WO2010044236A1 - スパークプラグおよびその製造方法 - Google Patents
スパークプラグおよびその製造方法 Download PDFInfo
- Publication number
- WO2010044236A1 WO2010044236A1 PCT/JP2009/005283 JP2009005283W WO2010044236A1 WO 2010044236 A1 WO2010044236 A1 WO 2010044236A1 JP 2009005283 W JP2009005283 W JP 2009005283W WO 2010044236 A1 WO2010044236 A1 WO 2010044236A1
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- WO
- WIPO (PCT)
- Prior art keywords
- ground electrode
- electrode
- protrusion
- center electrode
- spark plug
- Prior art date
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- 238000004519 manufacturing process Methods 0.000 title claims description 14
- 229910052751 metal Inorganic materials 0.000 claims description 34
- 239000002184 metal Substances 0.000 claims description 34
- 238000001125 extrusion Methods 0.000 claims description 26
- 239000012212 insulator Substances 0.000 claims description 25
- 230000015572 biosynthetic process Effects 0.000 claims description 5
- 238000011156 evaluation Methods 0.000 description 35
- 238000002474 experimental method Methods 0.000 description 24
- 238000012986 modification Methods 0.000 description 15
- 230000004048 modification Effects 0.000 description 15
- 230000005484 gravity Effects 0.000 description 13
- 238000002485 combustion reaction Methods 0.000 description 10
- 230000017525 heat dissipation Effects 0.000 description 10
- 238000003825 pressing Methods 0.000 description 10
- 238000010586 diagram Methods 0.000 description 8
- 238000000034 method Methods 0.000 description 6
- 239000000463 material Substances 0.000 description 5
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 4
- 238000005520 cutting process Methods 0.000 description 4
- 238000012545 processing Methods 0.000 description 4
- 229910000990 Ni alloy Inorganic materials 0.000 description 3
- 238000005452 bending Methods 0.000 description 3
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 2
- 229910052802 copper Inorganic materials 0.000 description 2
- 239000010949 copper Substances 0.000 description 2
- 239000011162 core material Substances 0.000 description 2
- 230000007423 decrease Effects 0.000 description 2
- 230000007547 defect Effects 0.000 description 2
- 238000006073 displacement reaction Methods 0.000 description 2
- 229910001026 inconel Inorganic materials 0.000 description 2
- 238000000465 moulding Methods 0.000 description 2
- 229910052759 nickel Inorganic materials 0.000 description 2
- 238000010008 shearing Methods 0.000 description 2
- 229910001209 Low-carbon steel Inorganic materials 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 229910010293 ceramic material Inorganic materials 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 230000000994 depressogenic effect Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000010304 firing Methods 0.000 description 1
- 238000005242 forging Methods 0.000 description 1
- 239000000446 fuel Substances 0.000 description 1
- 238000003780 insertion Methods 0.000 description 1
- 230000037431 insertion Effects 0.000 description 1
- 229910000510 noble metal Inorganic materials 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- 238000003466 welding Methods 0.000 description 1
Images
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01T—SPARK GAPS; OVERVOLTAGE ARRESTERS USING SPARK GAPS; SPARKING PLUGS; CORONA DEVICES; GENERATING IONS TO BE INTRODUCED INTO NON-ENCLOSED GASES
- H01T21/00—Apparatus or processes specially adapted for the manufacture or maintenance of spark gaps or sparking plugs
- H01T21/02—Apparatus or processes specially adapted for the manufacture or maintenance of spark gaps or sparking plugs of sparking plugs
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01T—SPARK GAPS; OVERVOLTAGE ARRESTERS USING SPARK GAPS; SPARKING PLUGS; CORONA DEVICES; GENERATING IONS TO BE INTRODUCED INTO NON-ENCLOSED GASES
- H01T13/00—Sparking plugs
- H01T13/20—Sparking plugs characterised by features of the electrodes or insulation
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01T—SPARK GAPS; OVERVOLTAGE ARRESTERS USING SPARK GAPS; SPARKING PLUGS; CORONA DEVICES; GENERATING IONS TO BE INTRODUCED INTO NON-ENCLOSED GASES
- H01T13/00—Sparking plugs
- H01T13/20—Sparking plugs characterised by features of the electrodes or insulation
- H01T13/32—Sparking plugs characterised by features of the electrodes or insulation characterised by features of the earthed electrode
Definitions
- the present invention relates to a spark plug (ignition plug) that ignites fuel by electrically generating a spark in an internal combustion engine, and more particularly to a ground electrode of the spark plug.
- Patent Document 1 discloses a technique for forming a protrusion on a ground electrode by “forging press” which is one of press processes.
- Non-Patent Document 1 discloses a technique for forming a protrusion on a ground electrode by “extrusion press” which is one of press processes.
- the present invention has been made in view of the above-described problems, and an object thereof is to provide a technique capable of improving the durability of a spark plug in which a ground electrode is formed by press working.
- the present invention has been made to solve at least a part of the problems described above, and can be realized as the following forms or application examples.
- the spark plug of Application Example 1 is joined to a shaft-shaped center electrode, an insulator that holds the outer periphery of the center electrode, a metal shell that holds the outer periphery of the insulator, and the metal shell.
- a projecting amount A from which the protrusion protrudes from the opposing surface satisfies 0.4 mm ⁇ A ⁇ 1.0 mm
- the tip of the ground electrode Width B of up to less recess is characterized by satisfying 0.4 mm ⁇ B ⁇ 2.5 mm.
- the width B may satisfy 0.4 mm ⁇ B ⁇ 1.1 mm.
- the heat dissipation of the protrusion can be improved.
- the durability of the spark plug in which the ground electrode is formed by press working can be further improved.
- the width C from the side end of the ground electrode to the press recess may satisfy 0.4 mm ⁇ C ⁇ 0.8 mm.
- the heat dissipation at the portion from the side end of the ground electrode to the press recess can be improved.
- the durability of the spark plug in which the ground electrode is formed by press working can be further improved.
- the spark plug of Application Example 7 is joined to the shaft center electrode, the insulator holding the outer periphery of the center electrode, the metal shell holding the outer periphery of the insulator, and the metal shell.
- the protrusion A from which the protrusion protrudes from the opposing surface satisfies 0.4 mm ⁇ A ⁇ 1.0 mm, and the width from the side end of the ground electrode to the press recess It is characterized by satisfying 0.4mm ⁇ C ⁇ 0.8mm.
- a spark plug manufacturing method includes a shaft-shaped center electrode, an insulator that holds the outer periphery of the center electrode, a metal shell that holds the outer periphery of the insulator, and the metal shell. And a ground electrode that forms a spark gap with the center electrode, the spark plug including a ground electrode facing the tip of the center electrode from the facing surface.
- a protrusion protruding toward the tip of the center electrode is formed by an extrusion press so that a protrusion amount A protruding from the facing surface of the protrusion satisfies 0.4 mm ⁇ A ⁇ 1.0 mm, and the grounding
- a press recess recessed from the back surface toward the front end of the center electrode has a width B from the front end of the ground electrode to the press recess. And forming so as to satisfy the .4mm ⁇ B ⁇ 2.5mm.
- the form of the present invention is not limited to the form of the spark plug and the manufacturing method thereof, and can be applied to various forms such as, for example, the ground electrode of the spark plug and the manufacturing method thereof, and the internal combustion engine including the spark plug. is there. Further, the present invention is not limited to the above-described embodiments, and it is needless to say that the present invention can be implemented in various forms without departing from the spirit of the present invention.
- FIG. 3 is a partial cross-sectional view showing, on an enlarged scale, a plane obtained by cutting the ground electrode at a cross section XX in FIG. 2.
- FIG. 4 is a partial cross-sectional view showing, in an enlarged manner, a surface obtained by cutting a ground electrode at a cross-section YY in FIG. 3. It is the elements on larger scale which looked at the ground electrode from the back side.
- FIG. 1 is an explanatory view mainly showing a partial cross section of the spark plug 100.
- the spark plug 100 includes an insulator 10, a center electrode 20, a ground electrode 30, a terminal fitting 40, and a metal shell 50.
- the rod-shaped center electrode 20 protruding from one end of the insulator 10 is electrically connected to a terminal fitting 40 provided at the other end of the insulator 10 through the inside of the insulator 10.
- the outer circumference of the center electrode 20 is insulated by the insulator 10, and the outer circumference of the insulator 10 is held by the metal shell 50 at a position away from the terminal fitting 40.
- the ground electrode 30 electrically connected to the metal shell 50 forms a spark gap G, which is a gap for generating a spark, between the tip of the center electrode 20.
- the spark plug 100 is attached to a mounting screw hole 201 provided in an engine head 200 of an internal combustion engine (not shown) via a metallic shell 50, and a high voltage of 20,000 to 30,000 volts is applied to the terminal fitting 40. Then, a spark is generated in a spark gap G formed between the center electrode 20 and the ground electrode 30.
- the insulator 10 of the spark plug 100 is an insulator formed by firing a ceramic material such as alumina.
- the insulator 10 is a cylindrical body in which the shaft hole 12 that accommodates the center electrode 20 and the terminal fitting 40 is formed at the center.
- a flange portion 19 having an increased outer diameter is formed at the center of the insulator 10 in the axial direction.
- a rear end side body portion 18 that insulates between the terminal metal fitting 40 and the metal shell 50 is formed on the terminal metal fitting 40 side of the flange portion 19.
- a front end side body portion 17 having an outer diameter smaller than that of the rear end side body portion 18 is formed on the center electrode 20 side with respect to the flange portion 19, and the front end side body portion 17 is further forward than the front end side body portion 17.
- the leg length portion 13 is formed with a smaller outer diameter, and the outer diameter decreases toward the center electrode 20 side.
- the metal shell 50 of the spark plug 100 is a cylindrical metal fitting that surrounds and holds a portion ranging from a part of the rear end side body portion 18 to the leg long portion 13 of the insulator 10.
- the low-carbon steel is used. Consists of.
- the metal shell 50 includes a tool engaging portion 51, a mounting screw portion 52, a seal portion 54, and a tip surface 57.
- a tool (not shown) for attaching the spark plug 100 to the engine head 200 is fitted into the tool engaging portion 51 of the metal shell 50.
- the mounting screw portion 52 of the metal shell 50 has a thread that is screwed into the mounting screw hole 201 of the engine head 200.
- the seal portion 54 of the metal shell 50 is formed in a hook shape at the base of the mounting screw portion 52, and an annular gasket 5 formed by bending a plate is inserted between the seal portion 54 and the engine head 200.
- the distal end surface 57 of the metal shell 50 is a hollow circular surface formed at the distal end of the mounting screw portion 52, and the center electrode 20 wrapped in the leg long portion 13 projects from the center of the distal end surface 57.
- the center electrode 20 of the spark plug 100 is a rod-shaped electrode in which a core material 25 having better thermal conductivity than the electrode base material 21 is embedded in an electrode base material 21 formed in a bottomed cylindrical shape.
- the electrode base material 21 is made of a nickel alloy containing nickel as a main component such as Inconel (registered trademark), and the core member 25 is made of copper or an alloy containing copper as a main component.
- the center electrode 20 is inserted into the shaft hole 12 of the insulator 10 with the tip of the electrode base material 21 protruding from the shaft hole 12 of the insulator 10, and is electrically connected to the terminal fitting 40 via the ceramic resistor 3 and the seal body 4. Connected.
- the ground electrode 30 of the spark plug 100 is an electrode that is joined to the front end surface 57 of the metal shell 50 and bends in a direction intersecting the axial direction of the center electrode 20 to face the front end of the center electrode 20.
- the ground electrode 30 is made of a nickel alloy mainly composed of nickel such as Inconel (registered trademark).
- FIG. 2 is an explanatory diagram mainly showing the detailed structure of the ground electrode 30.
- the ground electrode 30 is a tip surface 31 that constitutes the tip of the ground electrode 30, a facing surface 32 that faces the center electrode 20 among the surfaces of the ground electrode 30, and a surface opposite to the facing surface 32. And a back surface 33 facing the back.
- a protrusion 36 is formed by extrusion pressing so as to protrude opposite the tip of the center electrode 20.
- a spark gap G is formed between the protrusion 36 and the center electrode 20.
- a press recessed portion 37 is formed behind the protruding portion 36 along with the formation of the protruding portion 36 by extrusion molding.
- the centers of gravity of the protrusions 36 and the press recesses 37 are arranged substantially along the extension of the center axis of the center electrode 20.
- the projecting portion 36 is a cylindrical projection having a circular cross section
- the press recessed portion 37 is a cylindrical recess having a circular cross section.
- FIG. 3 is an enlarged partial cross-sectional view showing a surface obtained by cutting the ground electrode 30 in a cross section XX in FIG.
- FIG. 4 is a partial cross-sectional view showing, on an enlarged scale, a surface obtained by cutting the ground electrode 30 at the cross-section YY in FIG.
- FIG. 5 is a partially enlarged view of the ground electrode 30 as viewed from the back surface 33 side.
- the cross section XX is a plane that passes through the central axis of the center electrode 20, and is a plane that intersects the direction in which the ground electrode 30 protrudes from the metal shell 50 to the central electrode 20, and the cross section YY is It is a surface that passes through the central axis of the center electrode 20 and is substantially along the direction in which the ground electrode 30 protrudes from the metal shell 50 to the center electrode 20.
- the ground electrode 30 further includes side end surfaces 34 and 35 in addition to the front end surface 31, the opposing surface 32, and the back surface 33.
- the side end surfaces 34, 35 of the ground electrode 30 are surfaces that intersect the tip surface 31, the opposing surface 32, and the back surface 33, and constitute the side end of the ground electrode 30.
- the distance between the opposing surface 32 and the back surface 33, that is, the thickness T of the ground electrode 30 is 1.5 mm (millimeters)
- the electrode width W of the ground electrode 30 is 2.8 mm.
- the protrusion 36 of the ground electrode 30 includes a side surface 362 and a root portion 364.
- the side surface 362 of the protrusion 36 is a surface substantially along the direction in which the protrusion 36 protrudes from the facing surface 32, that is, the direction toward the center electrode 20.
- a root portion 364 of the protrusion 36 is a portion where the protrusion 36 rises from the facing surface 32 and is connected to the side surface 362.
- the side surface 362 of the protruding portion 36 is substantially perpendicular to the facing surface 32, and the root portion 364 of the protruding portion 36 is formed as a substantially perpendicular corner.
- the protrusion amount A that the protrusion 36 protrudes from the facing surface 32 preferably satisfies 0.4 mm ⁇ A ⁇ 1.0 mm. The evaluation value of the protrusion amount A will be described later.
- the facing surface 32 of the ground electrode 30 includes a flat surface 322 and a round corner 324.
- the flat surface 322 of the facing surface 32 is a flat surface that continues from the root portion 364 of the protrusion 36 to the side end surfaces 34 and 35 of the ground electrode 30.
- the rounded corner portion 324 of the facing surface 32 is a curved surface formed by deforming the rounded corner portion originally formed on the member of the ground electrode 30 before the projection portion 36 is molded as the projection portion 36 is molded. It is.
- the ratio between the distance E1 of the flat surface 322 extending from the root portion 364 of the protrusion 36 to the round corner 324 of the facing surface 32 and the distance E2 from the root portion 364 of the protrusion 36 to the side end surfaces 34 and 35 is 0.4 ⁇ (E1 / E2) ⁇ 1 is preferably satisfied.
- the evaluation value of the ratio between the distance E1 and the distance E2 will be described later.
- the press recessed portion 37 of the ground electrode 30 includes a bottom surface 371, side surfaces 372, and corner portions 374.
- the bottom surface 371 of the press recess 37 is a surface that is substantially parallel to the back surface 33 and that forms the bottom of the press recess 37.
- the side surface 372 of the press concave portion 37 is a surface substantially along the direction in which the press concave portion 37 is recessed from the back surface 33 toward the facing surface 32, that is, the direction toward the center electrode 20.
- the corner 374 of the press recessed portion 37 is a portion connected from the bottom surface 371 to the side surface 372 of the press recessed portion 37.
- the side surface 372 of the press concave portion 37 is substantially perpendicular to the bottom surface 371 of the press concave portion 37 and the back surface 33 of the ground electrode 30, and the corner portion 374 of the press concave portion 37 is formed as a substantially perpendicular corner portion.
- the width B from the side surface 372 of the press recess 37 to the tip surface 31 of the ground electrode 30 preferably satisfies 0.4 mm ⁇ B ⁇ 2.5 mm.
- the width C from the side surface 372 of the press recess 37 to the side end surfaces 34 and 35 of the ground electrode 30 preferably satisfies 0.4 mm ⁇ C ⁇ 0.8 mm. Evaluation values of the widths B and C will be described later.
- the projecting portion 36 is located inside the press recessed portion 37.
- the distance F at which the root portion 364 of the projection portion 36 is located on the inner side from the side surface 372 of the press concave portion 37 satisfies 0 mm or more.
- FIG. 6 is a flowchart showing the manufacturing process of the ground electrode 30.
- FIG. 7 and FIG. 8 are explanatory views showing how the ground electrode 30 is manufactured.
- the electrode member 301 which is the material of the ground electrode 30 is welded to the metal shell 50 (step S110).
- the electrode member 301 is a rod-shaped nickel alloy having a substantially rectangular cross section.
- the electrode member 301 is disposed between the holding die 610 and the receiving die 620 (step S120).
- the holding die 610 and the receiving die 620 are dies used for an extrusion press.
- the receiving mold 620 is formed with a molding groove 622 having substantially the same shape as the electrode member 301, and the electrode member 301 is accommodated in the molding groove 622 of the receiving mold 620.
- a pin hole 614 is formed in the holding die 610 at a position corresponding to the press recessed portion 37 of the ground electrode 30 in accordance with the position of the forming groove 622 formed in the receiving die 620, and the grounding electrode is provided in the receiving die 620.
- a pin hole 624 is formed at a position corresponding to the 30 protrusions 36.
- the receiving pin 630 is inserted into the pin hole 624 of the receiving die 620 (step S130).
- the receiving pin 630 is a pin having a diameter substantially the same as the diameter of the pin hole 624 of the receiving mold 620, and the protrusion amount A of the protrusion 36 is set according to the amount of insertion of the receiving pin 630 into the pin hole 624. It is possible to adjust.
- the processing pin 640 is press-inserted into the pin hole 614 of the presser mold 610, whereby an extrusion press is applied to the electrode member 301 (step S140). .
- a portion of the electrode member 301 adjacent to the pin hole portion 614 of the pressing die 610 is depressed by the processing pin 640.
- the press concave portion 37 is formed, and a portion of the electrode member 301 adjacent to the pin hole portion 624 of the receiving die 620 is pushed out to the pin hole portion 624 by the processing pin 640 to form the protrusion 36.
- the electrode member 301 is processed by extrusion pressing (step S140), the electrode member 301 in which the protruding portion 36 and the press recessed portion 37 are formed on the electrode member 301 is taken out from the mold (step S150). Thereafter, the electrode member 301 taken out from the mold is bent (step S160), and the ground electrode 30 is completed.
- the ground electrode 30 was manufactured by subjecting the electrode member 301 previously welded to the metal shell 50 to extrusion pressing and bending.
- the electrode member 301 is subjected to extrusion pressing and bending before welding to the metal shell 50.
- the ground electrode 30 may be manufactured, or the electrode member 301 subjected to extrusion press before being welded to the metal shell 50 may be bent after being welded to the metal shell 50.
- FIG. 9 is an explanatory view showing the ground electrode 30 of the first to third modifications.
- FIG. 9 shows a cross section XX corresponding to the cross section described in FIG. 2 and a cross section YY corresponding to the cross section described in FIG. 3 for each ground electrode 30 in the first to third modifications. Is shown.
- the ground electrode 30 of the first modified example is the above-described embodiment except that the shape of the root portion 364 of the projection portion 36 and the corner portion 374 of the press recessed portion 37 is a corner portion chamfered at an angle of about 45 °. It is the same.
- the distances E2 to 34 and 35 are shorter than the above-described embodiment by the root portion 364, respectively.
- the distance F at which the protrusion 36 is located on the inner side from the side surface 372 of the press recess 37 is greater than 0 mm.
- the ground electrode 30 of the second modification is the same as that of the above-described embodiment except that the shape of the root portion 364 of the projection portion 36 and the corner portion 374 of the press recessed portion 37 is a curved round corner portion.
- the distances E2 to 34 and 35 are shorter than the above-described embodiment by the root portion 364, respectively.
- the distance F at which the protrusion 36 is located on the inner side from the side surface 372 of the press recess 37 is greater than 0 mm.
- the ground electrode 30 of the third modified example is the same as that of the above-described embodiment except that the side surface 372 of the press recessed portion 37 is inclined so that the diameter decreases in the depth direction.
- the distance F at which the root portion 364 of the protrusion 36 is located on the inner side from the side surface 372 of the press concave portion 37 is greater than 0 mm.
- FIG. 10 is an explanatory view showing the ground electrode 30 of the fourth to eighth modifications.
- FIG. 10 shows a partially enlarged view of each ground electrode 30 in the first to third modifications as viewed from the back surface 33 side.
- the ground electrode 30 of the fourth modification is the same as that of the above-described embodiment except that the circular protrusion 36 is located inside the square press recessed portion 37 when the ground electrode 30 is viewed from the back surface 33 side.
- the ground electrode 30 of the fifth modified example is the same as the above-described embodiment except that when the ground electrode 30 is viewed from the back surface 33 side, a square protrusion 36 is located inside the circular press recessed portion 37.
- the ground electrode 30 of the sixth modified example is the same as the above-described embodiment except that the elliptical protrusion 36 is located inside the elliptical press recessed portion 37 when the ground electrode 30 is viewed from the back surface 33 side. It is.
- the ground electrode 30 of the seventh modified example is the same as the above-described embodiment except that the triangular protrusion 36 is located inside the square press recessed portion 37 when the ground electrode 30 is viewed from the back surface 33 side.
- the ground electrode 30 of the sixth modification is the same as that of the above-described embodiment except that a square protrusion 36 is located inside the triangular press recess 37 when the ground electrode 30 is viewed from the back surface 33 side.
- the shapes of the protrusions 36 and the press recesses 37 of the ground electrode 30 may be other polygons or a plurality of curves, depending on the embodiment. It may have a configured shape.
- FIG. 11 is an explanatory diagram showing the results of an evaluation experiment in which the influence of the protrusion amount A on the ignition performance is examined.
- experimental values are shown with the protrusion amount A on the horizontal axis and the ignition timing with a combustion fluctuation rate of 20% on the vertical axis.
- the ignition timing at which the combustion fluctuation rate is 20% is shown using the crank angle of the internal combustion engine.
- a plurality of spark plugs 100 having a diameter of the protrusion 36 of 1.5 mm and different protrusion amounts A of the protrusion 36 were prepared. These spark plugs 100 were mounted on a 2000 cc displacement, DOHC gasoline engine, and idling was performed at an intake pressure of ⁇ 550 mmHg and an engine speed of 750 rpm, thereby obtaining the experimental values shown in FIG. According to the experimental values in FIG. 11, it was found that when the protrusion amount A is smaller than 0.4 mm, the rapid ignition performance is drastically decreased.
- FIG. 12 is an explanatory diagram showing the results of an evaluation experiment in which the influence of the protrusion amount A on the durability performance was examined.
- the experimental value is shown with the protrusion amount A on the horizontal axis and the increase amount of the spark gap G on the vertical axis.
- a plurality of spark plugs 100 having a diameter of the protrusion 36 of 1.5 mm and different protrusion amounts A of the protrusion 36 were prepared.
- the experimental value of FIG. 12 was obtained.
- the protrusion amount A preferably satisfies 0.4 mm or more from the viewpoint of ignition performance based on the result of FIG. 11, and preferably satisfies 1.0 mm or less from the viewpoint of durability performance based on the result of FIG. 12. . That is, the protrusion amount A preferably satisfies 0.4 mm ⁇ A ⁇ 1.0 mm.
- Evaluation value of width B 13A and 13B are explanatory diagrams showing the results of an evaluation experiment in which the influence of the width B on the durability performance is examined.
- the horizontal axis indicates the width B
- the vertical axis indicates the temperature of the tip surface 31, and the experimental value is shown.
- the horizontal axis indicates the width B
- the vertical axis indicates the temperature of the protrusion 36.
- Experimental values are shown. 13A and 13B, a plurality of spark plugs 100 having different widths B from the front end surface 31 of the ground electrode 30 to the press recessed portion 37 were prepared.
- the thickness T of the ground electrode 30 is 1.5 mm
- the electrode width W of the ground electrode 30 is 2.8 mm
- the protrusion amount A of the protrusion 36 is 0.7 mm
- the diameter of the protrusion 36 is 1.
- the depth of the press concave portion 37 was 0.7 mm
- the diameter of the press concave portion 37 was 1.7 mm
- the width C from the side end surfaces 34 and 35 of the ground electrode 30 to the press concave portion 37 was 0.5 mm.
- the spark plug 100 is heated to 950 ° C. for 2 minutes with a burner and then cooled for 1 minute at room temperature. After 1000 cycles, the temperature of the tip 33 of the ground electrode 30 near the back surface 33 is measured.
- the experimental value of FIG. 13A was obtained
- the experimental value of FIG. 13B was obtained by measuring the temperature of the side surface 362 of the protrusion 36 on the side of the tip surface 31.
- the width B when the width B is smaller than 0.4 mm, the temperature of the tip surface 31 is rapidly increased to the allowable limit value of 1000 ° C. or more, and when the width B exceeds 2.5 mm. It has been found that the temperature of the tip surface 31 suddenly increases and reaches the allowable limit value of 1000 ° C. or higher. Therefore, the width B preferably satisfies 0.4 mm ⁇ B ⁇ 2.5 mm from the viewpoint of durability performance as a result of FIG. 13A.
- the temperature of the protrusion 36 is 962 ° C. when the width B is 0.4 mm, 955 ° C. when the width B is 0.6 mm, 957 ° C. when the width B is 1.0 mm,
- the temperature was 960 ° C.
- the width B was smaller than 0.4 mm, the temperature of the protrusion 36 rapidly increased, and became 985 ° C. when the width B was 0.3 mm, and 1005 ° C. when the width B was 0.2 mm.
- the width B is larger than 1.1 mm, the temperature of the protrusion 36 rapidly increases to 978 ° C. when the width B is 1.3 mm, and 981 ° C.
- the width B when the width B is 1.5 mm.
- the temperature was 985 ° C. Therefore, in the range where the width B satisfies 0.4 mm ⁇ B ⁇ 1.1 mm, the temperature of the protrusion 36 remains at about 960 ° C., and when the width B is smaller than 0.4 mm, or the width B is It has been found that when it is larger than 1.1 mm, it rapidly rises above 970 ° C.
- the protruding portion 36 of the ground electrode 30 is a portion where a spark generated between the tip of the center electrode 20 ignites, and the consumption of the protruding portion 36 is more likely to proceed as the temperature of the protruding portion 36 increases. Therefore, the durability of the protrusion 36 is improved as the temperature of the protrusion 36 is lowered. Therefore, it is more preferable that the width B satisfies 0.4 mm ⁇ B ⁇ 1.1 mm from the viewpoint of durability performance as a result of FIG. 13B.
- FIG. 14 is an explanatory diagram showing the result of an evaluation experiment in which the influence of the width C on the durability performance is examined.
- experimental values are shown with the width C on the horizontal axis and the temperature of the side end faces 34 and 35 on the vertical axis.
- a plurality of spark plugs 100 having different widths C from the side end surfaces 34 and 35 of the ground electrode 30 to the press recessed portion 37 were prepared.
- the thickness T of the ground electrode 30 is 1.5 mm
- the electrode width W of the ground electrode 30 is 2.8 mm
- the protrusion amount A of the protrusion 36 is 0.7 mm
- the depth of the press recess 37 is 0.
- the width B from the tip surface 31 of the ground electrode 30 to the press recess 37 is 0.6 mm
- the diameter of the press recess 37 is (electrode width W ⁇ (2 ⁇ width C)) mm
- the diameter of the protrusion 36 is ( (Diameter of the press recess 37) ⁇ 0.2) mm (maximum value 1.7 mm).
- the width C preferably satisfies 0.4 mm ⁇ C ⁇ 0.8 mm from the viewpoint of durability performance and formability according to the result of FIG.
- FIG. 15 is an explanatory diagram showing the result of an evaluation experiment in which the influence of the distance F on the moldability is examined.
- the ground electrode 30 is cracked when the root portion 364 of the protrusion 36 is located on the inner side from the side surface 372 of the press recessed portion 37 and the ground electrode 30 is extruded and pressed at the distance F.
- the crack generation rate indicating the ratio of occurrence of the crack is shown.
- the distance F takes a negative value in a state in which the protruding portion 36 protrudes outside the press recessed portion 37.
- the distance F is changed by changing the diameter of the protrusion 36, the thickness T of the ground electrode 30 is 1.5 mm, the electrode width W of the ground electrode 30 is 2.8 mm, The depth was 1.0 mm, the diameter of the press recess 37 was 1.7 mm, the center of gravity deviation D was 0 mm, and the ratio (E1 / E2) was 1.
- the evaluation experiment of FIG. 15 after a plurality of ground electrodes 30 having different distances F were processed by an extrusion press, the presence or absence of cracks generated in the ground electrode 30 was inspected.
- the distance F when the distance F becomes negative, the crack occurrence rate increases rapidly. Therefore, it is preferable that the distance F satisfies 0 mm or more.
- FIG. 16 is an explanatory diagram showing the results of an evaluation experiment in which the influence of the center-of-gravity deviation amount D on the moldability is examined.
- the ground electrode 30 is processed by extrusion pressing with the center of gravity 366 between the center of gravity 366 of the protrusion 36 and the center of gravity 376 of the press recess 37, and the center of gravity misalignment D, the ground electrode 30 is cracked. The crack generation rate indicating the ratio of occurrence of the crack is shown.
- FIG. 16 is an explanatory diagram showing the results of an evaluation experiment in which the influence of the center-of-gravity deviation amount D on the moldability is examined.
- the diameter of the protrusion 36 is changed according to the center-of-gravity shift amount D
- the thickness T of the ground electrode 30 is 1.5 mm
- the electrode width W of the ground electrode 30 is 2.8 mm
- the depth was 1.0 mm
- the diameter of the press recess 37 was 1.7 mm
- the distance F was 0 mm
- the ratio (E1 / E2) was 1.
- FIG. 17 is an explanatory diagram showing the results of an evaluation experiment in which the influence of the ratio (E1 / E2) on the moldability is examined.
- FIG. 17 shows a ratio (E1 / E2) indicating the ratio of the flat surface 322 to the opposing surface 32 of the ground electrode 30 and the ground electrode 30 processed by an extrusion press at the ratio (E1 / E2).
- the crack generation rate indicating the ratio of occurrence of cracks in the electrode 30 is shown.
- the thickness T of the ground electrode 30 is 1.5 mm
- the electrode width W of the ground electrode 30 is 2.8 mm
- the depth of the press concave portion 37 is 1.0 mm
- the diameter of the press concave portion 37 is 1.7 mm.
- the diameter of the protrusion 36 was 1.5 mm
- the center of gravity deviation D was 0 mm
- the distance F was 0 mm.
- the protrusion amount A of the protrusion 36 satisfies 0.4 mm ⁇ A ⁇ 1.0 mm, and the width B from the tip surface 31 of the ground electrode 30 to the press recess 37 is 0.4 mm ⁇ . Since B ⁇ 2.5 mm is satisfied, it is possible to improve the heat dissipation in the portion from the tip surface 31 of the ground electrode 30 to the press recess 37. As a result, the durability of the spark plug 100 in which the ground electrode 30 is formed by press working can be improved.
- the width B from the front end surface 31 of the ground electrode 30 to the press concave portion 37 satisfies 0.4 mm ⁇ B ⁇ 1.1 mm, the heat dissipation performance at the portion from the front end surface 31 of the ground electrode 30 to the press concave portion 37 is satisfied.
- the heat dissipation of the protrusion 36 can be improved.
- the durability of the spark plug 100 in which the ground electrode 30 is formed by pressing can be further improved.
- the width C from the side end surfaces 34, 35 of the ground electrode 30 to the press concave portion 37 satisfies 0.4 mm ⁇ C ⁇ 0.8 mm, in addition to the portion from the tip surface 31 of the ground electrode 30 to the press concave portion 37 In addition, it is possible to improve the heat dissipation in the portion from the side end surfaces 34 and 35 of the ground electrode 30 to the press concave portion 37. As a result, the durability of the spark plug 100 in which the ground electrode 30 is formed by pressing can be further improved.
- the projection 36 when the projection 36 is viewed from the direction facing the center electrode 20, the projection 36 is located inside the press recess 37, and therefore, when the ground electrode 30 is extruded, the corner of the press recess 37 is formed. Since the position of the projection part 36 deviates from the direction of the shearing force transmitted radially from 374, the generation of cracks in the projection part 36 and its surroundings can be suppressed. As a result, the durability of the spark plug 100 in which the ground electrode 30 is formed by pressing can be further improved.
- the center-of-gravity shift amount D between the protrusion 36 and the press recess 37 satisfies 0 mm ⁇ D ⁇ 0.3 mm, and thus is added to the protrusion 36.
- Load imbalance can be suppressed. As a result, it is possible to further suppress the occurrence of cracks in the protrusion 36 and its surroundings.
- the ratio (E1 / E2) indicating the ratio of the flat surface 322 to the opposing surface 32 of the ground electrode 30 satisfies 0.4 ⁇ (E1 / E2) ⁇ 1
- the amount of deformation around the protrusion 36 is suppressed. By doing so, it is possible to suppress the occurrence of cracks in the protrusion 36 and its surroundings. As a result, it is possible to further suppress the occurrence of cracks in the protrusion 36 and its surroundings.
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Abstract
Description
A-1.スパークプラグの構成:
図1は、スパークプラグ100の部分断面を主に示す説明図である。スパークプラグ100は、絶縁碍子10と、中心電極20と、接地電極30と、端子金具40と、主体金具50とを備える。絶縁碍子10の一端から突出する棒状の中心電極20は、絶縁碍子10の内部を通じて、絶縁碍子10の他端に設けられた端子金具40に電気的に接続されている。中心電極20の外周は、絶縁碍子10によって絶縁され、絶縁碍子10の外周は、端子金具40から離れた位置で主体金具50によって保持されている。主体金具50に電気的に接続された接地電極30は、火花を発生させる隙間である火花ギャップGを中心電極20の先端との間に形成する。スパークプラグ100は、内燃機関(図示しない)のエンジンヘッド200に設けられた取付ネジ孔201に主体金具50を介して取り付けられ、2万~3万ボルトの高電圧が端子金具40に印加されると、中心電極20と接地電極30との間に形成された火花ギャップGに火花が発生する。
次に、スパークプラグ100を製造する製造工程の一部である接地電極30の製造工程について説明する。図6は、接地電極30の製造工程を示すフローチャートである。図7および図8は、接地電極30を製造する様子を示す説明図である。接地電極30を製造する際には、まず、接地電極30の材料である電極部材301を主体金具50に溶接する(ステップS110)。本実施例では、電極部材301は、略長方形の断面を有する棒状のニッケル合金である。
図9は、第1変形例ないし第3変形例の接地電極30を示す説明図である。図9には、第1変形例ないし第3変形例における各々の接地電極30について、図2で説明した断面に相当する断面X-Xと、図3で説明した断面に相当する断面Y-Yとが示されている。
図11は、突出量Aが着火性能に与える影響を調べた評価実験の結果を示す説明図である。図11では、横軸に突出量Aをとり、縦軸に燃焼変動率20%の点火時期をとって、実験値が示されている。ここで、燃焼変動率とは、燃焼圧力から図示平均有効圧力(IMEP、Indicated Mean Effective Pressure)を求め、500サンプルの平均値と標準偏差に基づいて、「(燃焼変動率)=(標準偏差/平均値)×100(%)」として求められた値である。図11では、燃焼変動率20%となる点火時期が、内燃機関のクランク角度を用いて示されている。図11の評価実験では、突起部36の直径を1.5mmとし、突起部36の突出量Aが異なる複数のスパークプラグ100を用意した。これらのスパークプラグ100を、排気量2000cc、DOHC型ガソリンエンジンに装着した上で、吸気圧-550mmHg、エンジン回転数750rpmでアイドリング運転を行うことによって、図11の実験値を得た。図11の実験値によれば、突出量Aが0.4mmよりも小さくなると、急着火性能が急激に低下することが分かった。
図13Aおよび図13Bは、幅Bが耐久性能に与える影響を調べた評価実験の結果を示す説明図である。図13Aでは、横軸に幅Bをとり、縦軸に先端面31の温度をとって実験値が示され、図13Bでは、横軸に幅Bをとり、縦軸に突起部36の温度をとって実験値が示されている。図13Aおよび図13Bの評価実験では、接地電極30の先端面31からプレス凹部37までの幅Bが異なる複数のスパークプラグ100を用意した。これらのスパークプラグ100において、接地電極30の厚みTを1.5mm、接地電極30の電極幅Wを2.8mm、突起部36の突出量Aを0.7mm、突起部36の直径を1.5mm、プレス凹部37の深さを0.7mm、プレス凹部37の直径を1.7mm、接地電極30の側端面34,35からプレス凹部37までの幅Cを0.5mmとした。これらのスパークプラグ100を、バーナーで950℃に2分間加熱した後に室温で1分間冷却する工程を1000サイクル実施した後、接地電極30の先端面31における背面33寄りの部分の温度を測定することによって図13Aの実験値を得ると共に、突起部36の側面362における先端面31側の部分の温度を測定することによって図13Bの実験値を得た。
図14は、幅Cが耐久性能に与える影響を調べた評価実験の結果を示す説明図である。図14では、横軸に幅Cをとり、縦軸に側端面34,35の温度をとって、実験値が示されている。図14の評価実験では、接地電極30の側端面34,35からプレス凹部37までの幅Cが異なる複数のスパークプラグ100を用意した。これらのスパークプラグ100において、接地電極30の厚みTを1.5mm、接地電極30の電極幅Wを2.8mm、突起部36の突出量Aを0.7mm、プレス凹部37の深さを0.7mm、接地電極30の先端面31からプレス凹部37までの幅Bを0.6mm、プレス凹部37の直径を(電極幅W-(2×幅C))mm、突起部36の直径を((プレス凹部37の直径)-0.2)mm(最大値1.7mm)とした。これらのスパークプラグ100を、バーナーで950℃に2分間加熱した後に室温で1分間冷却する工程を1000サイクル実施した後、接地電極30の側端面34,35における背面33寄りの部分の温度を測定することによって、図14の実験値を得た。
図15は、距離Fが成形性に与える影響を調べた評価実験の結果を示す説明図である。図15には、突起部36の根元部364がプレス凹部37の側面372から内側に位置する距離Fと、その距離Fにて接地電極30を押出しプレスで加工した場合に、接地電極30にクラックが発生する割合を示すクラック発生率とが示されている。なお、接地電極30を背面33側から見た場合に、突起部36がプレス凹部37の外側に飛び出た状態では、距離Fはマイナスの値をとる。図15の評価実験において、突起部36の直径を変更することによって距離Fを変化させ、接地電極30の厚みTを1.5mm、接地電極30の電極幅Wを2.8mm、プレス凹部37の深さを1.0mm、プレス凹部37の直径を1.7mm、重心ズレ量Dを0mm、比(E1/E2)を1とした。図15の評価実験では、距離Fが異なる複数の接地電極30を押出しプレスで加工した後、接地電極30に発生したクラックの有無を検査した。
図16は、重心ズレ量Dが成形性に与える影響を調べた評価実験の結果を示す説明図である。図16には、突起部36の重心366とプレス凹部37の重心376との重心ズレ量Dと、その重心ズレ量Dにて接地電極30を押出しプレスで加工した場合に、接地電極30にクラックが発生する割合を示すクラック発生率とが示されている。図16の評価実験において、突起部36の直径は重心ズレ量Dに応じて変化させ、接地電極30の厚みTを1.5mm、接地電極30の電極幅Wを2.8mm、プレス凹部37の深さを1.0mm、プレス凹部37の直径を1.7mm、距離Fを0mm、比(E1/E2)を1とした。図16の評価実験では、重心ズレ量Dが異なる複数の接地電極30を押出しプレスで加工した後、接地電極30に発生したクラックの有無を検査した。
図17は、比(E1/E2)が成形性に与える影響を調べた評価実験の結果を示す説明図である。図17には、接地電極30の対向面32における平坦面322の割合を示す比(E1/E2)と、その比(E1/E2)にて接地電極30を押出しプレスで加工した場合に、接地電極30にクラックが発生する割合を示すクラック発生率とが示されている。図17の評価実験において、接地電極30の厚みTを1.5mm、接地電極30の電極幅Wを2.8mm、プレス凹部37の深さを1.0mm、プレス凹部37の直径を1.7mm、突起部36の直径を1.5mm、重心ズレ量Dを0mm、距離Fを0mmとした。図17の評価実験では、比(E1/E2)が異なる複数の接地電極30を押出しプレスで加工した後、接地電極30に発生したクラックの有無を検査した。
以上説明したスパークプラグ100によれば、突起部36の突出量Aが0.4mm≦A≦1.0mmを満たし、接地電極30の先端面31からプレス凹部37までの幅Bが0.4mm≦B≦2.5mmを満たすことから、接地電極30の先端面31からプレス凹部37までの部位における放熱性を向上させることができる。その結果、プレス加工によって接地電極30が形成されたスパークプラグ100の耐久性を向上させることができる。
以上、本発明の実施の形態について説明したが、本発明はこうした実施の形態に何ら限定されるものではなく、本発明の趣旨を逸脱しない範囲内において様々な形態で実施し得ることは勿論である。
Claims (8)
- 軸状の中心電極と、
前記中心電極の外周を保持する絶縁碍子と、
前記絶縁碍子の外周を保持する主体金具と、
前記主体金具に接合され、前記中心電極との間に火花ギャップを形成する接地電極であって、
前記中心電極の先端に対向する対向面と、
前記中心電極の先端に背を向ける背面と、
押出しプレスによって形成され、前記対向面から前記中心電極の先端に向けて突出する突起部と、
前記押出しプレスによる前記突起部の形成に伴って前記背面に形成され、前記背面から前記中心電極の先端に向けて窪むプレス凹部と
を有する接地電極と
を備えるスパークプラグであって、
前記突起部が前記対向面から突出する突出量Aは、0.4mm≦A≦1.0mmを満たし、
前記接地電極の先端から前記プレス凹部までの幅Bは、0.4mm≦B≦2.5mmを満たすことを特徴とするスパークプラグ。 - 請求項1に記載のスパークプラグであって、前記幅Bは、0.4mm≦B≦1.1mmを満たすことを特徴とするスパークプラグ。
- 請求項1または請求項2に記載のスパークプラグであって、前記接地電極の側端から前記プレス凹部までの幅Cは、0.4mm≦C≦0.8mmを満たすことを特徴とするスパークプラグ。
- 請求項1ないし請求項3のいずれか一項に記載のスパークプラグであって、前記突起部が前記中心電極の先端に突出する方向から見た場合、前記突起部は、前記プレス凹部の内側に位置することを特徴とするスパークプラグ。
- 請求項4に記載のスパークプラグであって、前記突起部が前記中心電極の先端に突出する方向から見た場合、前記突起部と前記プレス凹部との重心ズレ量Dは、0mm≦D≦0.3mmを満たすことを特徴とするスパークプラグ。
- 請求項1ないし請求項5のいずれか一項に記載のスパークプラグであって、前記突起部が立ち上がる根元部から前記接地電極の側端までの間の平坦な表面の距離E1と、前記根元部から前記接地電極の側端までの距離E2との比は、0.4≦(E1/E2)≦1を満たすことを特徴とするスパークプラグ。
- 軸状の中心電極と、
前記中心電極の外周を保持する絶縁碍子と、
前記絶縁碍子の外周を保持する主体金具と、
前記主体金具に接合され、前記中心電極との間に火花ギャップを形成する接地電極であって、
前記中心電極の先端に対向する対向面と、
前記中心電極の先端に背を向ける背面と、
押出しプレスによって形成され、前記対向面から前記中心電極の先端に向けて突出する突起部と、
前記押出しプレスによる前記突起部の形成に伴って前記背面に形成され、前記背面から前記中心電極の先端に向けて窪むプレス凹部と
を備えるスパークプラグであって、
前記突起部が前記対向面から突出する突出量Aは、0.4mm≦A≦1.0mmを満たし、
前記接地電極の側端から前記プレス凹部までの幅Cは、0.4mm≦C≦0.8mmを満たすことを特徴とするスパークプラグ。 - 軸状の中心電極と、
前記中心電極の外周を保持する絶縁碍子と、
前記絶縁碍子の外周を保持する主体金具と、
前記主体金具に接合され、前記中心電極との間に火花ギャップを形成する接地電極と
を備えるスパークプラグの製造方法であって、
前記接地電極において前記中心電極の先端に対向する対向面に、前記対向面から前記中心電極の先端に向けて突出する突起部を、前記突起部が前記対向面から突出する突出量Aが0.4mm≦A≦1.0mmを満たすように、押出しプレスによって形成し、
前記接地電極において前記中心電極の先端に背を向ける背面に、前記背面から前記中心電極の先端に向けて窪むプレス凹部を、前記接地電極の先端から前記プレス凹部までの幅Bが0.4mm≦B≦2.5mmを満たすように形成することを特徴とするスパークプラグの製造方法。
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US13/123,371 US8466608B2 (en) | 2008-10-14 | 2009-10-09 | Spark plug and manufacturing method thereof |
CN2009801401228A CN102177629B (zh) | 2008-10-14 | 2009-10-09 | 火花塞及其制造方法 |
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JPS5236238A (en) * | 1975-09-16 | 1977-03-19 | Shinkosumosu Denki Kk | Electric spark plug for automoyive internal combustion engine |
JPS55121290A (en) * | 1979-03-09 | 1980-09-18 | Nippon Soken | Ignition plug |
JP2006286469A (ja) | 2005-04-01 | 2006-10-19 | Denso Corp | 内燃機関用のスパークプラグ |
Non-Patent Citations (2)
Title |
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See also references of EP2339704A4 |
SHIN NISHIOKA ET AL.: "Super Ignition Spark Plug with Wear Resistive Electrode", SAE TECHNICAL PAPER SERIES 2008-01-0092, April 2008 (2008-04-01) |
Also Published As
Publication number | Publication date |
---|---|
JPWO2010044236A1 (ja) | 2012-03-15 |
EP2339704A4 (en) | 2013-12-04 |
EP2339704B1 (en) | 2016-01-27 |
CN102177629B (zh) | 2013-08-14 |
JP5134080B2 (ja) | 2013-01-30 |
EP2339704A1 (en) | 2011-06-29 |
CN102177629A (zh) | 2011-09-07 |
US20110241524A1 (en) | 2011-10-06 |
US8466608B2 (en) | 2013-06-18 |
KR20110084942A (ko) | 2011-07-26 |
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