also remove 0.002″ to 0.005″ of the original material of shell  32 . The acid will remove dirt and corrosion on the surface of the standard insulator  30 , but will have no effect on the integrity of the material that the standard insulator  30  is made of. 
         [0040]      FIG. 7  shows the standard insulator  30  that is still assembled with the shell  32 . There is a cavity  40  where the core was originally. 
         [0041]    The fourth step is to machine chamfers on the standard insulator  30 . An electrode seal surface  301  at the firing end and a terminal seal surface  303  at the terminal end. These will be at a predetermined angel, with respect to the center line. This angle will be the same as the angle of the inside surface  261  of the seal ring  26  shown in  FIG. 3 . 
         [0042]    The fifth step is to assemble the bolt core electrode  20 , the bolt core terminal  22 , and the seal rings  26  inside the standard insulator  28 . 
         [0043]      FIG. 8  shows how the bolt core electrode  20  passes through seal ring  26 E and slides in through the firing end of the standard insulator  30 . The bolt core terminal  22  passes through seal ring  26 T and slides in through the terminal end of the standard insulator  30 . At that point the bolt core electrode  20  and the bolt core terminal  22  will be screwed tight causing the seal ring  26 E to be sandwiched contiguously between the electrode end seal surface  301  and the inside surface  261  of the seal ring  26 E. This will also cause the seal ring  26 T to be sandwiched contiguously between the terminal end seal surface  303  of the and the inside surface  261  of the seal ring  26 T. 
         [0044]    The sixth step is to permanently attach the replacement ground prong  323  to the firing end of the shell  32 . This is usually done by welding, but can use any form of permanent attachment. 
         [0045]      FIG. 9  further shows detail about the bolt core terminal  22 . The terminal end  221  is where the high voltage is connected. The terminal nut  221  is used in step five to tighten the bolt core electrode  20  to the bolt core terminal  22 . The internal threads  225  is where the external threads  205  of the bolt core electrode  20  screw into, in step five. Seal cup  227  is where the seal ring  26 T will be after assembly. 
         [0046]      FIG. 10  shows the second embodiment  12  in its finished state. The standard insulator  30  and the shell  32  are parts that are recycled from used sparkplugs.