A semi-creeping discharge type spark plug

Abstract: In a semi-creeping discharge type spark plug, a cylindrical metal shell (1) and an insulator (2) are provided, the latter of which has an axial bore (22) and placed within the metal shell (1) so that a front end of the insulator (2) extends beyond the metal shell (1). A center electrode (3) is placed within the axial bore (22) of the insulator (2) so that a front end surface edge (311) of the center electrode (3) retracts by 0.1~ 0.6 mm behind from a front end surface (23) of the insulator (2) . A ground electrode (4), one end of which is connected to a front end (11) of the metal shell (1), and the other end of which is bent to oppose an outer surface of the insulator (2) so as to form an air-gap (g1) therebetween while permitting creeping spark discharges running along said front end surface (23) of said insulator (2). A foward edge portion (42) of a front end surface (41) of the ground electrode (4) extends by 0.0 ~ 1.0 mm forward from the front end surface (23) of the insulator (2).

Description: The invention relates to a semi-creeping discharge type spark plug in which a spark discharge gap is formed by an air-gap and a creeping spark discharge gap through which spark discharges run along a front end surface of an insulator. US-A-2,899,585 shows such a spark plug where a metal shell surrounds an insulator and a central electrode is within a bore in the insulator. The end of the electrode is withdrawn relative to the end of the insulator and relative to electrodes which are defined at the end of the metal shell. As shown in Fig. 6, a semi-creeping discharge type spark plug (J) has been known in which a cylindrical metal shell 1 and an insulator 2 are provided, the latter of which has an axial bore 22 and is placed in the metal shell 1 so that a front end of the insulator 2 extends from a front end surface 11 of the metal shell 1. Within the axial bore 22, a center electrode 3 is placed, a front end surface 31 of which is located at a level substantially the same as the front end surface 23 of the insulator 2. L-shaped ground electrodes are provided which are welded to the front end surface 11 of the metal shell 1 as designated at numeral 4. In this situation, the front end surface 31 of the center electrode 3 is generally in flush with a forward edge portion 42 of a front end surface 41 of the ground electrode 4. Upon applying a high voltage across the electrodes 3, 4, spark discharges creep along the front end surface 23 of the insulator 2. In EP-A-0 765 017 published on March 26, 1997 by the EPO, a semi-creeping discharge type spark plug similar to that of Fig. 6 has been disclosed which however remains silent about a geometrical dimensional relationship between the front end surface of the insulator and the forward edge portion of the front end surface of the ground electrode. Upon considering the purposes of the invention disclosed in the EP application publication No. 0765017, the publication puts an emphasis on a prevention of the channeling phenomenon rather than an avoidance of the soot fouling to insure an extended service life. On the contrary, the present invention makes much of preventing the soot fouling even though permitting the channeling phenomenon in a tolerable degree. As well known for those versed in the art, this type of the spark plug is, in fact, superior to a general air-gap type spark plug in the point of fouling resistance because the former burningly evaporate the carbon-related deposit collected on the front end surface of the insulator. In those known semi-creeping discharge type spark plugs, it is, however, recognised that the insulation resistance reduces due to the carbon-related deposit (Fig. 9) when the fouling resistance experimental test was carried out under very cold conditions (-15°C) in conformity with a predelivery pattern in Fig. 4 as described in detail hereinafter. Besides insuring a desirable fouling resistant property, it has generally been demanded to impart a good heat resistant property to a semi-creeping discharge type spark plug without inviting unfavourable channelling phenomenon. Therefore, it is a main object of the invention to provide a semi-creeping discharge type spark plug which is capable of concurrently insuring a good heat resistance and fouling resistance so as to maintain a desirable insulation resistance for an extended period of time. According to the invention, there is provided a semi-creeping discharge type spark plug comprising: a cylindrical metal shell; an insulator having an axial bore and placed within said metal shell; a center electrode placed within said axial bore of said insulator so that a front end surface edge of said center electrode is withdrawn from a front end surface of said insulator; characterised in that a front end of said insulator extends beyond said metal shell; said front end surface edge is withdrawn by 0.1 ∼ 0.6 mm from said front end surface; and by a ground electrode, one end of which is connected to a front end of said metal shell, and which electrode is bent so that its other end opposes an outer surface of said insulator so as to form an air-gap therebetween while permitting creeping spark discharges running along said front end surface of said insulator, a forward edge portion of a front end surface of said ground electrode extending by 0.0 ∼ 1.0 mm forward from said front end surface of said insulator. When the forward edge portion of the ground electrode is located behind the front end surface of the insulator, the heat resistant property is likely to reduce which is especially important upon running an internal combustion engine consecutively at high speed. This is because the spark discharges are supposed to occur across the air-gap between the ground electrode and insulator in order to ignite the air-fuel mixture injected into a combustion chamber. At the time of igniting the air-fuel mixture, the combustion spreads into a cylinder of the internal combustion engine to expose the insulator directly to the combustion flames. This may result in an excessive temperature rise of the front end of the insulator to reduce the heat resistance of the insulator to an unacceptable degree. When the forward edge portion of the ground electrode is located forward by 1.0 mm or more from the front end surface of the insulator, the spark discharges is likely to converge into a steady path without colliding agaist the outer surface of the insulator. This reduces the fouling resistance which affects particularly on the cold starting capability of the engine, and at the same time, inducing the channeling at the front end surface of the insulator which adversely influences the heat resistant property upon running the engine continuously at high speed. By way of illustration, a heat resistance exprimental test result data are shown in Fig. 11 in which an insulator nose is 13 mm, and a diameter of the front end of the insulator is 4.0 mm while a diameter of the center electrode is 2.0 mm, and a distance between the forward edge portion of the ground electrode and the front end surface of the insulator is 0.0∼ 0.5 mm. With the front end edge of the center electrode retracted by 0.1 mm or more behind from the front end surface of the insulator, it is possible to creep the spark discharges appropriately along the front end surface of the insulator when permitting the spark discharge between the front end surface of the center electrode and the ground electrode. This facilitates the self-cleaning action to burningly evaporate the carbon-related deposit collected on the front end surface of the insulator. When the front end edge of the center electrode is located by more than 0.6 mm behind from the front end surface of the insulator, it supposedly quickens the progress of the channeling. With the front end edge of the center electrode retracted by 0.1 ∼ 0.6 mm behind from the front end surface of the insulator, and the forward edge portion of the ground electrode located by 0.0∼ 1.0 mm forward from the front end surface of the insulator, it is possible to insure the good heat resistance and fouling resistance at once without sacrificing the channeling resistance. With the diameter of the front end of the center electrode thinned to 2.0 mm or less, it is possible to induce the spark discharges with a relatively low discharge voltage so as to meliorate the ignitability and fouling resistance by facilitating the self-cleaning action. From a point of preventing the spark erosion of the center electrode, it is necessary to increase the diameter of the front end of the center electrode to 1.0 mm or more (preferably 1.6 mm or more). With an inner edge portion of the front end surface of the insulator bevelled by 0.1 ∼ 1.0 mm (preferably 0.2 ∼ 0.8 mm) in terms of chamfer length (C) or rounded by 0.1 ∼ 1.0 1/mm (preferably 0.2∼ 0.8 1/mm) in terms of radius of curvature (R), it is possible to weaken an attraction of the spark discharges against the bevelled or rounded surface so as to effectively reduce the channeling with the least damage done thereon. When the chamfer length (C) or the radius of curvature (R) exceeds 1.0 mm (1.0 mm 1/mm), it reduces the fouling resistance while deteriorating the physical strength of the insulator. By providing a plurality of ground electrodes (preferably three or four), it is possible to diverge the spark discharge paths so as to prevent the spark erosion with the least channeling. This also facilitates the self-cleaning action due to the spark discharges so as to meliorate the fouling resistance. With a front end including the front end surface edge of the center electrode made of a spark erosion resistant metal tip, it is possible to improve the spark erosion resistant property of the center electrode, despite that the front end surface edge of the center electrode is likely to be spark eroded. Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which: Fig. 1 is a plan view of a semi-creeping discharge type spark plug (A) according to a first embodiment of the invention; Fig. 2 is a longitudinal cross sectional view of a front portion of the semi-creeping discharge type spark plug (A); Fig. 3 is a graphical representation showing a relationship between an insulation resistance and the number of cycles in accordance with the spark plug (A); Fig. 4 is an explanatory view of a predelivery pattern; Fig. 5 is a graphical representation showing how a fouling resistance (number of cycles (N) needed to reduce by 10 MΩ) changes depending on how far a front end surface of a center electrode extends beyond or retracts from a front end surface of an insulator; Fig. 6 is a plan view of a front portion of a prior art semi-creeping discharge type spark plug (J); Fig. 7 is a longitudinal cross sectional view of a front portion of a semi-creeping discharge type spark plug (B) according to a second embodiment of the invention; Fig. 8 is a graphical representation showing a relationship between an insulation resistance and the number of cycles in accordance with the spark plug (B); Fig. 9 is a graphical representation showing a relationship between an insulation resistance ( M Ω ) and the number of cycles (N) in accordance with the prior art spark plug (J); Fig. 10 is a longitudinal cross sectional view of a front portion of a semi-creeping discharge type spark plug (C) according to a third embodiment of the invention; and Fig. 11 is an explanatory view of experimental test result data on the fouling resistance and heat resistance obtained by varying a distance between a forward edge portion of a ground electrode and the front end surface of the insulator. Referring to Figs. 1 ∼ 5 which show a semi-creeping discharge type spark plug (A) according to a first embodiment of the invention, the spark plug (A) has a cylindrical metal shell 1 and a tubular insulator 2, an inner space of which serves as an axial bore 22 (approx. 2. 0 mm in diameter). The insulator 2 is placed within the metal shell 1 so that a front end of 21 of the insulator 2 extends beyond a front end 11 of the metal shell 1. Within the axial bore 22 of the insulator 2, a center electrode 3 is fixedly supported. As designated at numeral 4 in Figs. 1 and 2, four L-shaped ground electrodes are welded to the front end 11 of the metal shell 1. A front end surface 41 of each ground electrode 4 measures, for example, 1.1 mm in thickness and 2.2 mm in breadth. The metal shell (low carbon steel) 1 has a male threaded portion (M14) 12 through which the spark plug (A) is to be mounted on a cylinder head of an internal combustion engine by way of a gasket (not shown). The insulator 2 is made of a ceramic material with alumina as a main ingredient. The insulator 2 has a stepped portion 2a which rests on a shoulder portion 1a of the metal shell 1 by way of a packing 1b so as to stabilize the insulator 2 within the metal shell 1. By caulking a rear tail portion 1c of a hex nut 1d of the metal shell 1 against the insulator 2, the insulator 2 is fixedly stabilized with its front end 21 extended beyond a front open end 14 of the metal shell 1. The insulator 2 has a front end surface 23 substantially formed into a flat-shaped configuration so as to smoothly accept the semi-creeping spark discharges therealong. As designated by numeral 24 in Fig. 2, an inner edge portion of the front end surface 23 is bevelled by 0.2 mm in terms of chamfer length (C). In order to insure the channeling resistance without losing a good fouling resistance, the inner edge portion of the front end surface 23 is bevelled preferably by 0.2 ∼ 0.8 mm in terms of chamfer length (C) or otherwise rounded by 0.2 ∼ 0.8 (1/mm) in terms of radius of curvature (R). Further, the front end 21 of the insulator 2 has a straight portion 25 diametrically constricted to measure 3.0 ∼ 4.0 mm in diameter and 1.0∼ 2.0 mm in length. The presence of the straight portion 25 facilitates the self-cleaning action, and at the same time, making it easy to form an air-gap (g1) between an outer surface 26 of the insulator 2 and a front end surface 41 of the ground electrode 4. The center electrode (2.0 mm in diameter) 3 has a nickel-based alloy (e.g., Ni-Si-Mn-Cr: NCF600) in which a heat conductor copper core is embedded. To a forward end of the center electrode 3, a disc-shaped noble metal tip 30 is welded, a front end surface of which acts as a front end surface 31 of the center electrode 3. The disc-shaped noble metal tip 30 is made of Pt-20Ni based alloy, and measures 2.0 mm in diameter and 0.5 mm in thickness. Instead of Pt-20Ni based alloy, the noble metal tip 30 may be made of other spark erosion resistant metals such as Pt, Pt-based alloy, Ir-based alloy, Ir-Rh based alloy, W-Re based alloy, highly chromium-contained alloy or the like. In this instance, the front end surface 31 (equivalent to a front end edge 311) of the center electrode 3 is retracted by 0.2 mm behind from the front end surface 23 of the insulator 2. The ground electrode 4 is made of a nickel-based alloy (e.g., NCF600) and bent so that the front end surface 41 opposes the front end edge 311 of the center electrode 3 while forming the air-gap (g1) with the outer surface 26 of the insulator 2. Upon applying a high voltage between the electrodes 2, 4, the spark discharges runs through the air-gap (g1) and a creeping spark discharge gap (g2) between the front end surface 31 of the center electrode 3 and the front end surface 41 of the ground electrode 4. The ground electrode 4 has a forward edge portion 42 which extends by e.g., 0.5 mm forward from the front end surface 23 of the insulator 2. This arrangement makes it possible to insure the good fouling resistance without sacrificing the good heat resistant property as evidenced in detail hereinafter. Fig. 3 shows a relationship between an insulation resistance (MΩ) and the number of cycles (N) with a predelivery pattern incorporated into a fouling resistant experimental test. Upon carrying out the fouling resistant experimental test, a 2500 cc, straight line, 6-cylinder, four-valve DOHC engine was placed on a chassis dynamometer under a cold room temperature (-15 °C) with the semi-creeping discharge type spark plug (A) mounted thereon. The fouling resistant experimental test is in conformity with the paragraph 5.2 (1) JIS D1606 on the assumption that the engine is cold started along the predelivery pattern of Fig. 4 at the heavy traffic congestion in extremely cold districts. With the use of a megohmmeter (commonly called as "Megger"), the insulation resistance values were measured after the end of each cycle. As apparent by comparing the graphical representation of the semi-creeping discharge type spark plug (A) in Fig. 3 to the prior art spark plug (J) of Fig. 6, it is possible in the semi-creeping discharge type spark plug (A) to maintain the insulation resistance value over 10M Ω without sacrificing the good fouling resistance. Fig. 5 shows how the fouling resistance changes depending on how far the front end surface 31 of the center electrode 3 extends beyond or retracts from the front end surface 21 of the insulator 2. In this instance, the fouling resistance was measured in terms of the number of cycles (N) needed to reduce the insulation resistance by 10 M Ω. 32 types of spark plug specimens were prepared in the following combinations. d: 1.0 mm, 1.6 mm, 2.0 mm and 2.5 mm. t: -1.0 mm, -0.6 mm, -0.5 mm, -0.3 mm -0.2 mm, -0.1 mm, 0.0 mm and +0.2 mm. Where (d) is a diameter of the noble metal tip 30 and the front end of the center electrode 3, (t) is a length how far the front end surface 31 of the center electrode 3 extends beyond or retracts from the front end surface 21 of the insulator 2, which are in turn designated as an extension length (positive number) and retraction length (negative numbers). Upon carrying out a fouling resistant experimental test, the engine was placed on the chassis dynamometer under the cold room temperature (-15 °C) with the spark plug specimens respectively mounted thereon in conformity with the predelivery pattern (paragraph 5.2 (1) JIS D1606) in Fig. 4. In this instance, the experimental test results in Fig. 5 is depicted by plotting the number of cycles firstly reduced to 10 M Ω or less. From the experimental test results in Fig. 5, it was found that the good fouling resistance is maintained so long as the front end surface 31 of the center electrode 3 retracts by 0.1 mm or more behind from the front end surface 23 of the insulator 2. However, it becomes unacceptable when the retraction length (t) exceeds 0.6 mm because it quickens the progress of channeling and damage done on the front end surface 23 of the insulator 2. Although the preferable fouling resistance maintained when the diameter (d) of the front end of the center electrode 3 is 2.0 mm or less as indicated in Fig. 5, it is necessary to define the diameter (d) to 1.0 mm or more (preferably 1.6 mm or more) from the point of preventing an unacceptable amount of the spark erosion and the channeling due to the concentrated spark discharge paths. Insomuch as the retraction length (t) occupies within a bound as depicted by the double hatched region of Fig. 5, the following advantages are obtained. (a) Because the front end surface 31 of the center electrode 3 retracts by 0.1 mm or more behind from the front end surface 23 of the insulator 2, it is possible to dominantly creep the spark dicharges along the front end surface 23 of the insulator 2 so as to facilitate the self-cleaning action with the good fouling resistance. Besides the four ground electrodes 4 provided to diverge the spark discharges, the forward edge portion 42 is located by 0.5 mm forward from the front end surface 23 of the insulator 2 with the retraction length (t) as 0. 6 mm, it is possible to significantly delay the damage, flaking and channeling given to the front end surface 23 of the insulator 2. (b) With the front end of the center electrode 3 thinned to 2.0 mm or less in diameter (d), it is possible to favorably meliorate the ignitability. However, the diameterical dimension (d) brings no substantial influence on the good erosion resistant property because the front end of the center electrode 3 is not so thinned as to be short of 1.0 mm. (c) With the inner edge of the front end surface 23 of the insulator 2 bevelled by 0.2 mm in terms of chamfer length (C), it is possible to delay the channeling of the insulator 2 because the attraction of the spark discharges against the bevelled portion 24 is weakened. (d) With the noble metal tip 30 provided on the center electrode 3, it is possible to decrease an amount of the spark erosion so as to ameliorate the spark erosion resistant property of the center electrode 3. Figs. 7 and 8 show a second embodiment of the invention in which a semi-creeping discharge type spark plug (B) is provided. The spark plug (B) is quite similar structurally to the first embodiment of the invention of Figs. 1 and 2 except for the bevelled portion 24 which the semi-creeping discharge type spark plug (A) has. Fig. 8 shows a relationship between an insulation resistance (MΩ) and the number of cycles (N) with the predelivery pattern incorporated into a fouling resistant experimental test. Upon carrying out the experimental test, a 2500 cc, straight line, 6-cylinder, four-valve DOHC engine was placed on the chassis dynamometer under the cold room temperature (-15 °C ) with the semi-creeping discharge type spark plug (B) mounted thereon. The fouling resistant experimental test was conducted in the same manner as described above. With the use of the megohmmeter, the insulation resistance values were also measured after the end of each cycle. From the graph of Fig. 8, it was found that the insulation resistance value exceeds 50MΩ with the good fouling resistance, which is somewhat preferable than the semi-creeping discharge type spark plug (A) had exhibited. In the semi-creeping discharge type spark plug (A), it is possible to obtain the same advantages as listed in the items (a), (b) and (d). Fig. 11 is a chart depicted to show how the soot fouling resistance and the heat resistance are changed depending on a height level (H) which represents how far the forward edge portion 42 of the ground electrode 4 is removed from the front end surface 23 of the insulator 2. A soot fouling experimental test was carried out along the predelivery pattern (paragraph 5.2 (1) JIS D1606) with the retraction length (t) and the thickness of the front end surface 41 as 0.2 mm and 1.3 mm respectively. In this instance, the engine was placed on the chassis dynamometer under the cold room temperature (-15 °C), and the height level (H) was altered in turn to -0.25 mm, 0.0 mm, 0.25 mm, 0.5 mm, 0.75 mm, 1.0 mm and 1.25 mm. The heat resistance experimental test was carried out with the spark plug (B) mounted on a 4-cylinder, 1. 6L engine while advancing an angle of the ignition timing, and at the same time, varying the height level (H) in the same manner as described above. In the soot fouling resistance experimental test, an estimation was held with the number of cycles needed to firstly reduce the insulation resistance value to 10 M Ω or less as a criterion. In the heat resistance experimental test, an estimation was made with the ignition timing leading close to preignition as a criterion. In the chart of Fig. 11, circle (○) represents when the number of cycles was six or less, and crisscross (× ) represents when the number of cycles was short of six in the soot fouling resistance experimental test. In the heat resistance experimental test, the circle (○) represents when the ignition timing was 38° or more in terms of BTDC (Before Top Dead Center), and the crisscross ( × ) represents when the ignition timing was short of 38 ° in terms of BTDC. Such is the above experimental test results that the heat resistance is considerably ameliorated while the soot fouling resistance reduces with the increase of the height level (H) which represents how far the forward edge portion 42 of the ground electrode 4 is removed from the front end surface 23 of the insulator 2. In order to concurrently satisfy the good starting capability in a cold environment and the good heat resistance when running the engine consecutively at high speed, it is necessary to determine the height level (H) to be in the range from 0.0 to 1.0 mm. Fig. 10 shows a third embodiment of the invention in which a semi-creeping discharge type spark plug (C) is provided to be structurally similar to the spark plug (A) except that a tapered portion 25a is continuously formed from the front portion of the insulator 2 instead of the constricted straight portion 25. After carrying out the experimental test in conformity with the predelivery pattern (paragraph 5.2 (1) JIS D1606) of Fig. 4, it was found that the spark plug (C) has exhibited substantially as good a fouling resistance as attained by the spark plug (A). It is to be noted that a spark erosion resistant material may be used only to the front end of the insulator 2 so as to form a composite structure as a whole. It is also to be observed that the ground electrode 4 may be formed in integral with the metal shell 1 in lieu of welding discretely to the front end surface 11 of the metal shell 1.

Claims: A semi-creeping discharge type spark plug comprising: a cylindrical metal shell (1); an insulator (2) having an axial bore (22) and placed within said metal shell (1); a center electrode (3) placed within said axial bore (22) of said insulator (2) so that a front end surface edge (311) of said center electrode (3) is withdrawn from a front end surface (23) of said insulator (2); characterised in that a front end of said insulator (2) extends beyond said metal shell (2); said front end surface edge (311) is withdrawn by 0.1 ∼ 0.6 mm from said front end surface (23); and by a ground electrode (4), one end of which is connected to a front end (11) of said metal shell (1), and which electrode is bent so that its other end opposes an outer surface of said insulator (2) so as to form an air-gap (g1) therebetween while permitting creeping spark discharges running along said front end surface (23) of said insulator (2), a forward edge portion (42) of a front end surface (41) of said ground electrode (4) extending by 0.0 ∼ 1.0 mm forward from said front end surface (23) of said insulator. A semi-creeping discharge type spark plug according to claim 1, wherein an outer diameter (d) of a front end of said center electrode (3) is 1.0 ∼ 2.0 mm. A semi-creeping discharge type spark plug according to claim 1 or 2, wherein an inner edge portion of said front end surface (23) of said insulator (2) is bevelled by 0.1 ∼ 1.0 mm in terms of chamfer length (C) or rounded by 0.1 ∼ 1.0 (1/mm) in terms of radius of curvature (R). A semi-creeping discharge type spark plug according to any one of claims 1 ∼ 3, wherein a plurality of said ground electrodes (4) are provided. A semi-creeping discharge type spark plug according to any one of claims 1 ∼ 4, wherein a front end including said front end surface edge (311) of said center electrode (3) is made of a spark erosion resistant metal tip (30). A semi-creeping discharge type spark plug according to claim 5, wherein said spark erosion resistant metal tip (30) is formed from a material selected from the group consisting of Pt, Pt-based alloy, Ir-based alloy and Ir-Rh based alloy.

Inventors: KOKUBU AKIO, MATSUBARA YOSHIHIRO, YAMAGUCHI MAKOTO, YOSHIDA KAZUMASA, KOKUBU, AKIO, MATSUBARA, YOSHIHIRO, YAMAGUCHI, MAKOTO, YOSHIDA, KAZUMASA
Applicants: NGK SPARK PLUG CO, NGK SPARK PLUG CO. LTD.
Application year: 1998
Main classification: H01T13
IPC codes: H01T13