JP5134486B2 - Spark plug manufacturing method and spark plug manufacturing apparatus - Google Patents

Description

  The present invention relates to a spark plug manufacturing technique used for an internal combustion engine, and more particularly to a spark plug manufacturing method and a manufacturing apparatus characterized by bending of a ground electrode.

  A spark plug for an internal combustion engine such as an automobile engine includes, for example, a central electrode extending in the axial direction, an insulator provided outside the center electrode, a cylindrical metal shell provided outside the insulator, and a base end portion Comprises a ground electrode joined to the tip of the metal shell. Further, the ground electrode is disposed so that the tip thereof is bent back so as to face the tip of the center electrode, whereby a spark discharge gap is formed between the tip of the center electrode and the tip of the ground electrode. . The spark discharge gap is formed by bending the straight rod-shaped ground electrode to the center electrode side after the metal shell to which the ground electrode having a straight rod shape is joined and the insulator provided with the center electrode are assembled. It is generally formed by this.

Here, as a method of bending the ground electrode to the center electrode side, a bending spacer is disposed so as to face the tip surface of the center electrode, and then a bending punch in which a contact portion with the ground electrode forms an inclined surface is used. Using a bending punch having a flat abutment surface after removing the bending spacer and performing a preliminary bending process so as to press the ground electrode against the bending spacer. A method of bending a ground electrode to a position where a discharge gap is formed is known (for example, see Patent Document 1).
Japanese Patent No. 3389121

  By the way, in recent years, in order to improve durability and the like, the tip of the ground electrode is disposed so as to face the side surface of the center electrode, and a so-called horizontal discharge type spark plug that fires in a direction substantially perpendicular to the axis line, There has been proposed a so-called oblique discharge type spark plug in which the tip of the ground electrode is disposed so as to face the tip edge of the center electrode and fires obliquely with respect to the axial direction.

  Here, in the horizontal discharge type and oblique discharge type spark plugs, it is necessary to bend the ground electrode on the more proximal side (the side closer to the metal shell). Therefore, there is a limit to disposing the bending spacer on the proximal side, and it is difficult to bend the ground electrode on the proximal side. Therefore, a method is conceivable in which the ground electrode is bent in advance before assembling the metal shell and the insulator, and then the metal shell and the insulator are assembled. However, in this case, since the ground electrode is not bent after grasping the actual position of the center electrode tip, the position of the center electrode tip that may occur depending on the assembled state of the metal shell and the insulator As a result, the spark discharge gap may vary in size.

  The above-mentioned problem is not limited to a horizontal discharge type or an oblique discharge type spark plug, but is inherent to a spark plug of a type that discharges in the axial direction.

  The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a spark plug manufacturing method capable of bending the ground electrode more proximally even after the metal shell and the insulator are assembled. And providing a manufacturing apparatus.

  Hereinafter, each configuration suitable for solving the above-described object will be described in terms of items. In addition, the effect specific to the corresponding structure is added as needed.

Configuration 1. The manufacturing method of the spark plug of this configuration is as follows:
A rod-shaped center electrode extending in the axial direction;
A substantially cylindrical insulator having an axial hole extending in the axial direction and having the center electrode provided on a distal end side of the axial hole;
A substantially cylindrical metal shell provided on the outer periphery of the insulator;
A spark plug manufacturing method comprising a grounding electrode having a base end joined to the metal shell and an intermediate portion bent to form a spark discharge gap between the tip and the tip of the center electrode. ,
A bending step for bending the ground electrode toward the axis in a state in which the metal shell to which the ground electrode is bonded and the insulator provided with the center electrode are assembled;
The bending step includes
Between the side portion of the center electrode and the base end portion of the ground electrode, a curved surface attaching means having a curved surface portion corresponding to the bent shape of the ground electrode,
In order to prevent the base end portion of the ground electrode from being deformed to at least one of the center electrode side and the opposite side of the center electrode, the ground electrode is supported by the deformation preventing means,
Bending using means, said said center electrode ground electrode against the curved surface portion by pressing from the opposite side, seen including a bending process subjected to bending to the ground electrode,
The deformation preventing means includes
The ground electrode is disposed between a side portion of the center electrode and a base end portion of the ground electrode, and supports a side portion on the center electrode side of the base end portion of the ground electrode, and the ground electrode toward the center electrode side is supported. Inner deformation prevention means for preventing deformation;
The ground electrode is disposed on a side opposite to the center electrode, and supports a side portion of the ground electrode opposite to the center electrode at the base end portion, and the side toward the side opposite to the center electrode side is supported. An outer deformation preventing means for preventing deformation of the ground electrode is provided .

  A noble metal tip made of a noble metal alloy may be joined to the tip of the center electrode or the ground electrode. In this case, the noble metal tip forms part of the center electrode or the ground electrode.

  According to the configuration 1, in the bending step, the curved surface applying means is disposed between the base end portion of the ground electrode and the side portion of the center electrode. In other words, the curved surface portion serving as a reference for the bending position of the ground electrode is arranged on the proximal end side (at a position closer to the metal shell) without being obstructed by the center electrode, so Even in a state where the body is assembled, the ground electrode can be bent relatively easily on the base end side. Further, by supporting the ground electrode by the deformation preventing means, it is possible to more reliably prevent the ground electrode from falling to the center electrode side or bulging to the side opposite to the center electrode.

Further, the deformation of the ground electrode toward the center electrode is prevented by the inner deformation prevention means.

Further, since the deformation preventing means includes both the inner deformation preventing means and the outer deformation preventing means, it is possible to more reliably prevent the deformation of the ground electrode in the bending process.

Configuration 2 . The spark plug manufacturing method of this configuration is characterized in that, in the above configuration 1 , the deformation preventing means is formed by integrating the curved surface attaching means and the inner deformation preventing means.

According to the above configuration 2 , in the bending step, the curved surface arranging means and the inner deformation preventing means arranged between the ground electrode and the center electrode are integrated. For this reason, complication of the apparatus can be prevented.

Configuration 3 . The spark plug manufacturing method of this configuration is characterized in that, in the above configuration 1 or 2 , the inner deformation prevention means and the outer deformation prevention means are arranged so as to face each other with a base end portion of the ground electrode interposed therebetween. And

According to the configuration 3 , the ground electrode can be more reliably supported, and the deformation of the ground electrode in the bending process can be more reliably prevented.

Configuration 4 . The manufacturing method of the spark plug of this configuration is the above configuration 1 to 3 ,
An interval between the inner deformation prevention means and the outer deformation prevention means is configured to be changeable.

According to the configuration 4 , it is possible to deal with ground electrodes having various widths, and it is possible to more reliably prevent the deformation of the ground electrode.

Configuration 5 . The manufacturing method of the spark plug of this configuration is the above configuration 1 to 4 ,
The curved surface attaching means is arranged such that a center of curvature of the curved surface portion is located on the proximal side in the axial direction with respect to a plane including a distal end surface of the center electrode.

According to the configuration 5 , the curved surface attaching means is arranged so that the center of curvature of the curved surface portion is located on the proximal side in the axial direction with respect to the flat surface including the distal end surface of the center electrode. Therefore, the ground electrode can be further bent at the base end side, and in particular, a lateral discharge type or oblique discharge type plug can be manufactured relatively easily.

Configuration 6 . The manufacturing method of the spark plug of this configuration is the above configuration 1 to 5 ,
In the bending step, after the bending step,
Using a gap adjusting means capable of moving the tip of the ground electrode relative to the center electrode along a direction substantially perpendicular to the axis, a size along the direction perpendicular to the axis of the spark discharge gap. A gap adjusting step for adjusting the thickness is included.

According to the configuration 6 , the size of the spark discharge gap along the direction orthogonal to the axis can be adjusted by the gap adjusting means. Therefore, the spark discharge gap can be formed with higher accuracy.

Configuration 7 . The spark plug manufacturing method of this configuration is the above configuration 6 , wherein the gap adjusting means is disposed between the side of the center electrode and the base end of the ground electrode, A gap enlarging means capable of relatively moving in a direction away from the center electrode and enlarging a size along a direction perpendicular to the axis of the spark discharge gap;
The gap enlarging means is arranged on the tip side in the axial direction with respect to a plane including the tip surface of the insulator.

  In general, the space formed between the ground electrode and the insulator is relatively small. Therefore, when the gap enlarging means for relatively moving the ground electrode in the direction away from the center electrode is disposed in the space, the relative movement of the ground electrode to the center electrode side is limited by the gap enlarging means, There is a possibility that the adjustment of the size of the spark discharge gap may be relatively difficult.

In this respect, according to the configuration 7 , the gap enlarging means is disposed on the tip end side in the axial direction with respect to the plane including the tip end face of the insulator, that is, between the center electrode and the ground electrode having a relatively large space. Therefore, it is possible to suppress the relative movement of the ground electrode to the center electrode side by the gap expanding means, and the size of the spark discharge gap can be adjusted more easily and more accurately.

Configuration 8 . The manufacturing method of the spark plug of this configuration is the above configuration 6 or 7 ,
In the gap adjustment step, a restricting means for restricting relative movement of the tip of the ground electrode with respect to the center electrode to at least the tip in the axial direction is used.

  In the gap adjustment step, when the size of the spark discharge gap along the direction orthogonal to the axis is adjusted, the relative height position along the axial direction of the tip of the ground electrode with respect to the center electrode, which is adjusted in the bending step, that is, There is a possibility that a deviation occurs in the size of the spark discharge gap along the axial direction.

In this regard, according to the configuration 8 , the relative movement of at least the tip end portion of the ground electrode with respect to the center electrode to the tip end in the axial direction is restricted by the restricting means. As a result, it is possible to more reliably prevent the spark discharge gap from being displaced in the size along the axial direction, and to adjust the size of the spark discharge gap more accurately.

Configuration 9 The manufacturing method of the spark plug of this configuration is as follows:
A rod-shaped center electrode extending in the axial direction;
A substantially cylindrical insulator having an axial hole extending in the axial direction and having the center electrode provided on a distal end side of the axial hole;
A substantially cylindrical metal shell provided on the outer periphery of the insulator;
A spark plug manufacturing method comprising a grounding electrode having a base end joined to the metal shell and an intermediate portion bent to form a spark discharge gap between the tip and the tip of the center electrode. ,
A bending step for bending the ground electrode toward the axis in a state in which the metal shell to which the ground electrode is bonded and the insulator provided with the center electrode are assembled;
The bending step includes
Between the side portion of the center electrode and the base end portion of the ground electrode, a curved surface attaching means having a curved surface portion corresponding to the bent shape of the ground electrode,
In order to prevent the base end portion of the ground electrode from being deformed to at least one of the center electrode side and the opposite side of the center electrode, the ground electrode is supported by the deformation preventing means,
Using a bending means, including a bending step of bending the ground electrode by pressing the ground electrode against the curved surface portion from the side opposite to the center electrode;
The curved surface attaching means is arranged such that a center of curvature of the curved surface portion is located on the proximal side in the axial direction with respect to a plane including a distal end surface of the center electrode.

According to the present configuration 9, the same effect as the above configuration 5 is achieved.

Configuration 10 The manufacturing method of the spark plug of this configuration is the above configuration 9,
In the bending step, after the bending step,
Using a gap adjusting means capable of moving the tip of the ground electrode relative to the center electrode along a direction substantially perpendicular to the axis, a size along the direction perpendicular to the axis of the spark discharge gap. A gap adjusting step for adjusting the thickness is included.

According to the present configuration 10, the same effects as the above configuration 6 are achieved.

Configuration 11 The manufacturing method of the spark plug of this configuration is the above-described configuration 10,
The gap adjusting means is disposed between a side portion of the center electrode and a base end portion of the ground electrode, and relatively moves a tip end portion of the ground electrode in a direction away from the center electrode, so that the spark discharge is performed. A gap enlarging means capable of enlarging the size of the gap along the direction perpendicular to the axis;
The gap enlarging means is arranged on the tip side in the axial direction with respect to a plane including the tip surface of the insulator.

According to this structure 11, the same effect as the said structure 7 is show | played.

Configuration 12 The manufacturing method of the spark plug of this configuration is the above configuration 10 or 11,
In the gap adjustment step, a restricting means for restricting relative movement of the tip of the ground electrode with respect to the center electrode to at least the tip in the axial direction is used.

According to the present configuration 12, the same operational effects as those of the above configuration 8 are achieved.

Configuration 13 The manufacturing method of the spark plug of this configuration is as follows:
A rod-shaped center electrode extending in the axial direction;
A substantially cylindrical insulator having an axial hole extending in the axial direction and having the center electrode provided on a distal end side of the axial hole;
A substantially cylindrical metal shell provided on the outer periphery of the insulator;
A spark plug manufacturing method comprising a grounding electrode having a base end joined to the metal shell and an intermediate portion bent to form a spark discharge gap between the tip and the tip of the center electrode. ,
A bending step for bending the ground electrode toward the axis in a state in which the metal shell to which the ground electrode is bonded and the insulator provided with the center electrode are assembled;
The bending step includes
Between the side portion of the center electrode and the base end portion of the ground electrode, a curved surface attaching means having a curved surface portion corresponding to the bent shape of the ground electrode,
In order to prevent the base end portion of the ground electrode from being deformed to at least one of the center electrode side and the opposite side of the center electrode, the ground electrode is supported by the deformation preventing means,
Using a bending means, including a bending step of bending the ground electrode by pressing the ground electrode against the curved surface portion from the side opposite to the center electrode;
In the bending step, after the bending step,
Using a gap adjusting means capable of moving the tip of the ground electrode relative to the center electrode along a direction substantially perpendicular to the axis, a size along the direction perpendicular to the axis of the spark discharge gap. Including a gap adjustment step of adjusting the thickness,
The gap adjusting means is disposed between a side portion of the center electrode and a base end portion of the ground electrode, and relatively moves a tip end portion of the ground electrode in a direction away from the center electrode, so that the spark discharge is performed. A gap enlarging means capable of enlarging the size of the gap along the direction perpendicular to the axis;
The gap enlarging means is arranged on the tip side in the axial direction with respect to a plane including the tip surface of the insulator.

According to this configuration 13, the same effects as the above configurations 6 and 7 can be obtained.

Configuration 14 The manufacturing method of the spark plug of this configuration is the above-described configuration 13,
In the gap adjustment step, a restricting means for restricting relative movement of the tip of the ground electrode with respect to the center electrode to at least the tip in the axial direction is used.

According to this configuration 13, the same effect as that of the above configuration 8 is achieved.

Configuration 15 The manufacturing method of the spark plug of this configuration is the above-described configuration 9 to 14,
The deformation preventing means includes
The ground electrode is disposed between a side portion of the center electrode and a base end portion of the ground electrode, and supports a side portion on the center electrode side of the base end portion of the ground electrode, and the ground electrode toward the center electrode side is supported. It is characterized by comprising an inner deformation preventing means for preventing deformation.

According to the present configuration 15, in addition to the functions and effects of the configurations 9 to 14, the deformation of the ground electrode toward the center electrode is prevented by the inner deformation prevention means.

Configuration 16. The manufacturing method of the spark plug of this configuration is the above-described configuration 15,
The deformation preventing means is characterized in that the curved surface attaching means and the inner deformation preventing means are integrated.

According to the present configuration 15, since the deformation preventing means includes both the inner deformation preventing means and the outer deformation preventing means, it is possible to more reliably prevent the deformation of the ground electrode in the bending process.

Configuration 17 The method for manufacturing a spark plug of this configuration is the above configuration 1 to 16,
The bending means is a roller configured to be relatively movable with respect to the ground electrode along a direction substantially orthogonal to the axis, and is supported so as to be freely rotatable,
The ground electrode is bent by pressing the outer peripheral surface of the roller against the side surface of the ground electrode opposite to the center electrode.

As the bending means for pressing the ground electrode against the curved surface portion, for example, a bending punch configured such that the contact surface with the ground electrode is inclined as in the conventional technique described above can be used. However, in this case, since the ground electrode is bent while rubbing against the bending punch, the ground electrode may be damaged. In order to prevent the ground electrode from being scratched, a method is considered in which the ground electrode is pressed from the oblique tip side in the axial direction and the pressing direction is gradually changed in accordance with the bending degree of the ground electrode. However, when this method is adopted, there is a risk of complicating the apparatus.

In this regard, according to the above-described configuration 17, the bending means is configured by a roller that can move relative to the ground electrode along a direction substantially orthogonal to the axis and is supported so as to be freely rotatable. For this reason, the ground electrode can be more reliably pressed against the curved surface portion without changing the pressing direction of the ground electrode. In addition, since the roller is supported so as to be freely rotatable, it is possible to suppress the situation where the ground electrode is bent while rubbing against the roller as much as possible, and more reliably prevent the ground electrode from being damaged. be able to.

From the viewpoint of more reliably preventing the ground electrode from being scratched, the friction coefficient of the roller outer peripheral surface that can come into contact with the ground electrode and the bearing portion of the roller is relatively set. It is desirable to keep it low. Therefore, in order to reduce the friction coefficient, a coating film made of diamond-like carbon may be provided on the outer peripheral surface of the roller or the bearing portion.

Configuration 18 The method of manufacturing a spark plug of this configuration is the above configuration 1 to 17,
In the spark plug, the shortest distance between the center electrode and the ground electrode is formed between a tip edge portion of the center electrode or a side surface portion of the center electrode and a tip portion of the ground electrode. And

As in the configuration 18 , the shortest distance between the center electrode and the ground electrode is a so-called oblique discharge type plug formed between the tip edge portion of the center electrode and the ground electrode, or the side surface portion of the center electrode. In the so-called lateral discharge type plug formed between the ground electrode and the ground electrode, it is more significant to adopt the above configuration 1 or the like.

  In other words, by adopting the above-described configuration 1 or the like, a lateral discharge type such as bending of the ground electrode on the more proximal side and adjustment of the size along the direction perpendicular to the axis of the spark discharge gap, Problems that may occur when manufacturing an oblique discharge type plug can be solved all at once.

Configuration 19 . The spark plug manufacturing apparatus of this configuration is
A rod-shaped center electrode extending in the axial direction;
A substantially cylindrical insulator having an axial hole extending in the axial direction and having the center electrode provided on a distal end side of the axial hole;
A substantially cylindrical metal shell provided on the outer periphery of the insulator;
Manufacturing used for manufacturing a spark plug having a grounding electrode having a base end joined to the metal shell and an intermediate portion bent to form a spark discharge gap between the tip and the tip of the center electrode A device,
A bending device for bending the straight rod-shaped ground electrode toward the axis in a state where the metal shell to which the straight rod-shaped ground electrode is bonded and the insulator provided with the center electrode are assembled. With
The bending apparatus is
Curved surface means corresponding to the bent shape of the ground electrode, and a curved surface-applying means disposed between the side portion of the center electrode and the base end portion of the ground electrode;
And deformation preventing means for preventing said proximal portion of said ground electrode to deform at least one of the side opposite the center electrode side and the center electrode,
Wherein the center electrode have a means bending pressing the ground electrode from the opposite side with respect to the curved surface of the curved surface with means,
The deformation preventing means includes
The ground electrode is disposed between a side portion of the center electrode and a base end portion of the ground electrode, and supports a side portion on the center electrode side of the base end portion of the ground electrode, and the ground electrode toward the center electrode side is supported. Inner deformation prevention means for preventing deformation;
The ground electrode is disposed on a side opposite to the center electrode, and supports a side portion of the ground electrode opposite to the center electrode at the base end portion, and the side toward the side opposite to the center electrode side is supported. an outer deformation preventing means for preventing the deformation of the ground electrode, characterized in Rukoto.

Like the said structure 19 , it is good also as materializing the technical idea of the said structure 1 to the manufacturing apparatus of a spark plug. In this case, basically the same operational effects as those of the configuration 1 are achieved.

Configuration 20 . The manufacturing apparatus of this configuration is the above-described configuration 19 ,
The deformation preventing means is characterized in that the curved surface attaching means and the inner deformation preventing means are integrated.

According to the above configuration 20 , the same effect as the above configuration 2 is achieved.

Configuration 21 . The manufacturing apparatus of this configuration is the above configuration 19 or 20 ,
The inner deformation prevention means and the outer deformation prevention means are arranged so as to face each other with a proximal end portion of the ground electrode interposed therebetween.

According to the said structure 21 , the effect similar to the said structure 3 is show | played.

Configuration 22 . The manufacturing apparatus of this configuration is the above configuration 19 to 21 ,
An interval between the inner deformation prevention means and the outer deformation prevention means is configured to be changeable.

According to the said structure 22 , the effect similar to the said structure 4 is show | played.

Configuration 23 . The manufacturing apparatus of this configuration is the above configuration 19 to 22 ,
The curved surface attaching means is arranged such that a center of curvature of the curved surface portion is located on the proximal side in the axial direction with respect to a plane including a distal end surface of the center electrode.

According to the said structure 23 , the effect similar to the said structure 5 is show | played.

Configuration 24 . The manufacturing apparatus of this configuration is the above configuration 19 to 23 ,
The bending apparatus further includes:
Gap adjustment means is provided that can move the tip of the ground electrode relative to the center electrode along a direction substantially perpendicular to the axis, and the gap adjustment means is perpendicular to the axis of the spark discharge gap. The size along the direction is adjusted.

According to the said structure 24 , the effect similar to the said structure 6 is show | played.

Configuration 25 . The manufacturing apparatus of this configuration is the above-described configuration 24 .
The gap adjusting means is disposed between a side portion of the center electrode and a base end portion of the ground electrode, and relatively moves a tip end portion of the ground electrode in a direction away from the center electrode, so that the spark discharge is performed. A gap enlarging means capable of enlarging the size of the gap along the direction perpendicular to the axis;
The gap enlarging means is arranged on the tip side in the axial direction with respect to a plane including the tip surface of the insulator.

According to the configuration 25 , the same effect as that of the configuration 7 is achieved.

Configuration 26 . The manufacturing apparatus of this configuration is the above configuration 24 or 24 ,
The gap adjusting means includes
It further comprises a restricting means for restricting relative movement of the tip of the ground electrode with respect to the center electrode toward at least the tip in the axial direction.

According to the configuration 26 , the same function and effect as the configuration 8 can be obtained.

Configuration 27. The manufacturing device of this configuration is
A rod-shaped center electrode extending in the axial direction;
A substantially cylindrical insulator having an axial hole extending in the axial direction and having the center electrode provided on a distal end side of the axial hole;
A substantially cylindrical metal shell provided on the outer periphery of the insulator;
Manufacturing used for manufacturing a spark plug having a grounding electrode having a base end joined to the metal shell and an intermediate portion bent to form a spark discharge gap between the tip and the tip of the center electrode A device,
A bending device for bending the straight rod-shaped ground electrode toward the axis in a state where the metal shell to which the straight rod-shaped ground electrode is bonded and the insulator provided with the center electrode are assembled. With
The bending apparatus is
Curved surface means corresponding to the bent shape of the ground electrode, and a curved surface-applying means disposed between the side portion of the center electrode and the base end portion of the ground electrode;
Deformation preventing means for preventing the base end portion of the ground electrode from being deformed to at least one of the center electrode side and the opposite side of the center electrode;
Bending means for pressing the ground electrode from the opposite side of the center electrode to the curved surface portion of the curved surface attaching means;
The curved surface attaching means is arranged such that a center of curvature of the curved surface portion is located on the proximal side in the axial direction with respect to a plane including a distal end surface of the center electrode.

According to the above configuration 27, the same function and effect as the above configuration 9 are achieved.

Configuration 28. The manufacturing apparatus of this configuration is the above-described configuration 27.
The bending apparatus further includes:
Gap adjustment means is provided that can move the tip of the ground electrode relative to the center electrode along a direction substantially perpendicular to the axis, and the gap adjustment means is perpendicular to the axis of the spark discharge gap. The size along the direction is adjusted.

According to the above configuration 28, the same function and effect as the above configuration 10 are achieved.

Configuration 29. The manufacturing apparatus of this configuration is the above-described configuration 28.
The gap adjusting means is disposed between a side portion of the center electrode and a base end portion of the ground electrode, and relatively moves a tip end portion of the ground electrode in a direction away from the center electrode, so that the spark discharge is performed. A gap enlarging means capable of enlarging the size of the gap along the direction perpendicular to the axis;
The gap enlarging means is arranged on the tip side in the axial direction with respect to a plane including the tip surface of the insulator.

According to the above configuration 29, the same function and effect as the above configuration 11 are achieved.

Configuration 30. The manufacturing apparatus of this configuration is the above-described configuration 28 or 29.
The gap adjusting means includes
It further comprises a restricting means for restricting relative movement of the tip of the ground electrode with respect to the center electrode toward at least the tip in the axial direction.

According to the configuration 30, the same effect as the configuration 12 is achieved.

Configuration 31. The manufacturing device of this configuration is
A rod-shaped center electrode extending in the axial direction;
A substantially cylindrical insulator having an axial hole extending in the axial direction and having the center electrode provided on a distal end side of the axial hole;
A substantially cylindrical metal shell provided on the outer periphery of the insulator;
Manufacturing used for manufacturing a spark plug having a grounding electrode having a base end joined to the metal shell and an intermediate portion bent to form a spark discharge gap between the tip and the tip of the center electrode A device,
A bending device for bending the straight rod-shaped ground electrode toward the axis in a state where the metal shell to which the straight rod-shaped ground electrode is bonded and the insulator provided with the center electrode are assembled. With
The bending apparatus is
Curved surface means corresponding to the bent shape of the ground electrode, and a curved surface-applying means disposed between the side portion of the center electrode and the base end portion of the ground electrode;
Deformation preventing means for preventing the base end portion of the ground electrode from being deformed to at least one of the center electrode side and the opposite side of the center electrode;
Bending means for pressing the ground electrode from the opposite side of the center electrode to the curved surface portion of the curved surface attaching means;
The bending apparatus further includes:
Gap adjustment means is provided that can move the tip of the ground electrode relative to the center electrode along a direction substantially perpendicular to the axis, and the gap adjustment means is perpendicular to the axis of the spark discharge gap. Adjust the size along the direction,
The gap adjusting means is disposed between a side portion of the center electrode and a base end portion of the ground electrode, and relatively moves a tip end portion of the ground electrode in a direction away from the center electrode, so that the spark discharge is performed. A gap enlarging means capable of enlarging the size of the gap along the direction perpendicular to the axis;
The gap enlarging means is arranged on the tip side in the axial direction with respect to a plane including the tip surface of the insulator.

According to the configuration 31, the same function and effect as the configuration 13 can be obtained.

Configuration 32. The manufacturing apparatus of this configuration is the above-described configuration 31,
The gap adjusting means includes
It further comprises a restricting means for restricting relative movement of the tip of the ground electrode with respect to the center electrode toward at least the tip in the axial direction.

According to the said structure 32, the effect similar to the said structure 14 is show | played.

Configuration 33. The manufacturing apparatus of this configuration is the above configuration 27 to 32.
The deformation preventing means includes
The ground electrode is disposed between a side portion of the center electrode and a base end portion of the ground electrode, and supports a side portion on the center electrode side of the base end portion of the ground electrode, and the ground electrode toward the center electrode side is supported. It is characterized by comprising an inner deformation preventing means for preventing deformation.

According to the configuration 33, the same function and effect as the configuration 15 are achieved.

Configuration 34. The manufacturing apparatus of this configuration is the above-described configuration 33.
The deformation preventing means is characterized in that the curved surface attaching means and the inner deformation preventing means are integrated.

According to the configuration 34, the same function and effect as the configuration 16 can be obtained.

Configuration 35. The manufacturing apparatus of this configuration is the above configuration 19 to 34,
The bending means is a roller that is supported so as to be freely rotatable and is capable of moving toward and away from the ground electrode along a direction substantially orthogonal to the axis.

According to the configuration 35, the same function and effect as the configuration 17 are achieved.

Configuration 36. The manufacturing apparatus of this configuration is the above configuration 19 to 35,
In the spark plug, the shortest distance between the center electrode and the ground electrode is formed between a tip edge portion of the center electrode or a side surface portion of the center electrode and a tip portion of the ground electrode. And

According to the configuration 36 , the same function and effect as the configuration 18 are achieved.

  Hereinafter, an embodiment will be described with reference to the drawings. FIG. 1 is a partially cutaway front view showing a spark plug 1. In FIG. 1, the direction of the axis CL <b> 1 of the spark plug 1 is the vertical direction in the drawing, the lower side is the front end side of the spark plug 1, and the upper side is the rear end side.

  The spark plug 1 includes an insulator 2 as a cylindrical insulator, a cylindrical metal shell 3 that holds the insulator 2, and the like.

  As is well known, the insulator 2 is formed by firing alumina or the like, and in its outer portion, a rear end side body portion 10 formed on the rear end side, and a front end than the rear end side body portion 10. A large-diameter portion 11 that protrudes outward in the radial direction on the side, and a middle body portion 12 that has a smaller diameter on the tip side than the large-diameter portion 11 are provided. Further, the insulator 2 has a leg length portion 13 that is tapered toward the tip end side in the direction of the axis CL <b> 1 on the tip end side with respect to the middle body portion 12. The middle body portion 12 and most of the leg length portions 13 are accommodated in the metal shell 3. A tapered step portion 14 is formed at the connecting portion between the leg length portion 13 and the middle trunk portion 12, and the insulator 2 is locked to the metal shell 3 at the step portion 14.

  Further, the insulator 2 is formed with a shaft hole 4 penetrating along the axis CL1, and a center electrode 5 is inserted and fixed to the tip end side of the shaft hole 4. The center electrode 5 has a rod-like shape (cylindrical shape) as a whole, and its tip end surface is formed flat and protrudes from the tip of the insulator 2. The center electrode 5 includes an inner layer 5A made of copper or a copper alloy and an outer layer 5B made of a Ni alloy containing nickel (Ni) as a main component. Further, a cylindrical noble metal portion 31 made of a noble metal alloy (for example, an iridium alloy) is provided at the tip of the center electrode 5. More specifically, the noble metal portion 31 is provided by forming a melted portion 41 by laser welding or the like on the outer periphery of the contact surface between the outer layer 5B and the noble metal portion 31 (see FIG. 2 and the like).

  A terminal electrode 6 is inserted and fixed on the rear end side of the shaft hole 4 in a state of protruding from the rear end of the insulator 2.

  Further, a cylindrical resistor 7 is disposed between the center electrode 5 and the terminal electrode 6 of the shaft hole 4. Both ends of the resistor 7 are electrically connected to the center electrode 5 and the terminal electrode 6 through conductive glass seal layers 8 and 9, respectively.

  In addition, the metal shell 3 is formed in a cylindrical shape from a metal such as low carbon steel, and a screw portion (male screw portion) 15 for attaching the spark plug 1 to the engine head is formed on the outer peripheral surface thereof. Yes. In addition, a seat portion 16 is formed on the outer peripheral surface on the rear end side of the screw portion 15, and a ring-shaped gasket 18 is fitted on the screw neck 17 on the rear end of the screw portion 15. Further, on the rear end side of the metal shell 3, a tool engaging portion 19 having a hexagonal cross section for engaging a tool such as a wrench when the metal shell 3 is attached to the engine head is provided. A caulking portion 20 for holding the insulator 2 is provided.

  A tapered step portion 21 for locking the insulator 2 is provided on the inner peripheral surface of the metal shell 3. The insulator 2 is inserted from the rear end side to the front end side of the metal shell 3, and the rear end of the metal shell 3 is engaged with the step portion 14 of the metal shell 3. It is fixed by caulking the opening on the side radially inward, that is, by forming the caulking portion 20. An annular plate packing 22 is interposed between the step portions 14 and 21 of both the insulator 2 and the metal shell 3. Thereby, the airtightness in the combustion chamber is maintained, and the fuel air entering the gap between the leg long portion 13 of the insulator 2 exposed to the combustion chamber and the inner peripheral surface of the metal shell 3 is prevented from leaking outside.

  Further, in order to make the sealing by caulking more complete, annular ring members 23 and 24 are interposed between the metal shell 3 and the insulator 2 on the rear end side of the metal shell 3, and the ring member 23 , 24 is filled with powder of talc (talc) 25. That is, the metal shell 3 holds the insulator 2 via the plate packing 22, the ring members 23 and 24, and the talc 25.

  Further, a ground electrode 27 is joined to the distal end surface of the distal end portion 26 of the metal shell 3 by bending its own intermediate portion toward the center electrode 5 side. The ground electrode 27 has a noble metal tip 32 on the inner peripheral surface of the tip thereof, and the tip edge portion of the noble metal tip 32 and the tip edge portion of the noble metal portion 31 are opposed to each other. That is, the shortest distance between the center electrode 5 (the noble metal portion 31) and the ground electrode 27 (the noble metal tip 32) is formed between the leading edge portion of the noble metal portion 31 and the leading edge portion of the noble metal tip 32. As a result, a spark discharge gap 33 is formed between the distal end portion of the center electrode 5 and the distal end portion of the ground electrode 27 so that the spark discharge is performed obliquely with respect to the axis CL1.

  In a spark plug (for example, see Japanese Patent Application Laid-Open No. 2007-234435) of the type in which the front end surface of the center electrode (noble metal portion) and the side surface of the ground electrode face each other, discharge is performed substantially along the axial direction. That is, the size of the spark discharge gap means a distance along the axial direction between both electrodes. On the other hand, since the spark plug 1 in the present embodiment performs a spark discharge in an oblique direction as described above, the size of the spark discharge gap 33 is the axis CL1 between the electrodes 5 and 27 as shown in FIG. Is determined by the distance Gx along the direction orthogonal to the distance Gy along the axis CL1 between the electrodes 5 and 27. Therefore, in order to set the spark discharge gap 33 to a predetermined size, it is necessary to accurately adjust not only the distance Gy but also the distance Gx when the ground electrode 27 is bent back to the center electrode 5 side. Then, next, it is used in the process of manufacturing the spark plug 1, which is a feature of the present invention, for bending the ground electrode 27 to the center electrode 5 side and for forming the size of the spark discharge gap 33 to a predetermined size. The bending device 51 will be described in detail.

  As shown in FIG. 3, the bending device 51 includes a preliminary bending device 61, a main bending device 71, and a gap adjusting device 81. In this embodiment, the spark plug 1 is held by a holding means (not shown) such that its tip is upward and the axis CL1 is held along the vertical direction, and is conveyed by a conveyor or the like. By means (not shown), the pre-bending device 61, the main bending device 71, and the gap adjusting device 81 are conveyed in the order (in the order of arrows in the figure). Each of the devices 61, 71, 81 is provided with a positioning device (not shown) for positioning the ground electrode 27 at a certain circumferential position, and the circumferential position of the ground electrode 27 by the positioning device. Are arranged in the respective devices 61, 71, 81 in a state in which is constant.

  The preliminary bending device 61 preliminarily bends a position corresponding to a bent portion (intermediate portion) of the ground electrode 27 with respect to the spark plug 1 (see FIG. 4) including the ground electrode 27 in an unbent state (straight rod shape). That is, the ground electrode 27 is subjected to a preliminary bending process. As shown in FIG. 5, the preliminary bending device 61 includes first deformation preventing means 62 for preventing the ground electrode 27 from falling to the center electrode 5 side and bulging to the opposite side of the center electrode 5, And a roller 63 as a first bending means for bending the ground electrode 27.

  The first deformation preventing means 62 includes a first inner deformation preventing means 62A and a first outer deformation preventing means 62B each having a rod shape extending along the width direction of the ground electrode 27. The first inner deformation preventing means 62A and the first outer deformation preventing means 62B are configured to be movable toward and away from the spark plug 1 and when the ground electrode 27 is subjected to a preliminary bending process. The first inner deformation preventing means 62A is disposed between the proximal end portion of the ground electrode 27 and the side portion of the center electrode 5, and the first outer deformation preventing means 62B is disposed on the proximal end portion of the ground electrode 27. It arrange | positions so that it may contact | abut with an outer peripheral surface. Both the deformation preventing means 62A and 62B are provided with flat plane portions 64A and 64B. When the preliminary bending process is performed, the plane portions 64A and 64B face each other while the base portion of the ground electrode 27 is opposed. It arrange | positions so that a surface contact may be carried out with respect to an edge part. In addition, both the deformation preventing means 62A and 62B are supported by connecting portions (not shown) in the respective base end portions in a state in which the distance between them can be changed.

  The first inner deformation preventing means 62A is configured such that at least a portion of the first inner deformation preventing means 62A that is in contact with the ground electrode 27 has a triangular shape, but the plane portion 64A and the back surface of the plane portion 64A are disposed above. A curved curved surface portion 65 is provided at a portion connecting the side surfaces located. The curved surface portion 65 is a portion to which the inner peripheral surface of the ground electrode 27 is pressed when the ground electrode 27 is preliminarily bent by the roller 63, and has a shape corresponding to the bent shape of the ground electrode 27. That is, the first inner deformation preventing means 62A is provided for forming a curved shape of the ground electrode 27 (curving) and for preventing the ground electrode 27 from falling to the center electrode 5 side. The means is integrated. In the present embodiment, when the curved surface portion 65 is subjected to preliminary bending processing on the ground electrode 27, the center of curvature CC of the curved surface portion 65 is more than the axis CL1 than the plane PL1 including the tip surface of the center electrode 5 (the noble metal portion 31). It arrange | positions so that it may be located in the direction base end side.

  In addition, the roller 63 has an outer peripheral surface having a predetermined width (for example, 3 mm) and is supported so as to be freely rotatable. The roller 63 is configured to be movable in the horizontal direction (in the direction of the arrow in the figure) by a moving means (not shown). As a result, the roller 63 is opposite to the center electrode 5 of the ground electrode 27. It can be moved and pressed against the side surface. Further, a coating (not shown) made of diamond-like carbon (DLC) is formed on a portion of the outer peripheral surface of the roller 63 that can come into contact with the ground electrode 27 and a bearing portion of the roller 63. The coefficient of friction on the coating surface is 0.2 or less.

  The main bending device 71 bends the ground electrode 27 subjected to the pre-bending process at a substantially right angle (performs the main bending process), and also connects the ground electrode 27 (the noble metal tip) to the tip of the center electrode 5 (the noble metal part 31). 32) to adjust the relative height position of the tip portion along the direction of the axis CL1. As shown in FIG. 6, the main bending device 71 includes a pressing unit 72 as a second bending unit and a second deformation preventing unit 73 for preventing the ground electrode 27 from being deformed.

  The pressing means 72 is configured to be movable along the vertical direction, and is used for subjecting the ground electrode 27 to a main bending process by pushing down the tip of the ground electrode 27 toward the center electrode 5 side. is there. Of the pressing means 72, the lower surface portion 72A that contacts the ground electrode 27 during the final bending process is formed flat, and a film (not shown) made of DLC is formed on the surface of the lower surface portion 72A. Has been. For this reason, the friction coefficient of the lower surface portion 72A is relatively small.

  The second deformation preventing means 73 includes a second inner deformation preventing means 73A and a second outer deformation preventing means 73B each having a rod shape extending along the width direction of the ground electrode 27. Further, the second inner deformation preventing means 73A and the second outer deformation preventing means 73B are configured to be movable toward and away from the spark plug 1, and when the ground electrode 27 is subjected to a main bending process. The second inner deformation preventing means 73A is disposed between the ground electrode 27 and the center electrode 5 so as to be in contact with the inner peripheral surface of the proximal end portion of the ground electrode 27, and the second outer deformation preventing means 73B includes the ground electrode 27 27 is arranged so as to be in contact with the outer peripheral surface of the base end portion. Further, both deformation preventing means 73A and 73B are provided with flat plane portions 74A and 74B, and when the main bending process is performed, the plane portions 74A and 74B face the base end portion of the ground electrode 27. It arrange | positions so that it may contact | abut. As a result, the deformation of the ground electrode 27 when the ground electrode 27 is subjected to the main bending process can be prevented more reliably. Moreover, both deformation | transformation prevention means 73A and 73B are the state which can change both space | interval, and each base end part is supported by the connection part which is not shown in figure.

  Further, the bending device 71 includes first irradiation means (not shown) for irradiating predetermined light to the distal end portion (at least the distal end portion of the center electrode 5 and the distal end portion of the ground electrode 27) of the spark plug 1. 1st imaging means (not shown) which images the front-end | tip part of the spark plug 1 irradiated with light is provided. Further, the bending apparatus 71 acquires the size of the gap between the electrodes 5 and 27 (the noble metal portion 31 and the noble metal tip 32) from the imaging data imaged by the first imaging means, and the size of the gap. A control means (not shown) for calculating a pressing amount by the pressing means 72 (corresponding to an amount obtained by adding a springback amount to a displacement amount described later) based on the pressure means and controlling the pressing means 72 based on the pressing amount. It has. Here, it is as follows when the operation | movement by the said control means is explained in full detail.

  That is, the control means calculates the amount of deviation in the size along the vertical direction of the gap between the electrodes 5 and 27 with respect to the size along the axis CL1 direction of the spark discharge gap 33 in the design. Then, the grounding electrode 27 is bent by the pressing means 72 by pushing down the grounding electrode 27 by an amount obtained by adding the amount of spring back to the displacement. As a result, the relative height position of the tip portion (noble metal tip 32) of the ground electrode 27 with respect to the tip portion (noble metal portion 31) of the center electrode 5 A spark discharge gap 33 is formed so as to be substantially equal to the relative height position. That is, the spark discharge gap 33 is formed such that the distance Gy along the axis CL1 direction of the spark discharge gap 33 formed between the electrodes 5 and 27 is equal to the design distance Gy.

  The gap adjusting device 81 maintains the distance Gy along the axis CL1 of the spark discharge gap 33 adjusted by the main bending device 71, while maintaining the distance Gx along the direction orthogonal to the axis CL1 of the spark discharge gap 33. It is for adjustment. As shown in FIGS. 7 and 8, the gap adjusting device 81 is predetermined with respect to the second imaging means 82, the gap adjusting means 83, the regulating means 84, the image processing means 85, and the tip of the spark plug 1. Second irradiating means (not shown) for irradiating the light.

  The second imaging means 82 images the tip of the spark plug 1 irradiated with light by the second irradiation means, and outputs the obtained imaging data to the image processing means 85.

  The gap adjusting means 83 moves in the horizontal direction (arrow direction in FIG. 7) the arms 83A, 83B having a rectangular cross section extending along the width direction of the ground electrode 27 and the arms 83A, 83B. It is comprised with the connection part 83C supported in the possible state (in addition, the arm 83A is equivalent to a gap expansion means). Further, the gap adjusting means 83 is configured to be movable in a direction approaching / separating from the conveyed spark plug 1, and when adjusting the distance Gx, the arms 83A, 83B are Approaching the spark plug 1, the ground electrode 27 is held between the arms 83A and 83B. The distance Gx can be adjusted by horizontally moving both arms 83A and 83B.

  In addition, the arm 83A is formed to be relatively narrower than the arm 83B, and the arm 83A is disposed on the tip side of the axis CL1 with respect to the plane PL2 including the tip surface of the insulator 2. That is, the arm 83A is disposed between the center electrode 5 and the ground electrode 27 having a relatively large space.

  The restricting means 84 is controlled by the image processing means 85, and its lower surface portion 84A is formed flat. In addition, a film (not shown) of DLC is formed on the lower surface portion 84A. Further, the regulating means 84 is configured to be movable along the vertical direction, and is disposed in a stationary state at a position where the lower surface portion 84A abuts on the tip portion of the ground electrode 27 when adjusting the distance Gx. Is done. Thereby, when the distance Gx is adjusted by the gap adjusting means 83, the relative movement of the tip of the ground electrode 27 relative to the center electrode 5 along the direction of the axis CL1 can be restricted, and as a result, the distance formed by the main bending device 71. Gy can be maintained.

  The image processing unit 85 controls the operations of the gap adjusting unit 83 and the regulating unit 84 based on the imaging data imaged by the second imaging unit 82. More specifically, the image processing means 85 is designed so that the tip of the ground electrode 27 and the tip of the center electrode 5 obtained from the imaging data with respect to the distance Gx along the direction orthogonal to the axis CL1 of the spark discharge gap 33 in the design. The arms 83A and 83B are moved horizontally by an amount obtained by adding a springback amount to the amount of deviation of the distance along the horizontal direction between the portions.

  In the present embodiment, the distance Gx is adjusted by the gap adjusting means 83 in consideration of the return deformation of the ground electrode 27, and then the gap adjusting means 83 and the regulating means 84 are retracted from the spark plug 1. Thus, the imaging means 82 captures an image of the spark plug 1 again to check whether the distance Gx and the distance Gy of the spark discharge gap 33 are equal to the designed size. Here, when the distance Gx and the distance Gy are formed substantially as designed, the bending of the ground electrode 27 is completed. On the other hand, when the distance Gx or the distance Gy is different from the designed size, the distance Gx is readjusted by the gap adjusting unit 83, and the distance Gy is readjusted by the regulating unit 84. That is, the restricting means 84 in the present embodiment not only restricts the relative movement of the tip end portion of the ground electrode 27 with respect to the center electrode 5 toward the tip end side in the axis CL1 direction, but also places the tip end portion of the ground electrode 27 on the center electrode 5 side. The distance Gx can be adjusted by pressing to the right.

  Next, a bending method of the ground electrode 27 using the bending device 51 described above will be described.

  First, the spark plug 1 (see FIG. 4) on which the ground electrode 27 is positioned is transported to the preliminary bending device 61 by the transport means. Then, the first deformation prevention means 62 approaches the spark plug 1 and the base end portion of the ground electrode 27 is supported by the first deformation prevention means 62. Next, when the roller 63 moves to the ground electrode 27 side, the ground electrode 27 is pressed against the curved surface portion 65, and the ground electrode 27 is subjected to a preliminary bending process. Thereafter, the first deformation preventing means 62 and the roller 63 are retracted from the spark plug 1.

  Next, the spark plug 1 subjected to the preliminary bending process is conveyed to the main bending device 71 by the conveying means. Then, the tip of the spark plug 1 irradiated with light by the first irradiation unit is imaged by the first imaging unit, and the pressing amount is calculated by the control unit based on the imaging data. Next, the second deformation preventing means 73 approaches the spark plug 1, and the base end portion of the ground electrode 27 is supported by the second deformation preventing means 73. Then, the tip of the ground electrode 27 is pressed by the pressing amount by the pressing means 72, and the ground electrode 27 is subjected to a main bending process. As a result, the ground electrode 27 is bent at a substantially right angle, and a distance Gy is formed along the axis CL <b> 1 in the spark discharge gap 33. After the main bending process is performed, the pressing means 72 and the second deformation preventing means 73 are retracted from the spark plug 1.

  Next, the spark plug 1 subjected to the main bending process is transported to the gap adjusting device 81 by the transport means, and the tip of the spark plug 1 irradiated with light by the second irradiation means is the second portion. The image is picked up by the image pickup means 82. Then, based on the imaging data imaged by the second imaging unit 82, the image processing unit 84 places the gap adjusting unit 83 and the regulating unit 84 at predetermined positions. Next, the distance Gx is adjusted by the gap adjusting means 83 while the distance Gy is maintained by the restricting means 84. Thereafter, the gap adjusting means 83 and the regulating means 84 are retracted from the spark plug 1, and the tip of the spark plug 1 is imaged again by the second imaging means 82. Then, as necessary, the distance Gx and the distance Gy are readjusted by the gap adjusting unit 83 and the regulating unit 84 based on the re-acquired imaging data. As a result, the spark discharge gap 33 is formed in a predetermined (substantially designed) size, and the bending of the ground electrode 27 is completed.

  As described above in detail, according to the present embodiment, in the (preliminary) bending process, the means (curved surface portion 65) for applying a curved surface is the base end portion of the ground electrode 27 and the side portion of the center electrode 5. Between. That is, since the curved surface portion 65 serving as a reference for the bending position of the ground electrode 27 is arranged on the more proximal side (in a position closer to the metal shell 3) without being obstructed by the center electrode 5, Even when the metal shell 3 and the insulator 2 are assembled, the ground electrode 27 can be bent relatively easily on the base end side. Further, by supporting the ground electrode 27 by the first deformation preventing means 62, it is more reliable that the ground electrode 27 will fall to the center electrode 5 side or bulge to the opposite side to the center electrode 5. Can be prevented.

  Furthermore, when performing the (main) bending process, the relative height along the axis CL1 of the tip of the ground electrode 27 with respect to the tip of the center electrode 5 is based on the actual position of the tip of the center electrode 5. The position is adjusted. Thereby, the magnitude | size along the axis line CL1 direction among the spark discharge gaps 33 can be adjusted more correctly. Further, by supporting the ground electrode 27 by the second deformation preventing means 73, the ground electrode 27 can be more reliably prevented from falling or bulging.

  In addition, the gap adjusting device 81 can adjust the size of the spark discharge gap 33 along the direction orthogonal to the axis CL1. That is, in the present bending device 71, the spark discharge gap 33 can be formed in a predetermined amount along the axis CL1. In the gap adjustment device 81, the spark discharge gap 33 is orthogonal to the axis CL1. Since the size along the direction of the spark discharge can be adjusted, the spark discharge gap 33 can be formed with high accuracy.

  Further, the first bending means is constituted by a roller 63 that is movable relative to the ground electrode 27 along a direction substantially orthogonal to the axis CL1 and is supported so as to be freely rotatable. For this reason, the ground electrode 27 can be more reliably pressed against the curved surface portion 65 without changing the pressing direction of the ground electrode 27. Further, since the roller 63 is supported so as to be freely rotatable, a situation in which the ground electrode 27 is bent while rubbing against the roller 63 can be suppressed as much as possible, and the ground electrode 27 can be more easily damaged. It can be surely prevented.

  Furthermore, in this embodiment, in order to keep the friction coefficient of the portion of the outer peripheral surface of the roller 63 that can come into contact with the ground electrode 27 and the bearing portion of the roller 63 relatively low, the outer peripheral surface of the roller 63 and the bearing portion have DLC. A coating consisting of is provided. As a result, the ground electrode 27 can be more reliably prevented from being damaged.

  In addition, in the preliminary bending device 61, the curved surface portion 65 disposed between the ground electrode 27 and the center electrode 5 and the like and the first inner deformation preventing means 62A are integrated. For this reason, complication of the apparatus can be prevented.

  Further, the curved surface portion 65 is arranged such that the center of curvature CC of the curved surface portion 65 is located on the proximal side in the direction of the axis line CL1 with respect to the flat surface PL1 including the distal end surface of the center electrode 5. Therefore, the ground electrode 27 can be further bent at the base end side, and a transverse discharge type or oblique discharge type plug can be manufactured relatively easily.

  In addition, the arm 83 </ b> A is arranged on the tip side in the direction of the axis line CL <b> 1 with respect to the plane including the tip surface of the insulator 2, that is, between the center electrode 5 and the ground electrode 27 having a relatively large space. Therefore, it is possible to suppress the relative movement of the ground electrode 27 toward the center electrode 5 due to the presence of the arm 83A, and to adjust the size of the spark discharge gap 33 more easily and more accurately. Can do.

  Further, the restricting means 84 restricts relative movement of the tip end portion of the ground electrode 27 with respect to the center electrode 5 toward at least the tip end side in the axis CL1 direction. As a result, it is possible to prevent a deviation from occurring in the distance Gy along the direction of the axis CL <b> 1 in the spark discharge gap 33, and the size of the spark discharge gap 33 can be adjusted more accurately.

  In addition, it is not limited to the description content of the said embodiment, For example, you may implement as follows. Of course, other application examples and modification examples not illustrated below are also possible.

  (A) In the above embodiment, the first deformation preventing means 62 includes the first inner deformation preventing means 62A and the first outer deformation preventing means 62B, but the first inner deformation preventing means 62A and the first outer deformation preventing means 62B. Only one of the means 62B may be provided.

  (B) In the above-described embodiment, the roller 63 is used as the first bending means for performing the pre-bending process on the ground electrode 27. However, the means for performing the pre-bending process on the ground electrode 27 is limited to this. Is not to be done.

  (C) In the embodiment described above, the coating made of DLC is provided on the outer peripheral surface of the roller 63, the lower surface portion 72A of the pressing means 72, or the like, but the coating may not be provided.

  (D) In the above embodiment, the spark plug 1 is an oblique discharge type that discharges sparks obliquely with respect to the direction of the axis CL1, but the discharge direction of the spark plug 1 is not limited to this. Therefore, a horizontal discharge type that discharges a spark along a direction substantially orthogonal to the direction of the axis CL1 or a vertical discharge type that discharges a spark along the direction of the axis CL1 may be used. .

  (E) In the above embodiment, the case where the ground electrode 27 is joined to the distal end surface of the distal end portion 26 of the metal shell 3 is embodied. However, a part of the metal shell (or pre-welded to the metal shell) The present invention can also be applied to the case where the ground electrode is formed so as to cut out a part of a certain end fitting (for example, JP-A-2006-236906). Alternatively, the ground electrode 27 may be joined to the side surface of the distal end portion 26 of the metal shell 3.

  (F) In the above embodiment, the tool engaging portion 19 has a hexagonal cross section, but the shape of the tool engaging portion 19 is not limited to such a shape. For example, it may be a Bi-HEX (deformed 12-angle) shape [ISO 22777: 2005 (E)].

  (G) The arrangement positions of the first inner deformation preventing means 62A and the first outer deformation preventing means 62B during the pre-bending process may be determined based on the imaging data of the tip portion of the spark plug 1.

  (H) In the above embodiment, the first inner deformation preventing means 62A and the first outer deformation preventing means 62B, the second inner deformation preventing means 73A and the second outer deformation preventing means 73B, the arm 83A and the arm 83B are separate members. Although comprised, you may comprise by a single member.

  (I) In the above embodiment, the gap adjusting means 83 sandwiches the proximal end portion of the ground electrode 27. However, as the gap adjusting means, the distal end surface of the ground electrode 27 (having the noble metal tip 32). In such a case, the tip of the ground electrode base material excluding the noble metal tip 32 may be pressed.

It is a partially broken front view which shows the structure of the spark plug of this embodiment. It is a partially broken expanded front view which shows the structure of the front-end | tip part of a spark plug. It is a block diagram which shows the structure of a bending apparatus. It is the elements on larger scale which show the spark plug which has a ground electrode before a bending process. It is an expansion schematic diagram which shows a preliminary | backup bending apparatus etc. It is an expansion schematic diagram which shows this bending apparatus etc. (A) is a schematic front view showing the configuration of the gap adjusting device and the like, and (b) is a schematic side view showing the configuration of the gap adjusting device and the like.

DESCRIPTION OF SYMBOLS 1 ... Spark plug, 2 ... Insulator as an insulator, 3 ... Main metal fitting, 4 ... Shaft hole, 5 ... Center electrode, 26 ... Tip part of main metal fitting, 27 ... Ground electrode, 33 ... Spark discharge gap, 51 ... Bending device, 61 ... preliminary bending device, 62 ... first deformation preventing means, 62A ... first inner deformation preventing means, 62B ... first outer deformation preventing means, 63 ... roller, 65 ... curved surface portion, 71 ... main bending device, 72: pressing means, 73: second deformation preventing means, 81: gap adjusting device, 83: gap adjusting means, 83A: arm as gap expanding means, 84: regulating means.

Claims (36)

A rod-shaped center electrode extending in the axial direction;
A substantially cylindrical insulator having an axial hole extending in the axial direction and having the center electrode provided on a distal end side of the axial hole;
A substantially cylindrical metal shell provided on the outer periphery of the insulator;
A spark plug manufacturing method comprising a grounding electrode having a base end joined to the metal shell and an intermediate portion bent to form a spark discharge gap between the tip and the tip of the center electrode. ,
A bending step for bending the ground electrode toward the axis in a state in which the metal shell to which the ground electrode is bonded and the insulator provided with the center electrode are assembled;
The bending step includes
Between the side portion of the center electrode and the base end portion of the ground electrode, a curved surface attaching means having a curved surface portion corresponding to the bent shape of the ground electrode,
In order to prevent the base end portion of the ground electrode from being deformed to at least one of the center electrode side and the opposite side of the center electrode, the ground electrode is supported by the deformation preventing means,
Bending using means, said said center electrode ground electrode against the curved surface portion by pressing from the opposite side, seen including a bending process subjected to bending to the ground electrode,
The deformation preventing means includes
The ground electrode is disposed between a side portion of the center electrode and a base end portion of the ground electrode, and supports a side portion on the center electrode side of the base end portion of the ground electrode, and the ground electrode toward the center electrode side is supported. Inner deformation prevention means for preventing deformation;
The ground electrode is disposed on a side opposite to the center electrode, and supports a side portion of the ground electrode opposite to the center electrode at the base end portion, and the side toward the side opposite to the center electrode side is supported. A spark plug manufacturing method comprising: an outer deformation preventing means for preventing deformation of the ground electrode . The spark plug manufacturing method according to claim 1 , wherein the deformation preventing means is formed by integrating the curved surface attaching means and the inner deformation preventing means. It said inner deformation preventing means and the outer deformation preventing means, spark plug manufacturing method according to claim 1 or 2, characterized in that it is arranged so as to face each other across the proximal end portion of the ground electrode. The spark plug manufacturing method according to any one of claims 1 to 3, wherein an interval between the inner deformation prevention means and the outer deformation prevention means is configured to be changeable. As the center of curvature of the curved surface portion is positioned in the axial direction base end side than the plane including the distal end surface of the center electrode, according to claim 1 to 4, characterized in that said curved surface with means being arranged The manufacturing method of the spark plug of any one of Claims 1. In the bending step, after the bending step,
Using a gap adjusting means capable of moving the tip of the ground electrode relative to the center electrode along a direction substantially perpendicular to the axis, a size along the direction perpendicular to the axis of the spark discharge gap. The method for manufacturing a spark plug according to any one of claims 1 to 5 , further comprising a gap adjusting step of adjusting the height. The gap adjusting means is disposed between a side portion of the center electrode and a base end portion of the ground electrode, and relatively moves a tip end portion of the ground electrode in a direction away from the center electrode, so that the spark discharge is performed. A gap enlarging means capable of enlarging the size of the gap along the direction perpendicular to the axis;
The method for manufacturing a spark plug according to claim 6 , wherein the gap enlarging means is disposed closer to the tip end side in the axial direction than a plane including the tip end surface of the insulator. The spark according to claim 6 or 7 , wherein, in the gap adjusting step, a restricting means for restricting relative movement of the tip end portion of the ground electrode with respect to the center electrode to at least the tip end in the axial direction is used. Plug manufacturing method. A rod-shaped center electrode extending in the axial direction;
A substantially cylindrical insulator having an axial hole extending in the axial direction and having the center electrode provided on a distal end side of the axial hole;
A substantially cylindrical metal shell provided on the outer periphery of the insulator;
A spark plug manufacturing method comprising a grounding electrode having a base end joined to the metal shell and an intermediate portion bent to form a spark discharge gap between the tip and the tip of the center electrode. ,
A bending step for bending the ground electrode toward the axis in a state in which the metal shell to which the ground electrode is bonded and the insulator provided with the center electrode are assembled;
The bending step includes
Between the side portion of the center electrode and the base end portion of the ground electrode, a curved surface attaching means having a curved surface portion corresponding to the bent shape of the ground electrode,
In order to prevent the base end portion of the ground electrode from being deformed to at least one of the center electrode side and the opposite side of the center electrode, the ground electrode is supported by the deformation preventing means,
Bending using means, said said center electrode ground electrode against the curved surface portion by pressing from the opposite side, seen including a bending process subjected to bending to the ground electrode,
The spark plug manufacturing method , wherein the curved surface attaching means is arranged such that a center of curvature of the curved surface portion is located on the proximal side in the axial direction with respect to a plane including a distal end surface of the center electrode . In the bending step, after the bending step,
Using a gap adjusting means capable of moving the tip of the ground electrode relative to the center electrode along a direction substantially perpendicular to the axis, a size along the direction perpendicular to the axis of the spark discharge gap. The method for manufacturing a spark plug according to claim 9 , further comprising a gap adjusting step of adjusting the thickness. The gap adjusting means is disposed between a side portion of the center electrode and a base end portion of the ground electrode, and relatively moves a tip end portion of the ground electrode in a direction away from the center electrode, so that the spark discharge is performed. A gap enlarging means capable of enlarging the size of the gap along the direction perpendicular to the axis;
The method for manufacturing a spark plug according to claim 10 , wherein the gap enlarging means is disposed closer to the tip end side in the axial direction than a plane including the tip end face of the insulator. The spark according to claim 10 or 11 , wherein, in the gap adjusting step, a restricting means for restricting relative movement of the tip end portion of the ground electrode with respect to the center electrode to at least the tip end side in the axial direction is used. Plug manufacturing method. A rod-shaped center electrode extending in the axial direction;
A substantially cylindrical insulator having an axial hole extending in the axial direction and having the center electrode provided on a distal end side of the axial hole;
A substantially cylindrical metal shell provided on the outer periphery of the insulator;
A spark plug manufacturing method comprising a grounding electrode having a base end joined to the metal shell and an intermediate portion bent to form a spark discharge gap between the tip and the tip of the center electrode. ,
A bending step for bending the ground electrode toward the axis in a state in which the metal shell to which the ground electrode is bonded and the insulator provided with the center electrode are assembled;
The bending step includes
Between the side portion of the center electrode and the base end portion of the ground electrode, a curved surface attaching means having a curved surface portion corresponding to the bent shape of the ground electrode,
In order to prevent the base end portion of the ground electrode from being deformed to at least one of the center electrode side and the opposite side of the center electrode, the ground electrode is supported by the deformation preventing means,
Bending using means, said said center electrode ground electrode against the curved surface portion by pressing from the opposite side, seen including a bending process subjected to bending to the ground electrode,
In the bending step, after the bending step,
Using a gap adjusting means capable of moving the tip of the ground electrode relative to the center electrode along a direction substantially perpendicular to the axis, a size along the direction perpendicular to the axis of the spark discharge gap. Including a gap adjustment step of adjusting the thickness,
The gap adjusting means is disposed between a side portion of the center electrode and a base end portion of the ground electrode, and relatively moves a tip end portion of the ground electrode in a direction away from the center electrode, so that the spark discharge is performed. A gap enlarging means capable of enlarging the size of the gap along the direction perpendicular to the axis;
The spark plug manufacturing method , wherein the gap enlarging means is disposed on the tip end side in the axial direction with respect to a plane including the tip end surface of the insulator . 14. The spark plug according to claim 13 , wherein in the gap adjustment step, a restricting means for restricting a relative movement of the tip of the ground electrode with respect to the center electrode to at least the tip in the axial direction is used. Production method. The deformation preventing means includes
The ground electrode is disposed between a side portion of the center electrode and a base end portion of the ground electrode, and supports a side portion on the center electrode side of the base end portion of the ground electrode, and the ground electrode toward the center electrode side is supported. The spark plug manufacturing method according to any one of claims 9 to 14, further comprising an inner deformation prevention means for preventing deformation. The spark plug manufacturing method according to claim 15 , wherein the deformation preventing means is formed by integrating the curved surface attaching means and the inner deformation preventing means. The bending means is a roller configured to be relatively movable with respect to the ground electrode along a direction substantially orthogonal to the axis, and is supported so as to be freely rotatable,
Wherein the said central electrode of the ground electrode by pressing the outer peripheral surface of the roller with respect to the opposite side, any one of claims 1 to 16, characterized by applying bending to the ground electrode A method for producing a spark plug as described in 1. In the spark plug, the shortest distance between the center electrode and the ground electrode is formed between a tip edge portion of the center electrode or a side surface portion of the center electrode and a tip portion of the ground electrode. A method for manufacturing a spark plug according to any one of claims 1 to 17 . A rod-shaped center electrode extending in the axial direction;
A substantially cylindrical insulator having an axial hole extending in the axial direction and having the center electrode provided on a distal end side of the axial hole;
A substantially cylindrical metal shell provided on the outer periphery of the insulator;
Manufacturing used for manufacturing a spark plug having a grounding electrode having a base end joined to the metal shell and an intermediate portion bent to form a spark discharge gap between the tip and the tip of the center electrode A device,
A bending device for bending the straight rod-shaped ground electrode toward the axis in a state where the metal shell to which the straight rod-shaped ground electrode is bonded and the insulator provided with the center electrode are assembled. With
The bending apparatus is
Curved surface means corresponding to the bent shape of the ground electrode, and a curved surface-applying means disposed between the side portion of the center electrode and the base end portion of the ground electrode;
And deformation preventing means for preventing said proximal portion of said ground electrode to deform at least one of the side opposite the center electrode side and the center electrode,
Wherein the center electrode have a means bending pressing the ground electrode from the opposite side with respect to the curved surface of the curved surface with means,
The deformation preventing means includes
The ground electrode is disposed between a side portion of the center electrode and a base end portion of the ground electrode, and supports a side portion on the center electrode side of the base end portion of the ground electrode, and the ground electrode toward the center electrode side is supported. Inner deformation prevention means for preventing deformation;
The ground electrode is disposed on a side opposite to the center electrode, and supports a side portion of the ground electrode opposite to the center electrode at the base end portion, and the side toward the side opposite to the center electrode side is supported. spark plug manufacturing apparatus according to claim Rukoto an outer deformation preventing means for preventing the deformation of the ground electrode. 20. The spark plug manufacturing apparatus according to claim 19 , wherein the deformation preventing means is formed by integrating the curved surface attaching means and the inner deformation preventing means. 21. The spark plug manufacturing apparatus according to claim 19 or 20 , wherein the inner deformation prevention means and the outer deformation prevention means are arranged to face each other with a base end portion of the ground electrode interposed therebetween. The spark plug manufacturing apparatus according to any one of claims 19 to 21, wherein an interval between the inner deformation prevention means and the outer deformation prevention means is configured to be changeable. As the center of curvature of the curved surface portion is positioned in the axial direction base end side than the plane including the distal end surface of the center electrode, of claims 19 to 22, characterized in that said curved surface with means being arranged The spark plug manufacturing apparatus according to any one of the preceding claims. The bending apparatus further includes:
Gap adjustment means is provided that can move the tip of the ground electrode relative to the center electrode along a direction substantially perpendicular to the axis, and the gap adjustment means is perpendicular to the axis of the spark discharge gap. The spark plug manufacturing apparatus according to any one of claims 19 to 23 , wherein a size along the direction is adjusted. The gap adjusting means is disposed between a side portion of the center electrode and a base end portion of the ground electrode, and relatively moves a tip end portion of the ground electrode in a direction away from the center electrode, so that the spark discharge is performed. A gap enlarging means capable of enlarging the size of the gap along the direction perpendicular to the axis;
25. The spark plug manufacturing apparatus according to claim 24 , wherein the gap enlarging means is disposed on the tip end side in the axial direction with respect to a plane including the tip end surface of the insulator. The gap adjusting means includes
A spark plug manufacturing apparatus according to claim 24 or 25, wherein further comprising a restricting means for restricting the relative movement of the at least the axially forward end side of the distal end portion of the ground electrode relative to the center electrode. A rod-shaped center electrode extending in the axial direction;
A substantially cylindrical insulator having an axial hole extending in the axial direction and having the center electrode provided on a distal end side of the axial hole;
A substantially cylindrical metal shell provided on the outer periphery of the insulator;
Manufacturing used for manufacturing a spark plug having a grounding electrode having a base end joined to the metal shell and an intermediate portion bent to form a spark discharge gap between the tip and the tip of the center electrode A device,
A bending device for bending the straight rod-shaped ground electrode toward the axis in a state where the metal shell to which the straight rod-shaped ground electrode is bonded and the insulator provided with the center electrode are assembled. With
The bending apparatus is
Curved surface means corresponding to the bent shape of the ground electrode, and a curved surface-applying means disposed between the side portion of the center electrode and the base end portion of the ground electrode;
And deformation preventing means for preventing said proximal portion of said ground electrode to deform at least one of the side opposite the center electrode side and the center electrode,
Wherein the center electrode have a means bending pressing the ground electrode from the opposite side with respect to the curved surface of the curved surface with means,
The center of curvature of the curved surface portion than the plane including the distal end surface of the center electrode so as to be positioned in the axial direction base end side, the curved surface with means disposed spark plug manufacturing apparatus according to claim Rukoto. The bending apparatus further includes:
Gap adjustment means is provided that can move the tip of the ground electrode relative to the center electrode along a direction substantially perpendicular to the axis, and the gap adjustment means is perpendicular to the axis of the spark discharge gap. 28. The apparatus for manufacturing a spark plug according to claim 27 , wherein a size along the direction is adjusted. The gap adjusting means is disposed between a side portion of the center electrode and a base end portion of the ground electrode, and relatively moves a tip end portion of the ground electrode in a direction away from the center electrode, so that the spark discharge is performed. A gap enlarging means capable of enlarging the size of the gap along the direction perpendicular to the axis;
29. The spark plug manufacturing apparatus according to claim 28 , wherein the gap enlarging means is disposed on the tip end side in the axial direction with respect to a plane including the tip end face of the insulator. The gap adjusting means includes
30. The spark plug manufacturing apparatus according to claim 28 or 29 , further comprising a restricting means for restricting a relative movement of the tip end portion of the ground electrode with respect to the center electrode toward at least the tip end in the axial direction. A rod-shaped center electrode extending in the axial direction;
A substantially cylindrical insulator having an axial hole extending in the axial direction and having the center electrode provided on a distal end side of the axial hole;
A substantially cylindrical metal shell provided on the outer periphery of the insulator;
Manufacturing used for manufacturing a spark plug having a grounding electrode having a base end joined to the metal shell and an intermediate portion bent to form a spark discharge gap between the tip and the tip of the center electrode A device,
A bending device for bending the straight rod-shaped ground electrode toward the axis in a state where the metal shell to which the straight rod-shaped ground electrode is bonded and the insulator provided with the center electrode are assembled. With
The bending apparatus is
Curved surface means corresponding to the bent shape of the ground electrode, and a curved surface-applying means disposed between the side portion of the center electrode and the base end portion of the ground electrode;
And deformation preventing means for preventing said proximal portion of said ground electrode to deform at least one of the side opposite the center electrode side and the center electrode,
Bending means for pressing the ground electrode from the opposite side of the center electrode to the curved surface portion of the curved surface attaching means ;
The bending apparatus further includes:
Gap adjustment means is provided that can move the tip of the ground electrode relative to the center electrode along a direction substantially perpendicular to the axis, and the gap adjustment means is perpendicular to the axis of the spark discharge gap. Adjust the size along the direction,
The gap adjusting means is disposed between a side portion of the center electrode and a base end portion of the ground electrode, and relatively moves a tip end portion of the ground electrode in a direction away from the center electrode, so that the spark discharge is performed. A gap enlarging means capable of enlarging the size of the gap along the direction perpendicular to the axis;
The spark plug manufacturing apparatus , wherein the gap enlarging means is arranged on the tip side in the axial direction with respect to a plane including the tip surface of the insulator . The gap adjusting means includes
32. The apparatus for manufacturing a spark plug according to claim 31 , further comprising a restricting means for restricting a relative movement of the tip end portion of the ground electrode with respect to the center electrode toward at least the tip end side in the axial direction. The deformation preventing means includes
The ground electrode is disposed between a side portion of the center electrode and a base end portion of the ground electrode, and supports a side portion on the center electrode side of the base end portion of the ground electrode, and the ground electrode toward the center electrode side is supported. The spark plug manufacturing apparatus according to any one of claims 27 to 32, further comprising an inner deformation preventing means for preventing the deformation. 34. The spark plug manufacturing apparatus according to claim 33 , wherein the deformation preventing means is formed by integrating the curved surface attaching means and the inner deformation preventing means. 35. The roller according to any one of claims 19 to 34, wherein the bending means is a roller supported so as to be freely rotatable and movable toward and away from the ground electrode along a direction substantially orthogonal to the axis. or spark plug manufacturing apparatus according to item 1. In the spark plug, the shortest distance between the center electrode and the ground electrode is formed between a tip edge portion of the center electrode or a side surface portion of the center electrode and a tip portion of the ground electrode. The spark plug manufacturing apparatus according to any one of claims 19 to 35 .

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