Spark plug

Abstract: In a spark plug having a cylindrical metallic shell a front end of which is extended into a combustion chamber of an internal combustion engine, an insulator is provided within the metallic shell so as to provide an annular clearance between a front end of the metallic shell and that of the insulator, a width of the annular clearence being within a range of 0.65 mm ± 0.25 mm. An extension skirt which the metallic shell is extended into the combustion chamber has a length within a range from 1.0 mm to 3.0 mm. A tapered surface is provided by planing off an inner edge of a front end of the metallic shell, and the surface angularly falls within angles from 20 to 40 degrees. One end of an outer electrode is welded to the tapered surface while other end of the outer electrode is bent to oppose to a front end of a center electrode.

Description: This invention relates to a spark plug for use in an internal combustion engine, and particularly concerns a metallic shell which extends into the combustion chamber of an internal combustion engine. In a spark plug which is usually employed in an internal combustion engine, it has been suggested that a firing tip should extend further into the combustion chamber of the internal combustion engine to improve ignition efficiency. Along with the repositioning of the firing tip, the front end of the metallic shell of the spark plug is extended into the combustion chamber to protect the outer electrode against over-heating. In order to prevent the outer electrode from being accidentally broken a tapered surface is provided at the front end of the metallic shell to reduce the strain of bending of the outer electrode when the outer electrode is welded to the tapered end surface of the metallic shell. Further, it has been suggested that the annular clearance between the front end of the metallic shell and that of an insulator located within the metallic shell be reduced. This is a countermeasure against fouling of the front end of the insulator; which removes carbon deposits on the insulator by spark discharge occurring through the annular clearance. With the recent high-output performances of internal combustion engines, it is required to prevent the outer electrode from being accidentally broken, and at the same time, protect the insulator against fouling when operating the engine at low loads. To meet this requirement, the adoption of the individual countermeasures in combination has been considered. However, it is found that combining the individual countermeasures reduces the individual advantages leading to no improvement. US 4211952 refers to the presence of restriction gaps and their sizes in terms of the sizes of the spark gap and the creeping discharge gap. JP-A-1 302678 specifies the protrusion of a spark plug into the combustion chamber by between 1mm and 3mm, as well as the provision of an internal taper on the outer shell. US 2684060 discloses a skirt on the outer electrode with axial slits. According to the present invention, there is provided a spark plug comprising: a cylindrical metallic shell a front end of which is adapted to extend into the combustion chamber of an internal combustion engine; a tubular insulator adapted to be concentrically located within the metallic shell and to provide an annular clearance between the inner wall of the front end of the metallic shell and the outer wall of the front end of the insulator of a width in the range 0.4 mm to 0.9 mm inclusively; an extension skirt provided on the metallic shell, adapted to extend into the combustion chamber, the length of the extension skirt being in the range 1.0 mm to 3.0 mm inclusively a plurality of axial slits being provided circumferentially distributed in the extension skirt; a tapered surface provided on the front end of the extension skirt, the taper being defined by the diameter of the inner surface increasing towards the front end of the plug, the angle of taper being in the range 20 degrees to 40 degrees inclusively with regard to a plane perpendicular to the axis of the plug; and, wherein an outer electrode of the spark plug has one end which is securely welded to the tapered surface of the extension skirt, and another end bent to oppose a front end of a centre electrode to form a spark gap. With the extension of the front end of the metallic shell into the combustion chamber, it is possible to maintain good ignition with reduced incidence of misfires. An extension exceeding 3 mm could cause oxidation of the electrodes at high temperature. By decreasing the annular clearance between the front end of the metallic shell and that of the insulator, the heat resistance of the spark plug may be improved, since excessive heat is prevented from reaching it. Carbon deposit on the insulator decreases its electrical resistance with the result that the spark discharge runs through the clearance thus removing the carbon deposit. The optimum width of the clearance is found to be 0.65 mm ± 0.25 mm with the length of the extension skirt between 1 mm and 3 mm. In order to prevent the outer electrode from being accidentally broken when the outer electrode is bent, a tapered surface is provided at the front end of the metallic shell to reduce the strain of bending of the outer electrode when it is welded to the tapered end surface of the metallic shell. Increased taper of the end surface of the metallic shell, however, reduces the need to bend the outer electrode too much, but it often establishes an abnormal spark between the inner wall of the metallic shell and the front end of the insulator unless the taper is between 20 and 40 degrees. Moreover, the axial slits circumferentially provided in the extension skirt work to cool the insulator so as to further add heat-resistance to the spark plug when air-fuel mixture is taken into the combustion chamber to flow along the extension skirt. The invention will be further understood from the following description when taken together with the attached drawings, which are given by way of example only and in which: Fig. 1 is a side view of an embodiment of the invention; Fig. 2 is a bottom view of the spark plug; and Fig. 3 is a schematic diagram showing how anti-fouling effect and the incidence of misfire during idling operation change according to the annular clearance between a metallic shell and an insulator. Referring to Figs. 1 and 2 in which an embodiment of the invention is shown, numeral 1 designates a spark plug for use in an internal combustion engine. The spark plug 1 has a cylindrical metallic shell 2, the axial length (1) of which measures 20.5 mm somewhat longer than 19.0 mm of an usual spark plug. Within the metallic shell 2, is a tubular insulator 4 concentrically located into which a center electrode 5 is concentrically placed. In this instance, the front end of the insulator 4 extends beyond that of the metallic shell 2 by a length of 0 mm to 0.5 mm as designated at (n) in Fig. 1. On the other hand, the front end portion of the metallic shell 2 has an extension skirt 6 which is extended into a combustion chamber (Ch) of the engine. The length (m) which the extension skirt 6 is extended into the combustion chamber (Ch) is determined to be e.g 1.5 mm, but the length (m) of the skirt 6 is acceptable as long as it falls within a range from 1.0 mm to 3.0 mm inclusively. Meanwhile, the extension skirt 6 has a front end surface, an inner edge of which is planed off to form a tapered surface 7 which progressively decreases its diametrical dimension toward the rear end of the metallic shell 2. The tapered surface 7 determines its tapered angle (ϑ) to be e.g. 29 degrees, but it may angularly fall within angles from 20 to 40 degrees both inclusive. Numeral 3 is an outer electrode which is made of e.g. nickel-based alloy to impart it with spark-corrosion resistant property. The outer electrode 3 has one end securely welded to the tapered surface 7 of the metallic shell 2, while the other end of the outer electrode 3 is bent to vertically oppose the front end (firing tip) of the center electrode 5 so as to form a spark gap (Gs) therebetween. In this instance, the tapered surface 7 eliminates the necessity of bending the outer electrode 3 too much so as to prevent the outer electrode 3 from being accidentally broken. Further, the front end of the insulator 4 is located within the extension skirt 6 to provide an annular clearance 9 between an inner wall of the front end portion of the extension skirt 6 and the outer wall of the front end portion of the insulator 4. Width (p) of the annular clearance 9 is determined to be e.g. 0.65 mm which is narrow enough to substantially avoid heat from being introduced into the spark plug 1. However, the width (p) of the annular clearance 9 may fall within 0.65 mm ± 0.25 inclusively. With the extension skirt 6, are a plurality of axial slits 8 circumferentially provided which works to cool the insulator 4 so as to further impart heat-resistant property to the insulator 4 when air-fuel mixture is taken into the combustion chamber (Ch) to flow along the extension skirt 6. In this instance, the number of the axial slits 8 is e.g. four, and each width (q) of the axial slits 8 is determined to be 1.5 mm. Now, Fig. 3 is a schematic diagram showing how anti-fouling effect and incidence of misfire during idling operation of the engine change upon the width (p) of the annular clearance 9 between the extension skirt 6 and the metallic shell 2. In Fig. 3, how much the insulator 4 is fouled by carbon deposit piled on the insulator 4 is measured by its electrical resistance (MΩ). Fig. 3 apparently teaches how well the above-determined width (p) of the annular clearance 9 has improved the anti-fouling effect and the incidence of misfire during idling operation of the engine. As understood from the foregoing description, the extension skirt 6 is extended into the combustion chamber (Ch) to maintain good ignition without being oxidized by high temperature, and the tapered surface 7 prevents the outer electrode 3 from being accidentally broken without sacrifying the good ignition. Moreover, the axial slits circumferentially provided with the extension skirt 6 works to cool the insulator 4 so as to further impart heat-resistant property to the insulator so as to cope with the carbon deposit which otherwise is accumulated on the insulator 4. According to the invention, the spark plug 1 is capable of coping with high-output, high-rpm engine, and maintaining good ignition without misfire, and preventing an outer electrode from being accidentally broken, and at the same time, protecting the insulator against the fouling when operating the engine at low load. It is noted that the outer electrode may be secured to the extension skirt by means of brazing, spot welding or electrical resistant welding.

Claims: A spark plug (1) comprising: a cylindrical metallic shell (2) a front end of which is adapted to extend into the combustion chamber of an internal combustion engine; a tubular insulator (4) adapted to be concentrically located within the metallic shell (2) and to provide an annular clearance (9) between the inner wall of the front end of the metallic shell (2) and the outer wall of the front end of the insulator (4) of a width (p) in the range 0.4 mm to 0.9 mm inclusively; an extension skirt (6) provided on the metallic shell (2), adapted to extend into the combustion chamber, the length (m) of the extension skirt (6) being in the range 1.0 mm to 3.0 mm inclusively, a plurality of axial slits (8) being provided circumferentially distributed in the extension skirt (6); a tapered surface (7) provided on the front end of the extension skirt (6), the taper being defined by the diameter of the inner surface increasing towards the front end of the plug, the angle of taper (8) being in the range 20 degrees to 40 degrees inclusively with regard to a plane perpendicular to the axis of the plug; and, wherein an outer electrode (3) of the spark plug (1) has one end which is securely welded to the tapered surface (7) of the extension skirt (6), and another end bent to oppose a front end of a centre electrode (5) to form a spark gap. A spark plug according to claim 1 wherein the taper is obtained by removing an inner edge of the front end of the extension skirt (6). A spark plug according to claim 1 or 2 wherein the axial length (1) of the metallic shell (2) is 20.5 mm. A spark plug according to claim 1, 2 or 3 wherein the width (g) of the axial slits (8) is 1.5 mm. An internal combustion engine comprising a spark plug according to any one of the preceding claims.

Inventors: KAGAWA JUNICHI, MATSUTANI WATARU, KAGAWA, JUNICHI, MATSUTANI, WATARU
Applicants: NGK SPARK PLUG CO, NGK SPARK PLUG CO., LTD
Application year: 1991
Main classification: H01T13
IPC codes: H01T13